Weld Shape Feedback Control for Automatic Welding Correction
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Solution Overview
Problem
The existing welding systems face challenges in consistently achieving optimal welding conditions due to variations in workpiece states, welding equipment states, and environmental factors, leading to inconsistent weld quality and potential welding failures.
Innovation Solution
A welding system that includes a shape measurement unit, image processor, determination unit, and feedback unit for automatic correction of welding conditions based on real-time inspection data, using a welding apparatus with a welding head and output controller to adjust parameters such as power and wire feed speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual inspection and correction of welding conditions is used, then flexibility in handling diverse workpieces is maintained, but welding quality consistency deteriorates due to operator variability and inability to accurately correct for complex defect modes
Solution Approach 1:
The system implements automatic feedback control by measuring weld shape, determining defect modes, and correcting welding conditions based on pre-stored correction data. This closed-loop feedback mechanism replaces manual inspection and correction, ensuring consistent weld quality across diverse workpiece types without operator variability.
Solution Approach 2:
The welding system performs self-correction by automatically determining defect modes from measured weld shapes and applying appropriate condition corrections using pre-stored data. This self-service capability eliminates the need for operator intervention while maintaining the ability to handle diverse workpiece types.
2Reliability
If preset welding conditions are used for diverse workpieces, then productivity is maintained, but welding reliability deteriorates when conditions deviate from optimum due to workpiece state variations
Solution Approach 1:
The system performs preliminary actions by pre-storing correction data for multiple defect modes and workpiece types before actual welding. When welding occurs, the system quickly retrieves and applies the appropriate correction, maintaining high productivity while ensuring reliability through pre-prepared optimal conditions for various scenarios.
Solution Approach 2:
The system dynamically changes welding parameters based on measured weld shapes and determined defect modes. By automatically adjusting power, speed, and other welding conditions according to actual workpiece states and defect types, the system maintains optimal welding reliability across diverse workpieces without sacrificing productivity.
3Manufacturing precision
If detailed manual correction of welding conditions is performed for each workpiece type, then welding quality improves, but time consumption increases due to the complexity of delicate corrections
Solution Approach 1:
The system creates copies of optimal welding conditions by pre-storing correction data for various defect modes and workpiece types. Instead of performing time-consuming manual analysis and correction for each workpiece, the system quickly retrieves the appropriate pre-corrected conditions, achieving high weld shape accuracy while minimizing time loss.
Solution Approach 2:
The system replaces the mechanical process of manual inspection and correction with automated optical measurement and computer-based determination. By using shape measurement sensors and automated defect mode determination algorithms, the system achieves detailed weld shape control without the time consumption of manual operations.
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
This system enables accurate and automatic correction of welding conditions, reducing the likelihood of welding failures and improving weld quality by providing precise adjustments based on defect analysis.
Implementation Method 1
an image of an obtained shape line is captured by a measurement camera
Data Source
AI summary
A welding system includes a welding apparatus and an appearance inspection apparatus. The appearance inspection apparatus includes: a shape measurement unit that measures the shape of a weld; an image processor that generates image data based on data of the shape; a determination unit that determines whether the shape of the weld is good or bad based on the image data and a determination model; and a feedback unit that extracts shape defect information if the result of the determination by the determination unit is negative. An output controller of the welding apparatus corrects a welding condition for a workpiece based on the shape defect information extracted by the feedback unit.