Abstract: A robotic system includes a robotic arm, a base couple coupled to the robotic arm, and a controller. The robotic supports a work implement and is configured to move the work implement to perform an operation on a workpiece. The base is configured to be removably coupled to a mounting surface. The controller is in communication with the robotic arm, the work implement, and the base. Further, the controller is configured to disable the operation of at least one of the robotic arm and the work implement if a coupling parameter between the base and the mounting surface is below a threshold value.

Abstract: A robotic system includes a robotic arm, a base couple coupled to the robotic arm, and a controller. The robotic supports a work implement and is configured to move the work implement to perform an operation on a workpiece. The base is configured to be removably coupled to a mounting surface. The controller is in communication with the robotic arm, the work implement, and the base. Further, the controller is configured to disable the operation of at least one of the robotic arm and the work implement if a coupling parameter between the base and the mounting surface is below a threshold value.

Abstract: A method and system for forming a weld joint using additive manufacturing is disclosed. The method and system involve providing a non-additive manufactured metal structure that includes a first end portion, a second end portion opposite the first end portion, and a middle portion between the first end portion and the second end portion. The method and system further involve increasing an effective sectional area of the first end portion by additive manufacturing a metallic geometric structure substantially permanently on the first end portion of the non-additive manufactured metal structure, without creating any fatigue-sensitive notches. One or more free edges of the additive manufactured metallic geometric structure form a weld interface at which to form the weld joint to fix the non-additive manufactured metal structure to another metal or metallic structure.

Abstract: A consumable insert for welding a first component to a second component is provided. The first component is positioned with respect to the second component in such a manner that a gap is defined between adjacent surfaces thereof. The consumable insert includes a body having a profile. The profile of the body matches a scan of a profile of the gap between the adjacent surfaces. The consumable insert also includes a dam portion having a profile. The profile of the dam portion matches, at least in part, a scan of corresponding surfaces of the first component and the second component respectively. The dam portion is provided in contact with at least one end of the body. The dam portion is configured to control an overflow of a weld puddle therefrom. The body and the dam portion are formed using three dimensional printing.

Abstract: A consumable insert for welding a first component to a second component is provided. The first component is positioned with respect to the second component in such a manner that a gap is defined between adjacent surfaces thereof. The consumable insert includes a body having a profile. The profile of the body matches a scan of a profile of the gap between the adjacent surfaces. The consumable insert also includes a dam portion having a profile. The profile of the dam portion matches, at least in part, a scan of corresponding surfaces of the first component and the second component respectively. The dam portion is provided in contact with at least one end of the body. The dam portion is configured to control an overflow of a weld puddle therefrom. The body and the dam portion are formed using three dimensional printing.

Abstract: A welding apparatus for applying consecutive welding beads during a welding operation includes a welding unit including a torch head and a power circuit. The welding apparatus further includes a first pyrometer and a second pyrometer positioned respectively at a first and second pre-determined distance from a tip portion of the torch head, the first and second pyrometers are configured to respectively generate a first temperature signal and a second temperature signal indicative of temperatures of a portion of successive welds. The welding apparatus further includes a controller configured to receive the first temperature signal and the second temperature signal, determine a difference between the first and second temperature signals, set a predetermined threshold based, at least in part, on the determined difference, and adjust a welding parameter of the power circuit, wherein the adjusted welding parameter is lesser than the predetermined threshold.