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Since the first industrial robots were introduced in the early 1960s, the development of robotized welding has been truly remarkable and is today one of the major application areas for industrial robots. Robot welding is mainly concerned with the use of mechanized programmable tools, known as robots, which completely automate a welding process by b...
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... under the resistance welding, spot welding acts by generating heats with use of a high current, approximately about 1000A -100,000 A. The welding guns are the main part of the welding. It comes with 2 different kinds but the important is these guns do similar function as to make a close loop circuit, connecting the power supply to the weld spot ( Figure 6). ...
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The joining of two of any particular materials through friction stir welding (FSW) are done by a rotating tool and the work piece material that generates heat which causes the region near the FSW tool to soften. This in return will mechanically intermix the work pieces. The first objective of this study is to join aluminum plates and copper plates...
This study proposes improved welding tools for magnesium alloys. Two types of tools were used for friction stir welding (FSW). The effect of the welding tools on the FSW joints was investigated with a fixed welding speed of 200mm/min and various rotation speeds of 400 to 800 rpm. After FSW, the joints were cross-sectioned perpendicular to the weldi...
The aim of the project is to manufacture a welding machine which simplifies the work and improve the accuracy. The working principle of this machine is different other that of other welding machine. The aluminum work piece is held in the vice. The two pieces of aluminum work piece is welded with the help high speed drilling head with friction tool....
This review is on the various techniques and methodologies applied to sensor based monitoring of the quality and control of defects in an advanced joining process named friction stir welding (FSW). This study is aimed to come up with Industry 4.0 automation of the same, which will help in exchanging data efficiently for a sustainable growth in the...
This article focuses on fatigue life assessment of dissimilar lap-joined polymers. The strength of the friction stir welded polypropylene-to-polyethylene specimens under cyclic loading conditions was analysed. The fatigue life of the strongest welds was compared to both the parent material and blind riveting method with single and double-riveted sp...
Citations
... Another significant innovation in welding education is the use of robotic automation. Robotic welding systems are becoming increasingly common in industrial settings due to their efficiency and precision (Hong et al., 2014). Welding education has adapted to include training on robotic systems, preparing students for the automation-driven demands of modern manufacturing industries. ...
... Spot welding robots are used to join metal sheets efficiently with welding guns, connecting the power supply to the welding points. RSW robots work by generating heat between 1,000Amp to 100,000Amp [19]. Excessive heat, however, causes weld spatter that may cause defective welds, and damage surrounding equipment or sheet surfaces, requiring costly repairs. ...
Robotized welding processes in the manufacturing industry play a crucial role in enhancing competitiveness through automation, adaptability, and increased productivity. To optimize welding parameters, modeling approaches have gained significance, enabling users to simulate welding experiments and determine appropriate settings. With the growing need for reduced development phases and costs while maintaining quality standards and production volumes, flexible and robust manufacturing technologies are essential. In this paper, we present a literature review highlighting best practices for welding processes. We address five research questions related to welding techniques, planning models, factors affecting welding processes, and performance indicators. Our findings reveal various models and techniques for planning robot operations, focusing on welding robots. By this review, we contribute to the development of effective strategies for optimizing robotized welding processes, leading to improved efficiency in manufacturing systems.
... The development of robotized welding, which is now one of the main applications for industrial robots, has been truly remarkable since the introduction of the first industrial robots in the early 1960s. Robot welding is mainly concerned with the use of mechanized programmable tools, known as robots, which completely automate a welding process by both performing the weld and handling the part [7]. For the reason that they are so adaptable, robots have been used for resistance and arc welding among other types of welding. ...
