U.S. patent application number 16/127473 was filed with the patent office on 2019-05-30 for systems and methods supporting weld quality across a manufacturing environment.
The applicant listed for this patent is Lincoln Global, Inc.. Invention is credited to Joseph A. Daniel.
Application Number | 20190160601 16/127473 |
Document ID | / |
Family ID | 66633911 |
Filed Date | 2019-05-30 |
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United States Patent
Application |
20190160601 |
Kind Code |
A1 |
Daniel; Joseph A. |
May 30, 2019 |
SYSTEMS AND METHODS SUPPORTING WELD QUALITY ACROSS A MANUFACTURING
ENVIRONMENT
Abstract
Embodiments of systems and methods for supporting weld quality
across a manufacturing environment are disclosed. One embodiment
includes manufacturing cells within a manufacturing environment,
where each manufacturing cell includes a cell controller and
welding equipment. A communication network supports data
communications between a central controller and the cell controller
of each of the manufacturing cells. The central controller collects
actual weld parameter data from the cell controller of each
manufacturing cell, via the communication network, to form
aggregated weld parameter data for a same type of workpiece being
welded in each of the manufacturing cells. The central controller
analyzes the aggregated weld parameter data to generate updated
weld settings. The updated weld settings are communicated from the
central controller to the cell controller of each of the
manufacturing cells via the communication network.
Inventors: |
Daniel; Joseph A.; (Sagamore
Hills, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lincoln Global, Inc. |
Santa Fe Springs |
CA |
US |
|
|
Family ID: |
66633911 |
Appl. No.: |
16/127473 |
Filed: |
September 11, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62592072 |
Nov 29, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 9/133 20130101;
G05B 2219/32397 20130101; B23K 37/00 20130101; B25J 9/1664
20130101; B23K 9/0956 20130101; G05B 2219/45104 20130101; G05B
2219/32194 20130101; B23K 9/1087 20130101; B23K 9/126 20130101;
G05B 2219/32234 20130101; B23K 9/04 20130101; G06Q 10/20 20130101;
B23K 9/091 20130101; B23K 9/127 20130101; B23K 9/0953 20130101;
B25J 11/005 20130101; B23K 9/1062 20130101; G05B 19/41875 20130101;
B23K 10/027 20130101; B25J 9/1661 20130101; B23K 31/006 20130101;
G05B 2219/31087 20130101; B23K 31/003 20130101; B23K 31/125
20130101; B23K 9/095 20130101; B23K 26/342 20151001; B23K 9/1276
20130101; B25J 9/163 20130101; B23K 15/0086 20130101 |
International
Class: |
B23K 31/00 20060101
B23K031/00; B23K 31/12 20060101 B23K031/12; B23K 37/00 20060101
B23K037/00; B25J 11/00 20060101 B25J011/00; B25J 9/16 20060101
B25J009/16 |
Claims
1. A system supporting weld quality across a manufacturing
environment, the system comprising: a plurality of manufacturing
cells within a manufacturing environment, wherein each
manufacturing cell of the plurality of manufacturing cells includes
a cell controller and welding equipment; a central controller; and
a communication network operatively connected to the central
controller and the plurality of manufacturing cells and configured
to support data communications between the central controller and
the cell controller of each of the plurality of manufacturing
cells, wherein the central controller is configured to: collect
actual weld parameter data from the cell controller of each of the
plurality of manufacturing cells, via the communication network, to
form aggregated weld parameter data for a same type of workpiece
being welded in each of the plurality of manufacturing cells,
wherein the actual weld parameter data include values and ranges of
actual welding parameters used by the welding equipment in each of
the plurality of manufacturing cells to weld the same type of
workpiece, analyze the aggregated weld parameter data to generate
updated weld settings for the same type of workpiece being welded
in each of the plurality of manufacturing cells, and communicate
the updated weld settings to the cell controller of each of the
plurality of manufacturing cells via the communication network.
2. The system of claim 1, wherein the welding equipment of each of
the plurality of manufacturing cells is configured to: communicate
the actual weld parameter data to the cell controller, receive the
updated weld settings from the cell controller, and use the updated
weld settings for subsequent welding of the same type of
workpiece.
3. The system of claim 1, wherein the actual weld parameter data
include values and ranges of at least one of a welding voltage, a
welding current, an arc travel speed, a wire feed speed, a wire
electrode stick out distance, and a welding waveform.
4. The system of claim 1, wherein the updated weld settings include
values and ranges of at least one of a welding voltage, a welding
current, an arc travel speed, a wire feed speed, a wire electrode
stick out distance, a gas flow rate, and a welding waveform.
5. The system of claim 1, wherein at least a portion of the actual
weld parameter data is stored in a memory of the welding equipment
of each manufacturing cell of the plurality of manufacturing cells
as operator-selected weld parameter data.
6. The system of claim 1, further comprising at least one sensor,
in each manufacturing cell of the plurality of manufacturing cells,
configured to sense at least one of the actual welding parameters
used to weld the same type of workpiece, wherein the at least one
sensor includes at least one of a voltage sensor configured to
sense a welding voltage, a current sensor configured to sense a
welding current, a motion sensor configured to sense an arc travel
speed, a speed sensor configured to sense a wire feed speed, a
visual sensor configured to sense an electrode stick out distance,
or a flow sensor configured to sense a gas flow.
7. The system of claim 1, wherein the plurality of manufacturing
cells are robotic manufacturing cells.
8. The system of claim 1, wherein the plurality of manufacturing
cells are non-robotic manufacturing cells.
9. The system of claim 1, wherein the communication network is
configured to facilitate wired communication between the central
controller and each cell controller of the plurality of
manufacturing cells.
10. The system of claim 1, wherein the communication network is
configured to facilitate wireless communication between the central
controller and each cell controller of the plurality of
manufacturing cells.
11. A manufacturing cell supporting welding of a sequence of welds
to manufacture a workpiece, the manufacturing cell comprising:
robotic welding equipment configured to make robotic welds as at
least a portion of manufacturing a workpiece; non-robotic welding
equipment configured to allow a human operator to make non-robotic
welds as at least a portion of manufacturing the workpiece; and a
weld sequence controller configured to control timing associated
with making the robotic welds and the non-robotic welds as a
sequence of welds to manufacture the workpiece.
