Welding Fixture for Bar Truss Girder Automation
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Solution Overview
Problem
Existing welding fixtures for automatic equipment are inadequate for assembling complex structures like bar truss girders with a square section, as they obstruct the welding head and require manual finishing, leading to inconsistent quality and increased costs.
Innovation Solution
A welding fixture with movable plates and intermediate supporting elements that allow preassembly of pieces, enabling the automatic welding equipment to access all parts without obstruction, while being adaptable to different dimensions and sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding fixtures are used to support all sides of bar truss girders, then the pieces can be properly positioned for welding, but the welding head movement is obstructed and manual welding is required
Solution Approach 1:
The welding fixture is divided into two separate fixtures: a first welding fixture that supports and positions the carrying pieces, and a second welding fixture that supports and positions the secondary pieces. This segmentation allows each fixture to be optimized for its specific function, enabling the welding head to access all welding positions without obstruction while maintaining precise positioning accuracy for automated welding of the entire structure.
2Manufacturing precision
If welding fixtures are designed to support complex spatial structures, then assembly accuracy is improved, but the fixtures become difficult to remove and adapt to different dimensions
Solution Approach 1:
The welding fixtures incorporate movable and adjustable components, including movable plates that can slide along the carrying pieces, adjustable supporting elements that can be positioned at different locations, and removable coupling means. These dynamic features enable the fixtures to adapt to various dimensions and configurations of bar truss girders while maintaining precise assembly accuracy, and allow for easy removal and reuse on different structures.
3Adaptability or versatility
If manual welding is used to complete complex structures, then flexibility is maintained, but production quality becomes inconsistent and costs increase
Solution Approach 1:
The welding fixture system is designed as a universal multi-functional setup where the first and second welding fixtures can be used in combination to weld various types of bar truss girders with different configurations. The fixtures provide consistent positioning and support for automated welding across different structures, eliminating the need for manual welding while maintaining flexibility through their adjustable and adaptable design, thereby ensuring consistent production quality.
Data Source
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AI summary
The present invention concerns a welding process operated by an automatic equipment, comprising the following steps: - pre-assembling elements (11, 12, 13) to be welded coupling them according to the respective welding positions, - welding the pre-assembled elements (11, 12, 13) by means of an automatic welding equipment. The invention also relates to a welding fixture for being used according to said process.