Multi-Layer Overlay Welding Control With Single-Point Teaching
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Solution Overview
Problem
In multi-layer overlay welding, the time required for setting welding conditions increases with the size of the workpiece and weld length due to the need for multiple teaching or sensing points, which is not adequately addressed by existing technologies.
Innovation Solution
A welding control method and system that uses a welding robot, camera, and data processing device to determine welding conditions at the start position, adjust conditions based on image data during the first layer, and set teaching points for subsequent layers based on work information from the first layer, reducing the need for extensive pre-welding sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If teaching or sensing is performed at multiple points to ensure accurate welding conditions for multi-layer overlay welding, then welding quality is improved, but the time required for teaching or sensing increases significantly
Solution Approach 1:
The patent performs teaching or sensing at only one point before welding begins, rather than at multiple points during the process. This preliminary action at a single location establishes the teaching data that will be reused for all subsequent welding layers and positions, dramatically reducing the time required while maintaining welding accuracy through the controller's ability to apply this teaching data across the entire welding process
Solution Approach 2:
The teaching data obtained from a single point is made universal and applicable to all welding layers and positions. The controller stores this teaching data and reuses it for determining welding conditions across multiple layers, making the single-point teaching serve multiple functions and eliminating the need for repeated teaching at each layer or position
2Length of stationary object
If the size of the workpiece increases, then the weld length increases, but the number of teaching or sensing points required increases proportionally, making the process impractical for large workpieces
Solution Approach 1:
The system performs all necessary teaching or sensing actions before welding begins at a single location, rather than requiring proportional teaching points along the entire weld length. This preliminary single-point teaching establishes a reference that the controller can apply throughout the entire welding process, making the setup time independent of workpiece size and weld length
Solution Approach 2:
The teaching data obtained from one point is copied and reused for all subsequent welding operations. Instead of creating new teaching data for each position or layer, the system copies the original teaching data and applies it universally, making the condition setting process efficient regardless of how long the actual weld becomes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time required for condition setting and ensures accurate, automatic setting of welding conditions, improving efficiency and quality in multi-layer overlay welding.
Implementation Method 1
a camera, and a data processing device that processes image data obtained from the camera
Implementation Method 2
a welding robot... starts welding of a first layer based on the welding conditions
Data Source
AI summary
A welding control method for multi-layer overlay welding performed using a welding system including at least a welding robot, a robot control device that controls the welding robot, a camera, and a data processing device that processes image data obtained from the camera, includes: determining welding conditions at any position on a welding start side on a workpiece using the welding robot; starting welding of a first layer based on the welding conditions, receiving the image data obtained from the camera by the data processing device during welding of the first layer, outputting a feature value of the image data to the robot control device, and controlling at least one of the welding conditions based on the feature value by the robot control device; and determining teaching point information for second and subsequent layers based on work information obtained by control in the welding of the first layer.