AR Welding Robot Teaching to Avoid Wire Contact
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Solution Overview
Problem
Current robot welding systems face challenges in accurately teaching motion to welding robots due to the complexity of preparing precise three-dimensional models and the risk of the welding wire coming into contact with target objects during teaching, requiring skilled operator intervention.
Innovation Solution
A robot welding system equipped with a robot operation terminal featuring an image capturing device, display device, and terminal controller that calculates the attitude of the welding torch and superimposes motion information onto captured images, allowing for easy teaching and correction of the processing program without physical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulation is used to teach motion to welding robot, then contact between robot and nearby apparatus can be prevented, but preparation of precise three-dimensional models becomes complicated
Solution Approach 1:
The patent uses AR (augmented reality) technology to create a virtual overlay of the welding torch motion trajectory on the actual workpiece image, eliminating the need for complex 3D models. The system captures the actual workpiece through an image capturing device and superimposes motion information, creating a simplified virtual representation that achieves the same safety verification purpose without requiring detailed 3D modeling.
Solution Approach 2:
The patent replaces the traditional simulation-based teaching method with an AR-based visual guidance system. Instead of using complex 3D simulation environments, the system uses image capture and augmented reality display to provide real-time visual feedback on the welding torch trajectory, substituting mechanical simulation with optical and computational methods.
2Measurement precision
If teaching is performed while robot actually moves, then accurate teaching can be achieved, but welding wire may come into contact with target object and bend
Solution Approach 1:
The patent performs preliminary verification of the welding torch trajectory by displaying the motion path on the AR display unit before actual welding execution. The system calculates the attitude and position of the welding torch in advance, superimposes this information on the captured workpiece image, and allows the operator to verify the path. This preliminary action ensures accuracy while preventing harmful contact during the actual welding process.
Solution Approach 2:
The patent implements a feedback mechanism where the AR display unit provides real-time visual information about the welding torch position and trajectory during teaching. The system continuously displays the calculated welding torch attitude overlaid on the workpiece image, allowing the operator to see the motion path and make adjustments before actual contact occurs, ensuring both accuracy and safety.
3Object-affected harmful factors
If operator carefully operates robot during teaching, then welding wire contact can be prevented, but operator proficiency requirement increases teaching complexity
Solution Approach 1:
The patent introduces an intermediary AR display system that acts as a mediator between the operator and the robot operation. The display unit provides visual guidance showing the welding torch trajectory overlaid on the workpiece, serving as an intermediary that guides the operator's actions without requiring high proficiency. This intermediary system reduces the skill barrier while maintaining safety by providing continuous visual feedback on the motion path.
Data Source
AI summary
The purpose of the present invention is to provide a system that can easily teach a welding robot. A robot welding system according to one aspect of the present disclosure comprises: a robot; a robot controller; a welding torch; and a robot operation terminal including an image capturing device, a display device, and a terminal controller. The terminal controller includes a teaching accepting unit that accepts an input of teaching information for the robot. The robot controller or the terminal controller includes: an attitude calculation unit that calculates an attitude of the welding torch, on the basis of basic information about the robot, a processing program and the teaching information input to the teaching accepting unit; an AR display unit that displays motion information about the welding torch corresponding to an image captured by the image capturing device, on the display device in a superimposed manner over the image captured by the image capturing device; and a program recording unit that causes the robot controller to correct or newly store the processing program, on the basis of the teaching information.