Automatic welding path planner

Abstract

The present disclosure relates to a welding path planning method for welding a groove of a welding task by a welding machine. The method includes the steps of: determining dimensional characteristics of the groove at a plurality of locations along the groove; calculating, for each of the locations along the groove, at least one intermediate weld path solution based on the dimensional characteristics, thereby obtaining a plurality of intermediate weld path solutions; and generating at least one complete weld path solution for welding the entire groove based on the plurality of intermediate weld path solutions.

Description

[0001] The present disclosure relates to methods and systems for planning and executing a weld path for welding a groove.

[0002] background

[0003] Welding has become an essential method for joining metals in modern industry. Joining metal sheets, especially those of great thickness, often requires multiple weld layers and / or weld passes. Welding is performed in two or more layers, with each layer consisting of a single or multiple weld passes, to fill the entire groove and join the two objects. Furthermore, employing multiple passes and multiple layers helps achieve the necessary strength in the joint.

[0004] Welding paths are typically planned based on the practical experience of experienced individual welders. Individual welders must try various solutions to arrive at an efficient welding path for a given task. These manual labor-based solutions are far from accurate and precise, and weld quality cannot be guaranteed.

[0005] Therefore, the trend is towards the use of robots. However, their application is still subject to considerable limitations. As the number of weld passes (beads) increases during welding, the number of process and material parameters associated with the welding process increases. As a result, welding planning becomes very complex.

[0006] Multi-layer, multi-pass welding involves a large weld pool. Due to the heating and cooling cycles of the welding process, warping and residual stresses can occur in the weld. Deformation or warping undermines the aesthetic appeal of the product and affects the mechanical properties of the joint and the product's usability. Furthermore, residual stresses can cause the initiation of metal fractures, which can lead to failure of the welded product. Therefore, the solution to the welding task must take multiple parameters into account. However, controlling the weld pool in large-groove welding presents a significant challenge. While existing technologies can account for the influence of individual material and process properties during the welding process, highly coupled and controlled control of these properties has not been possible.

[0007] Furthermore, multi-pass and / or multi-layer welding is still primarily performed manually, requiring high labor intensity and reducing productivity. Due to the complexity of multi-pass and multi-layer welding processes, existing solutions have not been able to go beyond recommending individual weld passes at a time. In most cases, manual inspections are required between each weld pass. This results in production interruptions and reduced efficiency.

[0008] Therefore, there is a further need to provide a weld path solution for multi-layer and multi-pass welding that features a high level of automation and enhanced efficiency.The gap in the art extends to providing a weld path solution for automatically planning the welding of an entire groove.

[0009] Overview

[0010] The present method alleviates the above-mentioned disadvantages and provides a welding task planning system and method for welding the entire groove of a welding task.

[0011] In a first aspect, the present disclosure relates to a welding path planning method for welding a groove of a welding task using a welding machine, the welding path planning method comprising the following steps:

[0012] - preferably acquiring and / or receiving dimensional characteristics of the groove at a plurality of positions along the groove based on an optical scan,

[0013] - calculating at least one intermediate weld path solution based on said dimensional characteristics for each of said positions along the groove, thereby obtaining a plurality of intermediate weld path solutions, preferably calculating a plurality of intermediate solutions at each of said positions along the groove, and

[0014] - generating at least one complete welding path solution for welding the entire groove based on the plurality of intermediate welding path solutions.

[0015] The present disclosure provides at least one complete welding path solution for welding the entire groove. Therefore, a major advantage of the currently disclosed method is that the efficiency of the welding process is improved. The proposed method can obtain and / or receive an optical scan of the groove and determine the dimensional characteristics of the groove based on the optical scan, preferably the cross-sectional dimensions of the groove at multiple positions along the extension of the groove. The groove geometry can be determined at multiple positions based on the optical scan. Scans can be obtained at multiple positions for determining the groove geometry at the multiple positions. At least one intermediate welding path solution is calculated for each groove geometry, wherein each intermediate welding path solution includes a welding path plan for welding at least a portion of the groove. At least one complete welding path solution is then generated for welding the entire groove. Therefore, the at least one complete welding path solution, such as a complete solution, is generated based on the intermediate welding path solution.

[0016] Preferably, each intermediate weld path solution defines welding parameters used by the welding machine to weld the groove at a specific position / location of the groove, the welding parameters being selected from the group consisting of: a number of weld layers, a number of weld passes per weld layer, a wobble curve per weld pass, and a weld speed curve. The calculated intermediate weld path solutions associated with a position can be grouped by operating range (e.g., operating range for the wobble curve and the weld speed curve, e.g., in the form of minimum and maximum values ​​of the wobble curve and the weld speed curve).

[0017] For each scan image taken from the same groove but at a different position of the groove, an intermediate welding path solution is calculated. Preferably, multiple intermediate welding path solutions are calculated for each scanning position, so that the intermediate welding path solutions can provide solutions for welding the portion in which the scan image was taken. The at least one complete welding path solution is a complete solution for welding the entire groove, and the at least one complete welding path solution is generated (e.g., selected and / or calculated) so that the entire groove length can be welded using the complete solution. Therefore, the proposed method can generate at least one final welding path solution, for example, based on the evaluation of all intermediate solutions, so that the at least one welding complete path solution can be configured for welding the entire groove. Therefore, the at least one complete welding path solution can be easily executed for joining objects, i.e., performing a welding task, without requiring additional input from any other device or user.

[0018] Another important aspect of the present disclosure is that the dimensional characteristics of the groove are determined at multiple locations along the groove. The groove can be defined by the objects to be joined and generally extends along a direction of extension. The direction of extension can be linear or circular, and the groove can extend in any direction. The dimensions of the groove can vary along the direction of extension. The present disclosure obtains optical scans of the groove from multiple locations to evaluate the dimensional characteristics of the groove.

[0019] For each location, dimensional characteristics of the groove are determined. Based on the dimensional characteristics, at least one intermediate weld path solution is calculated. The intermediate weld path solution can be based on the cross-sectional area of ​​the scanned groove location. At least one intermediate weld path solution is calculated for each location. Generally, the method can calculate multiple possible welding scenarios. Each intermediate weld path solution includes a weld path plan for welding at least the portion of the groove for which the scan image was acquired.

[0020] The intermediate weld path solution can include the number of weld layers and the number of passes per layer. Because the dimensional characteristics of the groove can vary, the intermediate weld path solution calculated for each scan can be different. Furthermore, the proposed method can generate at least one complete weld path solution based on the intermediate solutions. Therefore, a major advantage of this method is that it can account for groove dimensional variations and tolerances.

[0021] This means that the unit volume of the groove can be different at different locations. Acquiring optical scans of the groove at multiple locations allows for accounting for volume effects. Advantageously, the presently disclosed method provides for improved quality of joined parts and minimized weld defects. For example, accounting for volume effects can minimize the risk of porosity, thereby improving the mechanical properties of the weld joint.

