Sensor-Based Robot Programming for Automated Manufacturing of High Orthogonal Volume Structures

This paper introduces an innovative method for the programming of welding robots in the area of steel volume structure production. The objectives of this programming method are reducing the effort of creating robot programs as well as increasing productivity in production. Starting point of the programming method is a three-dimensional digitalization of the current workpiece. Based on the 3D sensor data of the workpiece the individual components of the construction are identified automatically as well as the weld seams required for connecting them. In this process, 3D sensor data of the components are transformed into simplified regular geometric shapes that will be used later on for collision testing. Collision testing is part of a postprocessor with specially developed path planning algorithms to determine the robot movements required for welding the identified seams. Finally, the robot movements are converted into a system-specific robot program. The developed programming method has been integrated into an existing production facility at Warnow shipyard in Rostock-Warnemünde and was tested under real production conditions.