Automated Joining Table with Splatter-Shielded Grounding Channels
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Solution Overview
Problem
Existing welding tables lack automation and effective weld splatter protection, which can lead to manual handling of parts and potential electrical shorts due to splatter contact with welding equipment components.
Innovation Solution
An automated assembly and joining table with unique holder configurations, including zig-zag shaped channels for grounding wires and an inverted rack and pinion arrangement, to reduce or prevent weld splatter from reaching electrical components, while allowing for the secure holding and reconfiguration of various parts for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed on a standard welding table, then joining of pieces can be achieved, but weld splatter can contact electrical components causing electrical shorts
Solution Approach 1:
The patent introduces an intermediary protective structure (enclosure or barrier) between the weld splatter and electrical components. This intermediary element intercepts the harmful splatter before it can reach sensitive electrical systems, thereby preventing electrical shorts while allowing the welding process to continue.
Solution Approach 2:
The protective enclosure or barrier is positioned in advance to prevent weld splatter from contacting electrical components. By establishing this protective measure before welding begins, the system proactively counteracts the potential harmful effect of splatter deposition on electrical systems.
2Productivity
If manual handling is used to move parts on the welding table, then parts can be repositioned, but productivity is reduced and human exposure to splatter increases
Solution Approach 1:
The welding table incorporates automated mechanisms (such as robotic arms, conveyors, or automated positioning systems) that enable parts to be moved and repositioned automatically without human intervention. The system serves itself by performing the material handling tasks that would otherwise require manual labor, thereby increasing productivity while reducing human exposure to weld splatter.
3Productivity
If automated assembly is implemented, then productivity increases, but weld splatter can cause electrical shorts requiring production pause
Solution Approach 1:
Protective enclosures or barriers are introduced as intermediary elements that shield electrical components from weld splatter in automated assembly systems. This allows continuous automated operation without production pauses for cleaning or repair, maintaining both high productivity and operational reliability.
Solution Approach 2:
The system incorporates protective measures in advance (such as splatter shields, protective coatings, or enclosed welding chambers) that cushion against the potential harmful effects of weld splatter before it can cause damage. This beforehand protection ensures that automated assembly can proceed continuously without interruption.
4Ease of manufacture
If grounding wires are routed in straight channels, then electrical connection is simple, but weld splatter can easily reach and contact the wires
Solution Approach 1:
The grounding wire channels are designed with curved, serpentine, or meandering paths instead of straight lines. This curvature creates a more complex route that is less susceptible to direct splatter deposition while maintaining electrical connectivity. The curved geometry deflects splatter away from the wire surface.
Solution Approach 2:
The grounding wire routing is moved from a two-dimensional plane to a three-dimensional path, utilizing vertical clearance and lateral offsets to create a more protected route. By elevating the wire or routing it through multiple levels, the system adds dimensional complexity that shields the wire from splatter while preserving electrical function.
Data Source
AI summary
An assembly and joining table with weld splatter protection features are disclosed along with systems and methods for operating the same in at least partially automated fashion. The table includes holders positioned about platform providing a work surface. Parts are placed within certain of the holders for joining to create an assembly. The holders include conductive surfaces and recessed channels for wiring. A first end of each channel is located adjacent to a respective conductive surface, a second end is located below the respective conductive surface, and a continuous passageway with a plurality of turns extends between the first and second ends. A controller may operate motors of the table and command operations of robots for material handling and/or joining and a machine vision system to adjustably automate assembly.