Simultaneous Welding of Butted Profiles to Prevent Misalignment
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Solution Overview
Problem
The existing double-torch welding robot methods often result in misalignment and decreased welding quality when welding profiles without backing bars with profiles having double or single backing bars, leading to deformation issues.
Innovation Solution
A welding method where the two lateral parts of the profile without backing bars are welded simultaneously with corresponding profiles having double or single backing bars, forming an integer to prevent misalignment and enhance welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sequential welding of lateral parts is used, then welding process simplicity is maintained, but misalignment and welding quality deteriorate
Solution Approach 1:
The welding process is segmented into two independent simultaneous welding operations, each handling one lateral part. This segmentation allows each welding operation to be controlled independently, preventing the cumulative misalignment that occurs in sequential welding while maintaining process simplicity through standardized simultaneous execution.
Solution Approach 2:
The positions of both lateral parts are pre-positioned and fixed before welding begins. By establishing the correct spatial relationships in advance and welding both sides simultaneously, the method prevents misalignment from developing during the welding process, thereby maintaining both simplicity and precision.
2Device complexity
If sequential welding of lateral parts is used, then welding equipment simplicity is maintained, but welding quality deteriorates due to misalignment
Solution Approach 1:
The welding task is divided into two independent simultaneous welding operations. This segmentation enables the use of standard double-torch welding equipment to perform both operations concurrently, maintaining equipment simplicity while eliminating the misalignment issues that plague sequential welding and thereby improving welding quality reliability.
Solution Approach 2:
Both lateral parts are welded simultaneously in a continuous process rather than sequentially. This continuous simultaneous action eliminates the intermediate state where misalignment can occur between welding steps, maintaining equipment simplicity while significantly improving the reliability and quality of the final weld.
3Manufacturing precision
If simultaneous welding of lateral parts is implemented, then misalignment is avoided, but welding process complexity increases
Solution Approach 1:
The simultaneous welding process is segmented into two independent, standardized welding operations that occur in parallel. This segmentation allows each operation to follow a simple, proven welding procedure while achieving the benefit of simultaneous execution, thereby improving alignment precision without excessively increasing process complexity.
Solution Approach 2:
The method accepts and accommodates the asymmetric nature of welding different lateral parts (which may have different profiles or requirements) by treating them as independent simultaneous operations rather than forcing a symmetric sequential approach. This resolves the complexity issue by allowing each side to be welded according to its specific requirements while maintaining simultaneous execution for precision.
Data Source
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AI summary
The present invention provides a welding method of butted profile. The welding method of the butted profile comprises the following steps of: assembling a profile without backing bars and a profile with double backing bars and/or a profile with a single backing bar of the butted profile together; and welding two lateral parts of the profile without backing bars with the corresponding profile with double backing bars and/or the profile with a single backing bar at the same time. By welding the two lateral parts of the profile without backing bars with the corresponding profile with double backing bars and/or the profile with a single backing bar at the same time, the two lateral parts of the profile without backing bars can simultaneously form an integer with the corresponding profile with double backing bars and/or the profile with a single backing bar in the welding process, therefore, the phenomenon of misalignment at one side of the profile without backing bars when the other side of the profile without backing bars is welded is effectively avoided, and the welding quality of the butted profile is improved.