Robot Contour Welding with Sensor-Based Vector Correction
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Solution Overview
Problem
Existing robotic welding systems face inaccuracies when working with body parts that have tolerances and deformations, as they rely on mean positional vectors which can result in significant deviations from the actual contour, leading to suboptimal seam welding and sealing.
Innovation Solution
A process that involves positioning both ideal and real workpieces, acquiring contour data at predefined points using sensors, calculating individual displacement vectors to correct the robot's motion, and actuating the robot accordingly to match the tool's motion to the real contour, thereby compensating for tolerances and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mean positional vector is calculated from camera recordings to correct robot motion, then the robot can compensate for tolerances and deformations, but the robot tip does not travel exactly along the contour, resulting in significant deviations from the actual contour
Solution Approach 1:
The patent divides the contour into multiple predefined measurement points and calculates individual displacement vectors for each point rather than using a single mean positional vector. This segmentation allows the robot tip position to be corrected at each specific point along the contour, ensuring accurate travel along the actual contour while compensating for tolerances and deformations.
2Adaptability or versatility
If the robot is programmed to follow a curved contour line, then welding and sealing operations can be performed on complex body shapes, but deviations occur due to tolerances and deformations in real workpieces
Solution Approach 1:
The patent performs preliminary measurement of the actual contour at multiple predefined points using cameras before the robot executes the welding or sealing operation. Displacement vectors are calculated in advance based on the deviation between the ideal and actual contours, and these vectors are stored for robot compensation during the actual working process, ensuring accurate seam welding and sealing on complex body shapes.
Solution Approach 2:
The patent uses camera recordings to capture the actual contour position and compares it with the ideal contour from the CAD model. The displacement vectors derived from this comparison provide feedback to the robot control system, which then adjusts the robot tip position in real-time to follow the actual contour accurately, maintaining precision in seam welding and sealing operations.
3Manufacturing precision
If individual displacement vectors are calculated for each predefined point on the contour, then the robot tip follows the actual contour more accurately, but the process complexity increases compared to using a mean positional vector
Solution Approach 1:
The patent segments the contour into multiple predefined measurement points, calculating individual displacement vectors for each point. This segmentation approach improves accuracy by addressing local variations in the contour, and the modular structure of processing each point independently makes the increased complexity manageable through systematic organization.
Solution Approach 2:
The patent changes the parameter approach from a single mean positional vector to multiple individual displacement vectors, each with specific x, y, z components for predefined points. This parameter change enables more precise control of the robot tip position, and the structured storage and application of these vectors streamline the process despite the increased number of parameters.
Data Source
AI summary
A process for working a contour on at least one workpiece using a robot includes positioning the workpiece relative to the robot; acquiring an actual position of the workpiece; acquiring a real course of the contour on the workpiece at predefined points using at least one sensor; and actuating the robot according to individual vectors so as to correct a robot motion during the working of the contour.