Journal articles: 'Robotic welding simulation'

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Semjon, Ján, Mikuláš Hajduk, Rudolf Jánoš, and Marek Vagaš. "Modular Welding Fixtures for Robotic Cells." Applied Mechanics and Materials 309 (February 2013): 80–87. http://dx.doi.org/10.4028/www.scientific.net/amm.309.80.

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This paper describes the proposal of welding fixtures which achieves pre-arrangement of individual parts of fixture based on suitable modules. Also is focused on methodological process of their design using modularity principle and reconfigurability. Describe procedure of designing fixture with emphasis to specific requirements for welding fixtures in robotic welding. Take advantages of simple substitution of individual modules welding fixtures by database compatible with modules in 3D environment. Optimization and control of collision status is realized in simulation environment ABB Robot Studio.

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Pieskä, Sakari, Mikko Sallinen, Vesa-Matti Honkanen, and Jari Kaarela. "Robotic Simulation and Web-Technology Enabling Collaboration in Digital Manufacturing." Solid State Phenomena 113 (June 2006): 329–33. http://dx.doi.org/10.4028/www.scientific.net/ssp.113.329.

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In this paper, robotic simulation and web-technology are considered as collaborative tools, which enable enterprises to take steps towards digital manufacturing and product lifecycle management. Some results from developing the work of robot simulation and web-technology in research laboratories and industrial environments are presented. The application areas include robotic welding cells, robotic bending cells and robotic material handling cells. Experiences from the development work with different robot work cells confirm that digital manufacturing technology will become a practice in manufacturing networks in the future.

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Fernandes-Lara, Rodrigo, Andrés M. Moreno-Uribe, and Alexandre Q. Bracarense. "Development of a hatch system for the determination of diffusible hydrogen in underwater welding." Respuestas 25, no. 1 (January 1, 2020): 168–77. http://dx.doi.org/10.22463/0122820x.2433.

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The design and implementation of hatch mechanism aims to optimize the development of welding simulations performed in the Robotic, Welding and Simulation Laboratory. The project is part of the upgrade technologies applied to sciences of the sea, and make it possible to evaluate the influence of welding parameters on SMAW and FCAW processes, especially as regards the content of diffusible hydrogen specimen welding in different depths. Due to the specifications imposed by the gas chromatography standards applied to welding, tests must be carried out at short intervals, which requires a fast process. This research will promote the evaluation of commercial electrodes and promote the development of new consumables.

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Redza, Mohd Ridhwan Mohammed, Yupiter H. P. Manurung, Robert Ngendang A. Lidam, Mohd Shahar Sulaiman, Mohammad Ridzwan Abdul Rahim, Noor Syahadah Yussoff, and Abdul Ghalib Tham. "Transversed Residual Stress Analysis on Multipassed Fillet Weld 2D-Using FEM and Experiment." Advanced Materials Research 576 (October 2012): 181–84. http://dx.doi.org/10.4028/www.scientific.net/amr.576.181.

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In this project, the residual stress due to multipassed welding process at the fillet weld will be studied using 2D Finite Element Analysis (FEA) simulation method and experimental investigation. Due to the extensive capabilities and dedicated tools for the simulation of welding, including material deposit via element activation or deactivation and predefined or customized moving heat sources, SYSWELD 2010 was chosen as the FEA software. The material with a thickness of 9 mm was structural steel S355J2G3 for simulation and low carbon steel for the experiment. The clamping condition was selected to obtain the best relationship between simulation and experiment by using Strain Gage. The model was dedicated to multipassed welding using the robotic welding system

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Ghariblu, H., and M. Shahabi. "Path Planning of Complex Pipe Joints Welding with Redundant Robotic Systems." Robotica 37, no. 6 (February 11, 2019): 1020–32. http://dx.doi.org/10.1017/s0263574718001418.

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SummaryIn this paper, a path planning algorithm for robotic systems with excess degrees of freedom (DOF) for welding of intersecting pipes is presented. At first step, the procedure of solving the inverse kinematics considering system kinematic redundancy is developed. The robotic system consists of a 6 DOF robotic manipulator installed on a railed base with linear motion. Simultaneously, the main pipe is able to rotate about its longitudinal axis. The system redundancy is employed to improve weld quality. Three different simulation studies are performed to show the effect of the robotic system kinematic redundancy to plan a better path for the welding of intersecting pipes. In the first case, it is assumed that robotic manipulator base and main pipe are fixed, and the path is planned only with manipulator joints motion. In the second case, only the robot base is free to move and the main pipe is fixed, and in the third case, the main pipe is free to rotate together with the base of the manipulator. It is seen that kinematic constraints according to the system’s redundancy will help to plan the most efficient path for the welding of complex pipe joints.

