Abstract: A method and apparatus for welding with a robotic welder is disclosed. The system includes a power supply, preferably phase controlled, a controller and a robotic interface. The components are in a single housing. the controller is externally controlled. An adaptor cord connects a robot controller to the power supply. The controller also has an automatic set-up control connected to the power control output.

Abstract: A method and apparatus for welding with a robotic welder is disclosed. The system includes a power supply, a controller and a robotic interface. The controller includes, in a single housing, a robot-type detector and at least one power control output connected to the power supply. The robot-type detector is connected to the robot interface. An adaptor cord connects the robot controller to the power supply. The controller also has an automatic set-up control connected to the power control output.

Abstract: A workpiece enclosure system of the present invention includes a workpiece loading section, a laser workstation cell, and a workpiece unloading section. The workpiece loading section includes a materials handling robot arranged to move workpieces from an input conveyor to a light-tight pass-through enclosure in communication with the laser workstation cell. The laser workstation cell includes an additional materials handling robot arranged to move workpieces from the pass-through enclosure to one of two dual headstock/tailstock positioners for laser operations. Preferably, two sets of laser-cutting robots are arranged to perform laser-cutting operations on workpieces held by the headstock/tailstock positioners. The materials handling robot is further arranged to move workpieces from the headstock/tailstock positioners to an additional pass-through enclosure in communication with the workpiece unloading section.

Abstract: A method and device is provided for multistage calibration of multiple-axis measuring robots (6) and associated optical measuring devices (10), especially 3D sensors, in a measuring station (1) for workpieces (2), preferably the bodyshells of motor vehicles. Calibration occurs in a measuring cascade comprising at least three calibrating steps, whereby the optical measuring device (10) and the operating point (28) thereof, the manipulator (6) and the axes thereof and the allocation of the manipulator (6) with respect to the workpiece (2) are successively calibrated. The calibration device (47) includes a control and a calibration system (27) for the operating point (28), a calibration body (15) for the axes of the manipulator and a calibration device (12) for the allocation of the manipulator with respect to the workpiece.

Abstract: Welding controller 1 has CPU 1a, ROM1 1b, ROM2 1c and RAM 1d. Programs and data are written into the ROM1 1b and can be rewritten. Sequential welding data is written into the RAM 1d and can be rewritten. A write program for writing programs or data or sequential welding data into the ROM1 1b or the RAM 1d is stored in the ROM2 1c. When a welding control program or data or sequential welding data is input into the CPU 1a from an input device 10 or a computer 12, the CPU 1a executes the write program to write the inputted program or data or sequential welding data into the ROM1 1b or the RAM 1d. Preferably, ROM 1b is an in situ programmable memory, such as a flash memory or EEPROM.

Abstract: The present invention relates to a workpiece implementation device that fabricates individual workpieces, positions them at their point of use on a component, and connects the workpieces to the components. The device further comprises an accessory assembly capable of shaping the workpieces, coating the workpieces with a solderable material, burnishing the point of use on the component, and testing the connection between the workpieces and the component. The positioning, attaching, and accessory assemblies of the workpiece implementation device are adapted to selectively perform their individual functions without the necessity of first repositioning the component or the implementation device. Accordingly, the present invention increases overall production efficiency by integrating several separate implementation tools and workstations into a single, adaptable device.

Abstract: An arc welding apparatus and control method thereof, changes welding power in real time to achieve favorable welding quality. The welding apparatus includes a robot mechanism such as a welding robot, a welding unit including a welding torch at an articulated portion of the robot mechanism, and a control unit to set a welding profile in accordance with welding conditions and a welding path, and to control the robot mechanism and the welding unit in real time in accordance with the welding profile. The method includes setting a welding condition for a parent metal, setting a welding path on the parent metal, setting a welding profile and change factor in accordance with the welding condition and the welding path, and performing a welding operation in accordance with the welding profile. Therefore, the arc welding apparatus and control method thereof achieves a favorable welding result regardless of a type of parent metal by controlling welding power in real time according to conditions of the parent metal.

