The motion simulation of arc welding robot is the basis of the system of robot off-line programming, and it has been one of the important research directions. The UGNX 4. 0 is adopted to establish 3D simulating model ...The motion simulation of arc welding robot is the basis of the system of robot off-line programming, and it has been one of the important research directions. The UGNX 4. 0 is adopted to establish 3D simulating model of MOTOMAN-HP6 arc welding robot. The kinematic model under link-pole coordinate system is established by the second development function offered by UG/OPEN API and the method of programming using VC ＋＋ 6. 0. The methods of founding model and operational procedures are introduced, which provides a good basis for off-line programming technique under Unigraphies condition.展开更多
The links of Motoman HP6 arc welding robot are considered as an open kinematic chain which consists of a series of rotational joints through concatenation. One end of the open chain is fixed to the base or the earth, ...The links of Motoman HP6 arc welding robot are considered as an open kinematic chain which consists of a series of rotational joints through concatenation. One end of the open chain is fixed to the base or the earth, and the other end which is free fastens the end executor to complete various duties. Each link of this arc welding robot has four kinds of Denavit-Hartenberg parameters: common normal length between two adjacent links, angle of two adjacent joints, distance between the crossing of common normal length and two joints axes, and angle of two adjacent links. The displacement relation between each link of the Motoman HP6 arc welding robot is introduced, and the kinematic positive-going solution and the kinematic passive-going solution are calculated.展开更多
Industrial robots are currently applied for ship sub-assembly welding to replace welding workers because of the intelligent production and cost savings.In order to improve the efficiency of the robot system,a digital ...Industrial robots are currently applied for ship sub-assembly welding to replace welding workers because of the intelligent production and cost savings.In order to improve the efficiency of the robot system,a digital twin system of welding path planning for the arc welding robot in ship sub-assembly welding is proposed in this manuscript to achieve autonomous planning and generation of the welding path.First,a five-dimensional digital twin model of the dual arc welding robot system is constructed.Then,the system kinematics analysis and calibration are studied for communication realization between the virtual and the actual system.Besides,a topology consisting of three bounding volume hierarchies(BVH)trees is proposed to construct digital twin virtual entities in this system.Based on this topology,algorithms for welding seam extraction and collision detection are presented.Finally,the genetic algorithm and the RRT-Connect algorithm combined with region partitioning(RRT-Connect-RP)are applied for the welding sequence global planning and local jump path planning,respectively.The digital twin system and its path planning application are tested in the actual application scenario.The results show that the system can not only simulate the actual welding operation of the arc welding robot but also realize path planning and real-time control of the robot.展开更多
A measurement setup used for robot calibration was designed to meet the requirement of off line programming technique. The robot end effector pose (position and orientation) can be calculated indirectly by using thi...A measurement setup used for robot calibration was designed to meet the requirement of off line programming technique. The robot end effector pose (position and orientation) can be calculated indirectly by using this setup. The setup has been applied to RHJD4 1 arc welding robot. The experimental results show the method of pose measuring using the measurement setup is simple and reliable to finish pose measuring for robot calibration. In addition, the setup can measure the position repeatability of robot.展开更多
A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning...A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning level, a motion control level and a servo control level. The last three levels form a local real-time open robot controller, which realizes motion planning and motion control of a robot. A camera calibration method based on the relative movement of the end-effector connected to a robot is proposed and a method for tracking weld seam based on the structured light stereovision is provided. Combining the parameters of the cameras and laser plane, three groups of position values in Cartesian space are obtained for each feature point in a stripe projected on the weld seam. The accurate three-dimensional position of the edge points in the weld seam can be calculated from the obtained parameters with an information fusion algorithm. By calculating the weld seam parameter from position and image data, the movement parameters of the robot used for tracking can be determined. A swing welding experiment of type V groove weld is successfully conducted, the results of which show that the system has high resolution seam tracking in real-time, and works stably and efficiently.展开更多
Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of...Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of the most typical workcells. The inverse kinematics of robot and positioner is the foundation of the off line programming system. The previous researchers only focused on a special solution of the positioner inverse kinematics, which is the solution at down hand welding position. In this paper, we introduce a method for representing welding position. Then a general algorithm of rotating/tilting positioner inverse kinematics is presented, and an approach to find the unique solution of the inverse kinematics is discussed. The simulation experiment results show that the general algorithm can improve the ability of robotic arc welding off line programming system to program all types of welding positions.展开更多
It is of great significance to develop an intelligent monitoring system for weld penetration defects such as incomplete penetration and burn-through in real-time during robotic arc welding process. In this paper, robo...It is of great significance to develop an intelligent monitoring system for weld penetration defects such as incomplete penetration and burn-through in real-time during robotic arc welding process. In this paper, robotic gas metal arc welding experiments are carried out on the mild steel test pieces with Vee-type groove. Through-the-arc sensing method is used to capture the transient values of the welding voltage and current. The raw data of the captured welding current and voltage are processed statistically, and the feature vector SIO is extracted to correlate the welding conditions to the weld penetration information. It lays foundation for intelligent monitoring of weld quality in robotic arc welding.展开更多
