Image-Based Welding Rod Position Control for Consistent Arc Welding
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Solution Overview
Problem
Existing automatic arc welding systems using non-consumable electrodes face complexity in control due to separate management of electrodes and weld wires, requiring precise alignment and adjustment, which is challenging to automate effectively, especially in varying weld conditions.
Innovation Solution
A welding control device that determines the actual and target positions of electrodes and weld wires based on captured images, using image processing and machine learning to adjust positions dynamically according to weld conditions, reducing dependency on human skill and ensuring high-quality welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a non-consumable electrode is used with separate weld wire feeding, then welding precision can be maintained, but device complexity increases due to separate management of electrode and weld wire positions
Solution Approach 1:
The patent combines the electrode and weld wire into a single integrated welding rod, eliminating the need for separate management of electrode and weld wire positions. This merging reduces control complexity while maintaining welding precision through unified position control of the combined structure.
2Manufacturing precision
If the weld wire position is adjusted to maintain constant relative distance from the molten pool, then welding precision is improved, but the risk of electrode-weld wire contact increases under varying weld conditions
Solution Approach 1:
By merging the electrode and weld wire into a single integrated welding rod, the patent eliminates the relative position variation between separate components that could lead to contact. The unified structure moves as one unit, preventing the electrode-weld wire contact issue while maintaining position accuracy through single-body control.
3Extent of automation
If automated position control is implemented, then dependency on welder skill is reduced, but adaptability to varying weld conditions decreases without real-time adjustment capability
Solution Approach 1:
The patent implements dynamic position control that adapts to varying weld conditions by calculating and adjusting the target position based on real-time parameters such as weld condition identifiers, molten pool depth, and welding rod position. This dynamic adjustment capability allows the automated system to maintain high adaptability across different welding scenarios.
Solution Approach 2:
The system uses feedback from detected welding conditions and molten pool characteristics to continuously adjust the welding rod position. By incorporating real-time condition monitoring and position adjustment, the automated system achieves both high automation and adaptability to varying weld conditions.
Data Source
AI summary
A welding control device includes an actual position determination part configured to determine an actual position of the position control target on the basis of a weld characteristic amount detected from a captured image captured so as to include at least the position control target, the welding characteristic amount including at least one of a wire position of the weld wire or an electrode position of the electrode; a target position determination part configured to determine a target position being a target of the actual position corresponding to a weld condition for welding the weld target; and a position control part configured to execute a position control of the position control target to bring the actual position to the target position.