Overlay Welding Lamination Control for Variable Groove Shapes
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Solution Overview
Problem
Existing welding technologies face challenges in setting welding conditions for long welding operations, particularly in large structures, where groove shape variations and bending can lead to defects like undercuts and overlaps, and require frequent program changes, reducing efficiency and increasing difficulty.
Innovation Solution
A lamination design method that calculates reference groove shape data, determines the number of lamination layers and layer thickness, and sets welding conditions such as current, voltage, and travel speed based on this data to ensure consistent quality regardless of welding length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If welding is performed on large structures with long welding lengths, then the target welded structure size increases, but the groove processing accuracy and assembly accuracy deteriorate, causing groove shape variation and bending
Solution Approach 1:
The welding process is divided into multiple layers (lamination) with predetermined layer thicknesses and numbers. By segmenting the welding into discrete layers with controlled parameters, the system can compensate for groove shape variations and bending that occur in long welding operations on large structures, ensuring consistent weld quality despite deteriorating groove processing accuracy.
2Measurement precision
If the number of detection locations is increased to account for groove shape variation, then the measurement precision improves, but the device complexity and program complexity increase
Solution Approach 1:
The lamination design is performed in advance by predetermined values for layer thickness and number of layers based on reference groove shape data. This preliminary design accounts for expected groove shape variations without requiring complex real-time detection systems, simplifying the device while maintaining measurement precision through pre-calculated compensation parameters.
3Manufacturing precision
If welding conditions are manually adjusted for each welding location, then the manufacturing precision improves, but the productivity decreases due to frequent program changes
Solution Approach 1:
The system automatically determines welding conditions by changing parameters such as layer thickness, number of layers, and welding paths based on detected groove shapes. This automated parameter adjustment maintains manufacturing precision across different welding locations while eliminating the need for frequent manual program changes, thereby improving productivity.
4Productivity
If automatic welding is performed without considering groove shape variation, then the productivity increases, but the manufacturing precision deteriorates, causing defects like undercuts and overlaps
Solution Approach 1:
The system detects groove shapes at multiple locations and uses this feedback information to automatically adjust welding conditions including layer thickness, number of layers, and welding paths. This closed-loop feedback mechanism maintains manufacturing precision by compensating for groove shape variations while preserving the productivity benefits of automatic welding.
Data Source
AI summary
A lamination design method is capable of generally and easily setting welding conditions regardless of whether long welding is performed or not while securing welding quality. A lamination design method for performing multilayer overlay welding on a material to be welded provided with a groove shape using a welding robot includes: detecting a plurality of the groove shapes; calculating reference groove shape data based on a detected plurality of pieces of groove shape data; calculating at least the number of lamination layers and a layer thickness of each layer as reference lamination information based on the reference groove shape data; and calculating the number of lamination layers and a layer thickness of each layer as lamination information of each detection position based on the reference groove shape data, the groove shape data of each detection position, and the reference lamination information.