[0022] In a second aspect, the present disclosure relates to a groove welding system for welding a groove. The system includes a welding machine having a welding gun configured to perform a groove welding operation and a robotic controller configured to control the groove welding operation performed by the welding machine. The welding system further includes a sensor configured to acquire at least one scan of the groove. The welding system further includes a processing unit configured to perform the method disclosed above. The proposed system is configured to perform the groove welding operation based on at least one generated complete weld path solution for welding the entire groove.

[0023] Even before the welding operation begins, variations along the weld groove can be taken into account within the solution and adjusted for. Thus, an advantage is that the method can plan and execute the welding process without any interruption from the operator.

[0024] Furthermore, the present method can automatically plan welding paths for multiple grooves of varying sizes. A sensor can provide scan data that can be used to identify the groove geometry. A welding planner, such as a processing unit configured to perform the method disclosed above, can provide a welding sequence. The system can be configured to execute the welding sequence. The system can also be configured to compensate for variations and tolerances along the groove.

[0025] In a third aspect, the present disclosure relates to a system for planning a welding path for welding a groove of a welding task, the system comprising a non-transitory computer-readable storage device for storing instructions that, when executed by a processor, perform a welding path planning method for welding a groove of a welding task using a welding machine. Similarly, the presently disclosed method can be computer-implemented, for example, automatically executed to further automate the heavy structure fabrication industry.

[0026] Therefore, through the method and system according to the present disclosure, automatic planning of the entire welding path sequence of the groove is achieved at least before the welding operation begins, thereby improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will be described in more detail below with reference to the accompanying drawings:

[0028] Figure 1 Show the understanding tree.

[0029] Figure 2 An example of understanding a tree is shown.

[0030] Figures 3 and 4 A diagram of the groove and corresponding weld path solution is shown.

[0031] Figures 5 and 6 An embodiment of a welding system is shown.

[0032] Figure 7 A diagram showing a V-groove and the corresponding weld path solution.

[0033] Figure 8 A diagram showing a tulip groove and the corresponding weld path solution.

[0034] Figures 9A to 9B A diagram showing a tulip groove and the corresponding weld path solutions at two different locations along the groove is shown.

[0035] FIG. 10A to FIG. 10B A diagram showing a tulip groove and the corresponding weld path solutions at two different locations along the groove is shown. DETAILED DESCRIPTION

[0036] This method provides a welding path planning method for welding a groove in a welding task. As used herein, a groove in a welding task may be a groove defined by the objects to be joined. The groove may extend along an extension direction, where the extension direction may be a welding direction. A weld bead may be generated by depositing filler material into the groove between the metal objects, such that the weld bead extends along the extension direction.

[0037] In an embodiment, the disclosed method is used for welding components in the automotive industry and / or the marine industry and / or the heavy industry and / or wind turbines.

[0038] In industries such as heavy structural fabrication, pipelines, shipbuilding and repair, and pressure vessel fabrication, joining large objects may require multiple passes and layers of welding to fill large grooves. This means that the proposed method can plan multiple passes and multiple paths for welding the entire groove.

[0039] Typically, the thickness of the groove can indicate the need for multiple passes and multiple layers of welding. In an embodiment, the thickness of the groove can be any thickness. The thickness of the groove can be any thickness that is too large to be filled by a single weld pass.

[0040] Bevel characteristics

[0041] Optical scans of the groove can be acquired at multiple locations along the groove. The scanning of the groove can be based on non-invasive methods, such as non-contact measurement scanning. For example, a scanner can provide light on the groove, and the reflected light pattern can be detected by a sensor (such as a photodetector or an image sensor) and can be converted into an image and / or dimensional characteristics of the groove. Any reflection-based scanning system (such as a line scanner) can be used to scan the groove. Alternatively or additionally, the optical scan can be performed by a projection-based method (such as by lidar technology) by sending a laser beam to the groove and measuring the reflected light with a photodetector to determine the distance to the groove and generate a map of the groove. The scanning can be based on structured light projection. Thus, a known pattern can be projected onto the groove. When the camera observes the pattern from one (or more) perspectives, the surface features of the groove distort the pattern. The direction and magnitude of the pattern distortion can be used to reconstruct the surface topography of the groove.

[0042] In an embodiment, the plurality of locations are along the extension of the groove. The plurality of locations may be calculated based on the length of the groove. In an embodiment, the plurality of locations are at predetermined distances along the extension of the groove. In some examples, the distance between each scan may be based on the total number of scans to be acquired. In some examples, the distance may be based on the length of the groove. Each of the locations at which a scan of the groove is acquired may be equidistant from an adjacent location. Alternatively, the distance between each scan may vary. The distance between each scan may be arbitrarily selected. The distance between each of the locations may be any distance.

[0043] In an embodiment, the distance between each of the plurality of positions is between 1 mm and 5000 mm. In an embodiment, the distance between each of the plurality of positions is between 10 mm and 200 mm, preferably between 50 mm and 100 mm. Alternatively, the distance between each of the positions may be between 1 mm and 50 mm. The distance may be set based on the groove size so that potential geometric differences along the length of the groove can be captured. The distance may also be set based on the scan speed so that the entire method can be performed efficiently and effectively. Thus, acquiring (and / or receiving) multiple groove scans can provide improved flexibility for automated weld path planning for various welding tasks.

[0044] The method may be configured to receive sensor data representing a scanned image of a groove. In one embodiment, the optical scanned image of the groove is acquired by an optical sensor and / or scanner. The scanned image of the groove may be acquired, for example, by a laser scanner and / or a camera. The sensor may be any sensor capable of electronically capturing visual information of the groove in one, two, and / or three dimensions.

[0045] An important aspect of the present disclosure is determining the dimensional characteristics of a groove at multiple locations along the groove, for example, based on an optical scan as described above. This means that the dimensional characteristics of the groove can be calculated based on the optical scan. Furthermore, the present method can be configured to acquire and / or receive multiple images of the groove. The dimensional characteristics of the groove can be related to the dimensional characteristics of the groove's cross-sectional area, where the cross-sectional area can be transverse to the direction of extension.

[0046] In an embodiment, the dimensional characteristics of each groove are selected from the group consisting of: the height of the groove, the cross-sectional area of ​​the groove, the distance between the two top vertices of the groove cross-section, the distance between the two bottom vertices of the groove cross-section, the groove angle between each side edge of the groove relative to the base of the groove, and the angle of the bottom of the groove relative to the horizontal plane.

[0047] One or more of the groove's dimensional characteristics can be determined by manual inspection. For example, the groove's thickness can be manually determined. Advantageously, the groove's scan image can include data from which the groove's thickness and any other dimensional characteristics described above can be determined and / or calculated. Consequently, a weld path solution calculated based on the optical scan image can be more reliable.

