3D Offline Teaching for Robot Weld Inspection Scanning
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Solution Overview
Problem
Current offline teaching devices struggle to visualize and efficiently create scanning operation teaching programs for appearance inspection, as they cannot accurately represent the three-dimensional scannable range and sensor posture, leading to potential mismatches between taught and actual scanning ranges, requiring higher operator skill and increasing the risk of incomplete or incorrect inspection.
Innovation Solution
An offline teaching device and method that include an input unit for operator operations, an acquisition unit for welding line and sensor range data, a generation unit for creating a three-dimensional scanning region, and a control unit for generating an auxiliary screen displaying the welding line and scanning regions in a virtual space, allowing operators to move or rotate these regions and create a teaching program for a robot to scan, ensuring accurate scanning operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional offline teaching devices display only two-dimensional position information, then the device complexity is low, but the measurement precision of scanning range and sensor posture is insufficient
Solution Approach 1:
The patent transitions from two-dimensional position display to three-dimensional scanning range visualization. The generation unit creates three-dimensional scanning range data based on sensor position, scanning start/end points, and effective scanning ranges, then displays this data in a three-dimensional coordinate system alongside the workpiece model. This dimensional upgrade enables accurate representation of scanning volumes and sensor postures, resolving the contradiction between measurement precision and device complexity.
2Reliability
If operators manually create scanning operation teaching programs without three-dimensional visualization, then the ease of operation is high, but the reliability of inspection is insufficient
Solution Approach 1:
The patent creates a virtual copy of the scanning environment including the workpiece model, sensor model, and three-dimensional scanning range. Operators can visually confirm the scanning range and sensor posture in this virtual representation before executing actual inspection operations. This copying approach allows operators to easily verify and adjust teaching parameters without risking actual inspection quality, thereby improving reliability while maintaining ease of operation.
3Loss of information
If the system displays detailed three-dimensional scanning range information, then the loss of information is reduced, but the device complexity increases
Solution Approach 1:
The patent segments the scanning range information into distinct three-dimensional elements: workpiece model data, sensor model data, scanning start point, scanning end point, and effective scanning range. Each segment is processed and displayed separately in the three-dimensional coordinate system. This segmentation allows the system to maintain comprehensive information display while managing complexity through modular data handling and presentation.
Data Source
AI summary
An offline teaching device includes a generation unit that generates a three-dimensional region scanned by a sensor based on position information of a welding line and a scanning range, and a control unit that outputs an auxiliary screen in which the welding line and the three-dimensional region are disposed in a virtual space. A three-dimensional region is moved or rotated, a new auxiliary screen in which the welding line and at least one three-dimensional region including the moved or rotated three-dimensional region are disposed in a virtual space is generated and output, and a teaching program for causing a robot that drives a sensor to scan the at least one three-dimensional region is created and output.