Online programming system for robotic fillet welding in Industry 4.0

TL;DR

This paper introduces an online, low-cost robotic programming system for noncontact fillet welding that simplifies setup, reduces complexity, and enhances efficiency in Industry 4.0 manufacturing environments.

Contribution

It presents a novel online robot programming methodology that minimizes steps and components, enabling quick, automatic generation of welding programs for industrial robots.

Findings

System performs fillet welding efficiently with reduced setup time.

Uses fewer components than existing systems, lowering cost and complexity.

Achieves a transparent, operator-friendly welding process.

Abstract

Fillet welding is one of the most widespread types of welding in the industry, which is still carried out manually or automated by contact. This paper aims to describe an online programming system for noncontact fillet welding robots with U and L shaped structures, which responds to the needs of the Fourth Industrial Revolution. In this paper, the authors propose an online robot programming methodology that eliminates unnecessary steps traditionally performed in robotic welding, so that the operator only performs three steps to complete the welding task. First, choose the piece to weld. Then, enter the welding parameters. Finally, it sends the automatically generated program to the robot. The system finally managed to perform the fillet welding task with the proposed method in a more efficient preparation time than the compared methods. For this, a reduced number of components was used compared to other systems, such as, a structured light 3D camera, two computers and a concentrator, in addition to the six axis industrial robotic arm. The operating complexity of the system has been reduced as much as possible. To the best of the authors knowledge, there is no scientific or commercial evidence of an online robot programming system capable of performing a fillet welding process, simplifying the process so that it is completely transparent for the operator and framed in the Industry 4.0 paradigm. Its commercial potential lies mainly in its simple and low cost implementation in a flexible system capable of adapting to any industrial fillet welding job and to any support that can accommodate it.