Arc Sensor Adjustment via Up-Down Oscillation
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Solution Overview
Problem
Existing arc sensor adjustment methods for welding systems face challenges in achieving highly accurate adjustments due to unpredictable factors like dimensional errors in the welding subject and bending in the welding wire, particularly during weaving operations.
Innovation Solution
An arc sensor adjustment device and method that calibrate the welding torch by oscillating it in an up-down direction to measure welding current or voltage, calculating an adjustment value and correction amount to correct the torch position during copying control, thereby improving accuracy and reducing the impact of dimensional errors and wire bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If arc sensor adjustment is performed using conventional weaving methods, then the adjustment process can be completed, but the measurement precision is degraded due to dimensional errors and wire bending
Solution Approach 1:
The patent inverts the conventional weaving direction from left-right oscillation to up-down oscillation of the welding torch. This inversion allows the torch to move perpendicular to the workpiece surface, creating a stable waveform that is not affected by dimensional errors or wire bending, thereby achieving high-precision adjustment measurements
Solution Approach 2:
The patent changes the oscillation parameters by switching from horizontal left-right weaving to vertical up-down oscillation. This parameter change transforms the measurement conditions to eliminate the influence of harmful factors like dimensional errors and wire bending, enabling accurate arc sensor adjustment
2Stability of the object's composition
If conventional left-right weaving is used for arc sensor adjustment, then the adjustment can be performed, but the waveform stability deteriorates due to unpredictable factors
Solution Approach 1:
By inverting the weaving direction to up-down oscillation, the patent achieves stable waveform generation that is independent of workpiece dimensional errors and wire bending, thereby ensuring waveform stability for accurate arc sensor adjustment
Solution Approach 2:
The patent extracts the harmful effects of dimensional errors and wire bending from the measurement process by using up-down oscillation instead of left-right weaving, isolating the adjustment measurement from these unpredictable factors and achieving stable waveforms
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
This approach enables more accurate position correction and synchronization of the welding torch, enhancing the precision of copying control in welding systems by using a stable waveform obtained during up-down oscillation, which is less affected by dimensional errors and wire bending.
Implementation Method 1
an arc sensor configured to obtain a welding current or a welding voltage generated when copying control is carried out
Data Source
AI summary
An arc sensor adjustment device and adjustment method for carrying out highly-accurate copying control. A welding system includes a welding torch, a welding power source that supplies power to the welding torch, a robot and a robot controller that cause the welding torch to oscillate, and an arc sensor that obtains a welding current or a welding voltage generated during welding while oscillating the welding torch. The arc sensor obtains a welding current or a welding voltage generated during calibration, in which welding is carried out while oscillating the welding torch in an up-down direction, calculates, on the basis of the obtained welding current or welding voltage, a correction amount for the position of the welding torch during welding carried out while oscillating the welding torch in a left-right direction, and applies the calculated correction amount to copying control.