Repair Welding Range Control for Consistent Defect Coverage
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Solution Overview
Problem
Current repair welding processes rely on human operators to determine the appropriate start and end points for repair welding, leading to inconsistent quality due to skill level differences and potential errors.
Innovation Solution
A repair welding control device and method that automatically determines the repair welding start and end points based on acquired information about defective portions, ensuring the repair welding range includes the defective area and a wider range for improved quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human operators manually determine repair welding start and end points, then flexibility and adaptability are maintained, but quality consistency and reliability deteriorate due to skill level differences and potential errors
Solution Approach 1:
The system enables self-service by allowing the repair welding control device to automatically determine the start and end points of repair welding based on inspection data, eliminating the need for manual operator judgment and ensuring consistent quality through automated decision-making
Solution Approach 2:
The patent replaces the mechanical system of manual measurement and judgment with an automated optical measurement system and control algorithm that calculates repair welding parameters based on detected defect information, thereby improving reliability through objective data-driven decisions
2Manufacturing precision
If the repair welding range is expanded wider than the defective portion, then welding quality is improved, but material consumption and processing time increase
Solution Approach 1:
The system dynamically adjusts the repair welding range parameters based on the detected defect characteristics, calculating the optimal start and end points to achieve sufficient welding quality while minimizing unnecessary material consumption and processing time
Data Source
AI summary
A repair welding control device includes a memory that stores instructions and a processor that executes the instructions. The instructions cause the processor to perform acquiring information indicating a range of a defective portion in main welding of a workpiece, and determining a repair welding start point indicating a start point of repair welding and a repair welding end point indicating an end point of the repair welding such that a repair welding range includes all the range of the defective portion and a range wider than the range of the defective portion.