Welding Job Sequencer for Automatic Multi-Schedule Weld Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Semi-automatic welding work cells face inefficiencies due to the need for manual adjustments of welding schedules and increased human error, leading to reduced productivity and quality, especially when dealing with complex assemblies requiring multiple welding schedules.
Innovation Solution
A welding system with a welding job sequencer that identifies operators, selects appropriate welding sequences based on biometric data and RFID signals, and automatically adjusts equipment settings to perform welds without operator intervention, ensuring accurate sequencing and scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welding schedules are used for complex assemblies, then welding quality and compliance with specifications improve, but operator workload and potential for human error increase
Solution Approach 1:
The system automatically manages welding schedules without requiring operator intervention. The sequencer autonomously selects appropriate schedules, transitions between them, and adjusts equipment settings based on workpiece identification, allowing the system to serve itself rather than requiring continuous operator management
Solution Approach 2:
The patent replaces the manual mechanical process of schedule selection and equipment adjustment with an automated control system. The sequencer uses sensors, processors, and actuators to automatically configure welding parameters and transition between schedules, eliminating the need for manual operator actions
2Adaptability or versatility
If manual adjustment of welding schedules is required, then adaptability to varying welding conditions improves, but productivity decreases due to operator interruption
Solution Approach 1:
The system dynamically adapts welding schedules based on real-time conditions and workpiece identification. The sequencer automatically detects when a different schedule is needed and transitions between schedules without requiring manual intervention, maintaining both adaptability and continuous productivity
Solution Approach 2:
The welding sequencer acts as an intermediary between the welding equipment and the operator. It automatically interprets welding conditions, selects appropriate schedules, and manages equipment configuration, eliminating the need for direct operator intervention while maintaining system adaptability
3Ease of operation
If welding schedules are simplified to reduce operator workload, then ease of operation improves, but productivity and quality decrease
Solution Approach 1:
The system maintains multiple complex welding schedules in the database but automatically manages their selection and application. This allows the system to preserve full welding capability while presenting a simplified interface to the operator, who only needs to load the workpiece rather than manually configure schedules
Solution Approach 2:
The welding sequencer serves multiple functions: it identifies workpieces, selects appropriate schedules from multiple options, configures equipment settings, monitors welding parameters, and manages transitions between different welding operations. This multi-functionality consolidates complex tasks into a single automated system
4Productivity
If automated welding sequence selection is implemented, then productivity and consistency improve, but system complexity increases
Solution Approach 1:
The automated system is divided into distinct functional modules: workpiece identification module, schedule selection module, equipment control module, and monitoring module. Each module performs a specific function, making the overall complex system manageable through functional segmentation and modular design
Data Source
AI summary
The invention described herein generally pertains to a system and method for evaluating one or more conditions or preliminary weld condition related to a welding system and/or method that utilizes a welding sequence to perform two or more welds with respective welding schedules. In an embodiment, an operator registration is provided that verifies the operator and identifies welding sequences to which the operator is authorized to perform. In another embodiment, one or more fixture locations are monitored to determine whether a workpiece is accurately configured prior to a welding operation. In still another embodiment, locations on a workpiece can be displayed to assist an operator in performing two or more welds utilizing a welding sequence. Moreover, a wireless system communications a data signal to a welding work cell in which such data is used to identify a welding sequence.