Robotic Welding Trajectory Recording for Collision-Free Path Planning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Programming motion trajectories for robotic welding systems is complex due to challenges in programming weld trajectories, ingress and egress trajectories, and avoiding collisions with other objects in the welding environment.
Innovation Solution
A method is developed to determine a collision-free space for a robotic welding system by recording and translating data on the positions and orientations of the robotic arm within a 3D coordinate space, merging this data to create 3D geometry representing a continuous collision-free space, and planning collision-free motion paths using this data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to program motion trajectories for robotic welding systems, then the robot can perform welding operations, but the programming process becomes extremely complex and time-consuming due to the need to program weld trajectories, ingress and egress trajectories, and avoid collisions with other objects
Solution Approach 1:
The patent uses laser scanning to create a digital 3D copy of the workpiece geometry. This digital model is then used for collision detection and trajectory planning, eliminating the need for complex manual programming of weld paths, ingress, and egress trajectories. The digital twin approach allows automated path generation while avoiding collisions with the actual workpiece and fixtures.
Solution Approach 2:
The patent replaces traditional manual trajectory programming with automated collision-free path planning algorithms. These algorithms use the digital 3D model to automatically calculate safe welding paths, ingress trajectories, and egress trajectories, substituting complex mechanical programming operations with computational geometry and optimization routines.
2Manufacturing precision
If manual programming of weld trajectories is performed to ensure accuracy, then precise welding paths can be achieved, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent performs preliminary laser scanning to create a complete 3D digital model of the workpiece before any welding operations. This pre-acquired geometric information is stored and used for automated trajectory calculation, allowing precise welding paths to be generated automatically without time-consuming manual programming while maintaining high accuracy through the detailed digital model.
Solution Approach 2:
The system uses the digital 3D model of the workpiece to automatically generate collision-free trajectories without human intervention. The automated path planning algorithm serves itself by using the geometric data it has already captured to compute optimal welding paths, eliminating the need for manual trajectory programming while maintaining precision.
3Reliability
If the robotic arm is moved manually around the part to record positions and orientations, then collision-free space can be mapped, but the process requires significant user intervention and time
Solution Approach 1:
The patent replaces manual movement of the robotic arm for mapping with automated collision-free path planning algorithms. These algorithms use the digital 3D workpiece model to computationally determine all reachable positions and orientations without physical trial-and-error movement, maintaining accuracy while eliminating the need for extensive manual operation.
4Reliability
If comprehensive collision detection is implemented to avoid collisions with objects in the welding environment, then safety is improved, but the path planning becomes more complex and computationally intensive
Solution Approach 1:
The patent creates a digital 3D model that includes not only the workpiece but also fixtures, tooling, and other objects in the welding environment. This comprehensive digital twin allows the collision detection algorithm to check for intersections with all objects simultaneously, improving safety while managing complexity through efficient computational geometry operations on the digital model rather than physical trial-and-error.
Data Source
AI summary
An embodiment includes a method of determining a collision-free space for a robotic welding system. The method includes fixing a location of a part to be welded in a 3D coordinate space of a robotic welding system. An arm of the robotic welding system is moved around the part within the 3D coordinate space. Data corresponding to positions and orientations of the arm in the 3D coordinate space are recorded as the arm is moved within the 3D coordinate space around the part. The data is translated to swept volumes of data within the 3D coordinate space. The swept volumes of data are merged to generate 3D geometry data representing a continuous collision-free space within the 3D coordinate space.