Triangulation Laser Range Finder for Welding Torch Position Monitoring
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Solution Overview
Problem
Welding robots equipped with tracking cameras face challenges in monitoring the position of the welding torch relative to the camera, leading to potential collisions and misalignment, which can result in weld defects and require manual calibration, even with anti-collision systems.
Innovation Solution
A range finder device comprising a laser unit for projecting a triangulation laser mark and a camera unit with an image sensor, connected to a control unit that generates position data, allowing for real-time monitoring of the welding torch's position relative to the tracking camera.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed-location gauging block is used for alignment monitoring, then alignment detection is possible, but the robot operation must be stopped periodically and the torch displacement takes time and space
Solution Approach 1:
The patent replaces the mechanical alignment monitoring system (gauging block with physical wire contact) with an optical measurement system (laser projector and camera). The laser projects a triangulation pattern onto the torch, and the camera captures the pattern to calculate torch position and orientation continuously without mechanical contact or operation interruption.
Solution Approach 2:
The patent enables continuous monitoring of torch alignment during operation. The laser and camera system operates continuously throughout the welding process, providing real-time feedback on torch position and orientation without requiring periodic stops for manual measurement or alignment checks.
2Reliability
If the welding torch is equipped with rigid mounting for stability, then collision resistance is improved, but the torch may still experience permanent deformation and displacement relative to the camera
Solution Approach 1:
The patent implements a feedback system where the camera continuously monitors the laser pattern on the torch, calculates the torch's actual position and orientation, and provides this information to the control system. This feedback loop enables real-time detection of any displacement or deformation, allowing the system to compensate for mounting instability rather than relying solely on rigid mechanical mounting.
3Measurement precision
If a triangulation laser camera looks ahead at a fixed distance, then weld joint tracking is possible, but the area of the welding torch tip and the position of the welding torch relative to the camera cannot be monitored
Solution Approach 1:
The patent makes the camera system multi-functional by using it for both weld joint tracking (its original function) and torch position monitoring (new function). The camera captures images that contain both the weld joint information for tracking and the laser pattern on the torch for position calculation, eliminating the need for separate monitoring systems.
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 continuous, accurate monitoring of the welding torch's position, preventing collisions and misalignment, reducing weld defects, and allowing for automated calibration and operation, thereby enhancing the precision and reliability of the welding process.
Implementation Method 1
a laser unit having a laser and an operative projection arrangement for projecting a triangulation laser mark
Implementation Method 2
producing triangulation laser measurement data from the triangulation laser mark in the image signal
Data Source
AI summary
A range finder device for monitoring a 3D position of a robot processing tool relative to a tracking device mounted adjacent to the robot processing tool is disclosed. A body attachable to the tracking device supports a laser unit and a camera unit. The laser unit projects a triangulation laser mark on a target area of the processing tool. The mark, a tool center point and a processing area are in a field of view of the camera unit. A control unit controls operation of the laser unit and has an image analyzer circuit for receiving an image signal produced by the camera unit, producing triangulation laser measurement data from the triangulation laser mark in the image signal, generating a signal indicative of the position of the robot processing tool as function of the triangulation laser measurement data, and transmitting the image signal produced by the camera unit.