Sensor-Guided Squeeze Clamp for Welding Gap Control
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Solution Overview
Problem
Current welding systems for automotive sheet metal and structural welding face challenges in achieving consistent weld quality due to variations in substrate location, gap, and clamping, leading to discrepant welds during gas metal arc welding.
Innovation Solution
A system and method that utilize a squeeze clamp with motorized arms and sensors (such as electromagnetic flux, current, and gap sensors) for real-time control of the gap between substrates, allowing for programmable movement and adjustment during the welding process, enabling precise clamping and improved weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding systems are used without real-time gap control, then the system is simpler and requires less sophisticated sensors, but weld quality becomes inconsistent due to variations in substrate location and gap
Solution Approach 1:
The patent implements real-time gap measurement using electromagnetic flux sensors that provide feedback to the control system. The sensor measures the magnetic flux generated by the welding power source, which correlates with the gap between substrates. This feedback enables dynamic adjustment of welding parameters to maintain consistent weld quality despite variations in substrate positioning.
Solution Approach 2:
The patent replaces traditional mechanical gap measurement systems with electromagnetic flux-based sensing. Instead of using physical probes or contact-based measurement devices, the system utilizes the magnetic field generated during welding to infer gap measurements, eliminating the need for complex mechanical measurement apparatus.
2Adaptability or versatility
If dedicated tooling is used for each welding position, then welding precision is maintained, but the weight of robot end effectors increases and flexibility decreases
Solution Approach 1:
The patent employs a universal clamp system that can be positioned and used at multiple welding locations on the substrate assembly. Rather than requiring dedicated clamps for each position, the same clamp unit can be moved to different locations by the robot, reducing the overall weight of end effectors while maintaining adaptability to various welding positions.
Solution Approach 2:
The patent implements a dynamically positionable clamp system that can be moved to different locations during the welding process. The robot can reposition the clamp between welding operations, allowing a single lightweight clamp to serve multiple positions rather than requiring heavy, fixed dedicated tooling for each location.
3Manufacturing precision
If real-time gap measurement and control is implemented, then weld quality improves, but the control system becomes more complex requiring multiple sensors and control strategies
Solution Approach 1:
The control system uses electromagnetic flux sensor readings as feedback to determine the gap between substrates in real-time. The controller processes this feedback information and adjusts welding parameters accordingly, implementing precise gap control through a relatively simple feedback loop that leverages existing welding process physics.
Solution Approach 2:
The patent uses electromagnetic flux as an intermediary measurement mechanism. Rather than directly measuring the physical gap distance, the system measures the magnetic flux which serves as an indirect but reliable indicator of gap size. This intermediary approach simplifies the measurement process while maintaining precision.
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 achieves improved weld quality by allowing real-time adjustments and flexible positioning, reducing the need for dedicated tooling and weight, and enabling precise control of the welding process, resulting in more consistent and high-quality welds.
Implementation Method 1
At least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor is disposed on one of the first and second ends for determining a first measured variable between the first and second substrates
Data Source
AI summary
A clamp system and method for measurement and control of welding a first substrate to a second substrate is provided. The system comprises a squeeze clamp having to a first end and a second end. The system further comprises a motor connected to the squeeze clamp such that the first and second ends are movable to clamp the first substrate to the second substrate. The system further comprises at least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor disposed on one of the first and second ends for determining a first measured variable between the first and second substrates. The system further comprises a controller to control the motor to clamp the first substrate to the second substrate based on the first measured variable. The controller is in communication with the electromagnetic flux sensor, the current sensor, and the gap sensor.