Welding machining program setting device, welding machining control device, and welding machining system

Abstract

The present invention comprises a display unit capable of displaying a program creation condition setting screen image for setting a program creation condition for a welding machining program that includes operation information pertaining to a welding robot capable of holding a welding torch of a welding machine and welding machining conditions for the welding machine. The program creation condition setting screen image is configured to enable display of the operation information and is configured to enable setting of a welding machining condition. The operation information includes a movement stroke of the welding robot and a welding start position in the movement stroke. The welding start position includes at least a first welding start position and a second welding start position. The program creation condition setting screen image is configured to enable setting of a welding machining condition for each of the first welding start position and the second welding start position.

Description

Welding processing program setting device, welding processing control device, and welding processing system

[0001] The present invention relates to a welding program setting device, a welding control device, and a welding system.

[0002] Conventionally, there has been known a welding device that includes a welding robot, a welding machine including a welding torch and an oscillator that generates laser light that are integrally provided at the tip of the welding robot, and a control device that can control the welding robot based on a welding processing program (see, for example, Patent Document 1).In conventional welding devices, including the welding device described in Patent Document 1, the welding robot operates according to the welding processing program, the oscillator emits laser light based on welding processing conditions set in the welding machine, and the laser light emitted from the oscillator is irradiated from a welding torch held by the welding robot toward welding portions of the multiple workpieces, thereby welding the multiple workpieces.

[0003] Japanese Patent Application Laid-Open No. 2021-142571

[0004] However, in conventional welding devices, the control device controls only the welding robot, not the welding machine, which means that the welding conditions cannot be changed while the welding program is running. Therefore, when the welding conditions differ depending on the welding locations of multiple workpieces, a welding program must be created for each welding condition, and the welding conditions in the welding machine must be changed each time before each welding program is run, which reduces the efficiency of the worker.

[0005] One aspect of the present invention relates to a welding program setting device, a welding control device, and a welding system that are capable of changing welding conditions during execution of a welding program.

[0006] A welding processing program setting device according to one aspect of the present invention includes a display unit capable of displaying a program creation condition setting screen for setting program creation conditions for a welding processing program, the program creation condition setting screen including operation information of a welding robot capable of holding a welding torch of a welding machine and welding processing conditions of the welding machine, the program creation condition setting screen being configured to display the operation information and to be able to set the welding processing conditions, the operation information including a movement path of the welding robot and a welding start position in the movement path, the welding start position including at least a first welding start position and a second welding start position, and the program creation condition setting screen being configured to be able to set the welding processing conditions for each of the first welding start position and the second welding start position.

[0007] A welding processing control device according to one embodiment of the present invention includes a welding processing control unit capable of controlling at least the welding machine based on the welding processing program created based on at least the program creation conditions set by the welding processing program setting device, and the welding processing control unit is configured to be able to change the settings of the welding processing conditions in the welding machine according to the welding start position while the welding processing program is being executed.

[0008] A welding processing system according to one embodiment of the present invention comprises a program creation unit capable of creating a welding processing program based on at least the program creation conditions set by the welding processing program setting device, a welding machine including a welding torch, a welding robot capable of holding the welding torch, and a welding processing control unit capable of controlling at least the welding machine based on the welding processing program created by the program creation unit, and the welding processing control unit is configured to be able to change the settings of the welding processing conditions in the welding machine in accordance with the welding start position while the welding processing program is being executed.

[0009] According to one aspect of the present invention, a welding processing program setting device, a welding processing control device, and a welding processing system can be used to set the program creation conditions for a welding processing program, and therefore, the welding processing conditions can be set for each of the first welding start position and the second welding start position, making it possible to change the welding processing conditions while the welding processing program is being executed.

[0010] According to a welding program setting device, a welding control device, and a welding system according to an aspect of the present invention, it is possible to change welding conditions while a welding program is being executed.

[0011] FIG. 1 is a block diagram showing the configuration of a welding processing system according to the present embodiment. FIG. 2 is a diagram showing a program creation condition setting screen. FIG. 3 is a diagram showing a welding processing condition list screen. FIG. 4 is a diagram showing a welding processing start screen. FIG. 5 is a diagram showing a linear movement condition setting screen that is displayed when the "Line" icon is selected. FIG. 6 is a diagram showing a spot irradiation condition setting screen that is displayed when the "spot" icon is selected. FIG. 7 is a diagram showing a welding end condition setting screen that is displayed when the "off" icon is selected. FIG. 8 is a flowchart showing an example of a welding processing process.

[0012] Preferred embodiments for carrying out the present invention will be described below with reference to the drawings. Note that the following embodiments do not limit the inventions according to the claims, and not all of the combinations of features described in the embodiments are necessarily essential to the solution of the invention. Furthermore, in the present embodiments, the scale and dimensions of each component may be exaggerated, and some components may be omitted.

[0013] [Overall Configuration of Welding Processing System] FIG. 1 is a block diagram showing the configuration of a welding processing system according to this embodiment.

[0014] 1, the welding system 1 includes a welding machine 10 including a welding torch 11, a welding machine control device 20 capable of controlling the welding machine 10, a welding robot 30 capable of holding the welding torch 11, a robot control device 40 capable of controlling the welding robot 30, and a welding program setting device 50 capable of setting program creation conditions for a welding program. In this embodiment, the welding machine control device 20 and the welding program setting device 50, and the robot control device 40 and the welding program setting device 50 are configured to be able to communicate with each other via a communication network NW.

