Variable-Size Frame Welder With Robotic Handling for Sash Throughput
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Solution Overview
Problem
Current manufacturing processes for insulated glass units and sashes are mismatched in terms of production time, requiring extensive space, labor, and equipment, and are inefficient for producing variable window sizes needed for residential construction.
Innovation Solution
A variable size high-speed welder with two conveyors, robotic parts movers, staging and end-heating stations, a four-corner clamping structure, and a finished frame removal system, allowing synchronized robotic operations to efficiently produce sashes and frames at speeds compatible with insulated glass unit production, accommodating various sizes and reducing space and labor requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple conventional frame welders are used to manufacture sashes, then sash production capacity is improved, but floor space requirements increase significantly
Solution Approach 1:
The patent combines multiple welding stations (first and second welding stations with multiple clamps each) into a single integrated frame welder machine. This consolidation allows the production of multiple sashes simultaneously within one machine footprint, dramatically improving space utilization while maintaining high productivity. The machine can manufacture multiple different sized sashes in sequence without requiring multiple separate welding machines.
Solution Approach 2:
The frame welder incorporates adjustable clamps (first and second clamps at each welding station) that can be repositioned to accommodate different sash sizes. This dynamic adjustability allows a single machine to handle variable production requirements, replacing the need for multiple fixed-size welding machines and reducing overall floor space requirements.
2Productivity
If multiple conventional frame welders are deployed, then sash manufacturing capability is improved, but number of operators required increases
Solution Approach 1:
The patent integrates multiple welding stations and clamps into a single automated frame welder that can be operated by one or two operators. The machine automates the welding process across multiple stations, reducing the need for numerous operators while maintaining high production capacity. The centralized control system manages all welding operations from a single interface.
3Productivity
If conventional frame welders are used, then sash production is achieved, but work in progress storage and tracking complexity increases
Solution Approach 1:
The patent consolidates multiple welding operations into a single continuous process within one machine, eliminating the need for intermediate storage and handling between separate welding machines. The integrated design allows sashes to move directly through multiple welding stations in sequence, reducing work in progress inventory and simplifying tracking requirements.
4Productivity
If windows are manufactured in large batches of uniform size, then production efficiency is improved, but ability to accommodate variable residential window sizes decreases
Solution Approach 1:
The frame welder features adjustable clamps and positioning mechanisms that can be rapidly reconfigured to accommodate different window sizes. This dynamic adaptability allows the machine to switch between various window dimensions without requiring changeovers or retooling, maintaining high production efficiency while handling variable size requirements for residential construction.
Solution Approach 2:
The patent designs a universal frame welder that can manufacture multiple different sized windows using the same equipment. The machine incorporates adjustable fixtures and clamps that adapt to various window dimensions, allowing a single machine to serve multiple product configurations and eliminate the need for dedicated machines for each window size.
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 enables efficient production of 1,200 sashes per eight-hour shift, reducing space by 50% and labor by 20%, improving scheduling efficiency, and simplifying part distribution, while producing variable window sizes needed for residential construction projects.
Implementation Method 1
end-heating stations on each of four sides for a total of eight part-staging and end-heating stations
Implementation Method 2
heating ends of the parts to melt the polymers that the parts are made of
Implementation Method 3
a finished frame removal robotic structure positionable to lower downwardly to grasp the finished sash or frame and lift the finished sash or frame upwardly
Data Source
AI summary
A variable size welder that facilitates welding of polymer quadrilateral frame structures. The welder includes at least two parts conveyors that deliver parts from a remote location and parts staging stations and end heaters on each of four sides of the variable size welder. A centrally located four corner clamping structure and at least two robotic parts movers are configured to reach the at least two parts conveyors and also to reach the parts staging stations and end heaters. The at least two robotic parts movers are further configured to reach at least a portion of the four corner clamping structure.