Development of Robotized Laser Welding Applications for Joining Thin Sheets

Laser Welding (LW) is more often used in manufacturing due to its advantages, such as accurate control, good repeatability, less heat input, opportunities for joining of special materials, high speed, capability to join small dimension parts etc. LW is dedicated to robotized manufacturing, and the fabrication cells are using various level of flexibility, from specialized robots to very flexible setups. This paper features several LW applications using two industrially-scaled manufacturing cells at UPM Laser Centre (CLUPM) of Polytechnical University of Madrid (Universidad Politécnica de Madrid). The one dedicated to Remote Laser Welding (RLW) of thin sheets for automotive and other sectors uses a CO2 laser of 3500 W. The second has a high flexibility, is based on a 6-axis ABB robot and a Nd:YAG laser of 3300 W, and is meant for various laser processing methods, including welding. After a short description of each cell, several LW applications experimented at CLUPM and recently implemented in industry are briefly presented: RLW of automotive coated sheets, LW of high strength automotive sheets, LW vs. laser hybrid welding (LHW) of Double Phase steel thin sheets, and LHW of thin sheets of stainless steel and carbon steel (dissimilar joints). The main technological issues overcame and the critical process parameters are pointed out. Conclusions about achievements and trends are provided.

A Motor-less and Gear-less Bio-mimetic Robotic Fish Design

In this paper, we describe our current work on bio-inspired locomotion systems using a deformable structure and smart materials, concretely Shape Memory Alloys, exploring the possibility of building motor-less and gear-less robots. A swimming underwater robot has been developed whose movements are generated using such actuators, used for bending the backbone of the fish, which in turn causes a change on the curvature of the body. This paper focuses on how standard swimming patterns can be reproduced with the proposed design, using an actuation dynamics model identified in prior work.

Bending continuous structures with SMAs: a novel robotic fish design

In this paper, we describe our research on bio-inspired locomotion systems using deformable structures and smart materials, concretely shape memory alloys (SMAs). These types of materials allow us to explore the possibility of building motor-less and gear-less robots. A swimming underwater fish-like robot has been developed whose movements are generated using SMAs. These actuators are suitable for bending the continuous backbone of the fish, which in turn causes a change in the curvature of the body. This type of structural arrangement is inspired by fish red muscles, which are mainly recruited during steady swimming for the bending of a flexible but nearly incompressible structure such as the fishbone. This paper reviews the design process of these bio-inspired structures, from the motivations and physiological inspiration to the mechatronics design, control and simulations, leading to actual experimental trials and results. The focus of this work is to present the mechanisms by which standard swimming patterns can be reproduced with the proposed design. Moreover, the performance of the SMA-based actuators’ control in terms of actuation speed and position accuracy is also addressed.

Performance indices for robotic manipulators: a review of the state of the art

The performance indices are important tools for motion planning and design of robot manipulators. In this paper we present a collection of some of the performance indices that have generated interest in the robotics community. These indices are four different types: kinetostatic performance indices, dynamic performance indices, indices of joint limits, and finally global performance indices. In addition, we review the strategies that have been proposed to solve the problems that occur when the units of the Jacobian matrix elements are not homogeneous. At the end of this paper, we propose a set of global performance indices that can be useful in the design of robot manipulators.

Design and modeling of the multi-agent robotic system: SMART

This article presents the design, kinematic model and communication architecture for the multi-agent robotic system called SMART. The philosophy behind this kind of system requires the communication architecture to contemplate the concurrence of the whole system. The proposed architecture combines different communication technologies (TCP/IP and Bluetooth) under one protocol designed for the cooperation among agents and other elements of the system such as IP-Cameras, image processing library, path planner, user Interface, control block and data block. The high level control is modeled by Work-Flow Petri nets and implemented in C++ and C♯♯. Experimental results show the performance of the designed architecture.

