Welding Seam Point Calibration Using Virtual Face References
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Solution Overview
Problem
Manual calibration of welding seam points in robot welding is time-consuming and inefficient, as it requires users to manually find face references and input search parameters for each seam point, making the process less flexible and dependent on the geometry of each object to be welded.
Innovation Solution
A method and system that automatically determine three perpendicular reference faces and calculate start and search points for welding seam point calibration based on the object's geometry in a virtual model, enabling the automatic generation of search instructions and reducing the time, manpower, and cost required for calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual calibration method is used to determine search parameters for welding seam points, then the calibration can be performed with simple equipment, but the calibration process becomes time-consuming and labor-intensive
Solution Approach 1:
The system enables automatic determination of search parameters by having the robot autonomously identify face references and calculate start/search points based on object geometry, eliminating the need for manual user input and significantly reducing calibration time
Solution Approach 2:
The patent replaces manual mechanical operations (user finding face references, inputting parameters) with automated computational processes that calculate search parameters based on virtual model geometry and predetermined criteria
2Adaptability or versatility
If manual calibration method is used for each welding seam point, then the process can be adapted to specific object geometries, but the complexity of the calibration process increases
Solution Approach 1:
The system establishes a universal automated calibration framework that can handle different object geometries through a standardized process: automatically identifying face references and calculating search parameters based on virtual model geometry, making the process adaptable without increasing operational complexity
Solution Approach 2:
The patent uses virtual model geometry as a digital copy of the physical object to determine search parameters, allowing the system to adapt to specific object geometries through computational analysis of the virtual representation rather than requiring manual adaptation for each physical object
3Productivity
If automated method is used to determine search parameters, then calibration efficiency is improved, but the system complexity increases
Solution Approach 1:
The system achieves high calibration efficiency by enabling the robot to autonomously determine search parameters through self-service operations: automatically identifying face references and calculating start/search points without requiring complex external intervention or manual operations
Solution Approach 2:
The patent leverages the existing virtual model as a digital copy to automatically determine search parameters, utilizing predetermined criteria applied to the virtual geometry to generate calibration data without requiring additional complex hardware or systems
Data Source
AI summary
A method, system and apparatus of determining search parameters for welding seam point calibration. The method includes determining, for a seam vertex point on a welding seam, three reference faces which are perpendicular to each other, based on geometry of an object to be weld in a virtual model; and determining a start point and a search point of a search motion for welding seam point calibration based on the three reference faces and predetermined criteria respectively for the start point and the search point. Three reference faces can be extracted automatically, and search parameters needed for the search instructions can be determined based thereon which enables automatic generation of search instructions and thus the time, manpower and cost for the welding seam point calibration can be reduced greatly.