Multi-station robotic welding assembly

[0001] This application relates to a multi-station robotic welding assembly. The invention utilizes two or more industrial robots each including a welding torch at a distal end of a movable arm and wrist. Welding is carried out by moving the welding torch along a taught path relative to a workpiece. When a welding operation is started, a preset welding voltage and current are commanded from a robot control device to a controller of a welding machine. On receiving the command, the welding machine supplies electric power between the workpiece and an electrode of the welding torch. When an arc discharge is generated between the workpiece and the electrode, it is detected by the controller of the welding machine, which then supplies an arc generation signal to the robot control device. On receiving the arc generation signal, the robot control device commands welding voltage and current for normal welding to the controller of the welding machine, and at the same time, actuates the robot arm to move the welding torch along the taught path.

[0002] In a typical weld cell, a single industrial robot is used to weld all or part of a workpiece held in a fixture. The workpiece may include, for example, disassembled parts for bumpers, foot plates, headlight supports, arm rests, and other components commonly used in all-terrain vehicles (ATVs) and golf carts. The workpiece is first loaded into the fixture by an operator, who then waits as the welding process is completed. After welding, the assembled workpiece is removed from the fixture and generally powder coated before shipping to the customer. The cumulative operator “down time” during the welding process over a given shift is substantial, and results in a relatively inefficient process. The present invention addresses this problem. The invention further provides a multi-station robotic weld cell which can be quickly and conveniently relocated as a single unit without substantial disassembly or breaking down of parts.

[0003] Therefore, it is an object of the invention to provide a multi-station robotic welding assembly which offers increased production efficiency without increased labor cost.

[0004] It is another object of the invention to provide a multi-station robotic welding assembly which requires less floor space than comparable equipment operating at the same production rate.

[0005] It is another object of the invention to provide a multi-station robotic welding assembly which can be conveniently relocated without substantially disassembly or breaking down of parts.

[0006] It is another object of the invention to provide a multi-station robotic welding assembly which utilizes two weld robots which do not interfere with each other during welding.

[0007] It is another object of the invention to provide a multi-station robotic welding assembly which utilizes an electrical D-ring connector.

[0008] It is another object of the invention to provide a multi-station robotic welding assembly which utilizes two or more robots with only one weld fixture per robot, and one weld fixture at an operator station.

[0009] It is another object of the invention to provide a multi-station robotic welding assembly which requires less tooling and tooling costs as compared to standard multi-robot weld cells. In standard cells, two fixtures are generally serviced by a single robot.

[0010] It is another object of the invention to provide a multi-station robotic welding assembly including multiple robots which operate in separate and distinct work envelopes which do not cross each other. In standard two-robot systems, the work envelopes cross thus causing longer programming time. The crossing envelopes further increase the risk of the robots crashing into each other as a result of misprogramming.

[0011] It is another object of the invention to provide a method for welding a workpiece.

[0012] These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a multi-station robotic welding assembly. The assembly includes a mounting platform, and a plurality of robots attached to the mounting platform and located in respective weld stations. Each of the robots includes an elongated movable arm and wrist. A welding torch is attached to each of the robots, and is adapted for being manipulated by the movable arm and wrist. A rotatable fixture base is located on the mounting platform, and is adapted for supporting a plurality of fixtures. Each of the fixtures is adapted for holding and positioning a workpiece for welding in respective weld stations. A base indexer is adapted for repeatedly rotating the fixture base by a predetermined degree, such that the fixtures are positioned within respective weld stations for an index interval sufficient to complete welding of the workpieces.

[0013] According to another preferred embodiment of the invention, the fixture base includes a plurality of fixture indexers adapted for carrying respective fixtures. The fixture indexers repeatedly rotate the fixtures and attached workpieces in respective weld stations by a predetermined degree during welding.

[0014] According to another preferred embodiment of the invention, each fixture indexer has eight discrete positions.

[0015] According to another preferred embodiment of the invention, the fixture indexers are spaced 120 degrees apart.

[0016] According to another preferred embodiment of the invention, a station shield is located between each of the weld stations for shielding and protecting a surrounding area during welding.

[0017] According to another preferred embodiment of the invention, the fixture base includes a junction box which connects all indexers and houses an electrical D-ring, or slip ring. Unlike conventional indexers which rotate clockwise and counterclockwise in a 180-degree path, the present D-ring allows continuous 360-degree rotation of the base indexer, thereby avoiding winding and breakage of cables inside the junction box.