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Liu, Lei, Huai Chu Dai, and Ju Guang Lin. "Research on the Application of 3G Robotic Welding Guns to the Welding of Body-in-White Based on Delmia." Advanced Materials Research 756-759 (September 2013): 237–40. http://dx.doi.org/10.4028/www.scientific.net/amr.756-759.237.

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3G welding gun is a new kind of welding guns which uses servo motor as the driving device. And it is of modularity, simplicity, robustness and high performance and has obvious advantages compared with traditional welding guns. This paper exploited robot payload check program to make comparison of the differences between OBARA welding guns and 3G welding guns. The results verified the advantages of 3G welding guns. A case study to the application of 3G welding guns to the body side was conducted, and Delmia, a 3D platform for robotic simulation and OLP, was used to create the robot welding programs. Finally, the timing chart of welding process by means of 3G welding guns was analyzed.

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Sorenti, Peter. "Efficient robotic welding for shipyards ‐ virtual reality simulation holds the key." Industrial Robot: An International Journal 24, no. 4 (August 1997): 278–81. http://dx.doi.org/10.1108/01439919710176354.

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Redza, Mohd Ridhwan Mohammed, Yupiter H. P. Manurung, Robert Ngendang Ak. Lidam, Mohd Shahar Sulaiman, Mohammad Ridzwan Abdul Rahim, Sunhaji Kiyai Abas, Ghalib Tham, and Chan Yin Chau. "Distortion Analysis on Multipassed Butt Weld Using FEM and Experimental Study." Advanced Materials Research 311-313 (August 2011): 811–14. http://dx.doi.org/10.4028/www.scientific.net/amr.311-313.811.

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This paper investigates the simulation technique for analyzing the distortion behavior induced by welding process on welded plate which was clamped on one side. This clamping method is intended to enable the investigation of the maximum distortion on the other side. FEA software SYSWELD was employed to predict multipassed butt weld distortion of low carbon steel with thicknesses of 6 mm and 9 mm. The simulation begins with the development of model geometry and meshing type followed by suitable selection of heat source model represented by the Goldak’s double ellipsoid model. Other parameters such as travel speed, heat input, clamping method etc. were determined. The model is dedicated for multipass welding techniques using Gas Metal Arc Welding (GMAW). The experimental works were conducted by using Robotic welding process.

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Kvasnica, M., Š. Petráš, and I. Kočiš. "Simulation of Positioning Accuracy of the Torch in Adaptive Robotic Welding System." IFAC Proceedings Volumes 20, no. 12 (September 1987): 293–98. http://dx.doi.org/10.1016/s1474-6670(17)55646-3.

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Sharma, Aman, Pradeep Kumar Singh, and Rohit Sharma. "Numerical Simulation of Temperature Distribution in Robotic Arc welding by ARISTOTM Robot." IOP Conference Series: Materials Science and Engineering 1116, no. 1 (April 1, 2021): 012117. http://dx.doi.org/10.1088/1757-899x/1116/1/012117.

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Nowak, Mirosław, Daniel Wiśniewski, and Łukasz Czeladziński. "Innovative Robotic System for MAG Welding with Two Filler Metal Wire Feeders." Biuletyn Instytutu Spawalnictwa, no. 3 (June 2020): 83–89. http://dx.doi.org/10.17729/ebis.2020.3/8.

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The article describes an innovative robotic MAG method for the welding for ship elements. The method involves the use of two wire feeders and one torch, making it possible to weld two different steel grades. In addition, the robot application is equipped with an off-line programming DTPS system (Desk Top Programming & Simulation System) as well as an arc sensor, a gas nozzle touch sensor and a laser touch sensor featuring a seam finding function. The system is also provided with a welding parameter monitoring and archiving system.

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Bormanis, O., and L. Ribickis. "Power Module Temperature in Simulation of Robotic Manufacturing Application." Latvian Journal of Physics and Technical Sciences 58, no. 4 (August 1, 2021): 3–14. http://dx.doi.org/10.2478/lpts-2021-0029.

