Welding Control Switching Between Vision and Current Feedback
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Solution Overview
Problem
Existing welding technologies face challenges in automating torch operation control due to variations in root gap width and occlusion of the molten pool by obstacles, leading to difficulties in maintaining optimal welding conditions.
Innovation Solution
A welding device with an imaging unit, control unit, and switching mechanism that switches between control methods based on image data and welding current measurements to ensure consistent welding control, even in the presence of occlusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If visual sensor control is used to detect molten pool position and shape, then welding precision is improved, but the system becomes vulnerable to occlusion by obstacles which causes loss of information
Solution Approach 1:
The patent introduces welding current as an intermediary parameter that indirectly reflects molten pool state. When visual sensing is occluded, the control system switches to using welding current measurements to infer molten pool conditions and maintain control, thus mediating the information loss caused by occlusion.
Solution Approach 2:
The system dynamically switches between different control parameters based on sensing availability. When visual information is available, it uses image-based features (position, shape); when occluded, it transitions to using welding current parameters, thus adapting the control parameter set to current sensing conditions.
2Adaptability or versatility
If multiple control methods are implemented to handle various welding conditions, then adaptability is improved, but device complexity increases
Solution Approach 1:
The control system dynamically adjusts its operation mode based on real-time conditions. It switches between visual sensor-based control and welding current-based control depending on whether the visual sensor is occluded, making the system adaptable without requiring permanently active complex subsystems for all conditions.
Solution Approach 2:
The welding current measurement serves multiple functions: it is used for normal welding control and also serves as a backup control parameter when visual sensing fails. This multi-functionality reduces the need for separate dedicated backup systems, thereby managing complexity while maintaining adaptability.
3Reliability
If welding control switches between different methods based on sensing conditions, then reliability is improved, but control stability may be affected by switching frequency
Solution Approach 1:
The system prepares for potential visual sensor failure by having the welding current-based control method ready in advance. This backup control pathway is established beforehand to cushion against the reliability loss that would occur if visual sensing failed completely, ensuring continuous reliable control.
Solution Approach 2:
The system uses feedback from the occlusion detection mechanism to trigger appropriate control method switching. When occlusion is detected, feedback signals initiate the switch to welding current-based control; when occlusion is resolved, feedback triggers a return to visual sensor-based control, maintaining stability through condition-driven feedback loops.
Data Source
AI summary
A welding device includes: an image acquisition unit that acquires an image including a welded portion; a first control unit that performs control related to welding, based on the image acquired by the image acquisition unit; a measurement unit that measures a parameter related to a welding condition; a second control unit that performs the control related to welding, based on the parameter measured by the measurement unit; and a switching unit that switches between the first control unit and the second control unit.