AR Weld Torch Angle Correction for Robot Training Precision
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Solution Overview
Problem
Programming and setting precise angles and orientations of a welding or cutting torch for robots can be complex and error-prone, requiring detailed user input and knowledge.
Innovation Solution
A robotic welding system equipped with a depth camera and computer-based weld angle correction tool that uses stereoscopic image data to determine and correct torch angles, allowing users to record and adjust push and work angles relative to the weldment and seam, with augmented reality feedback for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a robot is programmed to weld with precise torch angles and orientations, then welding quality is improved, but the programming complexity and user expertise required increase significantly
Solution Approach 1:
The system uses the depth camera to automatically capture and analyze the actual torch angle and orientation during welding operations. The processor compares these captured parameters against ideal values and autonomously generates correction data, eliminating the need for complex manual programming while maintaining precise welding quality
Solution Approach 2:
The patent replaces complex mechanical programming and manual angle setting with an optical measurement system (depth camera) and automated image processing. The system captures visual data of the torch position and orientation, processes this data through algorithms, and automatically determines corrections without requiring intricate mechanical programming
2Manufacturing precision
If manual positioning of torch angles is required during robot training, then welding precision can be achieved, but the time and expertise required for training increase
Solution Approach 1:
The depth camera continuously captures the actual torch angle and orientation during the welding process. The processor compares these real-time measurements against ideal parameters and generates correction data that is fed back to the robot controller, enabling automatic adjustment without time-consuming manual repositioning during training
Solution Approach 2:
The system performs preliminary capture and analysis of the actual torch parameters during the welding operation itself. By analyzing the depth image data and determining the actual angle in advance, the system prepares correction data before the next welding cycle, eliminating the need for time-consuming manual adjustments during training
3Manufacturing precision
If detailed user input is required for torch orientation programming, then accurate welding can be achieved, but the ease of operation decreases
Solution Approach 1:
The depth camera system automatically captures the torch position and orientation data during welding operations. The processor independently analyzes this data and determines the actual torch angle without requiring detailed user input or manual measurement, maintaining welding accuracy while significantly simplifying operation
Solution Approach 2:
The system creates a digital copy of the actual torch angle and orientation by capturing depth image data. This copied data is then processed and compared against ideal values to generate corrections, eliminating the need for users to manually input detailed orientation parameters while maintaining precise control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and efficient correction of torch angles to ideal positions, reducing user expertise requirements and improving the training process for robotic welding systems by providing real-time feedback and automated angle adjustments.
Implementation Method 1
The weld angle correction tool includes a depth camera that acquires stereoscopic depth image data which is used to determine the actual torch angles of the torch, as positioned by the user, with respect to the joint/seam
Data Source
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AI summary
A method of correcting angles of a welding torch positioned by a user while training a robot of a robotic welding system is provided. Weldment depth data of a weldment and a corresponding weld seam is acquired and 3D point cloud data is generated. 3D plane and intersection data is generated from the 3D point cloud data, representing the weldment and weld seam. User-placed 3D torch position and orientation data for a recorded weld point along the weld seam is imported. A torch push angle and a torch work angle are calculated for the recorded weld point, with respect to the weldment and weld seam, based on the user-placed torch position and orientation data and the 3D plane and intersection data. The torch push angle and the torch work angle are corrected for the recorded weld point based on pre-stored ideal angles for the weld seam. The method also comprises displaying augmented reality symbols overlaid onto an image of the weldment indicating the location of the weld point and at least one torch angle.