Welding Seam Point Calibration Using Virtual Face Reference Extraction
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Solution Overview
Problem
The existing methods for welding seam point calibration in robot welding are time-consuming and inefficient, requiring manual input of three face references and lack flexibility due to dependence on the geometry of each object to be welded, leading to high manpower and cost expenditures.
Innovation Solution
Automatically extracting three face references from a virtual model to determine search parameters for search instructions, enabling the automatic generation of search instructions and reducing the time, manpower, and cost associated with welding seam point calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual method is used to find face references for each welding seam point, then the calibration can be performed, but the process is time-consuming and tedious
Solution Approach 1:
The system enables automatic extraction of face references from the virtual model of the object to be welded, allowing the calibration process to self-configure without manual intervention. The computer automatically identifies geometric features and generates search parameters, eliminating the need for operators to manually locate face references for each welding seam point.
Solution Approach 2:
The face references and search parameters are extracted in advance from the virtual model before the actual welding calibration process. By pre-processing the geometric data and identifying all necessary reference features beforehand, the system prepares the calibration configuration ahead of time, significantly reducing the time required during the actual calibration operation.
2Adaptability or versatility
If search parameters are determined manually for each object geometry, then the calibration can be adapted to specific objects, but the process lacks flexibility and efficiency
Solution Approach 1:
The system automatically determines search parameters (such as search directions, search distances, and via-points) based on the geometric parameters extracted from the virtual model of the object to be welded. By dynamically adjusting these parameters according to the specific object geometry, the system maintains adaptability while achieving high calibration speeds through automated parameter generation.
Solution Approach 2:
The system uses the virtual model (a digital copy) of the object to be welded to extract geometric information and determine search parameters. This digital copying approach allows the system to adapt to different object geometries by processing their respective virtual models, eliminating the need for manual reconfiguration while maintaining geometric adaptability across different welding applications.
3Reliability
If via-points are added to make robot moves smoother and collision-free, then the search program becomes more complete, but the programming complexity increases
Solution Approach 1:
The system automatically generates via-points and complete search instructions based on the extracted face references and welding seam geometry. The computer program self-configures the complete search path including intermediate via-points that ensure smooth, collision-free robot movements, eliminating the need for manual programming of these protective elements.
Solution Approach 2:
The system introduces an automated computation layer that acts as an intermediary between the face reference extraction and the search program generation. This intermediary process automatically calculates optimal via-points and search parameters, mediating the transformation from geometric data to executable robot instructions while ensuring reliability and reducing programming complexity.
Data Source
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AI summary
A method (100), system (1000) and apparatus (1100) of determining search parameters for welding seam point calibration are provided. The method (100) comprises determining (S101), for a seam vertex point (A1) on a welding seam (S1), three reference faces (F1, F2, F3) which are perpendicular to each other, based on geometry of an object to be weld in a virtual model; and determining (S102) a start point (B0) and a search point (B1, B2, B3) of a search motion for welding seam point calibration based on the three reference faces (F1, F2, F3) and predetermined criteria respectively for the start point (B0) and the search point (B1, B2, B3). Three reference faces (F1, F2, F3) can be extracted automatically, and search parameters needed for the search instructions can be determined based thereon which enables automatic generation of search instructions and thus the time, manpower and cost for the welding seam point calibration can be reduced greatly.