Robot welding process control

This final report documents the development and installation of software and hardware for Robotic Welding Process Control. Primary emphasis is on serial communications between the CYRO 750 robotic welder, Heurikon minicomputer running Hunter & Ready VRTX, and an IBM PC/AT, for offline programming and control and closed-loop welding control. The requirements for completion of the implementation of the Rocketdyne weld tracking control are discussed. The procedure for downloading programs from the Intergraph, over the network, is discussed. Conclusions are made on the results of this task, and recommendations are made for efficient implementation of communications, weld process control development, and advanced process control procedures using the Heurikon

Real-time control for manufacturing space shuttle main engines: Work in progress

During the manufacture of space-based assemblies such as Space Shuttle Main Engines, flexibility is required due to the high-cost and low-volume nature of the end products. Various systems have been developed pursuing the goal of adaptive, flexible manufacturing for several space applications, including an Advanced Robotic Welding System for the manufacture of complex components of the Space Shuttle Main Engines. The Advanced Robotic Welding System (AROWS) is an on-going joint effort, funded by NASA, between NASA/Marshall Space Flight Center, and two divisions of Rockwell International: Rocketdyne and the Science Center. AROWS includes two levels of flexible control of both motion and process parameters: Off-line programming using both geometric and weld-process data bases, and real-time control incorporating multiple sensors during weld execution. Both control systems were implemented using conventional hardware and software architectures. The feasibility of enhancing the real-time control system using the problem-solving architecture of Schemer is investigated and described

Technology for the Future: In-Space Technology Experiments Program, part 1

The purpose of the Office of Aeronautics and Space Technology (OAST) In-Space Technology Experiment Program (In-STEP) 1988 Workshop was to identify and prioritize technologies that are critical for future national space programs and require validation in the space environment, and review current NASA (In-Reach) and industry/university (Out-Reach) experiments. A prioritized list of the critical technology needs was developed for the following eight disciplines: structures; environmental effects; power systems and thermal management; fluid management and propulsion systems; automation and robotics; sensors and information systems; in-space systems; and humans in space. This is part one of two parts and is the executive summary and experiment description. The executive summary portion contains keynote addresses, strategic planning information, and the critical technology needs summaries for each theme. The experiment description portion contains brief overviews of the objectives, technology needs and backgrounds, descriptions, and development schedules for current industry, university, and NASA space flight technology experiments

Estimation and Control of Robotic Radiation-Based Processes

This dissertation presents a closed-loop control and state estimation framework for a class of distributed-parameter processes employing a moving radiant actuator. These radiation-based processes have the potential to significantly reduce the energy consumption and environmental impact of traditional industrial processes. Successful implementation of these approaches in large-scale applications requires precise control systems. This dissertation provides a comprehensive framework for: 1) integration of trajectory generation and feedback control, 2) online distributed state and parameter estimation, and 3) optimal coordination of multiple manipulated variables, so as to achieve elaborate control of these radiation-based processes for improved process quality and energy efficiency. The developed framework addresses important issues for estimation and control of processes employing a moving radiant actuator from both practical and theoretical aspects. For practical systems, an integrated motion and process control approach is first developed to compensate for disturbances by adjusting either the radiant power of the actuator or the speed of the robot end effector based on available process measurements, such as temperature distribution. The control problem is then generalized by using a 1D scanning formulation that describes common characteristics of typical radiant source actuated processes. Based on this 1D scanning formulation, a distributed state and parameter estimation scheme that incorporates a dual extended Kalman filter (DEKF) approach is developed to provide real-time process estimation. In this estimation scheme, an activating policy accompanying the moving actuator is applied in order to reduce the computational cost and compensate for observability changes caused by the actuator\u27s movement. To achieve further improvements in process quality, a static optimization and a rule-based feedback control strategy are used to coordinate multiple manipulated variables in open-loop and closed-loop manners. Finally, a distributed model predictive control (MPC) framework is developed to integrate process optimization and closed-loop coordination of manipulated variables. Simulation studies conducted on a robotic ultraviolet (UV) paint curing process show that the developed estimation and control framework for radiant source actuated processes provide improved process quality and energy efficiency by adaptively compensating for disturbances and optimally coordinating multiple manipulated variables