[0015] 1, welding machine 10 includes welding torch 11 capable of irradiating laser light toward welding portions of multiple workpieces, and oscillator 12 capable of emitting laser light based on welding processing conditions. Welding torch 11 is a handheld torch that can be held by welding robot 30. In this embodiment, welding torch 11 and oscillator 12 are connected to each other via a cable (not shown). Therefore, the laser light emitted from oscillator 12 is supplied to welding torch 11 via the cable. Note that known configurations can be adopted for welding torch 11 and oscillator 12, and detailed description thereof will be omitted.

[0016] 1, welding machine control device 20 includes memory 21 (welding machine memory) that stores predetermined welding conditions, and welding machine control unit 22 that can control welding machine 10 based on commands obtained from welding program setting device 50. The predetermined welding conditions stored in memory 21 are standard welding conditions for welding. The processes that welding machine control unit 22 can execute (the configuration of welding machine control unit 22) will be described later.

[0017] The welding machine control device 20 according to this embodiment may be arranged independently of the welding machine 10, or may be stored inside the housing (not shown) of the welding machine 10 together with the oscillator 12.

[0018] 1, the welding robot 30 includes a robot hand 31 capable of holding the welding torch 11 and an articulated robot arm 32 capable of moving the robot hand 31 to a predetermined position. The robot hand 31 is configured to detachably hold the welding torch 11, which is configured as a separate body. Note that the robot hand 31 and the robot arm 32 may have known configurations, and therefore detailed description thereof will be omitted.

[0019] [Configuration of robot control device] As shown in FIG. 1, robot control device 40 includes a memory unit 41 (robot memory unit) that stores operation information of welding robot 30, a program creation unit 42 that can create a welding processing program based on program creation conditions set by welding processing program setting device 50, and a robot control unit 43 that can control welding robot 30 based on the welding processing program created by program creation unit 42.

[0020] The memory unit 41 is configured to store operation information that has been taught to the welding robot 30 by teaching (e.g., direct teaching). Specifically, the memory unit 41 is configured to store, as operation information, the movement process of the welding robot 30, the movement mode of the welding robot 30, the welding start position and the welding end position in the movement process, and the welding mode for the welding portions of a plurality of workpieces.

[0021] The "movement process" is information indicating the movement process of the robot hand 31 of the welding robot 30 from the movement start position to the movement end position. In the present embodiment, the storage unit 41 is configured to store, as the movement process, the movement start position of the robot hand 31, one or more movement reference positions of the robot hand 31, and the movement end position (final movement reference position) of the robot hand 31. The "movement reference position" is information indicating a position that serves as an index for the movement of the robot hand 31. For example, if the storage unit 41 stores a first movement reference position and a second movement reference position as the movement reference positions, the robot hand 31 first moves from the movement start position toward the first movement reference position, then moves from the first movement reference position toward the second movement reference position, and ends its movement at the second movement reference position (movement end position).

[0022] The number of movement reference positions can be changed as appropriate depending on the shape of the workpiece to be welded, etc. In this embodiment, as an example, a case will be described in which the storage unit 41 stores the first to sixth movement reference positions.

[0023] The "movement mode" is information indicating how the robot hand 31 of the welding robot 30 moves. In this embodiment, the storage unit 41 is configured to store a linear movement mode and a curved movement mode as the movement mode.

[0024] The movement mode is changed as appropriate depending on the shape of the workpiece to be welded, etc. In this embodiment, as an example, a case will be described in which the movement mode from the second movement reference position via the third movement reference position to the fourth movement reference position is a curved movement mode, and the other movement modes are linear movement modes.

[0025] The "welding start position" is a position among the movement reference positions at which welding is started by the welding machine 10. In this embodiment, the memory unit 41 is configured to be able to store at least a first welding start position and a second welding start position as the welding start positions.

[0026] The number of welding start positions may be changed as appropriate depending on the shape of the workpiece to be welded, etc. Therefore, the memory unit 41 may store only the first welding start position as the welding start position, or may store other welding start positions (e.g., a third welding start position) in addition to the first welding start position and the second welding start position. In this embodiment, as an example, a case in which the memory unit 41 stores the first welding start position and the second welding start position will be described. Specifically, a case in which the first welding start position is the second movement reference position and the second welding start position is the fourth movement reference position will be described.

[0027] The "welding end position" is the position among the movement reference positions at which welding by the welding machine 10 ends. This welding end position is stored in the memory unit 41 only when the welding mode is the continuous irradiation mode described below, and is not stored in the memory unit 41 when the welding mode is the spot irradiation mode (spot welding) described below. In this embodiment, as an example, a case where the welding end position is the fifth movement reference position will be described.

[0028] "Welding mode" is information indicating how to weld the welding portions of multiple workpieces. In this embodiment, the memory unit 41 is configured to store, as welding modes, a mode of continuous irradiation from the welding start position to the welding end position and a mode of spot irradiation at the welding start position. In this embodiment, as an example, a case will be described in which the welding mode at the first welding start position is the mode of spot irradiation and the welding mode at the second welding start position is the mode of continuous irradiation.

