Office Action 1: Notice of Allowance (2025-02-25)

CLAIMS:
CLAIMS

What is claimed is:

1\. A method of programming multiple weld passes in a collaborative robot welding system to perform multi-pass welding, the method comprising:programming a root pass for a first weld seam into a collaborative robot welding system by manually positioning a tip of a welding torch, held by an arm of the collaborative robot welding system, at root pass points along the first weld seam, and automatically recording root pass position and angle data of the welding torch at the root pass points within the collaborative robot welding system;
programming a set of multiple secondary passes for the first weld seam into the collaborative robot welding system by:
manually positioning the tip of the welding torch at a start point and a stop point for each secondary pass of the set of multiple secondary passes, and automatically recording start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes within the collaborative robot welding system, and
automatically calculating numerical position and angle offset data corresponding to the set of multiple secondary passes based on the recorded root pass position and angle data of the root pass of the first weld seam, and based on the recorded start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes for the first weld seam;
storing the root pass position and angle data, as recorded, and the numerical position and angle offset data, as calculated, as a multi-pass template within the collaborative robot welding system; and
translating and applying the multi-pass template to a weld reference frame of a second weld seam to aid in programming a second set of multiple passes for the second weld seam, where the second weld seam is of a same type as the first weld seam.

2\. The method of claim 1, where the weld reference frame of the second weld seam is determined by manually positioning and recording positions of the tip of the welding torch
at a start point of the second weld seam, at a stop point of the second weld seam, and at a point on a base plate of a corresponding weldment of the second weld seam.

3\. The method of claim 1, where the weld reference frame of the second weld seam is determined by manually positioning and recording positions of the tip of the welding torch at a start point of the second weld seam, at a stop point of the second weld seam, and by teaching the collaborative robot system a location of a plane of a base plate of a corresponding weldment of the second weld seam.

4\. The method of claim 1, wherein the root pass position and angle data and the numerical position and angle offset data include data for torch push angles.

5\. The method of claim 1, wherein the root pass position and angle data and the numerical position and angle offset data include data for torch work angles.

6\. The method of claim 1, wherein the numerical position and angle offset data are numbers used in a motion program of the collaborative robot welding system, with respect to a path coordinate system, to drive where the multiple secondary passes are in space in relation to the root pass.

7\. The method of claim 1, wherein the automatic recording of the start and the stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes is initiated by a user pressing a button on the welding torch.

8\. The method of claim 1, further comprising using a weld angle correction tool to adjust the angle data of the root pass position and angle data.

9\. The method of claim 1, further comprising automatically linking the multiple secondary passes to a weld name within the collaborative robot system.

10\. The method of claim 1, further comprising providing displayed guided instructions to a user via a weld tools user interface component of the collaborative robot system, where the weld tools user interface component includes a software component and a display device of one of a teach pendant or a laptop computer.

11\. The method of claim 10, wherein the displayed guided instructions to the user are related to at least one of adding a weld pass to the multiple secondary passes, specifying the root pass to which the added weld pass is related, selecting the start point and the stop point for each secondary pass of the set of multiple secondary passes, and manually positioning the tip of the welding torch.

12\. A collaborative robot welding system to perform multi-pass welding, the system comprising:a robot controller;
a robot arm;
a welding torch attached to the robot arm; and
a weld tools user interface component having a display, and operatively interfacing to the robot controller,
wherein the robot controller, the robot arm, the welding torch, and the weld tools user interface component are configured to:
facilitate programming of a root pass for a first weld seam by allowing a user to manually position a tip of the welding torch, held by the robot arm, at root pass points along the first weld seam, and automatically record root pass position and angle data of the welding torch at the root pass points;
facilitate programming of a set of multiple secondary passes for the first weld seam by:
allowing the user to manually position the tip of the welding torch at a start point and a stop point for each secondary pass of the set of multiple secondary passes, and automatically recording start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes, and

automatically calculate numerical position and angle offset data corresponding to the set of multiple secondary passes based on the recorded root pass position and angle data of the root pass of the first weld seam, and based on the recorded start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes for the first weld seam;
facilitate storing of the root pass position and angle data, as recorded, and the numerical position and angle offset data, as calculated, as a multi-pass template; and
facilitate translating and applying of the multi-pass template to a weld reference frame of a second weld seam to aid in programming a second set of multiple passes for the second weld seam, where the second weld seam is of a same type as the first weld seam.

