Robotic Welding System with Orthogonal Dam Segments
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Solution Overview
Problem
Conventional welding methods face challenges in maintaining a continuous outer surface of welded seams due to molten material leakage from open ends, which can compromise structural integrity and aesthetics, and existing solutions like mechanical blocks are labor-intensive and increase material costs.
Innovation Solution
A robotic welding system that generates alternating layers of continuous welds with dam segments oriented orthogonally and main segments parallel to the seam length, using different welding modes to control molten material flow and prevent leakage, while minimizing stops and inclusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical blocks are installed at open ends of the seam to prevent molten material leakage, then the outer surface quality of the welded seam is improved, but the process becomes labor-intensive and material costs increase
Solution Approach 1:
The welding system creates its own containment structure by forming dams from weld material deposited at the open ends of the seam. The robotic welding device automatically builds these dams layer by layer without requiring separate mechanical blocks or manual intervention, allowing the system to serve itself by using the welding process to create both the weld and the containment structure
Solution Approach 2:
The invention extracts and eliminates the need for separate mechanical blocks by integrating the containment function directly into the welding process itself. The dam structure is formed from the same welding material and process that creates the seam, removing the need for additional components and reducing both labor and material costs
2Manufacturing precision
If mechanical blocks are used to prevent molten material leakage, then the outer surface quality is improved, but material cost increases
Solution Approach 1:
The welding system creates its own containment structure by forming dams from weld material deposited at the open ends of the seam. The robotic welding device automatically builds these dams layer by layer without requiring separate mechanical blocks or manual intervention, allowing the system to serve itself by using the welding process to create both the weld and the containment structure
Solution Approach 2:
The invention uses the same welding material to create both the seam and the dam structure, ensuring material homogeneity. The dam is formed from the identical filler material used for welding, eliminating the need for different materials or blocks and reducing overall material cost while maintaining structural consistency
3Object-affected harmful factors
If the robot welder welds dams separately from the main seam weld, then molten material leakage is prevented, but the number of starts and stops increases creating inclusions that reduce weld strength
Solution Approach 1:
The invention merges the dam welding and main seam welding into a single continuous operation. The robotic welding device performs both functions without stopping, creating the dam structure and filling the seam in an uninterrupted sequence. This eliminates the harmful effect of multiple starts and stops that would otherwise create inclusions and weaken the weld
Solution Approach 2:
The welding process maintains continuous operation by seamlessly transitioning between dam construction and seam filling. The robotic welding device operates without interruption, keeping the welding arc and material flow continuous throughout the entire process, which prevents inclusions and ensures weld integrity while still preventing molten material leakage
4Object-affected harmful factors
If multiple starts and stops are made during welding to create dams, then molten material leakage is prevented, but the welding time and operational complexity increase
Solution Approach 1:
The invention merges the dam welding and main seam welding into a single continuous operation. The robotic welding device performs both functions without stopping, creating the dam structure and filling the seam in an uninterrupted sequence. This eliminates the harmful effect of multiple starts and stops that would otherwise create inclusions and weaken the weld
Solution Approach 2:
The welding system performs preliminary action by first creating the dam structure at the open ends before filling the main seam. This preliminary dam construction is done in a controlled manner that prepares the containment structure in advance, allowing the subsequent seam filling to proceed efficiently without interruptions or time loss
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 produces high-quality welds with a continuous outer surface, reduced material leakage, and enhanced structural integrity, achieving efficient and aesthetically pleasing results with minimal inclusions and reduced operational complexity.
Implementation Method 1
Welding is a fabrication process used to join two components of similar material to one another through the application of heat and a filler material
Implementation Method 2
the pool of molten material is fluid during welding, the material can spill out of open ends of the seam
Data Source
AI summary
A welding system is disclosed for use in closing a seam. The welding system may have a mount configured to hold a work piece having the seam to be welded, and a robotic welding device movable relative to the mount. The welding system may also have a controller in communication with the robotic welding device and configured to control the robotic welding device to sequentially generate a plurality of weld layers within the seam. Each weld layer may have at least one dam segment extending generally orthogonal to a length direction of the seam, and a main segment extending in the length direction.