Welding Robot Offline Teaching for Sensor-Obstacle Scan Coverage
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Solution Overview
Problem
Current offline teaching devices for welding robots face challenges in visualizing interference between the scanning region of a sensor and obstacles, making it difficult to perform accurate appearance inspections and requiring manual checks, which increases the number of work steps and requires skilled operators.
Innovation Solution
An offline teaching device and method that acquire welding line information, sensor information, and obstacle information to calculate an inclusion rate, visualizing the interference and supporting the teaching of appropriate scanning operations by outputting this information to a screen, allowing for improved teaching of scanning operations without the need for manual checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual checks are performed to detect interference between sensor scanning region and obstacles, then measurement precision is improved, but device complexity and number of work steps increase
Solution Approach 1:
The patent creates a virtual model (copy) of the sensor scanning region and overlays it with obstacle information to detect interference. This virtual copying approach eliminates the need for manual physical checks while maintaining detection accuracy, as the system automatically calculates and visualizes the scanning region coverage and identifies areas blocked by obstacles.
2Measurement precision
If skilled operators perform manual interference detection, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The system performs automatic self-detection of interference by computing the virtual scanning region and comparing it with obstacle positions. This self-service capability eliminates dependence on skilled operators for manual checks, maintaining high detection precision while significantly improving productivity through automated processing.
3Manufacturing precision
If the scanning region is reduced due to obstacles, then manufacturing precision may be improved by avoiding false measurements, but loss of information increases
Solution Approach 1:
The system performs preliminary analysis by calculating the virtual scanning region and identifying obstacle interference before actual inspection. This allows operators to plan alternative scanning paths or adjust sensor positions in advance, ensuring complete coverage of all welding lines while avoiding false measurements caused by obstacles.
Data Source
AI summary
An offline teaching device includes: an acquisition unit that acquires welding line information indicating welding lines on a workpiece, sensor information indicating a measurement region of a sensor that measures an appearance shape of a bead formed on the workpiece based on the welding, and obstacle information including at least a position of an obstacle disposed between the sensor and the workpiece; a calculation unit that calculates, based on the welding line information, the sensor information, and the obstacle information, an inclusion rate indicating a rate of measurable welding lines in which measurement of the appearance shape is not impossible due to the obstacle during the measurement by the sensor; and an output unit that generates a calculation result of the inclusion rate and outputs the calculation result to a screen.