3D Weld Path Generation From Point Cloud Scanning
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Solution Overview
Problem
Existing robotic welding systems are limited in generating accurate and efficient weld paths, as they typically only scan specific areas and do not fully utilize the possible welding area, leading to inefficiencies and potential errors in the welding process.
Innovation Solution
A robotic system with advanced software and hardware components, including a database for procedure development, graphical user interfaces, and sensors like laser line scanners, capable of generating three-dimensional point clouds and processing them to create detailed weld paths with multiple degrees of freedom, allowing for precise scanning and welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing robotic welding systems scan only specific areas, then the scanning operation is simpler and faster, but the welding path accuracy and completeness deteriorates
Solution Approach 1:
The system transitions from 2D scanning to 3D point cloud scanning by introducing a laser line scanner that captures three-dimensional data of the entire welding area. This dimensional enhancement allows comprehensive coverage of complex geometries while maintaining scanning efficiency through automated processing pipelines.
Solution Approach 2:
The robotic system integrates multiple functions including 3D scanning, point cloud processing, weld path generation, and simulation capabilities within a single unified platform. This multi-functionality eliminates the need for separate specialized devices while achieving comprehensive welding area coverage and high precision path generation.
2Manufacturing precision
If the entire welding area is scanned, then the weld path completeness and accuracy improves, but the scanning time and processing complexity increases
Solution Approach 1:
The system performs preliminary 3D scanning and point cloud processing before actual welding operations to generate the complete weld path. By pre-processing the entire welding area and creating a digital twin model, the system eliminates the need for time-consuming real-time adjustments during welding, thus achieving both completeness and efficiency.
Solution Approach 2:
The system creates a digital copy (point cloud model) of the physical welding area that can be processed, analyzed, and simulated virtually. This digital twin allows comprehensive analysis of the entire welding area without physical constraints, enabling complete path planning while reducing actual welding time through virtual verification.
3Measurement precision
If complex 3D point cloud processing is performed, then the weld path accuracy improves, but the computational complexity and processing time increases
Solution Approach 1:
The complex point cloud processing pipeline is segmented into distinct modular stages: data acquisition, point cloud generation, feature extraction, path calculation, and simulation. Each module handles a specific aspect of the processing, making the overall complex system manageable and enabling parallel processing where applicable, thus maintaining precision while controlling computational 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
The system enables the generation of accurate and efficient weld paths by scanning the entire welding area, converting point cloud data into usable paths, and simulating these paths for precise robotic operation, enhancing the accuracy and efficiency of the welding process.
Implementation Method 1
sensors like laser line scanners, capable of generating three-dimensional point clouds
Data Source
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AI summary
Embodiments of the present disclosure are directed towards a robotic system and method. The system may include a robot and a three dimensional sensor device associated with the robot configured to scan a welding area and generate a scanned welding area. The system may include a processor configured to receive the scanned welding area and to generate a three dimensional point cloud based upon, at least in part the scanned welding area. The processor may be further configured to perform processing on the three dimensional point cloud in a two-dimensional domain. The processor may be further configured to generate one or more three dimensional welding paths and to simulate the one or more three dimensional welding paths.