Quick-Change Robotic Welding Coupling With Tapered Locking Adapters

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Solution Overview

Problem

Conventional robotic welding system couplers are difficult, time-consuming, and labor-intensive to install or replace, leading to significant interruptions and downtime due to collisions and component damage.

Innovation Solution

Quick change robotic coupling systems and adapters that include insulating adapters with tapered extensions and intermediate locks, allowing for simplified assembly and disassembly by separating and reattaching components at the welding torch mount, reducing downtime and component damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional couplers are used to couple robotic manipulators to welding torches, then reliable electrical connection is achieved, but installation and replacement become difficult, time-consuming, and labor-intensive

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinstallation and replacement ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The coupling system is divided into separate modular components: a coupler body that remains attached to the robotic manipulator, and a separate welding torch assembly that can be quickly detached and reattached. This segmentation allows the electrical connection to be maintained through a simplified interface while enabling rapid replacement of the torch assembly without manipulating multiple fasteners or complex connection elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediate quick-change coupling mechanism serves as a mediator between the robotic manipulator and welding torch. This intermediary component provides a simplified interface that maintains reliable electrical connection while enabling rapid attachment and detachment. The intermediary coupler absorbs the complexity of electrical connectivity, allowing the welding torch to be quickly replaced without compromising electrical reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If conventional couplers are used in robotic welding systems, then stable coupling is achieved, but replacement after collisions causes significant interruptions and downtime

Engineering Contradiction:

Improvecoupling stabilityVSAvoiddowntime during replacement

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The quick-change coupling mechanism is pre-configured with alignment features and simplified fastening elements that enable rapid reattachment. The coupler body maintains a ready-state interface that anticipates potential torch failures or collisions, allowing operators to quickly replace torches without complex alignment or multiple fastening steps, thereby minimizing downtime after collisions or component failures.

Inventive Principle:

Principle #10Preliminary action

3Strength

If conventional couplers with multiple fasteners and components are used, then secure attachment is achieved, but component count increases and assembly/disassembly complexity increases

Engineering Contradiction:

Improveattachment strengthVSAvoidcoupler component count and assembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple fastening functions and electrical connection elements are merged into a single integrated quick-change coupling mechanism. The coupler body combines mechanical attachment, electrical connectivity, and alignment features into one unified component that requires minimal fasteners and simplified assembly steps, reducing overall component count while maintaining secure attachment strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupler body is designed as a universal interface that performs multiple functions simultaneously: mechanical attachment, electrical connection, alignment, and rapid release. This multi-functional design eliminates the need for separate components for each function, reducing overall system complexity while maintaining secure and reliable coupling between the robotic manipulator and welding torch.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4650123A1Quick change robotic coupling systems and adapters and robotic welding systems having quick change robotic coupling systems and adapters

Publication Date: 2025.11.19 ILLINOIS TOOL WORKS INC

Figure 1
Figure 2A~2B
Figure 3A

AI summary

A quick change coupling system configured to couple components of a welding system comprises: a first adapter comprising a first tapered extension extending from a first outside diameter of the first adapter, the first tapered extension defining a second outside diameter of the first adapter greater than the first outside diameter of the first adapter; a second adapter comprising a second tapered extension extending from a third outside diameter of the second adapter, the second tapered extension defining a fourth outside diameter of the second adapter greater than the third outside diameter of the second adapter; and an intermediate lock configured to couple the first adapter and the second adapter by fastening the first tapered extension of the first adapter together with the second tapered extension of the second adapter.