12. The manufacturing cell of claim 11, wherein the timing and the
sequence of welds is predetermined and fixed before welding
begins.
13. The manufacturing cell of claim 11, wherein locations of the
non-robotic welds to be made to manufacture the workpiece cannot be
reached by the robotic welding equipment.
14. The manufacturing cell of claim 11, wherein the weld sequence
controller is configured to adapt at least one of a position and
timing of a subsequent weld to be made in the sequence of welds,
while manufacturing the workpiece, based on a condition of a
previous weld of the sequence of welds.
15. The manufacturing cell of claim 11, wherein the weld sequence
controller is configured to adapt the sequence of welds, while
manufacturing the workpiece, by adding a non-robotic weld as a next
weld to be made when an immediate previous weld in the sequence of
welds is a robotic weld that was missed by the robotic welding
equipment, and wherein a location on the workpiece of the next weld
to be made, non-robotically, is the same as a location of the
immediate previous weld.
16. The manufacturing cell of claim 11, wherein the weld sequence
controller is configured to determine if an immediate previous weld
made, of the sequence of welds, is defective based on at least one
quality parameter of the immediate previous weld made.
17. The manufacturing cell of claim 11, wherein the weld sequence
controller is configured to adapt the sequence of welds, while
manufacturing the workpiece, by adding a non-robotic weld as a next
weld to be made when an immediate previous weld in the sequence of
welds is a robotic weld that was determined to be defective, and
wherein a location on the workpiece of the next weld to be made,
non-robotically, is the same as a location of the immediate
previous weld.
18. The manufacturing cell of claim 11, further comprising at least
one sensor associated with the at least one weld of the sequence of
welds, wherein the at least one sensor is configured to sense at
least one quality parameter associated with generating the at least
one weld and report the at least one quality parameter, directly or
indirectly, to the weld sequence controller.
19. The manufacturing cell of claim 18, wherein the at least one
sensor includes at least one of a visual spectrum sensor, a
radiographic sensor, a laser sensor, an electromagnetic sensor, an
infrared sensor, a temperature sensor, a spectrometer sensor, or an
ultrasonic sensor.
20. The manufacturing cell of claim 18, wherein the at least one
quality parameter is related to at least one of a weld position on
the workpiece, a weld bead size, a weld bead shape, weld
penetration, weld fusion, weld porosity, weld cracking, weld
inclusion, a weld discontinuity, an arc plasma type, or an arc
plasma temperature.
Description
CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY
REFERENCE
[0001] This U.S. patent application claims priority to and the
benefit of U.S. Provisional Patent Application Ser. No. 62/592,072,
filed on Nov. 29, 2017, the disclosure of which is incorporated
herein by reference in its entirety. U.S. Pat. No. 9,937,577,
issued on Apr. 10, 2018, is incorporated herein by reference in its
entirety.
FIELD
[0002] Embodiments of the present invention relate to supporting
weld quality (e.g., weld quality correction and validation) across
multiple manufacturing cells of a manufacturing environment.
BACKGROUND
[0003] When welding workpieces of the same type across many
manufacturing cells within a manufacturing environment, it can be
challenging to maintain a consistent quality of those welded
workpieces across the manufacturing cells. Over time, weld settings
of the various welding equipment within the manufacturing cells can
get changed and become very divergent from one cell to the next. As
a result, the quality of a same type of welded workpiece can become
divergent from one cell to the next. However, it is desirable to
maintain a consistent "good" quality of workpieces across the
manufacturing environment.
SUMMARY
[0004] Embodiments of the present invention include systems and
methods related to supporting weld quality across a manufacturing
environment.
[0005] One embodiment includes a system supporting weld quality
across a manufacturing environment. The system includes multiple
manufacturing cells within a manufacturing environment. Each
manufacturing cell of the multiple manufacturing cells includes a
cell controller and welding equipment. The manufacturing cells may
be robotic manufacturing cells or non-robotic manufacturing cells
(e.g., semi-automatic or manual). The system also includes a
central controller and a communication network operatively
connected to the central controller and the multiple manufacturing
cells. The communication network is configured to support data
communications (e.g., wired and/or wireless communications) between
the central controller and the cell controller of each of the
multiple manufacturing cells. The central controller is configured
to collect actual weld parameter data from the cell controller of
each of the multiple manufacturing cells, via the communication
network, to form aggregated weld parameter data for a same type of
workpiece being welded in each of the multiple manufacturing cells.
The actual weld parameter data include values and ranges of actual
welding parameters used by the welding equipment in each of the
multiple manufacturing cells to weld the same type of workpiece.
The central controller is also configured to analyze the aggregated
weld parameter data to generate updated weld settings for the same
type of workpiece being welded in each of the multiple
manufacturing cells. The central controller is further configured
to communicate the updated weld settings to the cell controller of
each of the multiple manufacturing cells via the communication
network. In one embodiment, the welding equipment of each of the
multiple manufacturing cells is configured to communicate the
actual weld parameter data to the cell controller, receive the
updated weld settings from the cell controller, and use the updated
weld settings for subsequent welding of the same type of workpiece.
The actual weld parameter data and the updated weld settings may
include values and ranges of, for example, a welding voltage, a
welding current, an arc travel speed, a wire feed speed, a wire
electrode stick out distance, and a welding waveform. At least a
portion of the actual weld parameter data may be stored in a memory
of the welding equipment of each manufacturing cell of the multiple
manufacturing cells as operator-selected weld parameter data. In
accordance with one embodiment, the system includes at least one
sensor, in each manufacturing cell of the multiple manufacturing
cells, configured to sense at least one of the actual welding
parameters used to weld the same type of workpiece. The sensor may
include, for example, a voltage sensor configured to sense a
welding voltage, a current sensor configured to sense a welding
current, a motion sensor configured to sense an arc travel speed, a
speed sensor configured to sense a wire feed speed, a visual sensor
configured to sense an electrode stick out distance, or a flow
sensor configured to sense a gas flow.
