Flexible Guide Rail Welding Robot for Arc-Shaped Blind Areas
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the steel structure manufacturing industry, components with arc shapes require manual welding, which is inefficient and demanding in terms of operator skill, especially since conventional robots struggle to weld long blind areas and require high precision.
Innovation Solution
A robotic welding device employing a flexible guide rail, combined with a mini-type arc welding robot, enables automatic detection of welding grooves, remote monitoring and control of welding parameters, and oscillation capabilities to complete welding of long lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding robots are used for arc-shaped components, then welding precision may be maintained, but the robot cannot access long blind areas and requires high operator skill
Solution Approach 1:
The patent employs a flexible guide rail that can dynamically adapt to arc-shaped components of various radii and lengths, replacing rigid conventional robot paths. The flexible rail allows the welding tool to reach long blind areas while maintaining automated welding, reducing operator skill requirements.
Solution Approach 2:
The system changes the geometric parameters of the guide rail (flexibility, curvature radius, length) to match different arc-shaped components. This allows the same welding robot to handle various component shapes without requiring high operator skill for manual adaptation.
2Adaptability or versatility
If manual welding is used for arc-shaped components, then accessibility to complex shapes is achieved, but production efficiency is low and shaping quality requires high operator skill
Solution Approach 1:
The flexible guide rail system enables the welding robot to automatically adapt to arc-shaped components without human intervention for path planning. The system self-adjusts to the component geometry, maintaining high productivity while achieving excellent shaping quality on complex arc shapes.
Solution Approach 2:
The guide rail is pre-configured with the appropriate curvature and length to match the arc-shaped component before welding begins. This preliminary setup allows the automated welding process to proceed efficiently without requiring skilled operators to manually navigate complex shapes during welding.
3Productivity
If straight rails are used for welding, then high-speed automatic welding equipment can be used, but arc-shaped components cannot be welded automatically
Solution Approach 1:
The patent replaces straight rails with flexible guide rails that can be curved to match arc-shaped components. This curvature adaptation maintains high welding speeds through automation while enabling the equipment to handle arc-shaped geometries that straight rails cannot accommodate.
4Extent of automation
If a mini-type arc welding robot with flexible guide rail is used, then automatic welding of arc-shaped components is achieved, but device complexity increases
Solution Approach 1:
The flexible guide rail system serves multiple functions: it guides the welding robot, adapts to various arc shapes, and enables automatic welding across different component geometries. This multi-functionality justifies the increased device complexity by providing universal automation capability for arc-shaped components.
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
This solution allows for intelligent automatic welding of components with arc shapes, improving efficiency and quality while reducing operator skill requirements, and enabling remote monitoring and control of the welding process.
Implementation Method 1
the flexible guide rail is provided with a plurality of magnetic adhesion devices, and the plurality of magnetic adhesion devices are located on the same side of the flexible guide rail
Data Source
AI summary
A robotic welding device including a control box configured to pre-store various welding processes and generate a welding parameter. A wire feed mechanism configured to feed a welding wire to a welding gun and a flexible guide rail attached to a welding component. A welding robot including a robot body and a welding gun. A teaching apparatus in communication with the welding robot and the control box, controlling, a traveling path and an operation position of the welding robot, and adjusting oscillation and welding operations of the welding gun according to an instruction of the control box. A remote control terminal in communication with the control box, and in communication with a data acquisition device of the welding robot. The robotic welding device including a welding power supply.