Repair Welding Positioning From Weld Bead Inspection Feedback
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Solution Overview
Problem
Existing welding technologies lack the ability for a welding robot to automatically execute repair welding on defective portions of a workpiece based on appearance inspection results, often resulting in incomplete or inaccurate repairs due to positional inaccuracies and interference issues.
Innovation Solution
A repair welding device and method that acquires appearance inspection results to instruct a welding robot to repair defective portions by aligning the repair welding position with a predetermined width relative to the weld bead, using a system comprising a host device, robot control device, inspection control device, and welding robots to generate and execute precise repair welding programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a welding robot executes repair welding on defective portions, then the defective portions can be repaired, but positional inaccuracies cause incomplete or inaccurate repairs
Solution Approach 1:
The system captures images of the weld bead, detects its actual position and shape, and feeds this information back to the robot control device. The control device then adjusts the repair welding position based on this feedback, enabling accurate repair despite initial positioning errors. This closed-loop feedback mechanism directly resolves the positioning accuracy problem.
Solution Approach 2:
The system performs preliminary imaging and detection of the weld bead position before executing the repair welding. By capturing the weld bead's actual location and dimensions in advance, the system can pre-calculate the appropriate repair welding parameters and position, ensuring accurate repair execution. This preliminary action prevents positioning errors from causing incomplete repairs.
2Ease of manufacture
If repair welding is executed without considering weld bead width, then the process is simplified, but the repair positioning becomes inaccurate
Solution Approach 1:
The system measures the actual weld bead width through image processing and feeds this information back to determine the repair welding position. By using the detected weld bead width as a reference, the system automatically calculates the optimal repair position without requiring complex manual measurements or calculations, thus maintaining process simplicity while achieving high precision.
Solution Approach 2:
The system uses the weld bead's own characteristics (its width and position as captured by the imaging device) to determine the repair welding parameters. The weld bead essentially serves itself as the reference for its own repair, eliminating the need for external measurement tools or complex positioning calculations, thereby simplifying the process while ensuring accuracy.
3Productivity
If automatic repair welding is implemented, then productivity increases, but interference issues arise between the welding robot and workpiece
Solution Approach 1:
The system transitions from traditional two-dimensional robot motion control to three-dimensional spatial coordination by incorporating the weld bead's actual position and shape data. The robot control device calculates the repair welding position in 3D space, considering the workpiece geometry and robot approach angle, thereby avoiding interference while maintaining automatic operation efficiency.
Data Source
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.