Robot Feeder Positioning for Welding Wire Interference
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Solution Overview
Problem
Existing arc welding robots face challenges in efficiently feeding welding wire due to interference with workpieces and jigs, leading to disturbances in the feeding operation and limitations in taking various welding postures.
Innovation Solution
A robot design with a feeder positioned between the base end and tip end of the forearm, intersecting with the R axis, which supports the wrist arm and flange, allowing the welding torch to rotate about a T axis, preventing interference and enabling flexible welding postures while maintaining efficient wire feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feeder is positioned at the conventional location (tip of wrist arm or near torch), then the wire feeding path is short and responsive, but the feeder interferes with workpieces and jigs causing feeding disturbances
Solution Approach 1:
The feeder is extracted from the conventional location near the torch or wrist arm tip and repositioned to the forearm. This spatial extraction removes the feeder from the interference zone with workpieces and jigs, eliminating feeding disturbances while preserving the wire feeding function through the cable routing system.
Solution Approach 2:
The wire feeding path is extended into a different spatial dimension by routing the cable from the forearm-mounted feeder through the wrist arm to the torch. This dimensional change in the feeding path allows the feeder to be positioned away from interference zones while maintaining functional connectivity.
2Adaptability or versatility
If the feeder is repositioned to avoid interference, then welding posture flexibility improves, but the wire feeding path becomes longer and more complex
Solution Approach 1:
The wrist arm serves as an intermediary component that routes the wire cable from the forearm-mounted feeder to the torch. This intermediary structure allows the feeder to be positioned for optimal welding posture flexibility while the wrist arm's natural articulation handles the cable routing, minimizing additional complexity.
Solution Approach 2:
The wrist arm performs multiple functions: it supports the flange and torch, enables wrist articulation for positioning, and simultaneously serves as a cable routing channel for the wire feeding path. This multi-functionality avoids adding dedicated cable management components, keeping the system complexity low.
3Object-affected harmful factors
If the feeder is mounted on the forearm, then interference with workpiece is reduced, but the distance from feeder to torch increases affecting feeding responsiveness
Solution Approach 1:
A flexible cable connects the feeder on the forearm to the torch at the wrist arm tip. This flexible cable allows the feeder to be positioned away from interference zones while maintaining responsive wire feeding through the cable's ability to accommodate wrist arm movements and maintain tension without rigidity-induced delays.
Data Source
AI summary
A robot according to an embodiment includes a flange, a wrist arm, a forearm, and a feeder. The flange configured so that a welding torch is attached thereto and configured to rotate about a T axis. The wrist arm configured to rotate about a B axis substantially perpendicular to the T axis and configured to support the flange. The forearm configured to support the wrist arm. The feeder attached to a position between a base end and a tip end of the forearm and configured to feed a welding wire.