[0048] Weld grooves come in many shapes and sizes. They can be single or double. They can be V-shaped or Y-shaped. They can also be square. They can be beveled, J-shaped, U-shaped, flared, or tulip-shaped. They can be double-faced beveled or double-faced V-shaped. Combinations of these are also possible.

[0049] Dimensional characteristics, such as the distance between two vertices of the bottom of the groove section and / or the angle of the bottom of the groove relative to the horizontal plane, can indicate the type of groove. Therefore, different types of grooves may require different processing procedures. For example, when the distance between the two vertices of the groove section is higher than a predefined value, the method disclosed herein may include providing a backing plate that is configured to receive the weld pool during welding of at least the first layer. Therefore, the method disclosed herein can plan the welding path of the groove while taking into account the opening of the groove width, and / or the backing plate requirements, and / or the physical and / or thermal and / or mechanical properties of the backing plate. The backing plate can be positioned below the groove, at the bottom of the groove. Depending on the angle of the bottom of the groove relative to the horizontal line, the geometry of the backing plate and / or the position of the backing plate can be adjusted so that the surface of the backing plate can receive the weld pool along the first welding layer.

[0050] Intermediate welding path solution

[0051] Based on the dimensional characteristics, an intermediate weld path solution can be calculated. In an embodiment, each of the intermediate weld path solutions specifies the number of weld layers and the number of passes within each of the weld layers. Thus, the intermediate weld path solution can specify how many weld layers should be deposited to join the objects by welding and how many weld passes should be deposited within each layer. The intermediate weld path solution can alternatively or additionally specify a wobble profile for each weld pass, typically in the form of wobble frequency and amplitude, and / or a welding speed profile for the welding machine.

[0052] Typically, for each of the locations along the groove, multiple intermediate weld path solutions are calculated based on the dimensional characteristics, thereby obtaining multiple intermediate weld path solutions for each location. Furthermore, each intermediate weld path solution typically specifies the number of weld layers and the number of weld passes per layer, as well as an associated wobble curve and welding speed profile for each weld pass. This can result in many possible intermediate weld path solutions for each location. One way to group the intermediate weld path solutions associated with a location is to specify operating ranges, such as operating ranges for the wobble curve and welding speed profile, for example, in the form of minimum and maximum values ​​for the wobble curve and welding speed profile. These operating ranges for the wobble curve and welding speed profile can then indirectly provide ranges for the number of weld layers and the number of weld passes per layer, since the wobble curve and welding speed profile directly determine the size of the weld pass and are therefore associated with the number of layers and the number of passes per layer.

[0053] Thus, the intermediate weld path solutions associated with the locations of the groove can be defined using the operating ranges of the oscillation curve and the welding speed curve, and thus, the number of layers and the number of weld passes in each layer, and alternatively or additionally, the ranges of these quantities. With the operating ranges of the welding parameters at each location along the groove, it is computationally simpler to find at least one complete weld path solution that is common to at least one of the intermediate weld path solutions for each location.

[0054] The dimensional characteristics of the groove can be crucial for calculating the intermediate weld path solution. For example, the groove width along the groove height can be one of the important parameters used to calculate the intermediate weld path solution. Not only the width, but also the groove angle between each side edge of the groove relative to the base of the groove can vary. Advantageously, the present disclosure can provide an improved weld path solution because the inclination of the side edges of the groove and the variation in groove width can be considered when calculating the intermediate weld path solution.

[0055] This means that the method can couple the dimensional characteristics of the groove with the welding process parameters. For example, when the inclination of the side edges of the groove varies, the calculated intermediate solution can specify the welding speed profile for each pass adjacent to the side edge so that the final height of the weld layer is maintained.

[0056] In the examples presented herein, the number of weld layers is in the range of 5 to 12, and the number of passes (i.e., weld beads) in each weld layer is in the range of one to six. Thus, typically, the number of weld layers will be in the range of 1 to 20 or even 30 to 40, or possibly as high as 50 layers. The number of passes in each layer will typically be in the range of 1 to 10, or even as high as 10 or 20 or more passes for very large grooves.

[0057] Regarding the swing curve, a typical range of amplitudes is between 0.2 mm and 10 mm, considered as the total swing, i.e. the distance between the extremes, corresponding to an amplitude of between 0.1 mm and 5 mm. However, the swing amplitude can be as high as 10 mm, or even 15 mm or 20 mm or 30 mm, or more. A typical range of swing frequencies is between 1 Hz and 3 Hz, however frequencies in the range of 0 Hz to 5 Hz or even 0 Hz to 10 Hz or more may be possible.

[0058] Typical welding speeds are typically in the range of 25 cm / min to 50 cm / min, but may also be between 10 cm / min to 75 cm / min, possibly even in the range of 0 cm / min to 100 cm / min or even higher.

[0059] However, even with a limited operating range of welding parameters, the number of possible welding solutions at a particular location on the groove can become quite large, since the multiple welding parameters provide many possible intermediate welding path solutions. However, this is also a major advantage of the presently disclosed solution, as the multiple possible solutions increase the chances of identifying a complete welding path solution common to all locations on the groove. Furthermore, preferably, in certain situations, not only one complete solution can be selected, but multiple complete solutions, such as an optimal solution, can be selected.

[0060] constraint

[0061] In one embodiment, the presently disclosed method further includes the step of defining a set of welding constraints. Each welding process may involve numerous parameters, such as welding process parameters, material properties of the object, and welding conditions defined by the welding equipment. The method can be adjusted based on these parameters. In another embodiment, the at least one intermediate weld path solution is generated based on the set of welding constraints. The constraints can be defined before calculating the intermediate weld path solution. Alternatively and / or additionally, the calculated intermediate weld path solutions can be screened and / or evaluated such that one or more of the intermediate weld path solutions can be eliminated based on the defined constraints.

[0062] In another embodiment, the set of welding constraints is selected from the group consisting of: welding wire type, welding gas type, welding position, welding angle (such as positioning of the welding machine), welding gun type, welding process type, material properties of the welding task, type of groove, and welding speed. Therefore, the method is highly flexible and can adapt to a wide range of changes during welding.

[0063] For example, at higher welding speeds, less filler material can be deposited per unit time. When calculating intermediate weld path solutions, the deposition rate can be crucial, as the weld bead is produced by depositing filler material. In embodiments, the welding speed of the welding machine can be defined as a constraint. Thus, the proposed method can identify and / or calculate intermediate weld path solutions that meet the defined welding speed. The welding speed of the welding gun can be limited by the welding equipment. Therefore, the presently disclosed weld path method can provide an adaptable and flexible weld path solution.

[0064] The welding process may be, for example, metal inert gas welding, metal active gas welding, tungsten inert gas welding, submerged arc welding, etc. The filler material may be, for example, a welding wire, such as a metal welding wire, a solid welding wire, a flux-cored welding wire, or a metal-cored welding wire.

