Hybrid offline programming method for robotic welding systems
•Current automatic programming approaches for robotic manufacturing systems have been reviewed.•A hybrid offline programming method that combines CAD-based and vision-based offline approaches is proposed.•The vision-based and CAD-based activities of the proposed programming method with the support t...
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| Published in: | Robotics and computer-integrated manufacturing Vol. 73; p. 102238 |
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| Main Authors: | , , , , , , |
| Format: | Journal Article |
| Language: | English |
| Published: |
Oxford
Elsevier Ltd
01.02.2022
Elsevier BV Elsevier |
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| ISSN: | 0736-5845, 1879-2537 |
| Online Access: | Get full text |
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| Abstract | •Current automatic programming approaches for robotic manufacturing systems have been reviewed.•A hybrid offline programming method that combines CAD-based and vision-based offline approaches is proposed.•The vision-based and CAD-based activities of the proposed programming method with the support techniques are presented.•Vision & CAD interactive activities are proposed to identify the workplace, detect the deviation, and compensated the path.
Offline programming is an intuitive and automatic programming generation technique that does not use real robotic systems, thus greatly decreasing the downtime required for system programming, and resulting in enormous savings in terms of labor costs. Currently, offline programming can be generally categorized into computer-aided-design-based (CAD-based) and vision-based approaches; these two types of offline programming approaches have been widely applied in robotic welding systems. However, owing to the highly complex and diverse workpieces needed in the shipbuilding industry, neither of the aforementioned offline programming approaches can fully support the automatic generation of welding programs.
In this paper, a hybrid offline programming method systematically combining CAD-based, vision-based, and vision & CAD interactive activities is proposed to overcome the limitations of current automatic program generation methods for robotic welding systems. In the vision-based activities, the positions of the workpieces are obtained by using geometrical features gathered from the workpieces’ images, whereas in the CAD-based activities, the welding tasks are assigned to different mobile components of the welding torch; then, their welding paths are planned according to the workpieces’ CAD models. The vision & CAD interactive activities enable the mapping between the point cloud of a workpiece and its CAD model, so that the deviations caused by assembly errors can be detected and path compensation data can be determined. The effectiveness of the proposed hybrid offline programming method is demonstrated by integrating it into a subassembly welding robotic system. The experimental results indicate that this method can significantly improve the efficiency, accuracy, and flexibility of the robotic welding system. |
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| AbstractList | •Current automatic programming approaches for robotic manufacturing systems have been reviewed.•A hybrid offline programming method that combines CAD-based and vision-based offline approaches is proposed.•The vision-based and CAD-based activities of the proposed programming method with the support techniques are presented.•Vision & CAD interactive activities are proposed to identify the workplace, detect the deviation, and compensated the path.
Offline programming is an intuitive and automatic programming generation technique that does not use real robotic systems, thus greatly decreasing the downtime required for system programming, and resulting in enormous savings in terms of labor costs. Currently, offline programming can be generally categorized into computer-aided-design-based (CAD-based) and vision-based approaches; these two types of offline programming approaches have been widely applied in robotic welding systems. However, owing to the highly complex and diverse workpieces needed in the shipbuilding industry, neither of the aforementioned offline programming approaches can fully support the automatic generation of welding programs.