[0029] The operation information of the welding robot 30 stored in the storage unit 41 is transmitted to the welding program setting device 50 and displayed on a program creation condition setting screen 51 a (to be described later) of the welding program setting device 50 .

[0030] Furthermore, memory unit 41 is configured to store a welding program created by program creation unit 42 and a welding condition list L2 (described later) acquired from welding program setting device 50. Specifically, memory unit 41 is configured to store a welding program in association with welding condition list L2 created when setting program creation conditions for the welding program in welding program setting device 50. Storing a welding program in association with welding condition list L2 in memory unit 41 has the advantage of allowing welding to be performed again based on a past welding program and welding conditions.

[0031] Program creation unit 42 is configured to create a welding program based on the program creation conditions acquired from welding program setting device 50. Specifically, program creation unit 42 is configured to create a welding program based on the operation information of welding robot 30 and the welding conditions of welder 10 included in the program creation conditions.

[0032] The robot control unit 43 is configured to control the welding robot 30 based on the welding processing program stored in the storage unit 41. The processes that can be executed by the robot control unit 43 (the configuration of the robot control unit 43) will be described later.

[0033] The robot control device 40 according to this embodiment may be disposed independently of the welding robot 30, or may be formed integrally with or as an integral part of the welding robot 30.

[0034] [Configuration of Welding Program Setting Device] Welding program setting device 50 is, for example, a personal computer or a tablet terminal. In this embodiment, welding program setting device 50 is a tablet terminal that can be held and carried by an operator. Specifically, as shown in Fig. 1 , welding program setting device 50 includes display unit 51 that can display program creation condition setting screen 51a for setting program creation conditions for a welding program, including operation information of welding robot 30 that can hold welding torch 11 of welding machine 10 and welding conditions for welding machine 10, and memory unit 52 (welding memory unit) that stores a plurality of welding conditions.

[0035] 1, welding program setting device 50 includes welding control unit 53 that can control at least welding machine 10 based on the welding program. That is, welding program setting device 50 according to this embodiment also functions as a welding control device that can control at least welding machine 10 based on the welding program.

[0036] In the present embodiment, the welding program setting device 50 is described as functioning as the welding control device, but this is not limiting, and the welding program setting device 50 and the welding control device may be configured as independent devices. That is, the welding system 1 may include a welding program setting device 50 that can set program creation conditions for the welding program, and a welding control device that includes a welding control unit 53 that can control at least the welder 10 based on the welding program created based on the program creation conditions set by the welding program setting device 50.

[0037] The display unit 51 is a display capable of displaying various types of information. In this embodiment, the display unit 51 is a touch panel capable of displaying various types of information and accepting input operations by the worker. In other words, the display unit 51 also functions as an operation unit that accepts input operations by the worker. Note that in this embodiment, the display unit 51 and the operation unit are described as being configured as an integrated unit, but this is not limiting. For example, the operation unit may be configured as a keyboard, a mouse, or the like, and may be configured independently of the display unit 51.

[0038] Fig. 2 is a diagram showing a program creation condition setting screen, Fig. 3 is a diagram showing a welding processing condition list screen, and Fig. 4 is a diagram showing a welding processing start screen.

[0039] As shown in Figures 2 to 4, the display unit 51 is configured to be able to display a program creation condition setting screen 51a for setting welding program creation conditions, a welding processing condition list screen 51b for creating and editing a welding processing condition list L2, and a welding processing start screen 51c for starting welding processing.

[0040] At the bottom of the program creation condition setting screen 51a, the welding condition list screen 51b, and the welding start screen 51c, there are displayed a "program creation condition setting" icon corresponding to the program creation condition setting screen 51a, a "welding condition list" icon corresponding to the welding condition list screen 51b, and a "welding start" icon corresponding to the welding start screen 51c. The display unit 51 is configured to display a screen corresponding to an icon selected by the operator from among the "program creation condition setting" icon, the "welding condition list" icon, and the "welding start" icon. For example, when the operator selects the "program creation condition setting" icon, the display unit 51 is configured to display the program creation condition setting screen 51a.

[0041] In this specification, an "icon" is a graphic or pictogram that indicates predetermined information.

[0042] 2, the program creation condition setting screen 51a is configured to be able to display operation information of the welding robot 30 acquired from the robot control device 40. In the present embodiment, the program creation condition setting screen 51a is configured to be able to display a welding processing process list L1 that shows the operation information of the welding robot 30 acquired from the robot control device 40 as welding processing processes. This configuration has the advantage that the operator can easily visually recognize the operation information of the welding robot 30.

[0043] 2, the welding process list L1 includes an item "P." Here, "P" in the welding process list L1 indicates a movement reference position of the welding robot 30 included in the operation information of the welding robot 30 acquired from the robot control device 40. In this embodiment, the operation information of the welding robot 30 acquired from the robot control device 40 includes the first movement reference position to the sixth movement reference position as the movement reference positions of the welding robot 30, and therefore items "P1" to "P6" are displayed on the program creation condition setting screen 51a. In this way, the number of "P" items displayed on the program creation condition setting screen 51a corresponds to the number of movement reference positions of the welding robot 30 included in the operation information of the welding robot 30 acquired from the robot control device 40.