[0065] The welding gun angle and / or welding gun geometry (e.g., the diameter of the welding gun tip) can vary for different groove geometries, and / or applications, and / or welding system configurations. Furthermore, the welding gun tip can define the location where filler material is deposited. Advantageously, the present disclosure can provide a welding path solution that takes the welding system geometry into account and can adjust the solution. Alternatively, the present method can provide multiple solutions, each of which can specify a welding gun angle.

[0066] During welding, the metal can absorb the heat generated. The heat is transferred from the cutting edge through the body of the metal, wherein a zone is formed between the molten metal and the unaffected base metal. This zone can be referred to as the heat-affected zone (HAZ). In the HAZ, the heat can cause changes in the metal's microstructure, which can reduce the metal's strength. The HAZ can include the weakest point in the joined structure, and failure of a particular joined structure can occur within the HAZ zone. Therefore, it is important to understand the thermal characteristics of the welding task, i.e., the objects to be joined and the heat generation and transfer during the welding process.

[0067] This method can consider the thermal and mechanical properties of the HAZ. The heat input to the welded object can be calculated based on welding process parameters and the material properties of the welded object and the filler material. These parameters can be used as inputs for calculating an intermediate solution. Additionally or alternatively, these parameters can be provided as constraints.

[0068] Alternatively, a thermal factor may be defined. The amount of heat generated during the welding process may be a function of the welding current, voltage, and welding speed. In an embodiment, the set of welding constraints includes a thermal factor for the welding task. The thermal factor may define a temperature window for each welding process, such that the welding operation can occur within the defined temperature window. The temperature window may be defined such that the materials can be joined together without sacrificing the mechanical strength of the joined objects. The method may be configured to calculate intermediate weld path solutions based on the thermal factor. For example, already calculated intermediate weld path solutions may be recalculated to remove solutions that fall outside the defined thermal factor.

[0069] The proposed solution can calculate a first set of intermediate weld path solutions based on the weld groove geometry. This first set of weld path solutions can be unconstrained by welding process parameters. Depending on the specific welding process and equipment used, the user can define welding speed, welding temperature, thermal properties of the materials used in welding, and many other process-specific parameters. The proposed method can generate at least a second set of intermediate weld path solutions that can comply with the defined constraints.

[0070] Alternatively, the constraints may be applied to the complete weld path solution.Thus, the method may generate at least one complete weld path solution for welding the entire groove based on the plurality of intermediate weld path solutions, and may then define a set of welding constraints.

[0071] Complete welding path solution

[0072] Generally, the proposed method is based on generating at least one complete welding path solution for welding the entire groove based on the plurality of intermediate welding path solutions.

[0073] The intermediate weld path solution for each scan may be a solution tree having multiple solutions based on various constraints, parameters, and aspects.

[0074] In an embodiment, the complete weld path solution specifies the number of weld layers, the number of weld passes per weld layer, a wobble curve for each weld pass, and a weld speed profile for the welding machine. This means that each of the intermediate weld path solutions can specify the number of weld layers, the number of weld passes per weld layer, a wobble curve for each weld pass, and a weld speed profile for the welding machine. Thus, a solution tree can include multiple intermediate weld path solutions, wherein the multi-pass and multi-layer weld paths of each solution include a weld speed profile for welding the portion of the groove for which the scan was obtained, as well as a wobble curve for each pass.

[0075] After the step of calculating a plurality of intermediate welding path solutions for each position of the optical scan image, the method may further include the step of generating at least one complete welding path solution, wherein the at least one complete welding path solution is a common solution calculated for each position.

[0076] The selection of a complete weld path solution for welding the entire groove from among the multiple intermediate weld path solutions can be based on constraints. The multiple intermediate weld path solutions can be evaluated by calculating whether the solutions meet the constraints. For example, due to the constraints, specifying three weld passes in a layer may not be feasible for the complete solution, compared to specifying two weld passes in a layer. For example, if the welding speed is slower, the specified welding speed may result in a higher thermal factor for the three-pass weld due to the deposition of more filler material. Consequently, the predefined thermal factor may be exceeded. Therefore, a two-pass solution may be selected. Alternatively or additionally, the filler material deposition rate may be adjusted.

[0077] Therefore, the advantage of the proposed method is the interaction of all constraints so that the intermediate weld path solutions and thus the weld path solutions for welding the entire groove are automatically generated based on the application.

[0078] Finally, the at least one complete weld path solution for welding the entire groove can be a common solution calculated for each scan position. In particular, if the groove dimensions are relatively uniform, the calculated intermediate weld path solutions for each scan can be similar. However, if the groove dimensions along the groove extension are less uniform than the calculated intermediate dimensions, the weld path solutions can be different.

[0079] In an embodiment, the at least one complete weld path solution for welding the entire groove is generated so that, for the same layer, an intermediate weld path solution specifying a higher pass number at that location is selected as the at least one complete weld path solution. For example, for a larger width, for the same layer height, the solution may specify a higher pass number. In this case, the priority for generating complete weld path solutions may be based on selecting a higher pass number. Because a higher pass number can provide a sufficient amount of welding material for a wider section of the groove, this section can be joined with improved strength while preventing sand porosity. However, as previously described, a solution with a lower pass number may be selected so that the thermal factor of the solution is within a predefined value. This means that the height of each layer may vary.

[0080] In an embodiment, the at least one complete welding path solution specifies a variable number of layers so that the number of layers welded between adjacent positions is different while maintaining a predefined weld height tolerance and / or spacing between all groove images. In a further embodiment, the method comprises a step of calculating the height of the at least one weld layer for each of the at least one complete welding path solutions. This means that the proposed method can be configured to calculate the weld height between each scanning position and / or along each scanning position. The height of each weld bead can be calculated. The weld of each layer can be calculated. When the height difference calculated between each adjacent scan image is higher than a predefined value, further calculations can be performed to find the necessary number of weld bead to equal the height. This may be the case, for example, in the welding of grooves where the groove geometry changes. For example, when two cylindrical objects with tilted center axes are welded to each other.

[0081] Updated groove properties

[0082] The presently disclosed method is based on calculating multiple intermediate weld path solutions based on the dimensional characteristics of the groove at multiple locations along the groove, and calculating at least one complete weld path solution based on the intermediate weld path solutions. The actual welding operation can then be performed based on one of the at least one complete weld path solutions, and the groove can be welded based on the selected complete weld path solution. However, in some cases, it may be advantageous to obtain the dimensional characteristics of the groove during the welding operation, for example by optically scanning the groove. For example, halfway through the welding operation, after each weld layer, or after two or three weld layers have been completed, the groove can be scanned again, preferably at the same location, to ensure that everything went according to plan. One advantage is that the now at least partially filled groove can be treated as any "new" groove to be welded, and the presently disclosed weld path planning method can be performed on this at least partially filled groove. One possible outcome is that the welding process proceeds as planned, and the groove welding system can continue with the selected complete weld path solution. Another possible outcome is that another complete weld path solution generated based on the multiple recalculated intermediate weld path solutions is more optimal for the new situation with the at least partially filled groove.