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Abstract The paper presents a lifetime consumption estimation model of 6 degrees of freedom industrial robot arm. The primary goal of the research is to provide estimated lifetime data of semiconductor power modules of robot axis power supply circuit, providing new opportunities for cost-saving, predictive maintenance, with highly customized input for different manufacturing applications. Evaluation of thermal stress and estimation of isolated gate bipolar transistor current are completed, based on MATLAB model translating KUKA robot program code to electrical energy consumption, which is a novel approach. Energy losses are considered in the model to provide accuracy of the inverter load current. The simulation results prove that lifetime consumption depends on a robot application type, for more agile movement programs with large power amplitudes, such as handling, the degradation in power modules is significant compared to slower applications, such as gluing or welding. Various options for future development are suggested and considered in the paper.

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Korizis, G., and C. Doumanidis. "Scan Welding: Thermal Modeling and Control of Material Processing." Journal of Manufacturing Science and Engineering 121, no. 3 (August 1, 1999): 417–24. http://dx.doi.org/10.1115/1.2832697.

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This article provides a thermal analysis of scan welding, as a redesign of classical joining methods, employing computer technology to ensure the composite morphologic, material and mechanical integrity of the joint. This is obtained by real-time control of the welding temperature field by a proper dynamic heat input distribution on the weld surface. This distribution is implemented in scan welding by a single torch, sweeping the joint surface by a controlled reciprocating motion, and power adjusted by feedback of infrared temperature measurements in-process. An off-line numerical simulation of the thermal field in scan welding is established, as well as a linearized multivariable model with real-time parameter identification. An adaptive thermal control scheme is thus implemented and validated both computationally and experimentally on a robotic Gas-Tungsten Arc Welding setup. The resulting productivity and quality features of scan welding are comparatively analyzed in terms of material structure and properties of the joint.

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Bauchspiess, Adolfo, Sadek C. Absi Alfaro, and Leszek A. Dobrzanski. "Predictive sensor guided robotic manipulators in automated welding cells." Journal of Materials Processing Technology 109, no. 1-2 (February 2001): 13–19. http://dx.doi.org/10.1016/s0924-0136(00)00771-8.

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Huissoon, J. P., D. L. Strauss, J. N. Rempel, S. Bedi, and H. W. Kerr. "Multi-variable control of robotic gas metal arc welding." Journal of Materials Processing Technology 43, no. 1 (June 1994): 1–12. http://dx.doi.org/10.1016/0924-0136(94)90157-0.

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Agapakis, John E., Joel M. Katz, Joshua M. Friedman, and Geoffrey N. Epstein. "Vision-Aided Robotic Welding: An Approach and a Flexible Implementation." International Journal of Robotics Research 9, no. 5 (October 1990): 17–34. http://dx.doi.org/10.1177/027836499000900502.

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Anikin, P. S., G. M. Shilo, R. A. Kulykovskyi, and D. E. Molochkov. "Automation control system of 3d printing robotic platform with implemented wire + arc welding technology." Electrical Engineering and Power Engineering, no. 4 (December 30, 2020): 35–48. http://dx.doi.org/10.15588/1607-6761-2020-4-4.

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Purpose. Development of the robotic platform automated control system architecture, development of the software control algorithm. Methodology. To implement the algorithm of the control program, computer modeling of thermal regimes in CAE systems is used. The basic parameters of the single layer printing technique were obtained by experimental use of the wire plus arc additive manufacturing (WAAM) technology. Findings. Requirements for manufacturability and printing quality of the manufactured parts were defined in the form of geometric dimensions, surface waviness, parameters of the desired microstructure state, residual stresses, maintaining of the optimal manufacturing speed. Based on the requirements of manufacturability analysis, an algorithm for the control program was developed. Robotic platform automated control system architecture with feedback device for the thermal mode control, parameters of the geometrical form of the manufactured part and weld pool were developed. Three -level hierarchical model, which gives an ability to consider in the process of 3D printing each level individually in terms of welding bead, layer and wall, was developed. The input data for the operation of the automated control system of the robotic platform using the technology of electric arc welding are determined. Basic geometrical parameters and the simple welding bead and the methods of overlapping of two or more beads were shown. Critical differences between ideal and real welding overlapping models were considered for necessity of taking into account whilst generating robot control software. Analysis of the possibilities for the CAE simulation of the three-dimensional printing using wire plus arc additive manufacturing technology is performed to determine the influence of the temperature parameters, mechanical loads, toolpath change, and based on the data obtained, it became possible to determine residual stresses and defects in manufactured parts. Originality. Robotic platform automated control system architecture with feedback device for the control of thermal mode, parameters of the geometrical form of the manufactured part and weld pool was developed. Three-level hierarchical model for the wire plus arc additive manufacturing (WAAM) technology was created. Software control algorithm which provides an opportunity to improve geometrical and mechanical properties of the manufactured parts was developed. Practical value. Development of an automated control system for 3D printing robotic platform with WAAM implemented technology, which will provide an opportunity for increase in the printing accuracy of the manufactured parts and will help to reduce manufacturing time.

