3D Weld Path Generation With Point Cloud Simulation
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Solution Overview
Problem
Existing robotic welding systems are limited in generating accurate and efficient weld paths as they typically only scan specific areas and do not account for the entire possible welding area, lacking comprehensive scanning capabilities.
Innovation Solution
A system and method utilizing a robot equipped with three-dimensional sensor devices to scan the welding area, generate a three-dimensional point cloud, and process it in a two-dimensional domain for generating and simulating weld paths, incorporating features like binary image thinning, smoothing with moving average filters, and analysis of environmental or robot constraints, while maintaining weld formation with extra degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional scanning methods are used to generate weld paths, then the system complexity is reduced, but the welding area coverage is incomplete and measurement precision is insufficient
Solution Approach 1:
The patent transitions from traditional two-dimensional scanning to three-dimensional point cloud scanning, enabling comprehensive coverage of the entire welding area including complex geometries. The 3D sensor device captures spatial coordinates (x, y, z) of all welding surfaces, providing complete measurement data that 2D methods cannot achieve.
2Measurement precision
If comprehensive 3D scanning is implemented to cover the entire welding area, then measurement precision is improved, but processing complexity and computational requirements increase
Solution Approach 1:
The patent segments the complex 3D point cloud processing into distinct modular stages: data acquisition, point cloud generation, path planning, and simulation verification. Each module handles specific aspects of the data, reducing overall processing complexity. The system processes different portions of the welding area independently and integrates results systematically.
Solution Approach 2:
The patent introduces intermediate processing structures such as height fields and cross-sectional views that mediate between the raw 3D point cloud data and the final weld path. These intermediaries simplify the computational complexity by transforming complex 3D data into more manageable representations for path planning algorithms.
3Productivity
If weld paths are generated without simulation verification, then productivity is improved, but welding precision and reliability are compromised
Solution Approach 1:
The patent performs simulation verification before actual welding execution. The system simulates the weld path in the virtual 3D environment to check for collisions, verify accessibility, and validate path feasibility. This preliminary action prevents errors during actual welding, ensuring precision without significantly impacting productivity.
4Manufacturing precision
If the robot maintains welding formation with extra degrees of freedom, then welding precision is improved, but device complexity and control difficulty increase
Solution Approach 1:
The patent utilizes the robot's extra degrees of freedom by dynamically adjusting orientation and position parameters to maintain optimal welding formation. The system changes spatial parameters (angles, distances, orientations) in real-time based on the weld path requirements and gravitational effects, enabling precise weld pool control without requiring additional hardware complexity.
Data Source
AI summary
Embodiments of the present disclosure are directed towards a robotic system and method. The system may include a robot and a three dimensional sensor device associated with the robot configured to scan a welding area and generate a scanned welding area. The system may include a processor configured to receive the scanned welding area and to generate a three dimensional point cloud based upon, at least in part the scanned welding area. The processor may be further configured to perform processing on the three dimensional point cloud in a two-dimensional domain. The processor may be further configured to generate one or more three dimensional welding paths and to simulate the one or more three dimensional welding paths.