Sensor-Guided Welding Tip Replacement With Multi-Link Removal
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Solution Overview
Problem
Conventional welding tip supplying apparatuses for welders are inefficient in replacing welding tips, leading to decreased productivity and increased downtime due to manual errors and the need for frequent replacement of accommodation cases, which affects manufacturing line stability.
Innovation Solution
A welding tip supplying apparatus with a fixed bracket, actuator, and moving members that allow for automated and stable removal and insertion of welding tips, equipped with sensors to detect tip availability and minimize robot movement, enabling continuous supply and easy attachment to a support part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual welding tip replacement is used, then device complexity is reduced, but productivity decreases and replacing work time increases
Solution Approach 1:
The replacement apparatus is divided into multiple moving members (first moving member, second moving member, third moving member) that independently perform different functions: removing the old welding tip, holding the new welding tip, and coordinating their movements. This segmentation allows automated replacement without requiring a completely complex monolithic structure.
Solution Approach 2:
The accommodation case is designed to hold multiple welding tips simultaneously and can be automatically replaced when tips are consumed. The case serves multiple functions: storage, automatic supply, and easy replacement, reducing the need for separate systems for each function.
2Reliability
If accommodation case is replaced frequently, then welding tip supply continuity is maintained, but replacing work time increases and productivity decreases
Solution Approach 1:
Multiple welding tips are pre-loaded into the accommodation case before replacement is needed. The case is prepared in advance with sufficient tips to last through the replacement cycle, eliminating the need for frequent interruptions. The robot can continue welding while the case is being replaced in the background.
Solution Approach 2:
The accommodation case is designed with features that enable automatic replacement by the robot welder without requiring manual intervention. The case can be automatically detected, gripped, removed, and replaced by the robot's automated system, reducing downtime and maintaining productivity.
3Productivity
If welding tip absence is not detected, then apparatus structure is simplified, but replacing work errors increase and productivity decreases
Solution Approach 1:
A sensor is installed to detect the presence or absence of welding tips in the accommodation case and provide feedback to the control system. This feedback mechanism allows the robot to automatically recognize when tips are depleted and initiate the replacement process, preventing errors without requiring complex manual monitoring systems.
Solution Approach 2:
The manual visual inspection and manual replacement process is replaced with an automated sensor-based detection system and robotic manipulation. The sensor substitutes for human eyes, and the robotic arm substitutes for human hands, improving accuracy while maintaining reasonable system complexity through automation.
Data Source
AI summary
An apparatus for supplying a welding tip of a welder and an apparatus for replacing the same include a fixed bracket secured to a support. The apparatus includes an actuator coupled to the fixed bracket and a first moving member moved by the actuator. A second moving member is coupled to the first moving member and hingedly coupled to the fixed bracket. A third moving member is hingedly coupled to the second moving member. A first welding tip removal member is coupled to the third moving member to separate a welding to tip coupled to a shank. A fourth moving member is disposed opposite to the first moving member. A fifth moving member is coupled to the fourth moving member and hingedly coupled to the fixed bracket. A sixth moving member is coupled to the fifth moving member. A second welding tip removal member is coupled to the sixth moving member.