Smart Welding Torch Path Recording for Confined Cobot Programming
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Solution Overview
Problem
Current robotic welding systems are not collaborative and are difficult to program in confined spaces, requiring operators to hold a dead-man switch on a teach pendant, limiting their ability to use both hands and making remote welding impractical.
Innovation Solution
A collaborative robot (cobot) equipped with a 'smart' welding or cutting torch that allows operators to program welding paths using actuators on the torch, enabling remote operation and mounting in various positions without the need for a teach pendant, with data communication between the torch and robot controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional robot is used for welding, then welding automation is achieved, but the robot cannot be remotely mounted and is difficult to program in confined spaces
Solution Approach 1:
The system separates the control interface (teach pendant) from the robot execution unit. The teach pendant can be remotely located while the robot operates in confined spaces, allowing the operator to program and control the robot from a accessible location without interfering with the robot's compact operation in tight areas.
Solution Approach 2:
The teach pendant serves as an intermediary device between the operator and the robot controller. It transmits control signals and program data wirelessly or via cable to the robot, enabling remote programming and operation while maintaining ease of use through a handheld interface.
2Productivity
If an operator holds a dead-man switch on a teach pendant to program weld points, then welding path recording is enabled, but the operator cannot use both hands and experiences ergonomic issues
Solution Approach 1:
The dead-man switch function is extracted from the teach pendant and integrated into the welding torch itself. This allows the operator to activate recording and control functions directly through the torch, freeing both hands for manipulating the torch and observing the workpiece simultaneously.
Solution Approach 2:
The control functions (dead-man switch, recording activation) and the welding execution tool (torch) are merged into a single integrated device. This integration eliminates the need to switch between holding a teach pendant and manipulating the torch, improving ergonomics and operational efficiency.
3Adaptability or versatility
If a traditional robot system is used, then welding automation is achieved, but remote operation in confined spaces is impractical
Solution Approach 1:
The welding torch is designed with multiple functions: it serves as both the welding execution tool and the control interface (incorporating dead-man switch and recording activation). This multi-functionality reduces the need for separate control devices and simplifies the overall system architecture for remote operation.
Solution Approach 2:
The system replaces complex mechanical linkages and wired control connections with wireless communication technology. The teach pendant and torch communicate with the robot controller via wireless signals, eliminating the need for physical cable management in confined spaces and simplifying remote operation.
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3
AI summary
A torch (220) for use by a robot. The torch has a body (226) that can be connected to an arm of the robot. A first actuator (222) on the body can be activated by a user to initiate a recording cycle at a starting point of a desired welding or cutting path and to terminate the recording cycle at an ending point of the path. A second actuator (224) on the body can be activated by the user to indicate way points (227, 228, 229) from the starting point (227) to the ending point (229) as the user moves the torch along the path. The first actuator sends first information to a robot controller, operatively connected to and located remotely from the robot, to initiate and to terminate the recording cycle at the controller. The second actuator device sends the way points as second information to the controller to be recorded at the controller during the recording cycle.