Ultrasonic Weld Teaching Point Alignment for Robot Inspection
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Solution Overview
Problem
Current robot systems face challenges in easily setting teaching points for inspecting joined bodies, particularly when the position of the detector deviates from the center of the weld portion, leading to inaccurate inspection and potential damage to the detector.
Innovation Solution
A processing system that uses ultrasonic waves to detect reflected wave intensity and calculates the center position of the weld portion, adjusting the detector's position and orientation to set the teaching point based on intensity data, thereby ensuring accurate alignment and reducing manual adjustment and potential damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual positioning of the detector is used to set teaching points, then the setup process is simple, but the positioning accuracy is poor and the detector may be damaged
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated optical positioning system. The imaging device captures images of the weld portion, and the control device automatically calculates the center position based on these images, eliminating the need for manual detector positioning and reducing both human error and physical contact risks.
Solution Approach 2:
The system enables self-positioning through automated image processing. The imaging device and control device work together to automatically determine the teaching point position without requiring operator intervention, allowing the system to set teaching points autonomously based on captured images and calculated center positions.
2Measurement precision
If the detector position is not precisely aligned with the weld portion center, then the inspection accuracy deteriorates, but achieving precise alignment manually is difficult
Solution Approach 1:
The patent replaces manual alignment operations with automated image-based positioning. The imaging device captures the weld portion, and the control device automatically calculates the center position from the captured images, ensuring precise alignment without requiring manual adjustment skills or repeated trial-and-error positioning.
Solution Approach 2:
The patent introduces images as an intermediary between the detector and the weld portion. Instead of directly positioning the detector, the system first captures images of the weld portion, calculates the center from these images, and then positions the detector based on the calculated position, using images as a mediating reference.
3Reliability
If multiple attempts are made to position the detector, then the chance of damage increases, but fewer attempts reduce positioning accuracy
Solution Approach 1:
The patent performs preliminary positioning using images before the actual inspection. The imaging device captures images of the weld portion, and the control device calculates the center position in advance, allowing the detector to be positioned accurately on the first attempt without requiring multiple trial positions that could cause damage.
Solution Approach 2:
The patent replaces trial-and-error mechanical positioning with a single-step automated positioning process. By using image processing to calculate the center position beforehand, the system achieves accurate positioning in one attempt, eliminating the repeated positioning attempts that risk detector damage.
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
The system enables more precise and efficient setting of teaching points, improving the accuracy of weld inspection and reducing the risk of detector damage, allowing for automated inspection of joined bodies with increased reliability.
Implementation Method 1
The position teaching processing includes causing the detector to perform a probe of a weld portion of a joined body. The probe includes a transmission of an ultrasonic wave and a detection of a reflected wave.
Data Source
Figure 1
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Figure 3A~3C
AI summary
According to one embodiment, a processing system (1) teaches an operation to a robot (20). The robot (20) includes a detector (22) including detection elements (22a) arranged along first and second directions, and a manipulator (21) to which the detector (22) is mounted. The processing system (1) performs position teaching processing. The position teaching processing includes causing the detector (22) to perform a probe of a weld portion (53) of a joined body (50). The probe includes a transmission of an ultrasonic wave (US) and a detection of a reflected wave (RW). The position teaching processing includes calculating a center position of the weld portion (53) in a first plane based on first intensity data of an intensity of the reflected wave (RW), setting a teaching point of the robot (20) based on a first position of the detector (22), and moving the detector (22) along the first plane to a second position, and setting the teaching point based on the second position.