Tandem Arc Welding Robot Control Unit Trajectory Correction
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Solution Overview
Problem
In tandem arc welding systems, displacement from the teaching trajectory during welding due to positioning errors and thermal strain leads to low accuracy in arc-sensor control, resulting in welding defects, as the trailing electrode deviates from the intended path despite corrections made by the leading electrode.
Innovation Solution
A robot control unit with leading and trailing electrode detection and processing sections that calculate and apply correction amounts for horizontal, vertical, and rotational displacements, ensuring precise control of the welding torch along the weld line by detecting electrical changes and adjusting the trajectory accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If arc-sensor control corrects robot trajectory in horizontal direction using leading electrode, then leading electrode follows teaching trajectory, but trailing electrode deviates from teaching trajectory due to oblique displacement
Solution Approach 1:
The invention segments the correction task by assigning different correction responsibilities to different electrodes: the leading electrode corrects horizontal direction displacement while the trailing electrode corrects oblique direction displacement. This segmentation allows each electrode to specialize in correcting specific types of trajectory deviations, resolving the contradiction where single-electrode correction fails to maintain both leading and trailing electrode alignment with the teaching trajectory.
Solution Approach 2:
The invention introduces an intermediary correction mechanism where the leading electrode detection and correction sections work together with the trailing electrode detection and correction sections. The leading electrode serves as an intermediary that first corrects horizontal displacement, enabling the trailing electrode to then effectively correct oblique displacement, thereby achieving comprehensive trajectory accuracy that neither electrode could achieve alone.
2Ease of operation
If single electrode correction is used for horizontal direction, then leading electrode maintains trajectory, but overall welding accuracy deteriorates due to uncorrected oblique displacement
Solution Approach 1:
The invention merges the correction functions of both leading and trailing electrodes into a unified dual-correction system. The leading electrode correction section and trailing electrode correction section work in combination, with the leading electrode handling horizontal direction correction and the trailing electrode handling oblique direction correction. This merging of correction functions resolves the contradiction by maintaining operational simplicity while achieving comprehensive trajectory accuracy through coordinated action of both electrodes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the accuracy of arc-sensor control, reducing the occurrence of welding defects by concurrently or successively controlling the welding torch in horizontal, vertical, and rotational directions, thereby maintaining alignment with the weld line.
Implementation Method 1
a leading electrode detection section for detecting quantity of welding state during weaving the leading electrode; a trailing electrode detection section for detecting quantity of welding state during weaving the trailing electrode
Data Source
AI summary
A robot control unit for controlling a tandem arc welding system, which has a welding torch, a robot for weaving the welding torch, a leading electrode power supply, and a trailing electrode power supply, includes a leading electrode detection section and a trailing electrode detection section for detecting quantity of welding state during weaving; a leading electrode processing section for calculating amounts of electrical change; a leading electrode correction section for calculating correction amounts for correcting displacement in horizontal and vertical directions from a weld line of a weaving center trajectory based on the amounts of electrical change; a trailing electrode processing section for calculating an amount of electrical change; and a trailing electrode correction section for calculating a correction amount for correcting displacement in a rotational direction from the weld line of the weaving center trajectory based on the amount of electrical change.