Abstract: A robot controller for ensuring safety of an operator, which is capable of reducing operational cost by avoiding unnecessary emergency stop of a robot. A teaching pendant has an emergency stop button for interrupting drive power for the robot, and a main body of the controller has a signal part which receives an emergency stop signal from the teaching pendant when the emergency stop button is pushed, and a power interrupting part which interrupts the drive power for the robot when the signal part receives the emergency stop signal under a predetermined condition. Until a first predetermined period of time has passed after a connection/disconnection switch is operated, the power interrupting part does not interrupt the drive power when a connection-recognition signal representing that the teaching pendant is connected to the main body is not generated, even when the emergency stop signal is input from the teaching pendant.

Abstract: A system and method for the automated or “robotic” application of hardfacing to a surface of a drill bit.

Abstract: An optical device for detecting quality of welding gun electrodes An optical sensor device comprises a housing (10) with a pair of openings (11, 11a) communicating with a pair first (14) and a second (15) seat for accommodating a respective one of a pair of electrodes (E1, E2). A first set of lights (16, 17) emit a first (L1) and a second (L2) light beam in an intermediate geometric plane (p1) between the seats (14, 15). Two oblique reflecting elements (25, 26), interposed between the two seats (14, 15), to reflect the first (L1) and second (L2) light beams in two opposite directions perpendicular to the geometric plane (p1) toward the first and the second seats. Other lights (47, 32) emit third (L3) and fourth (L4) light beams on opposite sides of the geometric plane (p1) to illuminate the first and the second seat (14, 15).

Abstract: A welding operation is performed by moving or rotating an arc in a welding torch, and feeding a metal cored wire through the torch in a direct current, electrode negative welding process. The electrode may include one or more arc stabilizers. The welding process may be pulsed or non-pulsed. Moreover, the process may be used with a number of different base metals intended to be welded, such as thin plate, galvanized metals, painted metals, coated metals, and so forth.

Abstract: A welding carriage traveling with a welding torch mounted thereon includes: a carriage body; and a torch supporting part disposed between the front and rear ends of carriage body and supporting a tip of the welding torch in a state of positioning on a side surface side of the carriage body and facing diagonally downward. The torch supporting part includes a torch swinging unit and a weaving unit. The torch swinging unit includes a torch swinging mechanism which swings the tip of the welding torch in a forward and rearward direction of the carriage body, and thereby moves tip close to the welding line. The weaving unit includes a weaving mechanism which operates so as to integrally rotate a unit case and a torch mounting bar of the torch swinging unit about a screw, thereby to cause the welding torch to perform a weaving operation.

Abstract: A movement control system is provided for cutting and welding applications which uses a laser movement detection system to detect deflection or displacement in a guide rail movement system. A movement controller controls the movement of the cutting or welding operation based on the detected laser beam displacement.

Abstract: A superalloy substrate, such as a turbine blade or vane, is fabricated or repaired by laser beam welding to clad one or more layers on the substrate. Laser optical energy is transferred to the welding filler material and underlying substrate to assure filler melting and adequate substrate surface wetting for good fusion. Energy transfer is maintained below a level that jeopardizes substrate thermal degradation. Optical energy transfer to the filler and substrate is maintained uniformly as the laser beam and substrate are moved relative to each other along a translation path by varying the energy transfer rate to compensate for localized substrate topology variations.

Abstract: A laser processing head for processing a workpiece by means of laser beam, including a housing through which a beam path for the laser beam is led and which has a focusing optical unit for focusing the laser beam onto a joint of the workpiece to be processed. A light cutting device is fitted to the housing and has a light source for generating a light line on the workpiece. A camera is arranged in an observation beam path in front of the camera such that the camera images the light line at the location to be joined and also the portion. The system also includes an image processor which calculates a minimum distance between the stored target trajectory and the current welding path midpoint.

Abstract: According to one aspect of the invention, there is provided a method comprising: obtaining at least one image comprising at least one object; analyzing the at least one image to determine at least one gripping location to grip an object; selecting a gripping location from the at least one gripping location based on a predetermined criterion; and issuing at least one instruction to a gripper to grip the object at the selected gripping location.

Abstract: The installation provided includes at least one structure for receiving and holding guide tubes and structural elements; a carriage movable parallel to the guide tubes; at least one welding tool; and displacement means for moving the welding tool, the displacement means connecting the pincer to the carriage and presenting at least six degrees of freedom.