[0044] Each "P" item in the welding process list L1 is configured to display the movement mode of the welding robot 30 included in the operation information of the welding robot 30 acquired from the robot control device 40. Specifically, the program creation condition setting screen 51a is configured to display, among the movement modes of the welding robot 30 included in the operation information of the welding robot 30 acquired from the robot control device 40, a linear movement mode as a "Line" icon and a curved movement mode as a "Circle" icon.

[0045] In this embodiment, the operation information of the welding robot 30 obtained from the robot control device 40 includes information that the movement pattern from the second movement reference position via the third movement reference position to the fourth movement reference position is a curved movement pattern, and the other movement patterns are linear movement patterns, so the "Line" icon is displayed in the "P1", "P2", "P5", and "P6" items, the "Circle 1" icon is displayed in the "P3" item, and the "Circle 2" icon is displayed in the "P4" item.

[0046] Each "P" item in the welding process list L1 is configured to display the welding start position, welding end position, and welding mode included in the operation information of the welding robot 30 acquired from the robot controller 40. Specifically, the program creation condition setting screen 51a is configured to display the welding start position included in the operation information of the welding robot 30 acquired from the robot controller 40 as an "on" icon or a "spot" icon, and to display the welding end position as an "off" icon. Furthermore, the program creation condition setting screen 51a is configured to display, among the welding modes included in the operation information of the welding robot 30 acquired from the robot controller 40, the continuous irradiation mode as an "on" icon, and the spot irradiation mode as a "spot" icon.

[0047] In this embodiment, the operation information of welding robot 30 acquired from robot controller 40 includes information that the first welding start position is the second movement reference position and that the welding mode at the first welding start position is a spot irradiation mode, so a "spot" icon is displayed in the "P2" field. Also, in this embodiment, the operation information of welding robot 30 acquired from robot controller 40 includes information that the second welding start position is the fourth movement reference position, the welding end position is the fifth movement reference position, and that the welding mode at the second welding start position is a continuous irradiation mode, so an "on" icon is displayed in the "P4" field and an "off" icon is displayed in the "P5" field.

[0048] The program creation condition setting screen 51a is configured to allow detailed conditions related to welding to be set for each of the operation information ("movement mode," "welding start position," "welding end position," and "welding mode") of the welding robot 30 set in each "P" item in the welding process list L1. Specifically, the program creation condition setting screen 51a is configured to allow detailed conditions related to welding to be set for each of the icons ("Line," "Circle 1," "Circle 2," "spot," "on," or "off") displayed in the welding process list L1.

[0049] Fig. 5 shows a linear movement condition setting screen that is displayed when the "Line" icon is selected. Fig. 6 shows a spot irradiation condition setting screen that is displayed when the "spot" icon is selected. Fig. 7 shows a welding end condition setting screen that is displayed when the "off" icon is selected.

[0050] 5 to 7, the program creation condition setting screen 51a is configured to be able to display a detailed condition setting screen 60 on which detailed conditions related to welding can be set when the worker operates an icon displayed in the welding process list L1. Furthermore, the program creation condition setting screen 51a is configured to be able to display a different detailed condition setting screen 60 depending on the icon selected by the worker.

[0051] Here, when the operator selects the "Line" icon, the program creation condition setting screen 51a displays a linear movement condition setting screen 60a (see FIG. 5), and when the operator selects the "Circle 1" or "Circle 2" icon, the program creation condition setting screen 51a displays a curved movement condition setting screen (not shown). When the operator selects the "spot" icon, the program creation condition setting screen 51a displays a spot irradiation condition setting screen 60b (see FIG. 6), and when the operator selects the "on" icon, the program creation condition setting screen 51a displays a continuous irradiation condition setting screen (not shown). When the operator selects the "off" icon, the program creation condition setting screen 51a displays a welding termination condition setting screen 60c (see FIG. 7).

[0052] In this embodiment, as an example, conditions that can be set on the linear movement condition setting screen 60a, the spot irradiation condition setting screen 60b, and the welding end condition setting screen 60c will be described.

[0053] As shown in Fig. 5, the linear movement condition setting screen 60a is configured to allow the setting of the movement speed and pressing force conditions during processing of the welding robot 30. As shown in Fig. 6, the spot irradiation condition setting screen 60b is configured to allow the setting of the touch stop speed, trigger 2 OFF condition, preflow time, and filler cutting movement amount conditions, as well as welding processing conditions for performing welding processing by the welder 10. As shown in Fig. 7, the welding end condition setting screen 60c is configured to allow the setting of the trigger 2 OFF condition, postflow time, and filler cutting movement amount conditions.

[0054] In this way, the program creation condition setting screen 51a according to this embodiment has the advantage of being highly convenient, since it is possible to set detailed conditions related to welding processing for each operation information of the welding robot 30 set in each "P" item of the welding processing process list L1.

[0055] In addition, the operator can set any of the condition items displayed on the linear movement condition setting screen 60a, the curved movement condition setting screen, the spot irradiation condition setting screen 60b, the continuous irradiation condition setting screen, and the welding end condition setting screen 60c.

[0056] Furthermore, the welding conditions can be set only on the spot irradiation condition setting screen 60b or the continuous irradiation condition setting screen 60c. In other words, the operator can set the welding conditions only when he or she selects the "spot" icon or the "on" icon.

