Robotic Welding Tool Head for Dissimilar Metal Alignment Control
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Solution Overview
Problem
Existing welding technologies face challenges in accurately welding dissimilar metals, such as iron and aluminum, due to difficulties in maintaining the precise positioning and force control required for effective joint formation.
Innovation Solution
A robotic welding tool system that includes a welding torch, an element pusher, and a component pusher, controlled by a driving device, which inserts and positions a metallic welding element within a through-hole in the second component, allowing for precise alignment and force control to ensure accurate welding of dissimilar metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a welding element is inserted into a through-hole to weld dissimilar metals, then welding of dissimilar metals is enabled, but precise positioning and force control become difficult to maintain
Solution Approach 1:
The welding tool is divided into separate functional modules: a welding element holder that independently positions the welding element, a pusher mechanism that independently applies force, and a welding torch. This segmentation allows each module to be optimized for its specific function while working together as an integrated system, enabling both versatility in welding dissimilar metals and precision in positioning and force control
Solution Approach 2:
A pusher mechanism acts as an intermediary between the welding element holder and the workpiece, providing controlled force application. The pusher includes a pusher member that contacts the welding element and applies axial force, while being independently controllable from the welding element positioning system. This intermediary enables precise force control during the welding process without compromising positioning accuracy
2Manufacturing precision
If multiple components (welding element, through-hole, components to be welded) are precisely aligned, then welding accuracy improves, but device complexity increases
Solution Approach 1:
The welding tool head is designed with universal positioning features that can accommodate different welding element sizes and shapes while maintaining consistent positioning accuracy. The holder and pusher mechanisms are designed to work with various through-hole configurations and workpiece types, reducing the need for specialized fixtures for each welding scenario and thereby managing complexity while maintaining precision
Solution Approach 2:
The welding element is held within a holder that is itself positioned within the welding tool head, which contains the pusher mechanism, which is contained within the overall welding system. This nested arrangement allows multiple positioning and control functions to be integrated in a compact configuration, maintaining welding accuracy without proportionally increasing device complexity
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 system enhances welding accuracy by enabling precise positioning and force control, improving the quality of dissimilar metal welds by ensuring proper alignment and consistent contact between the welding element and the components.
Implementation Method 1
melting the welding element
Data Source
AI summary
A welding tool for a robot welds together a first component and a second component by using a metallic welding element disposed within a through-hole in the second component. The welding tool includes a welding torch attached to an arm, an element pusher that is attached to a distal end of the arm and disposes the held welding element between the welding torch and the through-hole and disposes at least a part of the welding element within the through-hole, a component pusher attached to the distal end of the arm and movable in an axial direction of a distal end of the welding torch, and a driving device that presses the component pusher against the second component. The element pusher is movable in the axial direction relative to the component pusher.