Robot Programming Method for Arc Welding with Laser Sensor Detection
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Solution Overview
Problem
In environments where workpiece displacements are minimal, existing methods that rely on position detection sensors for arc welding robots increase cycle time and costs due to the need for multiple sensors and continuous detection during tasks.
Innovation Solution
A programming method for arc welding robots that involves inputting sensing instructions at specific points, storing these with corresponding positions, and using the sensor for detection, allowing the robot to acquire workpiece locations and store them in a task program, enabling machining without continuous sensor use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous sensor detection is used during actual welding tasks, then workpiece position accuracy is maintained, but cycle time increases and power consumption rises
Solution Approach 1:
The patent applies preliminary action by performing sensor detection and workpiece position acquisition during the teaching phase before actual welding tasks. The robot learns the workpiece position and shape characteristics in advance, storing this information for later use. This eliminates the need for continuous detection during actual welding, thereby maintaining position accuracy while reducing cycle time and power consumption.
2Reliability
If multiple position detection sensors are mounted on the robot for each welding task, then detection reliability is improved, but device complexity and costs increase
Solution Approach 1:
The patent implements universality by designing a sensor system that can be shared across multiple robots rather than dedicating separate sensors to each robot. The sensor acquires workpiece position and shape information that is stored and reused by different robots performing welding tasks on the same workpiece, reducing the total number of sensors required while maintaining detection reliability.
Solution Approach 2:
The patent applies copying by creating a digital model or stored representation of the workpiece geometry and position characteristics during the teaching phase. This copied information is then used by the robot to guide welding operations without requiring continuous physical sensor contact, reducing hardware complexity while maintaining accuracy.
3Ease of manufacture
If rough taught data is created beforehand and corrected in real-time using sensors, then teaching tasks are simplified, but actual task cycle time increases due to continuous detection
Solution Approach 1:
The patent resolves this contradiction by performing all necessary sensor-based workpiece analysis and position correction during the teaching phase in advance. The rough taught data is refined using sensor detection before actual welding begins, eliminating the need for real-time detection during welding operations. This maintains teaching simplicity while avoiding time loss during production.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies teaching tasks and reduces actual task cycle time by eliminating the need for continuous sensor detection, allowing one sensor to be shared among robots and reducing power consumption.
Implementation Method 1
a laser sensor for detecting a position of a characteristic site of the workpiece
Data Source
Figure 1~2B
Figure 3
Figure 4~5
AI summary
An operator inputs a sensing instruction at a sensing point, which is a rough taught point, in a teaching mode (S22). The instruction and sensing point are stored in a second storage region 23b (S23). Further, a target angle and an advance/retraction angle are both input in the second storage region 23b (S24). A CPU 20 moves a robot to the sensing point (S33) in a sensing mode, to perform detection tasks by a laser sensor, thereby acquiring the shape of a workpiece (S33). The CPU 20 calculates a position and a posture of a welding torch to create a task program (S35). In such a manner, it is possible to greatly simplify teaching tasks in an environment free of workpiece displacements.