Welding Controller Data Transfer for Rapid Weld Reassignment
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Solution Overview
Problem
Existing welding systems face challenges in quickly and efficiently reassigning weld points to welding tools and controllers without compromising weld quality, especially during unforeseen events like tool failures or contamination, requiring significant effort and time to transfer data between controllers.
Innovation Solution
A welding system with communication devices that facilitate the transfer of welding data between controllers, allowing for quick and cost-effective reassignment of weld joints, even to unavailable controllers, using a communication device to initiate data transfer and manage data centrally, with features like XML files and parsers to ensure seamless data exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding data is manually transferred between controllers during unforeseen events, then weld quality requirements can be maintained, but significant time and effort are required causing production stoppages
Solution Approach 1:
The patent implements automated copying of welding data between controllers through a communication device. When a welding tool fails or needs reassignment, the system automatically copies the welding data (including design parameters, electrode cap specifications, contact pressure, welding current, and duration) from the source controller to the target controller, eliminating manual data transfer and enabling quick reassignment without production stoppages
Solution Approach 2:
The patent introduces a communication device as an intermediary between welding controllers. This mediator facilitates the automatic transfer of welding data between controllers, enabling seamless communication and data exchange without manual intervention, thus resolving the contradiction between maintaining weld quality and avoiding production stoppages
2Adaptability or versatility
If welding data is transferred between disconnected controllers, then reassignment of weld points can be achieved, but the transfer is either not possible within required timeframe or requires considerable effort
Solution Approach 1:
The communication device enables automated copying of welding data even between disconnected controllers. The system stores welding data locally and can transfer it automatically when controllers are connected, eliminating the need for manual data entry and reducing the effort required for reassignment operations
Solution Approach 2:
The patent implements preliminary storage of welding data in the communication device and controllers. This allows data to be prepared in advance and transferred automatically when needed, enabling quick reassignment without considerable effort even if controllers are temporarily disconnected
Data Source
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AI summary
A welding system (2) and a method for transferring specific data for producing a welded joint (7) between welding controls (11 to; 21 to 24; 31, 32) of the welding system (2) are provided. The welding system (2) has at least two welding controllers (11 to 13; 21 to 24; 31, 32) each configured to store welding joint data (1311 to 1317) for producing the weld joint (7), at least one welding tool (41) for producing a weld joint (7) on at least one workpiece (5; 5, 6) under control of one of the at least two welding controllers (11 to 13; 21 to 24; 31, 32) on the basis of the stored welding joint data (1311 to 1317), and a communication device (15; 25) for communicating with the at least two welding controllers (11 to 13; 21 to 24; 31, 32), wherein the communication device (15;25) is designed to initiate a transmission of welding joint data (1311 to 1317) stored on the communication device (15; 25) from a source welding control (11) of the at least two welding controls (11 to 13; 21 to 24; 31, 32) to a target welding control (12, 13; 21 to 24; 31, 32) of the at least two welding controls (11 to 13; 21 to 24; 31, 32).