Weld Seam Tracking With Independent Sensing and Path Adjustment
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Solution Overview
Problem
Existing welding systems lack effective methods for tracking the location of a seam between two parts being joined, leading to defects and compromised weld quality, which can result in reworking or scrapping of components and safety concerns.
Innovation Solution
A system and method utilizing a measuring device, such as a camera or scanner, to detect the seam location independently of the robot, with a controller adjusting the welding path to ensure precise seam tracking, and a software algorithm to generate and adjust the welding process accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding systems without seam tracking are used, then the system complexity is low, but weld quality and precision deteriorate leading to defects and rework
Solution Approach 1:
The patent introduces a measuring device as an intermediary component between the robot and the workpiece. This device independently determines the actual seam location and provides feedback to the controller, which then adjusts the welding path. This mediator approach enables precise seam tracking without requiring complex integration between the robot and sensing systems, resolving the contradiction between precision and complexity.
Solution Approach 2:
The patent implements a feedback mechanism where the measuring device continuously monitors the seam location and provides information to the controller. The controller uses this feedback to dynamically adjust the welding path in real-time, ensuring accurate seam tracking. This feedback loop enables high manufacturing precision while maintaining manageable system complexity through modular architecture.
2Reliability
If independent seam tracking system is implemented, then weld quality improves, but system complexity and cost increase
Solution Approach 1:
The patent segments the welding system into independent functional modules: the robot for positioning, the measuring device for seam detection, and the controller for path adjustment. This segmentation allows each component to perform its specific function optimally, improving weld quality consistency while keeping the overall system complexity manageable through clear module boundaries and independent operation.
3Productivity
If real-time seam tracking is performed, then productivity increases through reduced rework, but measurement and control difficulty increases
Solution Approach 1:
The patent replaces complex mechanical seam tracking mechanisms with a measuring device that uses optical or electromagnetic fields to detect seam location. This substitution eliminates the need for complex mechanical linkages and contact-based sensing, making real-time seam tracking easier to implement and more reliable, thereby increasing productivity without excessive measurement difficulty.
Data Source
AI summary
A system and method tracking location of a seam between metal parts before, during and/or after a process of joining the parts together is provided. The parts are typically formed of steel or aluminum and designed for use in a vehicle. The parts are typically joined together by welding, such as gas metal arc welding. A cell contains the parts to be joined, and a measuring device is mounted on a wall of the cell for detecting the location of a seam between the parts. The system further includes a software algorithm and a controller for determining a joining path, controlling and/or adjusting the joining process based on the location of the seam detected by the measuring device. The measuring device can detect other features, such as presence of a gap between the parts, height of the parts, and location of the weld seam after the joining process.