Spot Welding System Communication Delay Compensation
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Solution Overview
Problem
The cycle time of spot welding is prolonged due to communication delays between the robot and welding machine, which affect the operation time and efficiency of the welding process.
Innovation Solution
A spot welding system that includes a communication delay calculation unit to determine the communication delay time, allowing for the advancement of welding command and completion signal transmission timings, thereby reducing the overall cycle time by synchronizing the pressure and welding times with the calculated delay.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If communication delay is not compensated, then the system operation is simple, but the cycle time is prolonged
Solution Approach 1:
The communication delay time is calculated in advance based on the difference between pressure time and welding time, and this pre-calculated delay value is then used to advance the transmission timing of welding commands and completion signals, thereby compensating for communication delays without adding complex real-time adjustment mechanisms
Solution Approach 2:
The patent replaces physical timing adjustment mechanisms with a computational approach, using the communication delay calculation unit to compute delay values and the transmission timing advancement units to adjust signal timing based on these calculations, eliminating the need for mechanical timing devices
2Reliability
If pressure time is prolonged to account for communication delay, then the welding quality is maintained, but the cycle time is increased
Solution Approach 1:
The system uses feedback from the pressure completion signal and welding completion signal to calculate the actual communication delay time, then applies this feedback to advance the transmission timing of subsequent commands, creating a closed-loop system that maintains welding quality while minimizing cycle time
Solution Approach 2:
The patent dynamically adjusts the transmission timing parameter of welding commands and completion signals based on the calculated communication delay time, changing when these signals are transmitted to compensate for delay without extending the actual pressure or welding duration
Data Source
AI summary
To provide a spot welding system capable of shortening a cycle time of spot welding. A robot controller measures a time between a transmission time of a welding command signal to a welding machine and a reception time of a welding completion signal, after determining completion of pressuring by a spot welding robot, and subtracts a predetermined welding time from the measured time, thereby calculating a communication delay time between the robot controller and the welding machine. A spot welding system advances transmission timing of the welding command signal and the welding completion signal by the calculated communication delay time.