Hybrid Robot 3D Vision Welding for Large-Part Reach Expansion
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Solution Overview
Problem
Existing automatic welding systems for large structural parts using robots face challenges in expanding working range due to limited arm reach, requiring external shafts that increase cost and precision requirements, leading to accumulative errors and high system costs.
Innovation Solution
An automatic welding system utilizing a hybrid robot with a mobile robot and 3D vision for global calibration and positioning, allowing the system to expand its working range without external shafts, reducing costs and improving flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If external shafts are used to expand the working range of robots, then the working range is expanded, but the cost of the system increases sharply
Solution Approach 1:
The patent replaces the traditional mechanical external shaft system with a mobile robot platform that uses motion control and 3D vision for positioning. This substitution eliminates the need for complex mechanical guide rails and grating scales, thereby reducing system cost while maintaining expanded working range capability.
Solution Approach 2:
The patent introduces a mobile robot platform as an intermediary carrier that holds the MDOF robot. This mobile platform enables the robot to move to different positions on the workpiece, effectively expanding the working range without requiring a fixed external shaft structure, thus reducing system complexity and cost.
2Manufacturing precision
If external shafts with precise guide rails or grating scales are used to guarantee global positioning precision, then positioning precision is improved, but the system cost increases in equal proportion with the increase of moving distance
Solution Approach 1:
The patent replaces mechanical precision guidance systems (guide rails and grating scales) with a 3D vision system and motion control algorithm. The 3D camera captures workpiece geometry and positioning information, and through coordinate transformation and error compensation algorithms, achieves high positioning precision without requiring expensive mechanical precision components over long distances.
Solution Approach 2:
The patent implements a feedback mechanism using 3D vision to detect the actual position of the robot and workpiece, then uses coordinate transformation and error compensation to correct positioning deviations. This feedback loop maintains high positioning precision without relying on expensive mechanical precision components.
3Area of stationary object
If a driver and external shaft motor are added to control the external shaft, then the working range is expanded, but the device complexity and cost increase
Solution Approach 1:
The patent merges the functions of the mobile robot platform and the MDOF robot into a hybrid system. The mobile platform provides positioning and movement capabilities, while the MDOF robot provides welding execution. This integration eliminates the need for separate external shaft control systems, reducing overall system complexity while maintaining expanded working range.
Solution Approach 2:
The mobile robot platform serves multiple functions: it acts as the carrier for the MDOF robot, provides positioning through motion control, and enables expanded working range through mobile deployment. This multi-functionality eliminates the need for dedicated external shaft control components, reducing system complexity.
Data Source
AI summary
Disclosed are an automatic welding system and method for large structural parts based on hybrid robots and 3D vision. The system comprises a hybrid robot system composed of a mobile robot and an MDOF robot, a 3D vision system, and a welding system used for welding. The rough positioning technique based on a mobile platform and the accurate recognition and positioning technique based on high-accuracy 3D vision are combined, so the working range of the MDOF robot in the XYZ directions is expanded, and flexible welding of large structural parts is realized. The invention adopts 3D vision, thus having better error tolerance and lower requirements for the machining accuracy of workpieces, positioning accuracy of mobile robots and placement accuracy of the workpieces; and the cost is reduced, the flexibility is improved, the working range is expanded, labor is saved, production efficiency is improved, and welding quality is improved.