Repair Welding Program Correction for Consistent Weld Quality
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Solution Overview
Problem
Existing repair welding processes rely heavily on human operators to determine and execute repair welding, leading to inconsistent quality due to skill level differences and potential errors.
Innovation Solution
A repair welding control device and method that uses a processor to acquire repair portion information and generate or determine a second welding program based on this information, enabling automated repair welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated repair welding control is implemented, then welding quality consistency is improved, but device complexity increases
Solution Approach 1:
The system creates a copy of the original welding program and modifies it to generate a repair welding program. This copying approach allows the complex control logic to be replicated and adapted without requiring entirely new control systems, thereby improving welding quality consistency while managing device complexity through program replication rather than hardware complexity.
Solution Approach 2:
The system automatically adjusts welding parameters based on defect information from inspection results. By changing parameters such as welding current, voltage, speed, and position coordinates in the program, the system achieves consistent repair quality without requiring complex manual intervention, resolving the contradiction between quality consistency and control complexity.
2Device complexity
If manual repair welding is used, then device complexity is reduced, but welding quality stability deteriorates
Solution Approach 1:
The system performs self-correction by automatically generating repair welding programs based on inspection results without requiring manual programmer intervention. The control device itself services the defect correction process, improving welding quality stability while keeping the device complexity manageable through software-based self-adjustment rather than complex hardware systems.
Solution Approach 2:
The system uses inspection results as feedback to automatically adjust the welding program. The defect information from inspection feeds back into the program generation process, creating a closed-loop system that ensures welding quality stability without requiring complex manual quality control mechanisms.
3Productivity
If automated program correction is implemented, then productivity is improved, but measurement precision requirements increase
Solution Approach 1:
The system performs preliminary inspection and defect detection before generating the repair welding program. By conducting the measurement and analysis in advance, the system can automatically create accurate repair programs without requiring ultra-high precision measurement during the actual repair process, thereby improving productivity while managing measurement precision requirements through advance detection.
Data Source
AI summary
A repair welding control device includes a processor. The processor is configured to acquire repair portion information indicating a welded portion where repair welding is performed among welded portions in a workpiece welded by a first welding program, and generate a second welding program by correcting the first welding program based on the repair portion information.