Wearable soft robotic device for post-stroke shoulder rehabilitation: identifying misalignments

Stroke is the leading cause of long-term disability in the United States, affecting over 795,000 people annually. In order to regain motor function of the upper body, patients are usually treated by regular sessions with a dedicated physical therapist. A cost-effective wearable upper body orthotics system that can be used at home to empower both the patients and physical therapists is described. The system is composed of a thin, compliant, lightweight, cost-effective soft orthotic device with an integrated cable actuation system that is worn over the upper body, an embedded limb position sensing system, an electric actuator package and controller. The proposed device is robust to misalignments that may occur during actuation of the compliant brace or when putting on the system. Through simulations and experimental evaluation, it was demonstrated i) that the soft orthotic cable-driven shoulder brace can be successfully actuated without the production of off-axis torques in the presence of misalignments and ii) that the proposed model can identify linear and angular misalignments online.

Residual stress distribution in ferritic-austenitic steel joints made by laser welding

The present investigation addresse the influence of laser welding process-ing parameters used for joining dis-similar metals (ferritic to austenitic steel), on the induced residual stress field. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuous wave (CW), keyhole mode. The base metals (BM) employed in this study are AISI 1010 carbon steel (CS) and AISI 304L austenitic stainless steel (SS). Pairs of dissimilar plates of 200 mm x 45 mm x 3 mm were butt joined by laser welding. Different sets of parameters were used to engineer the base metals apportionment at joint formation, namely distinct dilution rates. Residual strain scanning, carried out by neutron diffraction was used to assess the joints. Through-thickness residual stress maps were determined for the laser welded samples of dis-similar steels using high spatial reso-lution. As a result, an appropriate set of processing parameters, able to mi-nimize the local tensile residual stress associated to the welding process, was found.

Residual stress distribution in ferritic to austenitic steel joints made by laser welding,

In this study, autogenous laser welding was used to join thin plates of low carbon ferritic and austenitic stainless steel. Due to the differences in the thermo-physical properties of base metals, this kind of weld exhibits a complex microstructure, which frequently leads to an overall loss of joint quality. Four welded samples were prepared by using different sets of processing parameters, with the aim of minimizing the induced residual stress field. The dissimilar austenitic-ferritic joints obtained under all welding conditions were uniform and free of defects. Variations in beam position did not influence the weld geometiy, which is a typical keyhole welding. Microstructural characterization and residual strain scanning (by neutron diffraction) were used to assess the features of the joints. By varying laser beam power density and by displacing the laser beam towards the carbon steel side, an optimum combination of processing parameters was found.

Overall vs. local mechanical behaviour of ferritic austenitic steel joints made by laser welding

The present investigation addresses the overall and local mechanical performance of dissimilar joints of low carbon steel (CS) and stainless Steel (SS) thin sheets achieved by laser welding in case of heat source displacement from the weld gap centreline towards CS. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuos wave (CW), keyhole mode. The tensile behavior of the joint different zones assessed by using a video-image based system (VIC-2D) reveals that the residual stress field, together with the positive difference in yield between the weld metal and the base materials protects the joint from being plastically deformed. The tensile loadings of flat transverse specimens generate the strain localization and failure in CS, far away from the weld.

Desing and development of a robotic platform for the evaluation of search algorithms

Plant diseases represent a major economic and environmental problem in agriculture and forestry. Upon infection, a plant develops symptoms that affect different parts of the plant causing a significant agronomic impact. As many such diseases spread in time over the whole crop, a system for early disease detection can aid to mitigate the losses produced by the plant diseases and can further prevent their spread [1]. In recent years, several mathematical algorithms of search have been proposed [2,3] that could be used as a non-invasive, fast, reliable and cost-effective methods to localize in space infectious focus by detecting changes in the profile of volatile organic compounds. Tracking scents and locating odor sources is a major challenge in robotics, on one hand because odour plumes consists of non-uniform intermittent odour patches dispersed by the wind and on the other hand because of the lack of precise and reliable odour sensors. Notwithstanding, we have develop a simple robotic platform to study the robustness and effectiveness of different search algorithms [4], with respect to specific problems to be found in their further application in agriculture, namely errors committed in the motion and sensing and to the existence of spatial constraints due to land topology or the presence of obstacles.