[0057] As described above, the program creation condition setting screen 51a according to the present embodiment is configured to be able to display operation information of the welding robot 30, and is also configured to be able to set welding conditions for the welder 10 via the spot irradiation condition setting screen 60b or the continuous irradiation condition setting screen. Specifically, the program creation condition setting screen 51a is configured to be able to set welding conditions for each welding start position (in the present embodiment, the first welding start position and the second welding start position). Therefore, the operator can set different welding conditions for each welding start position.

[0058] The spot irradiation condition setting screen 60b and the continuous irradiation condition setting screen are each configured to allow a predetermined welding condition to be selected from a plurality of welding conditions stored in the storage unit 52. In this embodiment, the spot irradiation condition setting screen 60b and the continuous irradiation condition setting screen are each configured to allow a predetermined welding condition to be selected from a welding condition list L2 (described later) stored in the storage unit 52. Specifically, the spot irradiation condition setting screen 60b and the continuous irradiation condition setting screen are each configured to display a pull-down menu from which a welding condition number in the welding condition list L2 stored in the storage unit 52 can be selected, and a desired welding condition can be selected from the pull-down menu. For example, when the welding condition number "1" is selected from the pull-down menu, the welding condition of the welding condition number "1" in the welding condition list L2 stored in the storage unit 52 is set.

[0059] In this way, program creation condition setting screen 51a according to this embodiment is configured so that predetermined welding conditions can be selected from a plurality of welding conditions stored in memory unit 52 via spot irradiation condition setting screen 60b or continuous irradiation condition setting screen. Specifically, program creation condition setting screen 51a is configured so that predetermined welding conditions can be selected from welding condition list L2 stored in memory unit 52 via spot irradiation condition setting screen 60b or continuous irradiation condition setting screen.

[0060] The programming conditions set on programming condition setting screen 51a are transmitted to robot controller 40 together with welding condition list L2 created when the programming conditions were set. Then, as described above, program creation unit 42 of robot controller 40 creates a welding program based on the programming conditions acquired from welding program setting device 50, and memory unit 41 of robot controller 40 stores the welding program in association with welding condition list L2.

[0061] As shown in Fig. 3, the welding condition list screen 51b is configured to display a welding condition list L2. The welding condition list L2 includes the following items: processing condition number, laser power, wobbling frequency, wobbling width, slope up, and slope down. In this embodiment, the information set for each of the items laser power, wobbling frequency, wobbling width, slope up, and slope down constitutes the welding conditions. However, the items in the welding condition list L2 are not limited to these, and the operator can set any items.

[0062] Welding condition list screen 51b is configured to allow each item in welding condition list L2 to be set by performing at least one of the following operations (1) to (4): (1) The operator inputs information into each item in welding condition list L2; (2) The operator operates an "Acquire" button displayed on welding condition list screen 51b to acquire welding conditions stored in memory 21 from welding machine control device 20 and set information into each item in welding condition list L2; (3) The operator selects a specific material and thickness from the pull-down menus for workpiece material and workpiece thickness displayed on welding condition list screen 51b, respectively, and sets information appropriate for the selected material and thickness in each item in welding condition list L2; (4) The operator operates a button corresponding to one of the welding condition numbers (1 to 9 in FIG. 3 ) displayed on welding condition list screen 51b to acquire a list of welding condition names stored in memory 21 from welding machine control device 20. Then, the operator selects the desired condition name from the condition name list, and information is set for each item of the welding processing conditions (i.e., the laser power item, etc.) for the processing condition number operated by the operator.

[0063] The welding condition list screen 51b is configured to allow creation of a welding condition list L2 for each welding program, so that a different welding condition list L2 can be created for each welding program.

[0064] 4, welding start screen 51c is configured to be able to display at least a welding process list L1 set on program creation condition setting screen 51a and a "START" button for starting welding. When the "START" button displayed on welding start screen 51c is operated, welding program setting device 50 transmits a welding start notification to robot control device 40, and robot control unit 43 of robot control device 40 executes processing based on the welding program.

[0065] The memory unit 52 is configured to store a plurality of welding conditions. In this embodiment, the memory unit 52 is configured to store the welding condition list L2 created and edited on the welding condition list screen 51 b. The memory unit 52 may store the welding condition list L2 only until the welding condition list L2 is transmitted to the robot control device 40, or may continue to store the welding condition list L2 after the welding condition list L2 is transmitted to the robot control device 40.

[0066] Welding control unit 53 is configured to control welding machine 10 based on a welding program created by program creation unit 42 of robot control device 40. Specifically, welding control unit 53 is configured to be able to change the settings of welding conditions in welding machine 10 in accordance with the welding start position while the welding program is being executed.

[0067] In addition, the welding processing control unit 53 can perform similar control even if the welding processing program includes other welding start positions (e.g., a third welding start position, etc.) in addition to the first welding start position and the second welding start position.

