Collaborative Robotic Welding Arm for Long Pipe Spool Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 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 over the welding process.
Innovation Solution
A collaborative robotic welding system is introduced, comprising a repositionable support structure and a robotic welding system with a supporting arm, a welding arm, rotary actuators, safety encoders, and a controller. This system allows for precise control and safe operation, enabling efficient welding of long pipe lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operation is used for spool welding, then flexibility and adaptability are maintained, but welding precision and control are insufficient
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated robotic welding system that uses computer-controlled actuators and sensors to achieve precise welding. The robotic arm with multiple degrees of freedom substitutes human manual dexterity with automated control systems, enabling consistent precision while reducing operational complexity through programmable sequences.
Solution Approach 2:
The welding system incorporates self-positioning capabilities through sensors and feedback mechanisms that automatically adjust the welding torch position and orientation. The system performs self-calibration and self-correction during operation, maintaining precision without requiring constant manual intervention or complex external positioning equipment.
2Productivity
If robotic automation is implemented, then welding precision and efficiency are improved, but safety risks increase due to uncontrolled force application
Solution Approach 1:
The robotic welding system incorporates force sensors and torque sensors that continuously monitor the forces applied during welding operations. This feedback mechanism allows the control system to detect abnormal force conditions and automatically adjust or stop operations to prevent safety hazards, enabling high-speed automation while maintaining safety through real-time monitoring and adaptive control.
Solution Approach 2:
The system implements pre-programmed safety limits and force thresholds that act as protective barriers before hazardous conditions can develop. Emergency stop mechanisms and force-limited operation modes are built into the control system to prevent excessive force application, protecting both equipment and operators from potential harm while maintaining efficient welding production.
3Adaptability or versatility
If traditional welding systems are used, then simplicity of operation is maintained, but collaborative operation with human workers is not enabled
Solution Approach 1:
The robotic welding system transitions from static, fixed-position welding to dynamic, adaptive positioning that responds to real-time conditions. The system can dynamically adjust its position, speed, and welding parameters to work safely alongside human operators, enabling flexible collaborative operations where the robot and human workers can share the workspace with coordinated movements and adaptive behavior patterns.
Data Source
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.