Scanner Controller for On-the-Fly Laser Path Synchronization
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Solution Overview
Problem
In remote laser welding robot systems, the scanner controller struggles to accurately recognize the position and attitude of the robot, leading to variations in machining results and potential over-travel issues, as it requires the scanner and robot to be stationary to initiate on-the-fly machining.
Innovation Solution
A scanner control system that includes a path creation device simulating scanner operations, creating programs with world and local coordinates, and a scanner controller with a program analysis unit, interpolation unit, position calculation unit, and on-the-fly start determination unit, allowing the scanner to start machining when the robot's position aligns within a predetermined threshold, enabling on-the-fly functionality without the need for initial stationarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the scanner controller requires the robot and scanner to be stationary to initiate on-the-fly machining, then synchronization accuracy is improved, but machining flexibility and productivity deteriorate due to inability to start from arbitrary positions
Solution Approach 1:
The patent replaces the mechanical stationary requirement with a computational solution. The position calculation unit computes real-time robot position and attitude using sensor data and transformation matrices, substituting the need for physical stationary alignment with mathematical coordinate transformation. This allows on-the-fly machining to start from any position while maintaining synchronization accuracy through continuous position calculation and threshold-based determination.
2Adaptability or versatility
If separate controllers are used for robot and scanner, then device versatility is improved, but control complexity and synchronization difficulty increase
Solution Approach 1:
The patent implements a feedback mechanism where the scanner controller continuously receives position and attitude data from the robot controller, calculates the current scanner position in world coordinates, and compares it with the ideal position from the program. The on-the-fly start determination unit uses this feedback to determine when to initiate machining based on threshold comparison, enabling synchronized operation of separate controllers without increasing overall system complexity.
3Device complexity
If the scanner controller cannot accurately recognize robot position and attitude, then device simplicity is maintained, but machining precision and reliability deteriorate due to variation in machining results and over-travel
Solution Approach 1:
The patent applies preliminary action by pre-defining a threshold value for position deviation before machining begins. The on-the-fly start determination unit compares the calculated position deviation against this predetermined threshold to determine when synchronization is sufficient to start machining. This preliminary threshold setting simplifies the controller logic while ensuring machining precision by only initiating operation when position accuracy requirements are met.
Data Source
AI summary
A scanner controller analyzes a position instruction in which a position in a world coordinate system and a position in a local coordinate system of a path of laser light are associated with each other and creates a movement command for a drive unit of a scanner based on the position of the local coordinate system. Further, the scanner controller calculates the current position of the scanner in the local coordinate system based on the position and attitude of a robot in the world coordinate system and the position in the world coordinate system in accordance with the position instruction. When the distance between the calculated position of the local coordinate system and the position in the local coordinate system in accordance with the position instruction is below a predetermined threshold, the scanner controller then determines to start machining and performs control of a drive unit of the scanner.