[0006] One embodiment includes a manufacturing cell supporting
welding of a sequence of welds to manufacture a workpiece. The
manufacturing cell includes robotic welding equipment configured to
make robotic welds as at least a portion of manufacturing a
workpiece, and non-robotic welding equipment configured to allow a
human operator to make non-robotic (e.g., manual or semi-automatic)
welds as at least a portion of manufacturing the workpiece. The
manufacturing cell also includes a weld sequence controller
configured to control timing associated with making the robotic
welds and the non-robotic welds as a sequence of welds to
manufacture the workpiece. In accordance with one embodiment, the
timing and the sequence of welds is predetermined and fixed before
welding begins. Locations of the non-robotic welds to be made to
manufacture the workpiece cannot be reached by the robotic welding
equipment, in accordance with one embodiment. In one embodiment,
the weld sequence controller is configured to adapt at least one of
a position and timing of a subsequent weld to be made in the
sequence of welds, while manufacturing the workpiece, based on a
condition of a previous weld of the sequence of welds. In one
embodiment, the weld sequence controller is configured to adapt the
sequence of welds, while manufacturing the workpiece, by adding a
non-robotic weld as a next weld to be made when an immediate
previous weld in the sequence of welds is a robotic weld that was
missed by the robotic welding equipment. The location on the
workpiece of the next weld to be made, non-robotically, is the same
as the location of the immediate previous weld. In one embodiment,
the weld sequence controller is configured to determine if an
immediate previous weld made, of the sequence of welds, is
defective based on at least one quality parameter of the immediate
previous weld made. In one embodiment, the weld sequence controller
is configured to adapt the sequence of welds, while manufacturing
the workpiece, by adding a non-robotic weld as a next weld to be
made when an immediate previous weld in the sequence of welds is a
robotic weld that was determined to be defective. The location on
the workpiece of the next weld to be made, non-robotically, is the
same as the location of the immediate previous weld. In one
embodiment, the manufacturing cell includes at least one sensor
associated with at least one weld of the sequence of welds. The
sensor is configured to sense at least one quality parameter
associated with generating at least one weld and report the quality
parameter, directly or indirectly, to the weld sequence controller.
A sensor may include, for example, a visual spectrum sensor, a
radiographic sensor, a laser sensor, an electromagnetic sensor, an
infrared sensor, a temperature sensor, a spectrometer sensor, or an
ultrasonic sensor. A quality parameter may be related to, for
example, a weld position on the workpiece, a weld bead size, a weld
bead shape, weld penetration, weld fusion, weld porosity, weld
cracking, weld inclusion, a weld discontinuity, an arc plasma type,
or an arc plasma temperature.
[0007] Numerous aspects of the general inventive concepts will
become readily apparent from the following detailed description of
exemplary embodiments, from the claims, and from the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate various
embodiments of the disclosure. It will be appreciated that the
illustrated element boundaries (e.g., boxes, groups of boxes, or
other shapes) in the figures represent one embodiment of
boundaries. In some embodiments, one element may be designed as
multiple elements or multiple elements may be designed as one
element. In some embodiments, an element shown as an internal
component of another element may be implemented as an external
component and vice versa. Furthermore, elements may not be drawn to
scale.
[0009] FIG. 1 illustrates one embodiment of a manufacturing cell
for manufacturing a workpiece within a manufacturing
environment;
[0010] FIG. 2 illustrates one embodiment of a system supporting
weld quality across a manufacturing environment having a plurality
of manufacturing cells that are in wired communication with a
central controller via a communication network;
[0011] FIG. 3 illustrates one embodiment of a system supporting
weld quality across a manufacturing environment having a plurality
of manufacturing cells that are in wireless communication with a
central controller via a communication network;
[0012] FIG. 4 illustrates one embodiment of a manufacturing cell
communicating weld parameter data to a central controller;
[0013] FIG. 5 illustrates one embodiment of a central controller
communicating updated weld settings to a manufacturing cell;
[0014] FIGS. 6A, 6B, and 6C illustrate embodiments of three types
of data analysis that may be performed by a central controller;
[0015] FIG. 7 illustrates example embodiments of sensors for
monitoring actual welding parameters within manufacturing cells of
a manufacturing environment;
[0016] FIG. 8 illustrates a flow chart of one embodiment of a
method to support weld quality across a manufacturing
environment;
[0017] FIG. 9 illustrates another embodiment of a manufacturing
cell for manufacturing a workpiece within a manufacturing
environment;
[0018] FIG. 10 illustrates a flow chart of one embodiment of a
method to support welding a sequence of welds within a
manufacturing cell;
[0019] FIG. 11 illustrates example embodiments of sensors for
monitoring quality parameters of a sequence of welds that are made
when manufacturing a workpiece within a manufacturing cell; and
[0020] FIG. 12 illustrates an example embodiment of a controller
(e.g., a central controller, a cell controller, or a weld sequence
controller used in the systems described herein).
DETAILED DESCRIPTION
[0021] Embodiments of systems and methods for supporting weld
quality are disclosed. For example, weld parameter data may be
observed across all manufacturing cells (an entire
factory/installed base), analyzed, and pushed back to individual
manufacturing cells as updated weld settings, providing the basis
of quality improvement with a larger group of machines from which
to learn which settings make quality ("good") welds on a particular
type of workpiece (this is different than just one machine setting
limits). Such a larger data set provides a more robust set of weld
parameter data to determine weld settings which produce quality
welds.
[0022] One embodiment includes multiple manufacturing cells within
a manufacturing environment, where each manufacturing cell includes
a cell controller and welding equipment. A communication network
supports data communications between a central controller and the
cell controller of each of the manufacturing cells. The central
controller collects actual weld parameter data from the cell
controller of each of the manufacturing cells, via the
communication network. The actual weld parameter data include
values and ranges of actual welding parameters used by the welding
equipment in each of the multiple manufacturing cells to weld the
same type of workpiece. The central controller aggregates and
analyzes the weld parameter data collected from across the
manufacturing cells to generate updated weld settings for the same
type of workpiece being welded in each of the manufacturing cells.
The updated weld settings are communicated to the cell controller
of each of the manufacturing cells via the communication network to
be used by the respective welding equipment.
