Robotic Welding Path Correction Using Touch-Based Seam Detection

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Solution Overview

Problem

Programming robots for repetitive welding operations is difficult, tedious, and error-prone, especially when dealing with parts that have tolerances exceeding the acceptable deviation from the programmed welding path.

Innovation Solution

The system employs a collaborative robotic welding system with a user interface and touch-based searching, allowing operators to define touch-based searching and apply corrections to the welding path using a welding-type torch, and includes touch detection circuitry to detect contact between the welding wire and the workpiece, adjusting the robotic manipulator's movements accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If traditional robotic welding programming is used, then welding automation is achieved, but programming complexity and error-proneness increase

Engineering Contradiction:

Improvewelding automationVSAvoidprogramming complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The system enables the robotic manipulator to automatically detect and correct welding path deviations through touch-based sensing during execution, eliminating the need for complex pre-programming of correction algorithms. The system serves itself by autonomously adapting to workpiece variations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates real-time feedback through touch detection circuitry that senses deviations from the programmed welding path and automatically generates correction instructions, creating a closed-loop control system that continuously adjusts the welding trajectory.

Inventive Principle:

Principle #23Feedback

2Extent of automation

If traditional robotic welding programming is used, then welding automation is achieved, but ease of operation deteriorates

Engineering Contradiction:

Improvewelding automationVSAvoidprogramming ease

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system automatically performs path correction without requiring operators to program complex correction routines, allowing even less skilled operators to achieve accurate welding results through simple setup procedures.

Inventive Principle:

Principle #25Self-service

3Device complexity

If fixed welding paths are used, then programming simplicity is maintained, but adaptability to part tolerances deteriorates

Engineering Contradiction:

Improveprogramming simplicityVSAvoidadaptability to part tolerances

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The system transitions from a static, fixed welding path to a dynamic trajectory that automatically adjusts based on real-time touch sensing feedback, allowing the welding path to adapt to workpiece variations while maintaining simple initial programming.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system dynamically changes welding path parameters during execution based on detected deviations, automatically modifying position coordinates and trajectory points to accommodate part tolerances without requiring complex pre-programming.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If manual position correction is implemented, then adaptability to deviations improves, but productivity decreases

Engineering Contradiction:

Improveadaptability to deviationsVSAvoidwelding speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system replaces manual operator intervention with automated touch-based sensing and algorithmic path correction, eliminating the need for operators to physically adjust the robotic manipulator while maintaining high welding speeds and adaptability to deviations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 the programming of robotic welding systems, enabling easier and more accurate welding path correction, even with parts that have deviations from the programmed path, by allowing operators to easily generate and apply position corrections.

Implementation Method 1

touch detection circuitry to detect contact between the welding wire and the workpiece

Methodology Applied

Scientific EffectElectrical contact detection: Conduction (electrical)

Data Source

PatentUS20260077510A1Systems and methods to perform robotic welding path correction

Publication Date: 2026.03.19 ILLINOIS TOOL WORKS INC

AI summary

Disclosed example robotic welding systems include: a welding-type power supply configured to output welding-type power to a welding-type torch; a robotic manipulator configured to manipulate the welding-type torch; and robot control circuitry configured to: load a welding program comprising a sequence of robotic welding instructions, the robotic welding instructions comprising a plurality of positions associated with a welding operation to be performed along a welding seam using the welding-type torch, the sequence further comprising a position correction instruction; in response to reaching the position correction instruction in the sequence: automatically control the robotic manipulator to move the welding-type torch to detect positions of one or more surfaces associated with the weld seam; and based on the detected positions of the one or more surfaces associated with the weld seam, applying a correction to ones of the positions associated with the position correction instruction; and perform the robotic welding instructions in the sequence based on the plurality of positions and based on the corrections.