Workpiece positioner and welding sequencer

Patent metadata

Field	Value
Publication number	US-10845778-B2
Application number	US-201815904570-A
Country	US
Kind code	B2
Filing date	Feb 26, 2018
Priority date	Mar 30, 2017
Publication date	Nov 24, 2020
Grant date	Nov 24, 2020

Abstract

Embodiments of welding work cells are disclosed. One embodiment includes a workpiece positioning system, a welding power source, and a welding job sequencer. The workpiece positioning system powers an elevating motion and a rotational motion of a workpiece mounted between a headstock and a tailstock to re-position the workpiece for a next weld to be performed. The welding power source generates welding output power based on a set of welding parameters of the power source. The welding job sequencer commands the workpiece positioning system to re-position the workpiece from a current position to a next position in accordance with a next step of a welding sequence of a welding schedule. The welding job sequencer also commands the welding power source to adjust a current set of welding parameters to a next set of welding parameters in accordance with the next step of the welding sequence of the welding schedule.

First claim

What is claimed is:

1. A welding work cell comprising:
a workpiece positioning system configured to power an elevating motion to adjust a height position of a workpiece and a rotational motion to adjust a rotational position of the workpiece to re-position the workpiece for a next weld to be performed by a human operator;
a welding power source configured to generate welding output power based on a current set of welding parameters of the power source, wherein the welding power source is part of a welding system used by the human operator for welding the workpiece; and
a welding job sequencer in communication with the workpiece positioning system and
the welding power source and configured to:
command the workpiece positioning system to re-position the workpiece from a current weld position to a next weld position in accordance with a next step of a welding sequence of a welding schedule, and
command the welding power source to adjust the current set of welding parameters to a next set of welding parameters in accordance with the next step of the welding sequence of the welding schedule,
wherein the welding job sequencer includes a memory that stores a set of user profiles, wherein the next weld position commanded by the welding job sequencer is adjusted based on a user profile of the set of user profiles corresponding to the human operator when the human operator is logged into at least one of the welding job sequencer, the welding power source, or the workpiece positioning system.

2. The welding work cell of claim 1 , wherein the next set of welding parameters commanded by the welding job sequencer is adjusted based on the user profile of the set of user profiles corresponding to the human operator when the human operator is logged into at least one of the welding job sequencer, the welding power source, or the workpiece positioning system.

3. The welding work cell of claim 1 , wherein the workpiece positioning system includes an interface controller comprising:
a communication interface configured to communicate with at least the welding job sequencer;
a memory storing at least one of user profiles or runtime files that include program data that is compiled and saved in an executable format to be used for human/machine interface applications;
at least one of a processor or a programmable logic controller; and
a human/machine interface including at least one of a graphical touch panel interface or push buttons.

4. The welding work cell of claim 1 , wherein the workpiece positioning system includes:
a headstock structure;
a tailstock structure;
a first hydraulic cylinder, a first pair of linear rails with bearings, a first hydraulic power unit, and a first linear encoder housed in the headstock structure; and
a second hydraulic cylinder, a second pair of linear rails with bearings, a second hydraulic power unit, and a second linear encoder housed in the tailstock structure,
wherein the first hydraulic cylinder, the first hydraulic power unit, the second hydraulic cylinder, and the second hydraulic power unit are configured to power the elevating motion of the workpiece along the first pair of linear rails and the second pair of linear rails in synchronization, wherein the synchronization is provided by the first linear encoder and the second linear encoder.

5. The welding work cell of claim 1 , wherein the welding job sequencer includes:
a communication interface configured to communicate with at least the workpiece positioning system and the welding power source;
a processor; and
a human/machine interface configured to provide the human operator with commands and instructions corresponding to the next weld to be performed by the human operator,
wherein the memory stores at least one of welding schedules, user profiles, or runtime files that include program data that is compiled and saved in an executable format to be used for human/machine interface applications.

6. The welding work cell of claim 1 , wherein the welding power source includes:
a communication interface configured to communicate with at least the welding job sequencer;
a memory storing a set of user profiles and sets of welding parameters;
power generation electronics;
a waveform generator;
a processor/controller; and
a human/machine interface.

7. A method of manipulating a welding work cell, the method comprising:
a welding job sequencer of the welding work cell sending first command data to a workpiece positioning system of the welding work cell holding a workpiece in a current weld position, wherein the first command data corresponds to a next weld position in accordance with a next step of a welding sequence of a welding schedule;
the workpiece positioning system, configured to power an elevating motion to adjust a height position of the workpiece and a rotational motion to adjust a rotational position of the workpiece, re-positioning the workpiece from the current weld position to the next weld position in response to the first command data for a next welding operation to be performed by a human operator;
the welding job sequencer sending second command data to a welding power source of the welding work cell configured to generate welding output power based on a current set of welding parameters, wherein the second command data corresponds to a next set of welding parameters in accordance with the next step of the welding sequence of the welding schedule; and
the welding power source adjusting the current set of welding parameters to the next set of welding parameters in response to the second command data,
wherein the welding job sequencer includes a memory that stores a set of user profiles, wherein the next weld position commanded by the welding job sequencer is adjusted based on a user profile of the set of user profiles corresponding to the human operator when the human operator is logged into at least one of the welding job sequencer, the welding power source, or the workpiece positioning system.

8. The method of claim 7 , further comprising the workpiece positioning system sending confirmation data to the welding job sequencer to confirm that the workpiece has been properly re-positioned in accordance with the first command data before sending the second command data to the welding power source.

9. The method of claim 8 , further comprising the welding power source sending confirmation data to the welding job sequencer to confirm that the current set of welding parameters have been properly adjusted to the next set of welding parameters in accordance with the second command data.

10. The method of claim 8 , further comprising displaying instructions, corresponding to the next step of the welding sequence, on a human/machine interface of the welding job sequencer to instruct the human operator to perform the next welding operation on the workpiece.

11. The method of claim 8 , wherein the first command data is sent wirelessly from the welding job sequencer to the workpiece positioning system.

12. The method of claim 8 , wherein the second command data is sent wirelessly from the welding job sequencer to the welding power source.

13. The method of claim 7 , further comprising modifying at least one of the first command data and the second command data based on the user profile of the human operator logged in to at least one of welding job sequencer, the workpiece positioning system, or the welding power source.

14. A networked welding work cell comprising:
a workpiece positioning system configured to power an elevating motion to adjust a height position of a workpiece and a rotational motion to adjust a rotational position

Assignees

• Lincoln Global Inc

Inventors

• Goddard Brad J
• Banks Thomas C
• Hann Mark A
• Zahradka Shaun A
• Rezabek Ryan J
• Petersen Bradley R
• Schlue Charles R
• Chantry Bruce J
• Daniel Joseph A

Classifications

• G06Q50/04

  Manufacturing · CPC title

• B23K37/047

  moving work to adjust its position between soldering, welding or cutting steps (B23K37/053 takes precedence) · CPC title

• B23K10/00

  Welding or cutting by means of a plasma · CPC title

• B23K9/32

  Accessories · CPC title

• B23K9/1062 Primary

  with computing means · CPC title