Abstract: A robot having a force sensor and a tool fixture for operating on a workpiece that may have a complex surface contour is programmed by an operator first teaching the robot by a suitable technique such as lead through teaching a few gross points of the contour. These points, known as guiding points, are used to generate a program to be followed by the robot under the control of the robot controller and using force control during which the robot finalizes the guiding points and teaches one or more points on the contour intermediate adjacent guiding points. The controller or other computing device uses the points so taught to generate the path the robot tool fixture will follow when the tool is to operate on the workpiece.

Abstract: In a teaching system including a display unit, an image generating unit generates a virtual image of a robot, a workpiece and a positioner for holding the workpiece. A display control unit controls the display unit to display the generated virtual image. Upon receiving an operator's operation of selecting a ridgeline of the workpiece of the virtual image, a work line generating unit extracts individual teaching target points of the ridgeline and generates a work line as a set of line segments each interconnecting the target points adjoining each other. A calculation unit calculates teaching values for positions and postures of the positioner on a point-by-point basis so that a vector direction of the work line at each target point becomes substantially parallel to a horizontal direction. A teaching program generating unit generates a teaching program for operating the positioner based on the calculated teaching values.

Abstract: The systems and methods are directed to mechanical arms and manipulators, and more particularly, to optical distance sensors in use for approach, grasping and manipulation. The system may include a manipulator having an arm and a multi fingered end-effector coupled to the distal end of the arm. The end-effector may include an optical proximity sensor configured to detect the distance to an object prior to contact with the object. The end-effector may include an optical proximity sensor configured detect a measurement of force applied to the object by the manipulator post contact with the object. The measurement of force may be a range of force measurements including a minimum, a maximum and a measurement between or within the minimum and the maximum.

Abstract: In a method for processing a point cloud using a computing device, a straight line fitted by the point cloud comprising border points is determined as a benchmark line. An inflection point in the point cloud of the benchmark line is determined. If the vertical distance of the inflection point is not greater than the preset filtration value, needless border points in the point cloud are deleted and a remainder point cloud is obtained. If the vertical distance between the inflection point and the benchmark line is greater than a filtration value, the point cloud is divided into two sub-point clouds, and the one sub-point cloud having border points less than the preset number is deleted, and the other sub-point cloud is set as a remainder point cloud.

Abstract: A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.

Abstract: An air-carbon arc system for reducing irregularities in a work piece surface including a control box, a torch head operationally connected to the control box and configured to cooperate with the work piece to generate an arc, and a pendant operationally connected to the control box and having a means for reducing irregularities in the work piece surface.

Abstract: A system for determining a welding sequence is disclosed. The system may have a welding sequence generator configured to create an initial population of welding sequences based on a user-generated constraint. The system may also have a welding simulator configured to simulate welding for at least one welding sequence in the initial population of welding sequences to model distortion for the at least one welding sequence. The welding sequence generator may be further configured to receive the distortion for the at least one welding sequence in the initial population from the welding simulator, determine whether a merit value derived from at least the distortion for the at least one welding sequence satisfies one or more predetermined criteria, output the at least one welding sequence as a potential welding sequence if the merit value satisfies the predetermined criteria.

Abstract: A method of providing a mold with a conformal cooling passage includes rough machining a mold cavity generally corresponding to a molded part shape using CAD data. Conformal cooling slots are cut in the mold cavity using the CAD data. The conformal cooling slots are welded shut using the CAD data to provide conformal cooling passages. A class A surface is machined over the conformal cooling passage and corresponds to a finished mold part shape using the CAD data.

Abstract: A system and method for precision welding using a fiber laser is disclosed in which varying intensity laser pulses are spread across the material junction in a number of high aspect ratio areas. The power density applied along each area is varied to accommodate differences in the material characteristics of each material while allowing for the creation of a more uniform weld pool alloy.

Abstract: A system and method for edging a deposit layer in any of cladding, building up, and hard-facing applications is provided. The system includes a high intensity heat source that heats a workpiece and creates a molten puddle. The system also includes a wire feeder that feeds a wire to the molten puddle. The wire melts in the molten puddle and creates a bond with the molten puddle to form the deposit layer on the workpiece. The system further includes an edging system that has at least one laser that emits a laser beam that impinges on at least one of a surface area and an edge area of the deposit layer to modify the deposit layer. The laser modifies the deposit layer by at least one of melting and vaporizing at least a portion of the surface area and/or the edge area.

Abstract: A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.

Abstract: The invention described herein generally pertains to a system and method related to energizing a welding wire based on a location of an electrode at an edge on a workpiece. An edge detector can be configured to identify an edge on the workpiece during a welding operation and a controller can be configured to mange a temperature of a puddle formed by the electrode by adjusting one or more welding parameters. The welding parameters can be, but are not limited to, an energizing of the welding wire, a wire feed speed, a temperature of a high intensity heat source (e.g.

