Pose Planning for the End-effector of Robot in the Welding of Intersecting Pipes

All-position robots are widely applied in the welding of complicated parts.Welding of intersecting pipes is one of the most typical tasks.The welding seam is a complicated saddle-like space curve,which puts a great challenge to the pose planning of end-effector.The special robots designed specifically for this kind of tasks are rare in China and lack sufficient theoretical research.In this paper,a systematic research on the pose planning for the end-effectors of robot in the welding of intersecting pipes is conducted. First,the intersecting curve of pipes is mathematically analyzed.The mathematical model of the most general intersecting curve of pipes is derived,and several special forms of this model in degraded situations are also discussed.A new pose planning approach of bisecting angle in main normal plane（BAMNP） for the welding-gun is proposed by using differential geometry and the comparison with the traditional bisecting angle in axial rotation plane（BAARP） method is also analytically conducted.The optimal pose of the welding-gun is to make the orientation posed at the center of the small space formed by the two cylinders and the intersecting curve to help the welding-pool run smoothly.The BAMNP method can make sure the pose vertical to the curve and center between the two cylinders at the same time,therefore its performance in welding-technique is superior to the BAARP method.By using the traditional BAARP method,the robot structure can become simpler and easier to be controlled,because one degree of freedom（DOF） of the robot can be reduced.For the special case of perpendicular intersecting,an index is constructed to evaluate the quality of welding technique in the process of welding.The effect of different combination of pipe size on this index is also discussed.On the basis of practical consideration,selection principle for BAARP and BAMNP is described.The simulations of those two methods for a serial joint-type robot are made in MATLAB,and the simulation results are consistent to the analysis.The mathematical model and the proposed new pose-planning method will lay a solid foundation for future researches on the control and design of all-position welding robots.

FLEXIBLE MAGNETIC WHEEL TYPE INTELLIGENT WELDING ROBOT FOR SPHERICAL TANK

An intelligent welding robot for spherical tank's all-position multi-layerwelds is developed. Based on the dynamics analyzing and simulation testing, a flexible magneticwheel mechanism is created as the robot's walking carriage. It makes the robot directly attracted tothe surface of the spherical tank so as to realize the all-position walking and welding withoutrail. At the same time, a CCD real-time tracing system is developed for the robot to repeatedlytrace the all-position and multi-layer seams. The welding tests show that the welding robot can makethe all-position and multi-layer welds with high tracing accuracy, excellent quality and reliablebehavior, and it can be applied for practical production.

Discerning Weld Seam Pro les from Strong Arc Background for the Robotic Automated Welding Process via Visual Attention Features

In the robotic welding process with thick steel plates,laser vision sensors are widely used to profile the weld seam to implement automatic seam tracking.The weld seam profile extraction(WSPE)result is a crucial step for identifying the feature points of the extracted profile to guide the welding torch in real time.The visual information processing system may collapse when interference data points in the image survive during the phase of feature point identification,which results in low tracking accuracy and poor welding quality.This paper presents a visual attention featurebased method to extract the weld seam profile(WSP)from the strong arc background using clustering results.First,a binary image is obtained through the preprocessing stage.Second,all data points with a gray value 255 are clustered with the nearest neighborhood clustering algorithm.Third,a strategy is developed to discern one cluster belonging to the WSP from the appointed candidate clusters in each loop,and a scheme is proposed to extract the entire WSP using visual continuity.Compared with the previous methods the proposed method in this paper can extract more useful details of the WSP and has better stability in terms of removing the interference data.Considerable WSPE tests with butt joints and T-joints show the anti-interference ability of the proposed method,which contributes to smoothing the welding process and shows its practical value in robotic automated welding with thick steel plates.

Kinematic Sensitivity Analysis and Dimensional Synthesis of a Redundantly Actuated Parallel Robot for Friction Stir Welding

Friction stir welding(FSW)has been widely applied in many fields as an alternative to traditional fusion welding.Although serial robots can provide the orientation capability required to weld along curved surfaces,they cannot adequately support the huge axial downward forces that FSW generates.Available parallel mechanism architectures,particularly redundantly actuated architectures for FSW,are still very limited.In this paper,a redundantly actuated 2 UPR-2 RPU parallel robot for FSW is proposed,where U denotes a universal joint,R denotes a revolute joint and P denotes a prismatic pair.First,its semi-symmetric structure is described.Next,inverse kinematics analysis involving an analytical representation of rotational axes is implemented.Velocity analysis is also conducted,which leads to the formation of a Jacobian matrix.Sensitivity performance is evaluated utilizing level set and convex optimization methods,where the local sensitivity indices are unit consistent,coordinate free,and of definite physical significance.Furthermore,global and hierarchical sensitivity indices are proposed for the design process.Finally,dimension synthesis is conducted based on the sensitivity indices and the optimal link parameters of the parallel robot are obtained.In summary,this paper proposes a dimensional synthesis method for a redundantly actuated parallel robot for FSW based on sensitivity indices.

