Weld Angle Correction for Faster Multi-Pass Cobot Programming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Programming motion trajectories for collaborative robots in welding or cutting is complex, particularly in setting and programming angles and orientations of the welding or cutting torch along weld joints.
Innovation Solution
A cobot welding system that automatically calculates positional offsets for secondary weld passes based on root weld data and start/stop points, allowing for simplified programming by inputting only physical positions rather than numerical offsets, and utilizing a weld angle correction tool to adjust torch angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual positioning and recording of torch angles is performed during robot training, then the robot can learn weld trajectories, but the programming complexity and time required increase significantly
Solution Approach 1:
The system uses the robot's own camera to capture images of the workpiece and automatically calculates torch angles from these images, eliminating the need for external measurement devices or manual angle input. The robot performs self-measurement and self-programming by processing visual data to determine precise torch orientations at each weld point.
Solution Approach 2:
The patent replaces manual mechanical angle measurement and input methods with an automated computer vision system. Instead of physically measuring angles with protractors or manually entering values, the system uses image processing to automatically calculate torch angles from captured images, substituting mechanical measurement with optical-digital computation.
2Manufacturing precision
If precise torch angle control is implemented during robot training, then weld quality improves, but the ease of operation decreases due to complex programming requirements
Solution Approach 1:
The system automatically determines torch angles by processing images of the workpiece captured during robot operation. The robot captures images, identifies weld features, calculates the required torch angles, and programs itself without external intervention, maintaining high weld quality while simplifying operation to basic image capture and processing.
Solution Approach 2:
The system creates a visual copy of the workpiece geometry through image capture and uses this digital representation to calculate torch angles. By working with image data rather than physical measurements, the system simplifies the programming process while maintaining precision, as the digital model can be easily processed and manipulated.
3Productivity
If automated offset calculation is implemented for multi-pass welds, then productivity increases, but device complexity increases
Solution Approach 1:
The system introduces image processing as an intermediary between the robot's physical actions and the programming requirements. By capturing images of the workpiece and calculating offsets from these images, the system automates the complex offset determination for multi-pass welds without requiring additional specialized hardware, thus increasing productivity while managing complexity through software-based intermediation.
Data Source
AI summary
A method of programming multiple weld passes in a collaborative robot welding system to perform multi-pass welding is provided. A root pass is programmed for a first weld seam by manually positioning a welding torch and automatically recording root pass position and angle data. Secondary passes for the first weld seam are also programmed. The tip of the welding torch is positioned at a start point and a stop point for each secondary pass. The start and stop position data of the start point and the stop point are automatically recorded for each secondary pass. Numerical position and angle offset data are automatically calculated. The root pass position and angle data and the offset data are stored as a multi-pass template. The template is translated and applied to a weld reference frame of a second weld seam to aid in programming secondary passes for the second weld seam.