Robotic Welding Control With Real-Time Visual Feedback
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Solution Overview
Problem
Existing robotic welding systems lack flexibility and real-time adaptability to varying component geometries and often require strict pre-programmed paths, limiting their application to components with precise dimensional and geometrical tolerances, and do not provide adequate safety for human welders during manual operations.
Innovation Solution
A multi-axis robotic welding apparatus equipped with a human-machine interface, image acquisition device, and control unit that allows for real-time control of welding parameters and feedback to operators, enabling remote and flexible welding operations with enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual welding operations are performed with a welding mask and tool, then the welder can directly control the welding process, but the welder is exposed to safety risks and must remain in proximity to the workpiece
Solution Approach 1:
The patent introduces a robotic arm as an intermediary device between the operator and the welding process. The robotic arm is equipped with a welding torch and can be controlled remotely through a control unit that receives input from the operator via a teaching interface. This allows the operator to control welding parameters and movements without being physically present at the welding zone, eliminating direct exposure to harmful factors while maintaining operational control.
Solution Approach 2:
The patent replaces the manual mechanical operation of holding and maneuvering a welding torch with an automated robotic mechanical system. The robotic arm with multiple degrees of freedom can position and orient the welding torch precisely, substituting the welder's physical actions with programmable robotic movements controlled through teaching interfaces and control units.
2Extent of automation
If pre-programmed robotic welding paths are used, then welding operations can be automated, but the system lacks flexibility to adapt to varying component geometries and unexpected situations
Solution Approach 1:
The patent implements a dynamic control system that allows the robotic arm to be taught and reprogrammed in real-time through a teaching interface. Instead of relying solely on fixed pre-programmed paths, the system can adapt to different component geometries by allowing operators to manually guide the robotic arm through desired welding paths during teaching mode, storing these paths for future automated execution. This dynamic reconfigurability provides both automation and flexibility.
Solution Approach 2:
The patent incorporates sensors and detection devices that can detect welding parameters, position, and potentially visual feedback from the welding area. This feedback is processed by the control unit to enable real-time adjustments during welding operations, allowing the system to respond to unexpected situations and variations in component geometry while maintaining automated operation.
3Productivity
If strict pre-programmed paths are required for robotic welding, then automation is achieved, but the system is limited to components with precise dimensional and geometrical tolerances
Solution Approach 1:
The patent employs a teaching phase where the robotic arm is manually guided through the desired welding path on the specific component before automated welding begins. During this preliminary teaching action, the system learns and stores the actual geometry and positioning requirements of the component. This preliminary adaptation allows subsequent automated welding operations to proceed efficiently without requiring the component to meet strict pre-defined tolerances, as the system has already adjusted to the actual component variations.
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
Enables remote, flexible, and safe welding operations by providing operators with real-time feedback and control over welding parameters, improving safety and adaptability to diverse component geometries.
Implementation Method 1
an image acquisition device (4) attached to said first end, said image acquisition device being configured to monitor a welding target (6) and to provide an image of the welding target (6) to an operator
Data Source
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AI summary
A welding apparatus (1) comprises a multi-axis robotic arm (2) having a first end (2a); a welding tool (5) attached to the first end (2a); an image acquisition device (4) attached to the first end (2a) and having a light filtering system (7); the image acquisition device (4) is configured to monitor a welding target (6) and to provide an image of the welding target (6) to an operator; a control unit (8) is configured to control the robotic arm (2) and the welding tool (5); an input interface (9) for a human operator is associated to the control unit (8) and is configured to provide an input signal (SI) to the control unit (8) and to control the robotic arm (2) and welding tool (5) substantially in real time.