Robotic Weld Seam Tracing for Mobile 3D Path Following
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Solution Overview
Problem
Conventional robotic welding systems are limited by the need for fixed-position welding stations, complex programming, and difficulty in adapting to different welding locations, which restricts their mobility and efficiency, especially in construction sites where welders are in short supply and rebar-reinforced structures require extensive welding.
Innovation Solution
A robotic welding system that uses an initial manual tracing of a weld seam, detectable by ferro-magnetic, light-reflective, or low-grade radioactive materials, allowing the robotic welder to autonomously follow the traced path in 3D space, eliminating the need for fixed fixtures and complex programming, and enabling mobility on overhead gantries or vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional robotic welding systems use fixed-position welding stations with complex programming, then welding precision can be maintained, but mobility and adaptability to different welding locations are severely restricted
Solution Approach 1:
The system performs preliminary manual tracing of the weld seam path using detectable materials (ferro-magnetic, light-reflective, or radioactive) to create a guide path before welding. This preliminary action eliminates the need for complex programming while maintaining precision, as the robot simply follows the pre-established trace.
Solution Approach 2:
The detectable trace material serves as an intermediary between the operator's intended weld path and the robotic welding system. The trace acts as a physical guide that the robot's detection system can follow, replacing complex programming with a simple follow-the-trace mechanism that enables mobility and adaptability.
2Ease of operation
If manual tracing with detectable materials is used to guide the robotic welder, then ease of operation and mobility are improved, but the welding process requires additional tracing materials and detection mechanisms
Solution Approach 1:
The robotic system integrates multiple detection capabilities (ferro-magnetic detection, light reflection detection, and radioactive detection) into a single multi-functional detection mechanism. This allows the same robot to work with different trace materials depending on the application, simplifying operation while maintaining versatility.
Solution Approach 2:
The system uses the trace material's inherent properties (ferro-magnetic attraction, light reflection, or radioactivity) to guide itself without requiring external active sensing systems. The trace essentially guides the robot using its own physical characteristics, reducing the complexity of detection mechanisms.
3Productivity
If robotic welding is implemented to speed up welding processes and reduce labor costs, then productivity increases, but the initial setup complexity and programming requirements create barriers to adoption
Solution Approach 1:
The system replaces complex mechanical positioning systems and programming logic with a simpler trace-following approach. Instead of programming the robot to calculate and execute precise movements, the robot physically follows the detectable trace, substituting mechanical complexity with a more intuitive guidance mechanism.
Solution Approach 2:
By performing the path planning action manually through tracing before the robotic welding begins, the system eliminates the need for complex programming during operation. The preliminary tracing action captures all the complexity, allowing the robot to execute simple follow-the-trace commands at high speed.
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
This approach simplifies and speeds up the welding process, reduces labor costs, and allows for automated welding at various locations without sacrificing speed or precision, while avoiding obstacles through real-time path adjustments, thus addressing the shortage of welders and improving construction efficiency.
Implementation Method 1
detecting means for detecting a path of a traced profile of ferro-magnetic, light-reflective, or low-grade radioactive material which is traced over or placed on a location of a desired weld seam
Implementation Method 2
detecting means for detecting a path of a traced profile of ferro-magnetic, light-reflective, or low-grade radioactive material
Data Source
AI summary
A robotic welding system having detection means for in one embodiment detecting a path of a ferro-magnetic, light-reflective or radioactive material traced over a weld seam, and a controller for providing machine commands to cause a torch tip electrode to move the weld seam. Alternatively the detection means comprises means for detecting and tracking a) a position in 3D space of a pointer tip which is in known positional relationship to determined GPS coordinates of a reference point on the welder when traced along a desired weld seam; b) the path of a point source of light when traced along a location of a desired weld seam; c) the path of light-reflective material traced or positioned over the desired weld seam; or d) a path of a tip of a digitized pointer object when traced along a desired weld seam. Methods of operating such robotic welder also disclosed.