3D Offline Teaching for Weld Line Robot Scanning
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Solution Overview
Problem
Current offline teaching devices struggle to visualize a three-dimensional scannable range and posture of inspection robots during appearance inspection, leading to potential failures in scanning the intended area, requiring skilled operators to create complex scanning programs for multiple welding portions or lines.
Innovation Solution
An offline teaching device that acquires position information of welding lines and scanning ranges, generates a three-dimensional region, and creates an auxiliary screen to visualize the welding line and region in a virtual space, allowing operators to create and edit scanning programs for robots to scan these regions efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If operators manually create complex scanning programs for multiple welding portions, then scanning coverage is improved, but operator skill requirements and program complexity increase
Solution Approach 1:
The system automatically divides the workpiece into multiple welding portions and generates separate scanning programs for each portion. This segmentation allows comprehensive scanning coverage without requiring operators to manually create complex unified programs, as the system handles the division and program generation automatically based on welding line positions and sensor scanning ranges.
2Manufacturing precision
If traditional offline teaching devices are used without 3D visualization, then device simplicity is maintained, but scanning accuracy and reliability deteriorate
Solution Approach 1:
The system introduces three-dimensional visualization to display welding lines, sensor scanning ranges, and generated scanning programs. This 3D representation allows operators to verify scanning accuracy and coverage before execution, significantly improving scanning precision while the automated generation processes keep the overall system complexity manageable.
3Reliability
If skilled operators create scanning programs, then program quality is improved, but operator skill requirements increase
Solution Approach 1:
The system performs automatic program generation by acquiring welding line position information and sensor scanning range data, then autonomously creating scanning programs for each welding portion. This self-service capability ensures high program quality through automated calculation and verification, while reducing operator skill requirements as the system handles the complex programming tasks automatically.
4Reliability
If multiple scanning programs are created for different welding portions, then scanning completeness is improved, but creation time and productivity decrease
Solution Approach 1:
The system performs preliminary automatic generation of multiple scanning programs by acquiring welding line positions and sensor scanning ranges before actual scanning execution. This preliminary action ensures all welding portions are covered in the scanning plan, while the automated generation process completes the program creation quickly, improving both scanning completeness and creation efficiency.
Data Source
AI summary
This offline teaching device includes an input unit capable of receiving an operator operation; an acquisition unit that acquires position information pertaining to a weld line of a workpiece and the scan range of a sensor for scanning the external shape of the workpiece; a generation unit that generates a three-dimensional region to be scanned by the sensor on the basis of the position information pertaining to the weld line and the scan range; and a control unit that generates and outputs an assistance screen image in which the weld line and the three-dimensional region are disposed in a virtual space, and that creates and outputs, on the basis of the operator operation, a teaching program for causing a robot that drives the sensor to scan the three-dimensional region shown in the assistance screen image.