Repair Welding Control Using Defect Ranking and Robot Feedback
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Solution Overview
Problem
Current repair welding methods require manual operation and are prone to instability due to individual skill variations and erroneous determinations, leading to inconsistent welding quality.
Innovation Solution
A repair welding system comprising an inspection device and a robot control device that automatically detects defective welds, assigns defect ranks, and generates repair welding programs to efficiently correct defects using integrated inspection and repair welding robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual operation is used for repair welding, then flexibility in handling different defect types is improved, but welding quality consistency deteriorates due to individual skill variations and erroneous determinations
Solution Approach 1:
The repair welding process is segmented into distinct phases: inspection phase (detecting defective portions and determining defect types), decision phase (determining whether repair welding is necessary based on defect type), and execution phase (performing repair welding). This segmentation allows automated robots to handle routine tasks consistently while maintaining flexibility for different defect types through programmed decision logic.
Solution Approach 2:
The system incorporates feedback mechanisms where inspection results (defect detection and classification) directly inform the repair welding execution. The inspection device provides real-time feedback on welded portion quality, enabling automated adjustment of repair parameters and ensuring consistent quality control across different defect types without relying on manual judgment variability.
2Reliability
If automated repair welding is implemented, then welding quality consistency is improved, but adaptability to different defect types deteriorates
Solution Approach 1:
The automated repair welding system is designed with multi-functionality to handle multiple defect types (defective penetration, defective shape, defective discontinuity) using a single integrated platform. The robot controller contains programmable logic that can adapt to different defect characteristics, enabling one automated system to perform multiple repair functions while maintaining consistent quality standards across all defect types.
Solution Approach 2:
The system automatically adjusts welding parameters (current, voltage, speed, torch position) based on the detected defect type and characteristics. This dynamic parameter modification allows the automated system to adapt its welding process to different defect scenarios while maintaining quality consistency, resolving the contradiction between automation and adaptability.
3Measurement precision
If comprehensive inspection of all welded portions is performed, then defect detection accuracy is improved, but inspection time and system complexity deteriorates
Solution Approach 1:
The inspection system focuses on local quality assessment by specifically examining welded portions that exhibit abnormal characteristics or are prone to defects. Rather than uniformly inspecting all welded portions with equal detail, the system applies enhanced inspection to critical areas while using faster scanning for routine areas, improving detection accuracy for actual defects while reducing overall inspection time.
Solution Approach 2:
The system performs partial inspection in the sense that it prioritizes inspection of welded portions based on risk assessment and defect probability. By concentrating inspection resources on portions most likely to contain defects or those with critical quality requirements, the system achieves high detection accuracy for actual defects without the time cost of exhaustive inspection of every welded portion at maximum detail.
Data Source
AI summary
A repair welding system includes an inspection device configured to inspect an appearance of a welded portion of a workpiece, and a robot control device that controls a robot configured to weld the workpiece. The inspection device determines whether there is a defective portion among welded portions of the workpiece based on a predetermined standard, and sets one of a plurality of defect ranks to the defective portion in a case that the defective portion is detected. The robot control device generates a repair welding program corresponding to the defect rank, and instructs the robot to execute, in accordance with the repair welding program, a repair welding on the defective portion to which the defect rank is set.