Arc Welding Torch Angle Calculation via Virtual Reference Plane
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Solution Overview
Problem
Conventional arc welding robot systems face challenges in efficiently teaching and correcting welding operation programs due to the difficulty in directly grasping and adjusting angle data, such as work and travel angles, which increases processing steps and time consumption.
Innovation Solution
A data processing apparatus that obtains position and orientation data, sets a virtual reference plane, calculates angle data, and performs displaying or correcting processes to facilitate easy understanding and adjustment of angle data for arc welding torches, reducing the burden on operators and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If position and orientation data are adjusted visually through jog-feeding in playback teaching, then the robot can be taught welding operations, but the work angle and travel angle cannot be directly grasped or adjusted, requiring repeated trial and error
Solution Approach 1:
The patent introduces an intermediary data processing apparatus that acts as a mediator between the welding operation program and the operator. This apparatus calculates and displays work angles and travel angles based on position and orientation data, allowing operators to indirectly grasp angle information without direct visual adjustment of robot arm parameters during teaching operations.
Solution Approach 2:
The patent replaces the mechanical visual adjustment method (jog-feeding and direct observation) with an automated computational system. The data processing apparatus automatically calculates angle data from position and orientation information, substituting the manual mechanical adjustment process with automated digital computation and display.
2Ease of manufacture
If off-line programming is used to define work-cells virtually, then programming can be done away from the actual job site, but errors between virtual and actual equipment layouts require data correction that changes work and travel angles
Solution Approach 1:
The patent implements a feedback mechanism where the data processing apparatus continuously monitors and displays work angles and travel angles after data correction. When virtual-to-actual layout errors require correction, the system automatically recalculates angle data and provides feedback to the operator, enabling verification that correction goals are met without requiring manual recalculation or repeated trial and error.
3Manufacturing precision
If position and orientation data are calculated manually to determine work and travel angles, then welding conditions can be optimized, but significant time is consumed in calculating and correcting program data
Solution Approach 1:
The patent enables the system to serve itself by automatically calculating work angles and travel angles from position and orientation data without requiring manual intervention. The data processing apparatus performs self-calculation and self-verification of welding conditions, eliminating the need for operators to manually calculate angles and reducing the time required for program preparation and correction.
Solution Approach 2:
The patent replaces manual calculation methods with automated computational processing. Instead of operators manually calculating work and travel angles from position and orientation data, the system uses automated algorithms to perform these calculations instantly, substituting manual mathematical operations with electronic computation.
4Reliability
If the robot arm position and orientation are adjusted to achieve appropriate torch angles, then welding quality can be maintained, but the number of processing steps increases significantly
Solution Approach 1:
The patent merges the functions of position/orientation data management and angle data calculation into a single integrated data processing apparatus. By combining these previously separate functions, the system reduces the number of processing steps while maintaining the ability to ensure appropriate torch angles for welding quality.
Data Source
AI summary
A data processing apparatus for processing data described in a welding operation program of an arc welding robot system. The data processing apparatus includes a data obtaining section for obtaining a plurality of position and orientation data at a plurality of different teaching points previously taught and included in the welding operation program; a reference plane setting section for setting a virtual reference plane as a reference defining a geometric placement of an arc welding torch relative to a workpiece during a welding operation, based on the position and orientation data obtained in the data obtaining section; an angle calculating section for calculating a plurality of angle data representing the geometric placement of the arc welding torch at every teaching points, by using the position and orientation data obtained in the data obtaining section and the virtual reference plane set in the reference plane setting section; and an angle processing section for performing at least one of a displaying process and a correcting process of the angle data calculated in the angle calculating section.