Coordinated Two-Axis Welding Torch Motion Without Mechanical Tilting
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Solution Overview
Problem
Existing welding systems require complex mechanical systems to adjust the work angle of the welding torch, leading to size and reliability issues due to the need for physical reorientation of motion axes.
Innovation Solution
A mechanized welding system utilizing a two-axis motion apparatus and a motion controller to adjust the welding torch's height and oscillation directions independently, accounting for the work angle without tilting the apparatus, through software-controlled coordination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If physical reorientation of motion axes is used to adjust work angle, then welding torch angle can be changed, but device complexity increases and reliability decreases
Solution Approach 1:
The patent replaces the traditional mechanical reorientation system with a software-based coordinated motion control system. The motion controller calculates and coordinates movements along the travel axis and height axis to achieve the desired work angle without any mechanical tilting or reorientation of the motion apparatus, thereby eliminating complex mechanical components while maintaining adaptability
Solution Approach 2:
The system changes the control parameters from physical orientation angles to coordinated linear movements along two independent axes. By controlling the travel distance and height adjustment as separate linear parameters, the system achieves work angle variation through software coordination rather than mechanical rotation or tilting
2Adaptability or versatility
If physical reorientation of motion axes is used to adjust work angle, then welding torch angle can be changed, but system size increases
Solution Approach 1:
The patent eliminates the need for mechanical tilting mechanisms, rotary joints, and complex reorientation assemblies by using software-controlled coordinated motion. This substitution dramatically reduces the physical size of the motion apparatus while preserving the ability to adjust work angle through independent linear movements along travel and height axes
3Adaptability or versatility
If mechanical tilting of motion apparatus is used, then work angle can be adjusted, but reliability decreases
Solution Approach 1:
The patent replaces mechanical tilting mechanisms with software-based coordinated control, eliminating moving parts that could fail. The motion controller uses computational algorithms to coordinate travel and height movements, removing mechanical joints, gears, and actuators that would reduce system reliability
Solution Approach 2:
The patent extracts and removes the mechanical tilting function from the system, keeping only the essential linear motion capabilities. By separating the work angle adjustment function into software coordination of independent linear axes, the system eliminates the unreliable mechanical tilting components
Data Source
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AI summary
A mechanized welding system (100) and associated methods are disclosed. The system includes a welding torch (150) and a two-axis motion apparatus (140) operatively connected to the welding torch and configured to move the welding torch in two independent axes of motion (e.g., X and Y) during an orbital or linear welding procedure to produce at least one of a fillet weld or a groove weld on a workpiece. The system also includes a motion controller operatively connected to the two-axis motion apparatus. The motion controller is configured to control movement of the two-axis motion apparatus along the two axes of motion in a coordinated manner to continuously and simultaneously adjust the welding torch in a height direction and an oscillation direction with respect to the workpiece, while accounting for a physical work angle of the welding torch with respect to the workpiece, and without the two-axis motion apparatus having to be tilted with respect to the workpiece when the physical work angle is changed.