[0023] The examples and figures herein are illustrative only and
are not meant to limit the subject invention, which is measured by
the scope and spirit of the claims. Referring now to the drawings,
wherein the showings are for the purpose of illustrating exemplary
embodiments of the subject invention only and not for the purpose
of limiting same, FIG. 1 illustrates one embodiment of a
manufacturing cell 10 for manufacturing a workpiece within a
manufacturing environment. The manufacturing cell 10 is discussed
in detail herein with respect to being configured with welding
equipment. The welding equipment may be robotic welding equipment,
non-robotic welding equipment (e.g., semi-automatic or manual), or
some combination thereof. It is envisioned that a manufacturing
cell may be used to weld a workpiece b y a process such as, for
example, gas metal arc welding (GMAW), flux-cored arc welding
(FCAW), or gas tungsten arc welding (GTAW). Other processes for
welding are possible as well, in accordance with other
embodiments.
[0024] With reference to FIG. 1, the manufacturing cell 10 is a
welding manufacturing cell and generally includes a frame 12, a
robot 14 disposed within the frame, and first and second welding
tables 16 and 18, respectively, also disposed within the frame. The
manufacturing cell 10 is useful for welding work pieces (parts) 22
and 24. In the depicted embodiment of FIG. 1, the frame 12 includes
a plurality of side walls and doors to enclose the robot 14 and the
welding tables 16 and 18. Even though a substantially rectangular
configuration in plan view is shown, the frame 12, and the cell 10,
can take numerous configurations.
[0025] A front access door 26 mounts to the frame 12 to provide
access to the interior of the frame. The front access door 26 can
take a bi-fold configuration where the door includes two hinge
sets: a first hinge set attaching the door 26 to the frame 12 and a
second hinge set attaching one panel of the door to another panel.
Nevertheless, the front access door 26 can take other
configurations such as a sliding door or a swinging door.
Similarly, a rear access door 28 also mounts to the frame 12. The
rear access door 28 in the depicted embodiment also takes a bi-fold
configuration; however, the rear access door can take other
configurations such as those discussed with reference to the front
access door 26. Windows 32 can be provided on either door (only
depicted on front door 26). The windows can include a tinted safety
screen, for example.
[0026] A control panel 40 is provided on the frame 12 adjacent the
front door 26. Control knobs and/or switches provided on the
control panel 40 communicate with controls housed in a controls
enclosure 42 that is also mounted to the frame 12. The controls on
the control panel 40 can be used to control operations performed in
the manufacturing cell 10 in a similar manner to controls used with
known manufacturing cells.
[0027] In one embodiment, the robot 14 mounts on a pedestal that
mounts on a support. The robot 14 in the depicted embodiment is
centered with respect to the welding tables 16 and 18 and includes
multiple axes of movement. If desired, the pedestal can rotate with
respect to the support similar to a turret. Accordingly, some sort
of drive mechanism, e.g. a motor and transmission (not shown), can
be housed in the pedestal and/or the support for rotating the robot
14. In accordance with another embodiment, the pedestal is replaced
with a positioner that holds and re-positions the workpiece (e.g.,
via rotation and/or changing elevation of the workpiece) for
welding a sequence of welds, for example.
[0028] In one embodiment, a welding gun 60 attaches to a distal end
of an arm of the robot 14. The welding gun 60 can be similar to
those that are known in the art. A flexible tube or conduit 62
attaches to the welding gun 60. Consumable welding electrode wire
64, which can be stored in a container 66, is delivered to the
welding gun 60 through the conduit 62. A wire feeder 68 attaches to
the frame 12 to facilitate the delivery of consumable welding wire
64 to the welding gun 60. Even though the robot 14 is shown mounted
to a base or lower portion of the frame 12, if desired, the robot
14 can mount to an upper structure of the frame and depend
downwardly into the manufacturing cell 10. In one embodiment, a
welding power source 72 for the welding operation mounts to and
rests on a platform 74 that is connected to and can be a part of
the frame 12.
[0029] In the embodiment of FIG. 1, a sensor 61 is mounted
proximate the welding gun 60. For example, in accordance with one
embodiment, the sensor 61 is a voltage sensor configured to sense a
welding voltage (one type of welding parameter) during a welding
operation. In other embodiments, the sensor 61 may be a different
type of sensor, possibly mounted elsewhere within the manufacturing
cell 10. For example, the sensor 61 may be a current sensor for
sensing a welding current, a motion sensor (e.g., having an
accelerometer) for sensing a travel speed of the welding gun 60
(and the arc produced by the welding gun 60), a speed sensor (e.g.,
a motor with an RPM output on the wire feeder 68) for sensing a
wire feed speed, a visual sensor (e.g., a camera) configured to
sense an electrode stick out distance, or a flow sensor for sensing
a gas flow (e.g., a rate of flow of a shielding gas). In general,
multiple sensors can be employed throughout the manufacturing cell
to sense actual welding parameters during a welding operation. The
welding parameters sensed by the sensors may be communicated (e.g.,
wired or wirelessly) to a welding power source and/or a controller
of the manufacturing cell 10. Sensor fusion or data fusion
techniques may be employed, in accordance with some embodiments, to
combine data from two or more sensors to generate weld parameter
data associated with a welding operation on a workpiece.
Furthermore, weld parameter data can include data representative of
welding parameters that were selected by a human operator, stored
in a memory of the welding equipment (e.g., a memory 43 within the
controls enclosure 42), and actually used by the welding equipment
to make welds on a workpiece.
[0030] In FIG. 1, another sensor 63 is mounted near a workpiece 22
to observe a quality parameter of welds created on the workpiece
22. In accordance with one embodiment, the sensor 63 is configured
to observe welds created on the workpiece 22. For example, the
sensor 63 may be a visual spectrum sensor (e.g., a camera), a
radiographic sensor, a laser sensor, an electromagnetic sensor, an
infrared sensor, a temperature sensor, a spectrometer sensor, or an
ultrasonic sensor. The quality parameter may be related to, for
example, a weld position on the workpiece/part 22, a weld bead
size, a weld bead shape, weld penetration, weld fusion, weld
porosity, weld cracking, weld inclusion, a weld discontinuity, an
arc plasma type, or an arc plasma temperature. Such sensing can be
accomplished during welding and/or after welding, in accordance
with various embodiments. Sensor fusion or data fusion techniques
may be employed, in accordance with some embodiments, to combine
data from two or more sensors to generate quality parameter data
associated with a weld. Furthermore, in one embodiment, a user
interface is provided for an operator to easily change weld
settings. For example, a user may change one or more weld settings
associated with welding a particular weld on a workpiece such that
a higher quality weld is created. The user interface may be, for
example, the control panel 40, in accordance with one
embodiment.
