Ultrasonic Weld Teaching for Accurate Robot Inspection Points
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Solution Overview
Problem
Existing robot systems face challenges in easily setting teaching points for inspection tasks, particularly when identifying the center of weld portions in joined bodies, which can be time-consuming and prone to inaccuracies due to manual adjustment and potential damage.
Innovation Solution
A processing system that utilizes a detector with detection elements to transmit ultrasonic waves and detect reflected waves, calculating the center position of weld portions based on intensity data, and adjusting the detector's position and orientation to set precise teaching points automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment is used to set teaching points for robot inspection, then the robot can be positioned at weld portions, but the process is time-consuming and prone to inaccuracies
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated ultrasonic detection system. The detector automatically probes the weld portion, calculates the center position based on reflected wave intensity data, and moves the robot to the teaching point without manual intervention, thereby improving both accuracy and efficiency
Solution Approach 2:
The system performs self-positioning by automatically detecting weld portion characteristics through ultrasonic waves, calculating the center position, and determining teaching points without requiring external manual adjustment. The robot system autonomously completes the teaching process
2Reliability
If manual adjustment is used to set teaching points, then positioning can be achieved, but damage may occur to the detector or joined body
Solution Approach 1:
The patent introduces ultrasonic waves as an intermediary to indirectly detect weld portion characteristics. Instead of direct contact that could cause damage, the ultrasonic detector probes the weld from a safe distance, calculating the center position based on reflected wave intensity, thereby preventing damage while maintaining ease of operation
Solution Approach 2:
The system replaces direct mechanical contact positioning with non-contact ultrasonic detection. The detector uses acoustic waves to identify weld portion boundaries and calculate center positions without physically touching or damaging the joined body or detector itself
3Measurement precision
If the detector probes the weld portion to calculate center position, then accurate teaching points can be set, but the detector must be precisely positioned and oriented
Solution Approach 1:
The system uses feedback from ultrasonic reflected wave intensity data to automatically determine detector positioning and orientation. The processing device analyzes the intensity data to identify weld portion boundaries and calculate the center position, providing feedback that guides the detector's position and orientation without requiring complex manual setup
Solution Approach 2:
The patent changes the approach from manually controlling detector position and orientation to automatically adjusting these parameters based on ultrasonic detection feedback. The system varies detector positioning parameters dynamically during the probing process, allowing accurate center position calculation while simplifying operational complexity
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
Enables efficient and accurate setting of teaching points for robot inspection, reducing manual adjustment time, minimizing damage, and enhancing inspection accuracy by using ultrasonic wave probing and data processing techniques.
Implementation Method 1
a detector (22) including a plurality of detection elements (22a) arranged along a first direction (X-direction) and a second direction (Y-direction), and a manipulator (21) to which the detector (22) is mounted
Implementation Method 2
The probe includes a transmission of an ultrasonic wave and a detection of a reflected wave
Data Source
AI summary
According to one embodiment, a processing system teaches an operation to a robot. The robot includes a detector including detection elements arranged along first and second directions, and a manipulator to which the detector is mounted. The processing system performs position teaching processing. 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. The position teaching processing includes calculating a center position of the weld portion in a first plane based on first intensity data of an intensity of the reflected wave, setting a teaching point of the robot based on a first position of the detector, and moving the detector along the first plane to a second position, and setting the teaching point based on the second position.