Robot Repair Welding Control for Ranked Weld Defects
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Solution Overview
Problem
Current repair welding methods for defective weld beads require manual operation, leading to unstable welding quality due to individual differences and skill-level variations among welding operators.
Innovation Solution
A repair welding system comprising an inspection device and a robot control device that automatically identifies defective weld beads, assigns defect ranks, generates repair welding programs, and instructs a robot to execute the repair welding, thereby enhancing efficiency and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used for repair welding, then flexibility in handling defective portions is improved, but welding quality stability deteriorates due to individual differences and skill-level variations
Solution Approach 1:
The system enables automatic repair welding where the robot performs the welding operation autonomously based on inspection results and pre-stored programs, eliminating the need for manual intervention while maintaining consistent quality across different defective portions
Solution Approach 2:
The system stores multiple welding programs with different parameters corresponding to various defect ranks, and automatically selects and executes the appropriate program based on the inspected defect severity, thereby adapting the welding parameters to match the specific defect conditions without manual adjustment
2Reliability
If automatic repair welding is implemented, then welding quality stability is improved, but device complexity increases due to integration of inspection and control systems
Solution Approach 1:
The system integrates the inspection device, defect ranking determination, program selection, and welding execution functions into a unified automated system, where the robot control device coordinates all operations based on inspection results, thereby managing complexity through systematic integration
Solution Approach 2:
Welding programs for different defect ranks are pre-stored in the robot control device before actual repair operations, allowing the system to quickly retrieve and execute appropriate programs without complex real-time decision-making, thereby simplifying the control process
3Productivity
If defect ranking system is implemented, then repair welding efficiency is improved through automated program selection, but measurement precision requirements increase for accurate defect classification
Solution Approach 1:
The inspection device evaluates multiple welding quality parameters simultaneously and determines defect ranks based on comprehensive assessment criteria, using sufficient measurement data to ensure accurate classification without requiring extreme precision in any single parameter
Solution Approach 2:
The system uses inspection results as feedback to automatically determine defect ranks and select appropriate welding programs, creating a closed-loop control system where measurement data directly drives the repair welding process with clear decision thresholds for each defect rank
Data Source
AI summary
A repair welding system includes an inspection device configured to inspect an appearance of a welded portion of a workpiece, and a robot control device that controls a robot configured to weld the workpiece. The inspection device determines whether there is a defective portion among welded portions of the workpiece based on a predetermined standard, and sets one of a plurality of defect ranks to the defective portion in a case that the defective portion is detected. The robot control device generates a repair welding program corresponding to the defect rank, and instructs the robot to execute, in accordance with the repair welding program, a repair welding on the defective portion to which the defect rank is set.