Constant Speed Control for Complex Cross-section Welding Using Robot Based on Angle Self-Test

Expandable profile liner（EPL） is a promising new oil well casing cementing technique, and welding is a major EPLs connection technology. Connection of EPL is still in the stage of manual welding so far, automatic welding technology is a hotspot of EPL which is one of the key technologies to be solved. A robot for automatic welding of＂8＂ type EPL is studied. Four quadrants of mathematical equations of the 8-shaped cross-section track of EPL, consisting of multiple arcs, are established. Mechanism program for complex cross-section welding of EPL based on angle detection is proposed according to characteristics of small size, small valleys, and large forming errors, etc. A welding velocity vector control model is established by linkage control of a welding vehicle, a small driven actuator, and a height tracking mechanism. A constant speed control model based on an angle and symmetrical analysis model of rectangular coordinate system for EPL is built. Constraint conditions of constant speed control between each section are analyzed with 4 sections in first quadrant as an example, and cooperation work mechanism of the welding vehicle and the small tracking actuator is established based on pressure detection. The constant speed control model using angle self-test can be used to avoid the need for a precise mathematical model for tracking control and to adapt manufacture and installation deviation of EPL workpiece. The model is able to solve constant speed and trajectory tracking problems of EPL cross-section welding. EPL seams welded by the studied robot are good in appearance, and non-destructive testing（NDT） shows the seams are good in quality with no welding defects. Bulge tests show that the maximum pressure of welded EPL is 35 MPa, which can fulfill expansion performance requirements.

Seam Tracking and Visual Control for Robotic Arc Welding Based on Structured Light Stereovision

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.

ALGORITHM AND IMPLEMENTATION OF AUTO-SEARCHING WELD LINE FOR WELDING MOBILE ROBOT

An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove before welding, and then adjust itself posture to the desired status preparing for welding, namely, it is a process that the robot autonomously aligns itself to the center of welding seam. Firstly, the configuration of welding mobile robot with the function of auto-searching weld line is introduced, then the algorithm and implementation of auto-searching weld line are presented on the basis of kinematics model of the robot, at last trajectory planning among auto-searching weld line is investigated in detail. The experiment result shows that the developed welding mobile robot can successfully implement the task of auto-searching weld line before welding, tracking error precision can be controlled to approximate ±1.5 mm, and satisfy the requirement of practical welding project.

Control algorithm based on trajectory and orientation of oblique intersection line welding-cutting robot

Working principle for a four-axis oblique intersection line welding robot is analyzed. A mathematical model for welding torch orientation angle is established, and an interpolation algorithm based on time division is proposed. The algorithm makes all interpolation points fall on a required curve in theory with no accumulated errors and a direct interpolation control on the saddle-shaped curve trajectory and space orientation angle can be achieved. It is shown by MATLAB simulation that the algorithm is real-time and fully meets the precision requirement. The algorithm has been applied to real robots.

3D reconstruction of worn parts for flexible remanufacture based on robotic arc welding

3D reconstruction of worn parts is the foundation for remanufacturing system based on robotic arc welding, because it can provide 3D geometric information for robot task plan. In this investigation, a novel 3D reconstruction system based on linear structured light vision sensing is developed. This system hardware consists of a MTC368-CB CCD camera, a MLH-645 laser projector and a DH-CG300 image grabbing card. This system software is developed to control the image data capture. In order to reconstruct the 3D geometric information from the captured image, a two steps rapid calibration algorithm is proposed. The 3D reconstruction experiment shows a satisfactory result.

Guiding the welding robot to the initial welding position with visual method

Using step pattern match technology with variational resolution can recognize the position and orientation of the weld seam in the image. According to using the image segmentation method based on pattern match, not only advanced the speed and anti-jamming capability, but also captured the edge information of the weld seam and the edge of the workpiece, and the image coordinate of the initial welding position can be obtained. The matrix for hand-eye relationship of the robot can be calculated by adopting the rapid calculation method. According to the depth calculating principle with the special point matching using binocular stereovision, the initial welding position can be confirmed by calculating the middle point of the perpendicular line of two radials in the space, and the function to guide the welding robot to the initial welding position can be realized.

Seam-tracking based on dynamic trajectory planning for a mobile welding robot

A new seam-tracking method based on dynamic trajectory planning for a mobile welding robot is proposed in order to improve the response lag of the mobile robot and the high frequency oscillation in seam-tracking.By using a front-placed laser-based vision sensor to dynamically extract the location of the weld seam in front of torch,the trend and direction of the weld line is roughly obtained.The robot system autonomously and dynamically performs trajectory planning based on the isometric approximation model.Arc sensor technology is applied to detect the offset during welding process in real time.The dynamic compensation of the weld path is done in combination with the control of the mobile robot and the executive body installed on it.Simulated and experimental results demonstrate that the method effectively increases the stability of welding speed and smoothness of the weld track,and hence the weld formation in curves and corners is improved.

Study on general inverse kinematics of rotating/tilting positioner for robotic arc welding off-line programming

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.

