Welding Robot Feedback Control for Real-Time Path Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional robotic welding systems lack real-time feedback and dynamic adjustment capabilities, leading to inaccuracies and poor weld quality due to discrepancies between model-based instructions and actual part dimensions, occlusions, and shifts during the welding process.
Innovation Solution
A computer-implemented method that uses sensors to generate point cloud data of the workspace, compares the estimated state of the welding robot to a desired state, and updates welding instructions in real-time, including adjustments to motion, motorized fixtures, and welding parameters, using techniques like geometric comparators, particle filters, and neural networks to ensure precise welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If model-based instructions (CAD models, kinematic models) are used to determine welding paths, then welding automation and productivity are improved, but manufacturing precision deteriorates due to discrepancies between model dimensions and actual part dimensions
Solution Approach 1:
The system performs preliminary scanning of the actual part geometry before welding begins, creating an updated point cloud model that reflects the true dimensions and variations of the workpiece. This preliminary action allows the system to compensate for discrepancies between CAD models and actual parts, ensuring both automation and precision are achieved.
Solution Approach 2:
The system continuously compares the actual part geometry (scanned via sensors) with the planned welding path, and dynamically adjusts the welding instructions based on this feedback. This closed-loop control ensures that welding precision is maintained despite variations in actual part dimensions from the original CAD model.
2Ease of manufacture
If fixed welding instructions are used, then programming simplicity is improved, but adaptability deteriorates when changes occur to the welding operation, seam, or part
Solution Approach 1:
The system transforms static, fixed welding instructions into dynamic, adaptive instructions that can change in real-time based on sensor feedback. The welding path and parameters are no longer fixed but are continuously adjusted to accommodate variations in part geometry, seam location, or welding conditions, while maintaining ease of programming through automated path generation.
Solution Approach 2:
The system incorporates continuous feedback from sensors during the welding process, allowing it to detect and respond to changes in the welding operation, seam position, or part geometry. This feedback mechanism enables the system to adapt to unexpected variations without requiring complex manual reprogramming.
3Manufacturing precision
If real-time feedback and dynamic adjustment are implemented, then manufacturing precision is improved, but device complexity increases due to additional sensors and processing requirements
Solution Approach 1:
The system integrates multiple functions into unified components. For example, the welding robot is equipped with sensors that serve both as positioning references and as sources of geometric data. The control system performs both real-time feedback processing and path adjustment functions, reducing the need for separate dedicated components and minimizing overall system complexity.
Solution Approach 2:
The system uses the welding robot's own motion and positioning data, combined with sensor feedback, to automatically generate and adjust welding paths without requiring external intervention or complex external control systems. The robot essentially guides itself using the feedback from its own position and the scanned part geometry, reducing the need for additional complex control infrastructure.
4Manufacturing precision
If continuous monitoring and real-time updates are performed, then weld quality is improved, but energy consumption increases
Solution Approach 1:
Instead of continuous monitoring at maximum intensity, the system performs periodic scans and updates at strategically chosen intervals during the welding process. This allows the system to maintain weld quality through regular feedback while reducing energy consumption by avoiding constant high-power sensor operation and processing.
Solution Approach 2:
The system applies real-time updates selectively rather than uniformly throughout the entire welding process. It focuses computational and sensing resources on critical sections of the weld or moments when variations are most likely to occur, achieving high weld quality without the excessive energy consumption of uniform continuous monitoring across all welding operations.
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 enables real-time dynamic adjustment of welding operations, improving weld precision and quality by accounting for actual part geometry and occlusions, reducing the likelihood of collisions and defects, and optimizing energy consumption.
Implementation Method 1
The apparatus can also comprise a welding head including at least one laser emitter configured to generate laser lines
Implementation Method 2
a receiver configured to receive reflected portion of the laser lines
Data Source
AI summary
Systems and methods for real time feedback and for updating welding instructions for a welding robot in real time is described herein. The data of a workspace that includes a part to be welded can be received via at least one sensor. This data can be transformed into a point cloud data representing a three-dimensional surface of the part. A desired state indicative of a desired position of at least a portion of the welding robot with respect to the part can be identified. An estimated state indicative of an estimated position of at least the portion of the welding robot with respect to the part can be compared to the desired state. The welding instructions can be updated based on the comparison.