Robotic Shear Stud Welding With Automated Stud and Ferrule Feeding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current stud welding systems require significant manual labor, leading to inefficiencies and operator fatigue due to the need for manual welding of numerous studs, especially in applications like shear stud installation on beams, where many studs must be welded quickly and accurately.
Innovation Solution
A robotic shear stud welding system comprising a stud feeder, ferrule feeder, controllable arm with a welding gun, and safety features like light curtains and electro magnets, which automates the welding process by accurately positioning and welding studs with reduced operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual welding is used for numerous studs, then welding can be performed with simple equipment, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces the manual mechanical welding system with an automated robotic welding system. The robotic arm equipped with a welding gun automatically performs the welding operation, substituting human labor with automated machinery. This resolves the contradiction by eliminating manual labor intensity while simultaneously increasing welding speed through continuous automated operation.
Solution Approach 2:
The welding system incorporates automatic stud feeding and positioning mechanisms that operate without continuous human intervention. The system feeds studs automatically, positions them precisely, and performs welding cycles autonomously, allowing the process to serve itself and resolve the labor intensity vs. productivity contradiction.
2Device complexity
If manual welding is used, then equipment complexity remains low, but operator fatigue increases and breaks are required
Solution Approach 1:
The manual welding system is replaced with an automated robotic welding system controlled by a computer or programmable logic controller. This substitution increases device complexity but eliminates operator fatigue and enables continuous operation without breaks, thereby improving reliability and operational continuity.
Solution Approach 2:
The robotic system is programmed with pre-defined welding paths, parameters, and sequences before operation begins. This preliminary programming allows the system to execute welding operations automatically without real-time human intervention, maintaining consistent quality and enabling continuous operation that improves reliability despite increased system complexity.
3Productivity
If automated robotic welding is implemented, then productivity and precision increase, but device complexity and initial labor requirements increase
Solution Approach 1:
The robotic welding system is designed with universal capabilities to handle multiple welding tasks, positions, and configurations through reprogramming. The same robotic arm and welding gun can perform various welding operations on different stud types and beam configurations, justifying the increased device complexity through enhanced productivity and versatility.
Solution Approach 2:
The manual welding system is replaced with an integrated automated system comprising robotic arm, welding gun, stud feeder, and control system. This substitution increases device complexity but delivers significant productivity gains through continuous automated operation, precise positioning, and elimination of manual labor bottlenecks.
4Ease of manufacture
If manual welding is used, then setup is simpler, but precision and consistency of stud placement decrease
Solution Approach 1:
The manual welding system is replaced with an automated robotic system that uses sensors, vision systems, or pre-programmed coordinates to achieve precise and consistent stud placement. This substitution increases setup complexity through programming and calibration but delivers superior manufacturing precision and repeatability that cannot be achieved through manual operation.
Solution Approach 2:
The robotic welding system incorporates feedback mechanisms such as sensors, vision systems, or position monitoring that continuously verify stud placement accuracy and welding parameters. This feedback loop allows real-time adjustments to maintain precise and consistent stud placement, resolving the contradiction between setup simplicity and manufacturing precision.
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 robotic system significantly reduces labor and time required for stud welding, enhancing efficiency and reducing operator fatigue by automating the feeding and placement of studs, allowing for faster and more precise welding of multiple studs without manual labor.
Implementation Method 1
Each of the at least two work zones may include an electro magnet configured to be energized to hold the workpiece down after the welding gun shoots the stud on the workpiece
Implementation Method 2
The arc continues for predetermined period of time until portions of the stud and the base plate have been melted
Data Source
AI summary
A robotic shear stud welding system includes a stud feeder, a ferrule feeder, at least one work zone, a robot, and a welding gun. The stud feeder is configured to hold a plurality of studs and feed a single stud therefrom. The ferrule feeder is configured to hold a plurality of ferrules and feed a single ferrule therefrom. The robot has a controllable arm that is configured to accurately move between the stud feeder, the ferrule feeder, and each of the at least one work zones. The welding gun is attached to the distal end of the controllable arm. The welding gun is configured to pick up the single stud from the stud feeder, pick up the single ferrule from the ferrule feeder and position the single ferrule at a bottom of the single stud, and shoot the single stud to a workpiece in one of the at least one work zones.