Industrial Welding Robot Research Articles

The Dynamics Stability Judging Method for a Gantry-type Welding Robot

In order to improve the dynamic performance of gantry-type welding robot, this paper introduces the structural dynamics model and Lyapunov stability criterion of the gantry-type welding robot frame with nine degrees of freedom. The dynamic equations of the welding robot satisfy the Euler–Lagrange form, and the calculation index of welding robot Lyapunov stability is judged by matrix eigenvalues. Combining with the specific design parameters of an industrial welding robot, the motion stability of the gantry-type welding robot frame and the displacement response of the welding torch are analyzed. The influence of the change of the frame design structure on the stability of the welding torch for end effector of welding robot is discussed, furthermore, the improvement direction of vibration damping and anti-interference of welding robot system is pointed out. Finally, the dynamics simulation of the optimized gantry-type welding robot end effector is carried out by using ADAMS software, and the torque variation curve of the end effector is obtained, which provides a strong basis for the selection of motor models and the design of control system.

Kinematic and Parametric Modeling of 6DOF(Degree-of-Freedom) Industrial Welding Robot Design and Implementation

Kinematic and Parametric Modeling of 6DOF(Degree-of-Freedom) Industrial Welding Robot Design and Implementation

Development of a vision system integrated with industrial robots for online weld seam tracking

This paper develops a laser-structured light vision system for the industrial welding manipulator. The designed structured light vision system consisting of a line laser projector and an industrial camera is a decent 3D object data acquisition platform. By applying the principle of triangulation, the depth value of the object can be obtained via the laser plane in the captured image. According to hand-eye calibration and the principle of triangulation, the 3D position of the objects in the robot coordinate system is calculated. Based on the discriminated convolution tracker and deep reinforcement learning that increases the accuracy and processing time of the tracker, allowing simultaneous scanning for seam data acquisition and welding along the weld path, a real-time seam tracking algorithm is developed to handle the square-groove butt joint with small gaps (i.e., <1 mm). Experiments are undertaken using a Yaskawa industrial welding robot integrating the designed laser-structured light vision system. Experiment results show the significant performance of the developed system in welding square-groove butt joints with curved profiles and small gaps, i.e., the welding absolute mean error is 0.31 mm, whereas in the case of using convolution tracker only, the welding absolute mean error 1.7 mm.

Path planning method of industrial intelligent welding robot based on cuckoo search algorithm

Path planning method of industrial intelligent welding robot based on cuckoo search algorithm

Path planning method of industrial intelligent welding robot based on cuckoo search algorithm

Path planning method of industrial intelligent welding robot based on cuckoo search algorithm

Path Optimization in Robotic Welding of Plate Heat Exchangers: An Improved Ant Colony Approach

In industrial robot welding heat exchanger plate route planning, there are drawbacks to using the traditional ant colony algorithm (ACA), including poor search efficiency and a propensity to trend toward the local optimum. To address the above issues, first of all, the article introduces the improved pheromone volatilization factor, which is adjustable based on iteration times in the ACA. Secondly, it combines the new perturbation strategy and the cross‐mutation operation, proposes an improved genetic algorithm, and fuses it into the ACA, which increases the diversity of the ACA’s path searching and improves the ability of the local and global search. Finally, the improved ACA mechanism is verified by experiments and compared with six existing path planning algorithms (including three ACA variant algorithms and three mainstream algorithms). The experimental results show that the IACAG algorithm has excellent performance in welding heat exchanger path planning and can achieve lower calculation time and iteration times under the conditions of optimal solution and zero deviation, showing comprehensive advantages in solution quality, stability, and efficiency.

Research and expectation on industrial welding robots

In the industrial producing field, the robots are gradually replacing the traditional manual works and their development is attracting more and more concern due to their great performance. The welding robot is a kind of typical industrial robot, which has been used in various fields to gradually replace the manual fields because of the advantages like high accuracy, persistent work, and fitness for complex environments. As China is transforming into the industrial powerful country, the demand for industrial welding robots is increasing. It is important to analyse the current development of welding robots. Through the analysis of the current situation of Chinas industrial welding robot industry, this article will introduce the concept of industrial welding robots, analyze the market shares of existing welding robots, summarize the key technologies and conclude the advantages and disadvantages of welding robots, to forecast the future market development of welding robots. This article may provide a reference for the development in future.