[0031] A cell controller 76 communicates with and controls various
portions of the welding equipment of the manufacturing cell 10
(including the robot 14), and rests and mounts on the platform 74.
For example, the cell controller 76 can communicate with the
controls in the controls enclosure 42 and the power source 72, in
accordance with one embodiment. The cell controller 76 is also
configured to communicate with an external central controller, as
discussed later herein. In one embodiment, the cell controller 76
and, for example, welding equipment (e.g., the welding power source
72) may communicate with each other (exchange data). The welding
equipment may communicate actual weld parameter data to the cell
controller 76 and the cell controller 76 may provide updated weld
settings to the welding equipment, in accordance with one
embodiment. The cell controller 76 may gather data from many
different devices (robot, power supply, control enclosure, tooling,
sensors, etc.) of the manufacturing cell in a wired and/or wireless
manner, in accordance with various embodiments.
[0032] FIG. 2 illustrates one embodiment of a system 200 supporting
weld quality across a manufacturing environment having a plurality
of manufacturing cells 210 that are in wired communication with a
central controller 220 via a communication network 230. For
example, each of the manufacturing cells 210 may be similar to the
manufacturing cell 10 of FIG. 1 supporting welding equipment and
having a cell controller (e.g., similar to cell controller 76 of
FIG. 1). In the embodiment of FIG. 2, communication between the
manufacturing cells 210 and the central controller 220 via the
communication network 230 is accomplished via wired communications
(e.g., copper wire or fiber optics). Similarly, FIG. 3 illustrates
one embodiment of a system 300 supporting weld quality across a
manufacturing environment having a plurality of manufacturing cells
310 that are in wireless communication with a central controller
320 via a communication network 330. Embodiments of systems having
combinations of wired and wireless communications are also possible
as well. In one embodiment, the manufacturing cells 210 and/or 310
are robotic manufacturing cells. In another embodiment, the
manufacturing cells 210 and/or 310 are non-robotic (e.g.,
semi-automatic or manual) manufacturing cells operated by a human
user to generate welds on a workpiece/part. In still another
embodiment, the manufacturing cells 210 and/or 310 include both
robotic and non-robotic welding equipment.
[0033] Referring again to FIG. 2 and FIG. 3, in accordance with one
embodiment, each manufacturing cell 210 (or 310) includes a cell
controller (e.g., similar to the cell controller 76 of FIG. 1).
Each cell controller and the central controller 220 (or 320) may
share one or more characteristics with the controller 1200 of FIG.
12 (discussed later herein). The communication network 230 (or 330)
may be configured as, for example, a local area network, a wide
area network, the internet, or some combination thereof and may
include, for example, a server computer, a network storage device,
a wireless router, a modem, or some combination thereof, in
accordance with various embodiments. The cell controller of each
manufacturing cell 210 (or 310) is configured to communicate with
the central controller 220 (or 320) via the communication network
230 (or 330).
[0034] In a simple (minimal) embodiment, the communication network
230 may be configured as, for example, digital communication cables
(e.g., copper or fiber optic) connected between digital
communication circuits at the central controller 220 and at the
manufacturing cells 210. The digital communication circuits are
configured to send and receive digital data between the central
controller 220 and the manufacturing cells 210 over the digital
communication cables. Also, in a simple (minimal) embodiment, the
wireless communication network 330 may be configured as, for
example, radio frequency antennas connected to wireless digital
communication circuits at the central controller 320 and at the
manufacturing cells 310. The wireless digital communication
circuits are configured to transmit and receive radio frequency
signals (e.g., WiFi signals) encoded with digital data between the
central controller 320 and the manufacturing cells 310 via the
antennas. Therefore, in accordance with various embodiments, the
communication network 230 (and 330) may have elements located away
from the central controller 220 (and 320) and the manufacturing
cells 210 (and 310) and/or at the central controller 220 (and 320)
and the manufacturing cells 210 (and 310).
[0035] A cell controller (e.g., cell controller 76 of FIG. 1) of a
manufacturing cell acts as a communication hub for the
manufacturing cell and gathers all of the actual weld parameter
data for that manufacturing cell. The central controller 220 (or
320) collects actual weld parameter data from the manufacturing
cells 210 (or 310) across the manufacturing environment over time
to form aggregated weld parameter data for a same type of workpiece
being welded in each of the multiple manufacturing cells across the
manufacturing environment. The actual weld parameter data include
values and ranges of actual welding parameters (sensed and/or
user-selected) used by the welding equipment in each of the
multiple manufacturing cells to weld the same type of workpiece.
The actual welding parameters may include, for example, a welding
voltage, a welding current, travel speed, wire feed speed,
electrode stick out distance, and gas flow rate. The values of the
actual welding parameters may be the same or different from weld to
weld on a workpiece, in accordance with various embodiments.
Therefore, in accordance with one embodiment, the aggregated weld
parameter data is sorted by specific weld locations on a particular
workpiece type.
[0036] FIG. 4 illustrates one embodiment of a manufacturing cell
210 communicating weld parameter data 400 to a central controller
220 as the central controller 220 collects weld parameter data from
multiple manufacturing cells across the manufacturing environment.
FIG. 5 illustrates one embodiment of the central controller 220
communicating updated weld settings 510 to a manufacturing cell
210. Referring to FIG. 4 and FIG. 5, the central controller 220
collects the weld parameter data 400 from the multiple cells to
form aggregated weld parameter data (AWPD) 500. The central
controller 220 analyzes the aggregated weld parameter data (AWPD)
500 and generates updated weld settings 510 which are communicated
to each of the multiple manufacturing cells 210 within the
manufacturing environment. Similar to the actual welding
parameters, the updated weld settings may include selectable
settings of values and ranges for a welding voltage, a welding
current, travel speed, wire feed speed, electrode stick out
distance, and gas flow rate, for example. The updated weld settings
may be the same or may be different for each weld to be made on a
particular type of workpiece, depending on the nature of the welds
to be made.