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Zwicker, Carola, and Gunther Reinhart. "System for the Estimation of Robot Cycle Times in Early Production Planning Phase." Applied Mechanics and Materials 840 (June 2016): 99–106. http://dx.doi.org/10.4028/www.scientific.net/amm.840.99.

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Obtaining the cycle time of robots mostly comes along with a simulation of the system. Setting up those simulations is time intensive and the costs for corresponding tools are often too high for small and medium sized enterprises. For manual assembly there are systems like MTM (methods-time-measurement) to calculate the cycle time in an easier way without using expensive software. For robotic applications like handling, assembly, welding, machining, and painting, such methods do not exist. This paper describes a method of a robot cycle time estimation. Starting with an analysis of the processes regarding their finite process elements, the robot tasks are divided into general elements and process related elements. In a second step, all elements are analysed regarding their characteristics and described in a mathematical way. Finally, the elements are combined to a calculation system.

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Kim, I. S., Y. J. Jeong, I. J. Son, I. J. Kim, J. Y. Kim, I. K. Kim, and Prasad K. D. V. Yaragada. "Sensitivity analysis for process parameters influencing weld quality in robotic GMA welding process." Journal of Materials Processing Technology 140, no. 1-3 (September 2003): 676–81. http://dx.doi.org/10.1016/s0924-0136(03)00725-8.

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Xu, De, Min Tan, Xiaoguang Zhao, and Zhiguo Tu. "Seam tracking and visual control for robotic arc welding based on structured light stereovision." International Journal of Automation and Computing 1, no. 1 (October 2004): 63–75. http://dx.doi.org/10.1007/s11633-004-0063-0.

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Zhou, Binghai, and Qiong Wu. "A novel optimal method of robotic weld assembly line balancing problems with changeover times: a case study." Assembly Automation 38, no. 4 (September 3, 2018): 376–86. http://dx.doi.org/10.1108/aa-02-2018-026.

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PurposeThe balancing of robotic weld assembly lines has a significant influence on achievable production efficiency. This paper aims to investigate the most suitable way to assign both assembly tasks and type of robots to every workstation, and present an optimal method of robotic weld assembly line balancing (ALB) problems with the additional concern of changeover times. An industrial case of a robotic weld assembly line problem is investigated with an objective of minimizing cycle time of workstations.Design/methodology/approachThis research proposes an optimal method for balancing robotic weld assembly lines. To solve the problem, a low bound of cycle time of workstations is built, and on account of the non-deterministic polynomial-time (NP)-hard nature of ALB problem (ALBP), a genetic algorithm (GA) with the mechanism of simulated annealing (SA), as well as self-adaption procedure, was proposed to overcome the inferior capability of GA in aspect of local search.FindingsTheory analysis and simulation experiments on an industrial case of a car body welding assembly line are conducted in this paper. Satisfactory results show that the performance of GA is enhanced owing to the mechanism of SA, and the proposed method can efficiently solve the real-world size case of robotic weld ALBPs with changeover times.Research limitations/implicationsThe additional consideration of tool changing has very realistic significance in manufacturing. Furthermore, this research work could be modified and applied to other ALBPs, such as worker ALBPs considering tool-changeover times.Originality/valueFor the first time in the robotic weld ALBPs, the fixtures’ (tools’) changeover times are considered. Furthermore, a mathematical model with an objective function of minimizing cycle time of workstations was developed. To solve the proposed problem, a GA with the mechanism of SA was put forth to overcome the inferior capability of GA in the aspect of local search.

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Kim, I. S., J. S. Son, I. G. Kim, J. Y. Kim, and O. S. Kim. "A study on relationship between process variables and bead penetration for robotic CO2 arc welding." Journal of Materials Processing Technology 136, no. 1-3 (May 2003): 139–45. http://dx.doi.org/10.1016/s0924-0136(02)01126-3.

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Xue, Yu, I. S. Kim, J. S. Son, C. E. Park, H. H. Kim, B. S. Sung, I. J. Kim, H. J. Kim, and B. Y. Kang. "Fuzzy regression method for prediction and control the bead width in the robotic arc-welding process." Journal of Materials Processing Technology 164-165 (May 2005): 1134–39. http://dx.doi.org/10.1016/j.jmatprotec.2005.02.174.

