Mobile Collaborative Robot Welding for Large Structure Deployment
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Solution Overview
Problem
Current welding technologies are costly, bulky, and require specialized training, making them inaccessible to smaller manufacturers and less experienced operators, while also posing challenges in remotely deploying robots for welding large structures due to high capital investment and labor requirements.
Innovation Solution
A highly-mobile, remotely deployable collaborative robot fabrication system that allows intuitive programming and operation, featuring a movable skid supporting a collaborative robot arm, enabling welding or cutting operations on large structures without extensive training or significant capital expenditures, and includes a user interface for graphical programming and magnetic attachments for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional automated welding systems are used, then weld quality and consistency are improved, but system cost and complexity increase significantly
Solution Approach 1:
The system divides the welding automation function into a portable robotic unit that can be separated from fixed infrastructure. The robotic welding system is mounted on a mobile platform with its own power supply and control systems, allowing it to be transported and deployed independently rather than being part of a large fixed automated welding cell.
Solution Approach 2:
The portable robotic welding system includes integrated power supplies, control systems, and welding equipment that operate autonomously without requiring connection to fixed factory infrastructure. The system serves itself with onboard resources, eliminating the need for complex external support systems.
2Productivity
If traditional robot welding systems are used, then welding productivity is improved, but capital investment and deployment cost increase
Solution Approach 1:
The system transitions from static, fixed robot welding cells to a dynamic, mobile robotic platform that can be moved between different work locations. This mobility allows the system to adapt to various production environments and job sites without requiring expensive installation and reinstallation of fixed systems.
Solution Approach 2:
The portable robotic welding system represents a lower-cost alternative to traditional fixed automation systems. By using commercially available collaborative robots and integrating them with portable power and control systems, the overall capital investment is reduced compared to custom-built fixed automation cells.
3Manufacturing precision
If specialized welding training is required, then weld quality is improved, but operator availability and ease of operation decrease
Solution Approach 1:
The system replaces skilled manual welding operations with automated robotic welding. The robotic system executes welding tasks based on programmed parameters and sensor feedback, eliminating the need for highly skilled welders while maintaining consistent weld quality. Operators with basic technical training can program and monitor the robotic system.
4Manufacturing precision
If fixed robot welding systems are used, then welding precision is improved, but mobility and adaptability decrease
Solution Approach 1:
The portable robotic welding system is designed to perform multiple welding tasks across different locations and applications. The mobile platform can be configured for various welding processes and adapted to different workpiece types, providing universal functionality that fixed systems cannot match.
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
Enables efficient and high-quality welding or cutting operations on large structures with reduced labor and capital costs, allowing less experienced operators to set up and operate the system, thereby addressing the shortage of skilled welders and improving productivity in high mix, low volume production environments.
Implementation Method 1
The movable base is releasably secured to a separate platform or skid
Data Source
AI summary
A highly-mobile remotely deployable programmable collaborative robot fabricating system for the assembly, construction, fabrication, and/or the completion of weldments on large structures in difficult to access or elevated locations and a method of deploying the system.