Robotic Welding Arc Warning Control for Collaborative Safety
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Solution Overview
Problem
Conventional robotic welding systems rely on physical barriers to exclude operators from the welding area, which is not feasible with collaborative robots, and there is a need to prevent exposure to UV radiation and visible light emitted during welding arcs without reducing productivity.
Innovation Solution
The system includes a robotic welding system with a robot control system that enforces visual and audible notifications before and during welding arcs, using predefined pre-arc events and spatial volumes to ensure operators are alerted to impending arcs, thereby reducing exposure to UV radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If physical barriers are used to exclude operators from the welding area, then operator safety is improved, but productivity is reduced and collaborative robot usage becomes infeasible
Solution Approach 1:
The system performs preliminary actions by detecting pre-arc events (gas flow, wire feed, robot movement) and issuing warnings before the harmful arc is generated. This allows operators to take protective measures in advance without requiring physical barriers, thus maintaining productivity while ensuring safety.
Solution Approach 2:
The control system acts as an intermediary between the welding system and operators. It monitors welding parameters, determines arc warning events, and communicates with operators through notifications. This intermediary function eliminates the need for physical barriers while maintaining safety, enabling collaborative robot operation.
2Object-affected harmful factors
If physical barriers are used to exclude operators from the welding area, then operator safety is improved, but device complexity increases
Solution Approach 1:
The system replaces the mechanical approach of physical barriers with an electronic/software-based solution. The control system uses software to monitor welding parameters, determine arc warning events, and issue notifications. This substitution reduces device complexity by eliminating physical barrier structures while maintaining safety functionality.
3Object-affected harmful factors
If arc warning events are configured to provide timely notifications, then operator safety is improved, but productivity may be reduced due to additional monitoring and notification processes
Solution Approach 1:
The system leverages pre-arc events that naturally occur before welding arcs as trigger points for warnings. By using existing process events (gas flow initiation, wire feed start, robot movement to arc position) as warning triggers, the system provides timely notifications without adding separate monitoring processes, thus maintaining productivity while improving safety.
Solution Approach 2:
The system implements feedback by continuously monitoring welding parameters and automatically issuing notifications when arc warning events are detected. This automated feedback loop eliminates the need for manual monitoring, maintaining productivity while ensuring operators are warned of impending arcs. The system only activates notifications when actually needed, avoiding unnecessary interruptions.
Data Source
AI summary
Disclosed example robotic welding systems include: a robotic manipulator configured to manipulate a welding torch; and a robot control system, comprising: a processor; and a machine readable storage medium comprising machine readable instructions which, when executed by the processor, cause the processor to, during a robotic welding procedure involving the robotic manipulator: prior to initiating an arc as part of the robotic welding procedure, identify an arc warning event; in response to the arc warning event, output at least one of a visual notification or an audible notification proximate to the robotic manipulator; and control the robotic manipulator to perform the robotic welding procedure involving initiating the arc using the welding torch.