Automatic Welding Machine Guidance Marking for Roof Seals
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Solution Overview
Problem
Automatic welding machines struggle to maintain a consistent weld seam width due to misalignment with the overlapping edge of material webs, leading to reduced weld quality and potential water permeability in roof seals, requiring frequent manual corrections by operators.
Innovation Solution
A temporary guidance marking is generated on the material web using a light source and detected by a sensor device, allowing the automatic welding machine to adjust its path automatically, ensuring the weld seam remains parallel to the edge and maintaining consistent width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment correction is performed by an operator, then weld seam quality is improved, but productivity decreases and operation complexity increases
Solution Approach 1:
The welding machine automatically performs alignment correction by detecting the guidance marking and adjusting its own position, eliminating the need for manual operator intervention. The system serves itself by using the sensor device to detect the marking and the steering unit to automatically correct the path, thereby maintaining high weld seam quality while preserving productivity.
2Manufacturing precision
If manual alignment correction is performed continuously, then weld seam quality is improved, but device complexity increases
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical-mechanical system. A sensor device detects the guidance marking optically, and a steering unit automatically adjusts the machine's path based on detected deviations. This substitution eliminates the need for continuous manual intervention while maintaining precise alignment through automated feedback control.
3Productivity
If the automatic welding machine moves at constant speed, then productivity is improved, but manufacturing precision deteriorates due to alignment deviations
Solution Approach 1:
The system continuously detects the position of the guidance marking relative to the welding machine's movement path and feeds this information back to the steering unit. The steering unit automatically adjusts the machine's trajectory in real-time based on the detected deviation, ensuring that the weld seam width remains consistent even while moving at constant high speed.
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
This method enhances weld seam quality and user friendliness by eliminating the need for continuous manual alignment, increasing welding speed and accuracy, and preventing water permeability in roof seals.
Implementation Method 1
A temporary guidance marking which moves along with the automatic welding machine and which defines a movement path for the automatic welding machine is generated on the overlapped material web by means of a marking device arranged on the automatic welding machine
Implementation Method 2
The movement path of the automatic welding machine is defined by means of the guidance marking, in which automatic welding machine the guidance marking is detected with a sensor device during the movement of the automatic welding machine
Data Source
AI summary
The invention relates to a method for connecting material webs disposed with overlapping edges, wherein an automatic welding machine having a driven chassis and a drive unit disposed thereon and a welding unit is guided along the overlap zone of the material webs to be connected, such that the carried welding unit connects the edges to be connected to one another. The invention further relates to an automatic welding machine for performing the method. The invention proposes that a temporary guide marking moving along with the chassis be generated along the edge of the overlapping material web by means of a marking unit disposed on the chassis, said guide marking always extending parallel to the edge and prescribing the path of the automatic welding machine on the overlapping material web and that the guide marking be detected by means of a sensor device during the movement of the automatic welding machine, wherein a control signal is generated for a display unit and/or the drive unit and the chassis is movable along the guide marking by means of the control signal.