[0083] Receiving and / or acquiring updated dimensional characteristics of the groove is particularly relevant when the groove is large and requires many weld layers and several weld passes in each layer, because the energy generated by the welding process may affect the metal material in the groove, especially the process of repeated heating and subsequent cooling from the welding process. In some cases, the result may be a reduction / contraction of the groove, thereby significantly affecting the dimensional characteristics of the groove. In this case, it is indeed reasonable and advantageous to receive and / or acquire updated dimensional characteristics at multiple locations along the groove during the welding process in order to recalibrate the welding process by recalculating at least one intermediate weld path solution based on the dimensional characteristics at each of the locations along the groove, and generating at least one complete weld path solution for welding the entire (remaining) groove based on the multiple intermediate weld path solutions.

[0084] An example of this recalibration with the updated dimensional properties of the groove and the new complete weld path solution can be seen in Figures 9-10, which are explained in further detail below.

[0085] Therefore, the present disclosure also relates to a groove welding method comprising the steps of planning a welding path as described herein, and initiating a groove welding operation based on at least one complete weld path solution generated for welding the entire groove, for example, with the aid of the presently disclosed groove welding system.

[0086] After at least one layer of the groove has been welded, a new / updated weld path can be planned as described herein, such that an updated weld path is planned over at least a portion of the welded groove. Preferably, the weld path plan is automatically updated at least once, preferably at least twice, and more preferably at least three times during the welding operation, such as after each welded layer, after every two welded layers, after every three welded layers, after every four welded layers, every quarter of the welding process, every third of the welding process, or half of the welding process, or any combination thereof. Whether and when the groove dimensional characteristics need to be updated during welding can be determined, for example, by an operator, which can be determined, for example, based on the characteristics of the groove prior to planning and / or prior to the welding operation.

[0087] A groove welding operation can be performed based on the generated at least one complete weld path solution for welding the entire groove, for example, with the groove welding system disclosed herein. During this time, a set of welding parameters can be adaptively adjusted.

[0088] system

[0089] The present disclosure further relates to a groove welding system. The system includes a welding machine having a welding gun configured to perform a groove welding operation. The welding machine can be any welding machine including a robotic arm and a welding gun. The groove welding operation performed by the welding machine can be controlled by a robotic controller. The system is configured to perform the groove welding operation based on at least one generated complete weld path solution for welding the entire groove.

[0090] The system further includes at least one sensor for acquiring at least one scan of the groove. The sensor may be a scanner disposed on a track system such that the scanner can be moved relative to the welding task, thereby acquiring a plurality of scans.

[0091] The system may include sensors configured to monitor the welding process. A controller may control the welding process based on the monitored data. In one embodiment, the system is configured to adaptively adjust the welding speed and / or the oscillation frequency of the welding machine during welding. For example, a robotic arm may move the welding gun to adjust the welding speed. In another embodiment, the system is configured to adaptively adjust the amount of welding wire used during welding. By controlling the deposition of filler material, the weld pool of each weld bead can be controlled, thereby improving weld quality.

[0092] In one embodiment, the system is configured to: 1) acquire at least one rescan of the groove with the aid of a sensor during a groove welding operation to obtain updated dimensional characteristics of the at least partially welded groove, and 2) execute the presently disclosed welding planning method based on the updated dimensional characteristics of the at least partially welded groove to generate at least one updated complete weld path solution for welding the at least partially welded groove. In this regard, the groove may be rescanned at least once, at least twice, at least three times, or at least four times during the welding process, for example, after each weld layer, after every two weld layers, after every three weld layers, after every four weld layers, every quarter of the welding process, every third of the welding process, or half of the welding process, or any combination thereof.

[0093] Thus, the present method can plan a welding path, perform a groove welding operation based on the generated welding path solution for welding the entire groove, and adaptively adjust a set of welding parameters during welding. In an embodiment, the set of welding parameters is one or more of the following: a wobbling profile of the welding machine, such as wobbling frequency and amplitude; and a wire amount.

[0094] In an embodiment, the welded groove is tracked in real time.In an embodiment, the method comprises the step of defining a thermal factor for the welding task, wherein the set of welding parameters is adjusted based on the thermal factor.

[0095] Therefore, the present method provides welding path planning for various welding tasks, wherein the calculated welding path solution can be adjusted before and during the welding operation based on various parameters and / or inputs and / or constraints that are interrelated with each other, thereby providing an efficient and flexible welding operation.

[0096] Detailed description of the drawings

[0097] The presently disclosed method can calculate all possible solutions or a set of possible solutions for welding the groove for each scan or multiple scans along the groove. In one example, the system finds a set of solutions that are common among these scans and selects the one that meets the requirements. The requirements can be fast execution time, a small number of weld passes, heat input preference, etc. The process can also be an iterative process, in which a first set of solutions for each scan is calculated (if no common solution is found), the limiting constraints are changed, and the process is repeated until a solution is found or all possible solutions are studied.

[0098] Figure 1 and Figure 2 Show the understanding tree. Figure 1 Technical parameters of each weld bead of each layer are further shown.After determining the dimensional characteristics of the groove at locations along the groove, at least one intermediate weld path solution is calculated based on the dimensional characteristics. Figure 1 and Figure 2 An intermediate solution calculated for determining the dimensions of the groove (eg based on a scan of the groove cross section) is shown.

[0099] Figure 1 Five intermediate welding path solutions A, B, C, D, E are shown. Each intermediate welding path solution A, B, C, D, E specifies at least the number of weld layers and the number of weld passes per weld layer. The solution begins by calculating the number of passes for the first layer 1. st Possible welding scenarios for welding. Figure 1 , first layer 1 st There is a single possible scene, for example, a weld bead. nd The scene is calculated based on the scene of the first layer. As shown in the figure, for the second layer 2 nd , one or two are possible. rd Based on the second layer 2 nd The calculations are based on these two different scenarios. th , four scenarios are proposed; the first two of them (from left to right) depend on the third layer 3 rdThe first scenario is calculated based on the scenarios of the previous layers. Each of these dependency scenarios defines a branch of the tree. Therefore, each intermediate solution A, B, C, D, and E represents a branch of the tree. Based on the calculation, intermediate solutions A and B specify five layers, while intermediate solutions C, D, and E specify filling the groove with four layers.

