Optical Welding Alignment for Precise Concentricity Checks
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Solution Overview
Problem
Current welding methods for components like electrohydraulic servo valves in aircraft manufacturing suffer from high scrap rates due to complex clamping device settings and imprecise concentricity measurements using dial gauges, which lack systematic documentation and result in quality control difficulties.
Innovation Solution
A welding device comprising a linear unit, optical measuring unit, and welding unit that enables automated component alignment and measurement, allowing for precise, non-contact optical measurement of components before and after welding, with an optional rotatable optical measuring unit to check concentricity from multiple angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual insertion and rigid clamping device settings are used for component positioning, then component alignment can be achieved, but the setting complexity increases and scrap rate increases
Solution Approach 1:
The patent replaces the mechanical dial gauge measurement system with an optical measurement system using cameras and image processing. The optical unit captures images of components on the linear unit, and concentricity is determined through digital image analysis rather than mechanical contact, eliminating the need for complex mechanical clamping device settings and manual measurement procedures
Solution Approach 2:
The system performs automatic self-measurement and self-positioning. The optical measuring unit automatically captures images of components, determines their positions and concentricity, and the linear unit automatically adjusts component positions based on measured data, eliminating manual intervention and complex setup procedures
2Reliability
If dial gauge measurement with physical contact is used for concentricity testing, then measurement can be performed, but measurement precision deteriorates due to spring force affecting the component
Solution Approach 1:
The patent replaces the mechanical dial gauge with an optical measurement system using cameras that capture images of the component. The concentricity is determined through digital image processing and analysis of component positions in the captured images, eliminating physical contact and the associated spring force that distorts measurements
Solution Approach 2:
The patent introduces light as an intermediary medium for measurement. Instead of direct mechanical contact between the measuring instrument and component, light captures component positions and characteristics, which are then analyzed digitally to determine concentricity, providing non-contact and distortion-free measurement
3Manufacturing precision
If individual manual positioning and repeated clamping device setup are performed for each product change, then component alignment can be achieved, but production time increases
Solution Approach 1:
The patent implements a dynamic, adaptive measurement and positioning system. The optical measuring unit automatically adapts to different components by capturing images and determining positions, and the linear unit dynamically adjusts positioning based on measured data, eliminating the need for manual re-setup when changing products
Solution Approach 2:
The system automatically adapts to different components by changing measurement and positioning parameters based on optical detection. The optical unit captures images of each component type, determines their specific positions and characteristics, and the system adjusts accordingly without manual intervention, enabling rapid product changeovers while maintaining precision
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 approach reduces scrap rates by ensuring precise component alignment and accurate concentricity testing, facilitating fully automatic welding with improved documentation and reduced production time, while avoiding measurement inaccuracies from physical contact.
Implementation Method 1
an optical measuring unit (2) comprising a detection region directed onto a portion of the linear unit (1) in order to measure a component placed on the linear unit (1)
Data Source
AI summary
The disclosure relates to a welding device for welding components which comprises a linear unit that is configured for moving a component placed thereon back and forth along one direction, an optical measuring unit comprising a detection region directed onto a portion of the linear unit in order to measure a component placed on the linear unit, and a welding unit which is configured for lifting a first component, optionally a sphere, from the linear unit and, after displacement of the linear unit, for welding it to a second component, optionally a wire, placed in the detection region.