Welding job sequencer

• US 10,496,080 B2
• Filed: 06/04/2015
• Issued: 12/03/2019
• Est. Priority Date: 12/20/2006
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Daniel, Joseph A., Brant, Dmitry
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Maye, Ayub A
• Application Number:
  US14/730,991
• Publication Number:
  US 20150268663A1
• Time in Patent Office: 1,643 Days
• Field of Search: 2191301, 21913021, 21913022, 21913051, 2191305, 2191377
• CPC Class Codes: B23K 31/125 Weld quality monitoring
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32001 Computer assisted machining, signals guide operator to manual machine object
• CPC Class Codes: G05B 2219/32007 Operator is assisted by expert system for advice and delegation of tasks
• CPC Class Codes: G05B 2219/45135 Welding
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A semi-automatic welding work cell, including a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell. The automatic selection may be by way of elapsed time, a detection of welding operations, a detection of the amount of welding wire supplied for the welding operation, or a detection of the amount of energy supplied for the welding operation.

Claims

1. A semi-automatic welding work cell for welding an assembly defined by a plurality of welds, the plurality of welds being defined by at least two weld schedules, the semi-automatic welding work cell comprising:

welding equipment for use by a welding operator to perform said plurality of welds and complete the assembly during a semi-automatic welding operation, said welding equipment having a plurality of functions; and

a welding job sequencer which selects and implements at least one of the plurality of functions to define at least a first weld schedule and a second weld schedule from the at least two weld schedules so as to organize a sequence of operations for creating the welded assembly, said first weld schedule contains at least one first weld set up parameter and at least one first weld instruction for said welding operator and said second weld schedule contains at least one second weld set up parameter and at least one second weld instruction for said welding operator, at least one of said first weld set up parameter and said first weld instruction is different from said second weld set up parameter and said second weld instruction, said welding job sequencer automatically modifying said welding equipment in accordance with said sequence of operations between the first weld schedule and the second weld schedule without said welding operator intervention for completing the welded assembly, with said welding operator performing said semi-automatic welding operation after said welding job sequencer automatically modifies said welding equipment in accordance with said sequence of operations based on said first and second weld schedules.

2. The semi-automatic welding work cell of claim 1, wherein the second weld schedule is defined according to an elapsed time of the first weld schedule.

3. The semi-automatic welding work cell of claim 1, wherein the at least one function detects completion of said first weld schedule by said operator and automatically changes from said first weld schedule to said second weld schedule.

4. The semi-automatic welding work cell of claim 1, wherein the at least one function detects when the operator is conducting said first weld schedule, and said second weld schedule is defined according to an amount of welding wire supplied for said first weld schedule.

5. The semi-automatic welding work cell of claim 1, wherein the at least one function detects when the operator is conducting said first weld schedule, and said second weld schedule is defined according to an amount of energy supplied for said first weld schedule.

6. The semi-automatic welding work cell of claim 1, wherein said at least one first weld set up parameter and said at least one second weld set up parameter comprise at least one of a welding process, wire type, wire size, WFS, volts, trim, wire feeder to use, or feed head to use.

7. The semi-automatic welding work cell of claim 1, wherein the said at least first and second weld schedules include a sequence of said at least one first weld instruction and a sequence of said at least one second weld instruction.

8. The semi-automatic welding work cell of claim 1, wherein the at least one function monitors quality measurables of said weld assembly, wherein the quality measurables comprise at least information about an arc used to form the weld created by the operator.

9. The semi-automatic welding work cell of claim 1, wherein the at least one function indicates information to the operator in the semi-automatic welding work cell.

10. The semi-automatic welding work cell of claim 1, wherein the at least one function accepts job information comprising at least a part ID number, operator ID number, or welding instructions.

11. The semi-automatic welding work cell of claim 1, wherein the at least one function produces a job report comprising at least one of a number of welds preformed, total arc time, individual arc time, sequence interruptions, errors, faults, wire usage, arc data.

12. The semi-automatic welding work cell of claim 1, wherein the at least one function includes a system check of said cell, the system check comprising at least a detection of wire supply, gas supply, and time.

13. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement a quality check function into the sequence of operations, wherein the quality check function performs a quality check of at least one of said plurality of welds.

14. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement a repeat function into the sequence of operations, wherein the repeat function instructs the welding operator to repeat one of said plurality of welds.

15. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement a notify welder function into the sequence of operations, wherein the notify welder communicates information to the welding operator.

16. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement an enter job information function into the sequence of operations, wherein the enter job information function requires the welding operator to enter information before the sequence of operations can continue.

17. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement a job report function into the sequence of operations, wherein the job report function creates a report on the welding operation.

18. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement a system check function into the sequence of operations, wherein the system check function determines whether the welding operation can continue.

19. The semi-automatic welding work cell of claim 1, wherein the welding job sequencer is configured to implement a perform welding operation function into the sequence of operations, wherein the perform welding operation function detects actual welding performed by the welding operator.

20. The semi-automatic welding work cell of claim 7, wherein the welding job sequencer includes an indicator of said sequence to the operator.

21. The semi-automatic welding work cell of claim 6, wherein said at least one first weld set up parameter and said at least one second weld set up parameter comprise a wire feeder for use by an operator in the semi-automatic welding work cell.

22. The semi-automatic welding work cell of claim 13, wherein the quality check function pauses the sequence of operations and alerts the welding operator if an abnormality is detected.

23. The semi-automatic welding work cell of claim 14, wherein the repeat function is implemented in response to a quality check of the weld.

24. The semi-automatic welding work cell of claim 15, wherein the notify welder function instructs the welding operator to check one of said plurality of welds.

25. The semi-automatic welding work cell of claim 16, wherein the entered information identifies a part or the welded assembly.

26. The semi-automatic welding work cell of claim 16, wherein the entered information is used to organize the sequence of operations for creating the welded assembly.

27. The semi-automatic welding work cell of claim 17, wherein the report includes at least one of efficiency and quality information.

28. The semi-automatic welding work cell of claim 18, wherein the system check function determines whether the welding operation can proceed based on at least one of a time and a material level necessary to complete the welding operation.

29. A welding production line comprising:

at least one semi-automatic welding work cell for welding an assembly defined by a plurality of welds, the plurality of welds being defined by at least two weld schedules, the semi-automatic welding work cell including welding equipment for use by a welding operator to perform the plurality of welds and complete the assembly during a semi-automatic welding operation, the welding equipment having a plurality of functions; and

a welding job sequencer which selects and implements at least one of the plurality of functions to define at least a first and a second weld schedule from the at least two weld schedules to organize a sequence of operations for completing the weld assembly, said first weld schedule contains at least one first weld set up parameter and at least one first weld instruction for said welding operator and said second weld schedule contains at least one second weld set up parameter and at least one second weld instruction for said welding operator, at least one of said first weld set up parameter and said first weld instruction is different from said second weld set up parameter and said second weld instruction, said welding job sequencer automatically modifying said welding equipment in accordance with said sequence of operations between the first weld schedule and the second weld schedule without said welding operator intervention for completing the assembly, with said welding operator performing said semi automatic welding operation after said welding job sequencer automatically modifies said welding equipment in accordance with said sequence of operations based on said first and second weld schedules.

30. The welding production line of claim 29, further comprising a monitoring system in communication with the welding job sequencer to monitor completion of the at least one weld instruction of each of the first and second weld schedule.

31. A semi-automatic welding work cell for use by an operator, comprising:

welding equipment having a plurality of functions for performing welds by the operator during a semi-automatic welding operation; and

a welding job sequencer selecting from the plurality of functions to set up and organize the welding equipment for the operator without operator intervention according to a sequence of operations, the plurality of functions including;

a weld schedule function defining at least one weld operation;

a notify function to instruct the operator to perform the weld schedule; and

a quality check function to monitor at least one weld operation;

wherein said welding job sequencer automatically modifies said welding equipment in accordance with said sequence of operations before the at least one weld operation without said operator intervention, with said operator performing said semi-automatic welding operation after said welding job sequencer automatically modifies said welding equipment in accordance with said sequence of operations based on said plurality of functions.

32. The semi-automatic welding work cell of claim 31, wherein the quality check function performs a quality check on a weld completed by the at least one weld operation.

33. The semi-automatic welding work cell of claim 31, wherein the quality check function monitors the at least one weld operation during the at least one weld operation.

34. The semi-automatic welding work cell of claim 31, wherein the quality check function monitors the at least one weld operation after completion of the at least one weld operation.

35. The semi-automatic welding work cell of claim 31, wherein the weld schedule function defines a plurality of weld schedules, each weld schedule having a first weld operation and at least a second weld operation.

36. The semi-automatic welding work cell of claim 31, wherein the quality check function monitors the at least one weld operation before allowing the sequence of operations to continue.

37. The semi-automatic welding work cell of claim 31, wherein when the quality check function detects an abnormality, the sequencer pauses the sequence of operations and the notify function alerts the operator of the abnormality.