Robot Repair Welding Using Inspection-Based Defect Positioning

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Solution Overview

Problem

Existing welding technologies lack the ability to automatically and efficiently repair welding defects in workpieces using a welding robot, as they require manual programming and struggle with positional accuracy and interference issues during repair welding.

Innovation Solution

A repair welding device and method that acquires appearance inspection results to instruct a welding robot to repair defects based on the relationship between the defect position and the weld bead, utilizing a host device, robot control device, and inspection control device to generate and execute repair welding programs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual programming is used for repair welding, then flexibility in handling defects is improved, but productivity and efficiency deteriorate

Engineering Contradiction:

Improveflexibility in handling defectsVSAvoidrepair welding efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system enables automatic repair welding by having the welding robot autonomously execute repair operations based on inspection data, eliminating the need for manual programming while maintaining adaptability to different defect positions and types

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system performs preliminary actions by capturing inspection data and pre-processing defect information before the actual repair welding, allowing the robot to automatically execute repairs without manual intervention during the repair process

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If manual programming is used for repair welding, then adaptability to different defect positions is improved, but device complexity and operation difficulty worsen

Engineering Contradiction:

Improveadaptability to different defect positionsVSAvoidprogramming complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system replaces manual programming operations with an automated information processing system that uses inspection data to automatically generate and execute repair welding programs, reducing operational complexity while maintaining adaptability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If manual programming is used for repair welding, then precision in defect location is improved, but time consumption and productivity worsen

Engineering Contradiction:

Improvedefect location accuracyVSAvoidrepair welding time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs preliminary capture and processing of inspection data that precisely identifies defect locations before the repair welding process, allowing automatic execution without manual measurement or programming time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses the inspection data to automatically determine and execute the precise defect location during repair welding, eliminating the time required for manual measurement and programming while maintaining high precision

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20260108990A1Repair welding device and repair welding method

Publication Date: 2026.04.23 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A repair welding device includes an inspection result acquisition unit configured to acquire an appearance inspection result including information about 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 instruct the welding robot to execute a repair welding on a position of the defective portion using the appearance inspection result based on a relationship between the position of the defective portion and a predetermined width related to the weld bead.