Collaborative Robot Welding System for Large Structures
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Solution Overview
Problem
The welding industry faces challenges in achieving reliable, consistent, and repeatable weld quality due to human and process variables, while also needing cost-effective, mobile, and versatile welding systems that can be operated by less experienced individuals, especially in high mix, low volume production environments and on large assemblies.
Innovation Solution
A highly-mobile collaborative robot fabrication system that includes a control system for intuitive hand-guided positioning, a user interface for graphical programming without requiring extensive training, and a mobile platform for easy relocation, enabling welding or cutting tasks on large structures with enhanced production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional automated welding systems are used, then weld quality consistency is improved, but system complexity and cost increase significantly
Solution Approach 1:
The patent introduces a control system as an intermediary between the collaborative robot and welding equipment. This control system coordinates the robot's movements and welding parameters, enabling consistent weld quality without requiring the full complexity of traditional automated welding systems. The control system acts as a mediator that simplifies the overall system architecture while maintaining weld quality consistency.
2Productivity
If highly automated welding systems are deployed, then productivity is improved, but ease of operation deteriorates due to specialized training requirements
Solution Approach 1:
The collaborative robot system provides self-service capabilities through intuitive programming interfaces and automated path planning. The system can be programmed using simple teach pendants or graphical interfaces that require minimal specialized training. The robot automatically manages welding parameters, movements, and quality control, allowing operators with basic training to achieve high productivity without extensive automation expertise.
3Manufacturing precision
If fixed automated welding cells are installed, then manufacturing precision is improved, but adaptability to different production environments deteriorates
Solution Approach 1:
The patent employs dynamic positioning systems and adjustable robot workspaces that allow the collaborative robot to adapt to different production environments. The system can dynamically adjust its base position, arm reach, and welding parameters to maintain manufacturing precision across various locations and configurations. This dynamic capability enables the same system to achieve consistent weld quality whether working on large assemblies in the field or in controlled shop environments.
4Ease of operation
If manual welding operations are performed, then ease of operation is maintained, but reliability of weld quality deteriorates due to human variables
Solution Approach 1:
The collaborative robot system incorporates feedback mechanisms that monitor welding parameters, robot position, and weld quality in real-time. This feedback is fed back to the control system, which automatically adjusts parameters to maintain consistent weld quality. The system provides visual and tactile feedback to operators, enabling them to maintain simple operations while achieving reliable, consistent weld quality through automated control and monitoring.
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 allows for rapid setup and operation of welding or cutting tasks on large structures, improving production efficiency by shifting repetitive tasks to collaborative robots and enabling less experienced operators to achieve high-quality weldments.
Implementation Method 1
electric arc welding has evolved from the use of essentially a bare electrode employed to create molten metal by generating an electric arc between one end of the electrode and a workpiece
Data Source
AI summary
A highly mobile multi-station collaborative robot fabrication system for the assembly, construction, fabrication, and/or the completion of weldments or performing cutting operations in fabrication shop or factory environments or on large structures in difficult to access or elevated locations and methods of deploying and operating the system.