Saw Tooth Hard Material Welding with Vision-Guided Feeding
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Solution Overview
Problem
Existing devices for welding hard material bodies to saw blades lack flexibility and efficiency in handling different geometries and orientations, requiring costly conversions and unable to handle pre-ground materials effectively.
Innovation Solution
A device with a movable plate for distributing hard materials, an image acquisition and processing system for selection based on specifications, and a robot gripping device for precise transfer to a welding electrode, along with a cleaning system and interchangeable electrode inserts, allows for flexible handling of various geometries and orientations, including pre-ground materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing separating and feeding devices are used for hard material bodies of a single specific geometry, then the device structure is simple, but the adaptability to different geometries is poor and costly conversions are required
Solution Approach 1:
The robot gripping device with vision guidance is designed to handle multiple geometries of hard material bodies through a single unified system. The image acquisition device captures the geometry of each body, the image processing device analyzes it, and the robot gripping device adjusts its gripping strategy accordingly, eliminating the need for multiple dedicated feeding devices for different geometries.
Solution Approach 2:
The patent replaces traditional mechanical separating and feeding devices with an automated system combining image acquisition, image processing, and robot gripping. This substitution allows the system to adapt to different geometries through software-based recognition and control rather than requiring physical reconfiguration of mechanical components.
2Productivity
If traditional feeding devices are used, then the device complexity is low, but the productivity and efficiency in handling various orientations are insufficient
Solution Approach 1:
The system enables hard material bodies to effectively present themselves for gripping through the image acquisition and processing sequence. The vision system automatically identifies suitable gripping positions and orientations without requiring complex mechanical manipulation devices, allowing the robot to adaptively grasp bodies in various orientations efficiently.
Solution Approach 2:
The image acquisition device provides real-time feedback on the position, orientation, and geometry of hard material bodies on the plate. This feedback is processed by the image processing device, which then guides the robot gripping device to select and grasp appropriate bodies, creating a closed-loop control system that enhances handling efficiency.
3Manufacturing precision
If manual selection and transfer of hard material bodies is used, then the device complexity is low, but the manufacturing precision and reliability are insufficient
Solution Approach 1:
The patent replaces manual selection and transfer operations with an automated vision-guided robot system. The image acquisition device captures precise positional information, the image processing device calculates optimal gripping parameters, and the robot gripping device executes the transfer with high precision, eliminating human error and variability.
Solution Approach 2:
The image acquisition device creates a digital copy or representation of the hard material bodies' positions and geometries on the plate. This optical copy is then processed to determine gripping strategies, allowing the system to plan and execute precise transfers without physical contact until the gripping moment, thereby enhancing positioning accuracy.
4Adaptability or versatility
If the plate is continuously moved to distribute hard material bodies, then the arrangement flexibility is improved, but the time for welding operations increases due to frequent plate stopping
Solution Approach 1:
The system performs preliminary actions by using the image acquisition device to identify and select suitable hard material bodies while the plate is still moving or before the welding operation begins. The image processing device pre-calculates gripping parameters, so that when the plate stops, the robot can immediately grasp and transfer the selected body without delay, minimizing the impact on welding cycle time.
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
Enables efficient and flexible welding of hard materials to saw blades with different geometries without costly conversions, ensuring precise positioning and automatic cleaning, thereby enhancing manufacturing flexibility and reliability.
Implementation Method 1
an image acquisition device for detecting the hard material bodies placed on the plate
Implementation Method 2
a robot gripping device for gripping the suitable hard material body from the plate and for transferring the gripped hard material body to the welding electrode
Implementation Method 3
a resistance welding device with a welding electrode that can be advanced into the work area and retracted again from the work area
Data Source
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AI summary
The invention relates to a device (2) for welding hard material bodies (4) to teeth (6) of a saw blade (8), having: a saw blade advance device (12) for moving the saw blade (8) in an advance direction (14) so that an intended tooth (6a) of the saw blade (8) can, on each occasion, be brought to a target position (16) in a working area (10) of the device (2); a feed device (28) for feeding each particular hard material body (4); and resistance welding equipment (24) with a welding electrode (26) which can be advanced into and withdrawn from the working area (10), wherein the feed device (28) is designed to pass each particular hard material body (4) to the welding electrode (26), and wherein the welding electrode (26) can be advanced with the hard material body (4) into the working area (10). According to the invention, the feed device (28) comprises a plate (102) which can be moved backwards and forwards to modify the arrangement of hard material bodies (4) placed on the plate (102), an image capture system (104) for detecting the hard material bodies placed on the plate, an image processing device (106) for selecting and determining the position of at least one suitable hard material body (4), and a robot gripper device (100) for picking up the hard material body (4) and passing it to the welding electrode (26).