Welding Positioner Control for Automatic Workpiece Positioning
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Solution Overview
Problem
The existing welding systems for large workpieces, such as steel frame structures, require manual and time-consuming positioning of the workpiece and positioner, which is inefficient and prone to errors.
Innovation Solution
A welding system that includes a control device capable of automatically calculating the position of the positioner based on reference position information and workpiece information, using a positioner position calculation means to optimize the holding mechanism's position for efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual positioning of the positioner is used based on worker experience, then positioning can be performed with simple equipment, but the work is very time-consuming and troublesome
Solution Approach 1:
The patent replaces the manual mechanical positioning system with an automated calculation system using a positioner position calculation unit. This unit automatically calculates the positioner position based on workpiece information (3D data, gravity center) and welding position data, eliminating the need for manual trial-and-error positioning while significantly reducing positioning time and improving work efficiency
Solution Approach 2:
The system enables self-service positioning by automatically determining the optimal positioner position without requiring worker intervention. The positioner position calculation unit autonomously processes workpiece data and welding requirements to calculate the correct position, making the positioning process self-sufficient and eliminating dependency on worker experience
2Extent of automation
If automated welding is implemented after manual positioning, then welding automation is achieved, but the positioning process remains manual and inefficient
Solution Approach 1:
The patent segments the welding system into distinct functional units: a positioner position calculation unit that handles automated positioning calculations, and a welding robot control unit that handles welding execution. This segmentation allows the positioning and welding functions to be independently optimized, enabling full automation of both processes while maintaining operational simplicity
Solution Approach 2:
The system performs preliminary automated calculation of the positioner position before the actual welding operation begins. The positioner position calculation unit computes the optimal position based on pre-input workpiece information and welding data, so that when welding starts, both the positioner and welding robot are already configured for automated operation without manual intervention
Data Source
AI summary
A welding system configured to weld a workpiece by using a welding device and a positioner includes a control device configured to control the welding device and the positioner. The positioner includes a workpiece position setting mechanism having reference position information, and at least one holding mechanism configured to hold the workpiece. The control device includes a positioner position calculation means for calculating a position of the holding mechanism when holding the workpiece based on the reference position information provided from the workpiece position setting mechanism and workpiece information inputted into the control device in advance.