Design and experiment verification of a new heavy friction-stir-weld robot for large-scale complex surface structures

Abstract

Purpose

This paper aims to present a new friction-stir-weld robot for large-scale complex surface structures, which has high stiffness and good flexibility.

Design/methodology/approach

The robot system is designed according to manufacturability of large aluminum products in aeronautic and astronautic area. The kinematic model of the robot is established, and a welding trajectory planning method is also developed and verified by experiments.

Findings

Experimental results show that the robot system can meet the requirements of friction stir welding (FSW) for large-scale complex surface structures.

Practical implications

Compared with other heavy robotic arm and machine tool welding devices, this robot has better working quality and capability, which can greatly improve the manufacturability for large-scale complex surface structures.

Originality/value

The friction-stir-weld robot system is a novel solution for welding large-scale complex surface structures. Its major advantages are the high stiffness, good flexibility and high precision of the robot body, which can meet the requirements of FSW. Besides, a welding trajectory planning method based on iterative closest point (ICP) algorithm is used for welding trajectory.

Citation

Wu, J., Zhang, R. and Yang, G. (2015), "Design and experiment verification of a new heavy friction-stir-weld robot for large-scale complex surface structures", Industrial Robot, Vol. 42 No. 4, pp. 332-338. https://doi.org/10.1108/IR-01-2015-0009