Abstract: An embodiment includes a robotic welding system for generating a motion program, having a programmable robot controller of a robot having a computer processor and a computer memory. The programmable robot controller is configured to digitally record, in the computer memory, a plurality of spatial points along an operator path in a 3D space taken by a calibrated tool center point (TCP) of the robot as an operator manually moves a robot arm of the robot along the operator path from a start point to a destination point within the 3D space. The programmable robot controller is also configured to identify and eliminate extraneous spatial points from the plurality of spatial points as digitally recorded, leaving a subset of the plurality of spatial points as digitally recorded, where the extraneous spatial points are a result of extraneous movements of the robot arm by the operator.

Abstract: A method of programming a curved path for a welding robot includes recording input of a first arc segment endpoint, a first intermediate point, and a second arc segment endpoint along the curved path. The first intermediate point is located between the first and second arc segment endpoints. The curved path is determined from the first and second arc segment endpoints and the first intermediate point. Input of a third arc segment endpoint is recorded. A distance of the third arc segment endpoint to the curved path is determined and compared to a threshold distance. A second intermediate point along the curved path between the second and third arc segment endpoints is automatically interpolated when the distance is less than the threshold distance. The first, second and third arc segment endpoints, and the first and second intermediate points are communicated to a robot controller to program movements of the welding robot.

Abstract: An embodiment includes a robotic welding system for generating a motion program, having a programmable robot controller of a robot having a computer processor and a computer memory. The programmable robot controller is configured to digitally record, in the computer memory, a plurality of spatial points along an operator path in a 3D space taken by a calibrated tool center point (TCP) of the robot as an operator manually moves a robot arm of the robot along the operator path from a start point to a destination point within the 3D space. The programmable robot controller is also configured to identify and eliminate extraneous spatial points from the plurality of spatial points as digitally recorded, leaving a subset of the plurality of spatial points as digitally recorded, where the extraneous spatial points are a result of extraneous movements of the robot arm by the operator.

Abstract: A welding system includes a collaborative robot, a robot controller, a welding torch having an end located at a tool center point (TCP), a welding power supply, and a teach pendant. The teach pendant includes a UI application configured for programming welding points and parameters. In a first operation mode, the UI application displays the plurality of welding points in a list that includes a highlighted closest welding point having a three-dimensional position that is closest to the TCP. The highlighted closest welding point automatically updates upon manual movement TCP. In a second operation mode, the list includes a highlighted selected welding point, and the UI further displays a selector button that shows a straight line distance of the TCP to a three-dimensional position of the highlighted selected welding point. Activation of the selector button causes the TCP to move to the position of the highlighted selected welding point.

Abstract: An embodiment includes a method of determining a collision-free space for a robotic welding system. The method includes fixing a location of a part to be welded in a 3D coordinate space of a robotic welding system. An arm of the robotic welding system is moved around the part within the 3D coordinate space. Data corresponding to positions and orientations of the arm in the 3D coordinate space are recorded as the arm is moved within the 3D coordinate space around the part. The data is translated to swept volumes of data within the 3D coordinate space. The swept volumes of data are merged to generate 3D geometry data representing a continuous collision-free space within the 3D coordinate space.

Abstract: An embodiment includes a robotic welding system for generating a motion program, having a programmable robot controller of a robot having a computer processor and a computer memory. The programmable robot controller is configured to digitally record, in the computer memory, a plurality of spatial points along an operator path in a 3D space taken by a calibrated tool center point (TCP) of the robot as an operator manually moves a robot arm of the robot along the operator path from a start point to a destination point within the 3D space. The programmable robot controller is also configured to identify and eliminate extraneous spatial points from the plurality of spatial points as digitally recorded, leaving a subset of the plurality of spatial points as digitally recorded, where the extraneous spatial points are a result of extraneous movements of the robot arm by the operator.