Collaborative Robotic Welding Arm With Safety Encoder Control
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Solution Overview
Problem
Current spool welding systems lack efficient and safe robotic solutions for welding long lengths of pipe, as they often require manual operation and lack precise control over the welding process, especially when working alongside human operators.
Innovation Solution
A collaborative robotic welding system with a repositionable support structure, featuring a supporting arm, welding arm, and rotary actuators controlled by a safety encoder and controller, allowing for precise motion control and force limitation to ensure safe operation alongside human workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a robotic welding system is introduced to improve welding precision and consistency, then manufacturing precision and productivity are improved, but the system complexity and safety requirements increase when working alongside human operators
Solution Approach 1:
A safety encoder is introduced as an intermediary component between the rotary actuator and the control system. This safety encoder monitors actuator position and velocity, and can emergency-stop the system if unsafe conditions are detected, thereby enabling safe human-robot collaboration without requiring complete system redesign
Solution Approach 2:
The safety encoder provides continuous feedback on actuator position and motion state to the controller. This feedback loop allows the controller to adjust operation modes (e.g., restricted vs. unrestricted motion) based on detected conditions, enabling precise control while maintaining safety for human operators working alongside the robotic system
2Productivity
If the robotic system is designed for full automation to improve productivity, then welding efficiency increases, but the ease of operation and flexibility for manual intervention decrease
Solution Approach 1:
The robotic system is designed with dynamic reconfigurability, allowing the controller to switch between different operation modes (restricted motion mode and unrestricted motion mode) based on real-time conditions. This enables the system to operate autonomously for high-productivity welding tasks while allowing manual intervention when needed, combining automation efficiency with operational flexibility
3Object-affected harmful factors
If safety measures are added to enable human-robot collaboration, then operator safety is improved, but the device complexity and control requirements increase
Solution Approach 1:
The safety encoder serves as a dedicated safety intermediary that specifically monitors rotary actuator conditions without requiring complex safety systems throughout the entire robotic architecture. This targeted approach provides necessary safety functionality while minimizing overall system complexity
Solution Approach 2:
The safety encoder performs self-monitoring of actuator position and velocity, and can autonomously trigger emergency stop conditions without requiring external safety systems. This self-service safety approach reduces the burden on the main control system while maintaining comprehensive safety monitoring
Data Source
AI summary
A robotic welding system comprises a supporting arm for attaching to a repositionable support structure, the supporting arm comprising a first mounting portion connectable to the repositionable support structure, and a second mounting portion rotatably coupled to the first mounting portion. A yaw rotary actuator rotates the second mounting portion about a yaw axis. A welding arm comprises a third mounting portion rotatably coupled to the second mounting portion of the supporting arm. A pitch rotary actuator rotates the third mounting portion about a pitch axis generally perpendicular to the yaw axis. A roll rotary actuator rotates a torch holder shaft about a roll axis generally perpendicular to the pitch axis. The shaft has a torch mounting portion for mounting a welding torch at an end thereof. A controller is operably coupled to the actuators to cause the welding torch to execute a welding pattern.