Molten Pool Image Feedback for Disturbance-Resistant Automatic Welding
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Solution Overview
Problem
Automated welding systems face challenges in maintaining welding quality and efficiency, particularly in difficult positions like horizontal, vertical, and overhead, due to disturbances such as misalignment, gas flow rate variations, magnetic arc blow, and other factors, which existing technologies fail to adequately address.
Innovation Solution
A welding control method that acquires image data of the molten pool, identifies feature points, calculates geometric quantity data, determines the appropriateness of the weld based on threshold values, and corrects welding conditions in real-time to mitigate disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic welding is implemented in difficult positions (horizontal, vertical, overhead), then productivity and labor savings are improved, but welding quality becomes unstable due to disturbances such as misalignment, magnetic arc blow, and gas flow rate variations
Solution Approach 1:
The patent implements real-time feedback control by monitoring welding parameters (arc voltage, current, wire feeding speed) and adjusting them dynamically to compensate for disturbances. The control device receives sensor data during welding and automatically modifies welding conditions to maintain stable molten pool behavior and welding quality, resolving the contradiction between automated productivity and quality stability.
Solution Approach 2:
The system dynamically changes welding parameters (voltage, current, wire feeding speed, torch position) in response to detected disturbances. By continuously adjusting these parameters based on real-time monitoring, the system maintains welding quality stability across difficult positions while preserving automated productivity benefits.
2Manufacturing precision
If touch sensing is used to detect misalignment before welding, then welding quality is improved, but the number of sensing points increases and welding work efficiency decreases
Solution Approach 1:
The system performs preliminary alignment detection using touch sensing at critical points before welding begins, establishing baseline position data. This preliminary action allows the real-time control system to focus on compensating for deviations from this baseline during welding, rather than continuously measuring all alignment parameters, thus maintaining precision while improving efficiency.
Solution Approach 2:
The patent replaces extensive mechanical touch sensing with optical or electromagnetic sensing during the welding process. This substitution reduces the number of physical sensing points required while maintaining detection accuracy, thereby improving welding work efficiency without sacrificing manufacturing precision.
3Reliability
If real-time disturbance detection is implemented, then welding quality is maintained, but device complexity increases
Solution Approach 1:
The control device performs multiple functions using integrated sensors and processing: it monitors arc voltage, current, wire feeding speed, and torch position simultaneously, and adjusts all these parameters through a unified control algorithm. This multi-functionality reduces the need for separate dedicated devices for each monitoring and adjustment task, thereby maintaining welding quality while limiting the increase in overall device complexity.
4Manufacturing precision
If welding parameters are continuously adjusted to compensate for disturbances, then welding quality is improved, but the complexity of control increases
Solution Approach 1:
The control system uses self-service by automatically detecting disturbances and adjusting welding parameters without external intervention. The integrated control algorithm processes sensor data and modifies welding conditions autonomously, reducing the need for complex external control mechanisms and operators, thereby improving welding quality while managing control complexity through automation.
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
Ensures high welding quality and efficiency even in situations with disturbances, by enabling real-time adjustments to maintain optimal welding conditions.
Implementation Method 1
welding to form a molten pool
Data Source
AI summary
A welding control method for welding to form a molten pool, the method including: an acquisition step for acquiring image data including the molten pool; an identifying step for identifying, on the basis of the acquired image data, a plurality of feature points near a boundary between the molten pool and an unmolten portion at least on the side in the direction of welding progress; a calculating step for calculating geometric quantity data on the basis of information about the plurality of feature points; a determining step for determining whether a weld is appropriate or inappropriate on the basis of the geometric quantity data and a predetermined threshold value; and a correcting step for correcting the welding conditions on the basis of a result of the determination in the determining step.