Arc Welding Speed Control From Molten Pool Tip Tracking
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Solution Overview
Problem
In horizontal welding, maintaining the welding torch at a proper position with respect to the molten pool is challenging due to variations in the molten pool's position caused by welding distortion and installation errors, especially when the torch is woven in alternating directions.
Innovation Solution
An automatic welding system that uses a camera to capture images of the molten pool and determines the correction of welding speed based on the distance between the arc and the leading end of the molten pool, employing a learned model to estimate positional coordinates and accuracy of feature points, ensuring the torch remains aligned with the molten pool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welding torch is woven in alternating directions to perform arc welding in a groove, then the welding coverage and penetration are improved, but the positional accuracy of the welding torch relative to the molten pool deteriorates due to welding distortion and installation errors
Solution Approach 1:
The system employs real-time feedback by capturing images of the molten pool with a camera, detecting its position, and using this information to dynamically correct the welding torch position. The correction amount is calculated based on the distance between the arc and the leading end of the molten pool, creating a closed-loop control system that compensates for positional deviations caused by weaving motion and distortion
Solution Approach 2:
The patent replaces mechanical position control with optical detection and computational correction. Instead of relying solely on mechanical precision of the welding robot, the system uses a camera to detect molten pool position and calculates correction amounts to substitute for mechanical positioning errors
2Productivity
If the welding torch travel speed is increased to improve productivity, then the welding efficiency is improved, but the ability to maintain proper position relative to the dynamically changing molten pool deteriorates
Solution Approach 1:
The real-time feedback system continuously monitors the molten pool position and dynamically adjusts the torch position based on detected deviations. This allows high travel speeds to be maintained while the feedback loop compensates for positional lag or lead, ensuring the torch remains properly positioned relative to the molten pool throughout the welding process
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 allows for high-quality automatic welding by maintaining the welding torch at a proper position relative to the molten pool, even under conditions of welding distortion and groove width deviations, thereby improving welding consistency and quality.
Implementation Method 1
a camera 2 configured to capture an image of an arc and a molten pool produced in the groove by the arc welding; a detecting unit 12 configured to detect a position of a leading end of the molten pool in a camera image captured by the camera 2
Data Source
AI summary
An automatic welding system, an automatic welding method, a welding assistance device, and a program wherein the amount of correction of the welding speed is determined on the basis of the distance between an arc and the tip of a molten pool when the distance between the arc and the tip of the molten pool is within a predetermined range in arc welding performed while alternately weaving a welding torch in the front downward direction and the rear upward direction when the welding progress direction is the frontward direction with respect to a horizontally extending groove formed between two members to be welded aligned in the vertical direction.