Portable Welding Robot Torch Angle Control on Curved Corners
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing portable welding robots face issues with torch angle control when welding corner portions and curved portions that are not on concentric circles, leading to spatter, poor bead appearance, and convex bead generation due to push or drag angles, especially when the curvature difference between the workpiece and guide rail is significant.
Innovation Solution
A portable welding robot control method that includes a torch position determination unit and a torch angle calculation unit to determine and correct the torch angle in real-time, ensuring a substantially constant torch angle during arc welding, even when the corner portion of the workpiece and the curved portion of the guide rail are not concentric, by using a movable portion to adjust the torch angle based on calculated corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the robot moves on a curved guide rail to weld corner portions, then the welding can cover curved geometries, but the torch angle becomes unstable and generates push or drag angles causing poor bead appearance
Solution Approach 1:
The patent applies dynamics by making the torch angle adjustable and adaptive during the welding process. The control unit dynamically modifies the torch angle based on the robot's position on the guide rail and the workpiece geometry, transitioning from a fixed angle to a variable angle that compensates for curvature effects. This dynamic adjustment prevents push and drag angles, maintaining manufacturing precision while welding curved geometries.
Solution Approach 2:
The patent changes the torch angle parameter in real-time based on the robot's position and the workpiece curvature. The control unit calculates the required torch angle adjustment and modifies it accordingly, transforming a static parameter into a dynamic one that adapts to different welding positions and geometries, thereby resolving the contradiction between versatility and precision.
2Device complexity
If the torch angle is not corrected on curved portions, then the welding process is simple, but spatter occurs forward and bead appearance deteriorates
Solution Approach 1:
The patent implements feedback by using the control unit to continuously monitor the robot's position on the guide rail and the workpiece geometry, then adjusting the torch angle accordingly. This closed-loop control system detects position information and feeds it back to modify the torch angle, preventing spatter and poor bead appearance while maintaining reasonable system complexity through automated control.
3Adaptability or versatility
If the corner portion curvature is small and differs significantly from the guide rail curvature, then the workpiece geometry is more complex, but the torch angle changes more causing worse bead appearance at boundaries
Solution Approach 1:
The patent applies dynamics by implementing real-time torch angle adjustment based on the specific geometry being welded. The control unit dynamically calculates the optimal torch angle for each position, particularly at boundary regions between straight and curved portions, adapting to complex workpiece geometries while maintaining precise bead appearance through continuous parameter optimization.
Data Source
AI summary
A method controls a portable welding robot to ensure good bead appearance even where a workpiece corner and a curved section of a guide rail are not located on a concentric circle and where there is a large difference in curvature between the workpiece corner and the curved section of the guide rail. A portable welding robot sets a guide rail with respect to a workpiece having a corner and performs arc welding on the workpiece while moving on the guide rail and a welding control device controls the portable welding robot. The control method includes determining a torch position on the workpiece via a torch position determination unit, calculating a torch angle at the torch position via a torch angle calculation unit, and controlling the torch angle via a movable part based on the calculated torch angle.