Adaptive Robotic Laser Welding Control via Latency Compensation
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Solution Overview
Problem
Current robotic laser braze/weld tools lack adequate signal timing adjustment capabilities, leading to suboptimal performance due to non-adaptive control of process parameters like wire feed speed and laser power, which are not synchronized with actual tool speed, resulting in difficulties in synchronizing timing control between laser power and wire feed speed during changes in welding speed and motion.
Innovation Solution
A software program generates process signals with synchronized execution timing, accounting for time latencies to independently control laser braze/weld parameters such as laser power, wire feed speed, and gas flow, allowing adaptive control based on actual welding speed and tool center point speed, ensuring precise timing adjustments and dynamic updates during acceleration, deceleration, and directional changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If process parameters are controlled based on commanded values in the weld schedule, then the control system is simple to implement, but the synchronization between laser power and wire feed speed cannot be accurately maintained during speed changes
Solution Approach 1:
The patent implements feedback control by continuously monitoring the actual tool center point speed and using this information to dynamically adjust process parameters. The system measures actual welding speed and feeds this information back to the control algorithm, which then modifies laser power and wire feed speed commands to maintain proper synchronization, resolving the contradiction between synchronization accuracy and control complexity.
Solution Approach 2:
The patent replaces traditional mechanical timing synchronization with a software-based adaptive control system. Instead of using fixed mechanical timing mechanisms to synchronize laser power and wire feed speed, the system uses real-time speed measurement and software algorithms to dynamically calculate and adjust the timing of process parameters, achieving more accurate synchronization while maintaining manageable system complexity.
2Adaptability or versatility
If the robot welding tool accelerates or decelerates during operation, then the actual move speed changes dynamically, but fixed process parameters cannot adapt to these speed changes, compromising weld quality
Solution Approach 1:
The patent applies dynamics by making the control system adaptive rather than static. The process parameters are continuously adjusted based on real-time robot speed measurements. When the robot accelerates or decelerates, the system dynamically recalculates the appropriate laser power and wire feed speed values to maintain optimal welding conditions, ensuring weld quality is preserved despite speed variations.
Solution Approach 2:
The patent implements parameter changes by continuously modifying process parameters (laser power, wire feed speed) based on actual welding speed. The control algorithm adjusts these parameters in real-time as the robot speed changes, allowing the system to adapt to acceleration and deceleration phases while maintaining consistent weld quality throughout the operation.
3Measurement precision
If adequate signal timing adjustment capability is provided for all process signals, then precise synchronization is achieved, but the software complexity and programming difficulty increase significantly
Solution Approach 1:
The patent implements a universal timing adjustment mechanism that handles multiple process signals (laser power, wire feed speed, gas flow) through a single integrated control algorithm. This multi-functional approach allows the same software module to synchronize different types of signals with their respective time latencies, achieving precise timing control without proportionally increasing software complexity for each individual signal.
Solution Approach 2:
The patent introduces an intermediary adaptive control algorithm that acts as a mediator between the robot motion control and the process parameter control. This intermediary layer receives the actual speed information, calculates the appropriate timing adjustments, and generates the synchronized process signals, simplifying the overall software architecture while maintaining precise timing control across multiple devices and parameters.
Data Source
AI summary
A method for adaptive control of a robotic operation of a robot includes providing a software program to generate process signals executable during the robotic operation, including one or more execution commands. A first Signal Value channel is provided to control at least one control process parameter of the robot, where the first Signal Value channel is subject to a first time latency. The execution timing of the first Signal Value channel is synchronized with the one or more execution commands by accounting for the first time latency in relation to the one or more execution commands. The software program is run to generate the process signals and the robot is operated in response to the synchronized execution timing of the execution commands.