Welding Position Detection Using a Virtual Line for Fillet Joints
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Solution Overview
Problem
Existing welding position detection systems, such as those using laser sensors, struggle to accurately detect the welding position when the cross-sectional shape patterns of two workpieces do not intersect, leading to potential erroneous welding positions, especially in cases like fillet welding where the straight lines are parallel.
Innovation Solution
A welding position detection device that calculates approximate straight lines of the workpieces, determines an end portion of one member, and uses a virtual straight line with a specific angle to detect an intersection point as the welding position, even when the original straight lines do not intersect, thereby improving detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the welding position is detected by calculating the intersection point of two straight lines specified by cross-sectional shape patterns of two workpieces, then the detection method is simple, but the detection accuracy deteriorates when the two straight lines are parallel and do not intersect
Solution Approach 1:
The patent introduces a virtual straight line as an intermediary element to solve the detection problem. When the two workpiece straight lines are parallel and do not intersect, the virtual straight line is calculated to connect the end portion of one workpiece to the other workpiece at a specific angle, serving as a mediator to enable intersection point detection. This intermediary approach allows the system to overcome the limitation of parallel lines while maintaining detection simplicity.
Solution Approach 2:
The patent changes the geometric parameters of the detection lines by introducing a virtual straight line with a specific angle relative to the workpiece straight lines. Instead of directly using the original parallel lines, the system modifies the line parameters (angle, position) to create a virtual line that intersects with the other workpiece line, thereby enabling accurate welding position detection in cases where direct intersection is impossible.
2Ease of operation
If the welding position detection system uses the original straight lines of workpieces, then the detection process is straightforward, but it fails to detect accurate welding positions in fillet welding and lap joint scenarios
Solution Approach 1:
The virtual straight line acts as an intermediary that bridges the gap between the workpiece geometry and the required welding position detection. In fillet welding and lap joint scenarios where original lines do not provide reliable intersection points, the virtual line connects the end portion of one workpiece to the other at a predetermined angle, serving as a reliable mediator for accurate position detection.
Solution Approach 2:
The system performs preliminary calculation of the virtual straight line based on the end portion of one workpiece and the predetermined angle before attempting to detect the welding position. This preliminary action ensures that the detection algorithm has a reliable reference line to work with, improving reliability in challenging welding configurations before the actual intersection point is calculated.
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 approach allows for accurate detection of the welding position even when the original straight lines do not intersect, ensuring precise alignment for objects to be joined, particularly in lap joints and fillet welding scenarios, by using a virtual straight line to determine the intersection point.
Implementation Method 1
a first calculation unit that irradiates two members to be joined with laser light to calculate approximate straight lines of the respective members
Implementation Method 2
irradiates two members to be joined with laser light to calculate approximate straight lines
Data Source
AI summary
Provided is a welding position detection device capable of improving the welding position detection accuracy. The welding position detection device includes a calculation unit that irradiates two members to be joined with laser light to calculate approximate straight lines of the respective members, calculates an end portion of one member of the two members on the basis of the approximate straight line of the one member, and calculates a virtual straight line which is a straight line connecting the calculated end portion of the one member and the approximate straight line of the other member of the two members and having a specific angle with respect to the approximate straight line of the one member, and a detection unit that detects an intersection point of the calculated virtual straight line and the approximate straight line of the other member as a welding position.