Welding Torch Position Correction Using Profile-Based Feedback

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Solution Overview

Problem

The challenge of accurately maintaining the target position of a welding torch during additive modeling of complex shapes is exacerbated by mechanical errors and tilting, leading to deviations that compromise shape accuracy and efficiency.

Innovation Solution

A method and device for controlling the welding torch's target position using a shape measurement unit to detect deviations and correct them through a control unit, employing a positioning index body and correction vectors based on reference and actual profiles.

Engineering Contradictions & Design Principles

VSEngineering 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 target position accuracy deteriorates due to mechanical errors

Engineering Contradiction:

Improveadaptability to complex geometriesVSAvoidtarget position accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback mechanism where the shape measurement unit continuously measures the actual position of the welding torch tip during tilting and rotation operations. The control unit compares the measured position with the intended target position and generates correction commands to compensate for deviations caused by mechanical errors, thereby maintaining high positioning accuracy while modeling complicated shapes

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces reliance on purely mechanical positioning accuracy with an optical measurement and computational correction system. The shape measurement unit uses optical methods to detect the welding torch tip position, and the control unit applies computational algorithms to calculate and apply position corrections, substituting mechanical precision requirements with sensor-based feedback

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the operator manually corrects the target position by operating the welding robot, then the positioning accuracy is improved, but the productivity deteriorates due to increased operation time

Engineering Contradiction:

Improvetarget position accuracyVSAvoidwork efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent implements a self-service system where the welding robot automatically detects and corrects its own target position deviations. The shape measurement unit monitors the welding torch tip position, and the control unit autonomously generates and applies correction commands without requiring manual operator intervention, thereby maintaining high positioning accuracy while preserving productivity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously measures the actual welding torch tip position during operation and automatically feeds back correction commands to the welding robot. This closed-loop feedback mechanism eliminates the need for manual position correction while maintaining high positioning accuracy throughout the modeling process

Inventive Principle:

Principle #23Feedback

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

Accurate correction of welding torch deviations ensures precise additive modeling without complex manual adjustments, enhancing shape accuracy and efficiency.

Implementation Method 1

a shape measurement unit 33 that measures a position of a tip of the welding torch 15

Methodology Applied

Scientific EffectOptical measurement: LIDAR

Implementation Method 2

a control unit 13 that calculates a correction vector corresponding to a deviation amount between the measured position and an intended position, and corrects a target position of the welding torch 15 based on the correction vector

Methodology Applied

Scientific EffectPosition correction:

Implementation Method 3

a modeling device for repeatedly forming weld beads on a base metal by melting and solidifying a filler metal supplied to a welding torch

Methodology Applied

Scientific EffectMelting and solidification: Melting

Data Source

PatentEP4360793B1Method for controlling modeling device, and corresponding modeling device

Publication Date: 2025.12.31 KOBE STEEL LTD

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AI summary

A method for controlling a modeling device correcting a target position of a welding torch includes: a step of 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 the manipulator to acquire an actual profile; a step of 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 a step of outputting an operation correction command of the manipulator for correcting the target position of the welding torch according to the deviation amount.