Adaptive V-Groove Seam Welding with Profilometric Torch Control
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Solution Overview
Problem
Existing autonomous welding robots face challenges in accurately adapting to the trapezoidal profile of chamfered joints, requiring manual operator intervention due to instability in torch movement and asymmetrical weld bead formation, and are not capable of reproducible, high-quality welds without continuous human control.
Innovation Solution
An autonomous welding system that uses robust monitoring and adaptive control methods, including profilometric measurements to calculate and adjust the amplitude of oscillations and timing of the welding torch, ensuring precise alignment and material deposition, even with less agile carriages, and incorporates multiple sensors and axes for precise movement and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adaptive programming is used to control torch oscillations and timing, then welding quality can be maintained, but the system becomes highly sensitive to measurement defects and uncertainties
Solution Approach 1:
The system continuously measures the actual weld bead profile during welding and uses this feedback to adjust torch oscillation amplitude and timing in real-time, maintaining welding quality while adapting to measurement variations through iterative correction
Solution Approach 2:
The system performs preliminary profilometric measurements of the joint geometry before welding begins, allowing it to pre-calculate appropriate oscillation parameters and timing delays, thereby reducing sensitivity to measurement uncertainties during the actual welding process
2Extent of automation
If crawling robots with magnetic tracks are used for movement, then autonomous operation is enabled, but positioning precision and movement control stability deteriorate
Solution Approach 1:
The system dynamically adjusts torch oscillation parameters based on real-time feedback from profilometric measurements, compensating for positioning variations introduced by the crawling robot's limited precision and maintaining weld quality despite movement instability
Solution Approach 2:
The system changes operational parameters (oscillation amplitude, frequency, and timing delays) adaptively based on measured joint geometry and weld bead profile, allowing the crawling robot to achieve precise welding results despite its inherent positioning limitations
3Manufacturing precision
If the welding torch oscillations are adapted to the joint profile, then weld quality improves, but the complexity of control systems increases
Solution Approach 1:
The system replaces complex mechanical control mechanisms with automated computational algorithms that calculate optimal oscillation parameters based on profilometric data, reducing mechanical complexity while maintaining or improving weld quality through software-based adaptation
Data Source
Figure 1
Figure 2A~3
AI summary
The invention relates to a self-contained system for welding two chamfered panels (191, 192), in particular along a plating seam, according to a welding sequence including a plurality of passes and comprising: a. a carriage (100) including motor-driven means for moving along a welded seam (190); b. a platform (120) supported by the carriage and including actuators and guide means, referred to as movement axes, for moving an effector relative to the carriage (100) according to a movement including two axes (y, z) perpendicular to the direction (x) in which the carriage (100) advances along the welded seam (190); c. a welding torch held by said platform (120); d. a profilometer (131) supported by the carriage and capable of acquiring a signal on the basis of the profile of the welded seam (190) in front of the welding torch in the direction (101) in which the carriage (100) advances along said welded seam; and e. a control computer (160, 161) capable of: ei. acquiring the signal from the profilometer (131); eii. carrying out calculations of the profile of the welded seam; and eiii. controlling the movement axes of the platform and the motor-driven means of the carriage on the basis of the calculation carried out in eii).