Abstract: A multi-axis articulatable robot with a weld gun having a pair of opposing arms, where at least one arm is movable relative to the other arm to apply pressure to a workpiece during a welding operation. At least one of the opposing arms of the weld gun can be rotatable or translatable relative to the other arm. At least one arm is moved relative to the other arm by an inverted roller screw linear actuator. The robot can include an electric controller for controlling the operation of the actuator of the weld gun as an additional axis of the robot movement. The actuator can be mounted on either of the opposing arms.

Abstract: A probe for touch sensing to determine the position of a workpiece in a robot welding system using a robot driven welding gun for advancing a welding wire in a given direction toward a workpiece. The gun is movable by a robot controlled arm in a selected weld path and the probe comprises a rigid, elongated feeler with a touch tip which feeler is carried by a mechanism fixed with respect to the gun and movable by the mechanism between a retracted position and a known extended position wherein the feeler extends from the mechanism a fixed distance having an outermost contact point for the touch tip where the point has a known spatial relation to the gun. A detector detects when the contact point touches the workpiece to locate the workpiece. Several touches are used to determine the orientation of the workpiece for automatic welding.

Abstract: A welding machine manipulated by automated equipment controls feeding of depositing metal independently of controlling a welding current, so that the welding can be finely controlled and quality welding is achievable. The welding machine includes a robot having an arm for moving a welding torch, a robot controller for controlling the movement of the robot, a welding power source coupled to the torch, a depositing metal feeder for feeding depositing metal to the welding torch, and a feeder controller for controlling the feeder. The robot controller is coupled to the feeder controller for transmitting a control signal, related to feeding the depositing metal, to the feeder controller.

Abstract: A technique for judging a welding quality for acceptance or rejection and displaying the result in diagrams, and an automatic welding device incorporating the technique therein. When an operation result record status judging means judges that past operation records are available, temperature distribution operation result records at joints of works to be welded are displayed by a weld penetration display means (23) and bead surface shape operation result records are displayed by a bead surface shape display means (25), whereby time required for operation by a temperature distribution operation means and time required for operation by a bead surface shape operation means (24) are omitted by an operation time omitting means incorporated in the automatic welding device.

Abstract: A method and apparatus for calibrating a welding-type power supply and a robot are disclosed. They include entering a calibration mode (in the welding-type power supply) and providing one or two predetermined commands (for a welding parameter) from the robot to the welding-type power supply, and comparing them to two standards. A command scaling curve for the parameter is calculated in response to the comparisons. Predetermined commands, relating to two or more different welding parameters, may be used to calibrate two or more parameters, and to create two or more command scaling curves. Parameters that are calibrated include wire feed speed, voltage and arc length (trim). Feedback from the welding-type power supply may be provided to the robot that is indicative of a commanded output. The predetermined commands may alternatively be user-determined, or provided by a user interface or a memory.

Abstract: Oil and gas industry employs a large quantity of hardware in its operations. They require periodic repair, maintenance and modification. Many of these hardware are located beyond direct human access and in inhospitable environment. The traditional solution methods are handicapped, in most cases, by inevitable guesses as to the nature of problems; solutions tend to be less efficient and cost effective due to lack of direct, real time control. The present invention, consisting of a combined system and process, alleviates those problems by extending a remote operator's visual contact and operations control to work area. It combines the principles of oil field operations, coiled tubing, robotics and video technologies. A working tool, 22, is conveyed to work area at the end of a coiled tubing, 20. The working tool, 22, is operated remotely from command center, 12, by operator. Working tool, 22, contains cameras, grinder, wire brush, welder, mounted on teleoperators and servomechanism to control them.

