Quick-Change Robotic Coupling With Tapered Locking Adapters
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Solution Overview
Problem
Conventional couplers for robotic welding systems are difficult, time-consuming, and labor-intensive to install or replace, leading to significant interruptions and downtime due to collisions and component damage.
Innovation Solution
Quick change robotic coupling systems and adapters that include insulating adapters with tapered extensions and intermediate locks, allowing for simplified disassembly and reassembly, reducing downtime and complexity in replacing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional couplers are used to couple robotic manipulators to welding torches, then the coupling is secure and reliable, but the installation and replacement process is difficult, time-consuming, and labor-intensive
Solution Approach 1:
The coupling system is divided into separate modular components: a coupler body, a coupling element, and a locking mechanism. These segments can be independently assembled and disassembled, enabling quick replacement of the coupling element without replacing the entire coupler assembly, thus reducing downtime while maintaining secure coupling.
Solution Approach 2:
The locking mechanism incorporates movable locking elements that can be quickly engaged and disengaged through actuation. This dynamic feature allows the coupling to be rapidly secured or released, transforming a static, time-consuming manual assembly process into a dynamic, quick-change operation that minimizes downtime.
2Stability of the object's composition
If conventional couplers are used, then the coupling provides stable connection, but the replacement process is labor- and material-intensive
Solution Approach 1:
By segmenting the coupler into a reusable body and replaceable coupling elements, the system maintains stable connection through the robust coupler body while allowing easy replacement of only the necessary components, reducing both labor and material costs.
Solution Approach 2:
The locking mechanism is designed to be self-actuating or easily actuated, reducing the need for complex tools and extensive manual labor. The coupling element can be quickly released and replaced through simple actuation, making the replacement process more straightforward and less labor-intensive.
3Reliability
If conventional couplers are used, then the coupling is secure, but the replacement process causes significant interruptions to welding operations
Solution Approach 1:
The dynamic locking mechanism allows for rapid engagement and disengagement of coupling elements, enabling quick replacement that minimizes interruptions to welding operations. The secure locking is achieved through movable elements that can be quickly actuated, maintaining coupling security while preserving productivity.
Solution Approach 2:
Multiple coupling elements can be prepared in advance, allowing for hot-swapping during operations. The preliminary preparation of replacement elements ensures that when a coupling needs to be replaced, a ready-to-install element is available, minimizing downtime and maintaining welding operation continuity.
Data Source
AI summary
A quick change coupling system configured to couple components of a welding system comprises: a first adapter comprising a first tapered extension extending from a first outside diameter of the first adapter, the first tapered extension defining a second outside diameter of the first adapter greater than the first outside diameter of the first adapter; a second adapter comprising a second tapered extension extending from a third outside diameter of the second adapter, the second tapered extension defining a fourth outside diameter of the second adapter greater than the third outside diameter of the second adapter; and an intermediate lock configured to couple the first adapter and the second adapter by fastening the first tapered extension of the first adapter together with the second tapered extension of the second adapter.