ItemArticle

Optimal setting of arc welding robot and laser sensor variables for getting maximal weld quality, positional accuracy, and smooth trajectory

Title
Optimal setting of arc welding robot and laser sensor variables for getting maximal weld quality, positional accuracy, and smooth trajectory
Creator
Rout, Amruta; Mahanta, Golak Bihari; Champatiray, Chiranjibi; Deepak, B.B.V.L.; Biswal, Bibhuti Bhusan
Description
Abstract: For seam-finding applications, a robotic welding system and laser sensor can be coupled to achieve improved repeatability and shorter cycle times. This manuscript investigates the impact of several robot variables, including robot orientation, robot travel speed, and focal length of the laser sensor, on three key factors: positioning error, associated joint jerk-torque rate, and weld quality. An Enhanced Multi-Objective NSGA-II (EMONSGA-II) is proposed, which combines NSGA-II with Nelder Mead local search to find the best values for robot and sensor variables. The goal is to acquire the lowest values for joint jerk-torque rate, positional error, and maximum weld quality metrics. The maximized weld quality is represented by maximized ultimate strength, yield strength, and penetration of weld joint, as minimized weld bead height and width. Fuzzy logic has been used to transform the multi-performance weld characteristics into one term of the weld quality. The experiments have been performed using the Arc 50 series welding system with AccuFast point laser sensor integrated MOTOMAN MA 1440 arc welding robot system. Finally, the optimal setting of the robot and sensor parameters have been validated through experimentation to observe the weld quality and positional accuracy. The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2025.
Source
International Journal on Interactive Design and Manufacturing;Volume;19;Issue;9;pp.6441-6456
Date
01-01-2025
Publisher
Springer-Verlag Italia s.r.l.
Subject
EMONSGA-II; Focal length; Fuzzy logic; Joint trajectory; Laser sensor; Robot orientation; Weld quality
Coverage
Rout A., Mechanical Engineering, Christ University, Karnataka, Bangalore, 560029, India; Mahanta G.B., Mechatronics and Automation Engineering, National Institute of Technology, Bihar, Patna, 800005, India; Champatiray C., Mechanical Engineering, Alliance University, Karnataka, Bangalore, 562106, India; Deepak B.B.V.L., Industrial Design, National Institute of Technology, Odisha, Rourkela, 769008, India; Biswal B.B., Mechanical Engineering, Odisha University of Technology and Research, Odisha, Bhubaneswar, 751029, India
Rights
Restricted Access; Hardcopy may be available in the library
Relation
ISSN: 19552513;
Format
online
Language
English
Type
Article

Citation

Rout, Amruta; Mahanta, Golak Bihari; Champatiray, Chiranjibi; Deepak, B.B.V.L.; Biswal, Bibhuti Bhusan, “Optimal setting of arc welding robot and laser sensor variables for getting maximal weld quality, positional accuracy, and smooth trajectory,” CHRIST (Deemed To Be University) Institutional Repository, accessed June 18, 2026, https://archives.christuniversity.in/items/show/21985.

Output Formats