Robot-Independent Weld Seam Tracking for Precise Welding Paths
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Solution Overview
Problem
Existing welding systems lack effective methods for tracking the location of a seam between 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 robot-independent seam tracking system that utilizes a measuring device, such as a camera or scanner, to detect the seam location before, during, and after the joining process, with a controller adjusting the welding path to ensure precise and consistent welds, independent of the specific robot or welding equipment used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If no seam tracking system is implemented, then the system remains simple, but weld quality deteriorates due to inability to track seam location
Solution Approach 1:
The system separates the measuring device from the robot and welding tool, creating an independent seam tracking subsystem. This segmentation allows the measuring device to independently detect seam location while the robot executes welding, resolving the contradiction by adding precision capability without significantly increasing overall system complexity.
Solution Approach 2:
The measuring device acts as an intermediary between the robot and the welding process. It provides seam location information that mediates the control between the robot's movement and the welding tool's operation, enabling precise weld quality without requiring direct integration of complex tracking mechanisms into the welding system.
2Adaptability or versatility
If a robot-dependent seam tracking system is used, then tracking can be integrated with welding, but the system lacks flexibility across different robots and welding equipment
Solution Approach 1:
The measuring device is designed as a universal, robot-independent component that can interface with multiple different robot systems and welding tools. This universality allows the same measuring device to work across various configurations without requiring custom integration for each robot, thereby improving adaptability while avoiding the complexity of multiple specialized systems.
Solution Approach 2:
The seam tracking functionality is extracted from the robot system and placed in a separate, independent measuring device. This extraction allows the tracking system to be universally applicable across different robots without being tied to any specific robot's control architecture, enhancing versatility while reducing integration complexity.
3Productivity
If seam location is not accurately tracked, then the system operates simply, but defects occur leading to rework or scrap
Solution Approach 1:
The measuring device performs preliminary detection of the seam location before the welding process begins and continues tracking during welding. This preliminary and continuous measurement ensures accurate seam location is established in advance, preventing defects that would lead to rework or scrap, thereby improving productivity through defect prevention rather than correction.
Solution Approach 2:
The system implements feedback by continuously measuring seam location with the measuring device and using this information to guide the welding process. This real-time feedback ensures the welding tool follows the actual seam position, preventing defects and reducing scrap, thus improving productivity through precision control.
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 enhances weld quality by accurately tracking and adjusting the welding path, reducing defects and ensuring precise, consistent seams, thereby minimizing scrap and improving safety.
Implementation Method 1
a measuring device spaced from the at least one robot and the at least one joining tool for determining location of a seam between the parts before, during, and/or after the joining step
Data Source
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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.