Arc Welding Robot Control System for Weaving Operation Precision
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Solution Overview
Problem
Existing arc welding robot control systems face challenges in maintaining consistent welding bead thickness during weaving operations, as they change welding conditions manually or linearly based on travel distance, leading to deviations in welding currents and wire following, resulting in inaccurate welds, especially at faster weaving cycles.
Innovation Solution
An arc welding robot control system that calculates and adjusts welding conditions in real-time based on a predetermined movement pattern, using a memory device to store start and finish points, and a device to determine correction values for changing conditions between these points, ensuring consistent welding parameters across the weaving cycle, and includes a delay-time adjustment to account for operational delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If welding conditions are changed linearly based on travelling distance during weaving operation, then welding conditions can be adjusted automatically, but welding bead thickness becomes deviated and welding precision deteriorates
Solution Approach 1:
The system pre-calculates the timing of welding condition changes based on the predetermined weaving operation pattern. By determining in advance when welding conditions should be changed (synchronized with weaving cycle completion), the system avoids the deviation caused by linear distance-based changes, thus maintaining welding precision while achieving automatic control.
Solution Approach 2:
The system uses feedback from the weaving operation completion signal to trigger welding condition changes. The welding condition changing device receives a signal when the welding torch completes one weaving cycle, and only then changes the welding conditions. This feedback mechanism ensures that condition changes are synchronized with the actual weaving operation, preventing bead thickness deviation.
2Device complexity
If welding conditions are changed at fixed positions regardless of weaving cycle timing, then control is simplified, but welding current inconsistency increases and welding quality deteriorates
Solution Approach 1:
The welding condition changing device is designed to receive a completion signal from the weaving operation and trigger condition changes based on this feedback. This ensures that welding conditions are changed only at the appropriate moment (when weaving completes), maintaining current consistency without overly complicating the control system.
Solution Approach 2:
The system changes welding conditions periodically, synchronized with the completion of each weaving cycle. This periodic action ensures that condition changes occur at consistent intervals relative to the weaving operation, maintaining reliability while keeping the control logic relatively simple.
3Productivity
If weaving cycle speed increases to improve productivity, then welding speed increases, but welding bead thickness deviation increases and welding precision deteriorates
Solution Approach 1:
The system pre-calculates welding condition changes based on the weaving operation completion timing, regardless of the weaving cycle speed. This allows the system to adapt to faster weaving cycles by maintaining the synchronization between condition changes and weaving completion, thus preserving precision even as productivity increases.
Solution Approach 2:
The system dynamically adjusts welding conditions based on the actual weaving operation progress and completion timing. By making the condition change timing dependent on the dynamic state of the weaving operation rather than fixed positions, the system can maintain precision across varying weaving speeds, enabling higher productivity without sacrificing quality.
Data Source
AI summary
An arc welding robot control system of the present invention includes memory devices, controlling devices, a welding condition changing position calculating device, a weaving operation controlling device that outputs a signal of completion of one weaving cycle every time when a welding torch completes to perform one weaving cycle of a predetermined movement pattern, a welding condition calculating device for calculating to-be-changed welding conditions, and a welding condition changing device that changes welding conditions of an arc welding robot, based on to-be-changed welding conditions, every time when a signal of completion of one weaving cycle is input. With this configuration, it enables a continuous change of welding conditions and a copying arc welding with high accuracy even in the case in which the arc welding robot performs a weaving operation.