Laser Seam Tracking With Hermite Trajectories for Corner Welds
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Solution Overview
Problem
Existing weld seam tracking methods struggle with sharp changes in weld seam direction, such as large curvatures or corner welds, due to the limitations of galvanometer motion and inertia of the motion mechanism, leading to impact and time loss.
Innovation Solution
A collaborative weld seam tracking method using laser line scanning sensing, which involves scanning the weld seam, converting sampling deviation values, and employing Hermite interpolation to adjust the motion trajectory of the motion mechanism and galvanometer, allowing for precise tracking even at large curvatures or corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rapid acceleration and deceleration through corners is performed to follow weld seam trajectories with sharp changes in direction, then weld seam tracking accuracy is improved, but significant impact and time loss occur due to the motion mechanism's large mass and inertia
Solution Approach 1:
The system performs preliminary action by using the laser line scanning sensor to detect weld seam deviations in advance and calculate optimal motion trajectories before the motion mechanism needs to respond. This allows the system to prepare acceleration and deceleration profiles that avoid sudden changes, reducing impact and time loss while maintaining tracking accuracy.
Solution Approach 2:
The system applies dynamics by implementing dynamic motion trajectory adjustment based on real-time weld seam detection. The motion mechanism adapts its velocity and acceleration profiles dynamically according to the detected weld geometry, allowing smooth transitions through corners and curves without rigid adherence to pre-programmed paths, thereby reducing impact from inertia.
2Adaptability or versatility
If the galvanometer deflection angle is increased to reach weld seam positions that deviate significantly from the motion direction, then processing range is improved, but the oscillation angle limit restricts the achievable processing range
Solution Approach 1:
The system resolves the oscillation angle limit by introducing another dimension of motion through the motion mechanism. Instead of relying solely on galvanometer deflection in one dimension, the motion mechanism provides additional degrees of freedom to position the laser beam, enabling the system to reach weld seam positions that deviate significantly from the motion direction without exceeding galvanometer angle limits.
Solution Approach 2:
The system merges the functions of the motion mechanism and galvanometer into a collaborative weld seam tracking system. The motion mechanism handles large-scale positioning while the galvanometer handles fine-adjustment and oscillation, combining their capabilities to achieve both extended processing range and precise control without the limitations of either component alone.
3Device complexity
If only the galvanometer is used for weld seam tracking, then device complexity is reduced, but the processing range is limited by the galvanometer's oscillation angle
Solution Approach 1:
The system merges the motion mechanism and galvanometer into a collaborative system where each component contributes its strengths. The motion mechanism provides extended range and position stability, while the galvanometer provides rapid response and precise oscillation control. This combination achieves both extended processing range and manageable complexity by distributing functions across two components rather than overloading a single device.
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
This method enables efficient and accurate tracking of weld seams with complex geometries, reducing impact on the motion mechanism and improving processing efficiency by utilizing both the galvanometer and motion mechanism collaboratively.
Implementation Method 1
scanning, by using a laser line scanning sensor, a weld seam to obtain an original sampling deviation value
Implementation Method 2
the deflection of the galvanometer is precisely controlled to direct the laser beam
Implementation Method 3
the beam is focused onto the workpiece surface through a focusing lens, creating a specific oscillation trajectory
Data Source
AI summary
A collaborative seam tracking method based on laser line scanning sensing includes: scanning, by using a laser line scanning sensor, a weld seam to obtain an original sampling deviation value; coordinate converting the original sampling deviation value to obtain a converted sampling deviation value, and then obtaining a first converted sampling deviation coordinate based on a current position coordinate of a motion mechanism; in response to an absolute difference between the converted sampling deviation value and a position value of a corresponding projection point on a preset path is less than a processing range of a galvanometer, performing a seam tracking; in response to the absolute difference between the converted sampling deviation value and the position value of the corresponding projection point on the taught path is greater than or equal to the processing range, performing Hermite interpolation, thereby obtaining an interpolation function as a motion trajectory.