Welding Robot Direct Teaching With Button Lockout Control
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Solution Overview
Problem
In arc welding robots, precise operations require operators to manually adjust the welding position and angle, but existing direct teaching methods risk erroneous activation of buttons due to unintentional button presses, leading to inefficiencies.
Innovation Solution
A robot system with a switch portion and button configuration that disables specific functions during direct operation, ensuring the switch remains on and preventing unintended button activations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If buttons are provided on the grip portion for direct operation, then operational functionality is improved, but the risk of erroneous button presses increases
Solution Approach 1:
The control functions are segmented into two distinct components: a switch portion for enabling/disabling direct operation and buttons for specific functions. These are physically separated onto different surfaces (switch on torch mount, buttons on handle), creating spatial segmentation that prevents simultaneous activation and reduces erroneous presses.
Solution Approach 2:
The switch portion acts as an intermediary gatekeeper between the operator and the button functions. When the switch is in the off state, it prevents button operations from being executed, serving as a protective intermediary that blocks erroneous activations while allowing intentional operations when switched on.
2Device complexity
If the switch portion and button are provided on the same component, then device complexity is reduced, but the likelihood of unintended button activation during direct operation increases
Solution Approach 1:
The system segments the control interface into two physically separate components: a switch portion mounted on the torch mount and buttons mounted on the handle. This spatial segmentation ensures that when the operator grips the handle for direct operation, the buttons are accessible but the switch remains on a different component, reducing the likelihood of simultaneous unintended activation.
Solution Approach 2:
The switch portion serves as an intermediary control element that must be activated (switched to on state) before the button functions become operational. This intermediary mechanism creates a protective barrier that prevents unintended button activations during direct operation, as the switch acts as a gatekeeper that must be deliberately engaged.
3Productivity
If the operator directly operates the robot by hand, then teaching efficiency is improved, but the precision of position and angle adjustment deteriorates
Solution Approach 1:
The system incorporates visual feedback through a display that shows the current operation mode and button availability status. This feedback mechanism helps the operator understand the system state, reducing confusion and improving the precision of adjustments by providing clear information about whether direct operation mode is active and which functions are available.
Data Source
AI summary
A robot system includes: a welding torch portion attached to a distal end of a robot arm; a switch portion that causes, when switched to an on state, the robot to be operable according to an external force; a button to which a specific function is assigned; a mode setting unit that sets an operation mode for operating the robot; and an operation disabling unit that disables an operation on the button while the operation mode is set to a direct operation mode in which an operator directly applies the external force to the robot by hand and operates the robot by moving the robot according to the external force, and the switch portion is maintained in the on state, in which the switch portion and the button are provided on any one of the robot arm or a member attached to the robot arm and attached at a position different from the tool portion.