Smart Welding Torch Path Teaching for Confined-Space Cobots
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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 inaccessible.
Innovation Solution
A collaborative robot (cobot) equipped with a 'smart' welding torch that allows operators to program welding paths by holding a dead-man switch on the torch, eliminating the need for a teach pendant and enabling remote operation in confined spaces through a magnetic base or concrete floor mounting, with actuator devices for recording and communicating welding points to a robot controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional robot is used for welding, then welding operations can be performed, but the robot requires physical guarding and cannot be operated remotely in confined spaces
Solution Approach 1:
The patent replaces traditional mechanical robot control systems with a collaborative robot that uses smart torch actuators for direct manual manipulation. The smart torch includes actuators that detect operator actions and translate them into robot movements, eliminating the need for teach pendants and physical guarding while enabling safe remote operation in confined spaces.
2Productivity
If a teach pendant is used to program the robot, then welding paths can be recorded, but the operator cannot use both hands and must hold a dead-man switch continuously
Solution Approach 1:
The patent merges the control functions into the smart torch itself. The torch contains actuators that combine the dead-man switch functionality with the ability to record welding paths. When the operator holds the torch, the actuators automatically detect movements and record waypoints, eliminating the need for separate teach pendant operation and enabling two-handed work.
Solution Approach 2:
The smart torch system performs self-recording of welding paths through its actuators. When the operator manipulates the torch, the actuators automatically detect the movements and record the welding path data without requiring the operator to manually trigger recording commands or hold additional controls.
3Length of stationary object
If a traditional robot is mounted near the porch, then control is simplified, but the robot cannot reach remote or confined welding locations
Solution Approach 1:
The patent makes the robot system dynamic by using a mobile collaborative robot that can be moved to different locations as needed. The cobot is equipped with a magnetic base for easy repositioning on metal surfaces or can be mounted on concrete floors at various positions. This dynamic positioning capability allows the robot to reach remote and confined welding locations while maintaining control through the smart torch.
Data Source
AI summary
A torch for use by a robot. The torch has a body that can be connected to an arm of the robot. A first actuator 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 on the body can be activated by the user to indicate way points from the starting point to the ending point 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.