Welding Robot Workpiece Search Calibration for Offset Part Sensing
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Solution Overview
Problem
Existing robot programming applications for collaborative robots (cobots) involved in metal fabrication operations, such as welding, are not intuitive and require precise location of workpieces to edit existing programs without reprogramming.
Innovation Solution
A user interface application on a teach pendant that simplifies the process of searching for and calibrating the physical location of workpieces by allowing users to input search start and end points, automatically determining the search vector, and calibrating the search by moving the tool center point until contact with the workpiece is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a workpiece search is programmed to determine the physical location of the workpiece, then the robot can adapt to location changes, but the programming process becomes complex and non-intuitive
Solution Approach 1:
The system performs self-calibration by automatically moving the tool center point along the search vector and detecting contact with the workpiece to determine the actual physical location. This self-service approach eliminates the need for complex manual programming of search parameters, as the system autonomously adjusts to the workpiece location through automated detection and calibration procedures.
Solution Approach 2:
The patent replaces complex manual programming operations with automated sensor-based detection. Instead of requiring programmers to manually calculate and input search vectors and calibration parameters, the system uses automated sensing mechanisms to detect workpiece contact and compute location adjustments, substituting mechanical programming complexity with automated electronic detection and control.
2Manufacturing precision
If precise workpiece location is required for program editing, then welding accuracy is maintained, but the ease of operation is reduced
Solution Approach 1:
The system performs preliminary calibration by automatically determining the workpiece physical location and adjusting the search vector before welding operations begin. This preliminary action ensures that subsequent program editing can proceed with relaxed location tolerances, as the system has already compensated for any offsets between the programmed search parameters and the actual workpiece location.
Solution Approach 2:
The system implements feedback through automated detection of the workpiece physical location during calibration. The detected location information is fed back to adjust the search vector and welding points, creating a closed-loop system that maintains welding accuracy while allowing flexible program editing. The feedback mechanism automatically compensates for location variations without requiring precise manual positioning.
3Adaptability or versatility
If the workpiece is located at an offset position, then flexibility in workpiece placement is achieved, but the existing program requires reprogramming
Solution Approach 1:
The system automatically changes the search vector parameters based on the detected workpiece location. When a workpiece is placed at an offset position, the system detects the new physical location and automatically adjusts the search vector coordinates and welding points, eliminating the need for manual reprogramming. This dynamic parameter adjustment maintains program validity across different workpiece placements.
Solution Approach 2:
The patent implements dynamic adaptation by allowing the search vector and welding parameters to be automatically adjusted in real-time based on the actual workpiece location. Instead of requiring static, pre-programmed fixed positions, the system dynamically recalibrates parameters when offset positions are detected, enabling flexible workpiece placement without time-consuming reprogramming operations.
Data Source
AI summary
A welding system includes a robot having a movable arm. A robot controller is operatively connected to the robot. A welding torch is attached to the robot. A welding power supply is operatively connected to the torch. A teach pendant is in communication with the robot controller and includes a user interface application configured for programming a plurality of welding points of a welding operation performed by the robot, and is configured for programming a workpiece search for a physical location of a workpiece. The user interface application is further configured to receive input of a search start point that is offset from the physical location of the workpiece, and to display a prompt to calibrate the search. Upon receiving user input to calibrate the search, the physical location of the workpiece is automatically detected and a calibrated indication is displayed confirming that the search is currently calibrated.