Integrated Weld Gun and Clamp End Effector for Robot
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Solution Overview
Problem
In the manufacturing of transportation vehicles, particularly in body-in-white assembly, the use of multiple robots for welding and material handling is inefficient due to the need for separate equipment and increased complexity, which hinders productivity and increases costs.
Innovation Solution
A single industrial robot equipped with a dual-function end effector, utilizing a single actuator to operate both a weld gun and a material handling clamp, allowing for concurrent movement and operation to reduce the number of robots and equipment required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate first robots are used to grasp components and separate second robots with weld guns are used to spot weld, then the functions are well-defined and reliable, but the number of robots and equipment increases and complexity increases
Solution Approach 1:
The patent combines the material handling clamp and weld gun into a single integrated end effector that can be operated by one robot. The clamp assembly includes first and second jaws that can independently actuate to grasp components, while the weld gun is positioned to spot weld the grasped component to a workpiece. This merging eliminates the need for separate robots for material handling and welding, reducing overall system complexity while maintaining functional reliability through coordinated operation of the integrated components.
Solution Approach 2:
The end effector is designed with multi-functionality, serving both as a material handling device through its clamp mechanism and as a welding device through the integrated weld gun. The single robot equipped with this end effector can perform multiple operations including grasping components, transporting them to the workpiece, positioning them accurately, and executing spot welds. This universal design reduces the number of specialized robots needed while maintaining the reliability of each function through dedicated mechanisms within the end effector.
2Reliability
If end effectors include both weld gun and clamp with separate actuators, then both functions are independent and reliable, but more equipment is required and robot capacity must be higher
Solution Approach 1:
The patent merges the actuation systems for the clamp and weld gun into a single actuator that controls both functions. The actuator is connected to the first jaw through a first linkage and to the second jaw through a second linkage, allowing one actuator to independently control both clamping and welding operations. This merging reduces the total equipment required and decreases the weight of the end effector compared to having separate actuators, while maintaining independent operation of both functions through the linkage mechanisms.
Solution Approach 2:
The patent uses linkage mechanisms as intermediaries to transmit actuator motion to both the first and second jaws. The first linkage connects the actuator to the first jaw, and the second linkage connects the actuator to the second jaw, allowing a single actuator to control both clamping and welding functions independently. These intermediary linkages enable one actuator to effectively perform the work of two separate actuators, reducing equipment weight while maintaining functional independence and reliability.
3Ease of manufacture
If multiple robots are used for welding and material handling, then each robot can be optimized for its specific function, but programming complexity and operational complexity increase
Solution Approach 1:
The patent combines material handling and welding functions into a single robot system with an integrated end effector, eliminating the need for coordination between multiple robots. The single robot performs all operations including grasping components, transporting them to the workpiece, positioning them accurately, and executing spot welds. This merging significantly reduces programming complexity and operational complexity compared to coordinating multiple specialized robots, while still allowing the system to be optimized for both functions through the integrated end effector design.
Data Source
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AI summary
A combination component handling and connecting device (10) connectable to a multi-axis robot for use in moving and connecting components and subassemblies includes a housing (16) and an actuator (22) fixedly connected to the housing (16). The actuator (22) includes an actuating link (24) movable from a first position to a second position. Connected to the actuating link is an end effector (26) for concurrent movement with the actuating link. The component handling and connecting device includes a clamp (36) having a first jaw (38) and a second jaw (48). The second jaw (48) is connected to the actuating link (24) for selectively moving the second jaw (48) toward the first jaw (38) operative to engage a component.