Robotic Welding Tip Changer for Burnback Recovery
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Solution Overview
Problem
The existing methods for replacing welding tips in robotic welders require manual intervention, which is hazardous, time-consuming, and disrupts the manufacturing process, especially when dealing with burnback issues, leading to productivity losses and calibration needs.
Innovation Solution
An automated system that includes a fixture with stations for removing and attaching welding tips, using sensors and motors to clamp, release, and cut the tips, along with holding units for unused tips, allowing for automated replacement without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tip replacement is performed, then the contact tip can be replaced, but the repair person is exposed to safety risks and the process consumes significant labor time
Solution Approach 1:
The system performs self-service by automatically detecting burnback conditions and replacing the contact tip without human intervention. The robotic arm executes the replacement sequence autonomously, eliminating the need for repair personnel to enter the work cell and manually replace tips, thus resolving both safety risks and time consumption issues
Solution Approach 2:
The patent replaces the manual mechanical tip replacement process with an automated robotic system. The robotic arm, equipped with specialized end effectors and control systems, substitutes human operators in performing the tip replacement task, achieving both safety improvement and time reduction through automated control
2Ease of manufacture
If manual tip replacement is performed, then the contact tip can be replaced, but the robotic welder settings or angle may be disturbed requiring re-calibration
Solution Approach 1:
The automated system performs self-service by precisely controlling the tip replacement process through programmed robotic movements. The system maintains welding torch alignment and angle by executing calibrated replacement sequences, eliminating the disturbance to settings that occurs with manual replacement and avoiding the need for re-calibration
Solution Approach 2:
The system incorporates feedback mechanisms through sensors that detect tip position, burnback conditions, and torch alignment during the replacement process. This feedback enables real-time adjustments to maintain manufacturing precision and ensures the robotic welder remains properly calibrated after tip replacement
3Productivity
If automated tip replacement is implemented, then safety risks are eliminated and productivity is enhanced, but the device complexity increases
Solution Approach 1:
The robotic arm system performs multiple functions: it executes welding operations, detects burnback conditions, and performs tip replacement. By making the robotic system multi-functional, the patent eliminates the need for separate manual intervention while enhancing productivity, justifying the increased device complexity through consolidated functionality
Solution Approach 2:
The patent merges the tip replacement function with the existing robotic welding system by integrating specialized end effectors and control routines into the robotic arm. This consolidation combines multiple operations (welding, monitoring, and tip replacement) into a single automated system, improving productivity while managing complexity through integration rather than addition
Data Source
AI summary
A fixture for automatically replacing a defective/burnback contact tip coupled to a torch arm of a robotic welder wherein the robotic welder is configured to feed a welding wire to the contact tip. The robotic welder includes a nozzle coupled to the torch arm which is disposed at the contact tip. The fixture includes a first station configured to remove the nozzle from the torch arm and to hold the nozzle for reattachment to the torch arm. A second station is configured to remove the contact tip from the torch arm. A third station includes a plurality of holding units each being configured to hold an unused contact tip, wherein the third station is configured to move one of the plurality of holding units to a predetermined location to locate the unused contact tip for attachment to the torch arm.