Welding Torch Weaving Control for Accurate Through-Arc Seam Tracking
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Solution Overview
Problem
The accuracy of through arc seam tracking in robotic weave welding is compromised by the use of welding waveforms with pulse portions, due to frequent changes in welding current levels, which affect the precision of weld quality assessment.
Innovation Solution
A robotic electric arc welding system that includes a welding torch, a robot controller for controlling weaving movements, and a welding power supply that samples weld parameters to generate a weld quality score, adjusts the sampling period based on weave frequency or period, and records through arc seam tracking information to calculate corrections to the weld path from welding current data classified as corresponding to pulse or low current portions of the waveform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If welding waveforms with pulse portions are used, then welding process flexibility is improved, but measurement precision of seam tracking deteriorates
Solution Approach 1:
The patent segments the welding current data into distinct pulse portions and low current portions based on the waveform characteristics. By dividing the continuous welding process into discrete segments corresponding to different current levels, the system can selectively process data from stable low current portions for seam tracking while maintaining the flexibility of pulsed welding waveforms.
Solution Approach 2:
The patent applies different processing qualities to different portions of the welding data. Specifically, it uses data from low current portions where the arc is more stable and less affected by pulse variations, while still utilizing the overall pulsed waveform for welding flexibility. This local quality approach ensures high measurement precision from stable data regions while preserving process adaptability.
2Measurement precision
If sampling frequency is increased to improve weld quality assessment accuracy, then measurement precision is improved, but use of energy increases
Solution Approach 1:
The patent extracts and utilizes only the portions of welding current data that are most suitable for accurate measurement - specifically the low current portions where the arc is stable. By taking out and focusing on these specific data segments rather than processing all data at high frequency, the system achieves high measurement precision with reduced energy consumption.
Solution Approach 2:
The patent applies partial action by processing only the necessary portions of the welding data (low current portions) at high sampling frequency, while using lower frequency or aggregated processing for other portions. This selective partial processing maintains weld quality assessment accuracy while minimizing overall energy consumption.
Data Source
AI summary
A robotic electric arc welding system includes a welding torch, a welding robot configured to manipulate the welding torch during a welding operation, a robot controller operatively connected to the welding robot to control weaving movements of the welding torch along a weld seam and at a weave frequency and weave period, and a welding power supply operatively connected to the welding torch to control a welding waveform, and operatively connected to the robot controller for communication therewith. The welding power supply is configured to sample a plurality of weld parameters during a sampling period of the welding operation and form an analysis packet, and process the analysis packet to generate a weld quality score, wherein the welding power supply obtains the weave frequency or the weave period and automatically adjusts the sampling period for forming the analysis packet based on the weave frequency or the weave period.