Magazine for Electrode Caps with Quick-Action Coupling
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Solution Overview
Problem
The existing solutions for magazines for electrode caps in welding robots require process interruptions for refilling, as they need to be manually positioned and reprogrammed, which is unsafe during automated production and leads to inefficiencies.
Innovation Solution
A magazine system comprising a magazine head and an interchangeable magazine with a quick-action clamping device, guide elements, and locking mechanisms that allow for automatic alignment and secure storage of electrode caps, enabling seamless integration and operation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If magazines are arranged in a defined position for welding tongs to approach, then welding tongs can receive new electrode caps, but manual refilling requires process interruption and is unsafe during automated production
Solution Approach 1:
The magazine is divided into a fixed magazine head and a removable magazine body. The magazine body can be detached and replaced without moving the entire magazine assembly, allowing refilling to occur without process interruption. The welding tongs approach the fixed magazine head, while the removable body is exchanged by external handling.
Solution Approach 2:
The removable magazine body is extracted as a separate component from the fixed magazine head. This extraction allows the body to be refilled or replaced independently without affecting the magazine's positioned installation or requiring process shutdown, resolving the contradiction between ease of refilling and production continuity.
2Ease of operation
If magazines are repositioned for refilling, then new electrode caps can be loaded, but coordinates of welding gun movement must be reprogrammed
Solution Approach 1:
By segmenting the magazine into a fixed head and removable body, the system eliminates the need to reposition the entire magazine assembly. The fixed magazine head maintains its programmed coordinates, while the removable body is exchanged without affecting positioning, thus avoiding reprogramming complexity.
Solution Approach 2:
The removable magazine body serves as a replaceable copy that can be refilled offline. Multiple identical bodies can be prepared in advance, allowing quick exchange without repositioning or reprogramming the welding gun coordinates, maintaining system simplicity.
3Ease of operation
If electrode caps are stored in cap guides parallel to the longitudinal axis, then electrode caps are easily accessible, but the magazine requires more space and manual positioning
Solution Approach 1:
The cap guides are arranged diagonally offset and nested within the compact magazine body structure. This nesting allows electrode caps to be stored in an organized, accessible manner while maximizing space utilization and minimizing the overall magazine footprint, reducing the area required.
Solution Approach 2:
The cap guides are positioned at diagonal offsets rather than purely parallel arrangements, utilizing three-dimensional space more efficiently. This dimensional optimization maintains accessibility of electrode caps while reducing the magazine's planar footprint and overall space requirements.
Data Source
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AI summary
The invention relates to a magazine for electrode caps of welding electrodes, in particular for welding tongs of welding robots, consisting of a magazine head (1) and a changer magazine (2) to be connected to said magazine head (1). A quick-action coupling unit (4 and 4a) is provided in order to connect the changer magazine (2) to the magazine head (1), and at least one interlocking guide device (5 and 5a) is arranged on the magazine head (1) and on the changer magazine (2). The electrode caps (3) to be kept available for supply are stored in the changer magazine (2) in two cap guides (11), which have a profile that corresponds to the shape of the electrode caps (3) and which are designed parallel to the longitudinal axis of the changer magazine (2) and in identical positions in relation thereto in the magazine head (1). Said cap guides (11) are introduced diagonally offset in the changer magazine (2) and magazine head (1) such that the contact surfaces of the electrode caps (3) are diagonally opposed to each other, a magazine closure mechanism (8) is arranged on the side of the changer magazine (2) facing the magazine head (1), and the side of the magazine head (1) facing away from the changer magazine (2) is opened in the form of an aperture (12) sufficiently far in the access direction of the welding tongs so as to expose the full diameter of the electrode cap (3) aperture positioned in the access direction. In order to fix the electrode cap (3) in said position, at least one clamping jaw (6) is arranged for each cap guide, and adjacent to each transfer aperture (12) in the magazine head (1) and on the housing of the magazine head, a pressure plate (7) is arranged opposite of the respective other aperture (12).