[0068] [Processes Executable by the Welding Machine Control Unit, Robot Control Unit, and Welding Process Control Unit] Welding machine control unit 22, robot control unit 43, and welding process control unit 53 are configured to execute the following processes (1) to (8). (1) Welding process control unit 53 commands welding machine control unit 22 to change the settings of welding conditions in welding machine 10 to welding conditions corresponding to the first welding start position. (2) Welding machine control unit 22 changes the settings of welding conditions in welding machine 10 to welding conditions corresponding to the first welding start position based on the command received from welding process control unit 53. (3) Robot control unit 43 operates welding robot 30 from the first welding start position and temporarily suspends the operation of welding robot 30 at the second welding start position. (4) Robot control unit 43 sends an operation temporary suspension notice to welding process control unit 53 indicating that the operation of welding robot 30 has been temporarily suspended. (5) After receiving the operation temporary suspension notice from robot control unit 43, welding control unit 53 commands welding machine control unit 22 to change the settings of welding conditions in welding machine 10 to welding conditions corresponding to the second welding start position. (6) Welding machine control unit 22 changes the settings of welding conditions in welding machine 10 to welding conditions corresponding to the second welding start position based on the command acquired from welding control unit 53. (7) Welding control unit 53 sends a condition change notice to robot control unit 43 indicating that the settings of welding conditions in welding machine 10 have been changed. (8) After receiving the condition change notice from welding control unit 53, robot control unit 43 resumes the operation of welding robot 30.

[0069] This allows multiple workpieces to be welded while changing the welding conditions during execution of the welding program.

[0070] [Welding Method] Fig. 8 is a flowchart showing an example of a welding process. Next, a welding method using the welding system 1 according to this embodiment will be described with reference to Fig. 8. Note that the following describes a case where welding is performed based on the welding process list L1 shown in Fig. 4, and also describes a case where the welding conditions are different between the first welding start position and the second welding start position.

[0071] When the operator operates the "START" button displayed on the welding start screen 51c, the welding program setting device 50 transmits a welding start notification to the robot control device 40 (S1).

[0072] When robot control device 40 receives the welding start notification from welding program setting device 50, robot control unit 43 operates welding robot 30 from the movement start position based on the welding program stored in storage unit 41, and temporarily stops the operation of welding robot 30 at the first welding start position (S2). Specifically, robot control unit 43 causes welding robot 30 to perform the following operations (1) to (3): (1) An operation of linearly moving welding robot 30 from the movement start position toward the first movement reference position; (2) An operation of linearly moving welding robot 30 from the first movement reference position toward the second movement reference position; and (3) An operation of temporarily stopping welding robot 30 at the first movement reference position (first welding start position).

[0073] After temporarily suspending the operation of the welding robot 30, the robot control unit 43 transmits an operation temporary suspension notice to the welding process control unit 53 indicating that the operation of the welding robot 30 has been temporarily suspended (S3).

[0074] The welding processing control unit 53, which receives a notification of temporary operation suspension from the robot control unit 43, instructs the welding machine control unit 22 to change the setting of the welding processing conditions in the oscillator 12 to welding processing conditions corresponding to the first welding start position (S4).

[0075] The welding machine control unit 22, which receives an instruction from the welding processing control unit 53, changes the setting of the welding processing conditions in the oscillator 12 to welding processing conditions corresponding to the first welding start position based on the instruction received from the welding processing control unit 53 (S5), and sends a change completion notification to the welding processing control unit 53 indicating that the change of the welding processing conditions has been completed (S6).

[0076] Upon receiving the change completion notification from welding machine control unit 22, welding control unit 53 transmits a condition change notification to robot control unit 43 indicating that the settings of welding conditions in welding machine 10 have been changed (S7). Upon receiving the condition change notification from welding control unit 53, robot control unit 43 resumes the operation of welding robot 30 based on the welding program and temporarily suspends the operation of welding robot 30 at the second welding start position (S8). Specifically, robot control unit 43 causes welding robot 30 to perform the following operations (1) to (3): (1) an operation of causing spot irradiation at the second movement reference position (first welding start position); (2) an operation of causing curvilinear movement from the second movement reference position via the third movement reference position to the fourth movement reference position; and (3) an operation of temporarily suspending the operation at the fourth movement reference position (second welding start position).

[0077] After temporarily suspending the operation of the welding robot 30, the robot control unit 43 transmits an operation temporary suspension notice to the welding process control unit 53 indicating that the operation of the welding robot 30 has been temporarily suspended (S9).

[0078] The welding processing control unit 53, which receives a notification of temporary operation suspension from the robot control unit 43, instructs the welding machine control unit 22 to change the setting of the welding processing conditions in the oscillator 12 to welding processing conditions corresponding to the second welding start position (S10).

[0079] The welding machine control unit 22, which receives an instruction from the welding processing control unit 53, changes the setting of the welding processing conditions in the oscillator 12 to welding processing conditions corresponding to the second welding start position based on the instruction received from the welding processing control unit 53 (S11), and sends a change completion notification to the welding processing control unit 53 indicating that the change of the welding processing conditions has been completed (S12).

[0080] Upon receiving the change completion notification from welding machine control unit 22, welding control unit 53 transmits a condition change notification to robot control unit 43 indicating that the settings of welding conditions in welding machine 10 have been changed (S13). Upon receiving the condition change notification from welding control unit 53, robot control unit 43 resumes the operation of welding robot 30 based on the welding program (S14). Specifically, robot control unit 43 causes welding robot 30 to perform the following operations (1) and (2): (1) an operation of moving welding robot 30 linearly from the fourth movement reference position to the fifth movement reference position and performing continuous irradiation from the fourth movement reference position (second welding start position) to the fifth movement reference position (welding end position); and (2) an operation of moving welding robot 30 linearly from the fifth movement reference position to the sixth movement reference position (movement end position) and ending welding.

