Collaborative Welding Arm Control for Long Pipe Spool Precision
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Solution Overview
Problem
Existing spool welding systems lack efficient and safe robotic solutions for welding long lengths of pipe, as they often require manual operation and lack precise control over the welding process.
Innovation Solution
A collaborative robotic welding system comprising a repositionable support structure and a robotic welding system with a supporting arm, a welding arm, rotary actuators, safety encoders, and a controller that allows for precise control of the welding process while ensuring safety for human operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operation is used for spool welding, then flexibility and adaptability are maintained, but welding precision and control are insufficient
Solution Approach 1:
The robotic welding system performs welding operations autonomously without continuous manual intervention. The controller automatically controls the welding torch movement and parameters based on pre-programmed sequences, enabling the system to serve itself and achieve consistent precision while reducing operational complexity.
Solution Approach 2:
The safety encoder provides real-time feedback on the position and motion of the robotic arm. This feedback mechanism allows the controller to precisely control welding movements and make automatic adjustments, ensuring high welding precision while maintaining ease of operation through automated closed-loop control.
2Productivity
If robotic automation is implemented, then welding precision and productivity are improved, but safety risks for human operators increase
Solution Approach 1:
The safety encoder acts as an intermediary safety device between the robotic welding system and human operators. It monitors the robotic arm's position and motion in real-time, and the controller uses this information to limit forces and prevent dangerous movements, thereby maintaining high productivity while eliminating safety risks for human operators.
Solution Approach 2:
The system implements safety measures in advance by incorporating the safety encoder and force-limiting control algorithms before welding operations begin. These preemptive safety mechanisms ensure that even if anomalies occur during high-speed automated welding, human operators are protected from harm, allowing productivity improvements without increasing safety risks.
3Reliability
If force limiting control is implemented, then safety for human operators is ensured, but control precision over the welding process is reduced
Solution Approach 1:
The force limiting control applies safety constraints selectively during specific phases of operation. The controller allows full precision control during automated welding tasks while imposing force limits only when human operators are in the workspace or during potentially dangerous movements. This partial application of force limiting maintains both operator safety and welding precision.
Solution Approach 2:
The control system dynamically adjusts force limits based on real-time conditions monitored by the safety encoder. During normal automated welding operations, the system maintains high precision control. When human operators are present or anomalies are detected, the controller dynamically reduces force limits to ensure safety, then restores full precision control when safe conditions are reestablished.
Data Source
AI summary
A robotic welding system comprises a supporting arm for attaching to a repositionable support structure, the supporting arm comprising a first mounting portion connectable to the repositionable support structure, and a second mounting portion rotatably coupled to the first mounting portion. A yaw rotary actuator rotates the second mounting portion about a yaw axis. A welding arm comprises a third mounting portion rotatably coupled to the second mounting portion of the supporting arm. A pitch rotary actuator rotates the third mounting portion about a pitch axis generally perpendicular to the yaw axis. A roll rotary actuator rotates a torch holding portion having a torch mount at an end thereof configured for mounting a welding torch about a roll axis generally perpendicular to the pitch axis. A controller is operably coupled to the actuators to cause the welding torch to execute a welding pattern.