Welding Weaving Control Using Offset Trajectory Adjustment
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Solution Overview
Problem
Existing simple welding devices, such as portable welding robots or carriages, lack the high-accuracy coordinate axes and manipulators needed to implement special weaving patterns or adjust them dynamically in response to welding speed variations, making automation of site welding difficult.
Innovation Solution
A welding control device with a database that associates and stores control reference and item information for changing the direction and distance of weaving reference trajectories, allowing the extraction of offset amounts based on input measured values to maintain any weaving pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple welding device (portable welding robot or carriage) is used, then device complexity is reduced and ease of manufacture is improved, but manufacturing precision and adaptability for special weaving patterns deteriorate
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting weaving control parameters (offset amounts, direction, distance) based on real-time measured values from sensors. The control device modifies weaving trajectory parameters on-the-fly to compensate for the lack of high-accuracy mechanical components, enabling simple welding devices to achieve precise weaving patterns through software-based parameter adjustment rather than relying on complex mechanical precision.
2Device complexity
If a simple welding device is used, then device complexity is reduced, but adaptability to change weaving pattern depending on situations deteriorates
Solution Approach 1:
The patent implements feedback control by continuously measuring actual welding conditions (gap variations, misalignment) using sensors and automatically adjusting weaving control parameters in response. This closed-loop feedback system enables the simple welding device to adapt to changing situations and maintain appropriate weaving patterns without requiring complex mechanical reconfiguration capabilities.
Solution Approach 2:
The patent applies dynamics by making the weaving control parameters dynamic rather than fixed. The control device continuously modifies offset amounts, weaving direction, and distance based on real-time measured values, enabling the system to adapt to varying welding conditions. This dynamic parameter adjustment compensates for the static, simple mechanical structure of the welding device.
3Manufacturing precision
If multi-axis robot with high-accuracy coordinate axis and manipulator is used, then manufacturing precision for special weaving pattern is improved, but device complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical precision systems with a control-based approach. Instead of relying on high-accuracy mechanical components (multi-axis robots, precision coordinate systems), the invention uses a control device with database and sensor feedback to achieve precise weaving patterns through software control and real-time parameter adjustment, substituting mechanical complexity with control system intelligence.
4Manufacturing precision
If weaving pattern is changed to maintain bead shape, then manufacturing precision is improved, but loss of time for adjustment increases
Solution Approach 1:
The patent implements continuity of useful action by making the weaving parameter adjustment continuous and automatic rather than discrete and manual. The control device continuously monitors measured values and automatically adjusts weaving parameters in real-time during the welding process, eliminating stoppages for manual adjustment and maintaining continuous productive action while preserving bead shape quality.
Data Source
AI summary
A welding control device includes a database that is constructed such that, when an information group including at least construction information, welding condition information, and weaving information is set as welding information, a control reference item selected from at least one item in the welding information and a control item selected from at least one item in the welding information are associated and stored for every standard item selected from at least one item in the welding information, and the control item includes at least an offset amount for changing a direction and a distance of at least one predetermined point in one cycle of a weaving reference trajectory in the weaving information. The weaving control method using the welding control device includes a step of extracting at least the offset amount from the database based on an input measured value of the control reference item.