13\. The system of claim 12, wherein the robot controller, the robot arm, the welding torch, andthe weld tools user interface component are configured to facilitate determination of the weld reference frame of the second weld seam by allowing manual positioning of, and recording of, positions of the tip of the welding torch at a start point of the second weld seam, at a stop point of the second weld seam, and at a point on a base plate of a corresponding weldment of the second weld seam.

14\. The system of claim 12, wherein the robot controller, the robot arm, the welding torch, andthe weld tools user interface component are configured to facilitate determination of the weld reference frame of the second weld seam by allowing manual positioning of, and recording of, positions of the tip of the welding torch at a start point of the second weld seam, at a stop point of the second weld seam, and by teaching the system a location of a plane of a base plate of a corresponding weldment of the second weld seam.

15\. The system of claim 12, wherein the root pass position and angle data and the numerical position and angle offset data include data for at least one torch push angle.

16\. The system of claim 12, wherein the root pass position and angle data and the numerical position and angle offset data include data for at least one torch work angle.

17\. The system of claim 12, wherein the numerical position and angle offset data are numbers used in a motion program of the robot controller, with respect to a path coordinate system,to drive where the multiple secondary passes are in space in relation to the root pass.

18\. The system of claim 12, wherein the automatic recording of the start and the stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes is initiated by the user pressing a button on the welding torch.

19\. The system of claim 12, further comprising a weld angle correction tool used by the user to adjust the angle data of the root pass position and angle data.

20\. The system of claim 12, wherein the weld tools user interface component is configured to facilitate linking of the multiple secondary passes to a weld name.

21\. The system of claim 12, wherein the weld tools user interface component is configured to provide displayed guided instructions to a user via the display of the weld tools user interface component, where the weld tools user interface component includes a software component.

22\. The system of claim 21, wherein the weld tools user interface component includes one of a teach pendant or a laptop computer.

23\. The system of claim 21, wherein the displayed guided instructions to the user are related to at least one of adding a weld pass to the multiple secondary passes, specifying the root pass to which the added weld pass is related, selecting the start point and the stop point for
each secondary pass of the set of multiple secondary passes, and manually positioning the tip of the welding torch.

OFFICE ACTION:
DETAILED ACTION
Foreign Priority
Receipt is acknowledged of certified copies of papers required by 37 CFR 1.55.
Information Disclosure Statement
The information disclosure statement (IDS) submitted is in compliance with the provisions of 37 CFR 1.97.  Accordingly, the information disclosure statement is being considered by the examiner.
Allowable Subject Matter
Claims 1 – 23 are allowed.
The following is an examiner’s statement of reasons for allowance: Upon further consideration and research, the prior art references does not disclose the claim invention set forth regarding the claim limitation with respect “
A method of programming multiple weld passes in a collaborative robot welding system to perform multi-pass welding, the method comprising: programming a root pass for a first weld seam into a collaborative robot welding system by manually positioning a tip of a welding torch, held by an arm of the collaborative robot welding system, at root pass points along the first weld seam, and automatically recording root pass position and angle data of the welding torch at the root pass points within the collaborative robot welding system; programming a set of multiple secondary passes for the first weld seam into the collaborative robot welding system by: manually positioning the tip of the welding torch at a start point and a stop point for each secondary pass of the set of multiple secondary passes, and automatically recording start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes within the collaborative robot welding system, and automatically calculating numerical position and angle offset data corresponding to the set of multiple secondary passes based on the recorded root pass position and angle data of the root pass of the first weld seam, and based on the recorded start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes for the first weld seam; storing the root pass position and angle data, as recorded, and the numerical position and angle offset data, as calculated, as a multi-pass template within the collaborative robot welding system; and translating and applying the multi-pass template to a weld reference frame of a second weld seam to aid in programming a second set of multiple passes for the second weld seam, where the second weld seam is of a same type as the first weld seam; a collaborative robot welding system to perform multi-pass welding, the system comprising: a robot controller; a robot arm; a welding torch attached to the robot arm; and a weld tools user interface component having a display, and operatively interfacing to the robot controller, wherein the robot controller, the robot arm, the welding torch, and the weld tools user interface component are configured to: facilitate programming of a root pass for a first weld seam by allowing a user to manually position a tip of the welding torch, held by the robot arm, at root pass points along the first weld seam, and automatically record root pass position and angle data of the welding torch at the root pass points; facilitate programming of a set of multiple secondary passes for the first weld seam by: allowing the user to manually position the tip of the welding torch at a start point and a stop point for each secondary pass of the set of multiple secondary passes, and automatically recording start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes and automatically calculate numerical position and angle offset data corresponding to the set of multiple secondary passes based on the recorded root pass position and angle data of the root pass of the first weld seam, and based on the recorded start and stop position data of the start point and the stop point for each secondary pass of the set of multiple secondary passes for the first weld seam; facilitate storing of the root pass position and angle data, as recorded, and the numerical position and angle offset data, as calculated, as a multi-pass template; and facilitate translating and applying of the multi-pass template to a weld reference frame of a second weld seam to aid in programming a second set of multiple passes for the second weld seam, where the second weld seam is of a same type as the first weld seam.”
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion



CITED REFERENCE SUMMARIES: Ref US10845343B2: Claims:
A process for producing a signal indicating a potential weld flaw indication, comprising the steps of: a. ultrasonically scanning a weld for indications of potential flaws in said weld using a scanning probe head; b. receiving weld scan data from said scanning probe head in a computer device; c. in said computer device, processing in real time said received scan data to remove non-meritorious defect indications; d. after said processing step, determining if any remaining defect indications satisfy a predetermined criterion; e. keeping a running tally of defect indications satisfying said predetermined criterion; and, f. responsive to said criterion determination step, issuing a signal indicative of the existence of any said remaining meritorious indications.
a. ultrasonically scanning a weld for indications of potential flaws in said weld using a scanning probe head;
b. receiving weld scan data from said scanning probe head in a computer device;
c. in said computer device, processing in real time said received scan data to remove non-meritorious defect indications;
d. after said processing step, determining if any remaining defect indications satisfy a predetermined criterion;
e. keeping a running tally of defect indications satisfying said predetermined criterion; and,
f. responsive to said criterion determination step, issuing a signal indicative of the existence of any said remaining meritorious indications.
The process as recited in claim 1 , wherein said step of processing said received scan data in real time comprises the steps of: a. establishing a first scanning data window of scanning slices of said weld; b. processing said first scanning data window for weld defect indications; c. establishing an indications set representing the number of indications found in said scanning data window; d. processing successive scanning data windows received from said scanning probe upon receipt by said computer device and updating said indications set; and, e. repeating said successive processing step until all scanning slices from said scanning probe head have been processed for indications.
a. establishing a first scanning data window of scanning slices of said weld;
b. processing said first scanning data window for weld defect indications;
c. establishing an indications set representing the number of indications found in said scanning data window;
d. processing successive scanning data windows received from said scanning probe upon receipt by said computer device and updating said indications set; and,
e. repeating said successive processing step until all scanning slices from said scanning probe head have been processed for indications.
The process as recited in claim 2 , wherein said step of keeping a tally comprises utilizing an up/down counter to keep track of said indications set, wherein said up/down counter counts responsively to a set of voxel reception rules operable on the number of voxels present in each said received scanning slice.
The process as recited in claim 3 , wherein said step of processing said received scan data in real time further comprises the step of establishing a minimum number of scanning slices for any scanning data window and receiving said minimum number of scanning slices prior to processing said first received scanning data window for indications.
The process as recited in claim 4 , wherein said step of determining if any remaining defect indications satisfy a predetermined criterion comprises meeting a minimum voxel indications magnitude value.
The process as recited in claim 3 , wherein said voxel reception rules includes the rule of if a newly received voxel is non-contiguous to any prior determined weld indication in the current set of weld indications then add a new indication to the current set of indications.
The process as recited in claim 6 , wherein said voxel reception rules includes the rule of removing old voxels not within the sliding window range of any newly received scanning data window.
The process as recited in claim 2 , wherein any step of processing a scanning data window in real time comprises the step of issuing a signal occurring with sufficient time for an output device connected to said scanning probe head to alert an operator as said scanning probe head is moved along said weld to scan for defects.
The process as recited in claim 2 , wherein any step of processing a scanning data window comprises the steps of: a. extracting all voxels held by said scan data window having a non-zero magnitude value and saving those voxels in an indications data file along with three-dimensional position information within said weld for each said voxel; and, b. assigning a unique group identifier for all voxels in said indications data file that are positioned immediately adjacent to one another in said weld such that each group identifier represents a separate weld indication.
a. extracting all voxels held by said scan data window having a non-zero magnitude value and saving those voxels in an indications data file along with three-dimensional position information within said weld for each said voxel; and,
b. assigning a unique group identifier for all voxels in said indications data file that are positioned immediately adjacent to one another in said weld such that each group identifier represents a separate weld indication.
A process for producing a signal while scanning a weld for defects, comprising the steps of: a. ultrasonically scanning a weld for indications of potential flaws in said weld using a scanning probe; b. receiving weld scan data from said scanning probe in a computer device; c. said computer device processing in real time said received weld scan data to find all meritorious defect indications in said scan data using a plurality of data window portions of said scan data to process said scan data; d. determining if any of said found indications meet a minimum criterion; and, e. sending a signal corresponding to all said found indications meeting said criteria for reception by a system connected to said computer device.
