TELEOPERATED ROBOT FOR FLOOD-WELDING OPERATIONS

• US 20170232615A1
• Filed: 02/08/2017
• Published: 08/17/2017
• Est. Priority Date: 02/11/2016
• Status: Active Grant

• Current Assignee: Darryl Hammock
• Original Assignee: Darryl Hammock
• Inventors: Hammock, Darryl
• Granted Patent: US 10,525,596 B2
• Time in Patent Office: Days
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: B23K 26/034 Observing the temperature of the workpiece
• CPC Class Codes: B23K 26/0884 in at least in three axial directions, e.g. manipulators, robots
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 31/125 Weld quality monitoring
• CPC Class Codes: B25J 9/1689 Teleoperation
• CPC Class Codes: G05B 2219/39451 Augmented reality for robot programming
• CPC Class Codes: G05B 2219/45104 Lasrobot, welding robot
• CPC Class Codes: Y10S 901/16 Cartesian, three degrees of freedom
• CPC Class Codes: Y10S 901/42 Welding
• CPC Class Codes: Y10S 901/47 Optical

Abstract

A remote controlled, tele-operated welder includes a multi-axis robot arm, video cameras, sensors a specialized control station that allows an operator to perform flood-fill welding operations at a remote location to avoid the heat, smoke and other environmental effects produced through typical flood-welding operations. The operator accesses the control unit (OCU) using a GUI and mouse, keyboard, joystick, or other custom controls, and observe the piece via the cameras (visual, thermal, or other) placed in the welding station via a feed displayed on the OCU display(s). Audio, video, and/or tactile feedback may be provided to indicate arm, welder, or other system status, for collision warning and arm motion singularity avoidance. Augmented reality informational graphic/textual overlays may provide guidance to an operator, and the apparatus may further include the ability to repeat series of steps needed to handle flood-weld on a given piece, repeatedly across many pieces.

Claims

1. A system for remotely performing flood-welding operations, comprising:

a welding station including;

a support adapted for placement of a work piece having a cavity to be filled through flood welding;

a multi-axis robot arm including a welding tip operative to access the cavity; and

at least one camera having a field of view including the cavity to be filled; and

an operator control unit (OCU) including;

a display operative to display images acquired by the camera; and

an interface enabling the operator to move the robot arm with respect to the work piece to flood fill the cavity in the work piece.

2. The system of claim 1, wherein the interface enabling the operator to move the robot arm includes a joystick.

3. The system of claim 1, wherein the display further includes a graphical user interface (GUI) and a mouse or other pointing device to define and implement a desired flood-welding operation.

4. The system of claim 1, further including one or more sensors to monitor the temperature of the work piece or other characteristics during a welding operation.

5. The system of claim 1, further including an infrared camera to view thermal characteristics of a welding operation.

6. The system of claim 1, further enabling the operator to set the alignment of the piece, such that the system knows the coordinates of the piece with respect to the mounting and robotic welding arm.

7. The system of claim 1, further including a teaching mode of operation wherein manual motions are recorded and automatically incorporated into subsequent welding operations.

8. The system of claim 1, further including a mode of operation that facilitates a repeated, layer-by-layer application of material to fill a cavity while under automated control, including the automated generation of weld-head routes that facilitate flood welding.

9. The system of claim 1, further including the ability to use the robotic arm in a fully manual mode including the manual generation of weld-head routes associated with flood welding.

10. The system of claim 1, further including the automated collection/logging of data as layers are applied in conjunction with a flood welding operation.

11. The system of claim 1, further including a memory for storing data associated with a welding operation and a processor for analyzing the data to determine weld quality.

12. The system of claim 1, further including audible, visual or tactile feedback to assist an operator in performing a welding operation.

13. The system of claim 12, wherein the feedback is provided at the joystick or controller to indicate robot arm, welder, or other system status.

14. The system of claim 12, wherein the feedback is based upon measured or estimated proximity of the robot arm to the work piece to provide for collision warning.

15. The system of claim 12, wherein the feedback is generated in response to the proximity of the arm to a motion singularity point, defined as a point at which a robot arm joint may become limited in motion.

16. The system of claim 1, further including memory or storing desired welding parameters, and wherein the system automatically analyzes measurements taken during a welding operation and automatically adjust welder settings or provides guidance to operator by comparing the measurements to the stored parameters.

17. The system of claim 1, further including a display generator operative to present augmented reality informational graphical/textual overlays on the display to provide guidance to the operator regarding the manner in which the robot arm or welding tip should be controlled to generate higher quality flood fill welds.

18. The system of claim 1, further including a processor for performing a teaching mode of operation an operator manually controls the robot welding arm to flood fill a single layer of material, whereupon the system captures the commands used and the motions generated, to creates a macro to automatically guide the system in creating successive layers.