Remote Welding Robot Path Prediction for Thermal Distortion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In remote-controlled welding robot systems, deviations in the welding trajectory due to thermal distortion of the workpiece lead to quality issues, increased operator fatigue, and vulnerability to communication delays, especially when frequent corrections are necessary to compensate for deformation.
Innovation Solution
A welding robot system that includes a camera, display device, acceptance unit, robot control unit, accumulation unit, and prediction unit to predict a welding path based on accumulated positions, reducing the need for frequent operator corrections by moving the welding torch along a predicted path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If remote control correction is performed based on video feedback, then welding trajectory deviation can be compensated, but operator fatigue increases due to frequent corrections
Solution Approach 1:
The system performs preliminary action by predicting the welding trajectory in advance based on accumulated position data and thermal distortion models. This prediction allows the robot to proactively adjust its path before actual deviation occurs, reducing the need for reactive operator corrections and thereby decreasing operator fatigue while maintaining welding precision.
Solution Approach 2:
The system implements feedback by continuously accumulating welding position data and using it to update trajectory predictions. The prediction unit processes historical position information to generate forward-looking trajectory adjustments, creating a closed-loop system that reduces reliance on continuous operator intervention while maintaining high welding accuracy.
2Manufacturing precision
If remote control correction is performed based on video feedback, then welding quality can be maintained, but system vulnerability to communication delays increases
Solution Approach 1:
By predicting the welding trajectory in advance using accumulated position data and thermal distortion models, the system prepares correction paths before communication delays occur. This preliminary trajectory prediction enables the robot to maintain welding quality even when video feedback is temporarily unavailable, as the predicted path serves as a reference that can be executed autonomously during communication interruptions.
Solution Approach 2:
The system performs self-service by using its own accumulated welding position data to generate trajectory predictions autonomously. This self-generated predictive information reduces dependence on external video feedback, allowing the system to maintain welding quality during communication delays without requiring continuous operator intervention or real-time video input.
3Ease of operation
If the welding torch moves along the teaching line at constant speed, then welding process is simple to control, but thermal distortion causes trajectory deviation
Solution Approach 1:
The system applies preliminary action by predicting thermal distortion effects and adjusting the welding trajectory in advance. The prediction unit uses accumulated position data and thermal models to calculate corrected paths before welding proceeds, allowing the robot to compensate for anticipated distortion while maintaining simple automated control without requiring complex real-time adjustments.
Solution Approach 2:
The system replaces mechanical feedback control with an information-based prediction system. Instead of relying on physical sensors to detect distortion and mechanically adjusting the path, the system uses computational prediction based on accumulated data and thermal models to generate corrected trajectories, substituting mechanical complexity with intelligent algorithms that maintain control simplicity while improving accuracy.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided is a remote-controlled welding robot system that can reduce the deviation of a welding torch from a welding portion of a workpiece. A welding robot system 10 includes: a welding robot 11; a camera 12 that captures video of an unwelded welding portion of a workpiece 5; a display device 13 that displays the captured video; an acceptance unit 15 that accepts an instruction to correct a welding position from an operator in response to the display of the video; a robot control unit 16 that controls the welding robot 11 to perform welding based on teaching data and performs control for correcting the welding position according to the accepted instruction; an accumulation unit 17 that accumulates positions of multiple points on a trajectory of the welding by the welding robot 11; and a prediction unit 18 that predicts a welding path using the accumulated positions of the multiple points. The robot control unit 16 controls the welding robot 11 such that the welding torch moves along the predicted welding path.