Welding Robot Tool Positioning for Centred Joints
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Solution Overview
Problem
Existing methods for joining sheets using industrial robots often result in off-centred joints due to inaccurate positioning, leading to surface quality issues and increased costs from the use of compressed-air or electrically controlled balancing systems.
Innovation Solution
A method where one of the tool arms detects the actual position of the sheets and the robot compensates to achieve a centred joint by calculating the difference between the actual and ideal positions, using either an electric servo motor or an electric circuit to adjust the tool's position, eliminating the need for compressed-air or electrically controlled equalizing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a compressed-air or electrically controlled balancing system is used to centre the tool, then positioning precision is improved, but device complexity and operating costs increase
Solution Approach 1:
The patent replaces complex compressed-air or electrical balancing systems with a simple mechanical solution: a movable electrode arm that can be positioned by the robot. The robot moves the electrode arm to compensate for sheet positioning errors, achieving centring without requiring additional balancing infrastructure. This substitutes sophisticated control systems with basic robotic positioning capability.
Solution Approach 2:
The system uses the robot's own positioning capability to centre the joint rather than requiring a separate balancing system. The robot detects sheet position and autonomously adjusts the electrode arm position to achieve centring, making the system self-sufficient without external balancing assistance.
2Manufacturing precision
If a compressed-air or electrically controlled balancing system is used to centre the tool, then positioning precision is improved, but operating costs increase
Solution Approach 1:
The patent eliminates the need for compressed-air cylinders or electrical servo motors dedicated to balancing by using the robot's standard positioning system. This removes ongoing costs associated with compressed air consumption or dedicated electrical power for balancing actuators, reducing operating expenses while maintaining precision.
3Ease of manufacture
If the second fixed arm is not centred with the sheets, then manufacturing simplicity is maintained, but surface quality deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the robot detects the actual sheet position and uses this information to adjust the electrode arm position accordingly. This closed-loop approach ensures that even if the tool is not initially centred, the system compensates to achieve proper alignment, maintaining surface quality without requiring perfect initial tool setup.
Solution Approach 2:
The patent makes the electrode arm position dynamic rather than fixed. The robot can move the electrode arm to different positions based on detected sheet location, allowing the system to adapt to positioning variations and maintain centring accuracy throughout the manufacturing process.
Data Source
AI summary
A method for joining together at least two sheets with a tool controlled by an industrial robot and including a first arm and a second arm that are mutually movable in relation to each other. An actual position of the sheets is detected by bringing one of the arms to sense the actual position of the sheets. The distance between an ideal position and the actual position is calculated and the actual position of the tool is moved the calculated distance, whereafter the sheets are joined together.