Six-Axis Workpiece Manipulator for Compressor Impeller Welding
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Solution Overview
Problem
Conventional multi-axis workpiece positioning devices require multiple setups and skilled operators to achieve optimal joint positioning for welding complex parts, leading to inefficiencies and the need for additional torch equipment to negotiate difficult part shapes.
Innovation Solution
A six-axis workpiece positioning device with two rectilinear axes, two pivotable axes, and two rotational axes, allowing for precise movement and orientation of a workpiece, compatible with both manual and robotic welding processes, and designed to position a torch for the most favorable angle between the torch centerline and the welding surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional two or three axes tilt-rotate positioner is used, then the equipment structure is simple, but multiple setups and special fixturing are required to obtain proper joint positioning for welding complex parts
Solution Approach 1:
The patent transitions from conventional 2-3 axis positioners to a 6-axis manipulator system, adding three rotational dimensions (azimuth, elevation, and wrist rotation) to the traditional two linear axes. This dimensional expansion enables the system to achieve any orientation and position required for welding complex 3D parts like compressor impellers, eliminating the need for multiple setups and special fixturing while maintaining equipment accessibility
2Manufacturing precision
If conventional multi-axis workpiece manipulators are used, then joint positioning for welding is improved, but the equipment becomes cumbersome and expensive
Solution Approach 1:
The manipulator is divided into distinct functional modules: a base with two linear axes (X and Y), a intermediate carriage with azimuth rotation, an arm with elevation pivot, and an end effector with wrist rotation. This segmentation allows each component to perform a specific function, simplifying the overall system design while achieving 6-axis capability, and reduces complexity compared to conventional monolithic multi-axis manipulators
Solution Approach 2:
The manipulator design integrates multiple functions into a single system: it can position workpieces in 3D space, orient them at any angle, and accommodate both manual and robotic welding processes. The system serves as a universal positioning platform that eliminates the need for separate fixturing systems and multiple specialized devices, reducing overall equipment complexity and cost
3Manufacturing precision
If skilled welders are used with conventional positioners, then high quality welds can be achieved, but the process requires highly skilled operators and is less efficient
Solution Approach 1:
The manipulator system performs the complex positioning and orientation functions automatically through programmed motion control, eliminating the need for highly skilled welders to manually manipulate workpieces into correct positions. The system serves itself by autonomously navigating the 6-axis coordinate system to achieve optimal welding angles and positions, thereby improving productivity while maintaining consistent weld quality without requiring operator expertise
Data Source
AI summary
Disclosed is a multi-axis workpiece manipulator or positioning device (10) having movement along two rectilinear axes (L1 and L2), two pivotable or tilt axes (T1 and T2) and two rotational axes (R1 and R2). The positioning device (10) includes a support base (12), a first member (18) attached to the support base (12) extending axially therefrom and a carriage (24) adjustably connected to the first member (18). The support base (12) is movable in a longitudinal path along a first rectilinear axis (L1) and the carriage is movable along the first member (18) in a vertical path along a second rectilinear axis (L2). A second member (30) is pivotably and rotatably attached to the carriage (24) and extends axially away from the carriage (24). The second member (30) can pivotably move along a first tilt axis (T1) with respect to the carriage (24) and can rotate in a circular path along a first rotational axis (R1). A third member (40) is pivotably and rotatably attached to an end of the second member (30), wherein the third member (40) can pivotably move along a second tilt axis (T2) with respect to the second member (30) and can rotate in a circular path along a second rotational axis (R2). A drive mechanism (D) operates the positioning device (10) for selectively positioning a workpiece (W) to be processed. This device (10) is particularly useful in fabricating compressor impellers.