Suspended Fastener Welding Head for Misaligned Part Positioning
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Solution Overview
Problem
Existing fastener welding technologies face challenges in properly welding fasteners to parts that are not perfectly positioned, as movable platforms often exhibit difficulty in movement and re-centering mechanisms perform poorly under the forces exerted by welders and their weight.
Innovation Solution
A fastener welding apparatus comprising a frame assembly, welding assembly, coupling assembly, and locating assembly, where the coupling assembly allows for selective movement of the welding assembly relative to the frame assembly through a pivoting suspension frame, enabling welding at a range of positions and orientations, with counterweights and actuators facilitating precise positioning and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a movable platform is used to allow welding assembly to adjust within a range of positions, then adaptability to different part positions is improved, but the platform exhibits difficulty in movement and re-centering mechanisms perform poorly under welding forces and weight
Solution Approach 1:
The welding assembly is mounted on a movable platform that can dynamically adjust its position within a range of adjustment relative to the frame assembly. The platform includes re-centering mechanisms that automatically return the welding assembly to a centered position after movement, enabling continuous adaptation to different part positions while maintaining reliable movement performance through active control rather than passive mechanical means
Solution Approach 2:
The re-centering mechanisms function as feedback systems that detect the position of the welding assembly on the movable platform and actively correct any deviation from the centered position. This closed-loop control compensates for the effects of welding forces and weight, ensuring reliable return to the home position despite the forces exerted during welding operations
2Extent of automation
If robotic arms are used to execute welding processes with minimal operator involvement, then automation level is improved, but difficulty in properly welding fasteners to parts not perfectly positioned increases
Solution Approach 1:
The welding assembly is mounted on a movable platform that can dynamically adjust its position within a range of adjustment relative to the frame assembly. This dynamic positioning capability allows the automated welding system to compensate for variations in part placement, maintaining welding precision even when parts are not perfectly positioned, while preserving the high level of automation
Solution Approach 2:
The system changes the positional parameters of the welding assembly by allowing movement of the platform within a predetermined range. This parameter adjustment enables the automated welding head to adapt to different part positions and orientations, maintaining manufacturing precision across variations in part placement while keeping the automation level high
3Productivity
If a single welder and robot arm are used to grab different parts in less than exact orientations, then versatility and assembly speed are improved, but difficulty in properly welding fasteners increases
Solution Approach 1:
The movable platform provides dynamic position adjustment capability that allows the welding assembly to quickly adapt to different part orientations and positions. This enables the system to handle parts in less than exact orientations while maintaining fastener positioning precision, thereby preserving both high assembly speed and welding quality
Solution Approach 2:
The system adjusts the positional parameters of the welding assembly within a predetermined range to compensate for variations in part placement. This parameter change capability allows the automated system to maintain fastener positioning precision even when parts are grabbed in less than exact orientations, preserving both productivity and manufacturing precision
Data Source
AI summary
A fastener welding apparatus having a frame assembly, a welding assembly, a coupling assembly and a locating assembly. The welding assembly has a welder frame and a welding electrode assembly coupled thereto. The coupling assembly has a suspension frame, a frame axle and a welding axle. The frame axle is fixedly engaged to the frame assembly and the welding axle is fixedly engaged to the welding assembly. The suspension frame is pivotably coupled to each of the frame axle and the welding axle. The locating assembly is structurally configured to selectively allow the suspension frame to pivot relative to the frame axle and the welding axle.