Probe-Guided Welding Head Positioning for Narrow Curved Gaps
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Solution Overview
Problem
Existing automatic welding technologies face challenges in welding narrow and curved joints with small radii or non-circular outlines, particularly in gaps with parallel surfaces close to each other, where the existing solutions are inadequate for precise and efficient welding.
Innovation Solution
A welding device with adjustable probe and welding heads that can be angled and controlled automatically or manually to match the geometry of the joint, equipped with sensor members and a flux channel to measure and adapt to the gap dimensions, allowing precise application of weld material in narrow and curved joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rotary arc-welding apparatus with a rotatable nozzle is used to weld circular joints, then the welding capability for circular joints is improved, but the device complexity increases and it cannot handle narrow gaps with very small radii
Solution Approach 1:
The welding device is divided into two independent functional modules: a probe head for measurement and a welding head for welding. This segmentation allows each module to be optimized independently, simplifying the overall device while maintaining versatility for different joint types including narrow circular gaps.
Solution Approach 2:
The probe head is designed to be universally applicable for measuring various joint geometries (circular, non-circular, different radii) before welding. This multi-functional probe head eliminates the need for specialized nozzles for different joint types, reducing device complexity while maintaining adaptability.
2Manufacturing precision
If the joint radius is reduced to create narrower gaps, then the welding precision is improved, but the accessibility of the welding nozzle becomes difficult
Solution Approach 1:
The probe head performs preliminary measurement of the gap geometry before the welding head executes the welding operation. This preliminary action allows the system to plan the welding approach in advance, ensuring the welding head can access narrow gaps effectively while maintaining precision.
Solution Approach 2:
The probe head provides real-time feedback about the gap dimensions and geometry to the control system. This feedback enables dynamic adjustment of the welding head's position and parameters, allowing precise welding in narrow gaps while maintaining ease of operation through automated compensation.
3Device complexity
If manual adjustment of the probe head angle is used, then the device complexity is reduced, but the adaptability to complex curved joints deteriorates
Solution Approach 1:
The probe head's angular position is made dynamically adjustable rather than fixed. The first adjustment means enable the probe head angle to be varied during operation to match different joint geometries, providing adaptability to complex curved joints while keeping the adjustment mechanism relatively simple.
Solution Approach 2:
The system changes the angular parameter of the probe head based on the measured joint geometry. By varying this parameter according to the specific joint requirements, the device achieves high adaptability to different curved joint types without requiring complex mechanical structures.
4Adaptability or versatility
If automatic control means are used to vary the probe head angle adaptively, then the adaptability to complex joints is improved, but the device complexity and cost increase
Solution Approach 1:
The probe head automatically measures the joint geometry and the control system automatically adjusts the probe head angle based on these measurements. This self-service capability provides high adaptability to complex joints while keeping the control architecture relatively simple and cost-effective.
Solution Approach 2:
Manual mechanical adjustment of the probe head angle is replaced with automatic control based on sensor measurements. This substitution provides adaptability to complex joints through automated decision-making rather than complex mechanical linkages, reducing overall device complexity.
Data Source
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AI summary
A welding device applies weld material between two work pieces (P1, P2) so as to connect the work pieces (P1, P2) mechanically with one another. The welding device has a welding head (110) and a probe head (120). The welding head (110) performs a welding action in respect of the work pieces (P1, P2) during transport of the welding device along an operating direction (OD) in a welding plane (WP); and the probe head (120), which is arranged upstream of the welding head (110) relative to the operating direction (OD), measures a set of geometric properties of a gap (G) between the work pieces (P1, P2). Thus, the welding head (110) can be properly positioned to attain a desired application of the weld material in the gap (G). Moreover, first adjustment means allow a position of the probe head (120) relative to a position of the welding head (110) to be varied angularly by rotating at least one of the probe head (120) and the welding head (110) around a first axis (A1 ) oriented essentially perpendicular to the welding plane (WP). Thereby, welding in narrow and curved gaps (G) is facilitated.