Motion-Assist Welding Torch for Flexible Automated Weld Travel
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Solution Overview
Problem
The welding industry faces challenges due to a shortage of skilled welders, with manual welding being ergonomically taxing and prone to errors, and existing automation solutions being costly, difficult to adapt, and limited in flexibility, especially for confined spaces and large workpieces.
Innovation Solution
A low-cost, motion-assist, point-and-shoot welding torch system that automates the welding operation while allowing manual movement of the weld tool between locations, providing ergonomic improvements and enabling operators with varying skill levels to perform high-quality welds by automating torch movements, including wire placement, torch angle, and travel speed, with features like solenoid-assisted arc start and multi-axis motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated welding robots are used, then welding consistency and speed are improved, but cost and system complexity increase significantly
Solution Approach 1:
The welding system is segmented into independent functional modules: a handheld torch assembly, a wire feeder unit, and a control system. This modular segmentation allows the complex welding automation functions to be distributed across separate components, reducing the complexity burden on any single device while maintaining overall system productivity.
Solution Approach 2:
The system incorporates self-regulating features where the wire feeder automatically controls wire feed speed based on arc voltage feedback, and the torch assembly maintains consistent arc length through automated wire extension control. This self-service capability reduces the need for complex manual intervention and simplifies operator tasks while preserving welding consistency.
2Productivity
If traditional robotic automation is implemented, then skilled welder shortage is addressed, but adaptability to part variations and confined spaces deteriorates
Solution Approach 1:
The system employs dynamic adjustment capabilities where welding parameters such as wire feed speed, travel speed, and arc voltage can be modified in real-time based on feedback from the welding process. This dynamic responsiveness allows the system to adapt to variations in part fit-up and geometry without requiring complex reprogramming, maintaining productivity while improving versatility.
Solution Approach 2:
The system utilizes parameter change strategies where key welding parameters (current, voltage, wire feed speed) are adjusted based on detected conditions such as arc length, travel speed, and material thickness. This parameter adaptation enables consistent welding quality across varying part configurations and confined spaces without sacrificing productivity.
3Ease of operation
If manual welding is performed, then flexibility and low cost are maintained, but operator fatigue and weld quality consistency worsen
Solution Approach 1:
The system incorporates feedback mechanisms where arc voltage, wire feed speed, and travel speed are continuously monitored and adjusted to maintain consistent welding parameters. This feedback control ensures uniform weld quality while the handheld torch design preserves operator flexibility and ease of operation in various positions and configurations.
Solution Approach 2:
The system replaces manual mechanical control of wire feed and torch movement with automated mechanisms. The wire feeder uses motorized control instead of manual cranking, and the torch assembly incorporates automated wire extension control. This substitution reduces operator physical fatigue while maintaining the flexibility of handheld operation, improving weld consistency without sacrificing ease of 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 system enhances welding productivity and quality by reducing operator fatigue, allowing unskilled workers to perform tack and short welds with minimal training, and offers flexible automation that surpasses manual welding in consistency and speed, while being cost-effective and adaptable to various welding tasks.
Implementation Method 1
a solenoid assembly configured to move the contact tip from a retracted position to an extended position
Data Source
AI summary
Hybrid manual and automated welding systems and methods are described. A hand-held welding tool is manually positioned to engage a workpiece. A weld is started from an initial position based on a first manual operator event. A welding heat source is automatically or autonomously moved along the weld relative to the workpiece from the first position to a second position relative to the workpiece during welding.