In this paper, a hybrid offline programming method systematically combining CAD-based, vision-based, and vision & CAD interactive activities is proposed to overcome the limitations of current automatic program generation methods for robotic welding systems. In the vision-based activities, the positions of the workpieces are obtained by using geometrical features gathered from the workpieces’ images, whereas in the CAD-based activities, the welding tasks are assigned to different mobile components of the welding torch; then, their welding paths are planned according to the workpieces’ CAD models. The vision & CAD interactive activities enable the mapping between the point cloud of a workpiece and its CAD model, so that the deviations caused by assembly errors can be detected and path compensation data can be determined. The effectiveness of the proposed hybrid offline programming method is demonstrated by integrating it into a subassembly welding robotic system. The experimental results indicate that this method can significantly improve the efficiency, accuracy, and flexibility of the robotic welding system. Offline programming is an intuitive and automatic programming generation technique that does not use real robotic systems, thus greatly decreasing the downtime required for system programming, and resulting in enormous savings in terms of labor costs. Currently, offline programming can be generally categorized into computer-aided-design-based (CAD-based) and vision-based approaches; these two types of offline programming approaches have been widely applied in robotic welding systems. However, owing to the highly complex and diverse workpieces needed in the shipbuilding industry, neither of the aforementioned offline programming approaches can fully support the automatic generation of welding programs. In this paper, a hybrid offline programming method systematically combining CAD-based, vision-based, and vision & CAD interactive activities is proposed to overcome the limitations of current automatic program generation methods for robotic welding systems. In the vision-based activities, the positions of the workpieces are obtained by using geometrical features gathered from the workpieces’ images, whereas in the CAD-based activities, the welding tasks are assigned to different mobile components of the welding torch; then, their welding paths are planned according to the workpieces’ CAD models. The vision & CAD interactive activities enable the mapping between the point cloud of a workpiece and its CAD model, so that the deviations caused by assembly errors can be detected and path compensation data can be determined. The effectiveness of the proposed hybrid offline programming method is demonstrated by integrating it into a subassembly welding robotic system. The experimental results indicate that this method can significantly improve the efficiency, accuracy, and flexibility of the robotic welding system. |
| ArticleNumber | 102238 |
| Author | Zheng, Chen Qin, Xiansheng Wang, Zhanxi An, Yushu Eynard, Benoît Zhang, Yicha Wu, Haoyu |
| Author_xml | – sequence: 1 givenname: Chen surname: Zheng fullname: Zheng, Chen email: chen.zheng@nwpu.edu.cn organization: School of Mechanical Engineering, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an Shaanxi, 710072, PR China – sequence: 2 givenname: Yushu surname: An fullname: An, Yushu organization: School of Mechanical Engineering, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an Shaanxi, 710072, PR China – sequence: 3 givenname: Zhanxi surname: Wang fullname: Wang, Zhanxi organization: School of Mechanical Engineering, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an Shaanxi, 710072, PR China – sequence: 4 givenname: Haoyu surname: Wu fullname: Wu, Haoyu organization: School of Mechanical Engineering, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an Shaanxi, 710072, PR China – sequence: 5 givenname: Xiansheng surname: Qin fullname: Qin, Xiansheng organization: School of Mechanical Engineering, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an Shaanxi, 710072, PR China – sequence: 6 givenname: Benoît surname: Eynard fullname: Eynard, Benoît organization: Department of Mechanical Systems Engineering, Sorbonne Universités, Université de Technologie de Compiègne, Roberval Laboratory - UMR CNRS 7337, CS 60319, 60203 Compiègne Cedex, France – sequence: 7 givenname: Yicha surname: Zhang fullname: Zhang, Yicha organization: Mechanical Engineering and Design Department, Université de Bourgogne Franche-Comté, Université de Technologie de Belfort-Montbéliard, ICB UMR CNRS 6303, 90010 Belfort Cedex, France |
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| Keywords | Geometrical feature Robotic welding systems Offline programming CAD-based programming Vision-based programming |
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| Snippet | •Current automatic programming approaches for robotic manufacturing systems have been reviewed.•A hybrid offline programming method that combines CAD-based and... Offline programming is an intuitive and automatic programming generation technique that does not use real robotic systems, thus greatly decreasing the downtime... |
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| SubjectTerms | Automatic welding CAD CAD-based programming Computer aided design Downtime Engineering Sciences Geometrical feature Mechanical engineering Mechanics Offline programming Physics Programming Robotic welding systems Robotics Shipbuilding Vision Vision-based programming Welding Workpieces |
| Title | Hybrid offline programming method for robotic welding systems |
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