Mechanical Positioning Aid for Welding Wire Feeder Changeovers
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Solution Overview
Problem
Existing methods for quickly and precisely adjusting the operating position of device components in production systems, such as welding systems, are inefficient due to complexity, susceptibility to contamination, and require extensive programming or manual effort, especially when handling small batch sizes and varying geometries.
Innovation Solution
A device comprising a positioning element with a changeable surface and an adjustment aid that interacts mechanically with the device component to facilitate quick and precise positioning, allowing for multiple operating positions to be set on a single element, reducing human error and enabling simultaneous multi-person operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automatic actuating units are used for positioning, then positioning speed and precision are improved, but device complexity increases and reliability decreases due to susceptibility to contamination and malfunctions
Solution Approach 1:
The patent extracts the complex automatic actuating units and replaces them with simple mechanical positioning aids and manual adjustment mechanisms. The positioning aid with markings and scales provides the necessary positioning functionality without requiring complex motors, sensors, or control systems, thereby reducing device complexity while maintaining positioning precision.
Solution Approach 2:
The positioning aid is designed as a simple, inexpensive mechanical component that can be easily replaced or adjusted. Rather than investing in expensive, complex automatic actuating units that are prone to failure, the patent uses a straightforward mechanical solution that is robust, easy to maintain, and sufficient for the positioning requirements.
2Measurement precision
If optical systems are used for positioning, then positioning precision is improved, but reliability decreases due to high sensitivity to contamination
Solution Approach 1:
The patent replaces optical positioning systems with a purely mechanical positioning aid. The mechanical system uses physical markings, scales, and direct contact measurement methods that are not sensitive to contamination from welding spatter, metal dust, or other environmental factors, thereby ensuring reliable operation in harsh welding environments.
3Speed
If automated actuating units are used, then positioning speed is improved, but loss of time increases due to required programming for new geometries
Solution Approach 1:
The positioning aid is designed to be self-explanatory and self-sufficient, providing all necessary positioning information through its markings and scales. Operators can directly read and interpret the positioning information without requiring programming knowledge or complex setup procedures, eliminating programming time while maintaining fast positioning capability.
4Ease of operation
If dimension strips are used for positioning, then ease of operation is improved, but loss of time increases due to complicated procedures and additional electronic aids
Solution Approach 1:
The patent merges the positioning information and measurement functions into a single integrated positioning aid. The positioning aid combines scale markings, reference points, and measurement indicators in one device, eliminating the need for separate dimension strips and electronic aids, thereby simplifying the procedure and reducing changeover time.
Data Source
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AI summary
The invention relates to a device (1) for setting a specific operating position of a device component (2), such as a wire feeder of a welding system (3), wherein the device component (2) is movable, in particular displaceable, for setting the specific operating position and, after being moved into the specific operating position, can be fixed in this position for operation. According to the invention, the device (1) comprises: - a positioning element (4) having a variable surface (5) on which the specific operating position for operation can be preset; - an adjustment aid (8) having at least one area that interacts with the variable surface (5) of the positioning element (4) and that is designed to abut the device component (2).Furthermore, the invention relates to a use of such a device (1) and a method for setting a specific operating position of a device component (2).