Vision-Guided Welding Robot for Precise Joint Alignment
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Solution Overview
Problem
Existing welding systems face limitations in precision, reproducibility, and suitability for complex piece topologies, leading to suboptimal welding quality and increased downtime.
Innovation Solution
A 6-axis welding robot system with a vision module mounted on the fourth axis, utilizing two optical sources and a camera to generate image data for determining a reference welding path, allowing for precise alignment and adjustment of the welding process based on virtual and real-time image processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If robot-based welding systems are used, then automation is achieved, but precision and reproducibility are limited
Solution Approach 1:
The patent replaces traditional mechanical positioning systems with a vision-based optical system. A camera captures images of the workpiece, and image processing algorithms automatically determine the precise location and orientation of welding joints, substituting mechanical measurement and positioning with optical detection and computational analysis to achieve higher precision in automated welding.
Solution Approach 2:
The patent creates a digital representation of the workpiece by capturing its image and processing it to extract geometric features. This virtual model serves as a reference for planning the welding path, allowing the system to adapt to actual workpiece variations without physical repositioning, thereby improving precision while maintaining automation.
2Productivity
If existing welding systems are used, then welding can be performed, but downtime is relatively long
Solution Approach 1:
The patent performs image capture and processing, along with welding path calculation, before the actual welding operation begins. By preparing the welding trajectory in advance based on the captured workpiece image, the system eliminates time-consuming adjustments and positioning during the welding process itself, thereby reducing downtime and improving overall productivity.
Solution Approach 2:
The patent implements a feedback loop where the vision system continuously monitors the workpiece, detects its actual geometry and joint positions, and adjusts the welding path accordingly. This real-time feedback mechanism allows the system to adapt to variations in workpiece positioning and geometry, maintaining high precision while minimizing downtime through automated adjustments without manual intervention.
3Adaptability or versatility
If traditional welding systems are used, then simple pieces can be welded, but complex piece topologies cannot be handled effectively
Solution Approach 1:
The patent transitions from 2D image capture to 3D spatial understanding by processing the captured image to extract three-dimensional geometric features of the workpiece and welding joints. This dimensional transformation enables the system to accurately determine welding paths for complex 3D topologies, maintaining precision across diverse and intricate geometries that traditional 2D-based systems cannot handle effectively.
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
Enhances precision and reproducibility, reduces downtime by enabling accurate detection and alignment of welding joints, and improves the quality of welding complex piece topologies.
Implementation Method 1
The at least one optical source is operable to irradiate the at least portion of the piece along at least two different irradiation paths. The camera is configured to receive light emanating from the at least portion of the piece upon irradiation by the at least one optical source and to generate therefrom image data representative of the at least portion of the piece to be welded.
Data Source
AI summary
The present disclosure concerns a system and associated method for welding a piece. The system includes a 6-axis welding robot including a robotized arm, a vision module and a computing device. The vision module is mounted to a fourth axis of the robotized arm and includes optical sources and a camera. The optical sources are operable to irradiate the piece along irradiation paths. The camera is configured to receive irradiated light from the piece and to generate image data. The computing device is operatively connected to the camera and includes non-transitory computer readable storage medium having stored instructions that, when executed by a processor causes the processor to receive the image data; obtain a reference welding path to be followed by the welding robot for welding the piece; send instructions to the welding robot to weld the piece according to the reference welding path.