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Prajadhiama, Keval P., Yupiter HP Manurung, Zaidi Minggu, Fetisia HS Pengadau, Marcel Graf, Andre Haelsig, Tom-Eric Adams, and Hui Leng Choo. "Development of Bead Modelling for Distortion Analysis Induced by Wire Arc Additive Manufacturing using FEM and Experiment." MATEC Web of Conferences 269 (2019): 05003. http://dx.doi.org/10.1051/matecconf/201926905003.

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In this research, Wire Arc Additive Manufacturing is modelled and simulated to determine the most suitable bead modelling strategy. This analysis is aimed to predict distortion by means of thermomechanical Finite Element Method (FEM). The product model with wire as feedstock on plate as substrate and process simulation are designed in form of multi-layered beads and single string using MSC Marc/Mentat. This research begins with finding suitable WAAM parameters which takes into account the bead quality. This is done by using robotic welding system with 01.2mm filler wire (AWS A5.28 : ER80SNi1), shielding gas (80% Ar/ 20% CO2) and 6mm-thick low carbon steel as base plate. Further, modelling as well as simulation are to be conducted with regards to bead spreading of each layers. Two different geometrical modelling regarding the weld bead are modelled which are arc and rectangular shape. Equivalent material properties from database and previous researches are implemented into simulation to ensure a realistic resemblance. It is shown that bead modelling with rectangular shape exhibits faster computational time with less error percentage on distortion result compared to arc shape. Moreover, by using the rectangular shape, the element and meshing are much easier to be designed rather than arc shape bead.

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Deniz, Cengiz, and Mustafa Cakir. "In-line stereo-camera assisted robotic spot welding quality control system." Industrial Robot: An International Journal 45, no. 1 (January 15, 2018): 54–63. http://dx.doi.org/10.1108/ir-06-2017-0117.

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Purpose The purpose of this study is to design a robotic inline measurement system for spot welding quality control to achieve process requirement without any operator during the manufacturing flow. Design/methodology/approach A robot manipulator carries a stereo-camera and an ultrasonic control probe. The center position of the spot welding point is determined by evaluating the results of the edge, gradient and symmetry approaches from the methods proposed up to now in the literature to increase reliability. The center position of the spot welding point, determined in the camera reference plane, is transferred to the robot base plane coordinates with the hand–eye calibration proposed in this manuscript. Weld quality is checked by the ultrasonic test probe located at the spot welding point. Findings While operators can only control welding quality, the developed station can also evaluate the quality based on geometric accuracy by processing the deviation of the position of the spot welding points. The proposed calibration method and the results of other methods in the literature are presented in this study by comparing it with synthetic data in simulations and in practical application. Research limitations/implications The quality control is performed not only for the spot welding made with robots but also for the manual welds as well. Because of vision configuration, and reliability issues, maximum allowable offset by the correct spot position is limited to 20 mm to position the manipulator for testing. The installation and pretest works of the developed robotic welding quality control station are completed in the Body Shop Area of Ford Otosan factory in Kocaeli/Turkey. The results of the robotic control process are monitored by the quality assurance team. Integration of automation with the production line will be completed and an inline measurement will be done. Originality value In this paper, a new hand–eye calibration method based on simple and closed-form analytical solutions has been presented. The objective function is defined as reducing the deviation in the point projection, rather than reducing the error in the calibration equation. To increase reliability, combining the results of existing centering algorithms for the detection of the strongly deformed spot welding spot center, although it is normally in a circular form, has been suggested.

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Hussein, Aseel, Ayesha Alkhoori, Abdelaziz Al Zaabi, Cesare Stefanini, Federico Renda, Syed Jaffar, Ibrahim Emre Gunduz, Kyriaki Polychronopoulou, Claus Georg Rebholz, and Charalabos Constantinos Doumanidis. "Underwater Robotic Welding of Lap Joints with Sandwiched Reactive Multilayers: Thermal, Mechanical and Material Analysis." MRS Advances 3, no. 17 (2018): 911–20. http://dx.doi.org/10.1557/adv.2018.310.

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ABSTRACTUnderwater welding using reactive materials pre-deposited at the junction surfaces as a self-contained, in-situ ignitable heat source mitigates external power and gas supply requirements. Consequently, lending itself to robotic implementation eliminating the cost along with health and safety hazards of human welder-divers. This project reports on lap joining of aluminum sheets with sandwiched commercial reactive Ni-Al multilayers that are perforated to allow for melt fusion under compression upon ignition, in saline and deionized water as well as air for comparison. Finite-element thermal simulations are employed to study the resulting welding temperature field and melt conditions. Infrared pyrometry and thermocouple measurements during welding were used to validate the computational simulations. The lap joints are subjected to standard shear testing, and comparable compliance, strength and toughness values of the welds are assessed for underwater and dry joints. Scanning electron (SEM) of the weld sections reveal rapidly melting and solidifying microstructures of the parent metal, with minimal melt flow and perfusion of nickel aluminide aggregates from the reacted multilayers, and no signs of cavitation.

