Design and study of an autonomous linear welding robot with mechanical referencing system

Abstract

The biggest challenge for welders is the byproduct of welding, like smoke, heat, and ultraviolet light. It is the process of melting two or more metal pieces to the point of fusion, allowing them to cool, and then connecting the pieces. Arc welding, Metal Inert Gas (MIG) Welding, Tungsten Inert Gas (GTAW or TIG) Welding, gas welding, resistance welding, laser welding, and other methods can all be used to complete the procedure. The welder has many health hazard issues, so the modal is designed to convert the manual welding operation to a fully automatic welding operation. A four-wheeled linear welding robot with a mechanical arm can perform the task. The detection method of the robot is to reference and analyze the structure of the welding job mechanically. There are many options for welding to make it effective. Like the welder can change the thickness of the welding, the thickness of the welding will be uniform. There is one more option for stitch welding for the initial welding operation. This process will enhance the product quality and quantity and minimize health issues as the person is not in direct contact with smoke, heat, or ultraviolet light. The primary purpose of the research is to automate the linear welding process economically so that it can get into the market and workers can be protected from industrial pollution. In addition, the parameters of welding are optimized so that the wastage of material can be reduced. Further, an experimental study is presented, which demonstrates that the robot successfully performs the welding operation continuously without human intervention.