Control system using working robot, and work processing method using this system

• US 7,605,347 B2
• Filed: 02/05/2004
• Issued: 10/20/2009
• Est. Priority Date: 02/06/2003
• Status: Expired due to Fees

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Ueda, Koji, Izawa, Akinobu, Era, Tetsuo, Yamagami, Takeshi
• Primary Examiner(s): Evans; Geoffrey S
• Application Number:
  US10/544,637
• Publication Number:
  US 20070145027A1
• Time in Patent Office: 2,084 Days
• Field of Search: 219/124.34, 219/121.63, 219/121.64, 228/7, 228/9, 228/102, 228/104, 228/105, 901/42
• US Class Current: 219/124.34
• CPC Class Codes: B23K 9/032 for three-dimensional seams
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/127 Means for tracking lines during arc welding or cutting copying in general B23Q35/00
• CPC Class Codes: B23K 9/1272 Geometry oriented, e.g. beam optical trading
• CPC Class Codes: B23K 9/1274 Using non-contact, optical means, e.g. laser means
• CPC Class Codes: B25J 19/022 using lasers
• CPC Class Codes: B25J 9/1684 Tracking a line or surface by means of sensors
• CPC Class Codes: B25J 9/1694 characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
• CPC Class Codes: G05B 19/42 Recording and playback systems, i.e. in which the programme is recorded from a cycle of operations, e.g. the cycle of operations being manually controlled, after which this record is played back on the same machine
• CPC Class Codes: G05B 2219/34096 Approximate, replace curve, surface with circle, linear segments, least error
• CPC Class Codes: G05B 2219/36407 Follow path with probe, store deviations for correction during normal operation
• CPC Class Codes: G05B 2219/36415 Adjust path and attitude tool by detecting path, line with a photosensor, laser
• CPC Class Codes: G05B 2219/36462 Minimize teach time, compress data, many points in curve, few in line
• CPC Class Codes: G05B 2219/45104 Lasrobot, welding robot
• CPC Class Codes: G05B 2219/4705 Detect edge during machining, welding, sewing
• CPC Class Codes: G05B 2219/49218 Compensation of workpiece dilatation

Abstract

The control system includes a welding robot which moves a welding torch along a work for welding the work. A robot controller controls driving of the welding robot. A laser sensor head detects a shape change in the work during welding by the welding torch, and a personal computer obtains instruction information for the welding robot in accordance with the shape change, based on a result of detection by the laser sensor head. The robot controller moves the welding torch by controlling the driving of the working robot, based on the instruction information obtained by the personal computer.

Claims

1. A welding control system comprising:

a robot which moves a welder along a work for welding the work;

a robot controller for controlling the robot;

a detector for detecting a shape change of a welding region of the work that results during the welding; and

a processor for obtaining instruction information for the robot in accordance with the shape change based on the detection by the detector;

the robot controller comprising means causing the robot to move the welder along a rehearsal welding path for a test work while causing the welder to perform rehearsal welding on the test work, said means of the robot controller also causing the robot to move the welder along a corrected welding path for another work, the corrected welding path being adjusted relative to the rehearsal welding path based on the instruction information obtained by the processor.

2. The control system according to claim 1, wherein the processor obtains data of a plurality of points representing the shape change of the welding region of the work, as data for candidate instruction points, and deletes part of the data which represents points satisfying a predetermined straight-line approximation condition for making the instruction information including data of a plurality of points.

3. The control system using a working robot according to claim 2, wherein the processor obtains data of a plurality of points representing the shape change of the welding region of the work, as data for candidate instruction points, and deletes part of the data which represents points satisfying a predetermined arc-line approximation condition for making instruction information including data of a plurality of points.

4. The control system according to claim 1, wherein the processor obtains data of a plurality of points representing the shape change of the welding region of the work, as data for candidate instruction points, and deletes part of the data which represents points satisfying a predetermined arc-line approximation condition for making the instruction information including data of a plurality of points.

5. A welding method by using a control system, the control system including a robot which moves a welder along a work for welding the work, a robot controller for controlling driving of the robot, and a detector for detecting a welding region of the work, the method comprising:

a first step of having the welder perform rehearsal welding to a test work along a rehearsal welding path while causing the detector to detect a shape change of the welding region of the work that results during the welding;

a second step of obtaining instruction information for the robot based on the shape change detected in the test work in the first stage to generate a corrected welding path that is adjusted relative to the rehearsal welding path; and

a third step of welding another work by moving the welder along the corrected welding path based on the instruction information obtained in the second stage.