Drag Conveyor Friction Bar for Workpiece Orientation in Welding
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Solution Overview
Problem
Current automation systems for welding complex assemblies, such as vehicles, are overly complex and costly, requiring specialized skills for setup, operation, and maintenance, which can be a barrier for many manufacturers due to high capital and inventory costs, and excessive sophistication that limits operational reliability.
Innovation Solution
A drag conveyor system with a continuous chain and multiple locating elements, including transfer pins, supported by a sprocket and adjustment assembly, allows for simple configuration and operation, enabling efficient orientation and loading of workpieces for welding, reducing the need for skilled labor and complex equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If complex automation systems with fixtures and vision systems are used to orient and position workpieces, then productivity and automation extent are improved, but device complexity and capital cost increase significantly
Solution Approach 1:
The workpiece itself performs the orientation function by being dragged across the friction bar, which uses friction to automatically orient the workpiece without requiring external vision systems or complex fixtures. The workpiece's own geometry and the friction bar's surface interaction provide the self-orienting mechanism.
Solution Approach 2:
The patent extracts the orientation function from complex vision systems and fixtures, separating it into a simple friction-based mechanism. The friction bar is a standalone element that provides orientation independently, removing the need for integrated complex automation systems.
2Reliability
If specialized skilled labor is employed to operate and maintain complex equipment, then productivity and reliability are improved, but capital cost and operational cost increase
Solution Approach 1:
The friction bar is a simple, inexpensive component that can be easily replaced or adjusted if needed. This approach uses simple, low-cost elements rather than expensive, complex systems that require specialized maintenance, making the equipment more accessible to operators without specialized training.
3Device complexity
If manual loading of workpieces is used, then equipment complexity is reduced, but productivity decreases due to operator time requirements
Solution Approach 1:
The friction bar orients the workpiece in advance before it reaches the welding position, preparing it for automated processing. This preliminary orientation action enables the subsequent automated welding operation to proceed at high speed without requiring the operator to manually orient each workpiece.
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 provides low-cost automation for high-speed welding of fasteners and other parts, minimizing equipment changeover time and complexity, thereby increasing labor and equipment productivity while reducing capital costs and operational downtime.
Implementation Method 1
a friction bar positioned beneath the chain and in proximity to the locating element. The friction bar is configured to drag the part from an unoriented position to an oriented position
Data Source
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AI summary
An assembly system, such as welding system, includes an assembly station that is configured to assemble a component to a part in a loaded position. A drag conveyor includes a movable conveyor member that supports multiple locating elements configured to cooperate with a locating feature on a part. A friction bar is arranged along the locating elements, and the locating elements extend beyond the friction bar. The friction bar is configured to support the part and reorient the part from an unoriented position to an oriented position. A robot is configured to transfer a part from the oriented position on the conveyor to the loaded position at the assembly station, such as a welding unit.