[0081] By the above steps, it is possible to weld a plurality of workpieces while changing the welding conditions during execution of the welding program. After that, when the welding is completed, the robot control unit 43 transmits a welding completion notice to the welding control unit 53 indicating that the welding is completed (S15).

[0082] In the welding processing system 1 according to this embodiment, the display unit 51 is configured to be able to display a welding processing program list (not shown) showing all welding processing programs stored in the memory unit 41 of the robot control device 40, and when the operator selects a desired welding processing program from the welding processing program list, past welding processing programs are displayed on the program creation condition setting screen 51a, making it possible to edit or re-execute the past welding processing program.

[0083] [Advantages of the welding processing program setting device according to this embodiment] As described above, the welding processing program setting device 50 according to this embodiment includes a display unit 51 capable of displaying a program creation condition setting screen 51a for setting program creation conditions for a welding processing program, including operation information of the welding robot 30 capable of holding the welding torch 11 of the welding machine 10 and the welding processing conditions of the welding machine 10. The program creation condition setting screen 51a is configured to be able to display the operation information and to be able to set the welding processing conditions, the operation information including a movement path of the welding robot 30 and a welding start position in the movement path, the welding start position including at least a first welding start position and a second welding start position, and the program creation condition setting screen 51a is configured to be able to set the welding processing conditions for each of the first welding start position and the second welding start position.

[0084] The welding program setting device 50 having such a configuration can set the welding conditions for each of the first and second welding start positions when setting the program creation conditions for the welding program, thereby offering the advantage of being able to change the welding conditions while the welding program is being executed. Unlike conventional welding devices, there is no need to change the welding conditions set in the welder 10 before executing each welding program, which improves the worker's work efficiency. Furthermore, unlike the welding device described in Patent Document 1, the welding torch 11 and the welding robot 30 are configured separately, which allows switching between robot welding using the welding robot 30 and handheld welding without the welding robot 30 depending on the workpiece, welding style, etc., resulting in high versatility.

[0085] Furthermore, welding program setting device 50 according to this embodiment further includes memory 52 for storing a plurality of welding conditions, and program creation condition setting screen 51a is configured to allow a predetermined welding condition to be selected from the plurality of welding conditions stored in memory 52. ​​Welding program setting device 50 having such a configuration has the advantage of making it easy to set welding conditions.

[0086] Furthermore, in the welding processing program setting device 50 according to this embodiment, the display unit 51 is configured to be able to display a welding processing condition list screen 51b on which a welding processing condition list L2 can be created, and the welding processing condition list screen 51b is configured to be able to create a welding processing condition list L2 for each welding processing program, the memory unit 52 is configured to be able to store the welding processing condition list L2 created by the welding processing condition list screen 51b, and the program creation condition setting screen 51a is configured to be able to select a predetermined welding processing condition from the welding processing condition list L2 stored in the memory unit 52.

[0087] In conventional welding devices, after a welding program is executed, the welding program and the corresponding welding conditions are linked and stored, allowing welding to be performed again based on a previous welding program and welding conditions. However, in conventional welding devices, a single welding condition list is created in the welding machine or control device, and when a welding program is executed, predetermined welding conditions are selected from the welding condition list to set the welding conditions for the welding program. Therefore, for example, if the contents of the welding condition list stored in the welding machine or control device are changed, the contents of the welding conditions stored in association with previously executed welding programs may also be changed, which may be detrimental to performing welding again based on the previous welding program and welding conditions. In this regard, in the welding program setting device 50 according to this embodiment, the welding condition list screen 51b creates a welding condition list L2 for each welding program. Therefore, changing the contents of one welding condition list L2 does not change the contents of other welding condition lists L2, allowing welding to be performed again based on the previous welding program and welding conditions.

[0088] Furthermore, the welding program setting device 50 according to this embodiment includes a welding control unit 53 capable of controlling at least the welder 10 based on the welding program, and the welding control unit 53 is configured to be able to change the settings of the welding conditions in the welder 10 in accordance with the welding start position while the welding program is being executed. The welding program setting device 50 having such a configuration has the advantage of being able to change the welding conditions while the welding program is being executed. Another advantage is that, unlike conventional welding devices, there is no need to change the settings of the welding conditions in the welder 10 each time before executing each welding program, which improves the efficiency of the worker.

[0089] [Modifications] The welding program setting device, welding control device, and welding system according to the present invention are not limited to the above-described embodiments, and various modifications can be made within the scope of the technical concept of the present invention.

[0090] For example, in the above-described embodiment, the spot irradiation condition setting screen 60b and the continuous irradiation condition setting screen are each configured to allow a predetermined welding condition to be selected from a plurality of welding conditions stored in the storage unit 52. However, this is not limited to this. For example, the spot irradiation condition setting screen 60b and the continuous irradiation condition setting screen may each execute a setting process similar to that of each item in the welding condition list L2 of the welding condition list screen 51b. Furthermore, the program creation condition setting screen 51a may execute a setting process similar to that of each item in the spot irradiation condition setting screen 60b and the continuous irradiation condition setting screen or in the welding condition list L2 of the welding condition list screen 51b.

