Virtual Commissioning of the Trajectory Tracking Control of a Sensor-Guided, Kinematically Redundant Robotic Welding System on a PLC

Abstract

This article shows the methodical procedure for the model-based systems engineering and virtual commissioning of the motion control of a complex robotic system in the application field of welding automation. By the integration of external sensor technology, the system semi-automatically detects the weld seams of the assemblies to be welded. As part of real-time multi-objective optimization, the system’s kinematic redundancy is used during motion execution to avoid singularities and to comply with joint limits, making it easier for the system operator to set up the welding system. The simulation models created in virtual commissioning serve as additional visual support during system setup. This provides an approach to robot-based automation of manufacturing processes in small and medium enterprises, which often fails due to small batch sizes and lack of personnel with robotics skills.