Hexapod Welding Torch Control for Weave Patterns and Orientation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing welding and plasma cutting torches face challenges in achieving desired weave patterns and maintaining torch orientation due to inertia in robotic systems, and inexperienced operators struggle with manual manipulation.

Innovation Solution

Integration of a hexapod actuator with six degrees of freedom in welding and plasma cutting torches to automatically move the distal portion, allowing for precise control of torch orientation and weave patterns, assisted by motion controllers and sensors like IMUs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a robot arm is used to perform welding operations with automatic torch manipulation, then productivity is improved, but the robot arm cannot accelerate the torch as needed to perform desired weave patterns due to inertia

Engineering Contradiction:

Improveautomatic welding operationVSAvoidtorch acceleration

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The welding torch system is segmented into two independent motion control components: the robot arm for positioning and the hexapod actuator for torch manipulation. This segmentation allows each component to perform its specialized function without being constrained by the other's inertia, enabling both automatic operation and rapid torch acceleration for weave patterns.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hexapod actuator serves as an intermediary device between the robot arm and the torch distal portion. It mediates the motion control by receiving commands from the robot arm for positioning while independently controlling the torch orientation and weave patterns, thus overcoming the robot arm's inertia limitations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If manual torch manipulation is used to achieve desired weave patterns and torch orientation, then ease of operation is maintained, but inexperienced welders must learn proper techniques and weld quality is inconsistent

Engineering Contradiction:

Improvemanual torch controlVSAvoidweld bead quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The hexapod actuator enables the torch to perform complex manipulation tasks automatically without requiring the operator to manually control torch orientation and weave patterns. The system serves itself by autonomously executing programmed motion sequences, eliminating the need for inexperienced welders to learn complex manual techniques while ensuring consistent weld quality.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates sensors including IMUs that provide feedback on torch position and orientation. This feedback loop allows the control system to automatically adjust torch manipulation, ensuring precise execution of weave patterns and maintaining consistent weld quality without relying on operator skill.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If a hexapod actuator is integrated into the welding torch to enable automatic torch manipulation, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvetorch orientation controlVSAvoidtorch structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The hexapod actuator provides six degrees of freedom that enable multiple functions including positioning, orientation control, and complex weave patterns within a single device. This multi-functionality justifies the added complexity by consolidating what would otherwise require separate systems into one integrated actuator.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces complex mechanical linkages and manual control mechanisms with a hexapod actuator system that uses computer-controlled actuation. This substitution reduces mechanical complexity while improving precision, as the hexapod can be controlled through software rather than complex mechanical transmissions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If the distal portion of the torch is moved with six degrees of freedom, then adaptability is improved for various welding positions and patterns, but device complexity and weight increase

Engineering Contradiction:

Improvetorch positioning capabilityVSAvoidtorch distal portion

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The hexapod actuator provides dynamic six-degree-of-freedom motion capability that allows the torch distal portion to adapt to various welding positions and patterns. The dynamic nature of the hexapod enables real-time adjustment of torch orientation and position, providing versatility for different welding applications while the modular design helps manage weight.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260014635A1Electric arc torch

Publication Date: 2026.01.15 LINCOLN GLOBAL INC

AI summary

A welding torch has a proximal portion, a distal portion including a contact tip and a diffuser, and a hexapod actuator located between the proximal portion of the welding torch and the distal portion of the welding torch. The hexapod actuator has a moving platform movable with six degrees of freedom and having a central opening through the moving platform. The distal portion of the welding torch is moved by said moving platform in said six degrees of freedom. A wire electrode is fed to the contact tip through the central opening of the moving platform during movement of the distal portion of the welding torch by the moving platform.