Optimal workplacement for robotic friction stir welding task

Abstract

Robotic manipulators are widely used in industry for welding processes. Inadequate joint stiffness in the manipulators often limits their use for high quality welding operations because of the deformation errors produced during the process. As a matter of fact, welding quality deteriorates with decreasing joint stiffness. This paper presents an approach to determine an optimal workspace of operation by minimizing the lateral deflection errors in position and orientation of the end effector during Friction Stir Welding. This has been done by estimating the errors in position and orientation of the end effector, also the point of contact with work piece which directly affects welding quality, when it experiences a wrench during welding operation. The technique was applied to an elastodynamic model of a 6 DOF manipulator with different path constraints for welding process to achieve optimal task placement. In a nutshell, optimal starting position or an optimal direction of motion for best welding quality can be precisely computed or even both together can be calculated but with numerical complexity.