[0018] According to another preferred embodiment of the invention, the plurality of industrial robots includes two robots located in respective first and second weld stations.

[0019] According to another preferred embodiment of the invention, an operator station is located between the first and second weld stations for loading and unloading the workpieces.

[0020] In another embodiment, the invention is a method for welding a workpiece. The method includes the step of loading a first workpiece into a first fixture located in an operator's station. The first fixture is indexed to locate the first workpiece in a first weld station. A first portion of the first workpiece is welded in the first weld station. During welding of the first portion of the first workpiece, a second workpiece is simultaneously loaded into a second fixture located in the operator's station. The first and second fixtures are indexed to locate the first and second workpieces in respective second and first weld stations. A first portion of the second workpiece is welded in the first weld station while simultaneously welding a second portion of the first workpiece in the second weld station. During this welding process, a third workpiece is simultaneously loaded into a third fixture located in the operator's station. The first, second, and third fixtures are indexed to locate the first, second, and third workpieces in the operator's station, the second weld station, and the first weld station, respectively. A first portion of the third workpiece is welded in the first weld station while simultaneously welding a second portion of the second workpiece in the second weld station. During this welding process, the first workpiece is simultaneously removed from the first fixture in the operator's station, reloaded, and the cycle continues in a 360 degree rotation.

[0030] Referring now specifically to the drawings, a multi-station robotic welding assembly according to the present invention is illustrated in FIGS. 1-3, and shown generally at reference numeral 10. The assembly 10 is especially applicable in a production environment for welding items such as bumpers, foot plates, headlight supports, arm rests, and other components commonly used in all-terrain vehicles (ATVs) and golf carts. The assembly 10 includes first and second arc welding robots 11 and 12 attached to a common mounting platform 14 and located in respective weld stations 15 and 16. A rotatable fixture base 18 is mounted to the platform 14 between the robots 11, 12, and includes a junction box 21 and three indexers 22, 23, and 24 adapted for carrying respective fixtures used for holding workpieces to be welded. The fixtures “F” and “W” are illustrated in FIGS. 4-8, discussed below. Each fixture is custom designed and secured directly to a face plate 22A, 23B, and 24A of the indexer 22, 23, and 24 using a series of bolts and locating dowels. Individual components of the workpiece are loaded into the fixture at an operator's station 25 prior to welding, and are held in place by releasable clamps and holding devices. The mounting platform 14 provides a single common base for all components of the assembly 10, thus allowing convenient transport and relocation of the assembly without substantial disassembly or breaking down of parts.

[0031] Each of the robots 11 and 12 includes a movable arm 31A, 31B and wrist 32A, 32B adapted for carrying and manipulating a welding torch 33A, 33B. The robots 11, 12 are preferably manufactured by Fanuc Robotics of Rochester Hills, Mich., and sold under the trademark ARC Mate 100iB Robot. Each robot 11, 12 has a six-axis modular construction, and is electric servo driven for precision high-speed welding and cutting. The welding torch 33A, 33B is preferably a robotic, air-cooled MIG gun manufactured by Tregaskiss, Ltd. of Ontario, Canada, and sold as Model AC/QC 22° 4′ 0.035″.

[0032] The rotatable fixture base 18 includes a three-position, DC driven, rotary cam indexer, such as that manufactured by Commercial Cam Co., Inc. (CAMCO) of Wheeling, Ill., and sold as Model #1305. The indexer has a cam-driven index drive which provides repeated movement of the fixture base 18 from one position to another, as indicated by arrow 36 in FIG. 3, thereby rotating the fixtures and attached workpieces between each of the two weld stations 15, 16 and the operator station 25. Typical cam-driven index drives have two basic elements: a cam attached to the input shaft (camshaft) and a follower wheel attached to the output shaft. As the cam rotates, followers on the follower wheel are guided through a path dictated by the shape of the cam. During part of the input rotation, the cam confines the followers (and therefore, the output) to a rigid, stationary position called “dwell.” During the remainder of the camshaft rotation, the cam geometry causes the followers to move and the output to rotate, or “index”. As the camshaft is rotated at a constant velocity, the output stops and starts (dwells and indexes) in a repeating pattern.

