An apparatus includes a welding torch, a laser capable of projecting a beam towards a seam on a surface, a camera directed towards the surface, a memory, and a processor. The processor receives an image of the surface from the camera. Next, the processor determines, based on the reflection of the laser beam from the surface, a vertical distance from the torch to the seam. The processor adjusts the brightness and contrast of the image, applies a gamma correction, and applies at least one gradient filter to the image to produce a new image. Next, the processor determines a horizontal location of the seam in the new image, which it uses to determine a horizontal distance from the torch to the seam. Based on the vertical and horizontal distances from the torch to the seam, the processor adjusts a vertical and a horizontal position of the torch.

A crawling welding robot, including an adjustable magnetic adhesion module, wheel-tracked walking mechanisms, a crawler frame, and a welding load device, wherein the welding load device is disposed on the crawler frame; the wheel-tracked walking mechanisms are disposed at two opposite ends of the crawler frame for supplying power for crawling of the crawler frame; and the adjustable magnetic adhesion module is disposed on the crawler frame and disposed between the two wheel-tracked walking mechanisms.

An arc-tracking welding method according to the present invention is an arc-tracking welding method in a consumable-electrode-type welding apparatus provided with a weaving function for swinging a torch in the welding direction, wherein a welding current and a welding voltage to be supplied to a consumable electrode include high-frequency components. A change in resistance value resulting from a fluctuation in electrode height is detected from the welding current and the welding voltage during welding. Then, a shift of a weld line is detected from information about the detected resistance value and both end positions of a weaving amplitude.

An arc-tracking welding method according to the present invention is an arc-tracking welding method in a consumable-electrode-type welding apparatus provided with a weaving function for swinging a torch in the welding direction, wherein a welding current and a welding voltage to be supplied to a consumable electrode include high-frequency components. A change in resistance value resulting from a fluctuation in electrode height is detected from the welding current and the welding voltage during welding. Then, a shift of a weld line is detected from information about the detected resistance value and both end positions of a weaving amplitude.

Embodiments of systems and methods for supporting predictive and preventative maintenance are disclosed. One embodiment includes manufacturing cells within a manufacturing environment, where each manufacturing cell includes a cell controller and welding equipment, cutting equipment, and/or additive manufacturing equipment. A communication network supports data communications between a central controller and the cell controller of each of the manufacturing cells. The central controller collects cell data from the cell controller of each of the manufacturing cells, via the communication network. The cell data is related to the operation, performance, and/or servicing of a same component type of each of the manufacturing cells to form a set of aggregated cell data for the component type. The central controller also analyzes the set of aggregated cell data to generate a predictive model related to future maintenance of the component type.

Embodiments of systems and methods for supporting predictive and preventative maintenance are disclosed. One embodiment includes manufacturing cells within a manufacturing environment, where each manufacturing cell includes a cell controller and welding equipment, cutting equipment, and/or additive manufacturing equipment. A communication network supports data communications between a central controller and the cell controller of each of the manufacturing cells. The central controller collects cell data from the cell controller of each of the manufacturing cells, via the communication network. The cell data is related to the operation, performance, and/or servicing of a same component type of each of the manufacturing cells to form a set of aggregated cell data for the component type. The central controller also analyzes the set of aggregated cell data to generate a predictive model related to future maintenance of the component type.

A system and method of enhanced automated welding of a first workpiece and a second workpiece are provided. The method comprises providing a system for intelligent robot-based welding of the first workpiece and the second workpiece. The method further comprises determining a geometrical location of the first workpiece and the second workpiece to be welded at a welding sequence based a predetermined process variable. The method further comprises adjusting the predetermined process variable based on the geometrical location of the first and second workpieces to define an actual process variable. The method further comprises welding a first portion of the first and second workpieces with the actual process variable to define a first welded portion. The method further comprises determining a weld quality of the first welded portion.

A welding automation system that uses the shape of a welding region includes a welding torch that is installed in a robot and welds a parent metal fixed on a mounting part. A line laser emits a laser beam to a welding line region that is spaced apart from a welding point of the welding torch. A detector images and detects, from a predetermined angle, the shape of the laser beam. A control unit receives information from the detector and controls transportation of the robot and drives the welding torch along the welding region so that the welding torch corresponds with the welding region. The welding torch is installed on a slider that moves vertically and laterally relative to the robot. The control unit controls movement of the robot and/or the mounting part to correspond to transportation coordinates obtained by the calculation unit, and controls driving of the welding torch.

A welding apparatus includes a welding torch mounted to a frame and electrically connectable in a source current path of a welding current source, and an electrically conductive return current roller rollably mounted to the frame a substantially fixed distance from the welding torch. The return current roller is electrically connectable in a return current path of the welding current source, and has a rim sized and shaped to roll in electrically conductive contact with an unwelded seam of a workpiece.

A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.