Robot Welding Torch Guidance for Real-Time Weld Line Adaptation
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Solution Overview
Problem
Existing welding processes face challenges in achieving precise geometric control and rapid responsiveness due to dynamic nature, leading to arduous conditions for welders, especially when dealing with complex and large parts that require extensive programming and are prone to weld pool behavior defects.
Innovation Solution
A welding assistance method using a robotic device with a human-machine interface and control system, allowing operators to define reference points and adjust the welding torch trajectory in real-time through a local coordinate system, enabling real-time adaptation to the weld line shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding automation is implemented using stationary robots or robotic arms with predetermined sequences, then productivity and consistency are improved, but adaptability to complex and unique parts deteriorates
Solution Approach 1:
The system transitions from static predetermined welding sequences to dynamic real-time control. The operator can modify welding parameters, torch position, and movement speed during the welding process itself, allowing the system to adapt to actual weld pool behavior and part geometry variations as they occur.
Solution Approach 2:
The system incorporates visual feedback through cameras that allow the operator to observe the weld pool in real-time and adjust parameters accordingly. This closed-loop control enables the operator to respond to actual welding conditions rather than following fixed predetermined sequences, resolving the contradiction between automation and adaptability.
2Manufacturing precision
If extensive programming is used for large and unique parts, then welding precision is improved, but device complexity and programming time deteriorate
Solution Approach 1:
Instead of complex mathematical modeling and programming of part geometries, the system uses visual copying where the operator guides the torch along the weld line while observing the actual part geometry through camera feedback. The control system captures the actual weld line path visually rather than requiring pre-programmed coordinates, significantly reducing programming complexity while maintaining precision.
Solution Approach 2:
The system allows the operator to define reference points and general direction of movement with minimal programming, then the operator themselves performs the precise trajectory adjustment in real-time based on visual feedback. This transfers the complexity from pre-programming to real-time operation, reducing overall system complexity while maintaining precision.
3Productivity
If the welding torch follows a predetermined trajectory, then welding speed and productivity are improved, but responsiveness to weld pool behavior deteriorates
Solution Approach 1:
The system maintains high welding speed through automated torch movement along the general direction of movement, but allows dynamic adjustment of the trajectory and parameters in real-time. The operator can deflect the torch from the predetermined path when weld pool behavior requires intervention, combining the benefits of both automated speed and manual responsiveness.
Solution Approach 2:
The welding process operates in cycles of automated movement interspersed with operator intervention. The torch follows the predetermined trajectory at high speed, then pauses or allows operator adjustment when visual monitoring indicates weld pool issues, creating a rhythmic pattern of automated execution and human oversight that balances speed and responsiveness.
4Reliability
If gravity acts on the weld pool for stabilization, then welding reliability is improved, but positioning flexibility deteriorates
Solution Approach 1:
The real-time visual feedback system allows the operator to monitor weld pool behavior regardless of position and make adjustments to compensate for the absence of gravitational stabilization. The operator can detect weld pool instability early and adjust parameters or trajectory to maintain reliability in positions where gravity does not contribute to stabilization.
Solution Approach 2:
The system allows dynamic modification of welding parameters such as heat input, travel speed, and torch angle in real-time to compensate for positioning challenges. By adjusting these parameters based on visual feedback, the operator can maintain weld pool stability and reliability even in positions where gravity does not provide natural stabilization.
Data Source
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AI summary
The present invention mainly relates to a method for welding together two parts (11, 12) along a weld line (13) by means of a welding system (10) enabling an operator to remotely perform welding operations, the method comprising: - a step of defining, by the operator, reference points on the parts (11, 12) to be welded and/or on the weld line (13) to be followed, - a step of defining a general movement direction of the welding torch (23) from the reference points, - a step of defining a local frame of reference relative to the general movement direction of the welding torch (23), - a step of automatically moving the welding torch (23) from a welding starting point in the general movement direction, - a step of generating a flow of movement instructions linked to actions of the operator on the human-machine interface (24) to move the welding torch (23) away from the general movement direction so as to adapt a trajectory of the welding torch (23) to an actual shape of the weld line (13), and - a step of actually moving the welding torch (23) corresponding to the flow of instructions generated by the human-machine interface (24).