Robot Resistance Welding Rotation Control for Variable Weld Time
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Solution Overview
Problem
Robot-assisted resistance welding processes face inefficiencies due to predefined rotational movement durations, leading to longer process times and potential welding without movement or unnecessarily long movements, especially when welding times are unknown due to varying materials.
Innovation Solution
A method where a robot arrangement performs a rotational movement during electric welding, with the start and end controlled by detected or commanded welding events, and the direction of rotation changed based on predefined parameters during contact, ensuring a sufficient and optimized rotational movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the duration of rotational movement is predefined in advance according to maximum welding time, then welding without rotational movement is avoided, but process times become longer
Solution Approach 1:
The control system continuously monitors the actual welding time and adjusts the rotational movement duration based on detected welding parameters and material characteristics, rather than using a fixed maximum time. This feedback mechanism ensures the rotational movement lasts sufficiently for quality welding without unnecessarily extending the process time.
Solution Approach 2:
The system transitions from a static, predefined rotational movement duration to a dynamic duration that adapts to actual welding conditions. The rotational movement time is adjusted in real-time based on detected welding parameters, material type, and process conditions, optimizing both quality and efficiency.
2Ease of operation
If the rotational movement duration is predefined in advance, then the control is simplified, but the welding result may be compromised when welding time varies
Solution Approach 1:
The control system uses feedback from welding parameters and material detection to automatically adjust the rotational movement duration, maintaining welding quality without requiring complex manual intervention. The system monitors welding conditions and adapts the rotation time accordingly.
Solution Approach 2:
The system performs self-adjustment of the rotational movement duration based on detected welding conditions and material characteristics. The control system automatically optimizes the process parameters without requiring external intervention, ensuring reliable welding results while maintaining operational simplicity.
3Ease of operation
If a fixed predefined rotational movement is used, then the system is simpler to operate, but it cannot adapt to different materials and welding conditions
Solution Approach 1:
The system dynamically adjusts the rotational movement parameters based on detected material type and welding conditions. The control system transitions from fixed parameters to adaptive parameters that automatically respond to different materials and process conditions.
Solution Approach 2:
The system changes operational parameters (rotational movement duration, speed, and characteristics) based on detected welding conditions and material properties. This parameter adaptation enables the system to handle various materials and welding scenarios while maintaining operational simplicity through automatic adjustment.
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 approach improves the welding result by ensuring a sufficiently long rotational movement while avoiding unnecessary extensions or interruptions, thus enhancing the efficiency and effectiveness of the welding process.
Implementation Method 1
a rotational movement is carried out for or during the electric welding of one or more, in particular at least two, workpiece(s) of a workpiece arrangement with the aid of a robot arrangement
Implementation Method 2
the welding is resistance and/or spot welding
Data Source
AI summary
A method for electric welding a workpiece arrangement having at least one workpiece with the aid of a robot arrangement including at least one robot. A rotational movement is carried out between the workpiece arrangement to be welded and at least one welding electrode which contacts the workpiece arrangement. The rotational movement is started as a function of a commanded and/or detected welding start and/or ended as a function of a commanded and/or detected welding end. The direction of rotation of the movement may be changed as a function of a predefined parameter during contact between the welding electrode and the workpiece arrangement.