Motion-Assist Welding Torch for Evenly Spaced Tack Welds
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Solution Overview
Problem
The welding industry faces challenges due to a shortage of skilled welders, ergonomic issues in tack welding, and the difficulty of automated systems in adapting to confined spaces and varying workpieces, particularly in high-mix, low-volume applications, where traditional automation is costly and inefficient.
Innovation Solution
A motion-assist, point-and-shoot weld torch system that automates the welding process while allowing manual movement of the weld tool, enabling the creation of evenly spaced overlapping spot welds with adjustable wire feed speed and weld current, reducing operator skill requirements and improving ergonomics by allowing tack welding in a standing position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated welding systems are used, then welding precision and consistency are improved, but device complexity and cost increase significantly
Solution Approach 1:
The automated welding system is segmented into modular components: a control unit, a motion assist mechanism with linear actuator, and a standard welding torch. This segmentation allows the system to achieve automated precision while keeping individual components simple and interchangeable, reducing overall device complexity.
Solution Approach 2:
The motion assist mechanism automatically adjusts the torch position and movement speed based on pre-programmed parameters, eliminating the need for complex manual operation. The system serves itself by automatically compensating for position variations and maintaining consistent weld quality without requiring highly skilled operators.
2Productivity
If traditional automated welding robots are used, then productivity is improved, but adaptability to confined spaces and varying workpieces deteriorates
Solution Approach 1:
The system employs a dynamic motion assist mechanism that can adapt its movement characteristics in real-time. The linear actuator can adjust stroke length, speed, and positioning based on the specific workpiece geometry and weld requirements, enabling the system to work in confined spaces and on varying workpieces while maintaining productivity.
Solution Approach 2:
The system allows easy modification of operational parameters such as travel speed, dwell time, and torch positioning through software configuration rather than physical reconfiguration. This enables rapid adaptation to different workpieces and weld types, improving versatility without sacrificing automated productivity.
3Manufacturing precision
If manual welding is performed by skilled welders, then weld quality is improved, but labor cost and operator availability worsen due to skill shortage
Solution Approach 1:
The system embeds welding expertise into the automated control software and motion assist mechanism, which automatically perform tasks that previously required skilled judgment. This allows less trained operators to achieve consistent weld quality, effectively transferring skill from human operators to the automated system and increasing operator availability.
4Temperature
If pulse welding process is used on conventional machines, then heat input is reduced, but wire burn-back occurs when welding out of position
Solution Approach 1:
The motion assist mechanism incorporates sensors and control algorithms that provide real-time feedback on torch position, wire feed rate, and welding parameters. This feedback loop allows the system to dynamically adjust wire feed speed and pulse timing to prevent burn-back, even when welding in out-of-position orientations, while maintaining low heat input through pulsed 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
This solution provides cost-effective, high-quality welding with reduced heat input, enabling low-skilled workers to perform welds efficiently and safely, improving productivity and reducing ergonomic strain and healthcare costs.
Implementation Method 1
a solenoid assembly is configured to move a contact tip from a first position to a second position
Implementation Method 2
making a linear weld... Join Solid
Data Source
AI summary
An example system includes: a hand-held welding tool that is manually placed in a welding position, wherein the hand-held welding tool is configured to be activated to cause a contact tip or a welding heat source to automatically move from a first position and to second position during a welding operation, and wherein a welding arc is automatically and repeatedly turned off and on while the contact tip or the welding heat source moves from the first position to the second position to make a plurality of welds between the first position and the second position, wherein, as a travel speed decreases, a time period between each arc on time increases to make equally spaced welds.