Welding Parameter Automation Using Component Data Records
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Solution Overview
Problem
Welding processes often require complex parameter settings and sequences, leading to errors and inconsistencies due to operator input, especially when dealing with multiple components and varying welding requirements.
Innovation Solution
A method where component-specific data records are used to automatically set welding parameters and sequences, eliminating the need for manual operator input by linking component identifiers to pre-defined parameter sets and sequences, ensuring accurate and consistent welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operator input is used for setting welding parameters and sequences, then the operator has flexibility to adjust parameters, but errors and inconsistencies occur due to operator input
Solution Approach 1:
Welding parameter sets and sequences are pre-defined and stored in the control device before the welding operation. The component data record contains pre-configured welding parameters that are automatically retrieved and applied, eliminating the need for manual parameter setting during operation and ensuring consistency across all welding tasks.
Solution Approach 2:
The welding system automatically retrieves component data records, identifies the correct welding parameters, and configures the welding machine without requiring manual operator intervention. The system serves itself by automatically matching component identifiers with corresponding welding parameter sets, reducing human error and improving reliability.
2Manufacturing precision
If complex welding sequences with multiple parameters are manually configured, then precise control is achieved, but the operation becomes time-consuming and error-prone
Solution Approach 1:
All welding parameters and sequences are pre-configured and stored in the control device before production. The component data records contain complete welding instructions that are automatically retrieved, eliminating the time-consuming process of manual parameter setup for each welding task while maintaining precision.
Solution Approach 2:
The system uses stored copies of welding parameter sets associated with specific component identifiers. Instead of manually configuring parameters each time, the system retrieves pre-saved parameter copies from the control device, significantly reducing setup time while maintaining manufacturing precision.
3Reliability
If welding parameters are stored in electronic memory for retrieval, then parameter consistency is improved, but the system complexity increases
Solution Approach 1:
The control device serves multiple functions: it stores component data records, retrieves welding parameters, identifies components, and controls the welding process. By making the control device universal and multi-functional, the patent avoids adding separate dedicated systems for each function, thereby managing complexity while improving reliability.
Data Source
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AI summary
The invention relates to a method for controlling a welding device (4), carried out on at least one device, including at least one welding device (4), in which a component data record assigned to a specific component is obtained, the welding parameter setpoint values for a process to be carried out on the component Specifies welding process, and in which the welding device (4) is automatically adjusted according to the specified welding parameter setpoints for the welding process. The invention further relates to a system (2) comprising a welding device (4), having control means (8) which are set up for carrying out and/or controlling the aforementioned method, and a computer program comprising program instructions which have at least one processor for executing and/or or cause control of the aforementioned method when the computer program is running on the at least one processor.