Portable Welding Robot Weaving Control for Consistent Penetration
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Solution Overview
Problem
In vertical and horizontal welding, existing portable welding robots face challenges in maintaining consistent weaving patterns due to independent movement of the welding torch in the weld line direction and groove width direction, leading to inadequate penetration and complex management of weaving conditions with varying welding speeds.
Innovation Solution
A weaving control method that synchronizes stop and departure signals with calculated speed conditions for each direction component of the portable welding robot, ensuring consistent weaving patterns and penetration across different welding positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding speed is increased to improve productivity, then the welding efficiency is improved, but gaps appear in the weaving pattern leading to inadequate penetration
Solution Approach 1:
The patent applies dynamics by making the weaving control adaptive to changing welding speeds. The control device dynamically adjusts the weaving pattern parameters (amplitude, frequency, phase) based on the actual welding speed to maintain consistent weaving quality. This resolves the contradiction by enabling the system to operate at higher speeds while preserving weaving pattern consistency through real-time parameter adjustment.
Solution Approach 2:
The patent implements feedback control where the control device monitors the welding speed and uses this information to adjust the weaving pattern. The control device receives feedback about the welding speed from the welding system and modifies the weaving parameters accordingly. This feedback mechanism ensures that even at increased welding speeds, the weaving pattern remains consistent and gaps are prevented.
2Device complexity
If independent control of welding torch movement in weld line direction and groove width direction is used to simplify control structure, then the device complexity is reduced, but synchronization between weaving and movement becomes difficult to maintain
Solution Approach 1:
The patent merges the control of welding torch movement in the weld line direction with the weaving control in the groove width direction. Instead of treating them as completely independent controls, the system integrates them through a unified control device that coordinates both movements. This merging ensures that the weaving pattern remains synchronized with the welding progress while maintaining relatively simple control structure through integrated rather than multiplexed control.
Solution Approach 2:
The control device acts as an intermediary that coordinates between the welding speed control and the weaving pattern control. It receives the welding speed information and uses it to generate appropriate weaving commands that are synchronized with the welding movement. This intermediary function ensures reliable synchronization without requiring complex direct coupling between all control elements.
3Manufacturing precision
If complicated weaving patterns such as serrated shape or rectangular shape are applied to obtain appropriate weld overlay, then the weld quality is improved, but the device complexity increases due to need for articulated robot
Solution Approach 1:
The patent achieves complicated weaving patterns by changing the control parameters (amplitude, frequency, phase, waveform type) rather than changing the physical structure of the robot. The system can generate serrated, rectangular, or other complex weaving patterns by adjusting software-controlled parameters of a simpler robotic system. This resolves the contradiction by producing high-quality weld overlays through parameter variation instead of requiring complex articulated robot structures.
Solution Approach 2:
The patent replaces the need for mechanically complex articulated robots with a control-based approach. Instead of relying on complex mechanical degrees of freedom to achieve complicated weaving patterns, the system uses software control to generate the desired patterns through coordinated movement of simpler mechanical components. This substitution of mechanical complexity with control intelligence achieves high-quality weld overlays while maintaining simpler device structure.
Data Source
AI summary
Provided is a weaving control method for obtaining an excellent weld quality of various kinds of position welding such as flat welding, horizontal welding, and vertical welding using a portable welding robot that moves on a guide rail. The weaving control method includes: a setting step of setting at least a condition of a weaving reference trajectory relating to a reference distance for determining a weaving pattern; and a speed condition calculation step of calculating a speed condition for giving an instruction to a robot movement mechanism that moves the portable welding robot for each of a plurality of predetermined direction components based on the weaving pattern determined based on the setting step, in which an instruction of a stop signal and an instruction of a departure signal to be given immediately after instructing the stop signal or after the lapse of a predetermined stop time are synchronized with the speed condition of each of the plurality of direction components calculated in the speed condition calculation step at least when a weaving end is reached.