Welding angle correction device

Abstract

Welding angle correction apparatus and methods of correcting angles of a welding torch positioned by a user when training a robot of a robotic welding system are provided. Weldment depth data of a weldment and a corresponding weld are acquired and 3D point cloud data is generated. A 3D plane and intersection data representing the weldment and the weld are generated from the 3D point cloud data. User placed 3D torch position and orientation data of welding points recorded along the weld are imported. Based on the user placed torch position and orientation data and the 3D plane and intersection data, a torch push angle and a torch work angle are calculated for the recorded welding points relative to the weldment and the weld. The torch push angle and the torch work angle are corrected for the recorded welding points based on ideal angles of the weld previously stored.

Description

[0001] Cross-reference to related applications / incorporation by reference

[0002] This U.S. patent application claims priority and interest to U.S. Provisional Patent Application Serial No. 63 / 349,180, filed June 6, 2022, which is incorporated herein by reference in its entirety. The entire contents of U.S. Patent Application Publication No. 2020 / 0139474A1 are incorporated herein by reference in their entirety. The entire contents of U.S. Patent No. 9,833,857B2 are incorporated herein by reference in their entirety.

[0003] field

[0004] Embodiments of the present invention relate to the use of robots (e.g., collaborative robots or cobots) for welding or cutting. More specifically, embodiments of the present invention relate to a welding angle correction tool and a method for correcting recorded robotic welding / cutting torch orientation positioned by a human user when training a robot to traverse a weld joint. background

[0005] Programming the motion trajectory of a robot (e.g., a collaborative robot) before actual welding or cutting can be quite complex. In addition to the challenges associated with programming the welding trajectory along the weld joint, there are other challenges associated with setting and programming the angle and orientation of the welding or cutting torch at points along the trajectory.

[0006] Overview

[0007] A robotic welding or cutting system is configured to allow a human user to train the robot by positioning a welding or cutting torch attached to a robotic arm at different points along the joint / seam of the workpiece to be welded or cut. The user moves the robot's arm to position the tip of the torch at a desired point along the joint / seam, and this point is recorded by the robot controller (i.e., the robot controller records the spatial coordinates and angular orientation of the torch at that point). According to one embodiment of the invention, the user does not need to pay particular attention to how the torch angles (e.g., push angle and working angle) are positioned by the user relative to the workpiece and the corresponding joint / seam. A welding angle correction tool includes a depth camera that acquires stereo depth image data used to determine the actual torch angle positioned by the user relative to the joint / seam. Once the user has positioned the torch and recorded the corresponding desired point along the joint, the user can activate the welding angle correction tool to select the recorded point and correct the recorded parameters (e.g., push angle and working angle) associated with that point.

[0008] In one embodiment, a method is provided for correcting the angle of a welding torch positioned by a user when training a robot welding system. The method involves acquiring stereoscopic image data of the weldment and the corresponding weld seam, and generating 3D point cloud data. 3D plane and intersection data representing the weldment and weld seam are generated from the 3D point cloud data. User-placed 3D welding torch position and orientation data of the weld points recorded along the weld seam are imported. Based on the user-placed welding torch position and orientation data, as well as the 3D plane and intersection data, a welding torch push angle and a welding torch working angle are calculated for the recorded weld points relative to the weldment and weld seam. The welding torch push angle and welding torch working angle are corrected for the recorded weld points based on pre-stored ideal angles for the weld seam.

