Welding Job Sequencing for Automatic Schedule Switching
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Solution Overview
Problem
Semi-automatic welding work cells face inefficiencies due to the need for manual adjustments between welding schedules, leading to reduced productivity and increased error rates, as operators must manually switch between schedules and manage multiple welding sequences, which can result in defective parts and rework.
Innovation Solution
A welding system with a job sequencer that automatically selects and implements welding schedules based on real-time data, allowing for the creation of welding sequences that define specific procedures for different welds on a workpiece, thereby eliminating the need for operator intervention in configuring equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of welding schedules is used, then adaptability to varying welding conditions is improved, but productivity is reduced due to operator intervention requirements
Solution Approach 1:
The system enables self-service by allowing the welding equipment to automatically adjust between different welding schedules without operator intervention. The control system monitors welding conditions and autonomously selects appropriate schedules, eliminating the need for manual adjustments while maintaining adaptability to varying conditions.
Solution Approach 2:
The system implements preliminary action by pre-programming multiple welding schedules into the control system before operation begins. When welding conditions change, the system can immediately switch between pre-configured schedules without requiring real-time manual setup, thus maintaining adaptability while improving productivity.
2Adaptability or versatility
If multiple welding schedules are stored in the work cell, then adaptability is improved, but device complexity increases due to schedule management requirements
Solution Approach 1:
The control system achieves universality by designing a single multi-functional device that can store and execute multiple different welding schedules. This universal controller handles various welding conditions through one integrated system rather than requiring separate equipment for each schedule, thus increasing adaptability without proportionally increasing device complexity.
Solution Approach 2:
The control system acts as an intermediary between the operator and the welding equipment. It manages the complexity of multiple welding schedules internally, presenting a simplified interface to the operator while handling schedule selection and parameter adjustments automatically, thus reducing the perceived complexity for the user.
3Productivity
If automated robotic work cells are used, then productivity is improved, but adaptability to varying welding conditions deteriorates
Solution Approach 1:
The system implements dynamics by making the welding schedule selection adaptive and flexible rather than fixed. The control system can dynamically switch between different pre-programmed schedules based on real-time welding conditions, combining the productivity of automation with the adaptability previously only available in manual operations.
Data Source
AI summary
The invention described herein generally pertains to a system and method for welder system that relates to creating a welding sequence for a welding environment in which the welding sequence is based upon real time data collected from a performed or previously performed welding procedure. Welding procedure information is collected and utilized to create a welding sequence to perform two or more welds in which at least one parameter is based on the collected welding procedure information (e.g., real world welding procedure).