Welding Robot Programming Device Using 3D Model Coordinate Rotation
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Solution Overview
Problem
Current welding robot programming methods lack efficiency in setting optimal welding positions that avoid interference with workpieces and peripheral devices, and ensure reachability along the welding line, often requiring manual adjustments and complex calculations.
Innovation Solution
A programming device and method that utilize three-dimensional models to specify a welding line, set a tentative coordinate system with axes aligned to the welding line and workpiece faces, and rotate the tool coordinate system based on target and advance angles to create an operating program for the welding robot, allowing for automatic adjustment of the welding position to avoid interference and ensure reachability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods are used to set welding positions and angles, then flexibility and precision in adjusting target and advance angles are improved, but programming time and operational complexity increase significantly
Solution Approach 1:
The system automatically calculates and sets welding positions by changing parameters (target angle and advance angle) based on workpiece geometry data. The control device computes optimal welding positions using the workpiece inner angle and automatically sets the target angle as half of this inner angle, eliminating manual parameter adjustment while maintaining precision.
Solution Approach 2:
The system uses three-dimensional model data and shape data of workpieces to create a virtual representation of the welding scenario. By copying geometric information from digital models, the system automatically determines welding positions and angles without requiring manual measurement or programming of each parameter.
2Productivity
If automated calculation of welding positions is implemented, then programming efficiency is improved, but accuracy in setting target and advance angles may deteriorate
Solution Approach 1:
The system establishes precise mathematical relationships between workpiece geometry and welding parameters. The target angle is calculated as exactly half of the workpiece inner angle, and the advance angle is derived from geometric relationships, ensuring high precision through formula-based calculation rather than approximation.
Solution Approach 2:
The system incorporates verification mechanisms to ensure calculated welding positions are accurate. The control device checks whether the calculated target and advance angles produce valid welding positions that meet geometric constraints, and can adjust calculations if interference or invalid positions are detected.
3Reliability
If complex geometric calculations are performed to determine optimal welding positions, then welding quality is improved, but computational complexity and processing time increase
Solution Approach 1:
The welding position determination process is divided into distinct calculation steps: first obtaining workpiece shape data, then calculating the workpiece inner angle, next determining the target angle as half of the inner angle, and finally calculating the advance angle based on geometric relationships. This segmentation simplifies the overall complex calculation into manageable stages.
Solution Approach 2:
The system pre-calculates and stores workpiece shape data and geometric properties before actual welding programming. By preparing geometric information in advance and establishing mathematical relationships beforehand, the system reduces real-time computational complexity during welding position determination.
4Object-affected harmful factors
If the tool coordinate system is frequently adjusted to avoid interference with workpieces and peripheral devices, then interference prevention is improved, but programming complexity and adjustment time increase
Solution Approach 1:
The control device automatically detects potential interference between the welding tool and workpieces or peripheral devices and self-adjusts the welding position and angles. The system monitors geometric relationships and autonomously modifies target and advance angles to eliminate interference without requiring external intervention or complex manual coordinate adjustments.
Solution Approach 2:
The system dynamically adjusts welding positions and angles based on real-time geometric analysis of the welding scenario. Rather than using fixed coordinate systems, the control device continuously adapts the tool orientation and position to maintain optimal welding conditions while avoiding interference, making the coordinate system flexible rather than static.
Data Source
AI summary
A programming device for a welding robot includes a model obtaining unit that obtains three-dimensional models; a welding-line specifying unit that specifies a welding line; a target-angle setting unit that sets a target angle; an advance-angle setting unit that sets an advance angle; a coordinate-system setting unit that sets a tentative coordinate system having a first axis set on the basis of the welding line, a second axis perpendicular to the first axis and parallel to a face of one of workpieces to be welded together, and a tool coordinate system by rotating the tentative coordinate system about the first axis in accordance with the target angle and about the third axis in accordance with the advance angle; a position setting unit that sets a welding position of the tool on the basis of the newly set tool coordinate system; and a program creating unit.