[0091] In the above-described embodiment, the program creation condition setting screen 51a is described as being configured to allow detailed conditions related to welding to be set for each piece of operation information for the welding robot 30 set in each "P" item in the welding process list L1. However, this is not limited to this. For example, the program creation condition setting screen 51a may be configured to allow detailed conditions related to welding to be set for each "P" item in the welding process list L1. For example, the program creation condition setting screen 51a may be configured to display the detailed condition setting screen 60 when the worker operates a "P" item in the welding process list L1. Furthermore, the detailed condition setting screen 60 may be configured to allow detailed conditions to be set in accordance with the operation information for the welding robot 30 set in the "P" item operated by the worker.

[0092] Furthermore, in the above-described embodiment, the welding control unit 53 has been described as controlling only the welding machine 10, but this is not limiting, and the welding control unit 53 may control the welding machine 10 and the welding robot 30. That is, in the above-described embodiment, the welding machine 10 has been described as being controlled by the welding control unit 53 via the welding machine control unit 22, and the welding robot 30 has been described as being controlled by the robot control unit 43, but the welding robot 30 may also be controlled by the welding control unit 53 via the robot control unit 43.

[0093] In the above embodiment, the robot control device 40 is described as having the program creation unit 42, but this is not limiting, and the welding program setting device 50 may have the program creation unit 42. In other words, the welding program may be created in the welding program setting device 50.

[0094] It is clear from the claims that the above-mentioned modifications are included within the scope of the present invention.

[0095] 1: Welding system 10: Welding machine 11: Welding torch 12: Oscillator 20: Welding machine control device 21: Memory unit 22: Welding machine control unit 30: Welding robot 31: Robot hand 32: Robot arm 40: Robot control device 41: Memory unit 42: Program creation unit 43: Robot control unit 50: Welding processing program setting device 51: Display unit 51a: Program creation condition setting screen 51b: Welding processing condition list screen 51c: Welding processing start screen 52: Memory unit 53: Welding processing control unit 60: Detailed condition setting screen 60a: Linear movement condition setting screen 60b: Spot irradiation condition setting screen 60c: Welding end condition setting screen L1: Welding processing process list L2: Welding processing condition list NW: Communication network

Claims

1. A welding processing program setting device comprising: a display unit capable of displaying a program creation condition setting screen for setting program creation conditions for a welding processing program including operation information of a welding robot capable of holding a welding torch of a welding machine and welding processing conditions of the welding machine; wherein the program creation condition setting screen is configured to be able to display the operation information and to be able to set the welding processing conditions; the operation information includes a movement path of the welding robot and a welding start position in the movement path; the welding start position includes at least a first welding start position and a second welding start position; and wherein the program creation condition setting screen is configured to be able to set the welding processing conditions for each of the first welding start position and the second welding start position.

2. A welding processing program setting device as described in claim 1, further comprising a memory unit that stores a plurality of said welding processing conditions, and said program creation condition setting screen is configured to enable selection of a predetermined welding processing condition from the plurality of said welding processing conditions stored in said memory unit.

3. The welding processing program setting device according to claim 2, wherein the display unit is configured to be able to display a welding processing condition list screen on which a welding processing condition list can be created, the welding processing condition list screen is configured to be able to create the welding processing condition list for each welding processing program, the memory unit is configured to be able to store the welding processing condition list created using the welding processing condition list screen, and the program creation condition setting screen is configured to be able to select a predetermined welding processing condition from the welding processing condition list stored in the memory unit.

4. A welding processing control device comprising a welding processing control section capable of controlling at least the welding machine based on the welding processing program created based on the program creation conditions set by the welding processing program setting device according to any one of claims 1 to 3, wherein the welding processing control section is configured to be able to change the settings of the welding processing conditions in the welding machine in accordance with the welding start position while the welding processing program is being executed.

5. A welding system comprising: a program creation unit capable of creating the welding program based on the program creation conditions set by the welding program setting device of any one of claims 1 to 3; a welding machine including a welding torch; a welding robot capable of holding the welding torch; and a welding control unit capable of controlling at least the welding machine based on the welding program created by the program creation unit, wherein the welding control unit is configured to be able to change the settings of the welding conditions in the welding machine in accordance with the welding start position while the welding program is being executed.

6. The welding machine further comprises a welding machine control unit capable of controlling the welding machine; and a robot control unit capable of controlling the welding robot based on the welding program, wherein the welding control unit commands the welding machine control unit to change the settings of the welding conditions in the welding machine to the welding conditions corresponding to the first welding start position, the welding machine control unit changes the settings of the welding conditions in the welding machine to the welding conditions corresponding to the first welding start position based on the command received from the welding control unit, the robot control unit operates the welding robot from the first welding start position and temporarily suspends the operation of the welding robot at the second welding start position, the robot control unit transmits an operation suspension notice to the welding control unit indicating that the operation of the welding robot has been temporarily suspend, and after receiving the operation suspension notice from the robot control unit, the welding control unit commands the welding machine control unit to change the settings of the welding conditions in the welding machine to the welding conditions corresponding to the second welding start position, 6. The welding processing system according to claim 5, wherein the welding machine control unit changes the setting of the welding processing conditions in the welding machine to the welding processing conditions corresponding to the second welding start position based on an instruction obtained from the welding processing control unit, the welding processing control unit sends a condition change notice to the robot control unit indicating that the setting of the welding processing conditions in the welding machine has been changed, and the robot control unit resumes operation of the welding robot after receiving the condition change notice from the welding processing control unit.

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