Welding Condition Estimation for Database-Free Parameter Setting

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Solution Overview

Problem

Existing welding control systems require a pre-prepared condition database that needs user updates, making it difficult to determine appropriate welding conditions for metal targets.

Innovation Solution

A welding condition determining system that includes a welding condition setter, estimator, and determiner, using a welding result estimation model to finalize adjustable welding conditions based on non-adjustable and provisional conditions, facilitating the setting of optimal welding parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a condition database storing welding conditions prepared in advance is used, then welding conditions can be determined based on stored data, but the system requires extensive database updates by users and becomes difficult to operate

Engineering Contradiction:

Improvewelding condition accuracyVSAvoiddifficulty in determining welding conditions

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The welding robot performs welding autonomously using welding conditions determined by the determination unit based on target information, eliminating the need for manual database updates by users. The system serves itself by automatically adapting to different welding targets without requiring user intervention to maintain condition databases.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical process of updating condition databases with an automated information processing system. The determination unit uses imaging information and learning model data to automatically determine welding conditions, substituting the manual database update mechanism with automated computational determination.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If welding conditions are manually determined and database updated, then welding quality can be improved, but time and effort are lost in the update process

Engineering Contradiction:

Improvewelding qualityVSAvoidtime for database updates

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The welding robot continuously performs welding operations using automatically determined conditions without interruption for manual database updates. The system maintains continuous productive operation by eliminating the time loss associated with manual condition determination and database maintenance.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system automatically determines welding conditions and updates its own operational parameters without requiring user intervention, thereby eliminating the time loss associated with manual database updates while maintaining welding quality through automated adaptation.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If a comprehensive condition database is maintained, then various welding scenarios can be covered, but the system complexity increases

Engineering Contradiction:

Improvecoverage of welding scenariosVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical database structure with an information processing system using imaging data and learning models. This substitution reduces system complexity by eliminating the need for manual database maintenance while maintaining versatility through automated condition determination based on target information.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system automatically adapts to various welding scenarios by using the determination unit to analyze target information and select appropriate conditions, eliminating the need for a comprehensive manually-maintained database and thereby reducing system complexity while maintaining adaptability.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250312861A1Welding condition determining system, learning system, welding system, and welding target manufacturing method

Publication Date: 2025.10.09 MITSUBISHI ELECTRIC CORP

AI summary

A welding condition determining system includes a welding condition setter, welding result estimator, and welding condition determiner. The welding condition setter receives data indicating a non-adjustable welding condition or a fixed welding condition for welding of welding targets, and a required welding result, and sets a provisional adjustable welding condition as a flexible welding condition. The welding result estimator estimates a welding result, based on the non-adjustable welding condition and provisional adjustable welding condition, using a welding result estimation model designed to output data indicating an estimated welding result from an output layer in response to input of data indicating the non-adjustable welding condition and provisional adjustable welding condition into an input layer. The welding condition determiner finalizes, based on the welding result estimated by the welding result estimator and the required welding result, a welding condition containing an adjustable welding condition.Buchanan