[0009] In one embodiment, a method is provided for correcting the angle of a welding torch positioned by a user when training a robot in a robotic welding system. The method includes acquiring weldment depth data of a weldment and a corresponding weld seam using a depth camera of a welding angle correction tool, and processing the weldment depth data using a computer of the welding angle correction tool. In one embodiment, the weldment depth data is stereoscopic image data. In one embodiment, the computer of the welding angle correction tool uses matrix manipulation techniques, point cloud manipulation techniques, and feature recognition techniques as part of processing the weldment depth data. The method also includes importing 3D welding torch position and orientation data, placed by the user in robot coordinate space for a recorded weld point along the corresponding weld seam, from the robot controller of the robotic welding system to the computer of the welding angle correction tool. The method further includes using the computer of the welding angle correction tool to calculate at least one welding torch angle of the recorded weld point relative to the weldment and the corresponding weld seam in robot coordinate space, based on the weldment depth data of the weldment and the corresponding weld seam processed by the computer of the welding angle correction tool, and the 3D welding torch position and orientation data placed by the user. The method also includes correcting at least one welding torch angle of the recorded weld point based on pre-stored ideal angles of the weldment and the corresponding weld seam. In one embodiment, processing of weldment depth data includes generating 3D point cloud data in robot coordinate space from stereo image data using a computer of the welding angle correction tool. In another embodiment, processing of weldment depth data includes generating 3D plane and intersection data representing the weldment and corresponding weld seam from the 3D point cloud data in robot coordinate space using a computer of the welding angle correction tool. The torch angle may include, for example, the torch push angle and / or the torch working angle. In one embodiment, weldment depth data is transmitted from a depth camera to the computer of the welding angle correction tool via at least one wired or wireless device. In another embodiment, 3D torch position and orientation data placed by the user is transmitted from a robot controller to the computer of the welding angle correction tool via at least one wired or wireless device. In one embodiment, the position of the depth camera is calibrated to either the tip of the torch or the robot's tool center point (TCP).

[0010] In one embodiment, a welding angle correction tool is provided for correcting the angle of a welding torch positioned by a user during the training of a robotic welding system. The welding angle correction tool includes a depth camera configured to acquire weldment depth data of a weldment to be welded by a robotic welding system with a welding torch and a corresponding weld seam. The welding angle correction tool also includes a computer device configured to receive the weldment depth data from the depth camera and 3D welding torch position and orientation data placed by the user at a recorded weld point along the corresponding weld seam from the robot controller of the robotic welding system. The computer device is further configured to calculate, in the coordinate space of the robotic welding system, at least one welding torch angle relative to the weldment and the corresponding weld seam at the recorded weld point, based on the weldment depth data and the user-placed welding torch position and orientation data. The computer device is further configured to calculate at least one corrected welding torch angle based on the calculated at least one welding torch angle at the recorded weld point and pre-stored ideal angles of the weldment and the corresponding weld seam. In one embodiment, the weldment depth data is stereoscopic image data. In one embodiment, the depth camera includes two imaging apertures for acquiring stereoscopic image data. In one embodiment, calculating at least one welding torch angle using a computer device includes generating 3D point cloud data from stereo image data in the coordinate space of the robotic welding system. In another embodiment, calculating at least one welding torch angle using a computer device includes generating 3D plane and intersection data representing the weldment and corresponding weld from the 3D point cloud data in the coordinate space of the robotic welding system. In one embodiment, the computer device is in the form of a laptop computer. In another embodiment, the computer device is integrated into the robot controller of the robotic welding system. In yet another embodiment, the computer device is integrated into the welding power supply of the robotic welding system. In one embodiment, a depth camera is configured to be removably attached to the welding torch. In yet another embodiment, the depth camera is configured to be mounted on joint 6 of the robotic arm of the robotic welding system.

[0011] Many aspects of the general inventive concept will become apparent from the following detailed description of exemplary embodiments, from the claims, and from the accompanying drawings. Brief description of the attached diagram

[0012] Various embodiments of the present disclosure are illustrated in conjunction with the accompanying drawings, which are incorporated in and form part of this specification. It should be understood that the element boundaries (e.g., boxes, sets of boxes, or other shapes) shown in the drawings represent one embodiment of a boundary. In some embodiments, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some embodiments, an element shown as an inner component of another element may be implemented as an outer component, and vice versa. Furthermore, elements may not be drawn to scale.

[0013] Figure 1 An embodiment of a welding system with a robot (e.g., a collaborative robot) is shown;

[0014] Figure 2 An embodiment of a welding angle correction tool is shown;

[0015] Figure 3 It shows the relationship with Figure 2 The welding angle correction tool is operably integrated. Figure 1 The robotic component of the welding system;

[0016] Figure 4 It shows when with Figure 1 When welding systems are operated together, Figure 2 A schematic block diagram illustrating the data input and output of the welding angle correction tool's algorithm;

[0017] Figure 5A The welding torch of the welding system is shown, which has been positioned by the user at the desired weld point at the joint / seam of the workpiece with a non-ideal push angle;

[0018] Figure 5B It shows Figure 5A The welding torch has been positioned by the user at a non-ideal working angle at the desired welding point of the workpiece joint / seam.

