Robotic Cylinder Welding With Parameterized Control Programs
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Solution Overview
Problem
Existing robotic welding systems face challenges in efficiently welding differently sized cylindrical workpieces, as open-loop systems require custom control programs and are not economical for small batches, while closed-loop systems are costly due to the need for feedback controls, and they struggle with welding workpieces not in the same horizontal plane and lack operator interaction for refined control.
Innovation Solution
A robotic welding system that uses a family of control programs adaptable to various workpiece sizes, with a motorized workpiece support for rotation and a manipulation control mechanism allowing operator interaction, enabling efficient welding of cylindrical workpieces of different sizes and orientations without the need for expensive feedback systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If open-loop control systems are used with customized control programs for each workpiece size, then welding precision can be maintained, but device complexity and programming time increase significantly
Solution Approach 1:
The patent implements a universal control program that can handle multiple workpiece sizes through parameterization. Instead of creating separate customized programs for each workpiece size, the system uses a single flexible program that adapts to different dimensions by receiving size inputs and automatically adjusting welding parameters, thereby reducing programming complexity while maintaining precision
Solution Approach 2:
The control program utilizes parameter changes to adapt to different workpiece sizes. By inputting workpiece dimensions, the system dynamically modifies welding parameters such as travel speed, torch position, and welding current without requiring separate program code for each size, thus maintaining precision across variations while simplifying the overall control structure
2Adaptability or versatility
If closed-loop feedback control systems are incorporated to allow real-time adjustments, then adaptability to different workpiece conditions improves, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the essential adaptability function from complex closed-loop feedback systems and implements it through parameterized control logic. By removing the need for expensive sensors, actuators, and real-time feedback control hardware, the system achieves adaptability through pre-programmed parameter adjustments based on input workpiece dimensions, thereby maintaining versatility while dramatically reducing device complexity
Solution Approach 2:
The system replaces expensive, complex feedback control infrastructure with a simpler, more economical parameterized control approach. Instead of investing in costly closed-loop systems with multiple sensors and real-time adjustment mechanisms, the patent uses a lightweight control program that adapts to different workpieces through parameter input, achieving the same adaptability goal at much lower cost and complexity
3Extent of automation
If traditional robotic welding systems are used for cylindrical workpieces, then automation level can be maintained, but ability to weld workpieces not in the same horizontal plane is limited
Solution Approach 1:
The patent implements dynamic adaptability in the control program to handle workpieces in different orientations and planes. The system can dynamically adjust welding parameters, torch positioning, and motion paths based on the specific geometric configuration and orientation of the cylindrical workpieces, enabling robotic automation to effectively weld components that are not aligned in the same horizontal plane while maintaining high automation levels
Data Source
AI summary
A first embodiment of the present application is directed to a method and system used to weld a cylindrical workpiece. A substantially cylindrical workpiece is loaded into a workpiece support, and a robotic welding arm is positioned located at a start position. A value representing a size of the cylindrical workpiece is input into a robot controller via a system interface. Inputting of the size value to the robotic interface obtains a control program. Operation of the obtained control program is initiated by an operator, causing the robot arm to move a preprogrammed distance toward a work surface of the workpiece. Then a welding process is performed by the welder carried on the robot arm in accordance with the control program. The process includes initiating operation of the welder, and moving the welder in a pattern appropriate for the welding operation. The workpiece and welder are moved relative to each other so as to perform the welding process as determined by the control program.