[0100] Figure 1 Each circle in the graph can be called a node. Each node specifies the layer volume range of the previous layer (minU to maxU) and the layer volume range of the current layer (minL to maxL). This means that a deposition rate can be specified for both the previous layer and the current layer. Therefore, one of the calculated parameters is the fill volume and deposition rate of the previous layer, thus forming a welding speed profile. Each node also specifies a channel containing technical parameters of the welding machine, such as the welding energy and / or voltage and / or current used in the weld.

[0101] A solution tree is calculated for a plurality of locations along the extended portion of the groove. After the plurality of intermediate weld path solutions are calculated for all scanned locations along the groove, at least one complete weld path solution is calculated for welding the entire groove. A branch (an intermediate solution) calculated for one location can be calculated for another location. The at least one complete weld path solution can be a common solution calculated for each location (e.g., each location at which a scan was obtained).

[0102] Furthermore, the proposed method allows the definition of a set of welding constraints. For example, after all possible welding path solutions are calculated, a set of constraints can be applied such that solutions that do not satisfy the given constraints are eliminated.

[0103] The set of constraints can, for example, be one or more of process and / or material properties. The set of constraints can relate to deposition rate, type of filler material, thermal and mechanical properties of the object and welding wire, welding speed, welding energy, and the like. Some constraints, such as the welding angle, can be applied after the welding solution is calculated. Alternatively or additionally, the set of constraints can be considered when calculating the welding solution. For example, the deposition rate for each pass can be calculated based on a predefined thermal factor, such as heat input. Heat input can vary depending on the welding process and the object being welded. Heat input can vary based on the filler material, melting temperature, and deposition rate. Therefore, changes in heat input requirements can affect the calculated volume range for each weld pass. After all possible complete weld path solutions are calculated, a thermal factor can also be set as a constraint. Another constraint can, for example, relate to welding energy and / or voltage and / or current, which can be varied based on the pass. A user can manually review the calculated complete weld path solutions and select one from among all solutions. The method can also automatically select one or more complete solutions.

[0104] Figure 3 A diagram shows a groove cross-section and the corresponding complete weld path solution. The small circles within the groove cross-section represent weld passes for the final solution. Weld passes are numbered using Arabic numerals. Based on the intermediate weld path solution shown, the first layer has one weld pass 1; the second layer specifies two weld passes 2 and 3; and the third layer includes three weld passes 4, 5, and 6. Based on this diagram of the complete weld path solution, a total of 52 weld passes are required to fill the groove.

[0105] Figure 4 is a diagram of a cross section of another groove, in which the axes provide the dimensional characteristics of the average groove cross section. Therefore, the average groove height is about 45 mm. The width of the groove increases from about 15 mm to about 30 mm along the groove height. The solution presented includes eleven layers, wherein the first layer has one weld bead 1 and the second layer has two weld bead 2 and 3. The calculated solution specifies two weld bead until the eighth layer. The eighth layer includes three weld bead 14, 15, and 16. After the eighth layer, the number of weld bead remains stable, that is, three weld bead are calculated for each of the ninth, tenth, and eleventh layers. When the groove has steeper side edges, the number of weld bead per layer varies less. In addition, the solid line (shown by the small circle) originating from each weld bead indicates the swing curve, wherein the substantially horizontal line indicates the amplitude of the swing. As shown in the figure, the solid line can have an inclination relative to the horizontal line. Therefore, the solid line also shows the angle of the welding gun. The welding gun follows the path shown by the solid line for each weld bead. As can be seen, a weld bead adjacent to the side surface of the groove is welded by moving the welding gun upward toward the upper surface of the side surface of the groove. The weld bead is calculated to fill the groove while maintaining a similar weld height for each weld bead within each layer. It may be desirable to maintain a similar weld height for each weld bead within the same layer. However, the thickness of each weld layer may vary.

[0106] Figure 7 A diagram shows a V-groove groove cross section and the corresponding weld path solution. The small circles within the groove cross section represent the weld passes of the final solution. The weld passes are numbered using Arabic numerals. According to the weld path solution shown, the first four layers have one weld pass, while the final layer has three weld passes. As can be seen from the illustrated solution, V-grooves with less steep edges are simpler to plan and execute, in part because the welding gun angle can remain constant.

[0107] Figure 8 A diagram showing a groove cross section of a groove and the corresponding final weld path solution is shown. According to the weld path solution shown, the first nine layers have two weld passes, while the last two layers have three weld passes each. Similar to Figure 4The steep edge of the groove necessitates a corresponding change in the welding gun angle. Line 81 shows a new scan of the groove acquired after the first layer, comprising weld passes 1 and 2, has been welded. This scan can be used to update the groove characteristics to verify that the first layer has been welded correctly, and a new round of intermediate and final weld path solutions can be calculated based on the new scan. As can be seen from line 81, the initially calculated final weld path solution remains applicable.

[0108] Figure 9A and Figure 9B A diagram of the groove cross section at two different locations along the groove is shown along with the corresponding complete weld path solution for the groove, i.e., Figure 9A shows a location along the groove and Figure 9B Another position is shown. The groove is an example of a so-called tulip groove. The complete weld path solution covers the entire groove and is preferably based on all scans from different positions along the groove. Figure 9A and Figure 9B As can be seen, there are 10 layers of groove welding, a total of 24 passes, and the welding path solution shown is for Figure 9A and Figure 9B is common, with two passes in the first six layers and three passes in the top four layers.

[0109] Figure 10A and Figure 10B Figure 1 shows a cross section of a tulip groove at two different locations along the groove. Figure 9A and Figure 9B The same bevel, but Figure 10A and Figure 10B The scans in the figure are taken after welding the first layer with welds "1" and "2" (in Figure 9A and Figure 9B That is, the groove characteristics have been updated with a new optical scan that provides updated dimensional characteristics of the groove that is now at least partially filled. With the new dimensional characteristics, the process of calculating the intermediate weld path solution and the complete weld path solution can be repeated, and the complete weld path solution (in Figure 10A and shown in Figure 10) is the optimal solution for the groove shown in the figure (in Figure 10A and Figure 10B Comparing Figures 9 and 10, it can be seen that the complete welding path solution generated from the groove (in Figure 9A and Figure 9B After welding the first layer and rescanning the groove, the complete weld path solution generated (in Figure 10A and Figure 10B ) contains five bottom layers, each with two paths - this corresponds to Figure 9A and Figure 9B The solution in is minus the already completed bottom layer. However, if Figure 10A and Figure 10B As seen in the figure, there are only three top layers, each with three paths, which is consistent with Figure 9A and Figure 9B This differs from the solution in [ ], which has four top layers, each with three passes. The reason for this is that the energy generated by the welding process, while heating and cooling the material, has caused the top layers of the groove to shrink. That is, the height of the groove has decreased after welding the first bottom layer. Performing a new scan of the groove after welding the first layer and repeating the weld path planning method ensures that the welding system can account for the changes in the groove's characteristics.

