Arc Welding Position Control for Dynamic Electrode Targeting
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Solution Overview
Problem
Existing arc welding technologies struggle to maintain high welding quality when dealing with complex welding objects or obstacles, as the appropriate target positions for the electrode and welding wire are not adjusted dynamically based on the attitude of the electrode and the shape of the welding object.
Innovation Solution
A welding control device that decides the target position of the welding wire or electrode based on input conditions including the attitude and shape information of the electrode and welding object, using image processing to align the actual position with the target position, and employs machine learning to refine this decision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automatic welding is executed with fixed target positions, then the welding procedure is simple, but the welding quality deteriorates when dealing with complex welding objects or varying electrode attitudes
Solution Approach 1:
The patent applies dynamics by making the target position of the welding wire dynamic rather than fixed. The control system calculates and adjusts the target position based on real-time electrode attitude (obtained from image processing) and welding conditions. This allows the system to adapt to complex welding objects and varying attitudes, maintaining high welding quality without requiring overly complex manual intervention while achieving both precision and adaptability.
2Manufacturing precision
If the target position is adjusted dynamically based on electrode attitude and object shape, then welding quality is maintained, but the control system becomes more complex
Solution Approach 1:
The system applies self-service by automatically calculating and adjusting the target position based on image processing of the electrode attitude and welding object shape. The control system performs self-adjustment without requiring manual intervention from the welder, maintaining welding quality while simplifying the operational process. The system serves itself by autonomously adapting to varying welding conditions.
3Measurement precision
If image processing is used to detect welding features, then position accuracy is improved, but the processing time increases
Solution Approach 1:
The patent applies preliminary action by performing image processing and target position calculation in advance within each control cycle. The system captures images, processes them to detect electrode attitude and welding features, calculates the appropriate target position, and prepares control commands before executing the welding action. This preliminary preparation ensures accurate position detection while minimizing real-time processing delays during actual welding operations.
Data Source
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AI summary
A welding control device configured to control a position control object which includes at least one of a welding wire used to weld a welding object or an electrode for melting the welding wire includes a first decision unit for deciding an actual position of the position control object based on a welding feature amount detected from an image which is shot to include at least the position control object, the welding feature amount including at least one of a wire position of the welding wire or an electrode position of the electrode, a second decision unit for deciding a target position which is a target of the actual position according to an input condition based on the input condition which includes at least one of attitude information of the electrode when the welding object is welded or shape information of the welding object, and a control unit for performing position control of the position control object so that the actual position becomes the target position.