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Du, Yong Zhong, Xue Liang Ping, Lu Gang Chen, and Wei Bin Xu. "Motion Control of Welding Robot Based on ADAMS and ACR-9000." Advanced Materials Research 542-543 (June 2012): 789–94. http://dx.doi.org/10.4028/www.scientific.net/amr.542-543.789.

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Based on some relevant theories of robotics such as trajectory planning, the forward and inverse kinematics solutions and DH convention, this paper proposes a new approach towards testing the physical prototype. The approach sets up a 3-D model for a 6-DOF welding robot , works out the simulation results of expected processing trajectory planning for six rods in MATLAB, verifies the trajectory simulation results with the built-in Robot Toolbox of MATLAB, And controls the robot to draw a circle with the ACR9000 motion controller.

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Wang, Ling, Xin Qing Fan, Fu Yan Qi, and Wan Hua Wei. "Trajectory Planning Research of the Filter Shell Special Arc Welding Robot." Advanced Materials Research 706-708 (June 2013): 1103–7. http://dx.doi.org/10.4028/www.scientific.net/amr.706-708.1103.

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The detailed analysis of the structure and paramerers of the connecting rod is put forward by using the improving D-H method to establish the link coordinate system and the kinematics equation, based on the special filer shell arc welding robot with six degrees of freedom designed. Therefor, the correctness of the kinematics equation is verified though the simulation of Matlab function with the robotics toolbox. The anasysis simulation results show that the rationality of the robot structure that based on the kinematics analysis, is feasible.

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Roesch, Oliver. "Model-Based On-Line Compensation of Path Deviations for Milling Robots." Advanced Materials Research 769 (September 2013): 255–62. http://dx.doi.org/10.4028/www.scientific.net/amr.769.255.

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Handling, welding or painting are currently the main fields of application for industrial robots. Due to their high flexibility and low investment costs industrial robots are increasingly used for machining processes in production environments. Robotic milling is one example of these processes, which nowadays can only be applied for tasks with low accuracy requirements and minor cutting forces. The main reason for this is the low stiffness of the robot structure and hence the huge deflection of the tool caused by the cutting forces. Robotic milling tests of aluminum show deviations of the programmed track in the millimeter range even with moderate depth of cut. To harness high possible savings of milling robots, a new method to increase the machining accuracy was developed at the Institute of Machine Tools and Industrial Management (iwb). The core of the method is a model-based controller for the compensation of deviations that are caused by the cutting forces. The input variables of the controller are the axis angles of the robot (provided by the robot controller) and the cutting forces (measured by a three-component force plate). Based on the cutting forces and the axis angles, the deflection of the Tool Center Point (TCP) is calculated by means of a simulation model. The calculated offset is transmitted to the robot controller so that the tool path is corrected. To implement the compensation strategy, a real-time model of the robot which includes all major compliances of the structure needs to be developed. Besides the real-time requirement, the model needs to be valid for the main working area of the robot. A major challenge in this regard is the determination of the relevant compliance parameters of the robot. In addition to the stiffness values of the gears and bearings the elasticities of the robot links need to be identified. The paper presents a novel method to determine the relevant stiffness parameters of a robot by measurements with a 3D-Scanning-Laser-Doppler-Vibrometer (LDV). In these measurements the robot is loaded with a defined force induced by an actuator at its TCP. During this process, the deflection of the robot is detected by the LDV at a multitude of measuring points. From the relative movements of the measuring points, the tilting-angles of the gears, bearings, and the structural components are calculated. Using the known torques caused by the defined load the stiffness parameters are calculated. In order to minimize the experimental effort it is aspired to identify all necessary parameters by one single measurement. To achieve this goal, the best measurement setup consisting of the position and the orientation of the TCP as well as the direction of the actuator force, is identified by a multibody system (MBS) to ensure sufficient torques in every axis of the robot and all directions (transmission direction and perpendicular to it). The simulation shows that such a measuring setup exists, so that the required parameters, which were validated in additional experiments, could be determined with a single measurement. The determined parameters are used in a controller model to calculate the displacement of the TCP due to the cutting forces during the machining process. Since this model needs to be very efficient regarding the computation time, a MBS cannot be used so that an analytical model must be developed. The analytical model is based on conventional forward kinematics, which is used for determining the position and orientation of the TCP of the robot. In conventional forward kinematics, the rotation of an axis is described by a transformation matrix, which also takes the (constant) dimensions of the robot arms into account. This description only includes a single degree of freedom to the joint angle of the axis and is extended to provide additional degrees of freedom to represent the elasticity of the gear and the bearing. To be able to consider the elasticity of the robot arms, additional transformation matrices are introduced in the center of the arm and the link arm. The computing time of this analytical model is in the range of 1 to 2 ms, so that the model is suitable for the control. In initial machining experiments with a robot of type KR 240 R2500 prime the proposed approach was validated. Milling tests with aluminium showed a significant reduction of the process-related path deviations using the presented control strategy.

