Saddle-Type T Joint Welding Path and Torch Pose Planning
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Solution Overview
Problem
Current methods lack a comprehensive solution for jointly planning the welding bead, welding torch pose, and welding process for saddle-type T joints, which are complex and require precise adjustments due to varying groove angles and cross-sectional areas, leading to inefficiencies and defects in the welding process.
Innovation Solution
A method involving the establishment of a groove cross-sectional model, calculation of welding bead and process parameters, and a welding torch pose mathematical model to generate offline commands for robot welding systems, allowing for segmented planning based on inclination angles and groove area variations, ensuring consistent and defect-free welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual arc welding or carbon dioxide gas shielded welding is used for saddle-shaped welded seams, then welding flexibility is maintained, but welding quality and efficiency are insufficient due to lack of skilled welders and high requirements
Solution Approach 1:
The patent replaces manual welding operations with an automated robot welding system. The robot welding machine executes pre-planned welding paths and parameters, substituting human manual operations with automated mechanical systems. This resolves the contradiction by providing both high efficiency through automation and consistent quality through precise control of welding parameters.
Solution Approach 2:
The patent employs offline programming to pre-plan the welding path, torch pose, and welding parameters before actual welding. The welding path is calculated and verified in advance using computer software, allowing optimization of welding parameters and prediction of welding quality before execution. This preliminary planning ensures both high efficiency and quality by avoiding trial-and-error during actual welding.
2Productivity
If robot welding is used for saddle-shaped welded seams, then welding efficiency is improved, but the complexity of torch pose adjustment increases due to varying groove angles and spatial positions
Solution Approach 1:
The patent replaces manual torch pose adjustment with automated computational methods. Offline programming software calculates the optimal torch pose at each welding position based on the saddle-shaped joint geometry and groove characteristics. This substitution of manual adjustment with automated calculation resolves the contradiction by maintaining efficiency while reducing operational complexity.
Solution Approach 2:
The patent dynamically adjusts welding parameters including torch pose, welding speed, and current based on the varying groove angles and spatial positions along the saddle-shaped seam. The offline programming system pre-calculates these parameter variations, allowing the robot to automatically adapt to changing geometric conditions without increasing operational complexity.
3Adaptability or versatility
If existing welding methods are used for saddle-type T joints, then some welding scenarios can be addressed, but comprehensive joint planning of welding bead, torch pose, and process parameters is still absent
Solution Approach 1:
The patent develops a comprehensive offline programming system that can handle various saddle-type T joint configurations, groove shapes, and welding scenarios through unified mathematical models and algorithms. The system provides universal solutions for different joint geometries while maintaining consistent welding quality through standardized planning procedures and parameter optimization.
Solution Approach 2:
The patent performs comprehensive planning of welding bead parameters, torch pose, and welding process parameters in advance through offline programming. The system calculates optimal parameters for each welding position and verifies the complete welding plan before execution, ensuring welding consistency across different scenarios without requiring trial-and-error adjustments during actual welding.
Data Source
AI summary
A method of automatically welding a welded seam of a saddle line for a saddle-type T joint belonging to the technical field of welding is provided, including: establishing a groove cross-sectional model, solving a variation law of a groove cross-sectional area, and planning a welding bead and a welding process parameter according to the groove cross-sectional area; establishing a welding torch pose mathematical model and obtaining a pose homogeneous transformation matrix T of a welding torch; establishing a three-dimensional model of a main pipe and a branch pipe, building a welding system through offline software, importing welding spot pose information, and generating welding torch pose offline command through the offline software; and performing automatic welding of the welded seam of the saddle line for the saddle-type T joint according to the planned welding bead and the welding process parameter and the generated welding torch pose offline command.