Rail-guided Clamping Frames for Space-saving Welding Stations
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Solution Overview
Problem
Existing geometry welding stations for motor vehicle bodies-in-white occupy valuable installation space with complex positioning systems, restricting accessibility for welding robots and limiting the number of processing tools that can be used for short cycle times.
Innovation Solution
A rail-guided infeed movement system with mutually cross-braced clamping frames provides precise locking in a space-saving manner, eliminating the need for transport robots and allowing easy placement of welding robots, while enabling the use of multiple clamping frame designs for different body types through a modular and adjustable frame assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex positioning systems (transport robots, manipulators, hoists) are used to move and lock clamping frames, then positioning precision is improved, but installation space is consumed and accessibility for welding robots is restricted
Solution Approach 1:
The patent extracts the complex positioning systems (transport robots, manipulators, hoists) from the processing station and replaces them with a simplified rail-guided infeed movement system. The clamping frames are moved along fixed guide rails using simple infeed mechanisms, eliminating the need for sophisticated positioning equipment while maintaining adequate positioning accuracy for welding operations.
Solution Approach 2:
Instead of using active positioning systems to move clamping frames into place, the patent employs passive positioning where the clamping frames are guided by fixed rails and locked into position by the welding robots themselves or simple locking mechanisms. This inverts the traditional approach by making the clamping frames self-positioning rather than robot-positioned.
2Measurement precision
If complex positioning systems are installed to ensure precise clamping frame positioning, then positioning accuracy is improved, but the number of welding robots that can be accommodated is reduced
Solution Approach 1:
The patent removes complex positioning systems from the station design, freeing up space that can then be utilized for installing additional welding robots. The simplified rail-guided system requires minimal space, allowing the station to accommodate more welding robots for short cycle times and higher productivity.
3Stability of the object's composition
If clamping frames are moved on guide rails and locked on floor-fixed pillars, then positioning stability is improved, but robot work area and accessibility to welding points are significantly restricted
Solution Approach 1:
The patent raises the guide rails and locking mechanisms to elevated positions rather than fixing them to the floor at ground level. This vertical dimensionality change allows welding robots to operate freely at ground level with unrestricted access to welding points, while the elevated rails provide stable guidance and positioning for the clamping frames.
4Stability of the object's composition
If cross braces are used to rigidly couple clamping frames for transport, then transport stability is improved, but the coupling must be removed and reassembled for every body change
Solution Approach 1:
The patent segments the cross braces into separate, modular components that can be independently positioned and coupled. This segmentation allows the cross braces to be quickly assembled and disassembled without requiring complete removal and reassembly of the entire coupling system, reducing changeover time when switching between different body types.
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 increases installation space for processing tools, enhances accessibility to body parts, and allows for efficient use of welding robots, achieving high shear rigidity and flexibility in accommodating various body types with reduced adjustment paths and play in the coupling area.
Implementation Method 1
The clamping frames are mounted movably on the guides via low-backlash roller cages
Implementation Method 2
these can each be provided with a centering cone and mechanically locked in the working position of the clamping frame
Data Source
AI summary
In a machining station and in particular a geometrical welding station for motor vehicle body shells, with vices (3.1, 3.2), which are arranged on both sides of the bodywork conveying system and are moveable from a standby position into a working position fixed exactly with respect to the body shell in order to position bodywork side parts transversely with respect to the conveying direction of the conveying system, the installation space for the transporting and locking system for the vices (3.1, 3.2) is significantly reduced according to the invention, without impairing the positionally precise fixing of the vices (3.1, 3.2) in the working position, by the vices (3.1, 3.2) being mounted in a linearly moveable manner in the lower edge region on guides (5.1, 5.2) running transversely with respect to the conveying direction of the conveying system and, in the working position, being positioned at stationary fixing points (6) on the floor and being joined to each other at least in the upper edge region via a plurality of transverse struts (7.1....7.4) mounted on the vices and via associated coupling parts (10A, 10B), which engage in each other when the vices (3.1, 3.2) are moved together and are connected rigidly to each other, to form a frame assembly which is resistant to shearing in the transverse direction.