A compensation method of end pose error of industrial welding robot based on internet of things

A compensation method of end pose error of industrial welding robot based on internet of things

A Compensation method of end pose error of industrial welding robot based on Internet of things

A Compensation method of end pose error of industrial welding robot based on Internet of things

感度解析に基づくロボット関節誤差拡大軌道の設計と動画による関節原点誤差計測

For industrial welding robots using the teaching-playback method, repeatability is more important than absolute accuracy. However, when a robot is replaced due to failure or other reasons, the tip position is shifted because the error factors related to tip positioning are different between the robot before and after the replacement. This can impede recovery. To overcome this problem at production sites where industrial robots are used, easy measurement without the use of expensive sensors is required. On the other hand, when the robot is replaced with another robot of the same model, the mechanical errors such as joint stiffness, arm stiffness and link length error are almost the same and their difference can be assumed to be extremely small, but the joint origin error remains as an individual difference and its effect on the tip misalignment is not small. Therefore, it is the joint origin error that has a large influence on tip misalignment as an individual difference. In recent years, inexpensive devices with high image resolution, such as consumer-use cameras and smartphones have become available at low cost and their use is effective to reduce tip misalignment caused by individual differences in robots at manufacturing sites. In this paper, we focus on the sensitivity of the tip position error with respect to the joint origin error and propose a method to estimate the joint origin error by designing a trajectory in which the tip error is magnified so that the joint origin error can be easily measured using movies of the tip position taken by a digital camera. We verify the effectiveness of this method using an experimental robot.

Experimental study of quality respones during Gas metal arc welding in industrial welding robots by using Response surface method

Input parameters of GMAW can vary continuously at any point of time when used in an industrial welding robot and thus have a huge influence at output quality responses of the weld joint. In advent of welding automation, Industrial robots are used by most manufacturers to boost production rate & reduce operational cost. This publication tries to establish an optimum process parameter band for quality weld joint during continuous robot welding. To establish a relationship between both parameters RSM method has been used in an empirical approach. Input parameters of GMAW which are considered for this study are current, wirefeed rate and industrial robot arm speed, and the corresponding output response in form of weld bead geometry which defines the quality of the process. These all-input parameters have different effect on welding quality independent to each other. Stainless steel material (SUS409) has been used as experiment material.

DEVELOPMENT OF A DIGITAL TWIN OF MOTOMAN MH-50 INDUCTRIAL ROBOT-MANIPULATOR FOR WELDING OPERATIONS OF COMPLEX STRUCTURES

At the present time automatic welding machines are used for welding operations in the production of electric-welded pipes. However, industrial robots are used when welding complex structures consist of pipes of different diameters and bending radius. Unlike welding machines, robots move according to a set coordinate, thus making it possible to obtain welding constructions that “classical” welding machines are not able to perform or require considerable time for their readjustment. Moreover, welding robots-manipulators can perform additional operations: pre-cleaning of the joint, weld preparation and cleaning from dirt. Methods of setting (setting coordinates) of welding robots-manipulators are considered. It was noted that when making settings on the robot's panel it is necessary to stop the technological process, therefore a more rational way is the preliminary imitation of the welding process by using a digital twin of an industrial robot. Using of digital twins of robots-manipulators is often connected with serious financial expenses, therefore development on the basis of the simplified mathematical model of the digital twin is actual, that allows fulfilling the technological process of welding of new kinds of difficult designs by virtual way. Here is a description of a digital twin of an industrial robot-manipulator Yaskawa Motoman MH50-35, developed in Matlab Simulink environment. The main task of developing the digital twin was to create a system of automatic control of the rotation angle on the basis of the position regulator. The elaborated digital twin was tested; the accuracy of processing the wrist rotation assignment is +-0.0001 rad, there is no position overshoot, and the time of a full wrist revolution reaches 1.07 s. The possibility has been shown to use the developed twin as a digital twin of an industrial welding robot taking into account the accepted assumptions.

INVESTIGATE THE INFLUENCE OF THE WELDING SEAMS PROFILE ON DRIVING ENERGY FOR INDUSTRIAL ROBOTS

This paper focuses on investigating the influence of the welding seams in the working space on the driving energy for the six degrees of freedom FD-V8 industrial welding robot. The system of kinematics equations is built on the basis of multi-bodies mechanics theory and industrial robotics theory. The AGV algorithm is applied to solve the inverse kinematics problem (IKP) for each specific welding seam. The Lagrange-Euler method is used to build the differential equations of the robot motion. The robot driving energy is determined on the basis of solving the inverse dynamics problem (IDP). The results of this study have important implications in designing an appropriate welding seams trajectory to reduce energy consumption, as a basis for step by step building the optimizing energy consumption and production costs problem meeting the challenge of the current energy shortage in modern industrial production.

