Repair Welding Path Alignment for Accurate Defect Rework
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Solution Overview
Problem
Existing welding robots lack the ability to automatically and efficiently perform repair welding on defective portions of welded workpieces produced by main welding, due to inaccuracies in detecting the defective portion's position and interference issues with the welding robot's operation trajectory.
Innovation Solution
A repair welding device and method that acquires appearance inspection results to identify defective portions and sets interpolation points on a virtual welding line based on the main welding program, allowing the welding robot to execute repair welding on the closest interpolation point to the defective area, thereby stabilizing the operation and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the welding robot directly repairs the detected defective position, then the repair accuracy should be high, but the operation trajectory may interfere with the main welding path causing conflicts
Solution Approach 1:
The welding line is divided into multiple discrete interpolation points that can be independently selected for repair. This segmentation allows the repair operation to target specific points without conflicting with the continuous main welding trajectory, resolving the operational interference problem while maintaining precise defect location targeting.
Solution Approach 2:
Interpolation points serve as intermediary targets between the detected defective position and the actual repair welding operation. Instead of directly welding at the detected defect location, the system uses pre-calculated interpolation points on the welding line as mediation, which eliminates trajectory conflicts while maintaining repair accuracy.
2Extent of automation
If manual inspection and repair methods are used, then flexibility is maintained, but automation level and efficiency are low
Solution Approach 1:
The system achieves self-service automation by automatically detecting defects, calculating the nearest interpolation points on the welding line, and executing repair welding without manual intervention. The welding robot autonomously navigates to interpolation points and performs repair operations, significantly improving both automation level and productivity compared to manual methods.
Solution Approach 2:
The system implements feedback control by detecting actual defective positions, comparing them with planned welding trajectories, and automatically adjusting repair operations to target the correct interpolation points. This closed-loop feedback mechanism enables high-level automation while maintaining repair accuracy and efficiency.
3Manufacturing precision
If repair welding is performed at the exact detected defective position, then repair precision is maximized, but positional inaccuracies and trajectory conflicts occur
Solution Approach 1:
The system performs preliminary calculation of interpolation points along the welding line before executing the repair operation. By pre-determining valid target positions that avoid trajectory conflicts, the system ensures both positional accuracy for repair precision and operational reliability without conflicts during execution.
Solution Approach 2:
The system dynamically adjusts the repair target from the statically detected defect position to dynamically calculated interpolation points that account for real-time operational constraints. This dynamic adaptation maintains manufacturing precision while improving operation stability by avoiding conflicting trajectories.
Data Source
AI summary
A repair welding device includes an acquisition unit configured to acquire an appearance inspection result including information about a position of 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 set a plurality of interpolation points on a virtual welding line of the main welding executed by the welding robot and instruct the welding robot to execute a repair welding on an interpolation point that is closest to the acquired position of the defective portion. The virtual welding line is simulated based on a main welding program for executing the main welding.