Geometric information is important for automatic programming of arc welding robot. Complete geometric models of robotic arc welding are established in this paper. In the geometric model of weld seam, an equation with ...Geometric information is important for automatic programming of arc welding robot. Complete geometric models of robotic arc welding are established in this paper. In the geometric model of weld seam, an equation with seam length as its parameter is introduced to represent any weld seam. The method to determine discrete programming points on a weld seam is presented. In the geometric model of weld workpiece, three class primitives and CSG tree are used to describe weld workpiece. Detailed data structure is presented. In pose transformation of torch, world frame, torch frame and active frame are defined, and transformation between frames is presented. Based on these geometric models, an automatic programming software package for robotic arc welding, RAWCAD, is developed. Experiments show that the geometric models are practical and reliable.展开更多
This paper describes a CIM system for robotic arc welding.The system is specially designed for producing workpieces in small and medium batch sizes.Based on the development of AUTOCAD and a structure-light visual sens...This paper describes a CIM system for robotic arc welding.The system is specially designed for producing workpieces in small and medium batch sizes.Based on the development of AUTOCAD and a structure-light visual sensor.low cost CIM is implemented. Feature modeling of weld workpiece is discussed.which provides complete geometric information and process information for off-line programming.The system provides powerful tools for programming of torch orientation to meet the requirents of achieving good welding quality,avoiding collision and not violating kinematics constraints.展开更多
Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controll...Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.展开更多
Recently, there has been a rapid development in computer technology, which has in turn led to develop the fully robotic welding system using artificial intelligence （AI） technology. However, the robotic welding syst...Recently, there has been a rapid development in computer technology, which has in turn led to develop the fully robotic welding system using artificial intelligence （AI） technology. However, the robotic welding system has not been achieved due to difficulties of the mathematical model and sensor technologies. The possibilities of the fuzzy regression method to predict the bead geometry, such as bead width, bead height, bead penetration and bead area in the robotic GMA （gas metal arc） welding process is presented. The approach, a well-known method to deal with the problems with a high degree of fuzziness, is used to build the relationship between four process variables and the four quality characteristics, respectively. Using these models, the proper prediction of the process variables for obtaining the optimal bead geometry can be determined.展开更多
The real-time detection of porosity in welding process is an important problem to be solved in intelligent welding manufacturing.A new on-line detection method for porosity of aluminum alloy in robotic arc welding bas...The real-time detection of porosity in welding process is an important problem to be solved in intelligent welding manufacturing.A new on-line detection method for porosity of aluminum alloy in robotic arc welding based on arc spectrum is proposed in this paper.First,k-shape and the improved k-means were used for the initial feature selection of the preprocessed arc spectrum to reduce the data dimension.Second,the secondary feature selection was carried out based on the importance of features to further reduce feature redundancy.Then,the optimal sample label library was established by combining the final characteristic parameters and the X-ray pictures of welds.Finally,an on-line detection method of porosity in gas tungsten arc welding of aluminum alloy based on light gradient boosting machine(LightGBM)was proposed.Compared with extreme gradient boosting(XGBoost)and categorical boosting(CatBoost),this method can achieve better detection performance.The new method proposed in this paper can be used to detect other welding defects,which is helpful to the development of intelligent welding technology.展开更多
An inverter type power source system for robot arc welding is considered. The power source includes several isolated gate bipolar transistor (IGBT) inverter power units. The output current of every individual power un...An inverter type power source system for robot arc welding is considered. The power source includes several isolated gate bipolar transistor (IGBT) inverter power units. The output current of every individual power unit is regulated by an identical single chip microcomputer to enable the whole power source system to work over a wide range of continuous output current with good dynamic properties. This inverter type power source satisfies robotic welding requirements.展开更多
This paper is to represent new algorithms to predict process parameters on top-bead width in robotic gas metal arc（GMA） welding process.The models have been developed：linear, curvilinear and intelligent model based...This paper is to represent new algorithms to predict process parameters on top-bead width in robotic gas metal arc（GMA） welding process.The models have been developed：linear, curvilinear and intelligent model based on full factorial design with two replications.Regression analysis was employed for optimization of the coefficients of linear and curvilinear models, while genetic algorithm（GA） was utilized to estimate the coefficients of an intelligent model.Not only the fitting of these models were checked and compared by using a variance test（ANOVA）, but also the prediction on top-bead width using the developed models were carried out based on the additional experiments.The developed models were employed to investigate the characteristic between process parameters and top-bead width.Resulting solutions and graphical representation showed that the intelligent model developed can be employed for prediction of bead geometry in GMA welding process.展开更多
基金Natural Science Foundation of Tianjin(No.07JCYBJC04400).
