International Journal of Robotics, Theory and Applications

International Journal of Robotics, Theory and Applications

Automatic Path Planning for GMAW Welding on Locomotive Bogie in Low Contrast by Welding Robot

Document Type : Original Article

Authors
1 Department of Mechatronics Engineering, School of Intelligent Systems, College of Interdisciplinary Science and Technology, University of Tehran, Tehran, Iran
2 Department of Mechatronics Engineering , School of Intelligent Systems, College of Interdisciplinary Science and Technology, University of Tehran,Tehran,Iran
3 School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran
Abstract
A locomotive is a rail vehicle that provides the driving power for a train. Railway vehicles consist of multiple components, among which bogies play a critical role as key load-bearing parts. They support the weight of the vehicle body and mitigate the impact of track irregularities to ensure smooth and safe operation. To achieve a lightweight assembly, bogie frames are typically constructed using welded structures. Welding is one of the most crucial methods in modern industrial manufacturing and is widely employed in the design of lightweight structures. However, during the welding process, major defects such as weld deformation and residual stresses are inevitable, which can affect assembly accuracy and increase production costs. Traditionally, this welding process is carried out manually, requiring high operator expertise and significant time to execute. This paper presents a welding path planning algorithm aimed at achieving higher welding quality, reducing the overall welding process time, eliminating the production process's dependence on the skills of specific operators, and enhancing the precision in manufacturing various structures used in the rail industry, such as locomotive bogies. The use of image processing for the identification and path planning of welding joints reduces the high costs associated with procuring online laser tracking devices. Moreover, this paper introduces a comprehensive method for processing the entire image and providing the welding path for offline robot programming without any prior knowledge of the joint location. Automatically and accurately determining the seam locations via the robot represents a significant advancement toward automating the arc welding process. The proposed methods have been tested and validated using a laboratory prototype of a 2DOF planar welding robot. The results confirm an accuracy of 2 mm for parabolic joints and 3 mm for straight joints, meeting the precision requirements of small and medium-sized industries.
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Volume 10, Issue 1
December 2024
Pages 22-31

  • Receive Date 26 June 2024
  • Revise Date 05 September 2024
  • Accept Date 30 December 2024
  • First Publish Date 30 December 2024