Independent Workpiece Transport Control for Precise Welding Offsets
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Solution Overview
Problem
The production of precision 'tailored blanks' in the automotive industry is hindered by deviations in workpiece offsets and dimensions, leading to inefficiencies, increased waste, and additional costs due to wear in transporting installations and dissimilar workpiece dimensions.
Innovation Solution
A method for controlling a cyclically operating joining device, specifically a welding station, where transporting installations for workpieces are actuated independently to set precise offsets between their head and tail ends using control variables, allowing for real-time detection and regulation of deviations to maintain high precision and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If transporting installations are used to convey workpieces, then productivity is improved, but manufacturing precision deteriorates due to wear and expansion of transporting segments
Solution Approach 1:
The patent implements a feedback mechanism where the actual offset of workpieces is measured and compared against the target offset. Based on this comparison, control variables are adjusted to compensate for deviations caused by transporting installation wear, ensuring precision is maintained despite continuous operation
Solution Approach 2:
The patent changes the parameters of the transporting installations by adjusting control variables that modify the position of transporting segments. This allows dynamic compensation for wear-induced expansions, maintaining precise workpiece positioning throughout the production process
2Device complexity
If fixed offset settings are used in transporting installations, then device complexity is reduced, but manufacturing precision deteriorates due to inability to compensate for wear and workpiece dimension variations
Solution Approach 1:
The patent transforms the static offset setting into a dynamic system where control variables can be adjusted in real-time. This allows the transporting installations to adapt to wear and workpiece variations, maintaining precision without requiring complete redesign of the control system
3Loss of substance
If transporting segments are enlarged due to wear, then loss of substance occurs, but manufacturing precision deteriorates due to dissimilar workpiece positions
Solution Approach 1:
The feedback mechanism detects position deviations caused by worn and enlarged transporting segments. The system then adjusts control variables to compensate for these deviations, ensuring that workpieces maintain correct positions despite the physical wear of the transporting segments
Data Source
AI summary
The invention relates to a method for controlling a cyclically operating joining device, in particular a welding station, for joining a plurality of workpieces to a circuit board, wherein the joining device comprises at least one first transport device for a first workpiece in a first transport segment, and a second transport device for a second workpiece in a second transport segment, and the transport devices are controlled, independently of each other, by at least one control variable to configure an offset between head ends and/or rear ends of the workpieces prior to joining, wherein the control variable is associated with at least one transport segment of one of the transport devices.