文摘The motion simulation of arc welding robot is the basis of the system of robot off-line programming, and it has been one of the important research directions. The UGNX 4. 0 is adopted to establish 3D simulating model of MOTOMAN-HP6 arc welding robot. The kinematic model under link-pole coordinate system is established by the second development function offered by UG/OPEN API and the method of programming using VC ＋＋ 6. 0. The methods of founding model and operational procedures are introduced, which provides a good basis for off-line programming technique under Unigraphies condition.
文摘The links of Motoman HP6 arc welding robot are considered as an open kinematic chain which consists of a series of rotational joints through concatenation. One end of the open chain is fixed to the base or the earth, and the other end which is free fastens the end executor to complete various duties. Each link of this arc welding robot has four kinds of Denavit-Hartenberg parameters: common normal length between two adjacent links, angle of two adjacent joints, distance between the crossing of common normal length and two joints axes, and angle of two adjacent links. The displacement relation between each link of the Motoman HP6 arc welding robot is introduced, and the kinematic positive-going solution and the kinematic passive-going solution are calculated.
基金This work was supported by the National Natural Science Foundation of China(Nos.62076095 and 61973120)National Key Research and Development Program(No.2022YFB4602104).
文摘Industrial robots are currently applied for ship sub-assembly welding to replace welding workers because of the intelligent production and cost savings.In order to improve the efficiency of the robot system,a digital twin system of welding path planning for the arc welding robot in ship sub-assembly welding is proposed in this manuscript to achieve autonomous planning and generation of the welding path.First,a five-dimensional digital twin model of the dual arc welding robot system is constructed.Then,the system kinematics analysis and calibration are studied for communication realization between the virtual and the actual system.Besides,a topology consisting of three bounding volume hierarchies(BVH)trees is proposed to construct digital twin virtual entities in this system.Based on this topology,algorithms for welding seam extraction and collision detection are presented.Finally,the genetic algorithm and the RRT-Connect algorithm combined with region partitioning(RRT-Connect-RP)are applied for the welding sequence global planning and local jump path planning,respectively.The digital twin system and its path planning application are tested in the actual application scenario.The results show that the system can not only simulate the actual welding operation of the arc welding robot but also realize path planning and real-time control of the robot.
文摘A measurement setup used for robot calibration was designed to meet the requirement of off line programming technique. The robot end effector pose (position and orientation) can be calculated indirectly by using this setup. The setup has been applied to RHJD4 1 arc welding robot. The experimental results show the method of pose measuring using the measurement setup is simple and reliable to finish pose measuring for robot calibration. In addition, the setup can measure the position repeatability of robot.
基金This work was supported by the National High Technology Research and Development Program of China under Grant 2002AA422160 by the National Key Fundamental Research and the Devel-opment Project of China (973) under Grant 2002CB312200.
文摘A real-time arc welding robot visual control system based on a local network with a multi-level hierarchy is developed in this paper. It consists of an intelligence and human-machine interface level, a motion planning level, a motion control level and a servo control level. The last three levels form a local real-time open robot controller, which realizes motion planning and motion control of a robot. A camera calibration method based on the relative movement of the end-effector connected to a robot is proposed and a method for tracking weld seam based on the structured light stereovision is provided. Combining the parameters of the cameras and laser plane, three groups of position values in Cartesian space are obtained for each feature point in a stripe projected on the weld seam. The accurate three-dimensional position of the edge points in the weld seam can be calculated from the obtained parameters with an information fusion algorithm. By calculating the weld seam parameter from position and image data, the movement parameters of the robot used for tracking can be determined. A swing welding experiment of type V groove weld is successfully conducted, the results of which show that the system has high resolution seam tracking in real-time, and works stably and efficiently.
基金ThispaperissupportedbyNationalNatureScienceFoundation (No .5 96 35 16 0 )AdvancedUniversityDoctoralSubjectFoundation (No .980 2 1311)
文摘Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of the most typical workcells. The inverse kinematics of robot and positioner is the foundation of the off line programming system. The previous researchers only focused on a special solution of the positioner inverse kinematics, which is the solution at down hand welding position. In this paper, we introduce a method for representing welding position. Then a general algorithm of rotating/tilting positioner inverse kinematics is presented, and an approach to find the unique solution of the inverse kinematics is discussed. The simulation experiment results show that the general algorithm can improve the ability of robotic arc welding off line programming system to program all types of welding positions.