Abstract: Shape of a long reach device, e.g., a welding torch, suitable for use within a portion of an object along a joint curve, e.g., a weld joint, is determined by dissecting the long reach device into a discrete number of portions, identifying ranges of movement between each of the portions, and discretizing the ranges of movement into a predetermined number of intervals. A total number of possible shapes is determined based on the total portions of the long reach device having the first movement range discretized into a predetermined number of intervals. A representation of the long reach device having one of the possible shapes is compared with the representation of the portion of the object.

Abstract: Disclosed is an apparatus for passing solid objects for use in a robotic tool changing system. The apparatus comprises a housing mounted on either a master assembly or a tool assembly. A tubular member is disposed in the housing and defines a passage through which solid objects can pass. The tubular member includes a head portion at one end and a stem portion at the other end that is connected to a solid objects feed tube. Means are provided for retaining the tubular member in the opening in the housing for movement relative to the housing during the coupling and uncoupling of the master and tool assemblies to accommodate misalignment of the master and tool assemblies. Another apparatus is disclosed for passing solid objects from a source to a work tool. The apparatus comprises first and second housings mounted on a master assembly and tool assembly, each housing tubular members.

Abstract: A method and apparatus for welding with a robotic welder is disclosed. The system includes a power supply, preferably phase controlled, a controller and a robotic interface. The components are in a single housing. the controller is externally controlled. An adaptor cord connects a robot controller to the power supply. The controller also has an automatic set-up control connected to the power control output.

Abstract: A method and apparatus for welding with a robotic welder is disclosed. The system includes a power supply, a controller and a robotic interface. The controller includes, in a single housing, a robot-type detector and at least one power control output connected to the power supply. The robot-type detector is connected to the robot interface. An adaptor cord connects the robot controller to the power supply. The controller also has an automatic set-up control connected to the power control output.

Abstract: A method of and device for automatically setting and updating a reference position of a welding tip of a servo spot welding gun to automatically compensate displacement of a distal end of a welding tip by abrasion thereof. A movable welding tip is moved towards a stationary welding tip to press the stationary welding tip until an estimated disturbance load reaches a fist threshold, and then moved in reverse direction away from the stationary welding tip until the disturbance load is reduced to a second threshold. The position of the movable welding tip when the disturbance load is reduced to the second threshold is set and updated as the reference position of an axis of the movable welding tip. The first threshold is set to be greater than a frictional force exerted on the axis of the movable welding tip in the motion towards the stationary welding tip, and the second threshold is set to be equivalent to the frictional force.

Abstract: A method for correcting a preset locus of a teaching point for a welding robot having a touch sensor, includes the steps of positioning a workpiece on a welding jig, performing a touch-sensor tracking for the workpiece relative to reference coordinate axes, calculating a displacement of the workpiece through the touch-sensor tracking, and obtaining a new locus of the teaching point based on a transformation matrix generated on the basis of the displacement. With these steps, the teaching points are correctly updated by a touch sensor tracking without an additional equipment for optional sensor tracking, such as laser sensors and arc sensors.

Abstract: An electric arc welding robot for welding a zone of a rail or the like comprises a movable, electric arc torch unit for operating the welding, first controlling means for controlling a first displacement of the torch unit substantially in front of the periphery of the zone to be welded, so that welding geometrical locations are read on said zone, by means of reading means connected to a memory unit, for memorizing said welding geometrical locations read on the rail, and second controlling means for automatically controlling a second displacement of the torch unit in front of the zone to be welded, within the limits of said reading and as a function of the welding geometrical locations, as memorized.

Abstract: Shape of a long reach device, e.g., a welding torch, suitable for use within a portion of an object along a joint curve, e.g., a weld joint, is determined by dissecting the long reach device into a discrete number of portions, identifying ranges of movement between each of the portions, and discretizing the ranges of movement into a predetermined number of intervals. A total number of possible shapes is determined based on the total portions of the long reach device having the first movement range discretized into a predetermined number of intervals. A representation of the long reach device having one of the possible shapes is compared with the representation of the portion of the object.

