Design and validation of a universal 6D seam-tracking system in robotic welding using arc sensing

This paper presents the design and validation of a novel and universal 6D seam-tracking system that reduces the need for accurate robot trajectory programming and geometrical databases in robotic arc welding. Such sensor-driven motion control together with adaptive control of the welding process is the foundation for increased flexibility and autonomous behavior of robotic and manufacturing systems. The system is able to follow any 3D spline seam in space with a moderate radius of curvature by real-time correction of the position and orientation of the welding torch, using the through-arc sensing method. The 6D seam-tracking system was developed in the Flexible Unified Simulation Environment (FUSE), integrating software prototyping with mechanical virtual prototyping, based on physical experiments. The validation experiments showed that this system was both robust and reliable, and is able to manage a radius of curvature less than 200 mm.