Robotic Weld Path Simulation for Collision-Prone Seams
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Solution Overview
Problem
Existing robotic welding systems fail to account for seams that are inaccessible or collision-prone, leading to potential damage and incomplete welds.
Innovation Solution
A system that simulates weld paths by evaluating candidate seams into waypoints, assessing feasibility, and adjusting welding parameters to enable access and avoid collisions, using a controller and user interface for color-coded feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding robot follows the generated weld path, then the welding process can be completed, but the robot may encounter collisions or be unable to access certain seam regions
Solution Approach 1:
The system performs preliminary simulation of the weld path before actual welding to predict and identify potential collisions or inaccessible regions. This advance evaluation allows the system to modify the weld path or warn the user before the welding robot encounters problems during execution.
Solution Approach 2:
The system provides feedback to the user about problematic seam regions through color-coded visual indicators (red for inaccessible, yellow for potential collision). This feedback mechanism allows users to review and modify the weld path or select alternative seams before welding begins, preventing collisions and ensuring accessible weld paths.
2Adaptability or versatility
If the welding robot accesses hidden or obstructed seam regions, then more seams can be welded, but the robot cannot physically reach or weld these portions
Solution Approach 1:
The system preliminarily evaluates the accessibility of each seam region by simulating the robot's movement and welding head positioning before actual welding. This advance check identifies regions that appear accessible in the CAD model but are actually inaccessible due to robot geometry or part obstacles, allowing users to modify the weld path or select feasible seams beforehand.
Solution Approach 2:
The system creates a virtual copy of the welding robot and its environment in the simulation, allowing the robot's geometry and movement constraints to be tested against the part model. This virtual replica enables accurate prediction of accessibility without requiring physical trial-and-error or complex real-time sensing.
3Loss of time
If existing path planning methods are used, then the weld path can be generated quickly, but inaccessible and collision-prone seams are not identified
Solution Approach 1:
The system performs preliminary simulation of the weld path using the CAD model and robot geometry before actual welding. This advance evaluation quickly identifies inaccessible and collision-prone regions by checking the virtual robot's ability to reach and position at each point along the proposed path, providing users with timely information about potential problems.
Solution Approach 2:
The system uses a virtual copy of the robot and part geometry in the simulation environment to quickly evaluate accessibility without physical prototyping or complex real-time sensing. This virtual replica allows rapid iteration and evaluation of multiple weld paths and seam selections to identify feasible options efficiently.
Data Source
AI summary
In some examples, a method for determining feasible portions of a seam includes receiving a representation of a part including the seam. The method also includes discretizing a representation of the seam into a plurality of waypoints. The method also includes evaluating each waypoint for feasibility of welding. The method further includes modifying at least one constraint on at least a first waypoint of the plurality of waypoints and generating a weld path through the plurality of waypoints.