[0037] In accordance with one embodiment, it is assumed that the
aggregated weld parameter data is representative of actual welding
parameters that were used to make "good" quality welds on the same
type of workpiece across the manufacturing environment. In
accordance with another embodiment, the collected weld parameter
data is tagged as being from a "good" quality weld or not, for
example. In this manner, the resultant updated weld settings 510
should be representative of values and ranges of weld settings that
will produce "good" quality welds.
[0038] FIGS. 6A, 6B, and 6C illustrate embodiments of three types
of data analysis that may be performed by a central controller on
aggregated weld parameter data (AWPD) to generate updated weld
settings. The first type of analysis 610 is statistical analysis.
For example, in one embodiment, a mean and a standard deviation of
actual weld parameter data (collected across the manufacturing
environment for a particular actual welding parameter used to make
a particular weld on a same type of workpiece in manufacturing
cells across the manufacturing environment) are calculated using
statistical techniques. The mean and standard deviation are then
used to generate an updated value and range (settings) for the
particular welding parameter. The second type of analysis 620 is
regression analysis and the third type of analysis 630 is cluster
analysis. In a similar manner, calculated characteristics resulting
from the regression analysis or the cluster analysis may be used to
generate an updated value and range (settings) for a particular
welding parameter. Other types of analyses may be possible as well,
in accordance with other embodiments.
[0039] The updated weld settings, for each welding parameter, are
communicated from the central controller to the cell controller of
each of the manufacturing cells in the manufacturing environment
via the communication network. In one embodiment, each cell
controller communicates the updated weld settings to the welding
equipment in each respective manufacturing cell, and the welding
equipment uses the updated weld settings (e.g., stored in a memory
of the welding equipment) to make subsequent welds on workpieces of
the same type of workpiece. For example, in a non-robotic
situation, the user is presented with the selectable values and
ranges of the updated weld settings to perform a welding operation
to create a particular weld on the same type of workpiece. The user
makes a selection from the updated weld settings. In a robotic
situation, the cell controller of the manufacturing cell limits the
robotic welding equipment to using only those welding parameters
defined by the updated weld settings for performing a welding
operation to create a particular weld on the same type of
workpiece. In this manner, by using the updated weld settings which
are based on the actual welding parameters previously used to
produce "good" quality welds across the manufacturing environment,
subsequent welds produced on the same type of workpiece should have
a better chance of being of "good" quality, and consistent quality
should be maintained across the manufacturing environment. The
updated weld settings prevent a user and/or a robotic system from
using weld settings that deviate from the values and ranges of the
updated weld settings, which would possibly result in "poor"
quality welds.
[0040] FIG. 7 illustrates example embodiments of sensors for
monitoring actual welding parameters within manufacturing cells of
a manufacturing environment (e.g., as sensor 61 of FIG. 1). The
sensors may be of different types mounted at various places within
a manufacturing cell or within equipment of a manufacturing cell.
For example, in accordance with one embodiment and referring to
FIG. 7, a voltage sensor 710 is configured to sense a welding
voltage (one type of welding parameter) during a welding operation.
Furthermore, a current sensor 720 is configured to sense a welding
current, a motion sensor 730 (e.g., having an accelerometer) is
configured to sense a travel speed of a welding gun (and the arc
produced by the welding gun), a speed sensor 740 (e.g., having a
motor with an RPM output on a wire feeder) is configured to sense a
wire feed speed, a visual sensor 750 (e.g., a camera) is configured
to sense an electrode stick out distance, and a flow sensor 760 is
configured to sense a gas flow (e.g., a rate of flow of a shielding
gas). In general, multiple sensors of various types can be employed
throughout a manufacturing cell to sense actual welding parameters.
Such sensing can be accomplished during a welding operation. The
welding parameters sensed by the sensors may be communicated (e.g.,
wired or wirelessly) to a welding power source and/or a cell
controller of the manufacturing cell. Sensor fusion or data fusion
techniques may be employed (e.g., in a cell controller or in a
central controller), in accordance with some embodiments, to
combine data from two or more sensors to generate weld parameter
data associated with a welding operation on a workpiece.
[0041] FIG. 8 illustrates a flow chart of one embodiment of a
method 800 to support weld quality across a manufacturing
environment. The method 800 includes, at block 810, collecting
actual weld parameter data from each of multiple manufacturing
cells across a manufacturing environment, via a communication
network, to form aggregated weld parameter data for a same type of
workpiece being welded in each of the multiple manufacturing cells.
The actual weld parameter data include value and ranges of actual
welding parameters (sensed and/or user-selected) such as, for
example, welding voltage, welding current, travel speed, wire feed
speed, electrode stick out distance, and gas flow rate used by
welding equipment in each of the multiple manufacturing cells to
weld the same type of workpiece. At block 820, the aggregated weld
parameter data is analyzed to generate updated weld settings for
the same type of workpiece being welded in each of the multiple
manufacturing cells. The updated weld settings include values and
ranges of, for example, welding voltage, welding current, travel
speed, wire feed speed, electrode stick out distance, and gas flow
rate. At block 830, the updated weld settings are communicated to
each of the multiple manufacturing cells across the manufacturing
environment via the communication network. For example, in
accordance with one embodiment, the central controller communicates
the updated weld settings to each of the cell controllers of the
multiple manufacturing cells, and each cell controller communicates
the updated weld settings to the respective welding equipment of
the respective manufacturing cell.
[0042] At block 840, the updated weld settings are stored and
programmed to be used in each of the multiple manufacturing cells
by the welding equipment for subsequent welding of the same type of
workpiece. For example, in a non-robotic situation, the user is
presented with the selectable values and ranges of the updated weld
settings to perform a welding operation to create a particular weld
on the same type of workpiece. In a robotic situation, the cell
controller of the manufacturing cell limits the robotic welding
equipment to using only those weld parameters defined by the
updated weld settings for performing a welding operation to create
a particular weld on the same type of workpiece. In this manner, by
using the updated weld settings which are based on the actual
welding parameters previously used to produce "good" quality welds
across the manufacturing environment, subsequent welds produced on
the same type of workpiece should have a better chance of being of
"good" quality, and consistent quality should be maintained across
the manufacturing environment.
