3D-Scanned Robotic Welding for Casting Pit Repair
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Solution Overview
Problem
Existing steel casting processes for large-format components face challenges such as complex post-processing, material composition changes, significant smoke and noise emissions, and electromagnetic interference due to high electrical currents, particularly in large-format components.
Innovation Solution
A method involving 3D measurement of a rough workpiece to generate actual dimension data, calculating movement paths for a robot-guided welding tool, and using plasma welding to fill grinding pits formed in the workpiece, along with a welding system that includes a busbar to reduce electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carbon arc gouging is used to remove excess material, then material removal efficiency is improved, but material composition changes (carburizing) and harmful emissions occur
Solution Approach 1:
The patent changes the fundamental parameter of the material removal process from thermal (carbon arc gouging) to mechanical (robotic grinding). This parameter change eliminates the harmful effects of thermal processing such as carburizing and smoke emissions, while maintaining efficient material removal capability through automated grinding operations.
Solution Approach 2:
The patent replaces the mechanical carbon arc gouging process with a robotic grinding system. This substitution eliminates the harmful thermal and chemical effects associated with carbon arc processing while achieving the same material removal objective through controlled mechanical grinding operations.
2Productivity
If high electrical currents are used for welding, then welding speed and productivity are improved, but electromagnetic interference increases
Solution Approach 1:
The patent extracts and removes the source of electromagnetic interference by eliminating the carbon arc gouging process that requires high electrical currents. By using robotic grinding instead, the system achieves material removal without generating significant electromagnetic interference, while welding is performed with controlled currents that minimize interference.
Solution Approach 2:
The patent introduces robotic grinding as an intermediary process between casting and welding. This intermediary mechanical process eliminates the need for high-current thermal processing, thereby removing the source of electromagnetic interference while maintaining production efficiency through automated operations.
3Adaptability or versatility
If manual post-processing is used for large-format workpieces, then flexibility is maintained, but measurement precision and automation level decrease
Solution Approach 1:
The patent implements self-service through automated 3D scanning and robotic processing. The system automatically measures the workpiece geometry, calculates required material removal, and executes grinding and welding operations without manual intervention. This maintains flexibility for large-format workpieces while significantly improving measurement precision and automation level.
Solution Approach 2:
The patent replaces manual measurement and post-processing with automated 3D scanning and robotic grinding systems. This substitution enables precise digital measurement of large-format workpieces and automated execution of material removal, achieving both high measurement precision and maintained process flexibility.
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
The method efficiently removes imperfections and avoids material changes, reduces smoke and noise emissions, and minimizes electromagnetic interference, effectively bringing the workpiece closer to its target dimensions.
Implementation Method 1
forming at least one grinding pit in the rough version of the workpiece; automatically measuring the manufactured rough version of the workpiece in 3D with the at least one grinding pit formed on it
Implementation Method 2
An electric arc formed between the consumable electrode and the excess material melts the material
Data Source
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AI summary
The invention provides a method and a welding system for manufacturing a workpiece. The method comprises the following steps: manufacturing (S30) a rough version of the workpiece (1-i) using a steel casting process; forming (S83) at least one grinding pit (2-i) in the rough version of the workpiece (1-i); automatically measuring (S70) the manufactured rough version of the workpiece (1-i) with the at least one grinding pit (2-i) formed thereon in three dimensions to generate actual dimensional data; automatically calculating (S91) the movement paths to be followed by a robot (200) which guides a welding tool (201, 202), based on the generated actual dimensional data and on stored target dimensional data for the workpiece (1-i); and automatically filling (S90) the at least one grinding pit (2-i) by means of production welding, wherein the robot (200) is controlled according to the calculated movement paths.