Method and tools for welding a vehicle component

• US 9,796,051 B2
• Filed: 02/11/2015
• Issued: 10/24/2017
• Est. Priority Date: 02/24/2014
• Status: Active Grant

• Current Assignee: Metalsa SA de CV (Grupo Proeza SA de CV)
• Original Assignee: Metalsa SA de CV (Grupo Proeza SA de CV)
• Inventors: Bricker, David, Adams, Marvin Lewis, Garcia, Juan Villarreal, Belcher, Jason, Fackler, Troy
• Primary Examiner(s): Saad, Erin
• Application Number:
  US14/619,904
• Publication Number:
  US 20150239067A1
• Time in Patent Office: 986 Days
• Field of Search: 228 43, 228 471, 228 491, 228 494
• CPC Class Codes: B23K 2101/006 Vehicles
• CPC Class Codes: B23K 2103/04 Steel or steel alloys
• CPC Class Codes: B23K 31/02 relating to soldering or welding dip or wave soldering in the manufacture of printed circuits H05K3/34
• CPC Class Codes: B23K 37/0229 the guide member being situated alongside the workpiece
• CPC Class Codes: B23K 37/0443 Jigs
• CPC Class Codes: B23K 37/0461 Welding tables
• CPC Class Codes: B23K 9/02 Seam welding; Backing means; Inserts
• CPC Class Codes: B23K 9/16 making use of shielding gas selection of media B23K35/38
• CPC Class Codes: Y10S 901/42 Welding

Abstract

A welding method and system (4) using a robotic arm (10), a welding robot (18) and a welding table (2) placed at an angle from horizontal to hold two C-channels (6 and 8) facing each other to maintain position and be welded together. C-channels (6 and 8) face each other to form a closed channel at increased welding speed with less materials having resulting benefits including constant welding, less distortion, and less welding material. Welding begins with restraining C-channels (6 and 8) in conjunction with the angled welding table (2). A robotic arm (10) handles C-channels (6 and 8) to move, place and restrain them relative to each other and the welding table (2). A pressing tool (12) may be a set of pressure-exerting tools (26). A welding robot (18) with a seam finding system (24) preferably welds the restrained C-channels (6 and 8) from top to bottom.

Claims

1. A process for welding two C-channels (6 and 8) comprising the steps of:

restraining a first C-channel (6) and a second C-channel (8) facing each other against a surface of a welding table (2) that is sloped at an angle from horizontal, wherein the first C-channel (6) is held on the welding table (2), under the second C-channel (8), by a holding element (22) that leaves lip edges of the first C-channel (6) exposed;

holding the second C-channel (8) against the first C-channel (6) with a set of pressure-exerting tools (26) on a robotic arm (10);

using a seam finding system (24) to sense an area to be welded between the first and second C-channels (6, 8) so a welding robot (18) knows precisely where to weld; and

performing a welding operation with the welding robot (18) from top to bottom to join the restrained first and second C-channels (6 and 8), wherein the second C-channel (8) is held with the set of pressure-exerting tools (26) during the welding operation.

2. The process of claim 1 wherein the angle is between 45°

and 65°

from horizontal, the process further comprising holding the angle fixed throughout the welding operation.

3. The process of claim 1 wherein the welding operation includes a second welding robot (20) on an opposite side of the welding table (2) that performs continuous welding on an opposite side of the first and second C-channels (6 and 8) from top to bottom to join the other side of the first and second C-channels (6 and 8) concurrently with welding robot (18).

4. The process of claim 1 wherein the robotic arm (10) also handles the first C-channel (6) and securely places it on the welding table (2).

5. The process of claim 1 wherein the robotic arm (10) handles the second C-channel (8) and places it aligned with the first C-channel (6) and holds the second C-channel (8) in place during the welding operation.

6. The process of claim 1 wherein the set of pressure-exerting tools (26) includes channel grasps (14 and 16) that hold the second C-channel (8) away from its edges while being handled and then while held in position against the first C-channel (6) during the welding operation.

7. The process of claim 1 wherein the welding operation is continuous.

8. A method of manufacturing a side-rail for a vehicle having joined a first C-channel (6) and a second C-channel (8) with cavities of the first C-channel (6) and the second C-channel (8) inwardly facing, the method comprising the steps of:

placing the C-channels (6 and 8) with a robotic arm (10) with the cavities of the C-channels (6 and 8) inwardly facing on a welding table (2) that is fixed at an angle between 45° and

65°

from horizontal;

holding the second C-channel (8) with a pressing tool (12) having channel grasps (14 and 16) that hold the second C-channel (8) away from its edges to be welded while first being handled and then while held in position against the first C-channel (6);

using a seam finding system (24) in conjunction with first and second welding robots (18 and 20) to sense a seam between the first and second C-channels (6, 8);

providing input from each seam finding system (24) to precisely position each of the first and second robots (18 and 20); and

welding the first and second C-channels (6 and 8) together concurrently with the first welding robot (18) and the second welding robot (20) on opposite sides of the welding table (2) to form the side-rail.

9. The method of claim 8 wherein welding is continuous from top to bottom along the entire length on each side of the C-channels (6 and 8).

10. The method of claim 8 wherein the welding table (2) is approximately 55°

from horizontal.

11. The method of claim 8 wherein the robotic arm (10) first handles the first C-channel (6) and securely places it in a holding element (22) on the welding table (2), and then the robotic arm (10) handles the second C-channel (8) and places it aligned with the first C-channel (6) and holds the second C-channel (8) in place with the pressing tool (12) during the welding of the first and second C-channels (6 and 8) together.

12. The method of claim 8 wherein the seam finding system (24) is a camera-vision system that provides input so the welding robots (18 and 20) go to the exact position to weld.