Mechanical Positioning Aid for Fast Wire Feed Retooling
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Solution Overview
Problem
Current methods for retooling welding installations, such as those used for manufacturing grating, are inefficient due to high costs, susceptibility to malfunctions and soiling, and require extensive programming and manual intervention, leading to prolonged retooling times and potential human errors.
Innovation Solution
A device comprising a positioning element with a modifiable surface and a setting aid that interacts mechanically with the apparatus component to rapidly and accurately set the desired operating position, allowing for quick and reliable reconfiguration of longitudinally displaceable components like wire feeds in welding installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automatic actuating units are used for positioning, then positioning can be automated, but the cost increases and the system becomes susceptible to malfunctions and soiling
Solution Approach 1:
The patent replaces complex automated actuating units (electrical, hydraulic, pneumatic) with a simple mechanical positioning system using a measuring rail and setting aid. The setting aid mechanically engages with the apparatus component and allows direct manual positioning against the measuring rail markings, eliminating susceptibility to malfunctions and soiling associated with automated systems.
Solution Approach 2:
The patent employs a simple, inexpensive measuring rail with markings that can be easily replaced or reset. The setting aid is a basic mechanical tool without complex components, making it cost-effective and resistant to the issues plaguing expensive automated systems.
2Measurement precision
If optical systems are used for positioning, then positioning accuracy can be improved, but sensitivity to soiling increases and only single-user operation is allowed
Solution Approach 1:
The patent replaces optical sensing systems with a purely mechanical measurement and positioning system. The measuring rail provides physical markings that can be read directly, and the setting aid provides mechanical guidance for positioning. This eliminates sensitivity to soiling while maintaining sufficient positioning accuracy for the application.
Solution Approach 2:
The measuring rail provides a physical copy or reference of the desired positions through markings, allowing multiple users to independently read and follow the same positioning information without interference from soiling that would affect optical sensors.
3Measurement precision
If measuring rails with markings are used, then positioning can be achieved, but the process becomes laborious and time-consuming
Solution Approach 1:
The setting aid serves as an intermediary tool that bridges the measuring rail and the apparatus component. It provides mechanical guidance and engagement features that make transferring the position information from the measuring rail to the apparatus component quick and intuitive, reducing the laborious nature of direct measurement reading.
Solution Approach 2:
The measuring rail is pre-marked with the necessary positioning information before the retooling process begins. The setting aid is designed with pre-configured engagement features that align with these markings, allowing operators to quickly set positions without complex measurements or calculations during the actual retooling operation.
4Extent of automation
If programming is required for new geometries, then automated operation is possible, but the cost and time for programming increase
Solution Approach 1:
The patent extracts the intelligence from automated programming and places it into the physical design of the measuring rail and setting aid. The positioning information is embedded in the physical markings and mechanical features rather than being stored in programmable memory, eliminating the need for programming while maintaining automated-capable precision.
Solution Approach 2:
The measuring rail and setting aid system is self-configuring through its physical design. When the rail is installed with its pre-marked positions, the system automatically provides the correct positioning information without requiring external programming input. The mechanical features self-align to provide the correct settings.
Data Source
AI summary
A device, use of the device and method for setting a specific operating position of an apparatus component, such as a wire feed of a welding installation. The apparatus component can be moved, in particular linearly displaced, to set the specific operating position and, after being moved into the specific operating position, can be fixed in place in said position for operation. The device includes a positioning element that has a modifiable surface on which the specific operating position can he preset for operation; and a setting aid that comprises at least one region interacting with the modifiable surface of the positioning element, and which is embodied to lie against the apparatus component.