Arc Welding Robot Speed Override for Wire Contact Teaching
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Solution Overview
Problem
Existing arc welding robot systems face challenges in preventing the bending of welding wires during contact with the welding target, as they lack effective control methods to manage speed adjustments during teaching operations.
Innovation Solution
A robot controller with a contact detection unit, override-value adjustment unit, and control unit that detects contact with the welding target and automatically adjusts the operating speed by temporarily stopping the robot and decreasing the override value when contact is detected, ensuring the welding wire is not bent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot operates at a high speed during teaching operations, then productivity is improved, but the welding wire may bend when contact with the welding target occurs
Solution Approach 1:
The robot controller dynamically adjusts the operating speed based on real-time contact detection. During teaching operations, the system operates at high speed for normal movement, but automatically reduces speed when contact between the welding wire and welding target is detected, preventing wire bending while maintaining overall productivity
Solution Approach 2:
The system implements feedback control by detecting contact between the welding wire and welding target during operation, then using this feedback information to automatically adjust the robot's operating speed. The contact detection unit provides real-time feedback that triggers speed reduction, creating a closed-loop control system that prevents wire bending
2Reliability
If the robot operates at a low speed to prevent welding wire bending, then reliability is improved, but productivity decreases
Solution Approach 1:
The system dynamically adjusts operating speed rather than maintaining a constantly low speed. The robot operates at high speed during normal teaching operations and only reduces speed when contact is detected, achieving both high productivity and reliability through adaptive speed control
Solution Approach 2:
The system changes the operating speed parameter based on contact detection status. During normal operation, the robot maintains high speed for productivity, but automatically changes to low speed when contact between welding wire and target is detected, preventing wire bending while minimizing impact on overall productivity
3Reliability
If manual intervention is used to stop the robot when contact occurs, then welding wire bending is prevented, but the complexity of operation increases and recovery work is required
Solution Approach 1:
The robot controller performs self-service by automatically detecting contact between the welding wire and welding target and autonomously stopping the robot without requiring manual intervention. The system monitors its own operation status and takes corrective action independently, simplifying operation and eliminating the need for operator intervention
Solution Approach 2:
The contact detection unit provides automatic feedback to the control system, triggering an autonomous stop response. This feedback mechanism eliminates the need for manual monitoring and intervention, as the system automatically detects contact conditions and responds by stopping the robot to prevent wire bending
Data Source
AI summary
A robot controller includes a contact detection unit that detects contact of a welding wire protruding from a welding torch with a welding target, an override-value adjustment unit that sets and changes an override value for increasing or decreasing an operating speed of the robot from a predetermined speed, and a control unit which receives an operation signal from a teaching operation device and that controls the robot according to the operation signal at the operating speed based on the override value which is set by the override-value adjustment unit. When the contact of the welding wire with the welding target is detected by the contact detection unit, the control unit temporarily stops the robot, and the override-value adjustment unit decreases the override value.