Offline Welding Teaching with 3D Scan Region Visualization
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Solution Overview
Problem
Current offline teaching devices for welding robots struggle to efficiently create scanning operation teaching programs, as they cannot visualize the three-dimensional scannable range linked with the robot's operation, leading to potential failures in scanning the intended area during appearance inspections.
Innovation Solution
An offline teaching device and method that acquire three-dimensional shape data of a workpiece and generate three-dimensional regions to be scanned by a sensor, allowing for the creation of a teaching program that accurately defines the scanning operation based on the disposed regions and operation trajectory, enabling efficient scanning by the welding robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional offline teaching devices are used to create scanning operation teaching programs, then the device complexity is reduced, but the manufacturing precision of the scanning operation deteriorates because the three-dimensional scannable range cannot be visualized
Solution Approach 1:
The patent transitions from two-dimensional display representations to three-dimensional virtual model representations of the scannable range. By constructing and displaying a 3D virtual model that visually represents the scanning range in spatial dimensions, the system enables operators to accurately understand and define the scanning area, thereby improving scanning operation precision without excessive increase in device complexity
Solution Approach 2:
The patent creates a virtual copy of the physical workpiece and scanning environment. By generating a virtual model that replicates the three-dimensional scannable range, the system allows operators to visualize and adjust scanning parameters in a virtual representation before executing actual scanning operations, improving precision while keeping the physical teaching device relatively simple
2Reliability
If the scanning range is not visualized in three-dimensional space, then the device complexity remains low, but the reliability of appearance inspection deteriorates due to potential failures in scanning the intended area
Solution Approach 1:
The patent performs preliminary visualization of the three-dimensional scannable range before actual scanning operations. By constructing and displaying the virtual model of the scanning range in advance, operators can identify and correct potential issues with scanning coverage before execution, thereby improving appearance inspection reliability without requiring complex real-time monitoring systems
Solution Approach 2:
The patent implements a feedback mechanism where the virtual model displays the calculated three-dimensional scannable range based on sensor specifications and robot trajectory. This visual feedback allows operators to verify that the scanning range covers the intended inspection areas, enabling corrective adjustments to be made before actual scanning, thus improving reliability
3Productivity
If manual creation of scanning teaching programs is used, then the device complexity is low, but the productivity of teaching program creation deteriorates due to time-consuming corrections
Solution Approach 1:
The patent implements automatic calculation and visualization of the three-dimensional scannable range based on sensor specifications and robot trajectory parameters. The system automatically generates the virtual model representation without requiring manual input or adjustment by operators, thereby improving teaching program creation efficiency while keeping the device complexity manageable through automated computations
Data Source
AI summary
An offline teaching device include an input unit that receives an operator operation, an acquisition unit that acquires three-dimensional shape data of a workpiece, an operation trajectory of the welding, and a scanning range of a sensor; a generation unit that generates three-dimensional regions to be scanned by the sensor based on the acquired scanning range and a scanning section; and a control unit that disposes at least one of the three-dimensional regions on the three-dimensional shape data of the workpiece based on the operator operation input to the input unit, and that creates and outputs, to a welding robot that performs the welding, a teaching program for scanning the three-dimensional region based on the disposed three-dimensional region and the operation trajectory of the welding.