[0019] Figure 6 It shows the result of Figure 2 The welding angle correction tool provides a camera view of the workpiece and the corresponding joint / seam, which shows the non-ideal angle of the welding torch before angle correction in an augmented reality manner;

[0020] Figure 7 It shows the result of Figure 2 The welding angle correction tool provides a camera view of the workpiece and the corresponding joint / seam, which shows the corrected / ideal angle of the welding torch after angle correction in an augmented reality manner;

[0021] Figure 8A The welding torch is shown to be aligned with the corrected / ideal push angle by the robot of the welding system relative to the joint / seam of the workpiece;

[0022] Figure 8B This illustrates the process of a robot in a welding system aligning the joint / seam of a workpiece to the ideal working angle for correction. Figure 8A welding torch;

[0023] Figure 9 Is it used with Figure 1 The welding system can be operably integrated. Figure 2 A flowchart illustrating an embodiment of a method for correcting welding torch angle using a welding angle correction tool; and

[0024] Figure 10 It shows that it can be used for example Figure 1 A block diagram of an exemplary embodiment of a controller in a welding system. Detailed description

[0025] The embodiments and accompanying drawings herein are merely illustrative and are not intended to limit the invention, which is to be measured by the scope and spirit of the claims. Reference is now made to the accompanying drawings, which are shown merely to illustrate exemplary embodiments of the invention and not to limit them. Figure 1 An embodiment of a welding system 100 having a robotic component 200 (e.g., a collaborative robot) is shown. Although the discussion herein focuses on welding systems, the inventive concepts herein can be equally well applied to cutting systems (e.g., robotic plasma cutting systems). See also... Figure 1 The welding system 100 includes a robot section 200, a welding power source 310, and a robot controller 320. The robot section 200 has an arm 210 configured to hold a welding torch (e.g., a welding gun) 220. The terms "torch" and "gun" are used interchangeably herein. The robot section 200 also includes a servo mechanism 230 configured to move the arm 210 of the robot section 200 upon command from the robot controller 320. In one embodiment, the welding system 100 includes a wire feeder (not shown) to feed consumable welding wire to the welding torch 220.

[0026] Figure 2An embodiment of a welding angle correction tool 400 is shown. The welding angle correction tool 400 includes a depth camera 410 and a computer device (e.g., a laptop computer 420). The depth camera 410 has two imaging apertures 411 and 412 and is configured to acquire stereo image data. The stereo image data allows the determination of the depth of a point in space. The stereo image data (via a wired or wireless device) is transmitted from the depth camera 410 to the laptop computer 420. As discussed later herein, the laptop computer 420 is programmed to convert the stereo image data into 3D point cloud data and then generate 3D plane / intersection data from the 3D point cloud data in the robot's coordinate space (robot coordinate space). In other embodiments, alternative coordinate spaces may be defined and used.

[0027] When the user positions the robotic arm 210, which is connected to the welding torch 220, at the desired welding point of the weld joint / seam of the workpiece, the robot controller 320 records the corresponding torch position and orientation data. The terms "workpiece" and "weld" are used interchangeably herein. The robot controller 320 sends (via wired or wireless means) the user-placed torch position and orientation data in the robot's coordinate space to a laptop computer 420. According to other embodiments, the laptop computer 420 may be some other form or type of computer device or controller (e.g., having at least one processor). In one embodiment, the functionality of the laptop computer may be integrated into the robot controller 320, or in another embodiment, into the welding power supply 310.

[0028] Figure 3 It shows the relationship with Figure 2 The welding angle correction tool 400 is operably integrated. Figure 1 The robotic component 200 of the welding system 100. Figure 3 In one embodiment, the depth camera 410 is mounted (e.g., removably attached) to the welding torch 220 behind the gas nozzle. In this way, when the welding torch 220 is positioned at the desired weld point at the weld joint / seam of the weldment, the field of view of the depth camera 410 will include the weld point and a portion of the weldment surrounding the weld point (along with its weld joint / seam). In another embodiment, the depth camera 410 may be mounted on joint 6 of the robotic arm 210 (near the distal end of the robotic arm 210). Other mounting locations are also possible according to other embodiments. Figure 3 In this embodiment, the laptop computer 420 communicates wirelessly with the depth camera 410 and the robot controller 320 (e.g., via...). (Or Wi-Fi). According to one embodiment, the position of the depth camera 410 is calibrated to, for example, the tip of a welding torch or the tool center point (TCP) of a robot (e.g., using eye-hand calibration software). The depth camera 410 can be "hardened" to withstand welding environments.

