Welding Robot Pose Control via Reaction Force Summation
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Solution Overview
Problem
In automated welding processes, positional deviations between the workpiece and the welding tongs can lead to deterioration or failure of the welding process, especially with high-strength and ultra-high-strength sheet metals, due to imprecise positioning and deformation, requiring complex and energy-consuming mechanics for compensation.
Innovation Solution
The use of force detection devices on welding tongs to determine the sum of reaction forces, allowing for precise control of the welding pose by canceling out contact pressure forces and compensating for positional offsets, thereby minimizing force transmission between the tongs and their connection, and regulating the welding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heavy and complex mechanics are used for compensation, then positioning precision is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent replaces heavy mechanical compensation systems with a control system that uses force detection data to calculate and adjust the sum of reaction forces. Instead of using complex mechanical structures to physically compensate for positioning deviations, the system uses computational methods to determine the correct positioning by analyzing force measurements, thereby substituting mechanical complexity with intelligent control.
Solution Approach 2:
The patent introduces force detection devices as intermediaries between the welding tongs and the positioning system. These sensors measure reaction forces during the welding process, providing information that mediates the control system's understanding of positioning accuracy. This intermediary measurement approach enables precise positioning control without requiring complex mechanical compensation mechanisms.
2Manufacturing precision
If heavy and complex mechanics are used for compensation, then positioning precision is improved, but energy consumption increases
Solution Approach 1:
The patent replaces energy-intensive mechanical compensation systems with a control system that calculates positioning based on force detection data. By substituting physical mechanical adjustments with computational analysis of reaction forces, the system achieves the same positioning precision without the high energy consumption associated with heavy mechanical actuators and compensation mechanisms.
Solution Approach 2:
The system uses the natural reaction forces generated during the welding process itself to determine positioning accuracy. Instead of requiring external energy input to actively compensate for positioning errors, the system leverages the forces already present during welding, allowing the process to self-regulate its positioning based on measured reaction forces.
3Manufacturing precision
If position control tries to reach reference position by force, then positioning accuracy is improved, but damage to workpiece and tool increases
Solution Approach 1:
The patent implements a feedback mechanism where force detection devices continuously measure reaction forces during the welding process. The control system uses this real-time feedback to monitor positioning accuracy and adjust the sum of reaction forces accordingly. This closed-loop feedback allows the system to achieve positioning accuracy through gentle force adjustments rather than aggressive force application, preventing damage to the workpiece and tooling.
Solution Approach 2:
The patent changes the control parameter from direct position control to control based on the sum of reaction forces. By measuring and regulating forces rather than directly enforcing position, the system achieves positioning accuracy through force-based adjustment. This parameter change allows the system to adapt to workpiece variations and positioning deviations without applying excessive forces that could cause damage.
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 precise positioning and reduced force transmission, ensuring accurate welding even with positional offsets, thereby improving the reliability and efficiency of the welding process without the need for heavy and complex mechanics.
Implementation Method 1
at least one force detection device for detecting reaction forces on the welding tongs
Data Source
Figure 1~4
AI summary
The method for controlling a welding robot (1), for welding with a welding tong (2) and a force detecting device for detecting reaction forces on the welding tong, comprises determining a sum of reaction forces on the welding tong, and regulating the pose of the welding robot on the basis of determined sum of the reaction forces. The sum of the reaction forces is determined on the basis of a difference between reaction forces that influence on two electrodes of the welding tong or on the basis of a power that influences between the welding tong and the welding robot. The method for controlling a welding robot (1), for welding with a welding tong (2) and a force detecting device for detecting reaction forces on the welding tong, comprises determining a sum of reaction forces on the welding tong, and regulating the pose of the welding robot on the basis of determined sum of the reaction forces. The sum of the reaction forces is determined on the basis of a difference between reaction forces that influence on two electrodes of the welding tong or the sum of the reaction forces is determined on the basis of a power that influences between the welding tong and the welding robot. The pose of the welding robot is regulated so that the difference between the reaction forces and/or the power that influences between the welding tong and its storage is regulated. A welding power is determined on the basis of reaction forces that are determined for determining the sum of reaction forces, and is regulated. The reaction forces are determined by piezosensors, strain gauges and/or current sensors. Independent claims are included for: (1) a device for controlling a welding robot; (2) a computer program; and (3) a computer program product with program mode.