Configurable Welding Table with Force Indicating Clamp
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Solution Overview
Problem
Existing welding technologies face challenges in securely mounting and rotating large workpieces for horizontal welding, which is essential for consistent and uniform welds, as they often require skilled labor and high-quality positioners to maintain precise positioning and force during the welding process.
Innovation Solution
A configurable welding table system with rotatable mounting clamps and adjustable mounting pieces that securely attach workpieces to the table, allowing for precise positioning and rotation, and incorporating a force-indicating mechanism to ensure the workpiece remains stationary during rotation, using a combination of clamps, crowders, and datums to manage the clamping force effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large positioners are used to rotate workpieces for horizontal welding, then weld quality is improved, but device complexity and cost increase
Solution Approach 1:
The welding table system is divided into modular components including multiple clamps positioned at different locations, each independently adjustable and configurable. This segmentation allows the workpiece to be securely held without requiring a single complex large positioner, as multiple simpler clamps work together to achieve the same positioning and rotation capability.
2Measurement precision
If clamps are used to secure workpieces to the welding table, then positioning precision is improved, but workpiece movement during rotation may occur
Solution Approach 1:
Different clamps are configured with different clamping forces and positioning characteristics suited to specific locations on the welding table. The system allows local optimization of clamping parameters at each position, ensuring that each clamp provides the appropriate level of securing force for its specific location, thereby maintaining workpiece stability during rotation while achieving precise positioning.
3Adaptability or versatility
If configurable mounting pieces are used to position workpieces, then adaptability is improved, but device complexity increases
Solution Approach 1:
The mounting pieces are designed as universal, multi-functional components that can be positioned and configured at various locations on the welding table to accommodate different workpiece sizes, shapes, and welding requirements. These standardized mounting pieces perform multiple functions including positioning, clamping, and rotation support, reducing the need for specialized equipment for each specific welding task.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and high-quality welding by allowing robotic welders to perform horizontal welds consistently, reducing the need for skilled labor and increasing production efficiency, while ensuring accurate clamping forces to prevent workpiece movement during rotation, thus improving the overall fabrication process.
Implementation Method 1
a spring that compresses in response to a force applied from the shaft that is transferred to the clamping lever and to the work piece
Implementation Method 2
a deflection gauge that measures the compression of the spring to provide a measurement of the force applied by the crowding tool to the work piece
Implementation Method 3
a clamping lever that applies a clamping force to hold the work piece securely to the configurable table
Data Source
AI summary
Disclosed is a configurable table that uses configurable mounting pieces to mount a work piece on the configurable table at a predetermined location. The configurable table includes a fixed portion of a mounting clamp that can engage a rotatable portion of a mounting clamp on a positioner or other device. The positioner can then rotate the configurable table and work piece to various orientations for performing horizontal welds, using robotic welders, as well as machining and cutting. The configurable table can also be used for initial fabrication, cutting, or working, which eliminates the need for separate fabrication and finish welding tables.