Remote Welding Torch Positioning With Contact Detection Feedback
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Solution Overview
Problem
Existing remote operation welding systems face challenges in performing delicate manual operations due to limited visual sensors, blind spots, and difficulty in recognizing the area of interest, which can lead to damage to the welding robot.
Innovation Solution
A remote operation method and system that includes acquiring image data using multiple imaging devices, displaying it on a display device, receiving instructions via an operation terminal, and adjusting the welding torch's position based on contact detection to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If one visual sensor is attached to the distal end of the welding robot, then the structure is simple, but blind spots occur and it is difficult to perform various works appropriately
Solution Approach 1:
The patent divides the visual monitoring function into multiple independent visual sensors positioned at different locations. Each sensor covers a specific area, and together they provide comprehensive coverage without requiring a single complex sensor system. This segmentation allows the system to eliminate blind spots while maintaining manageable complexity.
Solution Approach 2:
The patent transitions from a single-point visual sensor at the distal end to multiple sensors distributed across different spatial dimensions and locations. By adding spatial distribution as a new dimension, the system achieves comprehensive visual coverage that cannot be obtained from a single location, solving the blind spot problem.
2Ease of operation
If the welding robot is operated remotely without contact detection, then the operation is simple, but damage to the welding robot may occur
Solution Approach 1:
The patent implements a contact detection function that provides real-time feedback to the remote operator. When the welding torch contacts a workpiece or surrounding components, the system immediately notifies the operator, enabling timely corrective action. This feedback mechanism prevents damage while maintaining simple remote operation.
Solution Approach 2:
The welding robot performs self-monitoring through the contact detection function, automatically detecting contact conditions without requiring external monitoring equipment. This self-service capability enhances reliability by preventing damage through automated detection while keeping the operation interface simple.
3Device complexity
If image data is not clearly obtained, then the imaging system is simple, but the area of interest cannot be recognized with sufficient clarity
Solution Approach 1:
The patent combines multiple imaging functions and data sources into a unified visual presentation system. By merging images from multiple sensors and overlaying contact detection information, the system provides clear recognition of the area of interest without requiring complex individual imaging components.
Solution Approach 2:
The patent introduces an image processing and display intermediary that enhances the clarity of the area of interest. This intermediary processes raw image data from multiple sensors, applies appropriate enhancements, and presents optimized visual information to the operator, improving recognition clarity without complicating the basic imaging system.
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
Enables accurate and safe remote manual operation of welding robots by enhancing visibility and preventing contact with surrounding components, thus supporting precise manual operations.
Implementation Method 1
a process of receiving, from an operator via an operation terminal, an instruction to execute a contact detection function by a welding torch of the welding robot
Data Source
AI summary
A remote operation method for a welding system enabling manual operation of a welding robot includes: capturing image data for a certain position using one or more imaging devices, displaying the image data using a display device, receiving, from an operator via an operation terminal, an instruction to execute a contact detection function by a welding torch of the welding robot, moving the welding torch during execution of the contact detection function on the basis of the instruction given to the welding robot and received via the operation terminal, and adjusting, if the welding torch has detected contact with a surrounding component by the contact detection function, the position of the welding torch on the basis of the position of contact.