Machine Vision Stud Welding on I-Beams Without Manual Alignment

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Solution Overview

Problem

Manual stud welding in steel erection projects is slow, labor-intensive, and prone to worker injuries, increasing construction time and costs due to the need for repetitive bending and alignment of studs and ferrules.

Innovation Solution

A robotically-controlled stud welding system equipped with machine vision that automatically identifies and welds studs at pre-marked sites on beams, using a carriage with an imager and welding assembly to move along the beam, align, and weld studs with precision, reducing manual labor and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual techniques are used for feeding and aligning studs and ferrules, then the process requires repeated bending and alignment operations, but this increases construction time and leads to worker injuries

Engineering Contradiction:

Improvemanual operationVSAvoidwelding speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical system with an automated robotic system. The robotic arm with gripper automatically feeds studs and ferrules to the welding position, eliminating the need for manual bending and alignment operations. The system uses computer control to position components precisely, substituting human mechanical actions with automated mechanical and electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system performs all feeding, aligning, and welding operations autonomously. The controller automatically coordinates the robotic arm movements, gripper operations, and welding sequence without requiring manual intervention for each stud installation, enabling the system to serve itself through programmed automation.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If manual techniques are used for feeding and aligning studs and ferrules, then workers can perform the tasks, but this increases construction time and costs

Engineering Contradiction:

Improvemanual operationVSAvoidconstruction time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system operates continuously without interruption for each stud installation. The automated sequence of gripping, positioning, placing, and welding occurs in rapid succession without the delays inherent in manual operations, maintaining continuous productive action throughout the welding process.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If manual techniques are used for feeding and aligning studs and ferrules, then workers can complete the welding, but this leads to frequent worker injuries

Engineering Contradiction:

Improvemanual operationVSAvoidworker injuries

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

4Productivity

If automated robotic welding is implemented, then construction time and costs are reduced, but the system complexity increases

Engineering Contradiction:

Improvewelding speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic system is designed to perform multiple functions: gripping studs and ferrules, positioning them precisely, placing them on the beam, and executing the welding sequence. The single robotic arm with programmable controller handles all these operations, eliminating the need for separate manual operations and reducing overall system complexity despite the automation capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Ease of operation

If automated robotic welding is implemented, then manual labor is minimized, but the initial system cost increases

Engineering Contradiction:

Improveautomation levelVSAvoidsystem cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

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

The system significantly reduces construction time and costs by automating the welding process, enhancing safety by minimizing manual labor and repetitive bending, and ensuring precise alignment and welding of studs at predefined sites.

Implementation Method 1

at least one imager connected to the carriage, the imager being operably configured to capture a plurality of images of the surface of the beam

Methodology Applied

Scientific EffectImage capture: Photography

Implementation Method 2

at least one welding assembly attached to the carriage... to automatically place and weld a stud to the surface of the beam

Methodology Applied

Scientific EffectArc welding: Electric Arc

Data Source

PatentUS12076826B2Machine vision robotic stud welder

Publication Date: 2024.09.03 STRUCTURAL SERVICES INC

AI summary

The present disclosure teaches systems and methods for robotic welding of studs onto the surface of I-beams. These systems and methods will find industrial applicability in, for example, the steel erection industry.