Industrial robots play a pivotal role in modern industrial production, with robotic welding standing out as a crucial application. This paper analyzes the utilization of online and offline programming methods to optimize robotic welding processes, with an application of Gas Metal Arc Welding (GMAW) techniques. GMAW offers excep-tional versatility, including adaptability to various plate thicknesses, high productivity rates, compatibility with diverse materials, and the ability to weld coated metals. The synchronization of robotic movements and positioners plays a crucial role in ensuring precise welding execution. This complexity is particularly evident in scenarios involving weld-ing complex curves, where coordinated movement between the robotic arm and positioner is essential for successful outcomes. In this study, an experiment involving the welding of a pipe-pipe joint using a robot with 6 and positioner with 2 degree of freedom is presented. By applying synchronized movement, seamless welding operations are achieved, highlighting the importance of advanced programming techniques and synchronized operations in enhancing the effi-ciency and precision of robotic welding in industrial production.
... To attain manufacturing competitiveness, high productivity, low cost, and superior quality, automated and robotic welding is widely employed in the manufacturing sector [1]. On the other hand, manual teaching pendant programming is still often used for industrial welding robot task planning, which can be time-consuming, especially when dealing with large-scale welding joints or seams [2]. Intelligent robotic welding systems are developed to accomplish desired welding results due to their flexibility, efficiency, and precision. ...
This paper assesses the efficacy of intelligent path planning for welding robots utilizing splines. Traditional path planning methods can result in inefficient and inaccurate welding operations. The study reviews current research and case studies to appraise the practical application of spline-based path planning across diverse industrial scenarios. It underscores the benefits of discovering the shortest path and reducing cycle time while acknowledging challenges such as calibration accuracy and sensitivity to sensor data noise. The introduction of artificial intelligence algorithms in automobile welding path planning enables a more precise replication of the body's design curve, ensuring the continuity and smoothness of the welding process. This, in turn, fosters further automation and optimization of the automotive welding manufacturing process. The current research concentrates on integrating intelligent optimization algorithms and spline curves to provide an efficient and intelligent method for welding path planning. Intelligent path planning based on spline curves demonstrates significant potential in enhancing welding efficiency, determining the shortest path, and holds promising applications in the broader research field of welding path planning.
... In recent years, several welding robots have been proposed to improve the automation level of ship welding [15][16][17]. A plasma welded spider robot automatic transfer system for membrane corrugated plates of LNG Carrier (LNGC) was proposed [18]. ...
Liquefied natural gas (LNG) is commonly transported by LNG carriers and stored in cargo containment systems. The primary barrier of the MARK III cargo containment system is welded to a closed space with corrugated stainless steel plates. To meet the requirements of excellent sealing and thermal insulation for cargo containment, the welding process of the corrugated plate need to be strictly controlled, which poses a challenge to the development of related welding equipment. In this paper, we present a new five-axis automatic welding robot system used for plasma arc welding on corrugated surfaces. The moment transfer scheme of the dual linkage mechanism makes the rotary movement of the robot more accurate and stable which gives the system with simpler control algorithm and better overall force characteristics. To ensure tracking accuracy, a novel sensing method based on a LASER sensor, two contact sensors, and an angle sensor is proposed to implement multiple functions such as tracking the welding arc length, identifying corrugation shapes, and detecting welding gun posture. Based on the devised tracking sensor system and welding robot, a servo-control system with a surface-tracking welding control algorithm is established. The experimental results show that the robot system's welding speed is about 7 times that of hand welding and the welding qualification rate was 99%, significantly improving welding efficiency and quality as a critical equipment technology in the process of corrugated plate welding.
... Smart welding is the use of computers to mimic, enhance, and/or replace human operators in sensing, learning, decision-making, monitoring, and control [37,38]. Typical applications will include welding design, robot path planning, robot programming, process monitoring and diagnostics, forecasting, process control, quality inspection, and more [39][40][41]. These systems can intelligently adapt to changing welding tasks while maintaining high quality [42]. ...
... Some applications the robot in industry (e.g. Food manufacturing [1], Painting Applications [2], Welding Technology [3], lifting a heavy box [4], drilling Applications [5], assembly task [6]). Some application of the robot in agriculture (e.g. ...
