Smart Welding Torch Position Tracking for Variable Weld Joints
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Solution Overview
Problem
Current robotic welding systems face limitations in communication capabilities, which restrict control, speed, and accuracy due to restricted interconnectivity between welding cells and external systems, hindering efficient data exchange and real-time adjustments during the welding process.
Innovation Solution
The implementation of an Internet-of-Things (IoT) networked system that utilizes absolute and relative position sensors to calculate a correction vector, allowing for real-time adjustments of the welding torch's position to align with both planned and actual weld paths, enhancing communication and precision in robotic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional communication systems are used in robotic welding, then system complexity is reduced, but communication speed and real-time control capability are limited
Solution Approach 1:
The patent implements a feedback mechanism where the actual weld path is continuously monitored and compared with the planned weld path. A correction vector is calculated based on the deviation between actual and planned paths, and this correction is applied in real-time to adjust the torch position. This closed-loop feedback system enables high-speed communication and real-time control without requiring excessive system complexity.
2Manufacturing precision
If real-time position correction is implemented, then welding precision is improved, but system complexity increases due to additional sensors and calculations
Solution Approach 1:
The patent introduces an intermediary correction vector that mediates between the actual weld path and the planned weld path. Instead of directly complex sensor integration and real-time calculation, the system uses this correction vector as an intermediate element to translate position deviations into actionable adjustments. This intermediary approach simplifies the overall system architecture while maintaining high welding precision.
3Manufacturing precision
If correction vectors are calculated and applied, then welding accuracy is improved, but processing time increases
Solution Approach 1:
The patent performs preliminary calculations of the correction vector based on the deviation between actual and planned weld paths. By pre-calculating the correction needed before executing the welding motion, the system minimizes real-time processing delays. This preliminary action approach allows the robot to execute welding movements with pre-computed corrections, thereby maintaining high accuracy without significant processing time penalties.
Data Source
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AI summary
A system (200, 300, 400, 500) and method of electric arc welding that includes a welding apparatus having an electric arc welder torch (260, 360, 560) with sensors to determine the absolute position of the torch tip and the relative position of the torch tip to the weld joint during automatic welding. Combining absolute and relative positional data can be used to adjust the path of the robot during automated or robotic welding in response to variations in the weld joint.