Fusion Welding Hand Control Using Support-Based Force Sensing
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Solution Overview
Problem
Existing fusion welding methods cannot control the position and angle of a fusion welding hand with respect to workpieces using a force sensor, as the force sensor cannot detect the force acting on the fusion welding hand.
Innovation Solution
A fusion welding device equipped with a support that abuts on the workpieces, a force sensor to detect forces and moments, and a control section to adjust the robot arm's motion based on sensor inputs, allowing precise control of the fusion welding hand's position and angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a force sensor is used to detect workpiece forces, then position control precision is improved, but the fusion welding hand cannot detect forces because it is separated from the workpieces
Solution Approach 1:
The patent introduces a support as an intermediary component that contacts the workpiece and transmits forces to the force sensor. The support acts as a mediator between the fusion welding hand (which cannot directly contact the workpiece) and the workpiece itself, enabling force detection through mechanical coupling while maintaining the separation required for fusion welding operation.
2Reliability
If the fusion welding hand is separated from workpieces for fusion welding, then welding quality is improved, but force sensor detection capability deteriorates
Solution Approach 1:
The system is segmented into distinct functional components: the fusion welding hand for welding operations, the support for force transmission, and the force sensor for detection. This segmentation allows each component to perform its specialized function optimally - the welding hand maintains separation for quality welding, while the support-sensor combination provides force detection capability.
Solution Approach 2:
The support serves as an intermediary that bridges the gap between the non-contacting fusion welding hand and the workpiece. It transmits mechanical forces from the workpiece to the force sensor without requiring the welding hand to contact the workpiece, thus preserving welding quality while enabling force detection.
3Measurement precision
If a support is added to transmit forces to the force sensor, then force detection capability is improved, but device complexity increases
Solution Approach 1:
The support structure is designed to serve multiple functions: it provides mechanical support for the force sensor, transmits forces from the workpiece to the sensor, and maintains the geometric relationship between the welding hand and workpiece. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
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
Accurate control of the fusion welding hand's position and angle with respect to workpieces, even with irregular surfaces or curved shapes, is achieved by using a force sensor to maintain predetermined conditions.
Implementation Method 1
a force sensor for detecting a force and a moment exerted, through the support, by the workpieces
Data Source
AI summary
A fusion welding device includes: a robot arm; a fusion welding hand attached to the robot arm and including a fusion welding head for fusing and joining together workpieces while being separated from the workpieces; a support provided to the fusion welding hand and abutting on the workpieces; a force sensor for detecting a force and a moment exerted, through the support, by the workpieces; and a control section configured to control motion of the robot arm in accordance with parameters calculated from a signal outputted from the force sensor.