Adaptive Repair Welding Path for Weld Bead Defects
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Solution Overview
Problem
Existing welding technologies lack an efficient method for automatically repairing defective portions of welded workpieces produced by main welding, as they require pre-programmed repair welding programs and struggle with positional accuracy, especially when weld beads are thick or positional errors occur.
Innovation Solution
A repair welding device and method that acquires appearance inspection results to instruct a welding robot to execute repair welding based on the relationship between the defective portion's position and a predetermined width related to the weld bead, allowing for adaptive and accurate repair welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pre-programmed repair welding programs are used, then the welding robot can execute repair welding, but it cannot adapt to positional errors or thick weld beads, resulting in poor manufacturing precision
Solution Approach 1:
The patent implements a feedback mechanism where the inspection device detects the actual position and shape of the weld bead, and this information is fed back to the robot control device. The control device then adjusts the repair welding program based on this feedback, enabling the system to adapt to positional errors and achieve accurate repair welding. This closed-loop control resolves the contradiction by making the system both adaptable and precise.
Solution Approach 2:
The patent transforms the static pre-programmed welding path into a dynamic adaptive path. The robot control device generates a new welding program in real-time based on the detected weld bead position and shape, allowing the repair welding trajectory to dynamically adjust to actual conditions. This dynamic approach enables both adaptability to errors and maintenance of manufacturing precision.
2Productivity
If manual inspection and programming are used for repair welding, then positional accuracy can be achieved, but operational efficiency is reduced
Solution Approach 1:
The patent enables the system to perform self-inspection and self-correction. The inspection device automatically detects defects and their positions, and the robot control device automatically generates adjusted welding programs based on this information. This automated self-service process eliminates the need for manual inspection and programming, simultaneously achieving high operational efficiency and accurate defect position detection.
Solution Approach 2:
The patent replaces the manual mechanical process of inspection and program creation with an automated optical-mechanical system. The inspection device uses optical methods to detect weld bead positions, and the control device uses computational algorithms to generate welding programs, substituting manual operations with automated systems that achieve both high speed and high precision.
3Ease of operation
If the repair welding trajectory is fixed, then the welding robot can execute the program, but it may interfere with the workpiece or jigs when positional errors occur
Solution Approach 1:
The patent performs preliminary detection of the weld bead position and shape before executing the repair welding. The inspection device captures the actual state of the weld bead, and the control device uses this information to pre-adjust the welding trajectory to avoid fixed path interference with the workpiece or jigs. This preliminary action enables both ease of execution and prevention of harmful interference.
Data Source
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AI summary
A repair welding device includes an inspection result acquisition unit configured to acquire an appearance inspection result including information about a defective portion of a weld bead of a welded workpiece produced by a main welding that is executed by a welding robot, and a robot control unit configured to instruct the welding robot to execute a repair welding on a position of the defective portion using the appearance inspection result based on a relationship between the position of the defective portion and a predetermined width related to the weld bead.