Welding Sequencer Control 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 of welding schedules, leading to reduced productivity and increased error rates, as operators must manually switch between schedules and perform multiple tasks, including welding and inspections, which can result in defective parts and rework.
Innovation Solution
A welding job sequencer system that automatically identifies and configures welding sequences and schedules, allowing for real-time parameter collection and model generation to improve quality and efficiency by automating equipment adjustments and reducing operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple welding schedules are stored in the work cell to handle complex assemblies, then the ability to perform diverse welding procedures is improved, but the operator still needs to manually switch between schedules which reduces productivity
Solution Approach 1:
The system automatically selects and switches between welding schedules based on the workpiece being welded, eliminating the need for manual operator intervention. The work cell serves itself by autonomously determining which schedule to use and configuring the equipment accordingly, thus maintaining versatility while improving productivity.
Solution Approach 2:
The system pre-configures multiple welding schedules in advance and automatically selects the appropriate one before welding begins. This preliminary preparation eliminates the need for manual schedule switching during operation, allowing the operator to focus on welding while the system handles schedule management.
2Adaptability or versatility
If the operator manually adjusts welding schedules for different welds, then flexibility in handling varying welding conditions is improved, but the time required for setup and reconfiguration increases
Solution Approach 1:
The system automatically determines the appropriate welding schedule based on the workpiece and welding conditions, eliminating the need for manual adjustment. The work cell configures itself by selecting the correct schedule and adjusting parameters automatically, thus maintaining flexibility while reducing setup time.
Solution Approach 2:
The system pre-configures welding schedules for various conditions and automatically selects the appropriate one before welding begins. This preliminary preparation eliminates the need for manual schedule switching during operation, allowing the operator to focus on welding while the system handles schedule management.
3Reliability
If the operator performs multiple tasks including welding and inspections, then comprehensive quality control is improved, but the complexity of operation increases and error rates rise
Solution Approach 1:
The system extracts the schedule selection and equipment configuration tasks from the operator's responsibilities. By automating these functions, the operator's role is simplified to focusing on welding execution and quality inspection, reducing operational complexity while maintaining comprehensive quality control.
Solution Approach 2:
The system acts as an intermediary between the welding requirements and the operator, automatically managing schedule selection and equipment configuration. This intermediary function reduces the cognitive load on the operator while ensuring that quality control requirements are met through automated schedule management.
4Adaptability or versatility
If manual schedule switching is required between welds, then the ability to adapt to different welding procedures is improved, but the number of defects and rework increases
Solution Approach 1:
The system automatically selects and configures the appropriate welding schedule based on the specific weld requirements, eliminating manual intervention. This self-service approach ensures that the correct schedule is applied consistently, reducing human error while maintaining the ability to handle diverse welding procedures.
Solution Approach 2:
The system pre-configures welding schedules for various procedures and automatically selects the appropriate one before each weld. This preliminary preparation ensures that the correct parameters are set in advance, eliminating the risk of manual configuration errors and maintaining high weld quality across different procedures.
Data Source
AI summary
The invention described herein generally pertains to a system and method for collecting one or more welding parameters in real time during creation of one or more welds using a welding sequence. The one or more welding parameters can be associated with a particular welding sequence. Moreover, based on the one or more welding parameters collected, a modeled welding parameter can be generated to increase quality, efficiency, and the like. A collection component collects real time welding parameter data from which a quality manager component creates a modeled welding parameter. The modeled welding parameter can be employed for the welding sequence to monitor or track the welding parameter during a subsequent weld.