Autonomous Welding Robot Path Planning for Irregular Seams

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Solution Overview

Problem

Conventional welding techniques are labor-intensive, inefficient, and struggle with precision and flexibility, particularly in low- or medium-volume manufacturing settings, where irregularities in parts and the need for skilled operators to avoid collisions and misalignments lead to inefficiencies and defective products.

Innovation Solution

A computer-implemented method for generating welding instructions that uses movable sensors to map the workspace and parts in 3D space, allowing for accurate identification and welding of seams without prior information, dynamic path planning, and interaction with users to select candidate seams and adjust parameters, enabling precise and autonomous welding operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional welding techniques are used with skilled operators, then welding can be performed with some level of precision, but the process becomes labor-intensive and inefficient

Engineering Contradiction:

Improvewelding efficiencyVSAvoidskilled operator requirement

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The welding system performs self-positioning and self-alignment by automatically detecting seam locations and calculating robot pose using sensor data and CAD models, eliminating the need for skilled operators to manually position and align components

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical positioning and alignment operations are replaced by an automated vision-based detection system that identifies seam locations and computes robot positioning instructions through image processing and coordinate transformation algorithms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If rigid programming is used to avoid collisions and misalignments, then welding precision can be maintained, but the system lacks flexibility when part irregularities occur

Engineering Contradiction:

Improveflexibility to part irregularitiesVSAvoidwelding precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts welding paths and robot positioning based on real-time detection of actual seam locations and part geometries, allowing adaptation to irregularities while maintaining welding precision through automated recalibration

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses sensor feedback to detect actual seam locations and part positions, then automatically adjusts robot positioning instructions and welding paths to compensate for deviations from the CAD model, maintaining precision despite part irregularities

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If manual positioning and alignment are performed to accommodate part irregularities, then adaptability improves, but the process becomes more time-consuming and less efficient

Engineering Contradiction:

Improveability to handle part irregularitiesVSAvoidtime for positioning and alignment

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Time-consuming manual positioning and alignment operations are replaced by an automated vision system that rapidly captures images, processes sensor data, and calculates robot positioning instructions through computational algorithms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs automatic detection of part geometries and seam locations, then self-calculates the necessary robot positioning adjustments without requiring manual intervention, significantly reducing the time needed to accommodate part irregularities

Inventive Principle:

Principle #25Self-service

4Reliability

If skilled operators are used to avoid collisions and misalignments, then welding reliability improves, but labor costs and operational complexity increase

Engineering Contradiction:

Improvewelding reliabilityVSAvoidoperational complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The robot system autonomously detects seam locations, calculates positioning instructions, and executes welding operations without human intervention, maintaining reliability while eliminating the complexity of skilled operator requirements

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors part positions and seam locations through sensors, automatically adjusts robot positioning and welding parameters based on detected variations, and maintains welding reliability through real-time feedback control

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20240391109A1Autonomous welding robots

Publication Date: 2024.11.28 PATH ROBOTICS INC

AI summary

In some examples, an autonomous robotic welding system comprises a workspace including a part having a seam, a sensor configured to capture multiple images within the workspace, a robot configured to lay weld along the seam, and a controller. The controller is configured to identify the seam on the part in the workspace based on the multiple images, plan a path for the robot to follow when welding the seam, the path including multiple different configurations of the robot, and instruct the robot to weld the seam according to the planned path.