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Lobanov, Leonid M., E. A. Asnis, Ye G. Ternovy, Yu V. Zubchenko, I. I. Statkevich, V. S. Volkov, and S. A. Glushak. "Some Issues of Repairing Manned Space Vehicles in Outer Space Using Electron Beam Welding." Solid State Phenomena 315 (March 2021): 101–5. http://dx.doi.org/10.4028/www.scientific.net/ssp.315.101.

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A new generation of electron beam tool for welding during assembly and repair-restoration works on board of manned space vehicles in open space was demonstrated. The tool includes a small-sized electron beam gun (EBG) with an electron beam power of up to 2.5 kW and a high-voltage power source with a voltage of 10 kV. The design of the electron-optical system of EBG allows using it in both manual as well as in automatic mode applying robotic devices. Applying the manufactured EBG and manipulator, in vacuum chamber the works on simulating the repair of a spacecraft’s section of aluminum 2219 alloy were carried out. The obtained results of studying the structure and mechanical characteristics and also sealing of welds confirmed the high quality of welded joints and a reliability of the technology for repairing a damaged fragment of a spacecraft's body using electron beam welding.

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McGhee, Scott, Sivrama Nalluri, Ron Reeve, Robert Rongo, Fritz Prinz, and Jim Hemmerle. "Automatic Programming System for Shipyard Robots." Journal of Ship Production 13, no. 02 (May 1, 1997): 93–100. http://dx.doi.org/10.5957/jsp.1997.13.2.93.

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The application of robots to variable tasks in unstructured environments presents a series of problems that must be solved in order to achieve viable results Common teaching-type robots cannot be applied in these cases as the programming time and labor investment far exceed the time and cost of direct manual production. Numerically controlled (NC) robots programmed off-line by modified NC methods have been applied with economic success to program robots directly from computer-aided design (CAD) data where tasks are sufficiently repetitive and the operating environment is sufficiently structured Similarly, off-line programming systems have been developed by various robot manufacturers to generate instructions from CAD data for their robots. Likewise, developers of 3D simulation software have devised methods to merge CAD data with physical models of robots and system hardware to produce robot path programs that approximate the tasks to be performed. Each of these systems is unable to provide a totally automated means to program robot tasks directly from CAD data due to inaccuracies in the real-world elements and/or the models, and due to a lack of knowledge about the processes. A new approach to automatic robot programming is needed that is capable of dealing with:inherent differences between the CAD models and the real-world parts;uncertainties regarding the precise location and accessibility of the parts relative to the robot:process knowledge required to adapt these differences and uncertainties; andprocess knowledge essential to optimizing robot activities. Such an automatic robot programming system is being developed to meet the dual-use defense and commercial ship construction needs of American shipyards under the Technology Reinvestment Project (TRP) for Shipbuilding Robotics. This system automates the programmer's task of identifying location of welds, assigning weld process parameters and adaptive welding strategies to each joint. A procedural diagram for this system is shown in Figure 1. The results and benefits of this approach are described herein. Fig. 1Procedure for automatic off-line robot task planning

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Kovšca, Dejan, Bojan Starman, Aljaž Ščetinec, Damjan Klobčar, and Nikolaj Mole. "Advanced computational modelling of metallic wire-arc additive manufacturing." ESAFORM 2021, March 29, 2021. http://dx.doi.org/10.25518/esaform21.2340.

