Offline Welding Teaching Correction for Workpiece Position Changes
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Solution Overview
Problem
Existing offline teaching devices require extensive man-hours for correcting teaching points in welding programs due to positional deviations of workpieces, which can be caused by changes in facility layout, machining conditions, or individual differences in components, leading to inefficiencies in the welding process.
Innovation Solution
An offline teaching device and method that determine changes in workpiece production data and adjust the teaching program by calculating displacement amounts between the original and new positions of targets relative to the welding robot, creating a corrected teaching program to efficiently update the welding operation based on these changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional offline teaching devices are used to create welding programs, then the welding program can be created in advance, but extensive man-hours are required for correcting teaching points due to positional deviations
Solution Approach 1:
The system performs preliminary actions by detecting positional deviations of the workpiece before the welding operation begins. By using sensors to measure the actual position of the workpiece and calculating displacement amounts relative to the teaching program coordinates, the system prepares correction data in advance, eliminating the need for time-consuming manual corrections during or after welding setup.
Solution Approach 2:
The invention replaces the manual mechanical correction process with an automated computational system. Instead of manually adjusting teaching points based on visual inspection or physical measurement, the system uses sensors, coordinate transformation algorithms, and automated calculation of displacement amounts to substitute the mechanical correction process, significantly reducing correction time and human involvement.
2Manufacturing precision
If manual correction of teaching points is performed to account for positional deviations, then welding accuracy can be maintained, but productivity decreases due to extensive correction time
Solution Approach 1:
The system implements feedback by using sensors to detect the actual positional deviation of the workpiece, then feeding this information back into the coordinate transformation process. The displacement amount calculated from the sensor data is used to automatically adjust the teaching program coordinates, creating a closed-loop system that maintains welding accuracy while eliminating manual intervention.
Solution Approach 2:
The invention changes the parameters of the teaching program by automatically transforming coordinates based on detected positional deviations. Instead of maintaining fixed teaching points, the system dynamically adjusts the coordinates using calculated displacement amounts, allowing the welding program to adapt to actual workpiece position variations and maintain precision without manual correction.
3Adaptability or versatility
If the teaching program is created based on fixed facility layout and machining conditions, then the program can be reused, but it becomes invalid when layout or conditions change
Solution Approach 1:
The system introduces dynamics by making the teaching program adaptable to changes in facility layout and machining conditions. Instead of using fixed static coordinates, the program automatically transforms coordinates based on detected positional deviations, allowing it to remain valid even when workpiece positions or facility configurations change between production runs.
Data Source
AI summary
An offline teaching device includes a first determination unit configured to determine whether data related to production of a workpiece to be produced by welding is changed, a second determination unit configured to determine, in a case where the first determination unit determines that the data is changed, a target whose relative position between the workpiece and a welding robot that executes the welding is changed based on the changed data, and a teaching program creation unit configured to create and output a second teaching program obtained by correcting a first teaching program for executing the welding, based on a displacement amount between a position of the target after the change of the relative position and a position of the target before the change of the relative position.