[0033] The indexers 22, 23, and 24 mounted to the junction box 21 and carrying the fixtures are preferably eight-position, DC driven, rotary cam indexers, such as that manufactured by CAMCO and sold as Model #601. Each indexer 22-24 moves the fixture and attached workpiece between eight different positions during welding in each of the welding stations 15 and 16. The fixture indexers 22-24 are spaced 120 degrees apart, such that each indexer locates a fixture and workpiece in each of the two weld stations 15, 16 and the operator station 25. Protective shields 38A, 38B, and 38C are arranged between the weld stations 15, 16 and the operator station 25 for shielding and protecting the surrounding area during welding. The junction box 21 contains a precision, high-performance, electro-deposited D-ring, or slip ring (not shown), such as that manufactured by the Kaydon Corporation. The D-ring provides continuous electrical connection of the indexers to a main control panel. Unlike conventional indexers which rotate clockwise and counterclockwise in a 180-degree path, the present D-ring allows continuous 360-degree rotation of the base indexer 18, thereby avoiding winding and breakage of cables inside the junction box 21.

[0034] Each weld robot 11 and 12 has an individual ground cable. The ground cables are mounted to a brass block that is mounted to a dedicated pneumatic cylinder. After indexing to the respective station 15, 16, the ground changes are automated through the taught program. The grounds are pushed up against the outer surface of the face plates of the indexers 22, 23, and 24, and remain up until the welding is completed. After welding, the grounds are lowered out of the way, so that the next fixture can be indexed into the weld station 15, 16.

[0035] Referring to FIGS. 4-8, all stations of the robotic welding assembly 10 are initially empty prior to the operator's work shift. Customized fixtures “F” are mounted on respective indexers 22, 23, and 24 to accommodate the particular workpieces “W” to be welded, as shown in FIG. 4. Each indexer 22, 23, and 24 and fixture “F” cooperates to rotate the workpiece “W” between eight different positions during welding.

[0036] To begin the welding process, the operator activates the arc welding robots 11 and 12 located in the weld stations 15 and 16, respectively, and verifies the system programming applicable for the present shift. Programming for the robots 11, 12 is initiated to place the system in a complete automatic mode. The operator begins the shift by loading a first workpiece “W1” into the fixture “F1” at the operator station 25, as shown in FIG. 5. Once this fixture “F1” is loaded, the system program is initiated at a control panel. The fixture base 18 indexes approximately 120 degrees to move the first loaded workpiece “W1” directly in front of the robot 11 in the first weld station 15 for welding, as shown in FIG. 6. This action simultaneously moves the second fixture “F2” directly in front of the robot 12 in wait in the second weld station 16, and the fixture “F3” into the operator station 25 for loading. While robot 11 welds 50% of the workpiece “W1” in the first weld station 15, the operator loads a second workpiece “W2” into the fixture “F3”. When robot 11 has completed welding at the first weld station 15, the fixture base 18 indexes to simultaneously move the second workpiece “W2” in front of robot 11 in the first weld station 15, the first workpiece “W1” in front of robot 12 in the second weld station 16, and fixture “F2” to the operator station 25 for loading. In the position shown in FIG. 7, the robot 11 welds 50% of the second workpiece “W2” in the first weld station 11, while robot 12 completes welding of the first workpiece “W1” in second weld station 16. At the same time, the operator loads a third workpiece “W3” into the fixture “F2” at the operator station 25. After welding is completed in both of the weld stations 15 and 16, the fixture base 18 indexes to simultaneously move the third workpiece “W3” in front of robot 11 in the first weld station 15, the second workpiece “W2” in front of robot 12 in the second weld station 16, and the first workpiece “W1” to the operator station 25 for unloading. In the position shown in FIG. 8, the operator unloads a completely assembled, welded workpiece “W1” from the fixture “F1” at the operator station 25, and then reloads the fixture “F1” with a fourth workpiece “W4”. At the same time, robot 11 welds 50% of the third workpiece “W3” at the first weld station 15, while robot 12 completes welding of the second workpiece “W2” in the second weld station 16. This cycle continues for the remainder of the shift.

[0037] The above process maximizes operator production and efficiency by utilizing welding time to load and unload the fixtures “F” in the operator station 25. Moreover, the use of multiple robots substantially reduces the weld cycle time without requiring additional man power. With two robots 11, 12 welding 50% of the same workpiece “W”, as described above, welding is completed 50% faster and at half the labor cost. The present assembly 10 requires less floor space than a standard two-robot weld cell; the required floor space being generally the same as that of a single robot cell.

[0038] A multi-station robotic welding assembly is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.