Abstract: The present invention relates to an electrical terminal implementation device that fabricates individual terminals, positions the terminals at their point of use, and connects the terminals to the subject components. The present device may also include apparatus for attaching the terminals to a component, testing the connection between the terminal and the component, coating the terminals with flux, shaping the terminals, and burnishing the component. More specifically, the present invention includes a terminal feeder by which integrated terminals are fed into the device. The integrated terminals are directed from the feeder toward a punch by a selector assembly. Before an individual terminal is cut from the integrated terminals by the punch, a loader assembly grips the individual terminal. Once separated from the integrated terminals, the individual terminal is moved by the loader assembly to the positioner assembly.

Abstract: A system and a method for re-calibrating a robot, an end-effectuator of the robot and a fixture for holding a production part based upon measurements recorded by a sensor after contact or interception with random points along the three-dimensional contour of the end-effectuator of the robot.

Abstract: Motorized slides are inserted between the end of a robot arm and a robot tool/sensor arrangement to provide additional positioning ability. A control unit of the slides cooperates with the control unit of the sensor to maintain the tool correctly positioned over a feature while the robot arm moves following a programmed path. The control unit of the sensor has look-ahead and additional buffers from which corrected information is determined to compensate for robot teaching inaccuracies, calibration and robot arm response errors. A sensor with two distinct probing zones is used to get information about the position of the tool tip and of the feature to assist in calibrating the sensor/tool relation.

Abstract: A system for manipulating a workpiece in an industrial robot system having a manipulator device for manipulating the workpiece, a tooling adapter coupled to the manipulator device for manipulating the workpiece, and an image referencing system for acquiring image data corresponding to the workpiece without interference from the manipulator device.

Abstract: Various methods, systems and products are disclosed for providing an improved welding system which substantially improves the continuous operation of an automated welding system by increasing the amount of time between maintenance shutdowns. One of the disclosed method steps or system elements provides for dipping a welding nozzle [28 or 28a] and a portion of its related diffuser into a bath [12 or 12a] of fluid each time the automated welding system moves through a welding cycle. A product is also disclosed to best accomplish that step or element. Another method step or system element may include the removal of spatter accumulation via an electromagnetic field that magnetically pulls the spatter without direct contact with the nozzle or diffuser.

Abstract: Disclosed is an automatic welding system for cylinder block recycling. The system welds a cylinder head seating part, an upper cylinder liner assembly part, a lower cylinder liner assembly part and a main bearing assembly part, to enable a cylinder block of an engine to be recycled. The system comprises a supporting section for rotatably supporting the cylinder block; a driving section installed on the supporting section for rotating the cylinder block; a welding section for welding the cylinder head seating part, the upper cylinder liner assembly part, the lower cylinder liner assembly part and the main bearing assembly part of the cylinder block; a moving section for moving the welding section along a lengthwise direction of the cylinder block to a welding execution position; and a central controlling section for controlling the driving section, welding section and the moving section.

Abstract: Constituent pieces of a structure to be welded are arranged in a desired configuration on a support surface and are welded together at a plurality of weld points to form the welded structure. At least one image of the arrangement of the constituent pieces on the support surface is recorded and the positions of the weld points are determined from the image(s). The welding of the constituent pieces is controlled on the basis of the determined positions of the weld points.

Abstract: A gas turbine component can be refurbished and/or repaired with an arc welding process that is used in conjunction with a 6-axis robot, a camera and a robot controller/vision processor. Applied to a wire fed plasma welding process, the vision system identifies the part, constructs a weld path based on the part's individual contour, and calculates a trajectory (with or without sinusoidal oscillation) for the robot arm to follow.

Abstract: The light pinpointing device is for producing a pinpointing light signal at an operative center point of a robot tool. The pinpointing light signal is useful to properly position the robot tool during the teaching phase. The light pinpointing device comprises a frame having first and second opposite ends, the first end being provided with a fastener for fastening the frame to an end of the robot tool. A light source assembly is provided to produce a pair of light beams inside the frame. A lens in front of the light source assembly is provided for directing the light beams through the second end of the frame in converging directions so that the light beams intersect with each other at a distance from the end of the robot tool corresponding to the operative center point thereof, thereby providing the pinpointing light signal.

