Welding job sequencer

The invention relates to a method of welding in a semi-automatic production socket, a semi-automatic production socket, and a welding production line of the type known from EP-A-1 0780707.

2. Description of Related State of Technology [0002] In the related art, production sockets are used to produce welds or weldments. There are at least two broad production nest categories, including automated production slots and semi-automatic production slots.

[0003] In automated production sockets, the scheduling and execution of the welding operations are largely automated, with little operator intervention, see, for example, documents US-A-6 624 3

US-A6 847 956, US-A-7 102 098. Thus, these sockets generally have relatively low labor costs and relatively high efficiency. However, their repetitive activities can not easily be adapted to changing conditions and / or welding sequences.

[0004] However, semi-automatic production sockets (i.e., production sockets that involve at least some of the welding performed by providing less automation of the operator) substantially compared to automated production sockets, and therefore have relatively higher labor costs and relatively higher labor costs. lower performance. Nevertheless, there are many cases

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EP 2 094 426 in which the use of half an automatic production welding socket may in fact be advantageous in relation to automated production slots. For example, a semi-automatic production welding socket can more easily adapt to changing conditions and / or welding sequences.

[0005] Unfortunately, when welding more complex assemblies in semi-automatic production slots from a related prior art, many different welding schedules are often required for different types of welds on different elements of the assembly. In many systems, when a different welding schedule must be used, the operator is required to stop welding operations and manually adjust the production capacity of the semi-automatic equipment in accordance with the new schedule. In some other systems, this manual adjustment is eliminated by storing specific schedules in the production slot. Nevertheless, even in such systems, the operator still has to stop welding and press the button to select a new welding schedule before he can continue welding.

[0006] None of these procedures for setting a different welding schedule is particularly effective. Thus, in practice, the number of welding schedules used in the semi-automatic production nest is often limited in order to eliminate the need for continuous adjustment of the manufacturing capacity of the semi-automatic equipment. Although this limitation of welding schedules makes the entire operation easier for the welder, enforced simplification of this method can lead to reduced performance and lower overall quality.

[0007] In addition, with strict adherence to the quality control specifications, it is sometimes necessary to perform welds in a given sequence, verify that each weld is

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EP 2 094 426 made with a specific set of conditions, and to monitor the production capacity of the equipment during the welding operation. In an automated production nest, these requirements are easy to meet. However, in a semi-automatic production nest, these requirements are susceptible to human error because the operator has to follow all these aspects in addition to performing the welding operations themselves.

An illustrative example of the above problems is illustrated in the semi-automatic method of welding in the associated prior art schematically shown in FIG. 1. In this method, each of the various scheduling, sequencing, inspection and welding activities is organized and performed by the operator himself (i.e., a welder). In particular, the operator starts the welding task at step 10. Then, the operator sets up the welding equipment according to schedule A, at step 20. Then, the operator performs # 1 weld # 2 and weld # 3 using welding schedule A at steps 22, 24 and 26. Then, the operator stops welding and sets up the welding equipment according to schedule B at step 30. Then,

[0009] Of course, the method shown in FIG. 1 depends on the operator who is to correctly follow the sequencing sequencing for welds and has to change exactly between the control schedules,

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Welding (as in operation 30), and to perform the welding itself. Errors in any of these duties may end with either reprocessing (if errors are caught during an inspection at step 60) or that a defective item will be delivered to the end user. In addition, this exemplary semiautomatic welding method limits performance because the operator has to spend time configuring and reconfiguring welding schedules.

[0010] The above problems require improvement in the system from the related prior art.

BRIEF SUMMARY OF THE INVENTION [0011] According to one aspect of the invention, a semi-automatic production welding socket is provided in accordance with claim 10.

[0012] According to another aspect of the invention, a method of welding is provided in a semi-automatic production nest as claimed in claim 1.

[0013] The above-mentioned aspects, as well as other aspects, features and advantages of the invention, will become apparent to those skilled in the art after reading the following description.

