Segmented Spot Welding System for Large Panel Efficiency
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Solution Overview
Problem
Conventional spot welding systems are limited by the size of panels due to connected upper and lower electrodes, leading to reduced welding speed, increased equipment costs, and space requirements, making it difficult to manage larger welding guns and maintain efficiency.
Innovation Solution
A spot welding system with separate upper and lower moving units, each equipped with an electrode, allowing for independent positioning controlled by a synchronized robotic system, enabling high-speed welding regardless of panel size while reducing the need for multiple robots and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the upper and lower electrodes are connected by a welding gun arm, then the welding structure is compact and manageable, but the panel size is limited and welding speed deteriorates
Solution Approach 1:
The welding system is divided into separate upper and lower moving units, each with independent electrodes. The upper moving unit includes a welding gun mounted on a robot, while the lower moving unit includes a table with movable electrodes. This segmentation allows each unit to operate independently, enabling high-speed welding regardless of panel size while maintaining manageable equipment through modular design.
2Adaptability or versatility
If the entire size of the welding gun is increased to accommodate larger panels, then the welding coverage is improved, but the welding gun becomes too big and heavy to manage
Solution Approach 1:
Instead of increasing the size of a single welding gun, the system segments the welding function into separate upper and lower units. Each unit has its own electrodes that can be independently positioned, allowing the system to handle large panels without requiring an oversized, unmanageable welding gun.
Solution Approach 2:
The system transitions from a single-point welding approach to a distributed multi-point welding approach by separating upper and lower electrodes. This dimensional change in the welding architecture allows simultaneous or sequential welding at multiple locations, accommodating large panel sizes while keeping each electrode unit compact and manageable.
3Adaptability or versatility
If multiple robots are used to handle larger panels, then the welding coverage is improved, but the equipment costs and space requirements increase
Solution Approach 1:
The system uses one robot for the upper moving unit and one robot for the lower moving unit, with each robot controlling specific electrodes. This segmented approach allows coordinated welding across large panels while minimizing the total number of robots needed, as each robot manages a dedicated zone rather than requiring multiple robots to cover the entire panel.
Solution Approach 2:
The system merges the functions of multiple welding operations into a coordinated two-robot system. By combining the upper and lower moving units with synchronized control, the system achieves comprehensive panel coverage equivalent to or better than multiple independent robots, while reducing overall equipment complexity and space requirements.
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
This solution enables high-speed spot welding across various panel sizes, reduces equipment costs and space requirements, and enhances productivity and efficiency by allowing independent movement of upper and lower electrodes.
Implementation Method 1
a pushing actuator mounted to a lower portion of the gear box, and a first moving block where the upper electrode is mounted, mounted to the lower portion of the gear box. The first moving block selectively moves up and down by an operation of the pushing actuator.
Implementation Method 2
a first screw shaft disposed on both ends of the table along length direction of the table respectively, a second moving block engaged with and movable along the each first screw shaft, and a first motor (e.g., a servo motor) mounted to a side of the table and selectively rotating the first screw shaft
Implementation Method 3
a second motor, a second screw shaft connected with each of the second moving blocks along the width direction of the table and a third moving block engaged with and movable along the second screw shaft
Implementation Method 4
Spot welding is a welding method of bonding objects via a small concentrated weld, using electric resistance by applying electricity and pressure to weld together portions that overlap
Implementation Method 5
applying electric resistance to the fixed electrode and the moving electrode
Data Source
AI summary
A spot welding system is disclosed. In particular, the spot welding system includes an upper moving unit provided with an upper electrode and a lower moving unit mounted separately from the upper moving unit and provided with a lower electrode corresponding to the upper electrode. Together, the upper moving unit and the lower moving unit separately vary a position of the lower electrode to allow for reduced size restrictions of objects to be spot welded therein.