Abstract: A method provides an exact measurement of the tool center point (TCP) being carried out, preferably in the whole working area of the robot. In this measurement, the robot moves very slowly so that little heat is generated by the driving assemblies and the temperature gradients are as low as possible. The measurement can be made, for example, using a high-precision laser distance and angle measurement system. The measurement is carried out such that a measuring point is moved to working area points and then the deviations of the positions and/or orientations of the measuring point are determined using the laser distance and angle measurement system, i.e. a nominal/actual comparison is made. The TCP can preferably serve as the measuring point. The point must always be selected so that the positioning and orientation deviations of the kinematic chain with respect to the PCT can be determined with sufficient accuracy.

Abstract: A welding machine manipulated by automated equipment controls feeding of depositing metal independently of controlling a welding current, so that the welding can be finely controlled and quality welding is achievable. The welding machine includes a robot having an arm for moving a welding torch, a robot controller for controlling the movement of the robot, a welding power source coupled to the torch, a depositing metal feeder for feeding depositing metal to the welding torch, and a feeder controller for controlling the feeder. The robot controller is coupled to the feeder controller for transmitting a control signal, related to feeding the depositing metal, to the feeder controller.

Abstract: The floor of a motor vehicle which is assembled in a floor assembly station is transported to a subsequent station using at least two welding robots on each lateral side of the floor assembly station. These welding robots are constituted into dual-purpose welding robots for performing both welding work and transporting work. After the assembling of the floor has been finished, the floor is supported at four lateral and longitudinal jack-up points through the workpiece receiving member by the cooperation of these dual-purpose welding robots, and is transported from the floor assembly station to the subsequent station.

Abstract: An improved welding robot has the power fed to the welding nozzle through a slip-ring assembly so that the power cable does not have to rotate as the welding nozzle rotates during a circular welding process.

Abstract: A storage library includes a first robotic mechanism having an energy coupler and a second robotic mechanism having an energy coupler. The storage library further includes tracks disposed adjacent to media object storage cells for enabling access to each of the media object storage cells, and powered rails associated with the tracks for providing energy. The first robotic mechanism is movable toward the second robotic mechanism to enable the energy coupler of the first robotic mechanism to couple with the energy coupler of the second robotic mechanism to transfer energy from the first robotic mechanism to the second robotic mechanism. The energy couplers of the first and second robotic mechanisms couple together to transfer energy from the powered rails to the second robotic mechanism. The energy couplers of the first and second robotic mechanisms couple together to transfer energy between on-board energy sources.

Abstract: Parameters of a robot is displayed on a display device of an operation terminal in a manner that parameters having been changed and parameters having not been changed of all the parameters are displayed in a distinguished manner such that the background color of the parameters having been changed differs from that of other data.

Abstract: An intelligent welding gun is provided with a fixed side sensor in a fixed side portion. The mechanical impedance of the fixed side portion is kept small, which permits the mechanical impedance to be set in a range where the fixed side sensor can effectively detect at least one of a position of a fixed side welding tip and a pressing force imposed on the fixed side welding tip. The fixed side sensor and a moving side sensor constitute a redundant sensor measurement system. Various kinds of methods conducted using the above welding gun include a method of calibrating a sensor (including calibration of a reference point and a gain), a control method of suppressing a welding expulsion, a re-welding feedback control method, a control method of a welding strength, a control method of reducing a clearance between workpieces, a method of correcting a welding robot track, and a method of managing a positional accuracy change at a welding point.

