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The purpose of this paper is to design the localization and tracking algorithms for our mobile welding robot to carry out the large steel structure welding operations in industrial environment.

Extended Kalman filter, considering the bicycle-modeled robot, is adopted in the localization algorithm. The position and orientation of our mobile welding robot is estimated using the feedback of the laser sensor and the robot motion commands history. A backstepping variable is involved in the tracking algorithm. By introducing a specifically selected Lyapunov function, we proved the tracking algorithm using Barbalat Lemma, which leads the errors of estimated robot states to converge to zero.

The experiments show that the proposed localization method is fast and accurate and the tracking algorithm is robust to track straight lines, circles and other typical industrial curve shapes. The proposed localization and tracking algorithm could be used, but not limited to the mobile welding.

Localization problem which is neglected in previous research is very important in mobile welding. The proposed localization algorithm could estimate the robot states timely and accurately, and no additional sensors are needed. Furthermore, using the estimated robot states, we proposed and proved a tracking algorithm for bicycle-modeled mobile robots which could be used in welding as well as other industrial operation scenarios.

This paper aims to present a new intelligent wall-climbing welding robot system for large-scale steel structure manufacture, which is composed of robot body, control system and welding system.

The authors design the robot system according to application requirements, validate the design through simulation and experiments and use the robot in actual production.

Experimental results show that the robot system satisfies the demands of automatic welding of large-scale ferromagnetic structure, which contributes much to on-site manufacturing of such structures.

The robot can work with better quality and efficiency compared with manual welding and other semi-automatic welding devices, which can much improve large-scale steel structure manufacturing.

The robot system is a novel solution for large-scale steel structures welding. There are three major advantages: the robot body with reliable adsorption ability, large payload capability and good mobility which meet the requirements of welding; the control system with good welding seam tracking accuracy and intelligent automatic welding ability; and friendly human – computer interface which makes the robot easy to use.

The purpose of this paper is to discuss motion planning about crossing obstacles and welding trajectory for a new-model mobile obstacle-crossing welding robot system. The robot can cross the obstacle in this way that one of the three adhesion mobile parts is pulled off the ground in turn. An optimal obstacle-crossing approach needs to be studied to improve the welding efficiency.

According to the characteristics of this mobile welding robot, two methods for crossing obstacles are compared. A special method is used for obstacle-crossing and welding. The kinematic model is established. By the optimization method, the optimum parameters for crossing obstacles are calculated. The welding speed when the robot is crossing the obstacle is very important, so its value must be in a certain range. Finally, the tracks of the wheels when the robot is crossing the obstacle are analyzed in order to observe the obstacle-crossing process.

According to the analysis, the maximum speed of the vehicle in the obstacle-crossing is determined. When crossing the obstacle, the robot can do welding simultaneously. The welding speed cannot exceed a certain value. In the obstacle-crossing process, the tracks of the wheels can reflect the process. According to the obtained conclusion, the obstacle-crossing experiments are successfully completed, and the welding effect is good. The results can prove that the proposed method is feasible.

The speed of obstacle-crossing is not very large. It has some relationships with the lifting speed of the wheels, which is determined by the quality of drive motor. More efficient robot must be developed to meet the needs of industrial robot.

Based on the excellent obstacle-crossing and welding capabilities, the robot with the new mechanism has a widely applying prospect in the field of welding and inspecting large equipment.

The obstacle-crossing approach has certain innovation. The way that the robot can maintain continuous welding when crossing the obstacle is of a great significance.

Development and demonstration of an autonomous, mobile welding robot capable of fabricating large‐scale customised structures.

An autonomous welding robot has been developed under the EC Framework V Growth program. The system comprises a global vision system for part location and orientation, and a robot transport vehicle (RTV) which carries a 6‐axis robot, robot controller, welding equipment, and local sensors at the welding torch. The RTV path, robot arm motion and weld process programming are performed automatically using sensors and specially customised simulation software.

The technology developed within the project was demonstrated, in November 2004, to be capable of identifying and welding large scale customised structures as found in the earth moving equipment and bridge fabrication industries.

The project demonstrated that current sensor technology is capable of being applied successfully to autonomous robots, but further developments in sensor technology are required to improve accuracy and joint access.

The NOMAD concept of autonomous mobile robots provides an alternative solution to welding mass customised structures.

This project demonstrated, for the first time, the capability of autonomous robots to weld large scale customised structures.

The purpose of this study is to address the welding demands within large steel structures by presenting a global spatial motion planning algorithm for a mobile manipulator. This algorithm is based on an independently developed wall-climbing robot, which comprises a four-wheeled climbing mobile platform and a six-degree-of-freedom robotic manipulator, ensuring high mobility and operational flexibility.

A convex hull feasible domain constraint is developed for motion planning in the mobile manipulator. For extensive spatial movements, connected sequences of convex polyhedra are established between the composite robot’s initial and target states. The composite robot’s path and obstacle avoidance optimization problem are solved by constraining the control points on B-spline curves. A dynamic spatial constraint rapidlye-xploring random trees-connect (RRTC) motion planning algorithm is proposed for the manipulator, which quickly generates reference paths using spherical spatial constraints at the manipulator’s end, eliminating the need for complex nonconvex constraint modeling.

Experimental results show that the proposed motion planning algorithm achieves optimal paths that meet task constraints, significantly reducing computation times in task conditions and shortening operation times in non-task conditions.

The algorithm proposed in this paper holds certain application value for the realization of automated welding operations within large steel structures using mobile manipulator.

