Insulated Robotic Welding Tool Tips for Accurate Torch Programming
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Solution Overview
Problem
Conventional robotic welding teaching tips are prone to breakage and suffer from accuracy issues, particularly when using spring-loaded tips, which can lead to inaccurate positioning during the programming of robotic welding procedures.
Innovation Solution
The development of robotic welding tool tips made from non-conductive materials, such as phenolic, with angled surfaces that allow for direct contact with the workpiece, enabling accurate positioning and orientation, and preventing unintended welding arcs due to their insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring-loaded teaching tips are used, then the tip is protected from breakage, but positioning accuracy deteriorates due to inability to determine spring depression
Solution Approach 1:
The patent changes the physical state of the teaching tip from a spring-loaded mechanism to a rigid structure with a predetermined break point. This parameter change eliminates the ambiguity of spring depression while maintaining protection through the break point design that prevents complete tip failure.
Solution Approach 2:
The teaching tip is segmented into a main body and a removable insert portion with a predetermined break point. This segmentation allows the insert to break at a controlled point, protecting the expensive main body while providing clear visual feedback on contact status.
2Ease of operation
If conventional teaching tips contact the workpiece during programming, then positioning can be achieved, but the tips are prone to breakage
Solution Approach 1:
The teaching tip is pre-designed with a predetermined break point that will fail before the main tip body under excessive force. This preliminary action ensures that any contact during programming either provides accurate positioning feedback or triggers a controlled failure, preventing complete tip breakage and maintaining programming capability.
3Adaptability or versatility
If conductive teaching tips are used, then welding operations can be performed, but accidental welding arcs may occur during programming
Solution Approach 1:
The teaching tip serves as an intermediary component that is electrically insulated from the torch body during programming operations. The tip's design prevents electrical contact with the workpiece, acting as a mediator that enables safe programming without risk of accidental arcs, while still allowing the torch to perform welding functions when the tip is removed.
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
These tool tips enhance the accuracy and durability of robotic welding programming by allowing direct contact with the workpiece without risk of breakage and ensure precise positioning, improving the consistency of weld programs while preventing accidental welding arcs.
Implementation Method 1
their insulating properties
Data Source
AI summary
Disclosed example robotic welding tool tips include a body having a first end configured to be connected to a robotic welding torch in place of a nozzle and a second end having an angled surface.