Welding Torch Posture Correction for VR Robot Teaching
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Solution Overview
Problem
Existing welding teaching methods using virtual reality devices result in inconsistent torch postures at each teaching point, requiring manual correction in offline systems, which is cumbersome and time-consuming.
Innovation Solution
A welding teaching system that includes a controller, head-mounted display, and terminal device to calculate and correct the welding torch's posture based on a reference coordinate system, ensuring optimal alignment for each teaching point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If virtual reality device is used for welding teaching, then teaching operation is simplified and accessibility is improved, but torch posture consistency deteriorates requiring manual correction
Solution Approach 1:
The system performs automatic posture correction using the teaching device itself. The correction unit utilizes the teaching data and coordinate system information to automatically adjust torch postures without requiring external manual intervention, allowing the system to self-correct the inconsistencies introduced by VR teaching
Solution Approach 2:
The patent replaces manual mechanical correction operations with an automated computational system. The correction unit uses coordinate system transformations and automatic calculations to substitute the need for manual posture adjustment, thereby maintaining precision while preserving the ease of VR-based teaching
2Manufacturing precision
If manual correction of torch posture is performed in offline system, then welding precision is improved, but teaching time and operational complexity increase
Solution Approach 1:
The system performs posture correction automatically as part of the teaching process itself, rather than as a separate subsequent step. The correction unit processes and corrects torch postures during the teaching operation, eliminating the need for separate manual correction sessions and thereby reducing total teaching time
Solution Approach 2:
The automatic correction unit performs the precision-adjustment function that previously required manual intervention. By embedding the correction capability within the teaching system itself, it achieves high welding precision automatically without adding operational complexity or extending teaching duration
3Productivity
If automatic posture correction is implemented, then manual effort is reduced and teaching efficiency improves, but system complexity increases
Solution Approach 1:
The teaching device is designed to perform multiple functions: it serves as both the VR teaching interface and the automatic posture correction unit. By making the teaching device multi-functional, the system avoids adding separate dedicated correction hardware, thereby improving teaching efficiency without proportionally increasing system complexity
Solution Approach 2:
The system introduces a correction unit that acts as an intermediary between the VR teaching input and the final welding execution. This intermediary automatically processes posture data using coordinate system transformations, providing the needed correction functionality while maintaining a relatively simple overall system architecture through software-based mediation rather than complex mechanical additions
Data Source
AI summary
A welding system includes a teaching device that receives a teaching operation and a terminal device. The teaching device acquires a teaching point including a teaching position for teaching a position of a welding torch and a teaching posture for teaching a posture of the welding torch. The terminal device calculates a reference coordinate system related to the posture of the welding torch at the teaching position based on the teaching position of a plurality of acquired teaching points and information related to a workpiece, corrects the teaching posture to a set posture set in advance based on the teaching posture with respect to the reference coordinate system, and generates and outputs a welding teaching program for the welding robot based on the teaching positions of the plurality of teaching points and the teaching posture.