Welding Robot Touch Sensing Priority Cycle
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Solution Overview
Problem
In touch sensing for welding robots, there is a risk of false detection and potential safety issues due to high-speed movement and delayed stoppage, leading to data loss when processing detection signals in short cycles, especially in tandem arc welding, which can result in incomplete or lost critical detection data.
Innovation Solution
A welding robot mechanism that uses a serial bus communication line to prioritize and read high-importance detection signals in shorter cycles, separating them from lower-priority data to prevent data loss and ensure immediate stoppage, employing a processing unit that reads high-priority data every 5 milliseconds and lower-priority data at longer intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If detection signals are processed in short cycles to enable immediate stoppage, then response speed is improved, but data loss occurs due to processing overload
Solution Approach 1:
The detection signal processing is segmented into multiple priority levels (first priority for touch sensing data, second priority for other detection data). This segmentation allows the system to process critical data in shorter cycles while maintaining comprehensive data collection, thereby preventing data loss while achieving fast response for safety-critical functions.
Solution Approach 2:
The system implements feedback mechanisms where the control unit continuously monitors detection signals and adjusts processing cycles based on priority levels. High-priority touch sensing data triggers immediate processing and stoppage commands, while lower-priority data is processed in subsequent cycles, ensuring both rapid response and complete data utilization.
2Loss of information
If all detection data is processed in the same cycle, then data completeness is maintained, but critical touch sensing data may be lost due to processing time constraints
Solution Approach 1:
Detection data is segmented into priority groups: first-priority touch sensing data and second-priority other detection data. This segmentation ensures that critical touch sensing data is processed immediately in shorter cycles, guaranteeing its reliability, while other data is processed in subsequent cycles to maintain overall data completeness.
Solution Approach 2:
Different processing qualities are applied to different data types based on their importance. Critical touch sensing data receives high-priority processing with shorter cycles and higher reliability guarantees, while non-critical data receives standard processing. This local quality differentiation ensures touch sensing reliability without compromising overall system data completeness.
3Productivity
If the welding robot moves at high speed to maintain productivity, then production efficiency is improved, but false detection occurs due to position deviation during movement
Solution Approach 1:
The system performs preliminary detection by monitoring touch sensing signals before actual contact occurs. When a touch sensing signal is detected, the control unit immediately issues a stoppage command before the welding robot completes its high-speed movement, thereby preventing position deviation and false detection while maintaining high productivity during normal operation.
Solution Approach 2:
The system rushes through the critical detection and stoppage process by processing first-priority touch sensing data in the shortest possible cycle. This allows the system to quickly detect contact and stop the high-speed moving welding robot, minimizing the time window for position deviation to occur while maintaining overall production efficiency.
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 ensures that critical detection data is read without loss, allowing the welding robot to be stopped accurately and safely, reducing the risk of position deviation and maintaining on-site safety by prioritizing high-importance data transmission.
Implementation Method 1
a welding power source for supplying welding power to the welding robot
Implementation Method 2
a welding torch... where a voltage is applied to a welding torch and detecting a position where a welding wire of the welding torch comes into contact with the workpiece
Implementation Method 3
touch sensing for sensing a workpiece position... detecting a position where a welding wire of the welding torch comes into contact with the workpiece (that is, a position where an electric current between the workpiece and the welding wire is detected)
Data Source
AI summary
Provided is a welding robot mechanism that has: a welding robot having a touch sensing function; a welding power source for supplying welding power to the welding robot; and a control unit for controlling the welding robot, wherein the welding power source has a welding power source communication unit that receives detection signals with regard to control of the welding robot and the touch sensing, and transmits the detection signals outward. The control unit is linked to the welding power source communication unit via a serial bus communication wire. The detection signals comprise a mass of data including a detection data group designated as a first group and a detection data group designated as a second group, and is configured to read the detection data group designated as the first group in a shorter cycle than that for the detection data group designated as the second group. The detection data group designated as the first group includes a detection signal obtained by the touch sensing.