Automated Welding Table Layout for Splatter-Protected Grounding
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Solution Overview
Problem
Existing welding tables lack automation for component assembly and joining, and they often fail to protect against weld splatter, which can cause electrical shorts and disrupt operations.
Innovation Solution
An automated assembly and joining table with unique holder configurations, including zig-zag channels for grounding wires and an inverted rack and pinion arrangement, to prevent weld splatter from reaching electrical components, while allowing for the secure holding and reconfiguration of various parts for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed on a standard work surface, then joining of components is achieved, but weld splatter contacts electrical components causing electrical shorts
Solution Approach 1:
A shielding structure is introduced as an intermediary element between the welding area and electrical components. This shield acts as a physical barrier that intercepts weld splatter before it can reach sensitive electrical components, thereby protecting the electrical system while allowing welding operations to proceed
Solution Approach 2:
The grounding wire channel is designed with a zig-zag configuration that intentionally directs weld splatter away from critical areas. The harmful splatter is channeled through a controlled path that ultimately protects rather than harms the electrical system, converting the harmful effect into a beneficial protective feature
2Extent of automation
If manual repositioning of parts is performed on a welding table, then assembly flexibility is maintained, but automation capability is lacking
Solution Approach 1:
The table incorporates movable and adjustable components including repositionable holders and adjustable positioning mechanisms. These dynamic elements allow the table to adapt its configuration for different assembly tasks while being controllable through automated systems, bridging the gap between automation and versatility
Solution Approach 2:
The welding table is designed with universal features including multiple types of holders, adjustable positioning systems, and reconfigurable fixtures that can accommodate various component sizes and configurations. This multi-functionality allows a single automated table to handle diverse assembly tasks without requiring manual intervention
3Reliability
If grounding wires are routed directly across the work surface, then electrical connectivity is simple, but weld splatter causes electrical shorts
Solution Approach 1:
The grounding wire channel features a zig-zag curved path instead of a straight route. This curved configuration serves multiple functions: it provides mechanical protection for the wire, directs splatter away from the connection points, and maintains electrical connectivity while adding a protective geometric feature to the routing path
Data Source
AI summary
System and methods for automated joining of parts into an assembly are disclosed. A table includes holders for the parts positioned about a platform mounted to a base, the holders including a conductive surface to facilitate welding and a channel for receiving wiring to electrically ground the conductive surface. The table also includes motors for moving the holders relative to the platform. A controller is in electronic communication with the motors, industrial robot(s) for moving and welding the parts, and a machine vision subsystem for viewing a workspace including the table and operational area of the robot(s). The controller receives data describing the assembly to be formed and from the machine vision subsystem describing the parts and commands movement of at least some of the motors and robot(s) accordingly to move the parts into the holders and weld the parts into the assembly.