[0110] When receiving and / or acquiring new dimensional properties of the groove changes between groove and weld conditions. Figure 7 Small V-grooves in may not require rescanning during welding, whereas larger grooves with more than 20 weld passes (such as Figure 8 to Figure 1 0) can be an advantage. The frequency of updating the groove characteristics during the welding process can also be varied. Updating the groove characteristics after completing each layer may be easy to implement, but this also increases the time of the welding process. As can be seen in the comparison between Figures 9 and 10, only the top layer changes in the generated complete welding path solution, that is, at least the first 2, 3, 4, 5, or 6 bottom layers may have been completed without rescanning the groove. Therefore, during the welding process, the groove characteristics can be updated after each layer, after every two layers, after every three layers, after every four layers, or at one-quarter of the welding process, or at one-third of the welding process, or at one-half of the welding process, or any combination thereof.

[0111] Figure 5 and Figure 6 is an embodiment of a welding system comprising a welding machine having a welding gun 54, 64 and a robotic arm 55, 65 configured to perform a groove welding operation. The welding system further comprises a scanner 51, 61. Figure 5 The scanner 51 shown in FIG is arranged near the welding gun 54 so that the robot arm 55 controlling the welding gun 54 can move the scanner 51 to the position where the groove scan map is to be obtained. Alternatively, the scanner can be fixed. Figure 6 In the embodiment of the present invention, a plurality of fixed scanners 61 (two scanners are shown) are positioned along a track 66, wherein welding tasks can be positioned along the track. The welding system includes a welding machine center (53, 63) for controlling welding machine parameters, such as welding energy, by selecting a plurality of welding channels. The welding system further includes a robot controller (52, 62) for controlling groove welding operations performed by the welding machine.

[0112] Terms

[0113] 1. A welding path planning method for welding a groove of a welding task using a welding machine, the welding path planning method comprising the following steps:

[0114] - obtaining and / or receiving dimensional characteristics of the groove at a plurality of locations along the groove,

[0115] - calculating, for each of said positions along the groove, at least one intermediate weld path solution based on said dimensional characteristics, thereby obtaining a plurality of intermediate weld path solutions, and

[0116] - generating at least one complete welding path solution for welding the entire groove based on the plurality of intermediate welding path solutions.

[0117] 2. The method according to clause 1, comprising the step of acquiring and / or receiving a scan of the groove for determining dimensional characteristics.

[0118] 3. The method according to clause 2, wherein the scanned image of the groove is obtained by an optical sensor and / or a scanner.

[0119] 4. A method according to any of the preceding clauses, wherein the plurality of positions are along the extension of the groove.

[0120] 5. A method according to any of the preceding clauses, wherein the plurality of positions are at predetermined distances along the extension of the groove.

[0121] 6. The method according to clause 5, wherein the distance between each of the plurality of positions is between 1 mm and 5000 mm, between 10 mm and 200 mm, preferably between 50 mm and 100 mm.

[0122] 7. A method according to any of the preceding clauses, wherein the dimensional characteristics of each groove are selected from the group consisting of:

[0123] The height of the groove,

[0124] The cross-sectional area of ​​the groove,

[0125] The distance between the top two vertices of the groove section,

[0126] The distance between the two vertices at the bottom of the groove section,

[0127] the bevel angle between each side edge of the bevel relative to the base of the bevel, and

[0128] The angle of the bottom of the groove relative to the horizontal plane.

[0129] 8. A method according to any of the preceding clauses, further comprising the step of defining a set of welding constraints.

[0130] 9. The method according to clause 8, wherein the set of welding constraints is selected from the group consisting of: type of welding wire, type of welding gas, welding position, welding angle, type of welding gun, type of welding process, material properties of the welding task, type of the groove, and welding speed.

[0131] 10. The method of any of clauses 8 to 9, wherein the set of welding constraints includes a thermal factor for the welding task.

[0132] 11. The method of any of clauses 8 to 10, wherein the at least one intermediate weld path solution is generated based on the set of welding constraints.

[0133] 12. The method of any of the preceding clauses, wherein each of the intermediate weld path solutions specifies a number of weld layers and a number of passes in each of the weld layers.

[0134] 13. A method according to any of the preceding clauses, comprising the steps of calculating a plurality of intermediate weld path solutions for each position and generating at least one complete weld path solution, wherein the at least one complete weld path solution is a common solution calculated for each position.

[0135] 14. The method according to clause 12, wherein the at least one complete weld path solution for welding the entire groove is generated such that for the same layer, an intermediate weld path solution specifying a higher pass number at a location is selected as the at least one complete weld path solution.

[0136] 15. The method according to any of the preceding clauses, wherein the at least one complete weld path solution specifies a variable number of layers such that the number of layers welded between adjacent positions varies while maintaining a predefined weld height tolerance between all groove images.

[0137] 16. The method of clause 12, comprising the step of calculating the height of at least one weld layer for each of the at least one complete weld path solution.

[0138] 17. The method according to any of the preceding clauses, wherein each of the intermediate weld path solutions and / or the weld path solution specifies the number of weld layers, the number of weld passes per weld layer, the wobble curve per weld pass, and the welding speed curve of the welding machine.

[0139] 18. Method according to any of the preceding clauses, wherein the method is used for welding components in the automotive industry and / or the marine industry and / or heavy industry and / or wind turbines.

[0140] 19. A system for planning a welding path for welding a groove of a welding task, the system comprising a non-transitory computer-readable storage device for storing instructions, which, when executed by a processor, executes a welding path planning method for welding a groove of a welding task by a welding machine according to any one of the preceding clauses 1 to 18.

[0141] 20. A groove welding system for welding a groove, the groove welding system comprising

[0142] - a welding machine having a welding gun configured to perform a groove welding operation;

[0143] - a robotic controller configured to control the groove welding operation performed by the welding machine;

[0144] - a sensor for acquiring at least one scan of the groove;

[0145] - a processing unit configured to perform the method according to any of the preceding clauses 1 to 18,

[0146] The system is configured to perform the groove welding operation based on at least one generated complete weld path solution for welding the entire groove.

[0147] 21. The system of clause 20, configured such that the welding speed, such as the oscillation curve of the welding machine, is adaptively adjusted during welding.

[0148] 22. The system of any of clauses 20 to 21, configured such that the amount of welding wire used for welding is adaptively adjusted during welding.

[0149] 23. A groove welding method, comprising the following steps:

[0150] - planning a welding path according to any one of clauses 1 to 18,

[0151] - performing a groove welding operation based on the generated at least one complete weld path solution for welding the entire groove by the groove welding system according to any of clauses 20 to 22, and

[0152] - Adaptively adjust a set of welding parameters during welding.

[0153] 24. The method according to clause 23, wherein the set of welding parameters is one or more of: an oscillation curve of the welding machine, such as oscillation frequency and amplitude; and welding wire amount.

[0154] 25. The method according to any one of clauses 23 to 24, further comprising the step of tracking the welded groove in real time.

