Welding Torch Surface Scanning with Power-Source Edge Detection
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Solution Overview
Problem
Existing surface scanning methods for metallic workpieces using welding wires are slow and require significant computing power, limiting their efficiency and accuracy, especially when detecting edges on uneven or curved surfaces.
Innovation Solution
The method involves determining edges by setting an edge detection parameter in the welding power source, which is then transmitted to the manipulator, reducing data processing requirements and allowing faster scanning without loss of accuracy, and includes adjusting scanning parameters like edge height, inclination, and radius for optimal welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the manipulator processes all position data to detect edges, then edge detection accuracy is improved, but processing time increases and productivity decreases
Solution Approach 1:
The patent extracts only the essential edge detection parameter from the complete position data set. Instead of transmitting all position measurements to the manipulator for processing, the welding power source identifies and transmits only the critical edge detection parameter, dramatically reducing data volume while maintaining detection accuracy.
Solution Approach 2:
The welding power source performs preliminary edge detection processing before data transmission. By analyzing position data and identifying edge parameters in advance, the system prepares only the necessary information for the manipulator, reducing real-time processing requirements and enabling faster scanning speeds.
2Difficulty of detecting and measuring
If the manipulator performs complex data evaluation, then edge detection capability is improved, but device complexity increases
Solution Approach 1:
The welding power source acts as an intermediary that performs the complex data evaluation and edge detection algorithms. It processes the position data from the welding wire scanner, identifies edges, and transmits only the resulting edge detection parameter to the manipulator, eliminating the need for complex computational capabilities in the manipulator itself.
3Productivity
If scanning speed is increased, then productivity is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces the mechanical constraint of slow scanning with an intelligent data processing system. The welding power source uses algorithms to identify edges from position data even at higher scanning speeds, and the selective transmission of edge parameters ensures that precision is maintained without being limited by processing 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 approach enables quicker edge detection and scanning processes, reduces computational demands on the manipulator, and allows for precise adaptation of welding parameters based on edge characteristics, improving welding quality and efficiency.
Implementation Method 1
until contact of the welding wire with one of the workpieces is detected by a welding power source
Data Source
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AI summary
The invention relates to a method for scanning the surface (O) of metal workpieces (W) wherein, during a scanning process before a welding process is carried out, a welding torch (1) with a fusible welding wire (2) is moved over the surface (O) of the workpieces (W) and the welding wire (2) is moved to the surface (O) of the workpieces (W) at predefined times (ti) until a contact between the welding wire (2) and one of the workpieces (W) is detected, and the position (Pi) of the surface (O) of the workpieces (W) at each time (ti) is determined and stored in the welding current source (4), wherein an edge (K) is determined if the current position (Pi) of the surface (O) of the workpieces (W) exceeds at least one of the stored preceding positions (Pi-n) of the surface (O) of the workpieces (W) by a predefined threshold (S). To reduce the computing effort and to increase processing speed, the end of the edge (K) is identifiedi f the current position (Pi) of the surface (O) of the workpieces (W) remains the same with respect to at least one of the stored preceding positions (Pi-n), and in the event of an edge (K) being determined, an edge detection parameter (KP) is set and is output together with the current position value (Pi) and transferred to the manipulator (3).