System and method for welding workpieces of a motor vehicle

Patent metadata

Field	Value
Publication number	US-2021237212-A1
Application number	US-202016778861-A
Country	US
Kind code	A1
Filing date	Jan 31, 2020
Priority date	Jan 31, 2020
Publication date	Aug 5, 2021
Grant date	—

Abstract

A welding block for a welding system secures together first and second components of a workpiece for a motor vehicle to reduce distortion of the first and second components during a welding process. The welding block includes a jig mechanism that has a proximal surface for receiving a load from an arm of the welding system. The jig mechanism further includes a distal surface for engaging the first component and securing the first and second components to one another during the welding process. The jig mechanism defines a passage, such that heat flows from the distal surface to a coolant flowing through the passage. The welding block further includes a sensor coupled to the jig mechanism for detecting a measured variable associated with at least one of the first and second components.

First claim

What is claimed is:

1 . A welding block for a welding system that secures together first and second components of a workpiece for a motor vehicle to reduce distortion of the first and second components during a welding process, the welding block comprising:
a jig mechanism having a proximal surface receiving a load from an arm of the welding system and a distal surface for engaging the first component and securing the first and second components to one another during the welding process, where the jig mechanism defines an inlet, a passage having one end fluidly connected to the inlet, and an outlet fluidly connected to the other end of the passage, such that heat flows from the distal surface to a coolant flowing through the passage; and a sensor coupled to the jig mechanism for detecting a measured variable associated with at least one of the first and second components.

2 . The welding block of claim 1 wherein the jig mechanism comprises a three-dimensionally printed single-piece block that defines the passage.

3 . The welding block of claim 2 wherein the passage is arranged in a serpentine pattern extending between the inlet and the outlet.

4 . The welding block of claim 3 wherein the sensor is at least one of a Gauss meter probe, a magnet, a camera, a thermocouple, a load cell, a linear variable differential transformer, an ohmmeter, and a voltmeter.

5 . The welding block of claim 3 wherein the single-piece body defines a bore extending between the distal and proximal surfaces, and the bore has distal and proximal ends adjacent to an associated one of the distal and proximal surfaces, with the sensor being disposed within the distal end of the bore and a wire extending through the bore and electrically coupled to the sensor.

6 . The welding block of claim 3 wherein the single-piece body defines a bore extending between the distal and proximal surfaces, and the bore has distal and proximal ends adjacent to an associated one of the distal and proximal surfaces, with the sensor being disposed within the proximal end of the bore and a wire electrically coupled to the sensor and spaced from the bore.

7 . A welding system that secures together first and second components of a workpiece for a motor vehicle and reduces distortion of the first and second components during a welding process, the welding system comprising:
a clamp mechanism movable between open and closed positions, and the clamp mechanism includes first and second ends for securing the first and second components against one another in response to the clamp mechanism being disposed in the closed position; a motor for moving the clamp mechanism to the closed position; first and second welding blocks for transmitting a clamping force from an associated one of the first and second ends of the clamp mechanism to the first and second components, with each of the first and second welding blocks comprising:
a jig mechanism having a proximal surface for receiving a load from the welding system and a distal surface for engaging the first component and securing the first and second components to one another during the welding process, where the jig mechanism defines an inlet, a passage having one end fluidly connected to the inlet, and an outlet fluidly connected to the other end of the passage, such that heat flows from the distal surface to a coolant flowing through the passage; and
a sensor coupled to the jig mechanism for detecting a measured variable associated with at least one of the first and second components;
wherein the passages of the welding blocks are fluidly connected to one another;
a coolant source fluidly connected to the inlet of at least one of the welding blocks for supplying the coolant to the welding blocks; a pump fluidly connected to the coolant source for pumping the coolant through the passages; a welding device for welding the first and second components to one another at an interface adjacent to the jig mechanism; and a controller electrically coupled to the sensor, the pump, and the welding device; in response to determining the measured variable, the controller:
actuates the motor to move the clamp mechanism toward the closed position;
actuates the pump to pump the coolant through the passages; and
actuates the welding device for welding the first and second components to one another.

8 . The welding system of claim 7 wherein the passages of the welding blocks are fluidly connected to one another to form a series circuit where the coolant flows along one path in a closed circuit.

9 . The welding system of claim 7 wherein the passages of the welding blocks are fluidly connected to one another to form a parallel circuit where the coolant flows along a plurality of paths in a closed circuit.

10 . The welding system of claim 7 wherein each of the welding blocks defines a single passage.

11 . The welding system of claim 7 wherein each of the welding blocks defines a plurality of passages.

12 . A method of operating of a welding system having first and second welding blocks for securing together first and second components of a workpiece during a welding process, where each of the first and second welding blocks includes a jig mechanism having proximal and distal surfaces and a plurality of sensors coupled to the jig mechanism, the method comprising:
detecting, using the sensors, a plurality of measured variables associated with at least one of the first and second components; and in response to at least one of the measured variables:
actuating, using the controller, a pump to pump a coolant through a plurality of passages defined by the jig mechanisms;
actuating, using the controller, a welding device to weld the first and second components to one another at a location adjacent to the jig mechanism; and
transferring heat from the distal surface of the jig mechanisms to the coolant flowing through the passages.

13 . The method of claim 12 wherein detecting the plurality of measured variables comprises detecting, using a Gauss meter probe and a magnet, first and second changes in electromagnetic flux through at least one of the first and second components.

14 . The method of claim 13 further comprising determining, using the controller, that the welding block contacted one of the first and second components in response to the Gauss meter probe detecting the first change in electromagnetic flux.

15 . The method of claim 14 further comprising determining, using the controller, that the clamp mechanism is disposed in the closed position to close a gap between the first and second components at a location along a longitudinal axis of the workpiece, in response to the Gauss meter probe detecting the second change in electromagnetic flux.

16 . The method of claim 15 further comprising welding the first and second components to one another in response to detecting the second change in electromagnetic flux.

17 . The method of claim 12 wherein detecting the plurality of measured variables comprises:
detecting, using a camera, a plurality of gaps between the first and second components at a plurality of locations along a longitudinal axis of the first and second components;
determining, using a controller, a largest one of the gaps at an associated location along the longitudinal axis;
positioning at least one of the jig mechanisms at the associated location along the longitudinal axis; and
distributing the load from the distal surface of the jig mechanism to the first component at the associated location along the longitudinal axis.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Saez Miguel A
• Chakraborty Debejyo
• Skurkis Richard J
• Spicer John P
• Cai Wayne

Classifications

• B23K37/0435

  Clamps · CPC title

• B23K37/0443 Primary

  Jigs · CPC title

• B23K37/003 Primary

  Cooling means for welding or cutting · CPC title

• B23K37/00

  Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass · CPC title

• B23K31/003

  relating to controlling of welding distortion · CPC title