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Wire-arc welding-based additive manufacturing (WAAM) is a 3D printing technology for production of near-net-shape parts with complex geometry. This printing technology enables to build up a required shape layer by layer with a deposition of a consumable welding wire, where the welding arc is a source of heat. Welding is usually performed by CNC-controlled robotic manipulator, which provides a controlled location of material layer adding. Because the process itself involves thermo-mechanically complex phenomena, Finite Element-based virtual models are commonly employed to optimize the process parameters. This paper presents advanced computational modelling of the WAAM of a tube. A thermo-mechanical numerical model of the process is calibrated against experimental data, measured as temperature variation at the acquisition point. The virtual modelling starts with a preparation of the tube geometry in CAD software, where the geometry of the single-layer cross-section is assumed. The geometry is then exported to a G-code format data file and used to control robotic manipulator motion. On the other side, the code serves as an input to in-house developed code for automatic FEs activation in the simulation of the material layer-adding process. The time of activation of the finite elements (FEs) is directly related to the material deposition rate. The activation of the FEs is followed by a heat source, modeled with a double ellipsoidal power density distribution. The thermo-mechanical problem was solved as uncoupled to speed-up computation.

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Haitao, Luo, Wu Tingke, Fu Jia, and Zhao Fengqun. "Analysis of typical working conditions and experimental research of friction stir welding robot for aerospace applications." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, July 13, 2020, 095440622094155. http://dx.doi.org/10.1177/0954406220941558.

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In an attempt to address the limitations of single function and the poor process flexibility of existing friction stir welding equipment, a new friction stir welding robot has been developed to address practical problems in three-dimensional surface welding. Based on an analysis of the components of the robotic system, a kinematics model was established, and the forward and backward kinematics solutions were derived for the robot. An iterative nearest point algorithm, iterative closest point based on point cloud matching, was used to plan the welding trajectory for the most complex petal welding conditions, and an experimental study was conducted. The results show that the kinematic and dynamic test results were consistent with the acquired simulation curves for specific sizes of the rocket cap flaps under appropriate welding conditions. The normal error of the weld was less than 85 µm, the average tensile strength was 359 MPa, and the elongation was 7.20%, 78.0%, and 72.0% of 2A14-T6 aluminum alloy. The friction stir welding robot exhibited robust performance, and the proposed trajectory planning method is practical and effective. The appearance, geometric dimension, and mechanical properties of the weld achieved the expected criteria, and high-precision welding of large complex thin-walled surfaces is possible.

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Vallachira, Sathish, Mikael Norrlof, Michal Orkisz, and Sachit Butail. "A Transfer Entropy Based Approach for Fault Isolation in Industrial Robots." ASME Letters in Dynamic Systems and Control 2, no. 1 (July 16, 2021). http://dx.doi.org/10.1115/1.4051565.

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Abstract In this paper, we cast the problem of fault isolation in industrial robots as that of causal analysis within coupled dynamical processes and evaluate the related efficacy of the information-theoretic approach of transfer entropy. To create a realistic and exhaustive dataset, we simulate wear-induced failure by increasing friction coefficient on select axes within an in-house robotic simulation tool that incorporates an elastic gearbox model. The source axis of failure is identified as one which has the highest net transfer entropy across all pairs of axes. In an exhaustive simulation study, we vary the friction successively in each axis across three common industrial tasks: pick and place, spot welding, and arc welding. Our results show that transfer entropy-based approach is able to detect the axis of failure more than 80% of the time when the friction coefficient is 5% above the nominal value and always when friction coefficient is 10% above the nominal value. The transfer entropy approach is more than twice as accurate as cross-correlation, a classical time series analysis used to identify directional dependence among processes.

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Bera, Manas Kr, Bijnan Bandyopadhyay, and A. K. Paul. "Variable Gain Super-Twisting Control of GMAW Process for Pipeline Welding." Journal of Dynamic Systems, Measurement, and Control 137, no. 7 (July 1, 2015). http://dx.doi.org/10.1115/1.4029408.

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Quality control is the key issue that needs to be addressed in any gas metal arc welding (GMAW) system, especially in robotic pipeline welding system. This paper explores a second-order sliding mode control (SMC) strategy—a variable gain super-twisting control, to maximize the productivity, consistency in welding quality. This is achieved by the robust finite time output tracking of GMAW system. A nonlinear multi-input multi-output (MIMO) model of GMAW system has been considered here for the design of variable gain super-twisting (VGST) controller by which complete rejection of the bounded uncertainties/disturbances is possible and the adaptive characteristic of its gains help to use the control effort effectively. The stability of internal dynamics of the system is studied to establish the feasibility of solving the robust finite time output tracking problem. The stability of the overall system has been analyzed using Lyapunov stability criterion. The performance of the controller is demonstrated using the model of the system emulating the realistic conditions of operation. The simulation results are presented to illustrate the efficacy of the controller.

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Journal articles on the topic 'Robotic welding simulation'

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