a. ultrasonically scanning a weld for indications of potential flaws in said weld using a scanning probe;
b. receiving weld scan data from said scanning probe in a computer device;
c. said computer device processing in real time said received weld scan data to find all meritorious defect indications in said scan data using a plurality of data window portions of said scan data to process said scan data;
d. determining if any of said found indications meet a minimum criterion; and,
e. sending a signal corresponding to all said found indications meeting said criteria for reception by a system connected to said computer device.
The process as recited in claim 10 , wherein said step of processing said received weld scan data further comprises utilizing an up/down counter to keep track of said indications set, wherein said up/down counter counts responsively to a set of voxel reception rules operable on the number of voxels present in each received scanning slice of weld scan data.
The process as recited in claim 11 , wherein said step of processing said received weld scan data in real time further comprises the step of establishing a minimum number of scanning slices for each said plurality of data window portions and receiving said minimum number of scanning slices prior to processing said first received data window portion for indications.
The process as recited in claim 12 , wherein said step of sending a signal comprises the step of sending a signal to an electrically connected system selected from a group consisting of a marking module having coordinated movement with said scanning probe, a display screen, an acoustic device, and a printer.
The process as recited in claim 11 , wherein said voxel reception rules includes the rule of if a newly received voxel is non-contiguous to any prior determined weld indication in the current set of weld indications then add a new indication to the current set of indications.
The process as recited in claim 11 , wherein said voxel reception rules includes the rule of removing old voxels not within the sliding window data range of any newly received scanning slices of data.
A process for producing a signal while ultrasonically scanning a weld for defects, comprising the steps of: a. receiving weld scanning data from a scanning probe in a computing device, said weld scanning data including a plurality of scanning slices representative of said weld; b. processing said received weld scanning data in real time to find all meritorious defect indications in each said scanning slice using a scanning data window; c. determining if any defect indications found in said scanning data window satisfy a minimum criterion; and, d. if said minimum criterion is satisfied, sending a signal for reception by a system having coordinated operation with said scanning probe.
a. receiving weld scanning data from a scanning probe in a computing device, said weld scanning data including a plurality of scanning slices representative of said weld;
b. processing said received weld scanning data in real time to find all meritorious defect indications in each said scanning slice using a scanning data window;
c. determining if any defect indications found in said scanning data window satisfy a minimum criterion; and,
d. if said minimum criterion is satisfied, sending a signal for reception by a system having coordinated operation with said scanning probe.
The process as recited in claim 16 , wherein said step of processing said received weld scanning data in real time using a scanning data window comprises the steps of: a. extracting all voxels held by said scanning slice having a non-zero magnitude value and saving those voxels in an indications data file along with three-dimensional position information within said weld for each said voxel; and, b. assigning a unique group identifier for all voxels in said indications data file that are positioned immediately adjacent to one another in said weld for each meritorious indication such that each group identifier represents a separate weld indication.
a. extracting all voxels held by said scanning slice having a non-zero magnitude value and saving those voxels in an indications data file along with three-dimensional position information within said weld for each said voxel; and,
b. assigning a unique group identifier for all voxels in said indications data file that are positioned immediately adjacent to one another in said weld for each meritorious indication such that each group identifier represents a separate weld indication.
The process as recited in claim 17 , wherein said step of processing said weld scanning data in real time comprises the step of issuing a marking signal with sufficient time for a marking device connected to said scanning probe to mark said weld as said scanning probe is moved along said weld to scan for defects.
The process as recited in claim 16 , wherein said step of processing said received weld scanning data in real time further comprises the step of establishing a minimum number of scan slices for any scanning data window and receiving said minimum number of scan slices prior to processing said first received scanning data window for indications.
The process as recited in claim 16 , wherein said system having coordinated operation comprises a printer, and further including the step of after receiving all weld scanning data from said scanning probe representative of said weld, printing a report from said printer after the processing all scan data slices listing all meritorious indications.