Heavy Weldment Manipulator Rotation for Welding Accessibility
Solution Overview
Problem
Constructing large girders or heavy weldments is challenging due to their size, weight, and configuration, requiring extensive equipment and labor for welding and assembly, which is difficult to manage and time-consuming.
Innovation Solution
A system of manipulators, including first and second sets aligned along a central axis, with pivot frames and actuators, allows for the rotation and transfer of heavy weldments between positions, facilitating welding operations by rotating and repositioning the weldment to access all sides efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manufacturers assemble girders in sections to access all sides for welding, then welding accessibility is improved, but assembly time and labor increase
Solution Approach 1:
The patent employs a dynamic positioning system where the girder is held in a vertical orientation by manipulators, allowing it to be rotated and repositioned during welding operations. This dynamic approach eliminates the need for static section-by-section assembly, enabling welders to access all sides of the girder while it remains in one continuous position, thereby reducing assembly time while maintaining welding accessibility.
2Ease of operation
If extensive equipment and vehicles are used to move and manipulate the girder, then welding accessibility is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated manipulator system. The manipulators perform both the holding/support function and the positioning/rotation function that would traditionally require separate equipment. By merging these functions into one coordinated system, the patent achieves comprehensive welding accessibility without the complexity of multiple independent vehicles and equipment.
3Strength
If traditional assembly methods are used for heavy weldments, then structural integrity is maintained, but productivity decreases
Solution Approach 1:
The patent implements preliminary positioning and securing of the girder in a vertical orientation before welding operations begin. The manipulators are pre-configured to hold and position the girder optimally, allowing welding to proceed continuously without interruption for repositioning. This preliminary setup maintains structural integrity through proper positioning while significantly improving productivity by eliminating repeated handling and repositioning operations.
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 efficient welding of heavy weldments by allowing operators to access and weld components from multiple sides without extensive equipment, reducing assembly time and labor, and optimizing the use of space.
Implementation Method 1
a pivot actuator configured to apply a force to the pivot frame to rotate the pivot frame from the first seated position to the first raised position
Implementation Method 2
a transfer actuator configured to apply a force to the heavy weldment to move the heavy weldment from the first manipulator to the second manipulator
Data Source
AI summary
A system for moving a heavy weldment. The system includes at least a set of first manipulators that is longitudinally aligned and spaced apart along a central axis, and a set of second manipulators that is longitudinally aligned and spaced apart along the central axis and is transversely opposite to the set of first manipulators relative to the central axis. Each manipulator of the set of first manipulators and the set of second manipulators includes a base that operably engages with a ground surface, and a pivot frame that rotatably engages with the base between a seated position and a raised position, wherein the pivot frame is configured to hold and move the heavy weldment about the central axis.