Vision Sensing-Based Online Correction System for Robotic Weld Grinding

The service cycle and dynamic performance of structural parts are afected by the weld grinding accuracy and surface consistency. Because of reasons such as assembly errors and thermal deformation, the actual track of the robot does not coincide with the theoretical track when the weld is ground ofine, resulting in poor workpiece surface quality. Considering these problems, in this study, a vision sensing-based online correction system for robotic weld grinding was developed. The system mainly included three subsystems: weld feature extraction, grinding, and robot real-time control. The grinding equipment was frst set as a substation for the robot using the WorkVisual software. The input/output (I/O) ports for communication between the robot and the grinding equipment were confgured via the I/O mapping function to enable the robot to control the grinding equipment (start, stop, and speed control). Subsequently, the Ethernet KRL software package was used to write the data interaction structure to realize realtime communication between the robot and the laser vision system. To correct the measurement error caused by the bending deformation of the workpiece, we established a surface profle model of the base material in the weld area using a polynomial ftting algorithm to compensate for the measurement data. The corrected extracted weld width and height errors were reduced by 2.01% and 9.3%, respectively. Online weld seam extraction and correction experiments verifed the efectiveness of the system’s correction function, and the system could control the grinding trajectory error within 0.2 mm. The reliability of the system was verifed through actual weld grinding experiments. The roughness, Ra, could reach 0.504 µm and the average residual height was within 0.21 mm. In this study, we developed a vision sensing-based online correction system for robotic weld grinding with a good correction efect and high robustness.

Study on motion simulation of arc welding robot based on UG

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.

Seam tracking control for mobile welding robot based on vision sensor

To solve the seam tracking problem of mobile welding robot,a new controller based on the dynamics of mobile welding robot was designed using the method of backstepping kinematics into dynamics.A self-turning fuzzy controller and a fuzzy-Gaussian neural network(FGNN) controller were designed to complete coordinately controlling of cross-slider and wheels.The fuzzy-neural control algorithm was described by applying the Gaussian function and back propagation(BP) learning rule was used to tune the membership function in real time by applying the FGNN controller.To make the tracking more quickly and smoothly,the neural network controller based on dynamic model was designed,which utilized self-learning and self-adaptive ability of the neural network to deal with the partial uncertainty and the disturbances of the parameters of the robot dynamic model and real-time compensate the dynamics coupling.The results show that the selected control input torques make the system globally and asymptotically stable based on the Lyapunov function selected out;the accuracy of the proposed controller tracing is within ±0.4 mm and can satisfy the requirements of practical welding project.

Dynamic modeling and simulation for nonholonomic welding mobile robot

Based on the Newton-Euler method, the dynamic behaviors of the left and right driving wheels and the robot body for the welding mobile robot were derived. In order to realize the combination control of body turning and slider adjustment, the dynamic behaviors of sliders were also investigated. As a result, a systematic and complete dynamic model for the welding mobile robot was constructed. In order to verify the effectiveness of the above model, a sliding mode tracking control method was proposed and simulated, the lateral error stabilizes between -0.2 mm and ＋0.2 mm, and the total distance of travel for the slider is consistently within 4-2 ram. The simulation results verify the effectiveness of the established dynamic model and also show that the seam tracking controller based on the dynamic model has excellent performance in terms of stability and robustness. Furthermore, the model is found to be very suitable for practical applications of the welding mobile robot.

Inverse kinematics and welding experiments of the intersecting pipe welding robot

A robot used for multi-pass welding of the piping branch junctions and nozzle attachments to main pressure vessels is 4-DOF serial mechanism, two mobile joints and two rotary joints are adopted in design. The kinematic model was established with DH parameters, the inverse kinematics was solved. According to the forward and inverse kinematics equations, the robot kinematics was simulated in Matlab, the simulations indicate that the solution for inverse kinematics can satisfy the welding requirements well. As there are size errors, processing errors and welding deformation, the path of welding is forecasted according to the previous welding situation, and then, the path is taught at desired via-points, which plays an important role in submerged-arc welding. The submerged-arc welding experiments indicate that the robot and the welding methods are preferable to ensure welding quality.

Dynamic and control system analysis of two-wheeled robot for welding application

Aiming at the welding condition of space complex seam is uncertain and the intelligence of welding robot is unideal, a two-wheeled mobile robot is developed. It not only has the capacity of autonomous decision and avoiding obstacles, but also can flexibly move and strongly adapt variable environment. The composition of the welding robot is described and the dynamic model is established. The feasible control strategy and control algorithm is put forward. The simulation experiments of real world are conducted, the results are satisfying.

Planning of circlelocus for multi-path/multi-layer welding robot with automatical error-correction

In this paper, a planning algorithm for multi path/multi layer circular locus is poposed. The algorithm is applied to weld the nipples on the header of boiler. Multi path/multi layer circular locus is planned according to three teaching points, which is lapped head on end to satisfy the requirement of technology. For the nipples wherever they are arranged radially or axially, even if there are errors caused by positioning and thermal deformations, providing that nipple's position and orientation relative to the teaching one can be measured, the multi path/multi layer circular locus can be planned without teaching any more. The algorithm has been applied in welding robot for manufacturing power station' boiler.

An approach to measure the pose of RHJD4-1 arc welding robot for calibration

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.