Collaborative Robotic Welding Arm for Pipe Spool Positioning
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Solution Overview
Problem
Current spool welding systems lack efficient and safe robotic solutions for welding long lengths of pipe, as they often require manual operation and lack precise control, especially when working alongside human operators.
Innovation Solution
A collaborative robotic welding system with a repositionable support structure and rotary actuators, including safety encoders, to enable safe and precise motion control, allowing the system to be used alongside human operators and adapt to various welding positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operation is used for spool welding, then ease of operation is maintained, but manufacturing precision and productivity are insufficient
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated collaborative robotic system. The robot executes pre-programmed welding paths with high precision, eliminating manual operation inconsistencies while maintaining ease of use through intuitive programming interfaces and teach pendants.
Solution Approach 2:
The collaborative robot system performs welding operations autonomously based on programmed instructions. The system self-regulates motion control, welding parameters, and safety monitoring without continuous human intervention, achieving both precision and operational simplicity.
2Productivity
If traditional robotic welding systems are used, then productivity is improved, but safety for human operators deteriorates
Solution Approach 1:
The patent implements dynamic parameter changes in the robot control system, including variable speed limits, force thresholds, and safety zones. The system adjusts operational parameters based on real-time detection of human presence and robot motion state, maintaining high productivity while ensuring operator safety through adaptive parameter modification.
3Adaptability or versatility
If fixed welding systems are used, then manufacturing precision is maintained, but adaptability to different welding positions deteriorates
Solution Approach 1:
The patent employs a dynamic collaborative robot system with multiple degrees of freedom and repositionable support structures. The robot can adapt to various welding positions and orientations while maintaining precision through real-time motion control and coordinate system transformations. The system transitions from fixed to dynamic positioning capabilities.
Solution Approach 2:
The collaborative robot system is designed with universal applicability across different welding positions and configurations. Through programmable motion paths, adjustable end effectors, and repositionable support structures, the single robot system can perform welding operations in multiple positions without requiring dedicated fixed installations for each position.
4Ease of operation
If collaborative robotic systems are implemented, then ease of operation and safety are improved, but device complexity increases
Solution Approach 1:
The patent introduces several intermediary components to manage system complexity: teach pendants for intuitive programming, control panels for parameter adjustment, safety controllers for coordination, and sensors as intermediaries between the robot and environment. These intermediaries simplify operator interaction while handling complexity internally.
Data Source
Figure 1
Figure 1A~1B
Figure 1C
AI summary
A robotic welding system comprises a supporting arm for attaching to a repositionable support structure, the supporting arm comprising a first mounting portion connectable to the repositionable support structure, and a second mounting portion rotatably coupled to the first mounting portion. A yaw rotary actuator rotates the second mounting portion about a yaw axis. A welding arm comprises a third mounting portion rotatably coupled to the second mounting portion of the supporting arm. A pitch rotary actuator rotates the third mounting portion about a pitch axis generally perpendicular to the yaw axis. A roll rotary actuator rotates a torch holder shaft about a roll axis generally perpendicular to the pitch axis. The shaft has a torch mounting portion for mounting a welding torch at an end thereof. A controller is operably coupled to the actuators to cause the welding torch to execute a welding pattern.