Welding Quality Evaluation by Point-Specific Determination Algorithms
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Solution Overview
Problem
Existing welding systems face challenges in accurately evaluating welding quality at individual points due to variations in welding conditions, welder consumption state, and robot operation, leading to inconsistent and complex algorithm construction for quality evaluation.
Innovation Solution
A welding system that evaluates welding quality at each point using a determination algorithm associated with specific welding conditions, welder consumption state, and robot operation, incorporating data from voltage and current, and allows for state-specific algorithms and machine learning to improve accuracy and simplify algorithm construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single determination algorithm is used for all welding points, then the algorithm construction is simplified, but the welding quality evaluation accuracy decreases due to variations in welding conditions at different points
Solution Approach 1:
The patent divides the welding evaluation process into two levels: (1) segmentation by welding points, where a determination algorithm is created for each welding point to account for local condition variations, and (2) segmentation by consumption states, where algorithms are further divided based on welder condition. This hierarchical segmentation resolves the contradiction by maintaining simplicity at the implementation level while achieving accuracy through localized algorithms.
Solution Approach 2:
The patent applies local quality by creating determination algorithms that are specific to each welding point's local conditions. Each algorithm is tailored to the particular welding point's characteristics, such as joint type, material thickness, and positioning, thereby achieving high evaluation accuracy without requiring a single complex universal algorithm.
2Measurement precision
If detailed analysis of welding conditions at each welding point is performed, then welding quality evaluation accuracy improves, but the algorithm construction complexity increases
Solution Approach 1:
The patent introduces dynamics by making the determination algorithm selection adaptive based on the welder's consumption state. The system dynamically selects which algorithm to apply based on real-time assessment of electrode wear, contact tip condition, and other consumable states, allowing the system to maintain high accuracy without requiring a separate detailed algorithm for every possible condition combination.
Solution Approach 2:
The patent changes the parameter of algorithm selection from being based on welding point characteristics alone to being based on both welding point characteristics and consumption state parameters. This parameter change allows the system to maintain simpler algorithms while achieving detailed analysis accuracy by adjusting which algorithm is applied based on current system state.
3Device complexity
If the determination algorithm does not consider consumption state, then the algorithm is simpler, but the welding quality evaluation accuracy decreases due to data variation from consumption state changes
Solution Approach 1:
The patent applies preliminary action by assessing the consumption state before selecting and applying the determination algorithm. The system proactively evaluates electrode wear, contact tip condition, and other consumable parameters in advance, then selects the appropriate algorithm from a set of state-specific algorithms. This preliminary assessment prevents the need for complex real-time adjustments while maintaining evaluation accuracy.
4Measurement precision
If state-specific algorithms are used for different consumption states, then welding quality evaluation accuracy improves, but the algorithm construction process becomes more complex
Solution Approach 1:
The patent achieves universality by creating a framework where a single determination algorithm can serve multiple consumption states through parameter adjustments. Rather than building completely separate algorithms for each state, the system uses a unified algorithm structure that adapts its parameters based on the assessed consumption state, reducing the overall construction complexity while maintaining state-specific accuracy.
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
The system enhances the accuracy of welding quality evaluation by considering specific conditions and simplifies the algorithm construction process, providing detailed analysis and user-friendly feedback on welding quality deviations.
Implementation Method 1
a welder configured to weld a workpiece at welding points on the workpiece... the welder is configured to weld the welding points with an arc
Data Source
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AI summary
A welding system includes a welder configured to weld a workpiece at welding points on the workpiece, a data acquisition unit configured to acquire welding data indicating welding quality at the welding points, and a quality evaluation unit configured to evaluate the welding quality at each of the welding points based on the welding data according to a determination algorithm which is associated with each of the welding points.