Fish physiology put into practice: A robotic fish model

Underwater creatures are capable of high performance movements in water. Thus, underwaterrobot design based on the mechanism of fish locomotion appears to be a promising approach.Over the past few years, researches have been developing underwater robots based on underwatercreatures swimming mechanism.

An Implemented of a Real-Time Experimental Setup for Robotic Teleoperation System

The development of this work presents the implementation of an experimental platform, which will permit to investigate on a methodology for the design and analysis of a teleoperated system, considering the delay in the communication channel. The project has been developed in partnership with the laboratory of Automatic and Robotics of the Universidad Politécnica de Madrid and the Laboratory at the Centro de Tecnologías Avanzadas de Manufactura at the Pontificia Universidad Católica del Perú. The mechanical structure of the arm that is located in the remote side has been built and the electric servomechanism has been mounted to control their movement. The experimental test of the Teleoperation system has been developed. The PC104 card commands the power interface and sensors of the DC motor of each articulation of the arm. Has developed the drives for the management of the operations of the master and the slave: send/reception of position, speed, acceleration and current data through a CAN network. The programs for the interconnection through a LAN network, between the Windows Operating System and the Real-time Operating System (QNX), has been developed. The utility of the developed platform (hardware and software) has been demonstrated.

Ensayo no destructivo de soldaduras en pernos conectores mediante inspección acústica = Non-destructive test of welding headed studs through acoustic emission

Los pernos conectores aportan múltiples ventajas de uso, entre las que se encuentra el elevado margen de seguridad que ofrecen sus soldaduras ejecutadas mediante arco eléctrico. Estas soldaduras, aunque ampliamente fiables, son difícilmente comprobadas mediante ensayos no destructivos. Aparte de la inspección visual, que aporta gran información sobre la calidad de ejecución de la soldadura, el resto de ensayos no destructivos (líquidos penetrantes, partículas magnéticas, ultrasonidos, radiografías, etc.) resultan inviables en estos elementos. Por otro lado, los ensayos acústicos de piezas metálicas han existido siempre. Su comprobación se basaba en el análisis por medio de ¿un oído fino¿ del sonido resultante tras ser golpeado el elemento a evaluar. Con estas premisas se plantea el presente estudio de inspección de las soldaduras en pernos conectores mediante su espectro acústico. Analíticamente, la investigación se ha centrado en el cálculo informático de los primeros modos propios de vibración mediante elementos finitos. Se han modelizado diferentes grados de penetración de la soldadura mediante la modificación de las condiciones de contorno. Se ha observado que variando el número de movimientos coaccionados en los nodos pertenecientes a la soldadura se produce una reducción en su frecuencia de vibración.

Grasp Mapping Between a 3-Finger Haptic Device and a Robotic Hand

This paper presents the implementation of a robust grasp mapping between a 3-finger haptic device (master) and a robotic hand (slave). Mapping is based on a grasp equivalence defined considering the manipulation capabilities of the master and slave devices. The metrics that translate the human hand gesture to the robotic hand workspace are obtained through an analytical user study. This allows a natural control of the robotic hand. The grasp mapping is accomplished defining 4 control modes that encapsulate all the grasps gestures considered.

Evaluation of mission planning strategies of a robotic aerial vehicle for the AIRC international competition

The International Aerial Robotics Competition (IARC) is an important event where teams from universities design flying autonomous vehicles to overcome the last challenges in the field. The goal of the Seventh Mission proposed by the IARC is to guide several mobile ground robots to a target area. The scenario is complex and not determinist due to the random behavior of the ground robots movement. The UAV must select efficient strategies to complete the mission. The goal of this work has been evaluating different alternative mission planning strategies of a UAV for this competition. The Mission Planner component is in charge of taking the UAV decisions. Different strategies have been developed and evaluated for the component, achieving a better performance Mission Planner and valuable knowledge about the mission. For this purpose, it was necessary to develop a simulator to evaluate the different strategies. The simulator was built as an improvement of an existing previous version.