Robotic Welding Torch Neck Rigid Non-Tubular Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding torch necks are prone to inconsistencies in dimensions and rigidity, leading to inaccuracies in maintaining the tool center point (TCP) during robotic welding, and are susceptible to misalignment and collisions, which hinder precise and repeatable welding operations.
Innovation Solution
A rigid, non-tubular, elongated neck member with precision CNC machining, featuring webs and flanges defining shapes like I-beam, C-beam, or T-beam, that locates and holds the welding tip at a precise TCP without transmitting power, gas, or cooling water, and is designed to be structurally stronger and less prone to bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional tubular neck portions are used with brazing and bending operations, then the neck can be assembled with cable and tip portions, but manufacturing precision and repeatability deteriorate due to imprecise operations
Solution Approach 1:
The invention separates the functions of the neck portion into two distinct components: a rigid precision-machined locating member that provides TCP accuracy, and a separate flexible cable assembly that provides utility delivery. This segmentation allows each component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The invention extracts the TCP locating function from the traditional tubular neck structure and places it in a dedicated rigid locating member. This extraction allows the locating function to be performed with high precision while the cable assembly handles the flexible utility delivery separately.
2Ease of operation
If conventional soft tubular neck portions are used, then flexibility and assembly are easier, but structural rigidity and TCP stability worsen
Solution Approach 1:
The invention divides the neck assembly into a rigid locating member for structural stability and a separate flexible cable assembly for ease of connection. The rigid locating member maintains TCP stability while the cable assembly provides flexibility for assembly and movement.
Solution Approach 2:
The invention introduces a rigid locating member as an intermediary component between the mounting arm and the cable assembly. This intermediary provides a stable reference point for TCP location while allowing the cable assembly to remain flexible and easy to connect.
3Measurement precision
If precision machined mounting arms are used, then TCP location accuracy is improved, but the neck portion remains a weak link due to bending and soft materials
Solution Approach 1:
The invention separates the mounting arm function from the neck portion function. The mounting arm provides precision TCP location, while a dedicated rigid locating member reinforces the neck structure to prevent bending and maintain reliability throughout the assembly.
4Manufacturing precision
If manual checking and manipulation of TCP is performed after bending, then some accuracy can be restored, but time consumption and productivity worsen
Solution Approach 1:
The invention performs precision machining of the locating member before assembly, establishing accurate TCP location in advance. This preliminary precision work eliminates the need for time-consuming manual checking and adjustment after bending operations.
Solution Approach 2:
The rigid locating member is designed to self-align and maintain TCP accuracy through its precision-machined features, eliminating the need for operator intervention to check and adjust TCP location after assembly.
Data Source
AI summary
A neck for a welding torch includes a rigid, non-tubular, elongated member having opposite first and second ends. The first end is connectable to a rear portion of the welding torch. The second end is connectable to a welding tip portion of the welding torch. The member locates and holds the welding tip portion in a precisely given location, and does not communicate welding power, welding wire, shielding gas, or cooling water between the first and second ends.