Robotic Welding Training via Manual Weld Path Capture
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Solution Overview
Problem
Conventional robotic welding systems require cumbersome and time-consuming programming methods, limiting their use to high-volume welds and making them economically unfeasible for small and mid-sized fabricators to perform repetitive welds on various parts.
Innovation Solution
A training system that observes a manual welding operation to track the position, orientation, and parameters of a welding tool, generating a robotic welding procedure that can be replicated by the robotic system, reducing the need for manual programming and simplifying the setup process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional programming methods are used for robotic welding systems, then welding precision and automation are achieved, but programming difficulty and time consumption increase significantly
Solution Approach 1:
The system captures the manual welding procedure as a reference model and automatically generates robotic welding procedures by comparing and adapting the manual process. Sensors track the manual welding torch position, orientation, and parameters, creating a digital copy that is then translated into robotic control instructions, eliminating complex manual programming while preserving welding quality
Solution Approach 2:
The patent replaces manual mechanical programming operations with an automated sensor-based system. Instead of manually teaching robot positions and parameters through mechanical guidance, the system uses optical sensors, cameras, and computer vision to automatically detect and record welding parameters, transforming a mechanically intensive process into an automated sensing and data processing operation
2Manufacturing precision
If conventional programming methods are used for robotic welding systems, then welding precision is maintained, but time consumption and setup duration increase
Solution Approach 1:
The system performs preliminary capture and analysis of manual welding procedures before robotic execution. By recording and analyzing the manual welding process in advance, the system pre-processes all necessary positioning and parameter data, allowing the robotic system to execute the welding without time-consuming programming setup while maintaining the precision of the original manual procedure
Solution Approach 2:
The system creates a digital replica of the manual welding procedure through sensor tracking and data capture. This copy contains all position, orientation, and parameter information needed for robotic execution, enabling direct translation from manual to robotic operation without iterative programming and testing, thus maintaining welding precision while dramatically reducing setup time
3Productivity
If robotic welding systems are deployed with conventional programming, then high-volume production efficiency is achieved, but economic feasibility for small and mid-sized fabricators decreases
Solution Approach 1:
The system enables the robotic welding setup to be self-instructing by automatically capturing and analyzing manual welding procedures. The sensor system and computer vision algorithms autonomously extract welding parameters and generate robotic control code without requiring external programming expertise, allowing small and mid-sized fabricators to deploy robotic welding systems without hiring specialized programmers, thus improving economic feasibility while maintaining high productivity
Data Source
AI summary
An example robotic welding system includes: one or more sensors configured to determine a physical position and orientation of a welding tool with respect to a reference frame; and a processor configured to: communicatively connect to a welding-type power supply; during a welding operation performed using the welding tool: track the physical position and orientation of the welding tool within the reference frame; and monitor at least one of an input or an output of the welding-type power supply; and generate a robotic welding procedure based on the tracked physical position and orientation of the welding tool and based on the at least one monitored input or monitored output of the welding-type power supply.