BRIEF DESCRIPTION OF THE DRAWINGS [0014] The foregoing and / or other aspects of the invention will become more apparent thanks to the detailed description of exemplary embodiments of the invention with reference to the accompanying drawings in which:

FIG. 1 illustrates the welding operation of the related prior art utilizing a semi-automatic production welding seat; and

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FIG. 2 illustrates the welding operation in accordance with the invention using a semi-automatic production welding socket.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS [0015] Exemplary embodiments of the invention will now be described below with reference to the accompanying Figures. The exemplary embodiments described are intended to assist in understanding the invention and are not intended to limit the scope of the invention in any way. The same reference numerals refer to the same elements throughout the description.

[0016] In an exemplary embodiment of the invention, a welding job sequencer is provided. The welding task sequencing device improves the semi-automatic production socket from the related prior art by increasing the semiautomatic productivity of the production socket without jeopardizing the number of welding schedules useful in it. The welding task sequencing device makes this improvement by performing an automatic change in the semi-automatic production nest, and by providing the operator with a series of commands and instructions.

[0017] More specifically, in an exemplary embodiment, the welding task sequencing apparatus automatically selects and performs the function of a production welding socket. An example of such a function includes a specific welding schedule to be used with a semi-automatic production socket. In other words, a welding task sequencing device can select the welding schedule to be used for a particular weld, and modify the presetting of the semi-automatic production slot according to the selected one.

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EP 2 094 426 of welding schedules, the operator to proceed with the invention is 2, by operation

110, the device starts the operation, the welding schedule, automatically for the operator (i.e., without special intervention of the operator).

[0018] According to the invention, a welding task sequencing apparatus automatically indicates a sequence of actions that an operator should perform to form a final welded assembly. In connection with the automatic selection, this indicated sequence allows according to this sequence to form the final welded element, without having to spend time regulating, selecting, or viewing each individual schedule and / or welding sequence. [0019] Accordingly, since the welding task sequencing device sets up the welding equipment and organizes the work process, and because the operator only performs the welding operations themselves, the chance of an error in the welding operation is greatly reduced, and the efficiency and quality are improved.

[0020] An exemplary embodiment schematically shown in FIG. 2. In FIG.

sequencing the welding tasks and immediately sets the welding equipment to use the welding schedule A (activity 120) and instructs the operator to make welds # 1, # 2 and # 3. Then, the operator performs # 1, # 2 and # 3 using the welding schedule A (steps 122, 124 and 126). Next, the welding task sequencing device sets the welding equipment to use the welding schedule B (step 130), and instructs the operator to make the weld # 4. The operator then makes the # 4 weld using the welding schedule B (steps 132). After completing the welding schedule B, the welding task sequencing device sets the welding equipment to use the welding schedule C (step 150) and instructs the operator to weld

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EP 2 094 426 # 5 and # 6, and to check the element. Then, the operator performs weld # 5 and # 6 (steps 152, and 154) using the welding schedule C, and checks the finished element to confirm that it is correct (step 160). This check may include dimensional verification, visual confirmation of defects, or any other type of control that might be needed. In addition, step 160 may include the requirement that the operator affirmatively indicate that the check is completed, for example, by pressing the "OK" button before going to the next step. Finally, the welding task sequencing device indicates that the welding operation is at the end (step 170), and again set for the next activity.

[0021] In connection with this, as mentioned above, the sequencing and scheduling of the welding operation is completed by a device for sequencing the welding operations, and releases the operator to focus on making the welds according to the instructions.

[0022] A welding task sequencing device may select and perform a new function, such as selecting and executing welding schedules A, B and C shown in FIG. 2, based on various variables or input data. For example, the welding task sequencing device can simply select new welding schedules based on monitoring the time that has elapsed since the start of the welding operation or from ceasing welding (e.g., time after the weld # 3 in FIG. 2 above). Alternatively, a welding task sequencing device can monitor operator actions, compare these activities to an identified weld sequence, and select new welding schedules, respectively. Still further, various combinations of these methods, or any other effective method, may be implemented,

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EP 2 094 426 provide automatic selection and implementation of a function, such as a welding schedule, for use by the operator.

