Weld Torch Angle Correction for Tilted Plate Robot Welding
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Solution Overview
Problem
Current methods for programming robot welding or cutting systems are cumbersome and imprecise, particularly in setting and programming angles and orientations of the welding or cutting torch, leading to less precise welds due to manual adjustments and reliance on visual inspection, which are affected by plate tilting and slope.
Innovation Solution
A weld angle correction tool that uses a depth camera and computer software to acquire stereoscopic image data, calculate and correct torch angles in real-time, allowing users to make fine adjustments through a user interface, and automatically adjust angles based on tilt and pre-stored ideal angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning and visual inspection methods are used to set torch angles, then the programming process is simple, but the welding precision and angle accuracy deteriorate
Solution Approach 1:
The patent replaces manual visual inspection and mechanical positioning with an automated vision system using depth cameras and image processing algorithms. The system automatically detects weld joint geometry, calculates optimal torch angles, and guides robot positioning, eliminating the need for manual angle setting while achieving precise welding results.
Solution Approach 2:
The patent creates a digital 3D model of the weld joint by capturing depth data and generating point clouds. This virtual copy of the physical weld joint allows the system to calculate torch angles and trajectories in the digital space, then transfer these parameters to control the physical robot, ensuring high precision without complex manual programming.
2Measurement precision
If automated vision systems with depth cameras are implemented, then welding precision improves, but device complexity and cost increase
Solution Approach 1:
The patent integrates multiple functions into a unified system: the depth camera serves both for weld joint detection and torch angle measurement, the point cloud processing system handles both geometry recognition and trajectory calculation, and the robot controller manages both positioning and angle adjustment. This multi-functionality reduces the need for separate dedicated devices for each measurement task.
Solution Approach 2:
The vision system automatically performs calibration and adapts to different weld joint geometries without requiring manual intervention. The system self-calibrates by detecting feature points and automatically adjusts measurement parameters based on the detected joint type, eliminating the need for separate calibration procedures and reducing operational complexity.
3Reliability
If manual angle adjustment is used, then the system is easy to operate, but welding quality consistency deteriorates
Solution Approach 1:
The patent implements a closed-loop feedback system where the depth camera continuously monitors the actual torch angle and position during welding, compares it with the ideal parameters calculated from the 3D joint model, and provides real-time corrections to the robot controller. This feedback mechanism ensures consistent weld quality by automatically compensating for deviations without requiring manual adjustment.
Solution Approach 2:
The system performs all angle calculations, trajectory planning, and parameter optimization in advance during the vision processing phase, before the actual welding begins. The robot receives pre-calculated ideal torch angles and positions, eliminating the need for manual angle adjustment during operation and ensuring consistent quality throughout the welding process.
Data Source
AI summary
In one embodiment, weld torch angle tools are provided to present an operator with the work angle and travel angle measured as taught in the weld point. The operator is presented with buttons to make small adjustments which the robot will move to in live updates to independently tune each angle. If the base plate is tilted, a workflow is provided to the operator to teach that tilt to the robot, allowing the measured angles and axes to be adjusted accordingly. This allows the operator to accurately dial in the exact angle measures specified for a given weld and to visually confirm the validity of the weld point as adjusted, to prevent any unexpected collision or robot reach issues.