Floating Weld Gun Homing for High-Rate Fastener Welding
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Solution Overview
Problem
Current welding systems for securing fasteners to sheet metal workpieces are overly complex, requiring skilled labor and costly equipment, which limits their accessibility and operational reliability, especially in environments where specialized skills and resources are scarce.
Innovation Solution
A simplified welding system utilizing a robot and a feeder mechanism with a float assembly and homing guide, allowing for easy configuration, operation, and maintenance, which includes a feeder that advances and retracts electrodes to securely position and weld fasteners with minimal setup requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If complex vision systems and fixtures are used to enable robot automation, then productivity and automation extent are improved, but device complexity and capital cost increase
Solution Approach 1:
The welding gun is equipped with homing guides that enable it to automatically return to and locate its home position without external fixtures or complex vision systems. The gun's own structure includes the homing guides, making the system self-sufficient for positioning and eliminating the need for separate positioning infrastructure.
Solution Approach 2:
The homing guides are extracted from the machine frame and integrated directly into the welding gun structure. This separation allows the gun to independently manage its positioning without relying on complex external fixtures or vision systems mounted on the frame.
2Reliability
If skilled labor and specialized tools are used for equipment setup and maintenance, then operational reliability is improved, but device complexity and capital cost increase
Solution Approach 1:
The homing guides enable the welding gun to automatically self-position and self-align without requiring skilled operators to perform complex manual setup procedures. The system's own structure provides the positioning capability, eliminating dependence on specialized human expertise for routine operations.
3Productivity
If equipment changeover time is reduced through simplification, then productivity is improved, but manufacturing precision may worsen
Solution Approach 1:
Complex mechanical positioning systems, fixtures, and alignment tools are replaced with a simplified homing guide mechanism integrated into the gun. This mechanical substitution maintains positioning accuracy through the gun's own built-in guides rather than through complex external mechanical systems, enabling quick changeovers without sacrificing welding precision.
Data Source
AI summary
A securing system, such as a welding system, includes a robot configured to transfer a part to a home position. A securing station has a frame and a gun supported on the frame. The gun includes first and second members movable relative to one another, which are first and second weld gun electrodes, for example. The gun is configured to secure a component to the part in a securing position during a securing operation. A float assembly interconnects the gun to the frame and is configured to permit the gun to glide relative to the welding frame between the home position and the securing position. A homing assembly includes a homing guide configured to release the welding gun from the home position during the securing operation, such as resistance welding fasteners to sheet metal workpieces.