Weld Sequencer Statistical Limits for Real-Time Weld Validation
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Solution Overview
Problem
Semi-automatic welding work cells face challenges in adapting to varying welding conditions and sequences due to human error, making it difficult to detect suboptimal welds and requiring cumbersome manual review of reports to set weld parameter limits, which often results in either too strict or too lenient standards.
Innovation Solution
A weld sequencer system that performs statistical analysis on generated reports to automatically determine weld parameter limits, identifying and removing outlier data, and updating the sequence file with valid limits for future welds, thereby providing real-time validation and alerts for operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual review of reports is used to set weld parameter limits, then adaptability to varying welding conditions is improved, but device complexity and time consumption increase
Solution Approach 1:
The weld sequencer automatically performs statistical analysis on weld data and self-determines weld parameter limits without requiring manual operator intervention. The system serves itself by automatically retrieving weld data, performing statistical analysis, identifying outliers, and updating sequence files with determined limits.
Solution Approach 2:
The patent replaces the manual mechanical review process with an automated statistical analysis system. The weld sequencer uses computational algorithms to analyze weld data, calculate parameter limits based on standard deviations, and update sequences, substituting human manual review with automated computational processing.
2Adaptability or versatility
If manual review of reports is used to set weld parameter limits, then adaptability to varying welding conditions is improved, but loss of time increases
Solution Approach 1:
The weld sequencer continuously performs statistical analysis on weld data as it is generated, automatically updating weld parameter limits without interrupting the welding workflow. The system retrieves weld data, performs analysis, and updates sequences in a continuous automated process rather than through discrete manual review steps.
Solution Approach 2:
The system automatically determines weld parameter limits without requiring operator time for manual review. The weld sequencer self-manages the entire process of data retrieval, statistical analysis, outlier identification, and limit determination, eliminating time loss associated with manual intervention.
3Productivity
If automated robotic work cells are used, then productivity is improved, but adaptability to varying welding conditions deteriorates
Solution Approach 1:
The weld sequencer dynamically adjusts weld parameter limits based on statistical analysis of actual weld data. The system continuously retrieves weld data, performs statistical analysis to determine current parameter limits, and updates sequence files to reflect varying welding conditions, enabling robotic work cells to adapt dynamically rather than following fixed predetermined parameters.
Solution Approach 2:
The system uses feedback from actual weld data to automatically adjust weld parameter limits. The weld sequencer retrieves weld data from completed operations, performs statistical analysis to identify appropriate limits, and uses this feedback to update future welding sequences, creating a closed-loop system that adapts to varying conditions while maintaining high productivity.
Data Source
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AI summary
Various systems and methods are provided that allow a weld sequencer (102) to use a statistical analysis of generated reports to automatically determine weld parameter limits for the welds defined by various functions in a sequence file. For example, the weld sequencer (102) can take reports generated for a specific type of part and statistically analyze the weld data Included in the reports according to a set of analysis (708) parameters provided by a user. The weld sequencer (102) can use the statistical analysis to identify and remove outlier data and define a set of weld parameter limits based on the remaining data. The weld parameter limits can define a low limit and/or a high limit for one or more weld parameters associated with a function. The weld sequencer (102) can then update the sequence file to include the weld parameter limits.