... Welding technologies play an extremely important role in manufacturing processes in all industrial fields. The increase in productivity as well as the quality of products must consider the possibilities of mechanization/automation/robotization of industrial manufacturing processes [1][2][3][4]. Industry 4.0 (Fourth Industrial Revolution) offers the possibility of interconnecting computers, applications and industrial equipment with the aim of collecting data in order to analyze them and improve technological processes, thus becoming faster, more transparent at a high-quality standard. ...
The manufacturing of welded structures plays an important role in industrial processes. The new requirements related to the quality of the products and the productivity of the technological processes have led to the analysis of the possibility of implementing robotic processes. The use of mechanized/automatic/robotic production systems offer a more accurate control of the production process quality, but also the possibility of real-time monitoring and modification of process parameters with the aim of keeping the production process within functional limits. The industrial revolution offers the possibility of interconnecting industrial equipment used to monitor, analyze and improve production processes. The present paper analyses the possibility of implementing robotic welding in automotive industry. To weld the STEP E P 40 longeron, manufactured from S355J2H base material, using GMAW (Gas Metal Arc Welding) robotic welding, it was necessary to establish the welding technology as well as design, calibrate and validate the orientation and fixing devices. The design of the welding devices was based on the geometric and dimensional characteristics and considered the dimensional deviations of the assembly as well as the number of component parts of the longeron. The prototype of the device was used was used to fix the longeron during welding with the aim of validating it. After completing the welding, the longeron was subjected to the dimensional control process with the help of a measuring arms with four wavelengths of labor and six-axis. The characteristic dimensions of the longeron were measured in accordance with the quality requirements of the beneficiary. As a result of the measurements and analysis of the obtained results, it was found that a series of nominal dimensions do not respect the dimensional tolerances imposed by the designer. Considering the dimensional deviations, the orientation and fixation device was modified in terms of introducing new modular fixation elements and adjusting the dimensions of the seating elements. After modifying the device, the welding and dimensional control of another longeron was carried out. Analyzing the values obtained from the measurements, resulted that the dimensions fall within the dimensional deviations imposed by the designer and meet the quality requirements of the beneficiary. As a result of the values obtained, it was decided to validate the device and use it within the newly implemented robotic cell.
... Hong et al. [27] stated that welding robots require major improvements to suit modern applications' different needs. For best performance, these robots should be able to seamlessly integrate with their surroundings and mix existing knowledge with newly obtained information. ...
From its early beginnings to its current state, welding has played a vital role in manufacturing industries and has experienced significant advancement with time. Recently, the advancement and integration of robotics and digital technologies under Industry 4.0 (I4.0) transformed welding, improving quality, productivity, and safety. However, the welding Industry has already started the adoption of I4.0. Only a small percentage of industries found themselves fully prepared for its adoption due to the complexities associated with the welding industry. The paper attempts to identify and analyse the Welding 4.0 (W4.0) implementation barriers by Total Interpretive Structural Modelling (TISM) and MICMAC. The result suggests that for W4.0 implementation, barriers like complex programming, adaptability of present equipment, and intelligent decision-making are the driving barriers leading to overcoming other low-level barriers like resistance to change. The article also proposed few further research areas.
... Puma stands for "Programmable Universal Machine for Assembly". The Puma 560 was designed to perform repetitive industrial tasks such as assembly, material handling, welding, and polishing [1][2][3][4]. The Puma 560 is a six-axis robot that uses electric actuators to rotate each joint. ...
The objective of this article is to present the implementation of a backstepping control regulator on a Xilinx Zedboard Zynq FPGA using the HDL Coder tool through the FPGA in‐the‐loop option, and to study its effectiveness when applied to a three‐dimensional robotic manipulator model. The analysis is based on the application of the backstepping control law for the three degrees of freedom PUMA 560 model, through the development of a dynamic simulation model. The results of practical implementation using the FPGA in the loop technique demonstrate the effectiveness of the proposed method using the Xilinx Zedboard Zynq FPGA, which provides a useful insight into the benefits of using backstepping control laws in robotics applications.