[0043] FIG. 9 illustrates another embodiment of a manufacturing
cell 900 for manufacturing a workpiece within a manufacturing
environment. The manufacturing cell 900 is similar to the
manufacturing cell 10 of FIG. 1. However, the manufacturing cell
900 also includes a weld sequence controller (or welding job
sequencer) 910. In another embodiment, the weld sequence controller
910 is part of the cell controller 76. The weld sequence controller
910 may share one or more characteristics with the controller 1200
of FIG. 12 discussed later herein. The manufacturing cell 900 also
includes non-robotic welding equipment (e.g., for a human welder to
perform semi-automatic welding) which includes a welding gun 920
which can be similar to those that are known in the art. A flexible
tube or conduit 930 attaches to the welding gun 920. Consumable
welding electrode wire 940, which can be stored in a container 950,
is delivered to the welding gun 920 through the conduit 930. A wire
feeder 960 attaches to the frame 12 to facilitate the delivery of
consumable welding wire 940 to the welding gun 920.
[0044] In an alternative embodiment, the welding gun 920 is
replaced with a stick electrode holder (not shown) configured for
use in stick welding (a type of non-robotic welding performed by a
human welder). In accordance with another embodiment, instead of
the manufacturing cell 900 having both the welding gun 60 for
robotic welding and the welding gun 920 for non-robotic welding,
the welding gun 60 can be detached from the robot 14 and connected
to the wire feeder 960 to perform non-robotic welding. The same
welding power source 72 can support both robotic welding and
non-robotic welding, in accordance with one embodiment. In an
alternative embodiment, the welding power source 72 supports
robotic welding and an additional welding power source (not shown)
supports non-robotic welding (e.g., stick welding or semi-automatic
welding performed by a human welder).
[0045] In the manufacturing cell 900, the robotic welding equipment
is configured to make robotic welds as at least a portion of
manufacturing a workpiece. The non-robotic welding equipment is
configured to allow a human operator (welder) to make non-robotic
welds as at least another portion of manufacturing the workpiece.
The weld sequence controller 910 is configured to control the order
and timing associated with making the robotic welds and the
non-robotic welds as a sequence of welds to manufacture the
workpiece. The general concept of weld sequencing is described in
U.S. Pat. No. 9,937,577 which is incorporated herein by reference
in its entirety. However, as further described herein, weld
sequencing can include a sequence of welds that includes both
robotic and non-robotic welds. Furthermore, as described herein,
the sequence of welds may be adaptable based on one or more
conditions of a weld.
[0046] In accordance with one embodiment, the timing and the order
of the sequence of welds is predetermined and fixed before welding
begins. It may be assumed, in one embodiment, that locations of
non-robotic welds to be made on a workpiece cannot be reached by
the robotic welding equipment, therefore, a human welder intervenes
(in accordance with the defined sequence of welds) to make those
welds that the robotic welding equipment cannot reach.
[0047] In accordance with one embodiment, the weld sequence
controller 910 is configured to adapt at least one of position
(position in the sequence) and timing of a subsequent weld to be
made in the sequence of welds, while manufacturing the workpiece,
based on a condition of a previous weld made of the sequence of
welds. For example, in one embodiment, the weld sequence controller
910 is configured to adapt the sequence of welds, while
manufacturing the workpiece, by adding a non-robotic weld (in real
time) as a next weld to be made when an immediate previous weld in
the sequence of welds is a robotic weld that was missed by the
robotic welding equipment. Therefore, the location on the workpiece
of the next weld to be made, non-robotically, is the same as the
location of the immediate previous weld that was missed. In this
way, a human operator (welder) can be instructed by the weld
sequence controller 910 to intervene and complete the missed
weld.
[0048] In accordance with one embodiment, the weld sequence
controller 910 is configured to determine if an immediate previous
weld made, of the sequence of welds, is defective based on at least
one quality parameter of the immediate previous weld made.
Furthermore, the weld sequence controller 910 is configured to
adapt the sequence of welds, while manufacturing the workpiece, by
adding a non-robotic weld (in real time) as a next weld to be made
when the immediate previous weld made in the sequence of welds is a
robotic weld that was determined to be defective. Therefore, the
location on the workpiece of the next weld to be made,
non-robotically, is the same as the location of the immediate
previous weld. In this way, a human operator (welder) can be
instructed by the weld sequence controller 910 to intervene and
correct the defective weld.
[0049] FIG. 10 illustrates a flow chart of one embodiment of a
method 1000 to support welding a sequence of welds within a
manufacturing cell. The method includes, at block 1010, controlling
the timing (e.g., position within the sequence) associated with
making robotic and non-robotic welds as a sequence of welds while
manufacturing a workpiece in a manufacturing cell. For example, a
sequence of welds may include robotic welds to made that are
interleaved in time with non-robotic welds to be made, where the
timing of the non-robotic welds with respect to the robotic welds
is based, at least in part, on the robotic welding equipment not
being able to reach certain locations on the workpiece.
[0050] At block 1020, at least one of position and timing of a
subsequent weld to be made is adapted in the sequence of welds,
while manufacturing the workpiece, based on a condition of an
immediate previous weld of the sequence of welds. As one example of
block 1020, at block 1022, a determination is made as to whether
the immediate previous weld in the sequence of welds was missed (a
condition) by the robotic welding equipment based on at least one
quality parameter of the immediate previous weld. If so, then at
block 1024, a non-robotic weld is added to the sequence of welds as
a next weld to be made at the same location on the workpiece of the
immediate previous weld that was missed by the robotic welding
equipment. Thus, the subsequent weld that was going to be made in
the un-adapted sequence of welds is pushed out in time and position
in the adapted sequence to make room for the added non-robotic
weld.
[0051] As another example of block 1020, at block 1026, a
determination is made as to whether the immediate previous weld in
the sequence of welds is defective (a condition) based on at least
one quality parameter of the immediate previous weld. If so, then
at block 1028, a non-robotic weld is added to the sequence of welds
as a next weld to be made at the same location on the workpiece of
the immediate previous weld defectively made, for example, by the
robotic welding equipment. Again, the subsequent weld that was
going to be made in the un-adapted sequence of welds is pushed out
in time and position in the adapted sequence to make room for the
added non-robotic weld.
