Welding Torch Position Correction for Overhang Additive Modeling
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Solution Overview
Problem
During additive modeling of complicated shapes, errors in the target position of a welding torch due to mechanical inaccuracies and tilting can lead to deviations, making it difficult to achieve high accuracy in weld bead formation, especially in protruding or overhang portions, and manual corrections are inefficient.
Innovation Solution
A method and device that utilize a shape measurement unit to compare a reference profile of a positioning index body with an actual profile, calculating deviations and outputting correction commands to accurately adjust the welding torch's position, ensuring precise alignment and correction without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the welding robot tilts and rotates the welding torch to model complicated shapes, then the adaptability to complex geometries is improved, but the positioning accuracy of the welding torch tip deteriorates due to mechanical errors
Solution Approach 1:
The patent implements a feedback mechanism where the actual position of the welding torch tip is detected during operation, and deviation from the target position is corrected in real-time. The control unit receives detection results and generates correction commands to adjust the torch position, ensuring accurate weld bead formation despite mechanical errors during tilting and rotation operations.
2Manufacturing precision
If manual correction of target position is performed to improve accuracy, then the positioning precision is improved, but the productivity deteriorates due to increased operation time
Solution Approach 1:
The system performs self-correction of positioning errors through automated detection and control. The detection unit automatically measures the actual torch position, the control unit calculates deviations, and correction commands are generated and executed without manual intervention. This self-service mechanism maintains high positioning precision while preserving productivity by eliminating manual correction operations.
3Manufacturing precision
If the target position is corrected frequently to maintain accuracy, then the manufacturing precision is improved, but the complexity of the control system increases
Solution Approach 1:
The patent replaces complex mechanical positioning adjustment mechanisms with an automated control system based on detection and computation. Instead of requiring frequent manual mechanical adjustments, the system uses detection units to monitor position and control units to compute and execute corrections, simplifying the overall system while maintaining high precision through automated feedback control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for accurate correction of the welding torch's target position, enhancing the precision of weld bead formation and improving modeling accuracy without complicating the workflow, especially in complex shapes like overhangs and protrusions.
Implementation Method 1
measuring a shape of the positioning index body by a shape measurement unit attached to the welding torch or the manipulator to acquire an actual profile
Data Source
AI summary
A method for controlling a modeling device that corrects a target position of a welding torch in the modeling device. The method includes acquiring a reference profile prepared in advance and including a shape of a positioning index body implemented by at least a part of a base metal or a weld bead, a step of measuring a shape of the positioning index body by a shape measurement unit attached to the welding torch or a manipulator to acquire an actual profile, comparing the reference profile with the actual profile of the positioning index body to obtain a deviation amount of the target position of the welding torch based on a positional deviation of the positioning index body between the reference profile and the actual profile, and outputting an operation correction command of the manipulator for correcting the target position of the welding torch according to the deviation amount.