Abstract: An arc welding apparatus comprising a combination of a teaching-playback robot and an arc welding power source is provided. Even when, in changing a welding method, one welding power source for one welding method is replaced by another welding power source for another welding method, the welding apparatus does not require an adjustment between a robot controller and the latter arc welding power source for consistency between them. The arc welding apparatus comprises a teaching-playback robot comprising a robot body and a robot controller and a welding power source including a controller. The robot controller and the controller of the welding power source both have a communication controller, and communicate with each other using a digital signal. On the basis of information on the welding method transmitted from the welding power source, the welding method is automatically set into the robot controller.

Abstract: A robot controller is provided which can smoothly switch the mode between a position control in a free space and a position or force control to a contact surface, so that even if the contact surface has an unknown geometric error, the control system mode can be switched without the damage of a contact object and a workpiece and the out-of-control of the robot. The workpiece is moved to approach an estimated contact surface within the free space under a position control. Next, a groping motion is carried out under a position control from the estimated contact surface to an actual contact surface, and switched to a contact motion under a force control at the time point when the detected force value exceeds a certain threshold value. Then, a leaving motion is carried out.

Abstract: A welding method and system for welding a workpiece at weld locations includes a weld controller having control logic and stored data related to weld locations and workpiece dimensions. The weld controller is operable with a displacement sensor for monitoring the displacement between the electrodes of a weld gun. The control logic is programmed to generate a move signal based upon the stored data and the displacement between the electrodes. The weld controller also has stored data related to primary and alternate weld locations. The control logic is programmed to generate a fault signal based upon the stored data and a welding parameter such as the displacement between the electrodes. The weld controller provides a fault signal to the position controller to index the weld gun from a primary weld location to an alternate weld location when a comparison of the welding parameter to stored data related to the primary weld location indicates that the workpiece has been improperly welded.

Abstract: A method and system for automatically filing the narrow gap between facing end walls of adjacent first and second railway rails by depositing vertically spaced layers of molten metal in the gap with an electric arc welding torch using a robotic mechanism that moves the torch in a pattern controlled by a low level robotic execute program from a spatial position to a next spatial position, said method and system comprising: constructing a data array for a specific gap, said array constituting a series of positions making up an idealized progression of said torch to fill said gaps in vertically spaced layers made up of multiple positions, each of said fixed positions identified by at least four coordinates, including (1) at least x, y and z, (2) the layer in which said position is a part and (3) the welding parameters to be executed while said torch moves toward the next position; outputting data relating to a specific position from said data array; processing said welding parameters associated with said outputt

Abstract: A welding apparatus, wherein the robot controller of the teaching playback type robot thereof is combined with the control portion of the welding power source thereof, each of the control portions of the robot controller and the welding power source is a digital-control type and provided with a digital communication control portion, and welding condition commands including at least a welding current command value are transmitted by using digital data through the communication control portions from the robot controller to the control portion of the welding power source. The present invention can thus provide a welding apparatus excluding conversion errors because of the existence of analog circuits.

Abstract: Disclosed is a method for correcting teaching points for a welding robot. The method for correcting teaching points for a welding robot having a touch sensor, comprising the steps of mounting a workpiece to a welding jig; establishing at least one teaching point between an initial welding point and a terminating welding point; touch-sensing the workpiece at a point corresponding to the established teaching point through the touch sensor; identifying a point detected by the touch-sensing; and obtaining a new teaching point based on the difference between the established teaching point and the detection point. With these steps, the teaching points are correctly updated by a touch sensor tracking without an additional equipment for optional sensor tracking, such as laser sensors, arc sensors, etc., thereby performing the welding operation along the correct welding path.

Abstract: The invention provides an arc welding monitoring device by which it is possible to easily find how detected data such as a welding current and welding voltage correspond to trajectories of a robot, in other words, welding line information of a welding work. The arc welding monitoring device comprises means 4 and 5 for detecting at least either the welding current or welding voltage, a means 14 for storing the detected data, a means 14 for storing trajectories of a robot, and a means for displaying, on a screen display, at least either the welding current or welding voltage detected by said detecting means, and the trajectories of the robot stored by the storing means, wherein a range is determined on the trajectories displayed on the screen display, and arc welding monitoring display is enabled in compliance with the range.

