Magnetic Workpiece Conveyor for Precise Welding Cell Orientation

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Solution Overview

Problem

Conveyor systems used in welding operations face challenges in accurately locating and orienting workpieces, particularly those without holes, leading to lengthy setup times and potential safety hazards due to exposed drive elements.

Innovation Solution

A conveyor system utilizing discrete magnets beneath a non-magnetic static bed to magnetically drag and orient ferrous workpieces along a flow path, with adjustable magnet positioning and guide rails to ensure precise orientation and unloading, eliminating the need for pins and reducing setup time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pin-type conveyor with exposed drive elements is used, then workpiece locating is achieved, but safety hazards increase and setup time lengthens

Engineering Contradiction:

Improveworkpiece locating accuracyVSAvoidsafety hazards from exposed pins

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical pin-based drive system with a magnetic field-based system. Discrete magnets mounted on a moving belt create magnetic forces that drag ferrous workpieces along the conveyor path without any physical contact between the drive mechanism and workpiece, eliminating exposed mechanical elements while maintaining reliable workpiece movement and positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary between the conveyor drive system and the workpiece. The magnetic field acts as a non-contact mediator that transfers motion from the moving belt to the workpiece through magnetic attraction, allowing force transmission without physical contact and thus eliminating safety hazards from exposed mechanical parts.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If complicated locating features are incorporated, then workpiece positioning accuracy improves, but setup time increases

Engineering Contradiction:

Improveworkpiece positioning accuracyVSAvoidsetup time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent changes the fundamental operating parameter from mechanical engagement (pins requiring precise hole alignment) to magnetic field interaction. The magnetic field strength, pole orientation, and spacing can be adjusted to accommodate different workpiece configurations without physical reconfiguration of locating features, enabling rapid setup while maintaining positioning accuracy.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The magnetic conveyor system serves multiple functions: it provides workpiece movement, positioning, and orientation simultaneously through the magnetic field interaction. The same magnetic poles that provide the dragging force also create the positioning and orienting effects, eliminating the need for separate complicated locating features and reducing setup time.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If workpieces without holes are conveyed, then adaptability to different workpiece configurations improves, but locating capability deteriorates

Engineering Contradiction:

Improveworkpiece configuration compatibilityVSAvoidworkpiece locating capability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces the mechanical hole-based locating system with a magnetic field-based system. The magnetic field interacts directly with the ferrous material of the workpiece body itself, eliminating the requirement for holes or protruding features. This provides universal compatibility with any ferrous workpiece configuration while maintaining reliable locating and positioning capability through magnetic attraction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 magnetic conveyor system enhances safety by avoiding exposed drive elements, minimizes setup time, and ensures consistent workpiece orientation, allowing for efficient robotic picking and welding operations without workpiece-specific tooling, while accommodating a wide range of workpiece configurations.

Implementation Method 1

The drive includes multiple discrete magnets configured to move in a direction of the workpiece flow path

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS11305948B2Magnetic workpiece conveyor for robotic welding cell

Publication Date: 2022.04.19 DOBEN LTD

AI summary

A conveyor for ferrous workpieces includes a frame. A static bed is affixed to the frame. The static bed has a workpiece support portion constructed from a non-magnetic material. The workpiece support portion defines a workpiece flow path. A drive assembly is arranged beneath the workpiece support portion. The drive includes multiple discrete magnets configured to move in a direction of the workpiece flow path. At least one guide rail extends upward with respect to the workpiece support portion on a side opposite the drive assembly. The guide rail is configured to orient a workpiece to a desired position with respect to the workpiece flow path.