Dual-Mode Welding Control for Precise Die-Board Blade Joining
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Solution Overview
Problem
Conventional automatic welding apparatuses are not suitable for welding small or precisely shaped die-board blades due to the need for manual handling, which can lead to operational mistakes when workers are distracted.
Innovation Solution
An automatic-manual welding apparatus with a dual-table design, a workpiece-fixing unit, a welding unit, and a controller that allows for both automatic and manual operation modes, enabling precise welding with reduced human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automatic welding apparatuses are used for welding die-board blades, then automation is improved, but operational reliability deteriorates due to manual handling requirements
Solution Approach 1:
The welding apparatus is designed to automatically fix the workpiece using suction cups and automatic positioning mechanisms, eliminating the need for manual handling during the welding process. The system performs self-positioning and self-fixing operations, thereby maintaining automation while improving reliability by removing human intervention points where errors could occur.
2Ease of operation
If manual handling is used to fix workpiece to conventional automatic welding apparatus, then ease of operation is improved, but manufacturing precision deteriorates due to operational mistakes
Solution Approach 1:
The apparatus replaces manual mechanical handling with an automated system using suction cups for workpiece fixation and motorized mechanisms for positioning. This substitution eliminates human error while maintaining ease of operation through automated control, thereby improving manufacturing precision without sacrificing operational simplicity.
3Device complexity
If conventional automatic welding apparatus structure is used, then device complexity is reduced, but adaptability deteriorates for small or precisely shaped objects
Solution Approach 1:
The welding apparatus incorporates dynamically adjustable components including movable tables, adjustable suction cup positions, and flexible positioning mechanisms. These dynamic features allow the apparatus to adapt to various workpiece sizes and shapes, particularly small or precisely shaped objects like die-board blades, without significantly increasing overall structural complexity.
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
Enables automatic or manual welding processes with improved precision and reduced personnel errors, suitable for small or precisely shaped die-board blades, enhancing welding efficiency and quality.
Implementation Method 1
the two ends of the plate are welded to each other while contacting each other
Implementation Method 2
a forward/backward transfer screw coupled at a first end portion thereof to the forward/backward transfer motor, the forward/backward transfer screw being configured to be rotated in forward and reverse directions together with the forward/backward transfer motor
Data Source
AI summary
An automatic and manual welding apparatus includes an operation changeover switch which is provided to be capable of switching a manual input mode for switching off power supplied to an infeed motor to and from an automatic input mode for applying power supplied to the infeed motor, so as to switch the rotation of the infeed motor automatically and manually. A control unit controls the infeed motor such that the power supplied to the forward and backward transfer motor is switched off when the input of the operation changeover switch is in a manual input mode and the power to the infeed motor is applied when the input of the operation changeover switch is in an automatic input mode.