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The development of robotized welding is truly impressive and is today one of the major application areas for industrial robots. The first industrial robots were introduced in the early 1960s for material transfer and machine tending. Not long after that, robots were used for spot welding and in the early 1970s for arc welding as well. During the years, significant developments have taken place both concerning the robot equipment and the welding equipment to meet the different challenges within the application area. This paper describes the development and progress of robotization in welding over the years and also some projections and trends for the near future.

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.

Describes the use of welding robots for making bridge panels. The system uses a total of 14 sets of High Speed Rotating Arc welding robots and newly‐developed arc sensor techniques are used with both joint end and bead end sensors. A teaching‐less direct CADCAM system was developed to control the robots. The welding robot system is now in commercial operation with welding efficiencies that are twice those possible with conventional processes.

This paper describes the development of a variety of robot welding and grinding systems. Also discusses the benefits of running arc welding cables within the body of the robot and the use of a computer controlled welder. Also covers digitally controlled spot welding and communication with a supervisory computer. Finally, discusses de‐burring and the opportunities for further development in this area.

Whilst robots are of benefit in gas metal arc welding process parameters are the critical factors. Vernon Mangold of Kohol Systems discusses their influence on cell design.

This work demonstrates the development of a robot, which was designed for the orbital welding of pipes.

The robot consists of a small car pressed against the pipe by means of chains, which are used by the robot to move around it. To provide all necessary torch movements, the robot must have four degrees of freedom: torch travel speed, stick‐out, torch angle and lateral motion. Thus, using a look‐up table‐which was specially designed to this application‐it is possible to follow the optimal parameters (voltage, current, welding speed, torch angle and stick‐out) for each welding position (flat, vertical and overhead).

The robotization of the orbital welding process brings enhancement in the final product quality, considerable increase of repeatability, reduction of rework and reduction of the weld execution time. At the very least, the robot is capable to reproduce the weld bead of the best human welder, through the use of the same paramenters contained in a table.

The use of this robot in welding with GMAW proved to be extremely viable. It was shown that the bead shape did not suffer great variations from one welding postion to another, thanks to the use of a gradual change of parameters.

Although, by RIA definition the devices for the orbital welding shown in literature up to now are not robots, the developed device can be called a robot due to its capability of being completely programmable and automatically carrying through all welding activities.

The purpose of this paper is to develop a portable all‐position welding robot for the welding of intersected pipes.

A complete procedure is adopted to conduct the design. The task and motion of the robot are analyzed and a mathematical description of the pose and position of the welding tool is given. Based on that, three representative types of robot are chosen in the type synthesis of mechanism. Two new indices proposed to evaluate required properties of the robot, along with the traditional dexterity index, are chosen to be the criteria in the dimension synthesis of mechanism. Through the optimization by genetic algorithm, the best robot in type and dimension is determined after comparison on their performances. Finally, the prototype is developed.

The paper finds a new robot for welding intersected pipes.

A new robot is introduced for the welding of intersected pipes. A complete design procedure is adopted to conduct the design. Two new indices are constructed for evaluating the required properties of this robot.

This paper outlines the range of robots available and in use in Britain for arc welding, and gives examples of typical current industrial applications. Work at the National Engeering Laboratories and the Welding Institute has the objective of increasing the range and ease of robot arc welding, and recent developments in this area are introduced.

The control of weld penetration in gas tungsten arc welding (GTAW) is required for a “teach and playback” robot to overcome the gap variation in the welding process. This paper aims to investigate this subject.

This paper presents a robotic system based on the real‐time vision measurement. The primary objective has been to demonstrate the feasibility of using vision‐based image processing to measure the seam gap in real‐time and adjust welding current and wire‐feed rate to realize the penetration control during the robot‐welding process.

The paper finds that vision‐based measurement of the seam gap can be used in the welding robot, in real‐time, to control weld penetration. It helps the “teach and playback” robot to adjust the welding procedures according to the gap variation.

The system requires that the seam edges can be accurately identified using a correlation method.

The system is applicable to storage tank welding of a rocket.

The control algorithm based on the knowledge base has been set up for continuous GTAW. A novel visual image analysis method has been developed in the study for a welding robot.

A combination of new machines and new companies to make them is signalling a switch in emphasis from spot welding to arc welding robots in readiness for the next wave of increased sales, though this does not mean spot welding robots are by any means dead.