Collaborative Robot Welding with Vision-Guided Easy Programming
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Solution Overview
Problem
Current automated robot welding systems are costly, bulky, and require specialized training and extensive programming, making them unsuitable for high mix, low volume production environments and inaccessible to smaller manufacturers due to high capital investment requirements and labor shortages in the welding industry.
Innovation Solution
A collaborative robot welding system that allows intuitive programming and operation without extensive training, featuring a mobile base with a gridded work surface, a programmable robot arm, and a user-friendly interface, enabling easy setup and relocation, and incorporating safety features for operator protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional automated robot welding systems are used, then welding quality and consistency are improved, but system cost and complexity increase significantly
Solution Approach 1:
The system uses vision guidance to automatically locate and track weld joints, eliminating the need for complex pre-programming of weld paths. The robot autonomously adapts to part positioning variations through real-time image processing, making the system self-sufficient in handling positioning errors without requiring complex fixtures or manual intervention.
Solution Approach 2:
The patent replaces complex mechanical positioning systems and hard-coded robot programming with a vision-based guidance system. Instead of using sophisticated mechanical fixtures and precise mechanical alignment, the system uses cameras and image processing to locate and track weld joints, substituting mechanical complexity with optical sensing and computational processing.
2Manufacturing precision
If traditional automated robot welding systems are used, then welding quality is improved, but operator training requirements and ease of operation worsen
Solution Approach 1:
The vision guidance system automatically performs weld joint location, tracking, and parameter adjustment without requiring operator intervention. The system self-calibrates and adapts to different weld types and positions, eliminating the need for operators to manually program complex weld paths or adjust multiple parameters, thereby reducing training requirements.
Solution Approach 2:
The vision system acts as an intermediary between the operator and the robot welding system. Instead of requiring operators to directly program and control the robot, the vision system translates visual information into robot control commands, simplifying the operator's task to initiating and monitoring the welding process rather than managing complex programming and parameter settings.
3Adaptability or versatility
If flexible programming for high mix low volume production is implemented, then adaptability improves, but system complexity and programming requirements worsen
Solution Approach 1:
The vision guidance system automatically adapts to different weld types, positions, and configurations by capturing images and processing the visual data to determine appropriate welding parameters. The system self-configures for each weld joint without requiring manual programming, enabling high mix low volume production while keeping programming requirements minimal.
Solution Approach 2:
The system dynamically adjusts welding parameters based on real-time vision analysis of each weld joint. Instead of requiring pre-programmed parameter sets for different weld types, the vision system automatically determines and adjusts parameters such as weld speed, voltage, and wire feed rate based on the visual characteristics of each joint, enabling flexible production without complex programming.
4Object-affected harmful factors
If safety features for operator protection are added, then operator safety is improved, but system complexity and cost worsen
Solution Approach 1:
The vision system serves as an intermediary that enables safe remote operation. By providing real-time visual feedback of the welding process, the system allows operators to monitor and control welding from a safe distance, reducing exposure to harmful factors such as UV radiation, sparks, and molten metal without requiring complex physical safety barriers or interlocks.
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
Enables efficient and high-quality welding in various environments with reduced labor and capital costs, improving productivity and accessibility for manufacturers by allowing less experienced operators to set up and operate the system effectively, addressing labor shortages and capital investment constraints.
Implementation Method 1
electric arc welding has evolved from the use of essentially a bare electrode employed to create molten metal by generating an electric arc between one end of the electrode and a workpiece
Data Source
AI summary
A collaborative robot welding system for the assembly, construction, fabrication, and/or the completion of weldments. A method of assembly and fabrication of weldments employing the intuitive graphical interactive programming features of a robot welding system user interface to enhance productivity and versatility in high mix, low volume weld fabrication environments with minimal operator training.