Marker-Guided Welding Torch Feedback for Accurate Arc Positioning
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Solution Overview
Problem
Welding technologies face challenges in ensuring consistency and accuracy due to reliance on skilled operators, leading to issues with manpower costs, safety, and human errors, which affect the quality and efficiency of the welding process.
Innovation Solution
A welding system that includes a welding information providing device and a welding torch equipped with markers and sensors, which generate and display real-time information on the welding location and situation, providing guidance for operators to improve accuracy and safety through automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual welding operation is used, then flexibility and adaptability are maintained, but welding accuracy and consistency deteriorate
Solution Approach 1:
The system uses cameras to capture images of the welding workpiece and welding torch, processes these images to detect welding position and torch attitude, and provides real-time feedback through display units and audio outputs. This closed-loop feedback system enables automated welding operations to maintain high accuracy by continuously monitoring and adjusting based on actual welding conditions.
Solution Approach 2:
The patent replaces manual mechanical welding operations with an automated system that uses image processing and computer vision to detect welding positions and control torch movement. The mechanical welding task is substituted with an automated control system that processes visual information to achieve precise welding without manual intervention.
2Reliability
If skilled welding operators are used, then welding quality can be maintained, but manpower costs and safety issues increase
Solution Approach 1:
The welding system performs self-detection and self-correction by automatically capturing images, processing welding position data, and adjusting torch movement without human intervention. The system serves itself by using its own sensors and processors to maintain welding quality consistency, eliminating the need for skilled operators to make real-time adjustments.
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the welding torch and the workpiece. This intermediary captures visual information, processes it to determine welding positions and torch attitudes, and translates this information into controlled welding actions, thereby maintaining quality consistency without requiring human skill.
3Productivity
If automated welding is implemented, then productivity and consistency improve, but system complexity and initial costs increase
Solution Approach 1:
The welding system integrates multiple functions into a single automated platform: image capture, image processing, welding position detection, torch attitude detection, and real-time control. This multi-functional system achieves high productivity by consolidating what would otherwise require separate devices and operations into one integrated automated welding solution.
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
The system enhances welding accuracy and quality by providing real-time feedback and guidance, improving operator safety and reducing errors, while also enabling faster and more consistent welding operations through automation.
Implementation Method 1
a welding rod extending from the welding body and configured to generate an electric arc in a welding base material
Data Source
AI summary
A welding system includes a welding information providing device configured to generate and display information related to welding and a welding torch configured to generate an electric arc in a welding base material. The welding torch includes a first panel unit having mounted thereon a marker configured to identify a welding location.