Welding Device Automation for Steel Structure Preheating
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Solution Overview
Problem
Existing welding technologies face challenges in automating preheating and welding processes for large-size workpieces like steel structures, requiring extensive manual input and data entry for varying preheating conditions, leading to increased preparation time.
Innovation Solution
A welding device equipped with a welding robot, preheating device, and control system that automatically determines and applies preheating and welding conditions based on workpiece dimensions and joint shapes, using input units, storage units, and sensors to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If preheating work is automated using a removable tool attached to a welding torch, then preheating automation is achieved, but preparation time increases due to manual data input requirements
Solution Approach 1:
The patent combines the preheating device and welding robot into an integrated system where both functions are controlled by a single control unit. This merging eliminates the need for separate manual data input for preheating conditions, as the control unit automatically manages both preheating and welding parameters, thereby reducing preparation time while maintaining automation.
Solution Approach 2:
The control unit automatically determines preheating conditions based on workpiece information without requiring manual intervention. The system performs self-service by autonomously selecting and adjusting preheating parameters, eliminating the time-consuming manual data input process while maintaining automated preheating functionality.
2Reliability
If preheating conditions are manually adjusted for each weld place, then preheating quality is maintained, but workability decreases due to extensive manual input
Solution Approach 1:
The control unit automatically determines appropriate preheating conditions for each weld place based on workpiece information, eliminating the need for manual adjustment. This self-service approach maintains preheating quality through automated parameter selection while significantly improving workability by removing tedious manual input requirements.
Solution Approach 2:
The system automatically changes preheating parameters based on different weld places and workpiece characteristics. The control unit adjusts temperature, time, and other preheating parameters autonomously, maintaining optimal preheating quality for each specific location without requiring manual intervention, thereby improving ease of operation.
3Manufacturing precision
If data of preheating conditions is input for each weld place, then welding precision is ensured, but productivity decreases due to time-consuming preparation
Solution Approach 1:
The control unit automatically determines and applies appropriate preheating conditions for each weld place without requiring manual data input. This self-service capability ensures welding precision is maintained through automated parameter selection while eliminating the time-consuming data entry process, thereby improving productivity.
Solution Approach 2:
The system performs preliminary automatic determination of preheating conditions based on stored workpiece information before welding begins. By pre-configuring and automatically selecting parameters for multiple weld places in advance, the system ensures welding precision is maintained while reducing on-site preparation time, thus improving productivity.
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 significantly reduces preparation time by automating the selection and application of preheating and welding conditions, improving workability and efficiency in welding large-size workpieces.
Implementation Method 1
a preheating device that preheats the workpiece
Implementation Method 2
the preheating temperature is measured by a temperature sensor
Implementation Method 3
welding work is executed
Data Source
AI summary
A welding device for welding a workpiece using a welding robot includes a welding control device that controls operation of the welding robot and a preheating device that preheats the workpiece. The welding control device includes an input unit through which at least one or both of dimensions of the workpiece and a shape of a welding joint, and preheating information are inputted, and a storage unit that includes at least welding robot operation orbit teaching data, welding condition data, and preheating condition data. The welding control device automatically provides a preheating condition, a welding robot operation orbit, and a welding condition for the welding joint to be welded, and preheating and welding are performed.