Abstract: A simulator facilitates virtual welding activity of pipe and open root weld joints. The simulator may include a logic processor based system operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a section of virtual pipe having at least one virtual weld joint. It also includes a display connected to the logic processor based system for visually depicting the interactive welding environment, wherein the display depicts the section of virtual pipe. A mock welding tool is provided for performing virtual welding activity on the at least one weld joint in real time where one or more sensors are adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based system.

Abstract: In a method for controlling pulse arc welding where an arc is created between a wire and a base material, a pulse waveform different from the pulse waveform for steady-state welding is outputted when a predetermined time has passed since short-circuit welding control was started at arc start, and after a sufficiently large melt pool is formed, the pulse waveform for the steady-state welding is outputted. This reduces the generation of spatters after an arc is created and until the arc is stabilized.

Abstract: A process for identifying existence of a welded spot on a cut-out part and retention of the cut-out part on a workpiece in a wire electrode is disclosed which makes it possible to go ahead process steps while identifying automatically the retention of the cut-out part on a workpiece, ensuring unmanned work of the wire electrode discharge processor with saving the personnel and labor. The process comprises a rough cutting step to cut out the part from the workpiece, a welding step to partially weld the part with the workpiece, and an inspection step to detect whether the wire electrode comes into contact with a welded spot while moving the wire electrode along the cutting path of kerf in the workpiece. After the wire electrode has come into contact with the welded spot whereby the retention of the part on the workpiece has been identified, a step goes ahead to one of next procedures.

Abstract: The invention relates to a device (22) for evaluating an image (20) produced on a carrier material (8) by spot welding of a weld spot (19) using an optical image-detecting unit (23), comprising a camera (24) which consists of at least one detection means (25) and one lens (26). In order to create an evaluation device (22), by means of which the optical quality testing of spot-weld joints can be improved, the image-detecting means (23) comprises an illumination device (27) with a diffusor (28) for diffusively and homogeneously illuminating an image (20) of the spot-welding on the carrier material (8). Furthermore, the invention relates to a welding tool (1) for a spot-welding plant, in particular a welding gun (2), having an evaluation device (22) for analyzing an image (20) of a spot weld (19) on a carrier material (8).

Abstract: A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.

Abstract: Disclosed is a robot pre-heat and inter-pass welding device that is capable of pre-heating and welding one or more weld joints using a single robot. Pre-heating and welding models are used to ensure that a desirable pre-heat temperature is maintained on the weld piece at the location of the weld. Infrared temperature sensors are utilized to detect temperature of the weld piece, which are transmitted to a controller, which controls the operation of both the pre-heating and welding. Multiple welds can be performed if additional time is needed for cooling, which reduces the overall time required to perform the welding process.

Abstract: A welding device applies weld material between two work pieces (P1, P2) so as to connect the work pieces (P1, P2) mechanically with one another. The welding device has a welding head (110) and a probe head (120). The welding head (110) performs a welding action in respect of the work pieces (P1, P2) during transport of the welding device along an operating direction (OD) in a welding plane (WP); and the probe head (120), which is arranged upstream of the welding head (110) relative to the operating direction (OD), measures a set of geometric properties of a gap (G) between the work pieces (P1, P2). Thus, the welding head (110) can be properly positioned to attain a desired application of the weld material in the gap (G).

Abstract: A lead/lag torch angle adjustment system for a weld held. The weld head device includes a torch head assembly that includes an electrode. The weld head device also includes a support device that supports the torch head assembly and a barrel assembly that is operatively connected to the torch head assembly and the support device. The barrel assembly is configured to change at least one of a lead angle and a lag angle of the electrode with respect to a workpiece. The barrel assembly includes an adjustment mechanism that includes a first section that is operatively connected to the torch head assembly. The adjustment mechanism also includes a second section that is configured to accept the mount plate. The barrel assembly also includes a mount plate that is operatively connected to the support device and at least one barrel clamp. The barrel clamp is configured to attach to the mount plate and also configured to accept the second section.

Abstract: A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.

Abstract: A system and a method for tracking and analyzing welding activity. Dynamic spatial properties of a welding tool are sensed during a welding process producing a weld. The sensed dynamic spatial properties are tracked over time and the tracked dynamic spatial properties are captured as tracked data during the welding process. The tracked data is analyzed to determine performance characteristics of a welder performing the welding process and quality characteristics of a weld produced by the welding process. The performance characteristics and the quality characteristics may be subsequently reviewed.

Abstract: An offline programming device for preparing an operation program for making a robot with a hand perform a handling operation for an object with respect to a machine tool.

