Robot Welding Parameter Control Based on Cooling Behavior
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Solution Overview
Problem
Existing welding methods fail to accurately account for the cooling situation of a workpiece during the welding process, leading to inconsistent weld quality, requiring time-consuming test welds and expert knowledge, and are not reproducible or automatable.
Innovation Solution
A method and device that record and account for the cooling behavior along the welding path, using heat sources and detection devices to determine optimized welding parameters, allowing for real-time adjustments to ensure optimal weld quality without prior test welds or expensive expert intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If test welds are performed on test workpieces to adjust welding parameters to the respective cooling situation, then weld quality can be improved, but the process becomes time-consuming and requires expert knowledge
Solution Approach 1:
The cooling behavior is measured and recorded before the actual welding process takes place. This preliminary measurement allows the welding parameters to be optimized in advance based on actual cooling data from the specific workpiece, eliminating the need for time-consuming test welds during production.
Solution Approach 2:
The system uses the workpiece itself to generate the cooling behavior data by measuring its actual cooling characteristics during a preliminary phase. This self-measured data replaces the need for external expert judgment and test welds, making the process autonomous and reproducible.
2Manufacturing precision
If test welds are performed to determine welding parameters, then accurate cooling consideration is achieved, but the method is not reproducible and cannot be automated
Solution Approach 1:
The system measures the actual cooling behavior of the workpiece and uses this feedback information to automatically optimize the welding parameters. The measured cooling data is fed into the control system, which then adjusts the welding parameters accordingly, enabling full automation without expert intervention.
Solution Approach 2:
The manual process of performing test welds and expert judgment is replaced by an automated measurement and control system. The physical measurement of cooling behavior is converted into electronic signals that are processed by a control system, replacing the mechanical and cognitive processes of manual test welding.
3Manufacturing precision
If workpiece temperature is measured before welding to monitor cooling rate, then weld quality can be ensured, but preheating becomes necessary which increases costs and time
Solution Approach 1:
The cooling behavior is measured and recorded before the welding process to establish a baseline. This preliminary measurement allows for direct optimization of welding parameters based on actual cooling characteristics, eliminating the need for preheating operations that would otherwise be required to ensure weld quality.
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
Improves weld quality and reproducibility by accurately accounting for the cooling situation, enabling simpler and more cost-effective automation of the welding process, reducing the need for expert knowledge and eliminating the need for prior test welds.
Implementation Method 1
The cooling process is influenced by the input heat energy, the temperature of the workpiece and clamping devices, the local geometry of the workpiece and clamping devices, the ambient temperature or the workpiece's base temperature, and the respective material properties (specific heat capacity and thermal conductivity)
Implementation Method 2
Before the welding process, at least one parameter representing the cooling is recorded as a function of the position along the weld path
Data Source
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AI summary
The invention relates to a method for defining welding parameters (Pi(x)) for a welding process on a workpiece (4), in which a welding torch (2) fastened to a robot (11) is guided over the workpiece (4) along a predefined welding path (3) and, depending on the position (x) along the welding path (3), predefined welding parameters (Pi(x)) for processing the workpiece (4) are set. The invention also relates to a welding device (1) for carrying out a welding process. For the more exact definition of the welding parameters (Pi(x)), the invention proposes that, before the welding process is carried out, at least one parameter (PK(x)) representing the cooling is recorded depending on the position (x) along the welding path (3), and the at least one parameter (PK(x)) representing the cooling along the welding path (3) is considered for the welding process during the definition of optimised welding parameters (Pi,opt(x)) depending on the position x on the welding path (3).