[0029] Figure 4 It shows when with Figure 1 When the welding system 100 is operated together, Figure 2 A schematic block diagram of the data input and output of algorithm 425 (or a set of algorithms or processes implemented in software and / or hardware) on a laptop computer 420 of a welding angle correction tool 400. Algorithm 425 operates on two sets of input data: stereoscopic image data (depth data) of the weld joint / seam from depth camera 410 and robot torch position and orientation data from robot controller 320. Algorithm 425 is programmed to convert the depth data into 3D point cloud data and then generate 3D plane / intersection data from the 3D point cloud data, for example, in the robot's coordinate space. According to one embodiment, algorithm 425 uses matrix manipulation techniques, point cloud manipulation techniques, and feature recognition techniques. When operating on the two sets of input data (depth data and torch position / orientation data), algorithm 425 generates torch push angle and torch working angle relative to the weld joint / seam in the robot's coordinate space. Those skilled in the art of arc welding will understand the concepts of torch push angle and torch working angle.

[0030] The acquired depth data (in a single stereo image) allows the welding angle correction tool 400 to determine the features of the weld joint / seam in three-dimensional detail (i.e., what the geometry of the weld joint / seam looks like). Processing the acquired depth data eliminates any need to use touch sensing technology to determine the geometry of the weld joint / seam. Furthermore, the robot controller 320 "knows" the recorded position and orientation of the welding torch relative to the robot coordinate system, rather than relative to the position and orientation of the weldment / workpiece. The depth data and the robot welding torch position / or orientation data together allow for the determination of the actual welding torch angle positioned by the user. According to other embodiments, other welding torch parameters (e.g., stickout distance) can be determined from the weld joint / seam depth data and / or the robot welding torch position / or orientation data.

[0031] As an example, Figure 5A The welding torch 220 of the welding system 100 is shown, which has been positioned by the user at the desired weld point 510 (recorded by the robot controller 320) at the joint / seam 520 of the workpiece (welded part) 530. The welding torch is at a non-ideal push angle. Similarly, Figure 5B It shows Figure 5AThe welding torch 220 has been positioned by the user at a non-ideal working angle at the desired welding point 510 of the joint / seam 520 of the workpiece 530.

[0032] In one embodiment, the depth camera 410 is also configured to provide a conventional camera view (e.g., using only one of the two image apertures of the depth camera 410). For example... Figure 6 A camera view 600 showing workpiece 530 and the corresponding joint / seam 520 (by...) Figure 2 A welding angle correction tool 400 (provided via camera 410) shows, in an augmented reality manner, the non-ideal angle of the welding torch 220 before angle correction has been performed. Camera view 600 is displayed on display device 422 of laptop computer 420. AR marker 610 indicates the recorded position of the weld point 510 relative to workpiece 530 and the corresponding joint / seam 520. The working angle of the welding torch 220 (represented by AR symbol 615) (located by the user and calculated by algorithm 425) is 61 degrees (non-ideal). The push angle of the welding torch 220 (represented by AR symbol 617) (located by the user and calculated by algorithm 425) is -22 degrees (non-ideal). In this way, the user can view camera view 600, and AR symbols 610, 615, and 617 representing the weld point 510 and the non-ideal working and push angles, on display device 422 of laptop computer 420. Computer 420 is configured (e.g., via hardware and software) to command the display of various augmented reality symbols on display device 422.

[0033] Figure 7 It shows the result of Figure 2 The welding angle correction tool 400 provides a camera view 600 of the workpiece 530 and the corresponding joint / seam 520, which shows the corrected angle of the welding torch 220 after angle correction in an augmented reality manner. For example, in one embodiment, the user selects a gamut symbol 610 in the camera view 600 (e.g., using the user interface 427 of the laptop computer 420, e.g., a computer keyboard or computer mouse). The user command system (e.g., via the CNTL F command on the keyboard of the laptop computer 420) then corrects the push angle and working angle of the welding torch 220 at the welding point 510 to ideal angles for the type of workpiece 530 and joint / seam 520 relative to the characteristics of the workpiece 530 and joint / seam 520 (as characterized by the welding angle correction tool 400). The AR symbol is now in Figure 7 The figure shows a calibrated working angle symbol 615 representing 45 degrees and a calibrated push angle symbol 617 representing 10 degrees.