Abstract: A method is provided for teaching a transfer robot used in conjunction with a workpiece processing system including a pedestal assembly, a light sensor having an optical input fixedly coupled to the pedestal assembly, a transfer robot having an end effector, and a processing chamber containing the pedestal assembly and light sensor. The method includes the steps of producing light within the processing chamber, moving the end effector over the optical input such that amount of light reaching the light sensor varies in relation to the position of the end effector, and recording the signal gain as the end effector is moved over the optical input. The method also includes the step of establishing from the recorded signal gain a desired position of the end effector relative to the pedestal assembly.

Abstract: The invention relates to a method for controlling and/or adjusting a welding process, using a melting welding wire (13) wherein after ignition of an electric arc, a welding process is carried out, the welding process being adjusted on the basis of several different welding parameters and being controlled or adjusted by a control device and/or welding current source. In order to determine the position of distance between the end of the welding wire (13) and the workpiece (16), which is to be processed, in a manner which is as accurate as possible, at least one mechanical adjustment process (41) is carried out during the welding process, enabling the position of said welding wire (13) being used as a sensor.

Abstract: An industrial robot has a base for installation, a first arm, a second arm, a third arm, a wire feeder, a welding torch, and a torch cable. The first arm rotates with respect to the base. The second arm pivots with respect to the first arm. The third arm pivots with respect to the second arm. The torch cable is coupled to the wire feeder and feeds a welding wire to a welding torch. The wire feeder is provided to the second arm and is rotatable around a rotation axis.

Abstract: An industrial robot, having an end-effector supporting mechanism for holding an end-effector and accommodating an imaging device of a visual sensor, which is free from the interference with the periphery and capable of taking an image of the working position. A container-shaped adaptor of the end-effector supporting mechanism is attached to a distal end of a wrist flange provided in a robot wrist supported by a robot arm. The adaptor has a first attachment section provided with a first attachment surface to be attached to the wrist flange, and a second attachment section provided with a second attachment surface disposed generally parallel to a wrist flange surface at a position apart from the first attachment section by a predetermined distance along a rotary center axis of the wrist flange. On the second attachment surface, a tool holding member of the end-effector supporting mechanism for holding the working tool is attached.

Abstract: A device for detecting the position of a seam on a welded pipe in a three-dimensional laser beam machine for processing pipes. The three-dimensional laser beam machine has a chuck 62 for holding, rotating and axially moving a cylindrical pipe 400. A weld seam detection device 100 is equipped with a sensor head 110 provided on a laser processing main body 30. The sensor head 110 has a master lever 120 that moves along an inner wall surface 410 of the cylindrical pipe 400 and a sensor lever 140. When the cylindrical pipe 400 is rotated and the sensor lever 140 contacts the weld seam, the movement of the sensor lever 140 is detected by a micro switch 150, which sends a signal to an NC device 90 by which the weld seam position is recognized.

Abstract: The control system includes a welding robot which moves a welding torch along a work for welding the work. A robot controller controls driving of the welding robot. A laser sensor head detects a shape change in the work during welding by the welding torch, and a personal computer obtains instruction information for the welding robot in accordance with the shape change, based on a result of detection by the laser sensor head. The robot controller moves the welding torch by controlling the driving of the working robot, based on the instruction information obtained by the personal computer.

Abstract: Embodiments of the invention are directed to a system arrangement and method for the optical control of the work result of a tool and/or guiding the tool with all-around view, wherein tool and workpiece are moved relative to each other, along a straight path or, particularly, on curved path. According to an aspect, the tool is positioned centrically in the image field and a tool support is located centrically in the beam path or in a pupil of the optics, or in an optical vicinity of the pupil. An arrangement for 3D analysis is also indicated. Advantageously, only one camera need be used, providing a lean design of viewing and illumination, and usable under cramped space conditions. Guiding, processing and control are possible in a single operation using a single camera. Methods for, e.g., applying viscous masses, welding, deburring, and related applications are also disclosed.

Abstract: A method and system are provided for a trackless autonomous crawling all-position arc welding robot with wheels and permanent magnet caterpillar belts. A sensor detects a welding seam position and transmits the position to a tracking controller. The tracking controller sends instructions to a welding torch which may be moved in generally horizontal and vertical directions based upon the instructions. Additionally, a crawler drive controller receives the welding seam position and sends a control signal to an AC servomotor drive that positions the crawler based on the control signal.

