Modular Welding Equipment Tooling Cart Latch Mechanism
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Solution Overview
Problem
Existing modular welding machines require dedicated carts for each tooling module and necessitate new control programming for each switching operation, leading to inefficiencies and economic losses due to the need for scrapping entire machines when production needs change.
Innovation Solution
The implementation of a modular welding system with a base operating machine, a tooling cart, and a tooling cart latch that secures the tooling module during transfer and storage, allowing for easy switching between modules without the need for dedicated carts and enabling modular programming of welding sequences through a user interface, reducing the requirement for rewriting ladder logic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated welding machines with custom tooling are used, then welding precision and reliability for specific parts are improved, but adaptability to different parts deteriorates and economic loss increases when production needs change
Solution Approach 1:
The welding machine is divided into a base machine and separate tooling modules. The base machine contains the welding power source and control system, while tooling modules (fixtures, clamps, positioning devices) are detachable and can be swapped between different welding tasks. This segmentation allows the base machine to remain while only the tooling module needs to be changed when production needs change, maintaining welding reliability through the consistent base machine while improving adaptability through module interchangeability.
Solution Approach 2:
The base welding machine is designed with universal interfaces and mounting structures that can accommodate multiple different tooling modules. The machine frame includes standardized tooling module stations and alignment features that work with various module types. This universality allows a single base machine to perform multiple welding operations on different parts by simply changing the tooling module, eliminating the need for dedicated machines for each part type.
2Ease of manufacture
If entire welding machines are scrapped when tooling is no longer usable, then resource allocation is simplified, but economic loss increases due to discarding functional base machines
Solution Approach 1:
By separating the durable base machine from the wear-prone tooling modules, the system allows selective replacement of only the tooling module when it becomes worn or obsolete. The base machine with its expensive welding power source, control system, and frame structure can be retained and reused for multiple different tooling modules, significantly reducing economic loss while maintaining simple asset management through clear distinction between reusable base equipment and replaceable tooling components.
3Measurement precision
If alignment pins and sockets are used for tooling cart positioning, then vertical and lateral alignment is improved, but relative movement during module transfer still occurs and positioning precision deteriorates
Solution Approach 1:
The system uses preliminary alignment through pins and sockets to guide the tooling cart into approximate position, then employs latch members that engage between the cart and base machine to lock the relative positioning before tooling module transfer begins. This preliminary action ensures both high alignment precision and stable positioning throughout the module transfer operation, eliminating relative movement while maintaining the simplicity of mechanical alignment features.
4Extent of automation
If new control programming is required for each tooling module switching, then welding sequence control is improved, but programming time and operational complexity increase
Solution Approach 1:
The control system stores standardized welding sequences and parameters that can be copied and applied to different tooling modules. Instead of programming each module from scratch, the system allows operators to select from pre-configured welding sequences and make minor adjustments as needed. This copying approach maintains automated welding sequence control while dramatically reducing programming time and operational complexity when switching between different tooling modules.
Data Source
AI summary
Welding equipment that includes a tooling cart for transferring interchangeable tooling modules to a welding machine. A latch is mounted to the welding machine for latching the tooling cart to the welding machine, and a latch is provided for latching the tooling modules onto the tooling cart. A two-piece tooling cart includes a removable upper section for securing tooling modules thereto and a reusable lower section for use with other tooling modules. A welding method permits operation of a welding machine using a user interface that permits modular programming of at least one operational sequence of welding machine valves and weld operations for a variety of different tooling modules. An operator inputs a new sequence of operations using the user interface rather than having to rewrite ladder logic just to switch over the welding machine to use with a different tooling module.