Collaborative Robotic Welding Arm for Long Pipe Spool Welding
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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 over the welding process, especially when working alongside human operators.
Innovation Solution
A collaborative robotic welding system with a repositionable support structure, featuring a supporting arm, welding arm, and rotary actuators, controlled by a safety encoder and controller, allowing for precise motion control and force limitation to ensure safe operation alongside human workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used for spool welding, then flexibility and ease of setup are improved, but welding precision and safety control deteriorate
Solution Approach 1:
The robotic welding system performs welding operations autonomously without continuous manual intervention. The controller automatically controls the welding torch motion, positioning, and welding parameters based on pre-programmed sequences, enabling the system to serve itself and achieve consistent precision while reducing manual operation requirements
Solution Approach 2:
The patent replaces manual mechanical operation with an automated robotic system. The robotic arm with multiple joints and actuators substitutes human operators, providing programmable precision and consistency while maintaining operational flexibility through software control
2Extent of automation
If robotic welding system is introduced, then welding precision and automation are improved, but system complexity and safety risks worsen
Solution Approach 1:
The robotic welding system is divided into distinct functional modules: a robotic arm with multiple joints for positioning, a welding torch assembly, a controller for coordination, and a power supply. This segmentation allows each component to be optimized independently and simplifies maintenance and troubleshooting while maintaining high automation capability
Solution Approach 2:
The robotic welding system is designed with universal features that enable it to perform multiple welding operations and adapt to different welding scenarios. The programmable controller can execute various welding patterns and parameters, making the system versatile for different pipe sizes and welding positions without requiring completely different equipment
3Productivity
If robotic welding system operates alongside human workers, then productivity is improved, but safety risks increase
Solution Approach 1:
The controller serves as an intermediary between the robotic welding system and human operators. It manages the automated welding processes, monitors system status, and coordinates operations to minimize direct interaction between humans and the robotic system during welding, thereby reducing safety risks while maintaining high productivity
Solution Approach 2:
The system incorporates feedback mechanisms that monitor welding parameters, robot position, and system status in real-time. This feedback allows the controller to adjust operations dynamically, ensure safe operating conditions, and provide status information to human operators, enabling productive collaboration while maintaining safety through continuous monitoring and control
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.