Remote Robotic Welding With Ultra-Low-Latency Motion Control
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Solution Overview
Problem
Human welders with expertise in specific types of welding are often unavailable when needed, leading to downtime and safety issues, especially in inhospitable environments or remote locations.
Innovation Solution
A system for long distance, real-time remote welding that allows a human welder to control a robotic welding system using a mock welding tool, with ultra-low-latency communication ensuring synchronized movements and feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a human welder travels to the remote location to perform welding operations, then welding expertise can be applied directly, but travel time increases and safety risks are incurred in inhospitable environments
Solution Approach 1:
The system creates a virtual copy of the welding environment through video feeds and audio transmissions, allowing the expert welder to operate remotely as if present. The mock welding tool replicates the physical welding tool's functions, and the head-mounted display reproduces the visual and auditory experience of being at the remote location, enabling expert-level welding without physical travel.
Solution Approach 2:
The system introduces multiple intermediaries between the expert welder and the remote welding site: video cameras transmit visual information, microphones transmit audio, the mock welding tool transmits control signals, and the head-mounted display transmits sensory feedback. These intermediaries enable real-time remote operation while maintaining welding quality and eliminating travel time.
2Ease of operation
If video communication is used for remote welding control, then real-time monitoring is enabled, but communication latency causes cyber sickness
Solution Approach 1:
The system changes the latency parameter of the communication channel by using optimized video transmission protocols and processing methods. The video feed is processed with minimal delay, and the head-mounted display presents visual information with timing adjustments that synchronize with the operator's movements, reducing latency-induced discomfort and preventing cyber sickness while maintaining real-time control capability.
3Productivity
If expert welders are deployed to remote locations, then critical repairs can be performed, but exposure to hazardous environmental factors increases safety risks
Solution Approach 1:
The system extracts the expert welder from the hazardous environment and places them in a safe, controlled location. The welding operations are performed by a robotic system or local operator at the remote site, while the expert provides guidance and control from a safe distance through the remote interface system, eliminating exposure to environmental hazards while maintaining repair capability.
4Ease of operation
If long distance remote control is implemented, then access to remote locations is enabled, but communication delays increase
Solution Approach 1:
The system performs preliminary actions by pre-processing video feeds, pre-positioning robotic components, and pre-synchronizing communication protocols before remote operation begins. The mock welding tool is calibrated in advance to match the remote welding tool's characteristics, and communication channels are tested and optimized beforehand, reducing operational delays and improving responsiveness despite long distances.
Data Source
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AI summary
Embodiments of systems (100) and methods for remotely controlling a robotic welding system (200) over a long distance in real time are disclosed. One embodiment is a method that includes tracking movements and control of a mock welding tool (310) operated by a human welder at a local site and generating control parameters corresponding to the movements and control. The control parameters are transmitted from the local site to a robotic welding system (200) at a remote welding site over an ultra-low-latency communication network (400). The round-trip communication latency over the ultra-low-latency communication network (400) is between 0.5 milliseconds and 10 milliseconds, and a distance between the local site and the remote welding site is at least 10 kilometers. An actual welding operation of the robotic welding system (200) is controlled to form a weld at the remote welding site via remote robotic control of the robotic welding system (200) in response to the control parameters.