Offline Welding Teaching for Automatic Weld and Scan Updates
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Solution Overview
Problem
Welding operation and scanning operation teaching programs for welding robots require frequent updates due to changes in workpieces, leading to inefficient management and maintenance, as operators need to manually update both programs for each fine correction in teaching points.
Innovation Solution
An offline teaching device and method that acquires production data from welded workpieces, creates and updates welding and inspection teaching programs based on changes in the workpiece's welding line, allowing for automated generation of new programs to adapt to changes in workpiece dimensions and positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If operators manually update both welding and scanning teaching programs for each fine correction in teaching points, then the teaching programs can be updated to adapt to workpiece changes, but the time and effort required for program maintenance increases significantly
Solution Approach 1:
The patent combines the welding teaching program and scanning teaching program into a single integrated program structure. When workpiece changes occur, the system automatically updates both welding and scanning teaching points simultaneously based on the same workpiece data, eliminating the need for separate manual updates of each program and significantly reducing maintenance time.
Solution Approach 2:
The system implements automatic detection and update capabilities where the teaching program creation unit autonomously acquires workpiece data, detects changes in welding lines and scanning lines, and generates updated teaching programs without operator intervention. This self-service mechanism adapts to workpiece variations while minimizing human time investment.
2Manufacturing precision
If operators manually update teaching programs for each fine correction, then program accuracy can be maintained, but the complexity and burden of program management increases
Solution Approach 1:
The system automatically detects changes in workpiece geometry and recalculates teaching points for both welding and scanning operations. The teaching program creation unit autonomously compares new workpiece data with existing programs, identifies required corrections, and generates updated programs, thereby maintaining precision while eliminating the operational burden of manual management.
Solution Approach 2:
The system implements a feedback mechanism where the teaching program creation unit continuously monitors workpiece data, detects deviations from the original teaching program, and automatically generates corrective updates. This closed-loop approach ensures teaching point accuracy is maintained through automatic correction of any drift or changes, reducing the need for complex manual verification and management.
3Reliability
If frequent updates are made to teaching programs to adapt to workpiece changes, then the quality of welding operations is maintained, but the efficiency of operation decreases due to repeated manual interventions
Solution Approach 1:
The system autonomously handles the complete update cycle: acquiring new workpiece data, detecting changes in welding and scanning lines, calculating updated teaching points, and generating revised teaching programs. This self-service capability ensures welding quality is maintained through frequent adaptations while eliminating the productivity loss associated with repeated manual interventions.
Solution Approach 2:
The system performs preliminary automatic updates of teaching programs before actual welding operations begin. By proactively detecting workpiece changes and generating updated teaching programs in advance, the system ensures quality welding operations can proceed without interruption or delays caused by manual program updates during production, thereby maintaining both quality and productivity.
Data Source
AI summary
An offline teaching device provided with an acquisition unit for acquiring first production data about a workpiece to be produced, and a teaching program creation unit for acquiring a first weld line of the workpiece from the first production data, and creating and outputting a first welding teaching program for executing welding by means of a welding robot, and a first inspection teaching program for executing an inspection of a weld bead, wherein, on the basis of a second weld line, a second welding teaching program for a workpiece to be produced using second production data and a second inspection teaching program are created and output.