Slidable Wire Feeder Mounting Assembly for Robotic Cable Stress Relief
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Solution Overview
Problem
In through-arm robotic MIG welding torch systems, the fixed length of the power cable causes stress and binding issues as the robotic arm moves, leading to premature cable failure and downtime due to inability to extend or contract.
Innovation Solution
A self-adjusting wire feeder mechanism with a slidable adapter plate and resilient members allows the wire feeder to move linearly relative to the robotic arm, adjusting the power cable length and reducing stress and binding by absorbing forces applied during arm articulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire feeder is fixedly mounted on the robotic arm, then the mounting structure is simple and stable, but the power cable experiences stress and binding during robotic arm movement
Solution Approach 1:
The wire feeder mounting assembly transitions from a fixed static mounting to a dynamic slidable mounting. The adapter plate can slide along the robotic arm axis within guide slots, allowing the wire feeder position to dynamically adjust during robotic arm movement. This dynamic adjustment prevents power cable binding and stress accumulation while maintaining a relatively simple mounting structure using guide slots, springs, and limit blocks.
2Ease of operation
If the power cable has a fixed length, then the cable structure is simple, but it causes stress and binding when the robotic arm articulates
Solution Approach 1:
The slidable adapter plate acts as an intermediary mechanism between the fixed-length power cable and the moving wire feeder. When the robotic arm articulates, the adapter plate slides along the guide slots to accommodate cable length changes, preventing direct stress transmission to the cable. The spring-loaded design provides controlled movement that absorbs cable tension while maintaining electrical connectivity.
3Reliability
If the wire feeder is stationary relative to the robotic arm, then the system structure is simple, but binding and snapping occur during arm movement
Solution Approach 1:
The mounting mechanism incorporates a slidable adapter plate that moves dynamically along guide slots on the robotic arm. This dynamic positioning allows the wire feeder to adjust its position relative to the arm during articulation, preventing cable binding and snapping. The mechanism uses simple components like guide slots, springs, and limit blocks to achieve this dynamic adjustment without excessive complexity.
4Duration of action of stationary object
If the power cable cannot extend or contract, then the cable structure is simple, but stress accumulates leading to premature failure
Solution Approach 1:
The spring-loaded slidable adapter plate provides beforehand cushioning for the power cable. The spring mechanism absorbs and cushions the stress that would otherwise accumulate in the fixed-length cable during robotic arm movement. This cushioning effect prevents stress concentration and premature cable failure, extending cable lifespan while adding only moderate complexity to the mounting assembly.
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 self-adjusting mechanism reduces wear and stress on the power cable, preventing binding and snapping, thereby extending the cable's lifespan and minimizing downtime.
Implementation Method 1
At least one resilient member biases the slidable adapter plate relative to the mounting bracket
Data Source
AI summary
A self-adjusting wire feeder mounting assembly includes a mount fixedly connectable to a multi-axis robotic arm, and a slidable, floating adapter plate for mounting of a wire feeder thereon. The adapter plate is coupled with and slidable about the mount, and the adapter plate is moveable relative to the mount when a force is applied to the wire feeder.