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Search Results (3)

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Keywords = multi-degree-of-freedom welding

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29 pages, 20381 KiB  
Article
A Study on the Force/Position Hybrid Control Strategy for Eight-Axis Robotic Friction Stir Welding
by Wenjun Yan and Yue Yu
Metals 2025, 15(4), 442; https://doi.org/10.3390/met15040442 - 16 Apr 2025
Viewed by 762
Abstract
In aerospace and new-energy vehicle manufacturing, there is an increasing demand for the high-quality joining of large, curved aluminum alloy structures. This study presents a robotic friction stir welding (RFSW) system employing a force/position hybrid control. An eight-axis linkage platform integrates an electric [...] Read more.
In aerospace and new-energy vehicle manufacturing, there is an increasing demand for the high-quality joining of large, curved aluminum alloy structures. This study presents a robotic friction stir welding (RFSW) system employing a force/position hybrid control. An eight-axis linkage platform integrates an electric spindle, multidimensional force sensors, and a laser displacement sensor, ensuring trajectory coordination between the robot and the positioner. By combining long-range constant displacement with small-range constant pressure—supplemented by an adaptive transition algorithm—the system regulates the axial stirring depth and downward force. The experimental results confirm that this approach effectively compensates for robotic flexibility, keeping weld depth and pressure deviations within 5%, significantly improving seam quality. Further welding verification was performed on typical curved panels for aerospace applications, and the results demonstrated strong adaptability under high-load, multi-DOF conditions, without crack formation. This research could advance the field toward more robust, automated, and adaptive RFSW solutions for aerospace, automotive, and other high-end manufacturing applications. Full article
(This article belongs to the Section Welding and Joining)
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14 pages, 4361 KiB  
Article
An Improved Deviation Coupling Control Method for Speed Synchronization of Multi-Motor Systems
by Ying Mu, Liqun Qi, Mingyuan Sun and Wenbo Han
Appl. Sci. 2024, 14(12), 5300; https://doi.org/10.3390/app14125300 - 19 Jun 2024
Cited by 7 | Viewed by 1436
Abstract
In order to enhance the synchronization of welding robot arms and improve welding quality, this study proposes a fuzzy PID-based improved deviation coupling multi-axis synchronous control method. Firstly, in response to the intricacies inherent in the compensation mechanism of the deviation coupling control [...] Read more.
In order to enhance the synchronization of welding robot arms and improve welding quality, this study proposes a fuzzy PID-based improved deviation coupling multi-axis synchronous control method. Firstly, in response to the intricacies inherent in the compensation mechanism of the deviation coupling control structure and the substantial volume of system computation, the integration of average speed and sub-average speed is proposed to optimize the speed compensator. This integration aims to mitigate speed synchronization errors, minimize synchronization adjustment time, and elevate overall system synchronization performance. Moreover, the fuzzy PID algorithm is employed to design the controller to realize the single-motor adaptive control, leading to improvement in both system stability and dynamic response performance. Finally, a simulation model for six-axis synchronization control and an experimental platform were developed. Both simulation and experimental results demonstrate that the improved deviation coupling control method exhibits superior synchronization performance. The proposed multi-axis synchronous control method effectively heightens the synchronous performance of the six-degrees-of-freedom robotic arm. Full article
(This article belongs to the Special Issue Advanced Control Systems and Applications)
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20 pages, 5929 KiB  
Article
Optimization Design and Flexible Detection Method of Wall-Climbing Robot System with Multiple Sensors Integration for Magnetic Particle Testing
by Xiaojun Zhang, Xuan Zhang, Minglu Zhang, Lingyu Sun and Manhong Li
Sensors 2020, 20(16), 4582; https://doi.org/10.3390/s20164582 - 15 Aug 2020
Cited by 20 | Viewed by 4852
Abstract
Weld detection is vital to the quality of ship construction and navigation safety, and numerous detection robots have been developed and widely applied. Focusing on the current bottleneck of robot safety, efficiency, and intelligent detection, this paper developed a wall-climbing robot that integrates [...] Read more.
Weld detection is vital to the quality of ship construction and navigation safety, and numerous detection robots have been developed and widely applied. Focusing on the current bottleneck of robot safety, efficiency, and intelligent detection, this paper developed a wall-climbing robot that integrates multiple sensors and uses fluorescent magnetic powder for nondestructive testing. We designed a moving mechanism that can safely move on a curved surface and a serial-parallel hybrid flexible detection mechanism that incorporates a force sensor to solve the robot’s safe adsorption and a flexible detection of the curved surface to complete the flaw detection operation. We optimized the system structure and improved the overall performance of the robot by establishing a unified mechanical model for different operating conditions. Based on the collected sensor information, a multi-degree of freedom component collaborative flexible detection method with a standard detecting process was developed to complete efficient, high-quality detection. Results showed that the developed wall-climbing robot can move safely and steadily on the complex facade and can complete the flaw detection of wall welds. Full article
(This article belongs to the Special Issue Sensing Applications in Robotics)
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