Abstract: A switch-off box for a robot system has a two-part housing and a coupling device resiliently mounted in the housing and connected to a torch body and a hose pack or to a torch handle connected with the hose pack, and having a supporting surface for punctual contact on the housing. There are contacting or switching elements connected to the coupling device. Two oppositely located openings are provided in the housing for connection of the coupling device to the torch body and for connection of the coupling device to the hose pack or the torch handle. The supporting surface is connected with the contacting or switching elements so that a respective contacting or switching element will be activated or deactivated by lifting of the supporting surface from the housing, and a signal will be transmitted from the contacting or switching element to an interfaced control device, or the robot system.

Abstract: A welding torch having a flange portion to be coupled to a wrist of a robot. A shock sensor is attached to the flange portion. A nozzle is attached to the shock sensor. The welding torch includes a wire feeding pipe socket arranged at a center of the flange portion. A cooling pipe socket is arranged at a position offset from a central portion of the flange portion. A cooling hose for feeding cooling water from the flange portion to the nozzle is provided while bypassing the shock sensor.

Abstract: A welding apparatus using ultrasonic sensing is described and which includes a movable welder having a selectively adjustable welding head for forming a partially completed weld in a weld seam defined between adjoining metal substrates; an ultrasonic assembly borne by the moveable welder and which is operable to generate an ultrasonic signal which is directed toward the partially completed weld, and is further reflected from same; and a controller electrically coupled with the ultrasonic assembly and controllably coupled with the welding head, and wherein the controller receives information regarding the ultrasonic signal and in response to the information optimally positions the welding head relative to the weld seam.

Abstract: A welded structure is formed by arranging multiple pieces on a three-dimensional support base to provide an assembly in accordance with the structure to be welded and making a picture map of the assembly by photographing the assembly. Weld points are identified from the picture map and welding parameters are determined from the picture map. Control data specifying the weld points and welding parameters are supplied to welding equipment that is operable in a three-dimensional X-Y-Z coordinate system. The welding equipment is moved in the X-Y plane on the basis of the picture map and said control data. The welding equipment is moved along the Z-axis on the basis of Z-axis position data that are acquired by repeatedly measuring the Z-axis position of the support base.

Abstract: A welding method is disclosed for butt welding a first base material 1 and a second base material 2 with each other. To also permit stable and efficient formation of a bead in the form of a fillet weld on a back side of a groove by conducting arc welding from the side of the groove without arranging a bead beforehand on the back side of the groove, the first member 1, on which a root face 1a and a single groove face 1b have been formed, is brought at its root face 1a into contact with a flat surface 2a of the second base material 2. A welding wire 6 is arranged facing on the groove formed by the contact between the first base material 1 and the second base material 2. The first base material 1 and the second material 2 are caused to fuse at an area of contact between them by an arc from the welding wire 6. A melt, which has been formed by the fusion at the area of contact and the like, is forced out to the back side of the groove to form a bead B4 in the form of a fillet weld on the back side of the groove.

Abstract: The invention relates to a toolholder (10) for coupling a welding torch to an industrial robot (14), comprising a first fixing device (16) for fixing the welding torch (12) to the toolholder (10) and comprising a second fixing device (18) for fixing the toolholder (10) to the industrial robot (14). The first and second fixing devices (16, 18) can be displaced or repositioned with regard to one another counter to the action of spring elements (22, 24). The toolholder also comprises a protective circuit (26) for deactivating the welding torch (12) when predetermined displacements or repositionings are exceeded. A component (28) connected to the first fixing device (16) can be repositioned in the Z-direction (30) (toolholder longitudinal axis) and can be displaced in the X-direction and/or Y-direction (32, 34) with regard to the second fixing device (18).

Abstract: Methods and apparatuses for calibrating and teaching a robot to accurately work within a work environment. The present invention preferably provides one or more tactile sensor devices that may be operatively coupled with a robot or positioned at one or more desired locations within a work environment of the robot. In one aspect of the present invention a method comprises the steps of providing a touch sensitive surface in the work environment, causing the touch sensitive surface to contact an object, generating a signal indicative of the position of the contact with respect to the touch sensitive surface, and using information comprising the generated signal to teach the robot the location of the contact in the work environment.

Abstract: The present invention provides an arc welder in which a robot controller of a teaching playback type robot and a welding power source are of digital control type and the robot controller and the welding power source are coupled through a bus. A welding condition command required for welding and a real welding condition are transmitted digitally through the bus in a parallel mode.

Abstract: A system and a method for tracking and analyzing welding activity. Dynamic spatial properties of a welding tool are sensed during a welding process producing a weld. The sensed dynamic spatial properties are tracked over time and the tracked dynamic spatial properties are captured as tracked data during the welding process. The tracked data is analyzed to determine performance characteristics of a welder performing the welding process and quality characteristics of a weld produced by the welding process. The performance characteristics and the quality characteristics may be subsequently reviewed.