Welding Sequence Generator Optimizes Distortion
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Solution Overview
Problem
Existing welding methods face challenges in determining an optimal sequence of welding operations to minimize mechanical distortion in assemblies with multiple weld joints, as current approaches are computationally intensive and do not consider user-generated constraints, leading to resource wastage and limited applicability.
Innovation Solution
A computer-implemented method and system that generates an initial population of welding sequences based on user-generated constraints, simulates welding to model distortion, and determines a merit value to output potential sequences that satisfy predetermined criteria, optimizing the welding sequence while reducing computational resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a genetic algorithm with thermomechanical model is used to determine optimal welding sequence, then distortion minimization is achieved, but computational resources are excessively consumed
Solution Approach 1:
The patent applies preliminary action by pre-establishing a welding sequence database through finite element analysis simulations before actual welding operations. The system pre-calculates distortion values for multiple welding sequences and stores them in a database, allowing rapid retrieval and comparison during production without performing real-time computational simulations, thus significantly reducing computational resource consumption while maintaining distortion minimization capability
Solution Approach 2:
The patent uses copying by creating a virtual model of the welding process through finite element analysis. Instead of performing repeated physical welding trials or real-time simulations, the system creates a digital copy of the welding process with pre-calculated distortion outcomes stored in a database, enabling rapid selection of optimal sequences without consuming excessive computational resources during actual production
2Manufacturing precision
If all possible welding sequences are evaluated to find optimal sequence, then distortion minimization is achieved, but time consumption increases
Solution Approach 1:
The system performs preliminary evaluation of welding sequences by pre-calculating distortion values using finite element analysis and storing results in a database before production. During actual welding operations, the system rapidly retrieves pre-evaluated sequences from the database based on specific constraints, avoiding time-consuming real-time evaluations while still achieving distortion minimization
Solution Approach 2:
Instead of evaluating all possible welding sequences exhaustively, the system performs partial evaluation by assessing only a selected subset of sequences that meet predetermined constraints and criteria. The finite element analysis is applied to evaluate specific candidate sequences rather than all permutations, reducing time consumption while maintaining effectiveness in finding optimal sequences
3Adaptability or versatility
If user-generated constraints are incorporated into sequence determination, then applicability to specific manufacturing scenarios is improved, but system complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the welding sequence determination process into distinct modules: constraint input module, finite element analysis simulation module, database storage module, and sequence selection module. Each module handles specific aspects of the process independently, allowing user-generated constraints to be incorporated through the constraint input module without overwhelming system complexity, as each segment processes information in a controlled manner
4Manufacturing precision
If multiple evaluation criteria are used to assess welding sequences, then solution quality is improved, but computational intensity increases
Solution Approach 1:
The system applies partial action by evaluating welding sequences based on a selective subset of criteria rather than all possible parameters. The finite element analysis focuses on calculating specific distortion metrics relevant to the application, and the selection process considers only the most important constraints and objectives, reducing computational intensity while maintaining solution quality
Solution Approach 2:
The patent extracts only the essential evaluation criteria needed for optimal welding sequence determination from the full set of possible parameters. By identifying and isolating the most critical distortion metrics and constraints through finite element analysis, the system eliminates unnecessary computational calculations while preserving the quality of sequence optimization
Data Source
AI summary
A system for determining a welding sequence is disclosed. The system may have a welding sequence generator configured to create an initial population of welding sequences based on a user-generated constraint. The system may also have a welding simulator configured to simulate welding for at least one welding sequence in the initial population of welding sequences to model distortion for the at least one welding sequence. The welding sequence generator may be further configured to receive the distortion for the at least one welding sequence in the initial population from the welding simulator, determine whether a merit value derived from at least the distortion for the at least one welding sequence satisfies one or more predetermined criteria, output the at least one welding sequence as a potential welding sequence if the merit value satisfies the predetermined criteria.