Welding Assembly for Tubular Components with Complex Geometries
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Solution Overview
Problem
Existing welding assemblies for joining tubular components with non-orthogonal intersection curves are inefficient and costly due to manual operation and limited automation, as they struggle with large and heavy components, and require multiple robots for complex angles, leading to incomplete welds and increased production time.
Innovation Solution
A flexible and compact welding assembly with a 6-axis open kinematic chain manipulator unit and a supply module that allows the welding tool to rotate 360° around the tube longitudinal axis, enabling uninterrupted welds on components with varying diameters and angles, using a securing assembly with radially extendable friction elements for secure attachment and a modular design for easy deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual welding is used for large and heavy tube components, then welding quality can be maintained, but production is lengthy and inefficient
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated welding robot system. The robot executes pre-programmed welding paths and parameters, eliminating manual labor while maintaining weld quality through precise control of welding current, speed, and position. This substitution directly addresses the contradiction by automating the process to improve productivity without sacrificing manufacturing precision.
Solution Approach 2:
The patent employs programmable control to optimize welding parameters (current, voltage, speed, torch angle) for different tube configurations. By changing parameters digitally rather than manually, the system maintains high welding quality across various joint types while significantly improving production efficiency through automated parameter adjustment and consistent execution.
2Manufacturing precision
If multiple welding robots are used for complex tube angles, then complete welds can be achieved, but device complexity and cost increase
Solution Approach 1:
The patent designs a universal welding robot system with adjustable end-effectors and programmable paths that can handle various tube angles and configurations (X-joints, Y-joints, K-joints, double-K joints) with a single robot. The system achieves weld seam completeness through sophisticated path planning and positioning rather than multiple robots, reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent employs a dynamically adjustable welding system where the robot can change its approach angles, torch orientations, and welding parameters in real-time based on the joint configuration. This dynamic adaptability allows a single robot to perform tasks that would traditionally require multiple fixed-position robots, simplifying the overall system while ensuring complete weld coverage for complex geometries.
3Productivity
If automated welding is implemented, then production efficiency improves, but adaptability to different tube configurations decreases
Solution Approach 1:
The patent uses pre-programmed welding paths and parameters stored in memory for different joint types (X, Y, K, double-K). Before welding begins, the system loads the appropriate program corresponding to the specific tube configuration. This preliminary preparation allows the automated system to adapt to different configurations quickly without reprogramming during operation, maintaining both high productivity and versatility.
Solution Approach 2:
The patent divides the welding process into discrete, programmable segments or modules, each optimized for specific joint types. The system can select and execute the appropriate segment based on the tube configuration. This segmentation allows the automated system to maintain high efficiency through specialized routines while adapting to various joint geometries by simply switching between pre-defined segments.
4Manufacturing precision
If welding is performed on tube joints with angles less than 45°, then spatial challenges arise and welding tool rotation is limited, but welding must still be completed
Solution Approach 1:
The patent approaches the welding problem by utilizing multiple spatial dimensions and approach angles. Instead of being constrained to a single welding direction, the robot can approach the joint from different angles and positions in three-dimensional space. This dimensional flexibility allows the system to access and complete welds on tight-angle joints (less than 45°) that would be inaccessible from a single direction, maintaining weld completion while improving spatial accessibility.
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
The solution enables efficient, high-quality welding of tubular components with complex geometries by allowing continuous, uninterrupted welds and reducing production time and costs, as it can handle components with diameters up to several centimeters and angles less than 45° without additional supports, ensuring complete weld seam filling and scalability for various tube joint configurations.
Implementation Method 1
radially extendable friction elements for secure attachment
Data Source
AI summary
The invention relates to a welding assembly for the permanent joining of a first tubular component with a second component along a two- or three-dimensional intersection curve, along which both components contact, comprising a securing assembly for detachably securely joining on a tubular end of the first component facing away from the intersection curve, a manipulator unit mounted directly or indirectly on the securing assembly such that it can pivot about a tube longitudinal axis assigned to the first component. The manipulator unit has a freely positionable manipulator end, with a welding tool attached to the freely positionable manipulator end. The securing assembly comprises a clamping module that can at least partially be introduced into the tubular end of the first component on the end side and in an axial manner. The clamping module is detachably securely to a tube inner wall of the first tubular component, as well as a carrier ring module which is rotatably attached to the clamping module, which axially extends beyond the tubular end of the first tubular component.