Magnetic Crawling Welding Robot for Guide-Free Curved Welding
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Solution Overview
Problem
Current welding robots are inadequate for performing welding operations on large and medium-sized flat or curved structural members, requiring high labor intensity, skilled workers, and resulting in inconsistent quality and low productivity due to environmental challenges.
Innovation Solution
A crawling welding robot equipped with an adjustable magnetic adhesion module, wheel-tracked walking mechanisms, and a welding load device, allowing it to crawl on surfaces without guides and adapt to various curvatures, combined with advanced control methods for precise welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual welding operation is performed on large and medium-sized flat or curved structural members, then welding can be carried out, but high labor intensity is involved and the working environment is poor
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated crawling robot system. The robot equipped with welding equipment can autonomously perform welding tasks on large and medium-sized structural members, eliminating the need for workers to manually position themselves in difficult-to-reach areas, thereby improving working conditions while achieving automation.
Solution Approach 2:
The crawling robot is designed to autonomously navigate and position itself on the workpiece surface using its crawling mechanism. The robot can independently move to required welding positions without external assistance, performing welding operations automatically, which reduces labor intensity and improves ease of operation.
2Reliability
If multiple workers cooperate for welding operation on curved surfaces, then welding can be performed, but welding quality cannot be ensured due to many affecting factors
Solution Approach 1:
The patent extracts the welding operation from the complex human coordination system and transfers it to a single automated robot system. By removing multiple workers from the process and replacing them with one controlled robot, the sources of variability and inconsistency are eliminated, ensuring more reliable and consistent welding quality.
Solution Approach 2:
The robot system maintains consistent welding parameters through automated control, eliminating the variations introduced by manual operations. The crawling mechanism allows the robot to maintain optimal welding positions and angles consistently, ensuring uniform welding quality across different locations on the structural member.
3Adaptability or versatility
If articulated welding robots are used, then welding automation is achieved, but they cannot perform welding operations on large and medium-sized flat or curved structural members
Solution Approach 1:
The patent employs a crawling robot mechanism that can dynamically adapt its position and orientation on the workpiece surface. Unlike fixed articulated robots, this crawling system can move freely across large and curved surfaces, maintaining welding capability while achieving high adaptability to different workpiece geometries and sizes.
Solution Approach 2:
The crawling robot is designed as a universal welding system that can perform welding operations on various types of structural members including large flat surfaces and curved surfaces. The multi-functional crawling mechanism allows a single robot to handle diverse welding applications that would otherwise require multiple specialized systems.
4Productivity
If manual welding is performed on large structural members, then welding operation can be carried out, but productivity is low due to high labor intensity and coordination requirements
Solution Approach 1:
The crawling robot autonomously navigates to welding positions and performs operations without requiring coordination among multiple workers. The self-service capability of the robot eliminates the organizational complexity of managing multiple workers while significantly improving welding productivity through continuous automated operation.
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 robot significantly reduces auxiliary welding time, enhances productivity, and ensures high-quality welding on large and medium-sized structural members by maintaining stable adhesion and precise tracking of weld seams, with the ability to operate on both flat and curved surfaces.
Implementation Method 1
an adjustable magnetic adhesion module, disposed on the crawler frame and disposed between the two wheel-tracked walking mechanisms
Data Source
AI summary
A crawling welding robot, including an adjustable magnetic adhesion module, wheel-tracked walking mechanisms, a crawler frame, and a welding load device, wherein the welding load device is disposed on the crawler frame; the wheel-tracked walking mechanisms are disposed at two opposite ends of the crawler frame for supplying power for crawling of the crawler frame; and the adjustable magnetic adhesion module is disposed on the crawler frame and disposed between the two wheel-tracked walking mechanisms.