Seam Welding Roller Electrode Torque Synchronization
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Solution Overview
Problem
Existing seam welding systems face issues with synchronization between the robot arm and the welding gun, leading to stress and displacement during the welding process due to torque and thrust changes when a current flows between the roller electrodes, resulting in an unstable welding line.
Innovation Solution
A seam welding system that includes a pair of roller electrodes, an electrode movement mechanism, and a controller to regulate the rotation of the roller electrodes based on torque changes in the drive sources, ensuring that the torques remain within a predetermined range, thereby maintaining synchronization with the robot arm and stabilizing the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the robot arm moves the roller electrodes along the welding line, then the welding system can perform seam welding on complex-shaped workpieces, but synchronization between the robot arm and welding gun becomes difficult, causing stress and displacement
Solution Approach 1:
The control device receives torque information from both the robot arm drive source and welding gun drive source, compares these torque values, and adjusts the rotation speed of the welding gun's roller electrodes based on the torque difference. This feedback mechanism ensures that the welding gun follows the robot arm's movement accurately, maintaining synchronization even when moving along complex welding lines.
Solution Approach 2:
The control device integrates the control of two previously independent systems (robot arm movement and welding gun rotation) into a unified control system. By receiving torque information from both drive sources and coordinating their operation based on torque comparison, the system merges the motion control and welding execution into a synchronized operation, eliminating the synchronization problems that arose when these systems operated independently.
2Productivity
If torque changes occur when current flows between roller electrodes, then welding current can be applied to perform seam welding, but stress and displacement occur due to torque and thrust changes
Solution Approach 1:
The control device proactively compensates for the torque changes that occur when welding current flows by comparing torque values before and during welding operation. When torque changes are detected, the system adjusts the roller electrode rotation speed in advance to counteract the resulting stress and displacement, preventing welding line instability rather than reacting after the problem occurs.
Solution Approach 2:
The system dynamically changes the rotation speed parameter of the welding gun's roller electrodes based on real-time torque conditions. By adjusting this parameter in response to torque changes during welding current flow, the system maintains stable welding line positioning while allowing the welding process to proceed productively.
3Ease of operation
If dedicated motors rotate each roller electrode independently, then each electrode can be controlled separately, but synchronization control between robot arm and welding gun becomes complex
Solution Approach 1:
The control device uses torque feedback from the independently controlled roller electrode motors to achieve synchronization. By monitoring the torque output of each dedicated motor and using this information to adjust rotation speeds, the system maintains independent control capability while achieving coordinated synchronization through a relatively simple feedback mechanism rather than complex multi-variable control.
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 ensures a stable welding line by controlling the rotation of the roller electrodes, minimizing displacement and stress, and maintaining synchronization with the robot arm, even when a current flows between the electrodes, thus improving the performance and readiness of the seam welding process.
Implementation Method 1
a pair of roller electrodes, configured to hold a to-be-welded object between circumferential surfaces of the pair of roller electrodes, configured to rotate while holding the to-be-welded object between the circumferential surfaces, and configured to perform seam welding on the to-be-welded object when a current flows between the pair of roller electrodes while the pair of roller electrodes are rotating
Data Source
AI summary
A seam welding system includes a pair of roller electrodes. The pair of roller electrodes hold a to-be-welded object between circumferential surfaces of the roller electrodes, rotate while holding the to-be-welded object between the circumferential surfaces, and perform seam welding on the to-be-welded object when a current flows between the roller electrodes while rotating and holding the to-be-welded object between the circumferential surfaces. To an electrode movement mechanism, the roller electrodes are mounted. The electrode movement mechanism moves the roller electrodes along a welding line of the to-be-welded object. Drive sources respectively rotate the roller electrodes and a joint of the electrode movement mechanism. A controller controls an amount by which the roller electrodes rotate based on a torque change in the drive sources so as to keep torques respectively acting on the roller electrodes within a predetermined range.