[0023] The parameters of the selected welding schedule may include variables such as welding process, wire type, wire size, WFS, voltage, trim (trim) that the wire feed unit is to be used or which feed head is to be used, but are not them limited.

[0024] Although the description above focuses on the selection of a welding schedule as a function that is automatically selected and implemented, the welding task sequencing device is not limited to using only this function.

[0025] For example, another possible function that can be selected and implemented using a welding task sequencing device is to select one of the plurality of wire feeders on a single power source according to the welding schedule. This feature provides even greater variation in the welding tasks that can be performed by the operator in a semi-automatic production nest, since different wire feeders can provide a large variation, for example, size and wire types.

[0026] Another example of a function compatible with the welding task sequencing device is the Quality Control function. This function performs weld quality control (either during welding or after the weld is finished) before allowing the sequence of tasks to continue. The quality control may monitor various welding parameters and may interrupt the welding operation and alert the operator if an abnormality is detected. An example of a measurable welding parameter using this function would be the arc data.

[0027] A further example of such a function would be the Repeat function. This function would instruct the operator to repeat a specific weld or weld sequence. An example of using this function includes the situation when the function

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Quality Control shows an abnormality, or when many cases of the same weld are required.

[0028] A further example of such a function would be a Welder Notification function that transmits information to the welder. This function would display information, give an audible signal, or communicate with the welder using some other means. Examples of the use of this function include an indication to the operator that he is free to start welding, or an indication that the operator should check a certain section of the welded element for quality.

[0029] A further example of such a function would be the Entry of Task Information function. This feature will require the welder to enter information such as the element's serial number, personal ID number, or other specific conditions before the welding job sequencing unit can continue to operate. This information could also be read from the item itself or inventory markings via RFID, barcode scanning, or the like. The welding task sequencing device could then use the input information for the welding operation. An example of using this function would be a support for the entire welding operation, so as to indicate the device for sequencing the welding tasks that the schedules and / or sequences should be selected.

[0030] A further example of such a function would be the Task Report function. This function will create a report on the welding task that could contain information such as the number of joints welded, total and individual adjustment of arc glow time, sequence breaks, errors, defects, wire use, arc data, and the like. An example of using this function would be reporting to the production quality department about the efficiency and quality of welding processes.

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EP 2 094 426 [0031] A still further example of such a function would be the System Check function. This function will determine whether the welding task can be continued, and could monitor such parameters as: wire delivery, gas supply, remaining time for change (compared to the time required to complete the task), and the like. This function could then determine if the parameters indicate that there is not enough time and / or material for the welding task to continue. This feature would prevent downtime due to material depletion, and prevent that teams in the course of work activities would be delayed, which could lead to quality problems due to thermal issues and scheduling.

[0032] Furthermore, as mentioned above, the welding task sequencing apparatus can select and perform a new function based on various variables or input data. These variables and input data are not particularly limited, and may even be a different function. For example, another function compatible with the welding task sequencing device is the function Perform Welding Action. This function is intended to detect the actual welding performed by the operator, and to report this welding, so that the welding task sequencing device can determine whether to proceed with further operations. For example, this function can work by starting when the operator pulls the trigger to start the welding operation and by ending, when the operator releases the trigger after the welding is finished, or after a predetermined period of time after commissioning. This function could end when the trigger is released or could be configured to automatically shut off after a certain period of time, a certain amount of wire, or some amount of energy has been provided. This function can be used in

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EP 2 094 426 to determine when to select a new function, such as a new welding schedule, as discussed above.

[0033] Still further, various semi-automatic and / or automated production sockets can be integrated in one network, and sequencing of steps in a single production nest can be fully integrated into a complete production schedule that can itself be modified when it is needed to track changes in the production schedule. sequencing and / or scheduling can

The information also be stored in a database, be stored as a date as archival information, and be available to provide various production reports.

[0034] Although the invention has been specifically exemplified of the embodiments limited to those and described with reference to its implementation, the invention is not exemplary. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention as defined by the following claims.

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