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Automatic estimation of weldgun size using section geometry

  • US 7,974,733 B2
  • Filed: 01/30/2009
  • Issued: 07/05/2011
  • Est. Priority Date: 01/30/2009
  • Status: Expired due to Fees
First Claim
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1. A method for estimating final values of a plurality of geometric parameters of a weld gun, wherein the plurality of geometric parameters define the size of the weld gun, wherein the weld gun performs a welding operation at a weld point, said method comprising:

  • a. generating part section curves corresponding to a direction of approach of the weld gun to the weld points, wherein the part section curves are generated by using a part section plane, and wherein the part section plane is a plane containing the weld gun approach direction and a normal to the weld point;

    b. storing the part section curves as a link list of obstructions in an array of Y scan lines to analyze a given part geometry for available clearance space;

    c. determining values of a first geometric parameter of the plurality of geometric parameters, wherein the value of the first geometric parameter is determined based on the presence of the part section curves in a pre-defined area;

    d. estimating a first maximum and a first minimum limit for a second geometric parameter of the plurality of geometric parameters, wherein the first minimum limit for the second geometric parameter is determined based on the limit for the first geometric parameter, and wherein the first maximum limit of the second geometric parameter is determined based on the type of weld gun used;

    e. estimating a maximum and a minimum limit for a third geometric parameter of the plurality of geometric parameters, wherein the maximum limit for the third geometric parameter is calculated based on the value of the first geometric parameter and the first maximum and the first minimum limit for the second geometric parameter, and wherein the minimum limit for the third geometric parameter is estimated based on the first maximum and the first minimum limit for the second geometric parameter, and wherein the maximum and the minimum limit for the third geometric parameter are calculated based on the part section curves;

    f. estimating a valid maximum and a valid minimum limit for the third geometric parameter based on a value of the third geometric parameter for a first standard weld gun;

    g. computing a second maximum and a second minimum limit for the second geometric parameter corresponding to the valid maximum and the valid minimum limit for the third geometric parameter, wherein the second maximum and the second minimum limit for the second geometric parameter are calculated based on the part section curves;

    h. estimating a valid maximum and a valid minimum limit for the second geometric parameter based on a limit for the second geometric parameter of a second standard weld gun; and

    i. repeating the steps e, f, g and h until each of the valid maximum and the valid minimum limit for the second geometric parameter converge and each of the valid maximum and the valid minimum limit for the third geometric parameter converge, wherein the first maximum and the first minimum limit for the second geometric parameter are replaced with the valid maximum and the valid minimum limits for the second geometric parameter, respectively, and wherein the limit for the first geometric parameter, the converged valid minimum limit for the second geometric parameter, the converged valid maximum limit for the second geometric parameter, the converged valid minimum limit for the third geometric parameter and the converged valid maximum limit for the third geometric parameter are the estimated final limits for the plurality of geometric parameters.

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