Welding Parameter Interface With Real-Time Pictograph Guidance

Solution Overview

Problem

Existing welding power supply systems require operators to manually calculate or adjust parameters through trial and error, leading to potential errors in settings, which can result in poor weld quality, increased material costs, and reduced productivity, especially for less experienced welders.

Innovation Solution

A robotic system with a user interface that includes a display and processor to analyze and adjust welding parameters, providing pictographic warnings and real-time visual representations of parameter changes, allowing for intuitive adjustments and preventing improper settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If operators manually calculate or adjust welding parameters through trial and error, then they can achieve desired weld results, but this leads to potential errors in settings, poor weld quality, increased material costs, and reduced productivity

Engineering Contradiction:

Improveweld qualityVSAvoidproductivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs self-diagnosis and self-adjustment of welding parameters. The processor automatically analyzes welding conditions and adjusts parameters without requiring manual intervention or trial-and-error by operators, thereby improving both weld quality and productivity simultaneously

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates real-time feedback mechanisms where the processor continuously monitors welding parameters and provides immediate adjustments based on analyzed data, preventing errors before they occur and maintaining optimal weld quality without reducing productivity

Inventive Principle:

Principle #23Feedback

2Ease of operation

If operators manually calculate or adjust welding parameters, then they can control the welding process, but this requires extensive experience and leads to errors for less experienced welders

Engineering Contradiction:

Improveease of parameter adjustmentVSAvoidreliability of parameter settings

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system performs self-diagnosis and self-adjustment of welding parameters. The processor automatically analyzes welding conditions and adjusts parameters without requiring manual intervention or trial-and-error by operators, thereby improving both weld quality and productivity simultaneously

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical adjustment of parameters with an automated electronic control system. The processor electronically analyzes and adjusts parameters based on sensor data, eliminating the need for operators to manually calculate or physically adjust settings, thereby improving both ease of operation and reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If operators experiment by adjusting welding profile to achieve desired weld, then they can find suitable parameters, but this results in reduced quality, lost productivity and increased material costs

Engineering Contradiction:

Improveability to adapt welding parametersVSAvoidmaterial costs

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The system performs preliminary analysis of welding parameters before the actual welding process begins. The processor pre-calculates optimal settings based on workpiece characteristics and welding conditions, preventing material waste by avoiding trial-and-error adjustments during production

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system performs self-diagnosis and self-adjustment of welding parameters. The processor automatically analyzes welding conditions and adjusts parameters without requiring manual intervention or trial-and-error by operators, thereby improving both weld quality and productivity simultaneously

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11847298B2User interface with real time pictograph representation of parameter settings

Publication Date: 2023.12.19 LINCOLN GLOBAL INC

AI summary

Provided is an electric arc generation system comprising a robot, an electric arc torch attached to the robot, a power supply configured to provide an electrical power output to the torch, and a user interface for adjusting a plurality of power supply parameters. The user interface comprises a display. The system includes a processor configured to receive respective settings of the plurality of power supply parameters, and configured to analyze the settings of the plurality of power supply parameters and control the display to display a pictograph warning associated with a current parameter setting, based on a result of analyzing the settings of the plurality of power supply parameters. Said pictograph warning graphically indicates an adjustment direction for the current parameter setting. The processor is configured to automatically adjust one or more of the settings of the plurality of power supply parameters based on a predetermined operating angle of the torch.