Welding Robot Workpiece Sensing for Calibrated Point Search
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Solution Overview
Problem
Existing robot programming applications for welding and similar metal fabrication operations are not very intuitive, requiring precise location of workpieces, which can be challenging and time-consuming, especially when editing existing programs or dealing with workpieces that are offset from the expected location.
Innovation Solution
A user interface application integrated with a teach pendant that simplifies the process of searching for and calibrating the physical location of workpieces by allowing users to input a search start and end point, automatically determining the search vector, and calibrating the search by moving the tool center point until contact with the workpiece is detected, thereby adjusting the search vector and providing a calibrated indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a workpiece search is included in the welding program to determine the actual location of the workpiece, then the system can adapt to workpiece location variations, but the programming process becomes less intuitive and more complex
Solution Approach 1:
The system performs self-calibration by automatically detecting the workpiece location and adjusting the search parameters without requiring manual reprogramming. The calibration process is initiated by the operator through simple commands, but the system autonomously completes the adjustment by comparing expected vs. actual workpiece positions and modifying the search vector accordingly.
Solution Approach 2:
The system performs a preliminary calibration process during which the workpiece location is detected and the search parameters are adjusted before actual welding operations begin. This preliminary action establishes the correct reference frame for subsequent welding operations, preventing the need for complex real-time adjustments during programming.
2Manufacturing precision
If the workpiece must be located precisely at an expected location to edit an existing program, then the welding points remain accurate, but the ease of editing is reduced and time is lost
Solution Approach 1:
The system performs a preliminary calibration detection when the workpiece is placed on the fixture, determining the actual location before welding operations or program edits begin. This preliminary detection allows operators to edit programs with the workpiece in its actual position rather than requiring precise pre-placement, significantly reducing editing time while maintaining welding point accuracy through automatic coordinate adjustment.
3Measurement precision
If the tool center point is manually positioned for workpiece search calibration, then the search accuracy can be achieved, but the operation becomes time-consuming and complex
Solution Approach 1:
The system replaces manual mechanical positioning of the tool center point with an automated detection system. The system automatically moves the tool center point along the search vector and detects the workpiece location using sensors, eliminating the need for manual positioning while maintaining high search accuracy. This substitution of mechanical manual operation with automated detection significantly increases calibration speed.
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 solution streamlines the workpiece search and calibration process, reducing the need for precise initial placement of workpieces, enhancing user intuitiveness, and allowing for easy recalibration during program edits, thus improving efficiency and accuracy in robot welding operations.
Implementation Method 1
A welding power supply is operatively connected to the welding torch to supply welding current to the welding torch
Implementation Method 2
the tool center point is automatically moved along the search vector until a point of contact with the workpiece is detected
Data Source
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AI summary
A welding system includes a robot having a movable arm. A robot controller is operatively connected to the robot. A welding torch is attached to the robot. A welding power supply is operatively connected to the torch. A teach pendant is in communication with the robot controller and includes a user interface application configured for programming a plurality of welding points of a welding operation performed by the robot, and is configured for programming a workpiece search for a physical location of a workpiece. The user interface application is further configured to receive input of a search start point that is offset from the physical location of the workpiece, and to display a prompt to calibrate the search. Upon receiving user input to calibrate the search, the physical location of the workpiece is automatically detected and a calibrated indication is displayed confirming that the search is currently calibrated.