Welding Wire Surface Scanning for Fast Edge Detection
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Solution Overview
Problem
Existing methods for scanning the surface of metallic workpieces before welding are slow due to the need for extensive software implementation in manipulator controllers, requiring significant computing capacity and resulting in low welding torch speeds for accuracy.
Innovation Solution
The method involves using a welding torch with a meltable welding wire to detect edges by setting an edge detection parameter and transferring only this parameter, along with the current position value, to the manipulator, allowing for faster processing and scanning without the need for extensive computing capacity in the manipulator, enabling faster edge detection and evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extensive software implementation is performed in manipulator controllers to evaluate surface position data, then edge detection accuracy is improved, but processing time increases and productivity decreases
Solution Approach 1:
The patent extracts the complex evaluation logic from the manipulator controller and relocates it to the welding power source. Only essential edge detection parameters are transmitted to the manipulator, while detailed surface position analysis is performed centrally at the power source, reducing data transmission requirements and processing burden on the manipulator controller
Solution Approach 2:
The patent combines the evaluation functions previously distributed across manipulator controllers into a single centralized evaluation at the welding power source. This consolidation allows for more efficient processing of surface position data and reduces the need for extensive software implementation in each manipulator controller
2Measurement precision
If high computing capacity is provided in manipulator controllers for real-time evaluation, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the complex evaluation algorithms from the manipulator controller and implements them in the welding power source instead. This reduces the computing capacity requirements and software complexity in the manipulator controller while maintaining accurate edge detection capabilities
Solution Approach 2:
The welding power source is given additional functionality to perform surface position evaluation and edge detection, replacing the need for specialized high-capacity computing in manipulator controllers. This multi-functional approach simplifies the overall system architecture
3Loss of information
If all surface position data is transmitted to the manipulator for evaluation, then measurement completeness is improved, but data transmission time and processing load increase
Solution Approach 1:
The patent extracts only the essential edge detection parameters from the complete surface position data and transmits only these to the manipulator. The welding power source retains and processes the complete data set, achieving both data completeness and reduced transmission requirements
Solution Approach 2:
The patent segments the data processing tasks by separating complete surface position data evaluation (performed at the welding power source) from edge detection parameter transmission (sent to the manipulator). This segmentation allows each system to operate with appropriate data volumes
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
This approach significantly increases processing speed and reduces data transmission requirements, allowing for accurate edge detection on uneven or curved surfaces, and enables precise measurement of edge height, inclination, and radius, which can be used to adjust welding parameters for optimal quality.
Implementation Method 1
a welding torch with a meltable welding wire is moved over the surface of the workpieces using a manipulator along a predefined path and at a specified speed, and at predefined times the welding wire is moved towards the surface of the workpieces at a first forward speed until a contact of the welding wire with one of the workpieces is detected by a welding power source
Data Source
AI summary
Method for scanning the surface (O) of metallic workpieces (W), wherein, during a scanning process before a welding process is carried out, a welding torch (1) with a meltable welding wire (2) is moved over the surface (O) of the workpieces (W), and at predefined times (ti) the welding wire (2) is moved towards the surface (O) of the workpieces (W) until a contact of the welding wire (2) with one of the workpieces (W) is detected, and the position (Pi) of the surface (O) of the workpieces (W) at each time (ti) is determined and stored in the welding power source (4), wherein an edge (K) is determined if the current position (Pi) of the surface (O) of the workpieces (W) exceeds at least one of the stored previous positions (Pi-n) of the surface (O) of the workpieces (W) by a predefined threshold value (S). To reduce the computing effort and to increase processing speed, the end of the edge (K) is determined if the current position (Pi) of the surface (O) of the workpieces (W) remains the same with respect to at least one of the stored previous positions (Pi-n), and if an edge (K) is determined, an edge detection parameter (KP) is set and output together with the current position value (Pi) and transferred to the manipulator (3).