Robotic arc welding sensors and programming in industrial applications

Abstract

Technical innovations in robotic welding and greater availability of sensor-based control features have enabled manual welding processes in harsh work environments with excessive heat and fumes to be replaced with robotic welding. The use of industrial robots or mechanized equipment for high-volume productivity has become increasingly common, with robotized gas metal arc welding (GMAW) generally being used. More widespread use of robotic welding has necessitated greater capability to control welding parameters and robotic motion and improved fault detection and fault correction. Semi-autonomous robotic welding (i.e., highly automated systems requiring only minor operator intervention) faces a number of problems, the most common of which are the need to compensate for inaccuracies in fixtures for the workpiece, variations in workpiece dimensions, imperfect edge preparation, and in-process thermal distortions. Major challenges are joint edge detection, joint seam tracking, weld penetration control, and measurement of the width or profile of a joint. Such problems can be most effectively solved with the use of sensory feedback signals from the weld joint. Thus, sensors play an important role in robotic arc welding systems with adaptive and intelligent control system features that can track the joint, monitor in-process quality of the weld, and account for variation in joint location and geometry. This work describes various aspects of robotic welding, programming of robotic welding systems, and problems associated with the technique. It further discusses commercially available seam-tracking and seam-finding sensors and presents a practical case application of sensors for semi-autonomous robotic welding. This study increases familiarity with robotic welding and the role of sensors in robotic welding and their associated problems.

Artificial Neural Network Controlled GMAW System: Penetration and Quality Assurance in a Multi-Pass Butt Weld Application

“…A primary concern in automated welding is the inability to adapt effectively to varying welding conditions, leading to inconsistent welding quality. Hence, the more stringent weld quality requirements of optimized structures, resulting from the use of thinner materials, high-strength steels and reduction of weld material, are difficult to achieve [1][2][3]. Additionally, the quality and penetration inconsistency, caused by the inability to adapt, affects drastically to fatigue life and strength properties of the weld joint [4][5][6][7].…”

Development of a Current Sensor with Broad Current Measurement Range Using High- and Low-Range Parts

“…The demand for control and protection technologies to monitor the current usage of systems, equipment, and robots in preventive diagnosis, management, operation, and service industry applications will also increase. Thus, components that can accurately measure currents are required [1]- [3]. For current measurement, electrical shunts, Rogowski coils, Current transformer and current sensors are the primary components used.…”

An agile robotic system mounted on scaffold structures for on-site construction work

“…This is carried out using some form of contact or non-contact type of sensing. The readers can refer to Kah et al (2015) for a detailed analysis of the advantages and drawbacks for each of these types of sensing technique.…”