Automated Brazing System with Vision and Temperature Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated brazing systems are ineffective and unreliable for joining complex or hard-to-reach aluminum workpieces due to challenges in controlling heat, particularly when the melting points of the base metal and brazing materials are close, leading to overheating and quality issues dependent on operator skill.
Innovation Solution
A system that combines a positioning unit, vision system, and temperature probe to precisely position a brazing unit relative to the workpiece, using image processing and temperature monitoring to adjust the brazing unit's position and heat output, enabling accurate and automated brazing of complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated brazing systems are used for simple geometries, then productivity is improved, but reliability deteriorates when applied to hard to reach joints or parts with high variability
Solution Approach 1:
The system incorporates a vision system that captures images of the workpiece and provides real-time feedback to the controller. The controller processes these images to determine the actual position and orientation of joints, then adjusts the brazing unit's position and heating parameters accordingly. This closed-loop feedback mechanism enables the automated system to adapt to manufacturing tolerances and complex geometries, maintaining both high productivity and reliable joining quality
Solution Approach 2:
The system dynamically adjusts the brazing unit's position and orientation based on real-time image processing results. The controller modifies heating parameters and unit positioning on-the-fly to accommodate variations in joint location and workpiece geometry, transforming a static automated process into a dynamic adaptive one that can handle complex and variable geometries effectively
2Reliability
If manual brazing is used for complicated or hard to access joints, then reliability is improved through operator skill, but productivity deteriorates due to increased cycle time
Solution Approach 1:
The system enables automated self-positioning and self-adjustment capabilities through integrated vision sensing and controller processing. The brazing unit automatically locates joints, determines optimal positioning, and adjusts heating parameters without human intervention, capturing both the productivity benefits of automation and the reliability benefits of adaptive control previously requiring skilled operators
Solution Approach 2:
The patent replaces manual mechanical positioning and sensing with an automated vision-based system. The vision system captures images and the controller processes them to determine joint positions, substituting the operator's visual inspection and manual positioning skills with automated optical sensing and computational processing, thereby maintaining reliability while dramatically improving productivity
3Manufacturing precision
If heat input is increased to ensure proper brazing, then manufacturing precision is improved, but object-affected harmful factors worsen due to overheating and melting
Solution Approach 1:
The vision system provides continuous feedback on the brazing process, allowing the controller to monitor and adjust heat input in real-time. This enables precise control of thermal energy application, ensuring sufficient heat for proper brazing while immediately detecting and responding to conditions that could lead to overheating or melting, thus achieving manufacturing precision without harmful effects
Solution Approach 2:
The system dynamically changes heating parameters based on real-time conditions detected by the vision system. The controller adjusts parameters such as heating power, exposure time, and unit positioning to optimize the thermal process for each specific joint configuration, ensuring adequate heat input for quality brazing while preventing excessive heat that would cause overheating or melting
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures consistent quality and repeatable heat control, automatically aligning the brazing unit with joints and adapting to manufacturing tolerances, reducing the reliance on operator skill and improving cycle time and cost efficiency.
Implementation Method 1
a temperature probe for monitoring a temperature
Implementation Method 2
a vision system obtaining an image of an item to be joined on a workpiece
Implementation Method 3
Brazing is used to join metal workpieces by heating a joint of the workpieces
Implementation Method 4
The filler melts into the joint, and when cooled creates a mechanical attachment between the workpieces
Data Source
AI summary
A system for joining articles includes a joining unit; a positioning unit coupled to the joining unit, the positioning unit positioning the joining unit; a vision system obtaining an image of an item to be joined on a workpiece; a controller for processing the image and controlling a position of the joining unit relative to the item to be joined in response to the image; and a temperature probe for monitoring a temperature; wherein the controller adjusts the position of the joining unit in response to the temperature.