Handheld Robotic Welding Path Capture for Faster 3D Programming
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Solution Overview
Problem
Current robotic welding systems are cumbersome and time-consuming due to the complexity of programming multi-axis robotic devices, which requires manual movement and precise positioning of the robot to capture 3D points, leading to slow point acquisition and increased risk of user error and machine damage.
Innovation Solution
A robotic welding system that uses a handheld controller with a touch probe to capture points and orientations in 3D space, allowing intuitive programming by mimicking hand gestures and movements, enabling the robot to follow the controller's path without moving the robot itself, and integrating multiple position and orientation capture technologies for sub-millimeter precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-axis robotic programming methods are used, then the robot can perform precise welding operations, but the programming process becomes time-consuming and cumbersome
Solution Approach 1:
The system creates a virtual copy of the welding environment using 3D scanning technology. The handheld controller captures spatial coordinates and creates a digital twin of the workpiece and robot positions, allowing operators to program welding paths by simply pointing and clicking in the virtual model rather than manually moving the physical robot through complex multi-axis coordinate systems.
Solution Approach 2:
The patent replaces traditional mechanical teaching methods (manually moving the robot through space while recording positions) with a combination of 3D scanning technology and virtual reality interfaces. The system substitutes physical robot movement during programming with digital model manipulation, where the robot's position and orientation are determined by matching virtual model coordinates rather than physical teaching pendant operations.
2Measurement precision
If manual robot movement is used to capture 3D points, then accurate position data can be obtained, but the process increases risk of user error and machine damage
Solution Approach 1:
The system uses 3D scanning to create a virtual replica of the work environment, allowing all position measurements and path planning to be performed in the digital model. This eliminates the need to physically move the robot during the programming phase, removing the risk of accidental collisions with workpieces, tools, or operators while maintaining sub-millimeter positioning accuracy through the scanning system.
Solution Approach 2:
The system performs all position capture, path planning, and collision analysis in advance using the virtual 3D model before the actual welding operation begins. The robot's complete welding path is pre-calculated and verified in the virtual environment, ensuring safety and accuracy are established before any physical movement occurs.
3Ease of operation
If complex multi-axis programming is required, then the robot can achieve precise control, but operator fatigue increases and ease of operation decreases
Solution Approach 1:
The system allows operators to program welding paths using intuitive handheld controller gestures that mirror natural hand movements. The virtual reality interface automatically interprets these gestures and translates them into precise robot commands, eliminating the need for operators to learn complex multi-axis coordinate systems and programming languages. The system adapts to the operator's natural interaction style rather than requiring the operator to adapt to the system's complexity.
4Adaptability or versatility
If traditional teaching methods are used, then the robot can be programmed for welding, but the complexity of multi-axis coordination increases device complexity
Solution Approach 1:
The patent introduces a virtual 3D model as an intermediary layer between the operator and the physical robot. This virtual model serves as a simplified interface that translates complex multi-axis robot coordinates into intuitive 3D spatial relationships. The system handles the complex coordinate transformations and multi-axis coordination algorithms in the background, presenting a simplified point-and-click interface to the operator while maintaining full versatility for different welding applications.
Data Source
AI summary
This disclosure describes systems, methods, and devices related to robotic point capture and motion control. A robotic device may synchronize one or more first axes of the robotic device with one or more second axes of a handheld device. The device may determine a welding path using the handheld device. The device may perform a weld by the traversing of an end effector of the robotic across the welding path, wherein the end effector comprises a welding tip.