[0155] 26. The method according to any of clauses 23 to 25, further comprising the step of defining a thermal factor for the welding task, wherein the set of welding parameters is adjusted based on the thermal factor.

Claims

1. A welding path planning method for welding a groove of a welding task using a welding machine, the welding path planning method comprising the following steps: - acquiring and / or receiving dimensional characteristics of the groove at a plurality of locations along the groove, - calculating, for each of the positions along the groove, a plurality of intermediate welding path solutions based on the dimensional characteristics, each intermediate welding path solution defining welding parameters used by the welding machine to weld the groove at the position, the welding parameters including: a number of welding layers, a number of weld passes per welding layer, a wobble curve for each weld pass, and a welding speed curve, thereby obtaining a plurality of intermediate welding path solutions at each of the positions; and - generating at least one complete welding path solution for welding the entire groove based on the multiple intermediate welding path solutions, wherein the at least one complete welding path solution defines welding parameters of the welding machine for welding the entire groove, the welding parameters including: the number of welding layers, the number of welding passes for each welding layer, the wobbling curve of each welding pass, and the welding speed curve of the welding machine for welding the entire groove.

2. The method according to claim 1, comprising the step of acquiring and / or receiving a scan of the groove for determining dimensional characteristics, and wherein: The scanned image of the groove is obtained by an optical sensor and / or a scanner.

3. A method according to any one of the preceding claims, wherein The plurality of positions are located along the extension of the groove at predetermined distances along the extension of the groove, and / or wherein the distance between each of the plurality of positions is between 1 mm and 5000 mm, between 10 mm and 200 mm, preferably between 50 mm and 100 mm.

4. A method according to any one of the preceding claims, wherein A plurality of intermediate welding path solutions are calculated for each of the positions of the groove, and wherein welding parameters associated with a position are grouped by operating range to define operating ranges for the wobble curve and the welding speed curve.

5. A method according to any one of the preceding claims, wherein The welding parameters of the intermediate welding path solution and / or the welding parameters of at least one complete solution include an angle of a welding gun of the welding machine, preferably an angle relative to the horizontal.

6. A method according to any one of the preceding claims, wherein The dimensional properties of each groove are selected from the group consisting of: - the height of the groove, - the cross-sectional area of ​​the groove, - the distance between the top two vertices of the groove section, - the distance between the two vertices at the bottom of the groove section, - the bevel angle between each side edge of the bevel relative to the base of the bevel, and -The angle of the bottom of the groove relative to the horizontal plane.

7. A method according to any one of the preceding claims, further comprising the step of defining a set of welding constraints, wherein The set of welding constraints is selected from the group consisting of: type of welding wire, type of welding gas, welding position, welding angle, type of welding gun, type of welding process, material properties of the welding task, type of the groove, welding speed, and wherein the at least one intermediate welding path solution and / or the at least one complete welding path solution are generated based on the set of welding constraints.

8. A method according to any one of the preceding claims, wherein The set of welding constraints includes a thermal factor, and wherein the at least one intermediate weld path solution and / or the at least one complete weld path solution are generated based on the set of welding constraints.

9. The method according to any one of the preceding claims, comprising the step of calculating a plurality of said intermediate welding path solutions and / or generating at least one complete welding path solution for each position, wherein The at least one complete weld path solution is a common solution calculated for each location.

10. A method according to any one of the preceding claims, wherein Each of the intermediate weld path solutions specifies the number of weld layers and the number of passes in each of the weld layers.

11. A method according to any one of the preceding claims, wherein The at least one complete weld path solution specifies a variable number of layers such that the number of layers welded between adjacent locations varies while maintaining a predefined weld height tolerance between all groove images.

12. The method of claim 10, comprising the step of calculating the height of at least one weld layer for each of the at least one complete weld path solution.

13. A method according to any one of the preceding claims, wherein The method is used for welding components in the automotive industry and / or the marine industry and / or heavy industry and / or wind turbines.

14. A groove welding system for welding a groove, the groove welding system comprising - a welding machine having a welding gun configured to perform a groove welding operation; - a robotic controller configured to control the groove welding operation performed by the welding machine; - a sensor for acquiring at least one scan of the groove to obtain dimensional characteristics of the groove; - a processing unit configured to perform the method according to any one of the preceding claims 1 to 13, Wherein, the system is configured to perform the groove welding operation based on at least one generated complete weld path solution for welding the entire groove.

15. The system of claim 14, the system being configured such that a welding speed is adaptively adjusted during welding, such as a wobbling curve of the welding machine, and / or an amount of welding wire used for welding is adaptively adjusted during welding.

16. A system according to any one of the preceding claims 14 to 15, wherein: The system is configured to 1) acquire at least one rescan of the groove with the aid of the sensor during the groove welding operation to obtain updated dimensional characteristics of the at least partially welded groove, and 2) perform the method of any one of claims 1 to 13 based on the updated dimensional characteristics of the at least partially welded groove to generate at least one updated complete weld path solution for welding the at least partially welded groove.

17. The system according to claim 16, wherein: The groove is rescanned after each weld layer, after every two weld layers, after every three weld layers, after every four weld layers, every quarter of the welding process, every third of the welding process, or half of the welding process, or any combination thereof.

18. A groove welding method, comprising the following steps: - planning a welding path according to any one of claims 1 to 13, and - starting a groove welding operation based on the generated at least one complete weld path solution for welding the entire groove, for example by means of a groove welding system according to any one of claims 14 to 17.

19. The groove welding method according to claim 18, comprising planning a welding path according to any one of claims 1 to 13 after at least one layer of the groove has been welded, so that an updated welding path is planned on the at least partially welded groove.

20. The groove welding method according to claim 19, wherein: The welding path plan is automatically updated at least once during the welding operation, such as after each weld layer, after every two weld layers, after every three weld layers, after every four weld layers, every quarter of the welding process, every third of the welding process, or half of the welding process, or any combination thereof.

21. A groove welding method according to any one of the preceding claims 18 to 20, comprising performing a groove welding operation based on at least one complete weld path solution generated for welding the entire groove, for example by means of a groove welding system according to any one of claims 14 to 17, and 22. A groove welding method according to any one of the preceding claims 18 to 21, comprising adaptively adjusting a set of welding parameters during welding.

23. The groove welding method according to any one of the preceding claims 18 to 22, wherein: The set of welding parameters is one or more of the following: an oscillation curve of the welding machine, such as oscillation frequency and amplitude; and welding wire amount.

24. The groove welding method according to any one of the preceding claims 18 to 23, wherein: The method includes the step of tracking the welded groove in real time.

25. The groove welding method according to any one of the preceding claims 18 to 24, wherein: The method further comprises the step of defining a thermal factor for the welding task, wherein the set of welding parameters is adjusted based on the thermal factor.

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