3D Welding Sequence Planning for Robot Programming Bottlenecks
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Solution Overview
Problem
The automation level of welding in shipbuilding is low due to the complexity and time-consuming nature of robot programming, which hinders the effective use of robots in performing welding operations on large and complex structures.
Innovation Solution
A method and apparatus for scheduling welding operations that involve identifying seams on a three-dimensional model of the welding object, determining a welding sequence based on geometry and process requirements, generating an operation procedure for a welding robot, and adjusting robot path parameters to ensure feasibility, thereby reducing programming time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If robot programming is performed manually for welding operations, then welding precision and automation can be achieved, but programming time and complexity increase significantly
Solution Approach 1:
The patent uses 3D digital models (copies) of the welding object to automatically generate robot programming instructions, replacing manual programming. The system extracts geometric information from the digital model to automatically determine welding seams, sequences, and robot paths, eliminating the need for time-consuming manual programming while maintaining welding precision.
Solution Approach 2:
The system enables self-service by allowing the 3D model and welding parameters to automatically generate the robot operation procedures without human intervention. The automated programming system processes the digital model, identifies welding features, and generates executable code autonomously, significantly reducing programming time and complexity.
2Manufacturing precision
If manual programming is used for complex welding structures, then welding quality can be maintained, but the complexity and cost of programming increase
Solution Approach 1:
The patent replaces the mechanical/manual programming process with an automated computer-based system. Instead of manually writing programming code, the system uses algorithms to automatically extract geometric information from 3D models and generate robot paths, reducing programming complexity while maintaining welding quality through precise digital modeling and automated calculation.
Solution Approach 2:
The system creates a digital copy (3D model) of the welding object that contains all geometric information needed for programming. This digital replica allows the system to automatically analyze and generate programming instructions without manual intervention, reducing complexity while ensuring accurate reproduction of welding requirements.
3Productivity
If automated welding is implemented on large-scale structures, then productivity increases, but programming time and resource requirements increase
Solution Approach 1:
The patent performs preliminary action by creating detailed 3D digital models of welding objects before actual welding operations. The system pre-processes the digital model to identify all welding seams, calculate optimal welding sequences, and generate complete programming instructions in advance, enabling efficient automated welding execution without time-consuming on-site programming.
Solution Approach 2:
The automated programming system performs self-service by autonomously processing 3D models and generating operation procedures without human intervention. This self-automated approach significantly reduces programming time and resource requirements while maintaining high welding productivity through efficient automated execution.
Data Source
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AI summary
Embodiments of the present disclosure relate to a method and apparatus of scheduling welding operations. In an embodiment of the present disclosure, the method comprises identifying seams on a welding object in a three-dimensional model for the welding object based on geometry of bodies contained in the welding object. The method also comprises determining a welding sequence based on the seams, welding parameters and welding process requirements. The method further comprises generating an operation procedure for a welding robot based on another three-dimensional model for the welding robot, the welding sequence, robot path parameters and the welding parameters to schedule the welding operations of the welding object. With embodiments of the present disclosure, the welding procedure could be generated in an automatic way and thus a robot can be used in welding huge and complex structures or structures manufactured in a small batch so that the automatic level can be increased remarkably and the production cost can be reduced accordingly.