文摘It is of great significance to develop an intelligent monitoring system for weld penetration defects such as incomplete penetration and burn-through in real-time during robotic arc welding process. In this paper, robotic gas metal arc welding experiments are carried out on the mild steel test pieces with Vee-type groove. Through-the-arc sensing method is used to capture the transient values of the welding voltage and current. The raw data of the captured welding current and voltage are processed statistically, and the feature vector SIO is extracted to correlate the welding conditions to the weld penetration information. It lays foundation for intelligent monitoring of weld quality in robotic arc welding.
基金This paperis supported by National Nature Science Foundation! (No.5963 51 60 )Advanced University Doctoral Subject Foundatio
文摘Geometric information is important for automatic programming of arc welding robot. Complete geometric models of robotic arc welding are established in this paper. In the geometric model of weld seam, an equation with seam length as its parameter is introduced to represent any weld seam. The method to determine discrete programming points on a weld seam is presented. In the geometric model of weld workpiece, three class primitives and CSG tree are used to describe weld workpiece. Detailed data structure is presented. In pose transformation of torch, world frame, torch frame and active frame are defined, and transformation between frames is presented. Based on these geometric models, an automatic programming software package for robotic arc welding, RAWCAD, is developed. Experiments show that the geometric models are practical and reliable.
文摘This paper describes a CIM system for robotic arc welding.The system is specially designed for producing workpieces in small and medium batch sizes.Based on the development of AUTOCAD and a structure-light visual sensor.low cost CIM is implemented. Feature modeling of weld workpiece is discussed.which provides complete geometric information and process information for off-line programming.The system provides powerful tools for programming of torch orientation to meet the requirents of achieving good welding quality,avoiding collision and not violating kinematics constraints.
文摘Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.
文摘Recently, there has been a rapid development in computer technology, which has in turn led to develop the fully robotic welding system using artificial intelligence （AI） technology. However, the robotic welding system has not been achieved due to difficulties of the mathematical model and sensor technologies. The possibilities of the fuzzy regression method to predict the bead geometry, such as bead width, bead height, bead penetration and bead area in the robotic GMA （gas metal arc） welding process is presented. The approach, a well-known method to deal with the problems with a high degree of fuzziness, is used to build the relationship between four process variables and the four quality characteristics, respectively. Using these models, the proper prediction of the process variables for obtaining the optimal bead geometry can be determined.
基金the National Natural Science Foundation of China(Nos.61873164 and 51575349)。
文摘The real-time detection of porosity in welding process is an important problem to be solved in intelligent welding manufacturing.A new on-line detection method for porosity of aluminum alloy in robotic arc welding based on arc spectrum is proposed in this paper.First,k-shape and the improved k-means were used for the initial feature selection of the preprocessed arc spectrum to reduce the data dimension.Second,the secondary feature selection was carried out based on the importance of features to further reduce feature redundancy.Then,the optimal sample label library was established by combining the final characteristic parameters and the X-ray pictures of welds.Finally,an on-line detection method of porosity in gas tungsten arc welding of aluminum alloy based on light gradient boosting machine(LightGBM)was proposed.Compared with extreme gradient boosting(XGBoost)and categorical boosting(CatBoost),this method can achieve better detection performance.The new method proposed in this paper can be used to detect other welding defects,which is helpful to the development of intelligent welding technology.
文摘An inverter type power source system for robot arc welding is considered. The power source includes several isolated gate bipolar transistor (IGBT) inverter power units. The output current of every individual power unit is regulated by an identical single chip microcomputer to enable the whole power source system to work over a wide range of continuous output current with good dynamic properties. This inverter type power source satisfies robotic welding requirements.
基金supported by the 2006 research funds from Mokpo National University
文摘This paper is to represent new algorithms to predict process parameters on top-bead width in robotic gas metal arc（GMA） welding process.The models have been developed：linear, curvilinear and intelligent model based on full factorial design with two replications.Regression analysis was employed for optimization of the coefficients of linear and curvilinear models, while genetic algorithm（GA） was utilized to estimate the coefficients of an intelligent model.Not only the fitting of these models were checked and compared by using a variance test（ANOVA）, but also the prediction on top-bead width using the developed models were carried out based on the additional experiments.The developed models were employed to investigate the characteristic between process parameters and top-bead width.Resulting solutions and graphical representation showed that the intelligent model developed can be employed for prediction of bead geometry in GMA welding process.