[0034] The robot controller 320 "knows" the type of workpiece and joint / seam. For example, in one embodiment, the working angle correction tool 400 determines the type of workpiece and joint / seam based on 3D point cloud data and notifies the robot controller 320. In one embodiment, the computer 420 of the welding angle correction tool 400 calculates the ideal angle based at least on weld depth data. In another embodiment, the type of workpiece and joint / seam (and the ideal angle) is pre-stored in the robot controller 320. The laptop computer 420 communicates with the robot controller 320, and the robot controller 320 changes the recorded working angle (relative to the workpiece and joint / seam) to an ideal working angle of 45 degrees and changes the recorded push angle (relative to the workpiece and joint / seam) to an ideal push angle of 10 degrees (e.g., ...). Figure 7 (As shown in camera view 600).

[0035] Then, the robot controller 320 can command the robot arm 210 to reposition the welding torch 220 at the welding point 510, but with corrected angles of 45 degrees and 10 degrees. Figure 8A The welding torch 220 is shown to be adjusted to an ideal push angle of 10 degrees relative to the joint / seam 520 of the workpiece 530 by the robot of the welding system 100. Figure 8B This illustrates the ideal working angle of 45 degrees achieved by the robot of welding system 100 relative to the joint / seam 520 of workpiece 530. Figure 8A 220 welding torch.

[0036] When training the robot, the welding angle correction tool 400 operates in real time alongside the robotic welding system 100. In this way, the user can position the tip of the welding torch at the desired weld point in the weld joint / seam, and then use the welding angle correction tool 400 to adjust the torch angle to the ideal angle for that type of workpiece (which has a specific type of weld joint / seam). Therefore, the user of the welding system does not need detailed welding knowledge of how to set the various angles of the welding torch.

[0037] Figure 9 Is it used with Figure 1 The welding system 100 is operablely integrated. Figure 2 A flowchart illustrates an embodiment of a welding angle correction tool 400 for correcting the welding torch angle using a method 900. Typically, a single stereo depth image is used to reliably locate the planes, plane intersections, and extents of the plane intersection lines of the weldment and the corresponding joint / seam in 3D robot coordinate space. For example, in one embodiment, the welding angle correction tool uses a weld with two plane normals to calculate and display the current working angle set by the user, and also finds the ideal working angle relative to the joint / seam.

[0038] In step 910 of method 900, a depth camera of the welding angle correction tool acquires stereoscopic image data of the welded part and its corresponding weld joint / seam. In step 920 of method 900, the computer of the welding angle correction tool acquires the stereoscopic image data and generates 3D point cloud data representing the welded part and its corresponding weld joint / seam in robot coordinate space. In step 930 of method 900, the computer of the welding angle correction tool processes the 3D point cloud data to generate 3D planes and intersection data representing the welded part and its corresponding weld joint / seam in robot coordinate space.

[0039] In step 940 of method 900, the computer of the welding angle correction tool imports 3D torch position and orientation data from the robot controller. The 3D torch position and orientation data represents the position and orientation of the torch, positioned by the user at a recorded weld point along the weld joint / seam, in the robot coordinate space. In step 950 of method 900, the computer of the welding angle correction tool calculates the torch push angle and torch working angle at the recorded weld point relative to the weldment and its weld joint / seam in the robot coordinate space. The computer of the welding angle correction tool uses the torch position and orientation data placed by the user, as well as 3D plane and intersection data of the weldment and the weld joint / seam, to calculate the torch push angle and torch working angle. In step 960 of method 900, when commanded by the user via the welding angle correction tool, the robot controller corrects the torch push angle and torch welding angle at the recorded weld point relative to the weldment and its weld joint / seam based on pre-stored ideal angles of the weldment and its weld joint / seam. According to one embodiment, the ideal angles are stored in the robot controller.

[0040] Other embodiments may also provide additional capabilities. For example, in one embodiment, a weld point can be defined by pointing a depth camera at the weld joint / seam and “clicking” a point, rather than moving the welding torch into the weld joint / seam. Furthermore, in teach mode, the welding wire of the torch can be fully retracted, and the weld point can be taught to the system with the correct extension using a depth camera, preventing the wire from bending during teaching. Two-dimensional (2D) and three-dimensional (3D) wire search motions can be automatically defined using detected planes. The inner angles at the start and end of a fillet weld can be detected, and the push angle can be modified to prevent the robot from colliding with the weld. By using an AR guide to display the position of the part in front of the robot to the user and using a depth camera to teach the characteristics of accurately locating the part in space, the need for expensive custom part fixtures can be eliminated. In one embodiment, finding the intersection of three (3) seams can be used to quickly teach a part workpiece frame, allowing easy reuse of the program between different robots or the manufacture of multiple identical parts. In one embodiment, data acquired by a depth camera and related algorithms can be used to detect and characterize small lap joints.