[0052] In these ways, a weld sequence can be adapted "on-the-fly"
while manufacturing a workpiece to allow for the efficient
manufacturing of the workpiece within the manufacturing cell. The
ability to determine that a weld was "missed" and/or is "defective"
is discussed next herein with respect to sensors that detect
quality parameters.
[0053] FIG. 11 illustrates example embodiments of sensors (e.g., as
sensor 63 of FIG. 1 and FIG. 9) for monitoring quality parameters
of a sequence of welds that are made when manufacturing a workpiece
within a manufacturing cell. The sensors are configured to observe
welds created on the workpiece and report the quality parameters,
directly or indirectly, to the weld sequence controller of the
manufacturing cell. A quality parameter can be an indication of a
missed weld or an indication of the nature of a defective weld
(e.g., poor weld penetration).
[0054] For example, a sensor for sensing a quality parameter of a
weld may be a visual spectrum sensor (e.g., a camera) 1110, a
radiographic sensor 1120, a laser sensor 1130, an electromagnetic
sensor 1140, an infrared sensor 1150, a temperature sensor 1160, a
spectrometer sensor 1170, or an ultrasonic sensor 1180. Other types
of sensors are possible as well, in accordance with other
embodiments. A quality parameter may be related to, for example,
the presence/absence of a weld at a weld position on the
workpiece/part, a weld bead size, weld penetration, weld fusion,
weld porosity, weld cracking, weld inclusion, a weld discontinuity,
an arc plasma type, or an arc plasma temperature. Other quality
parameters are possible as well, in accordance with other
embodiments. Such sensing can be accomplished on-the-fly in real
time during welding, in accordance with one embodiment. Sensor
fusion or data fusion techniques may be employed, in accordance
with some embodiments, to combine data from two or more sensors to
determine the existence of a missed weld or a defective weld.
[0055] FIG. 12 illustrates an example embodiment of a controller
1200 (e.g., a central controller 220 or 320, a cell controller 76,
or a weld sequence controller 910 used in the systems described
herein). The controller 1200 includes at least one processor 1214
which communicates with a number of peripheral devices via bus
subsystem 1212. These peripheral devices may include a storage
subsystem 1224, including, for example, a memory subsystem 1228 and
a file storage subsystem 1226, user interface input devices 1222,
user interface output devices 1220, and a network interface
subsystem 1216. The input and output devices allow user interaction
with the controller 1200. Network interface subsystem 1216 provides
an interface to outside networks and is coupled to corresponding
interface devices in other computer systems. For example, the cell
controller 76 of the manufacturing cell 10 may share one or more
characteristics with the controller 1200 and may be, for example, a
conventional computer, a digital signal processor, and/or other
computing device.
[0056] User interface input devices 1222 may include a keyboard,
pointing devices such as a mouse, trackball, touchpad, or graphics
tablet, a scanner, a touchscreen incorporated into the display,
audio input devices such as voice recognition systems, microphones,
and/or other types of input devices. In general, use of the term
"input device" is intended to include all possible types of devices
and ways to input information into the controller 1200 or onto a
communication network.
[0057] User interface output devices 1220 may include a display
subsystem, a printer, a fax machine, or non-visual displays such as
audio output devices. The display subsystem may include a cathode
ray tube (CRT), a flat-panel device such as a liquid crystal
display (LCD), a projection device, or some other mechanism for
creating a visible image. The display subsystem may also provide
non-visual display such as via audio output devices. In general,
use of the term "output device" is intended to include all possible
types of devices and ways to output information from the controller
1200 to the user or to another machine or computer system.
[0058] Storage subsystem 1224 stores programming and data
constructs that provide or support some or all of the functionality
described herein (e.g., as software modules). For example, the
storage subsystem 1224 may include analysis software modules that
are used in a central controller to analyze aggregated weld
parameter data and generate updated weld settings for welding
equipment of manufacturing cells across a manufacturing
environment.
[0059] Software modules are generally executed by processor 1214
alone or in combination with other processors. Memory 1228 used in
the storage subsystem can include a number of memories including a
main random access memory (RAM) 1230 for storage of instructions
and data during program execution and a read only memory (ROM) 1232
in which fixed instructions are stored. A file storage subsystem
1226 can provide persistent storage for program and data files, and
may include a hard disk drive, a floppy disk drive along with
associated removable media, a CD-ROM drive, an optical drive, or
removable media cartridges. The modules implementing the
functionality of certain embodiments may be stored by file storage
subsystem 1226 in the storage subsystem 1224, or in other machines
accessible by the processor(s) 1214.
[0060] Bus subsystem 1212 provides a mechanism for letting the
various components and subsystems of the controller 1200
communicate with each other as intended. Although bus subsystem
1212 is shown schematically as a single bus, alternative
embodiments of the bus subsystem may use multiple buses.
[0061] The controller 1200 can be of varying types including a
workstation, server, computing cluster, blade server, server farm,
or any other data processing system or computing device. Due to the
ever-changing nature of computing devices and networks, the
description of the controller 1200 depicted in FIG. 12 is intended
only as a specific example for purposes of illustrating some
embodiments. Many other configurations of the controller 1200 are
possible having more or fewer components than the controller
depicted in FIG. 12.
[0062] While the disclosed embodiments have been illustrated and
described in considerable detail, it is not the intention to
restrict or in any way limit the scope of the appended claims to
such detail. It is, of course, not possible to describe every
conceivable combination of components or methodologies for purposes
of describing the various aspects of the subject matter. Therefore,
the disclosure is not limited to the specific details or
illustrative examples shown and described. Thus, this disclosure is
intended to embrace alterations, modifications, and variations that
fall within the scope of the appended claims, which satisfy the
statutory subject matter requirements of 35 U.S.C. .sctn. 101. The
above description of specific embodiments has been given by way of
example. From the disclosure given, those skilled in the art will
not only understand the general inventive concepts and attendant
advantages, but will also find apparent various changes and
modifications to the structures and methods disclosed. It is
sought, therefore, to cover all such changes and modifications as
fall within the spirit and scope of the general inventive concepts,
as defined by the appended claims, and equivalents thereof.
* * * * *