Technology for the Future: In-Space Technology Experiments Program, part 2

The purpose of the Office of Aeronautics and Space Technology (OAST) In-Space Technology Experiments Program In-STEP 1988 Workshop was to identify and prioritize technologies that are critical for future national space programs and require validation in the space environment, and review current NASA (In-Reach) and industry/ university (Out-Reach) experiments. A prioritized list of the critical technology needs was developed for the following eight disciplines: structures; environmental effects; power systems and thermal management; fluid management and propulsion systems; automation and robotics; sensors and information systems; in-space systems; and humans in space. This is part two of two parts and contains the critical technology presentations for the eight theme elements and a summary listing of critical space technology needs for each theme

Process planning for robotic wire ARC additive manufacturing

Robotic Wire Arc Additive Manufacturing (WAAM) refers to a class of additive manufacturing processes that builds parts from 3D CAD models by joining materials layerupon- layer, as opposed to conventional subtractive manufacturing technologies. Over the past half century, a significant amount of work has been done to develop the capability to produce parts from weld deposits through the additive approach. However, a fully automated CAD-topart additive manufacturing (AM) system that incorporates an arc welding process has yet to be developed. The missing link is an automated process planning methodology that can generate robotic welding paths directly from CAD models based on various process models. The development of such a highly integrated process planning method for WAAM is the focus of this thesis

A Framework for Hybrid Manufacturing in Robotic Cells

Compared to other additive technologies, Wire and Arc Additive Manufacturing (WAAM) offers high deposition rates, flexibility and a larger build volume as well as reduction of material waste. WAAM can be combined with a subtractive technology in hybrid robotic cells to further increase the application scope, thus producing products with improved surface finish where needed. However, there are some open issues that limit this process. So, the main goal of this paper is to review current research developments and provide a framework aimed at manufacturing parts by hybrid cells. A procedure is defined which moves from the evaluation of the designed shapes, their analysis to identify a proper manufacturing sequence until the elaboration of the instructions for the cell automaton controllers. Main WAAM issues are outlined to identify main research directions, and a test case is presented to highlight the process phase

Inverse kinematic control algorithm for a welding robot - positioner system to trace a 3D complex curve

The welding robots equipped with rotary positioners have been widely used in several manufacturing industries. However, for welding a 3D complex weld seam, a great deal of points should be created to ensure the weld path smooth. This is a boring job and is a great challenge - rotary positioner system since the robot and the positioner must move simultaneously at the same time. Therefore, in this article, a new inverse kinematics solution is proposed to generate the movement codes for a six DOFs welding robot incorporated with a rotary positioner. In the algorithm, the kinematic error is minimized, and the actual welding error is controlled so that it is always less than an allowable limit. It has shown that the proposed algorithm is useful in developing an offline CAD-based programming tool for robots when welding complex 3D paths. The use of the algorithm increases the accuracy of the end-effector positioning and orientation, and reduces the time for teaching a welding robot - positioner system. Simulation scenarios demonstrate the potency of the suggested method

A Tutorial on Learning Human Welder\u27s Behavior: Sensing, Modeling, and Control

Human welder\u27s experiences and skills are critical for producing quality welds in manual GTAW process. Learning human welder\u27s behavior can help develop next generation intelligent welding machines and train welders faster. In this tutorial paper, various aspects of mechanizing the welder\u27s intelligence are surveyed, including sensing of the weld pool, modeling of the welder\u27s adjustments and this model-based control approach. Specifically, different sensing methods of the weld pool are reviewed and a novel 3D vision-based sensing system developed at University of Kentucky is introduced. Characterization of the weld pool is performed and human intelligent model is constructed, including an extensive survey on modeling human dynamics and neuro-fuzzy techniques. Closed-loop control experiment results are presented to illustrate the robustness of the model-based intelligent controller despite welding speed disturbance. A foundation is thus established to explore the mechanism and transformation of human welder\u27s intelligence into robotic welding system. Finally future research directions in this field are presented

Computer hardware and software for robotic control

The KSC has implemented an integrated system that coordinates state-of-the-art robotic subsystems. It is a sensor based real-time robotic control system performing operations beyond the capability of an off-the-shelf robot. The integrated system provides real-time closed loop adaptive path control of position and orientation of all six axes of a large robot; enables the implementation of a highly configurable, expandable testbed for sensor system development; and makes several smart distributed control subsystems (robot arm controller, process controller, graphics display, and vision tracking) appear as intelligent peripherals to a supervisory computer coordinating the overall systems