Compact Robot Welding Head with Nested Harnessing
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Solution Overview
Problem
Existing electric spot welding heads for multi-axis industrial robots face issues with compactness and protection of cables and pipes from interference and deterioration due to exposure to aggressive agents in industrial environments, leading to frequent replacements and reduced productivity.
Innovation Solution
The welding head design features a compact transformer configuration with output poles arranged on different walls, and a casing that completely encloses the structure, with cables and pipes integrated within the robot's passage, eliminating external exposure and using quick connectors for fluid supply pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the output poles of the transformer are arranged on different walls (one on front wall, one on end wall), then the longitudinal dimension of the welding head is reduced, but the internal space arrangement becomes more complex
Solution Approach 1:
The transformer output poles are arranged on different walls of the transformer casing rather than on the same wall or opposite walls. Specifically, one output pole is positioned on the front wall and the other on an end wall, utilizing three-dimensional space efficiently. This spatial arrangement allows the linking strips to connect to electrode-holding arms from different directions, reducing the longitudinal dimension of the welding head while maintaining functional connectivity.
2Ease of manufacture
If cables and pipes are exposed externally for connection to the welding head, then installation and maintenance become easier, but they are vulnerable to interference from foreign bodies and aggressive agents (welding splatter, dirt)
Solution Approach 1:
The cables and pipes for power supply and fluid supply are routed through the internal passage of the robot wrist and integrated directly into the welding head structure. The harnessing is nested within the robot's own structure rather than being external, protecting it from exposure to welding splatter, dirt, and other aggressive agents in the industrial environment. This nested arrangement eliminates the need for separate external cable management while ensuring protection.
3Duration of action of stationary object
If the harnessing is protected from external exposure, then its lifespan is extended, but the complexity of integrating cables and pipes through the robot structure increases
Solution Approach 1:
The robot wrist structure serves multiple functions: it provides mechanical support for the robot arm, defines a continuous internal passage for cable and pipe routing, and integrates directly with the welding head mounting flange. By making the robot wrist multi-functional, the design protects the harnessing from external damage while avoiding the need for separate protective structures or complex external cable management systems.
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 design significantly extends the lifespan of the harnessing from 1.5-2 years to 8-10 years, reducing replacement frequency and maintaining productivity, while maintaining ease of maintenance and compatibility with various robot types.
Implementation Method 1
two output poles of the transformer, connected electrically to the two electrode-holding arms
Implementation Method 2
a casing with a rear wall facing the rear end portion for attachment to the robot wrist, a front wall opposite the rear wall, two side walls parallel to a general plane defined by the two electrode-holding arms and two end walls
Implementation Method 3
through the chain of mutually articulated robot elements and through the robot wrist an internal continuous passage is defined where one or more cables and/or pipes for the power supply and/or the fluid supply to the tool are received
Data Source
AI summary
An electric spot welding head for a multi-axis industrial robot that has a compact configuration, particularly in a longitudinal direction that goes from the end of the head for the attachment to the robot wrist towards the welding electrodes. This result is achieved primarily by the fact that the electrical transformer mounted on the head has its output connected to the electrode-holding arms arranged, respectively, on a front wall of the body of the transformer and on an end wall of the body of the transformer, for the connection to the electrode-holding arms of the head. The structure of the welding head is completely covered by a casing having a rear opening for connection to the robot wrist and a front opening from which the electrode arms of the welding head protrude.