[0041] Figure 10 It shows that it can be used for example Figure 1 A block diagram illustrating an exemplary embodiment of the controller 1000 in the welding system 100. For example, the controller 1000 may be used as a robot controller 320 and / or as a controller in the welding power supply 310. Furthermore, the controller 1000 may represent... Figure 2 The laptop computer 420, or other computer platforms in other embodiments that represent most of the functions of the welding angle correction tool 400.

[0042] Reference Figure 10 The controller 1000 includes at least one processor 1014 (e.g., a microprocessor, central processing unit, graphics processing unit) that communicates with a plurality of peripheral devices via a bus subsystem 1012. These peripheral devices may include a storage subsystem 1024 (which includes, for example, a memory subsystem 1028 and a file storage subsystem 1026), a user interface input device 1022, a user interface output device 1020, and a network interface subsystem 1016. The input and output devices allow users to interact with the controller 1000. The network interface subsystem 1016 provides an interface to an external network and couples to corresponding interface devices in other devices.

[0043] User interface input device 1022 may include a keyboard, pointing devices such as a mouse, trackball, touchpad, or graphics tablet, a scanner, a touchscreen integrated into a display, audio input devices such as a voice recognition system, a microphone, and / or other types of input devices. Generally, the term "input device" is used to encompass all possible types of devices and methods of inputting information into the controller 1000 or communication network.

[0044] User interface output device 1020 may include a display subsystem, a printer, or a non-visual display such as an audio output device. The display subsystem may include a cathode ray tube (CRT), a flat panel device such as a liquid crystal display (LCD), a projection device, or some other mechanism for creating a visible image. The display subsystem may also provide a non-visual display, for example, via an audio output device. Generally, the term "output device" is used to encompass all possible types of devices and methods for outputting information from controller 1000 to a user or another machine or computer system.

[0045] Storage subsystem 1024 stores programming and data structures that provide some or all of the functions described herein. For example, computer-executable instructions and data are typically executed by processor 1014 alone or in combination with other processors. Memory 1028 used in storage subsystem 1024 may include multiple memories, including main random access memory (RAM) 1030 for storing instructions and data during program execution and read-only memory (ROM) 1032 for storing fixed instructions. File storage subsystem 1026 can provide persistent storage for program and data files and may include hard disk drives, solid-state drives, floppy disk drives, and associated removable media, CD-ROM drives, optical drives, or removable media cartridges. Computer-executable instructions and data that implement the functions of some embodiments may be stored by file storage subsystem 1026 in storage subsystem 1024 or in other machines accessible to processor 1014.

[0046] The bus subsystem 1012 provides a mechanism for allowing various components and subsystems of the controller 1000 to communicate with each other as intended. Although the bus subsystem 1012 is schematically shown as a single bus, alternative embodiments of the bus subsystem may use multiple buses.

[0047] The controller 1000 can be of different types. Due to the constantly evolving nature of computing devices and networks, Figure 10 The description of the controller 1000 depicted herein is intended only as a specific example for illustrating some embodiments. Many other configurations of the controller are possible, which have more... Figure 10 The controller depicted has 1000 or fewer components.

[0048] Although the disclosed embodiments have been shown and described in considerable detail, it is not intended to limit the scope of the appended claims or in any way to such detail. Of course, it is impossible to describe every conceivable combination of components or methods in order to describe all aspects of the subject matter. Therefore, this disclosure is not limited to the specific details or illustrative examples shown and described. Consequently, this disclosure is intended to include changes, modifications, and variations that fall within the scope of the appended claims, satisfying the statutory subject matter requirements of 35 U.S.SC § 101. The above description of specific embodiments has been given by way of example. From the given disclosure, those skilled in the art will not only understand the general inventive concept and accompanying advantages but will also discover obvious variations and modifications to the disclosed structures and methods. Therefore, it is sought to cover all such variations and modifications that fall within the spirit and scope of the general inventive concept as defined by the appended claims and their equivalents.

