Orbital Welding Torch Motion Control Without Axis Tilting
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Solution Overview
Problem
Existing mechanized orbital welding systems require complex mechanical systems to adjust the work angle of the welding torch, leading to size and reliability issues due to the physical reorientation of motion axes.
Innovation Solution
A two-axis motion apparatus and motion controller system that adjusts the welding torch's height and oscillation direction independently, accounting for the work angle without tilting the apparatus, using software-controlled coordination and real-time feedback from a welding power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If physical reorientation of motion axes is used to adjust work angle, then welding torch angle can be changed, but device complexity increases and reliability decreases
Solution Approach 1:
The patent replaces the mechanical reorientation system with a software-based coordinate transformation system. The motion controller performs real-time calculations to convert torch position commands from the workpiece coordinate system to the robot base coordinate system, eliminating the need for physical reorientation mechanisms and their associated complexity
Solution Approach 2:
The system changes the parameter representation from physical orientation angles to coordinate system transformation matrices. By modifying how work angle is represented and calculated (through coordinate transformations rather than mechanical rotations), the system achieves angle adjustment without increasing mechanical complexity
2Adaptability or versatility
If physical reorientation of motion axes is used to adjust work angle, then welding torch angle can be changed, but system size increases
Solution Approach 1:
The patent eliminates bulky mechanical reorientation mechanisms by substituting them with software-based coordinate transformations. The motion controller performs real-time coordinate system conversions, replacing what would otherwise require large physical adjustment mechanisms and reducing overall system volume
3Manufacturing precision
If coordinated motion control of height and oscillation is implemented, then weld quality improves, but control complexity increases
Solution Approach 1:
The system implements feedback through the welding power source that provides real-time torch height information to the motion controller. This feedback loop enables automatic height adjustment during welding, improving weld quality while the coordinated control algorithms manage the complexity of simultaneous height and oscillation control
Solution Approach 2:
The motion controller performs multiple functions including coordinate transformations, height control, oscillation control, and synchronization with the welding power source. By consolidating these functions into a single controller, the system achieves precise coordinated motion without proportionally increasing overall system complexity
Data Source
AI summary
A mechanized welding system and associated methods are disclosed. The system includes a welding torch and a two-axis motion apparatus operatively connected to the welding torch and configured to move the welding torch in two independent axes of motion (e.g., X and Y) during an orbital welding procedure to produce at least one of a fillet weld or a groove weld on a workpiece. The system also includes a motion controller operatively connected to the two-axis motion apparatus. The motion controller is configured to control movement of the two-axis motion apparatus along the two axes of motion in a coordinated manner to continuously and simultaneously adjust the welding torch in a height direction and an oscillation direction with respect to the workpiece, while accounting for a physical work angle of the welding torch with respect to the workpiece, and without the two-axis motion apparatus having to be tilted with respect to the workpiece when the physical work angle is changed.