Welding Robot Feedback Control for Real-Time Seam Tracking
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Solution Overview
Problem
Conventional robotic welding systems lack real-time feedback and dynamic adjustment capabilities, leading to inaccuracies and poor weld quality due to discrepancies between model-based instructions and actual part dimensions, occlusions, and shifts during the welding process.
Innovation Solution
A computer-implemented method that uses sensors to generate point cloud data of the workspace, compares an estimated state to a desired state, and updates welding instructions in real-time, including adjustments to the welding robot's motion and parameters, allowing for precise welding without prior knowledge of the seam or gap shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If model-based welding instructions (CAD/kinematic models) are used to control the welding robot, then the welding process can be automated and executed efficiently, but the welding accuracy deteriorates due to discrepancies between model dimensions and actual part dimensions
Solution Approach 1:
The patent implements real-time feedback by using sensors (laser line laser, cameras) to continuously monitor the actual position of the welding robot and the actual geometry of the part during welding. This feedback is compared with the model-based instructions to detect deviations, which then trigger dynamic adjustments to the welding path and parameters, resolving the accuracy problem while maintaining automation
Solution Approach 2:
The system dynamically adjusts welding instructions in real-time based on sensor feedback. The welding robot's motion path, speed, and other parameters are continuously modified during the welding process to compensate for deviations from the original CAD model, enabling the system to adapt to actual part variations while maintaining high productivity
2Ease of operation
If fixed welding instructions are programmed to follow a predetermined path, then the welding process is simple to program and execute, but the system cannot adapt to changes in the welding operation, seam position, or part geometry resulting in bad welds
Solution Approach 1:
The system maintains ease of operation by using model-based initial path planning from CAD files, which is simple to generate. Real-time feedback from sensors then automatically adjusts the path during welding, providing adaptability without requiring complex programming. The feedback loop handles the complexity of adaptation while the initial programming remains straightforward
Solution Approach 2:
The welding system performs self-adjustment through automatic feedback processing. The system monitors its own performance and part geometry in real-time, automatically correcting deviations without human intervention. This self-service capability provides adaptability while keeping the operation simple for the user
3Manufacturing precision
If real-time sensor feedback and dynamic adjustment are implemented to improve welding accuracy, then weld quality improves by accounting for part geometry variations, but the system complexity increases due to multiple sensors and real-time processing requirements
Solution Approach 1:
The patent merges multiple sensors (laser line laser, cameras, other sensors) into an integrated sensing system that works together to capture part geometry and monitor welding position. This combined sensor system processes data through a unified feedback loop, achieving high weld quality while managing complexity through integration rather than separate independent systems
Solution Approach 2:
The sensor system is designed to perform multiple functions: capturing part geometry, tracking welding position, detecting seam variations, and providing feedback for path adjustment. This multi-functionality reduces the need for separate specialized sensors and processing systems, achieving high precision while controlling overall system complexity
4Speed
If conventional welding systems operate without real-time feedback, then the system is simple and fast to execute, but collisions and bad welds occur when the robot deviates from the programmed path due to imprecise instructions or physical changes
Solution Approach 1:
The system maintains fast welding execution through efficient real-time feedback processing. Sensors continuously monitor the welding path and part geometry, and the control system rapidly processes this data to detect potential collisions or deviations. When issues are detected, the system automatically adjusts the path, preventing collisions and bad welds while maintaining high welding speed through optimized feedback loops
Data Source
AI summary
Systems and methods for real time feedback and for updating welding instructions for a welding robot in real time is described herein. The data of a workspace that includes a part to be welded can be received via at least one sensor. This data can be transformed into a point cloud data representing a three-dimensional surface of the part. A desired state indicative of a desired position of at least a portion of the welding robot with respect to the part can be identified. An estimated state indicative of an estimated position of at least the portion of the welding robot with respect to the part can be compared to the desired state. The welding instructions can be updated based on the comparison.