Claims

1. A method for correcting the angle of a welding torch positioned by a user when training a robot welding system, the method comprising: A depth camera using a welding angle correction tool acquires a single image of the weldment and the corresponding weld depth data. The computer uses the welding angle correction tool to process the depth data of the welded part; The 3D welding torch position and orientation data, which are recorded in the robot coordinate space for the welding point along the corresponding weld seam, are imported from the robot controller of the robot welding system into the computer of the welding angle correction tool. The computer using the welding angle correction tool calculates at least one welding torch angle in the robot coordinate space relative to the weldment and the corresponding weld, based on the weldment depth data of the weldment and the corresponding weld processed by the computer of the welding angle correction tool, and the 3D welding torch position and orientation data placed by the user. as well as Based on the pre-stored ideal angles of the welded parts and corresponding welds, the angle of at least one welding torch at the recorded weld point is corrected.

2. The method according to claim 1, wherein the depth data of the welded part is stereoscopic image data.

3. The method according to claim 2, wherein, The processing of the weldment depth data includes generating 3D point cloud data in the robot coordinate space from the stereo image data using the computer with the welding angle correction tool.

4. The method according to claim 3, wherein, The processing of the weldment depth data includes the computer using the welding angle correction tool generating 3D planes and intersection data representing the weldment and the corresponding weld from the 3D point cloud data in the robot coordinate space.

5. The method according to claim 1, wherein the at least one welding torch angle includes a welding torch pushing angle.

6. The method according to claim 1, wherein the at least one welding torch angle includes the welding torch working angle.

7. The method according to claim 1, wherein, The weld depth data is transmitted from the depth camera to the computer of the welding angle correction tool via at least one wired or wireless device.

8. The method of claim 1, wherein the 3D welding torch position and orientation data placed by the user are transmitted from the robot controller to the computer of the welding angle correction tool via at least one of a wired or wireless device.

9. The method of claim 1, wherein the position of the depth camera is calibrated to one of the tip of the welding torch or the tool center point (TCP) of the robot.

10. The method according to claim 1, wherein, The computer of the welding angle correction tool uses matrix manipulation technology, point cloud manipulation technology, and feature recognition technology as part of processing the depth data of the welded part.

11. A welding angle correction tool for correcting the angle of a welding torch positioned by a user during the training of a robotic welding system, the welding angle correction tool comprising: A depth camera is configured to acquire a single image of the weldment to be welded by a robotic welding system with a welding torch and the depth data of the corresponding weld seam. as well as Computer equipment, configured to receive: Depth data of the weldment from the depth camera, and The 3D welding torch position and orientation data, from the robot controller of the robotic welding system, are recorded by the user for the welding point along the corresponding weld seam. The computer device is configured to: Based on the depth data of the weldment and the position and orientation data of the 3D welding torch placed by the user, at least one torch angle of the recorded welding point relative to the weldment and the corresponding weld is calculated in the coordinate space of the robotic welding system. Based on the calculated at least one torch angle of the recorded welding point and the pre-stored ideal angles of the weldment and the corresponding weld, at least one corrected torch angle is calculated.

12. The welding angle correction tool according to claim 11, wherein, The depth data of the welded component is 3D image data.

13. The welding angle correction tool of claim 12, wherein calculating the at least one welding torch angle using the computer device includes generating 3D point cloud data in the coordinate space of the robotic welding system from the stereo image data.

14. The welding angle correction tool of claim 13, wherein calculating the at least one welding torch angle using the computer device includes generating 3D planes and intersection data representing the weldment and the corresponding weld from the 3D point cloud data in the coordinate space of the robotic welding system.

15. The welding angle correction tool according to claim 11, wherein, The computer device is in the form of a laptop computer.

16. The welding angle correction tool according to claim 11, wherein, The computer equipment is integrated into the robot controller of the robotic welding system.

17. The welding angle correction tool according to claim 11, wherein, The computer equipment is integrated into the welding power source of the robotic welding system.

18. The welding angle correction tool according to claim 11, wherein, The depth camera is configured to be removably attached to the welding torch.

19. The welding angle correction tool according to claim 11, wherein, The depth camera is configured to be mounted on the joint (6) of the robotic arm of the robotic welding system.

20. The welding angle correction tool according to claim 11, wherein the depth camera includes two imaging apertures for acquiring stereo image data.

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