Pipe Welding Machine Modernization

There are the results of pipelines rolled joints welding machine modernization. The machine is designed using a welding rotator, linear electric drives, stepper motors, CNC system. The machine is controlled by a CNC system according to ISO 6983-1: 2009. The machine consists of: stepping rotary device, welding torch stepping device, controlled TIG welding power source, controlled welding wire feeder, welding current control system, workpiece rotation control system and welding torch. The welding torch movement trajectory controlling software has been created. It allows to weld by any type of welding torch recommended movements. The modernizing machine allows welding the pipelines rolled joints in automatic mode both in one pass and in multi-pass. The machine can be used for industrial pipeline elements welding, for welding modes testing, for studying the effect of welding modes on the quality of pipeline welds. The results can be adapted for sheet structures welding using the standard commands of the ISO 6983-1: 2009 standard. The results can be adapted to industrial welding robots control. The welding machine can be used for MIG / MAG welding and surfacing.

Selection of industrial arc welding robot with TOPSIS and Entropy MCDM techniques

Industrial robots have enabled manufacturing firms to produce high-quality products cost-effectively and thus are essential components of advanced manufacturing technologies. Industrial robots are designed for various applications such as welding, painting, assembly, disassembly, pick and place for printed circuit boards, packaging and labelling, palletizing, product inspection, and testing. All the features are accomplished with high endurance, speed and precision. The performance of industrial robots is determined by multiple and conflicting criteria that have to be simultaneously considered in a robust selection procedure. In this study, a simple multi-criteria decision-making (MCDM) methodology based on the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method is presented to choose an industrial robot for the arc welding operation. The weights of significance are attained with objective preferences using the Entropy weight method. The order of ranking obtained with the TOPSIS-Entropy technique is presented. The results showed that the MCDM approaches for robot selection are quite useful. The novelty of the study lies to prioritize industrial arc welding robots with TOPSIS-Entropy MCDM methods.

Key Technology Analysis and Application Analysis of Industrial Robot Welding

Key Technology Analysis and Application Analysis of Industrial Robot Welding

Research on Continuous Trajectory Planning of Industrial Welding Robot Based on CAD Technology

Research on Continuous Trajectory Planning of Industrial Welding Robot Based on CAD Technology

Vision Based Self Adaptive Algorithm for 6 Axis ABB Industrial Welding Robot

The ultimate aim of this work “Vision Based Self Adaptive Algorithm for 6 Axis ABB Industrial Welding Robot” is to develop a self-adaptive RAPID algorithm based on the captured image of the work piece. The image of the work piece is captured using NI Guppy pro F031C camera which has 300 DPI with 120 FPS resolution. The captured image is transferred to the LabVIEW software for developing the self-adaptive algorithm through RS232 serial communication protocol. The LabVIEW vision assistant module is used to develop an algorithm based on the geometry of the captured image. The various image processing operations like Thresholding, Morphological operation (Thinning), and edge detection are carried out. The caliper tool is used to measure the distance between the coordinate points (welding distance). With the aid of Visual Basic, the measured values are converted into coordinates. The coordinates are used to develop a RAPID program with the aid of ABB Robot Studio library functions. The virtual server is established between the ABB Robot Studio and IRC5 Controller with the use of MOD-BUS protocol with VISA. After receiving the data from the MOD-BUS, the IRC5 controller moves the ABB Industrial Robot End effectors along with the welding gun for the welding purpose. The work piece is located on the designed jigs and fixtures. The different types of welding with different design can be incorporated with the Vision Assistant module for further development. To illustrate the developed algorithm, robot assisted MIG welding process is carried out. The welded work-pieces are tested for its strength quality and the results are verified. Optimal welding parameters for the good quality of weldment identified by using Taguchi method of optimization.

Methodology for Human Robot Interface in Arc Welding Operation - An Industry Case study

Welding is a significant industrial application that has been implemented since the early 18th century. The introduction of welding robots in the 19th century resulted in drastic improvements in the field of welding like improving the accuracy of welding, quality of the weld, etc., However, there is no literature which briefs the industry methodology to interface HMI with the industrial robots. In this paper, MOTOMAN AR1440 Industrial Welding Robot is interfaced with the Human Machine Interface (HMI) panel to improve the communication between the machine and the operator. This improves the safety and handling of the robot. The robot trajectory is taught using a teach pendant and the HMI panel is designed to control the robot. The robot and the HMI panel are interfaced via Ethernet communication. Thus, the main objective of this paper is to brief an industry methodology to interface an AR1440 robot with an HMI panel for arc welding application thereby, improving the communication between the machine and the worker.

ALGORITHM FOR IMPROVING FEEDING RATES OF INDUSTRIAL WELDING ROBOT TA 1400 IN COMBINATION WITH A TURNTABLE FRAME

An algorithm for improving feeding rates of industrial welding robot TA 1400 of Panasonic with 6 degrees of freedom is presented. The kinematics and dynamics of the robot are calculated on MATLAB software. The proposed algorithm for improving feeding rates is mathematically analyzed and the performance of the system is evaluated in a simulation environment. The simulation results are used for proving the efficiency of the solution. Based on the achieved results, the algorithm can be applied for reducing time and improving the productivity of other industrial robots in the future