Reusable Stud Welding Ferrule for Automated Site Positioning
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Solution Overview
Problem
Conventional arc welding technologies face challenges in using reusable ferrules that can withstand high temperatures and maintain mechanical strength, while also efficiently identifying and positioning welding sites without manual intervention, leading to increased labor costs and inefficiencies.
Innovation Solution
A robotic stud welding apparatus with a three-axis stud positioning system and a reusable ferrule composed of refractory ceramic materials like BN—ZrO2—SiC, which automatically positions and closes around the stud, using solenoids and extension springs for control, and an imaging system to identify suitable welding sites on the base metal surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ceramic ferrules are used for each weld, then the weld is properly contained and protected, but the labor cost and time increase due to manual positioning and removal of each ferrule
Solution Approach 1:
The ferrule is divided into two separate sections that can be independently positioned and closed around the stud. This segmentation allows the ferrule to be reused across multiple welding operations while maintaining proper containment and protection for each individual weld.
Solution Approach 2:
The ferrule sections are equipped with automatic closing mechanisms that enable them to self-position and self-close around the stud without manual intervention. This eliminates the need for operators to manually place and remove ferrules for each weld, significantly improving productivity while maintaining weld quality.
2Productivity
If a reusable ferrule is implemented, then labor costs are reduced, but the ferrule must withstand repeated high-temperature exposures which challenges material durability
Solution Approach 1:
The ferrule sections are constructed from composite materials that combine refractory ceramics with metal reinforcement structures. This composite construction provides both the high-temperature resistance needed for repeated welding exposures and the mechanical strength required for durability during reuse cycles.
Solution Approach 2:
The ferrule design incorporates features that allow it to adapt to varying thermal and mechanical conditions across multiple welding operations. The material properties and structural parameters are optimized to maintain integrity under repeated thermal cycling and mechanical stress.
3Manufacturing precision
If manual ferrule positioning is used, then precise alignment can be achieved, but the process is time-consuming and increases labor requirements
Solution Approach 1:
The manual mechanical positioning process is replaced with an automated system using solenoids and extension springs to position and close the ferrule sections. This mechanical automation maintains precise alignment while eliminating the time-consuming manual operations.
Solution Approach 2:
The ferrule sections are pre-positioned in an open state before the welding operation begins. This preliminary positioning allows the welding process to start immediately without waiting for manual ferrule placement, reducing cycle time while ensuring proper alignment is achieved through the automated closing mechanism.
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 solution enables efficient, automated welding with reduced labor costs by maintaining ferrule integrity and accuracy in site identification, ensuring consistent weld quality and increased productivity.
Implementation Method 1
Activating the welder initiates a pilot arc between the bottom area of the stud shank and the base metal surface for a short amount of time after which a large welding current is then permitted to flow. As the large welding current flows a high temperature arc is produced which melts both the bottom of the stud shank and the surface of the base metal forming a pool of molten metal.
Implementation Method 2
Each bracket is further spring-ably biased in an outward direction away from the shank of the stud by an extension spring.
Data Source
AI summary
A system for automatically identifying one or more welding site locations on a surface of a target metal marked with a plurality of welding site candidates, includes an imager configured to acquire an image of the surface of the target metal, wherein the acquired image includes a plurality of pixels each having a corresponding intensity value; and a processing circuit configured to: compare each intensity value to an intensity threshold, identify a plurality of pixel clusters, wherein each pixel cluster is made up of contiguous pixels that have intensity values that are equal to or greater than the intensity threshold, for each pixel cluster, determine whether a total pixel area of the pixel cluster is less than a threshold pixel area, and remove any pixel cluster from consideration as a welding site location if the total pixel area of the pixel cluster is less than the threshold pixel area.