The purpose of this paper is to introduce structured light image processing technology into pipeline welding automation projects, and develop a vision‐based pipeline girth‐welding robot. The welding torch can accurately track the weld and complete the omni‐orientation welding automatically.

Weld image processing adopts the base theory including Laplacian of Gaussian filter, neighbourhood mean filter, largest variance threshold segmentation and morphologic, etc. obtains good effect of weld recognition.

The paper uses a vision sensor to achieve the weld character's recognition and extraction, directly control the robot tracking weld to complete automation welding. Compared with the existing pipeline welding devices, it does not need the lay orbit or plot tracking mark, which can shorten the assistant time to improve the productivity.

The research findings can satisfy the need of whole‐directional automation welding for large diameter transportation pipe's circular abutting weld. It fits for the automation welding for the long‐distance transportation pipe of petroleum, natural gas, and water.

Aiming at the character recognition and extract of V‐type weld, the method combining the neighbourhood mean filter algorithm with the largest variance threshold segmentation is proposed to obtain the quick weld image processing speed.

This study aims to improve the welding quality and efficiency, and an algorithm should be designed to realize tracking space-curved fillet weld joints.

Fillet weld joints tracking based on the two wheels and the horizontal slider coordinated movement has been studied. The method of pattern recognition is used to identify the height deviation, and the analysis of the accuracy corresponding to recognizing height deviations has been researched. The proportional control algorithm is used to control the vertical and horizontal sliders movement, so fillet weld joints tracking in the height direction has been achieved. Based on wheels and vertical and horizontal sliders coordinated movement, the algorithm of space-curved fillet weld joints tracking has been researched.

Some experiments have been done, and experimental results show that the welding robot can track space-curved fillet weld joints with high accuracy and good reliability.

The welding robot can improve the welding quality and efficiency.

The welding robot can track fillet weld joints in ship panels, and it was shown that the welding robot could track space-curved fillet weld joints with high accuracy and good reliability.

The welding robot has many industrial and social applications.

There are various forms of fillet weld joints in the industry, and the fillet weld is curved in the space. Experimental results show that the welding robot can track space-curved fillet weld joints with good stability and high precision.

The purpose of this paper is to establish a maturity evaluation model for the application of construction steel structure welding robotics suitable for the actual situation and specific characteristics of engineering projects in China and then to assess the maturity level of the technology in the application of domestic engineering projects more scientifically.

The research follows a qualitative and quantitative analysis method. In the first stage, the structure of the maturity model is constructed and the evaluation index system is designed by using the ideas of the capability maturity model and WSR methodology for reference. In the second stage, the design of the evaluation process and the selection of evaluation methods (analytic hierarchy process method, multi-level gray comprehensive evaluation method). In the third stage, the data are collected and organized (preparation of questionnaires, distribution of questionnaires, questionnaire collection). In the fourth stage, the established maturity evaluation model is used to analyze the data.

The evaluation model established by using multi-level gray theory can effectively transform various complex indicators into an intuitive maturity level or score status. The conclusion shows that the application maturity of building steel structure welding robot technology in this project is at the development level as a whole. The maturity levels of “WuLi – ShiLi – RenLi” are respectively: development level, development level, between starting level and development level. Comparison of maturity evaluation values of five important factors (from high to low): environmental factors, technical factors, management factors, benefit factors, personnel and group factors.

In this paper, based on the existing research related to construction steel structure welding robot technology, a quantitative and holistic evaluation of the application of construction steel structure welding robot technology in domestic engineering projects is conducted for the first time from a project perspective by designing a maturity evaluation index system and establishing a maturity evaluation model. This research will help the project team to evaluate the application level (maturity) of the welding robot in the actual project, identify the shortcomings and defects of the application of this technology, then improve the weak links pertinently, and finally realize the gradual improvement of the overall application level of welding robot technology for building steel structure.

This paper aims to provide details of vision-assisted robotic welding technologies and their applications.

Following a short introduction, this paper first considers the background of vision-assisted robotic welding, the functions of the vision systems and the scenarios where the technology is of benefit. The main section provides examples of vision-assisted welding applications, together with details of the systems and products employed. Finally, brief concluding comments are drawn.

This shows that modern machine vision technologies, often based on lasers, can allow robotic welding systems to compensate for dimensional variations and errors, eliminate the need for complex and costly welding fixtures and act as an alternative to skilled human welders. This technology allows robotic automation to be deployed in welding applications where it was hitherto impossible, technically difficult or not cost-effective.

By considering a section of applications, this paper provides an insight into how machine vision technologies can enhance the capabilities of robotic welding systems.

This paper aims to automate the welding operation that motion control, sensor integration and coordination with the welding power source. Therefore, there is a need for sophisticated technologies to control precisely the process in terms of positioning the welding torch, and controlling the welding parameters through the use of correct devices which are aided by appropriate control tools and techniques.

A new seam tracking methodology, named sewing technique, has been introduced for the welded joints available in computer-aided design (CAD) environment. This methodology gives the seam path by drawing a line through the adjacent centroids of curve fitted in the weld joint volume. Obtained geometric path and kinematic constraints are given as input to the modeled robot for performing welding operation followed by desired trajectory.

In this investigation, a novel and efficient weld seam technique has been developed to produce uniform welded joints. The key feature of this approach is that the initial and end positions of the weld seams can be obtained easily. Because of this, the robot can be controlled flexibly during welding operation.

This investigation deals with the development of an automated seam tracking methodology for the welded joints available in CAD environment. Validation of the developed methodology has been done through simulation results while performing welding operations for different weld profiles.