Abstract: The Boiler Automated Welding System (BAWS) is an automatic welding system for repair of worn boiler tubes in cyclone boilers. Repair of these tubes is essential for extending the life of this component used within electrical power plants. The BAWS utilizes: 1) a multiaxis positioner which forms the required cylindrical coordinate motion system, 2) a tube tracking systems for determination of motion paths during welding, 3) a two axis gimbaled welding torch holder for orientation of the welds relative to the motion path, 4) an integrated welding system and 5) a computer controller which coordinates these devices in a logical method. The BAWS multiaxis positioner allows for orientation of the system within the cyclone boiler to take advantage of the symmetry of the tube layout (cylindrical coordinates). The positioner allows each individual tube to be scanned and a weld path determined using a laser scanning device.

Abstract: In a shift correcting method of correcting a shift of a tool working position in a robot manipulation system, a working tool (7) is rotated around a tool longitudinal axis (m) as a rotating center axis on a tool coordinate system to change a posture of the working tool, and the working tool is moved in one direction toward a specified part of a contact detecting member (21) to be brought into contact therewith to detect a contact and the data of the detected contact position is stored to obtain a difference as a shift amount between the actual tool working position and a theoretical tool working position.

Abstract: A robotic safety clutch that provides a wireless connection between the safety clutch and an robotic/automatic arm controller. The safety clutch includes a sensor for sensing a crash event and a radio frequency transmitter for transmitting a crash signal in response to the sensed crash event to a radio frequency receiver. The radio frequency receiver is connected to the robotic/automatic arm controller. Upon receiving the crash signal from the transmitter, the receiver sends a crash signal to the controller and in response to the crash signal, the controller shuts down all robotic/automatic functions.

Abstract: An arc welding torch for robotic applications having sensing capabilities to provide intelligent diagnostics monitoring of the welding process in real time. A plurality of modular sensors are integrated with the torch to provide real-time monitoring of wire speed, arc voltage, gas flow, seam-tracking, welding current temperature and contact tip wear. The torch includes a contact tip wear sensor for sensing the wearing of the tip during the welding process. The shielding gas flow is measured by a gas flow sensor mounted between the main housing and the gooseneck. A seam-tracking sensor is mounted on the outside of the housing to detect the position of the seam to be welded. The speed of the consumable electrode is measured by a wire speed sensor module. To ensure that operating temperatures of components near the arc region are within predetermined ranges for optimum performance of the torch, temperature sensors are mounted on the torch.

Abstract: Axes used for posture alignment are selected from the axes of a work coordinate system W and a tool coordinate system T, and an angle of intersection between those selected axes are set. A robot is then driven so that the selected axes intersect with each other by the set angle of intersection in response to a posture alignment instruction, causing the tool to assume a target posture with respect to a workpiece. Further, angles for rotating the work coordinate system about each axis thereof are set, then the robot is automatically moved so that a coordinate system produced by rotating the work coordinate system by the set angle in response to a posture alignment instruction. Further, the tool coordinate system set at a movable part of a tool is automatically reset according to an amount of movement every time the movable part of the tool move, and the robot is manually fed based on the tool coordinate system thus reset.

Abstract: A welding system includes an imaging system that takes frame by frame pictures of a weld puddle. The imaging system is located in the weld torch. From the images puddle length and width are determined. The length and width are applied against stored membership functions that cover a range of different weld current characteristics and the degree of membership of each dimension in those functions is determined, producing an alpha factor for each membership function. This provides a fuzzy current requirement. Stored values for moment and area for each membership function are multiplied by the alpha for the respective function. The total of the moments is divided by the total of the areas to produce a desired weld current. The weld head includes a weld wire feeder that is driven by a servo by which the wire can be feed along either side of the weld joint. The wire feeder is gear driven in such a way that it does not interfere with the optics in the weld torch. The optics include a strobe to illuminate the puddle.