Remote Robotic Welding With Ultra-Low-Latency VR Control
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Solution Overview
Problem
Human welders face challenges in accessing critical structures due to distance and hazardous environments, leading to downtime and safety issues, as expert welders may not be readily available, especially in inhospitable locations like space or areas with harsh environmental conditions.
Innovation Solution
A system enabling remote welding through a human welder controlling a robotic welding torch via an ultra-low-latency communication network, allowing real-time control of a robotic welding system at a remote location using a mock welding tool and head-mounted display, with sensors and feedback mechanisms to maintain precise control and minimize latency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a human welder travels to a remote location to perform welding operations, then the welding quality and expertise are ensured, but the travel time and downtime increase significantly
Solution Approach 1:
The system creates a virtual copy of the welding environment through VR technology, allowing the welder to operate remotely as if physically present. The mock welding tool replicates the actual welding torch's movements and sensations, while the VR headset reproduces the visual and auditory environment, enabling expert welding quality without physical travel
Solution Approach 2:
The patent introduces a robotic arm as an intermediary between the welder and the workpiece. The robotic arm executes the welding operations based on commands from the welder's mock tool, acting as a mechanical mediator that transfers the welder's intentions to the remote location with high precision, eliminating the need for the welder to physically travel
2Reliability
If a human welder works in an inhospitable environment, then the repair can be performed on-site, but the safety risks and environmental hazards increase
Solution Approach 1:
The system creates a virtual replica of the hazardous environment through the VR headset, allowing the welder to experience and navigate the environment safely from a remote location. The haptic feedback in the mock welding tool provides tactile information about the workpiece without requiring physical contact with hazardous materials
Solution Approach 2:
The robotic arm is equipped with sensors and actuators that allow it to autonomously position itself and execute welding movements based on the welder's commands. The system performs the dangerous work autonomously while the welder provides supervisory control from a safe location, effectively making the robotic system serve the hazardous environment
3Object-affected harmful factors
If remote welding control is implemented over long distances, then the welder's safety is improved, but the communication latency increases causing cyber sickness
Solution Approach 1:
The system performs preliminary actions by pre-rendering the virtual environment and pre-positioning the robotic arm based on anticipated welder movements. The VR environment is prepared in advance, and the robotic system is positioned ready before the welder begins operations, reducing the perceived latency by having systems ready ahead of time
Solution Approach 2:
The system implements real-time feedback loops where the robotic arm's actual position and the VR environment are continuously updated based on the welder's movements. This closed-loop feedback synchronizes the virtual and physical worlds, preventing the sensory mismatch that causes cyber sickness while maintaining long-distance safety
4Object-affected harmful factors
If a robotic welding system is used remotely, then the welder can work from a safe location, but the complexity of the control system increases
Solution Approach 1:
The mock welding tool is designed as a universal interface that combines VR headset, haptic feedback mechanisms, and motion tracking in a single device. This multi-functional tool simplifies the overall system complexity by consolidating multiple control and sensing functions into one integrated unit that the welder interacts with naturally
Data Source
AI summary
Embodiments of systems and methods for remotely controlling a robotic welding system 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 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 at a remote welding site over an ultra-low-latency communication network. The round-trip communication latency over the ultra-low-latency communication network is between 0.5 milliseconds and 20 milliseconds, and a distance between the local site and the remote welding site is at least 50 kilometers. An actual welding operation of the robotic welding system is controlled to form a weld at the remote welding site via remote robotic control of the robotic welding system in response to the control parameters.