Robot Welding Program Editing via Lead-Through Teaching
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Solution Overview
Problem
The complexity of programming robotic welding tasks, particularly for small to medium enterprises lacking resources and expertise, increases manufacturing costs and time, especially when producing small numbers of repetitive parts.
Innovation Solution
A method that simplifies programming and editing of robot motion by using a lead-through teaching approach with a handle and input units, allowing operators to define and modify robot positions and actions without understanding the program's syntax or text format, and enables editing specific points in a program without altering the rest.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional robot programming methods are used, then programming precision and control accuracy are improved, but programming complexity and training requirements increase significantly
Solution Approach 1:
The patent introduces a lead-through handle as an intermediary device between the operator and the robot program. The handle includes input units that capture operator actions and automatically generate corresponding program commands, eliminating the need for operators to directly interact with complex programming syntax while maintaining programming precision
Solution Approach 2:
The patent replaces manual text-based programming with a physical mechanical interface. The lead-through handle uses physical buttons and input mechanisms that automatically translate mechanical actions into digital program commands, substituting the complex cognitive task of programming with simple physical operations
2Loss of time
If lead-through teaching method is used, then programming time is reduced, but programming precision and accuracy may deteriorate
Solution Approach 1:
The patent implements real-time feedback through the lead-through handle system. As the operator manipulates the handle and presses input units, the system immediately captures the position and action data, providing instant feedback that ensures accuracy while maintaining rapid programming speed. The system continuously validates the programmed parameters against the physical actions performed
3Measurement precision
If operators edit program points directly in text format, then editing precision is improved, but ease of operation and training requirements worsen
Solution Approach 1:
The patent uses the lead-through handle as an intermediary for program editing. Instead of requiring operators to navigate and edit text-based program code, the handle provides a physical interface where operators can select and modify program points through button inputs, automatically translating these actions into precise program edits while maintaining ease of operation
4Reliability
If detailed program syntax knowledge is required, then program reliability is improved, but ease of operation and accessibility worsen
Solution Approach 1:
The patent implements self-service programming where the lead-through handle automatically generates and validates program commands based on the operator's physical actions. The system handles all syntax requirements and validation internally, allowing operators to program reliably without needing to understand or manually construct complex program syntax, thereby maintaining both reliability and ease of operation
Data Source
AI summary
Abstract of the Disclosure The Invention describes a method to train and edit robot programs without the need to directly interact with the robot program or code. A new program is created by guiding the robot to desired locations in the program and then teaching those program positions with a button or similar input. An existing program is edited by moving the robot end-effector to a position in its workspace that is near the desired location of the program to be edited. An algorithm then is used to find the nearest program point in the existing program to the current robot end effector position. The algorithm then drives the robot to this nearest location. The operator can then visually confirm that this is the correct point in the program to edit, or move the robot again and repeat the algorithm search. Once the operator is satisfied that the robot is at the location of the program to edit, the operator can delete that point by pressing an appropriately labeled button. The operator could also add positions by first finding an edit point in the program using the manual move near the edit point and then running the search algorithm. The operator will then move the robot to the new position and press a button or input to add this new program position to the program. This process can be repeated as needed to edit the program. In this manner, the weld technician is not required to interact with code that defines the robot program but rather work with the end effector to spatially position the end-effector and edit the program.