Colloquia

Summary

This thesis presents a methodology to replace jig-based welding systems with jigless solutions utilizing articulated robots. The goal is to reduce overall cycle time and increase flexibility to handle more product variations. The methodology entails setting the requirements first, followed by designing a robotic cell layout, selecting suitable grippers, defining required components, and experimental verification via simulation. It is applied to a case study of welding steel brackets. The application successfully designs customized solutions tailored to the bracket parameters. Simulation confirms the feasibility of the proposed cell layout and 21-second cycle time with a 74% reduction. Further prototyping is needed to quantify improvements versus jig welding. This research demonstrates the methodology's potential for flexible, automated jigless welding to improve productivity. The methodology involves four key steps:

1. Cell Layout Design: The overall arrangement of robots, workstations, and material flows is planned to optimize cycle time and collisions. 

2. Gripper Design: Robotic grippers are selected and designed to securely hold parts for welding without jigs. A 3-finger servo gripper is proposed.

3. Component Definition: Complementary equipment like vision systems, controls, and safety measures are specified. 

4. Simulation: The conceptual designs are tested and refined through simulation before physical implementation. 

The methodology is applied to a case study of welding HK5 and FK5 steel brackets. Solutions for the cell layout, gripper, and simulation model are developed based on bracket parameters. The simulation verifies the feasibility and 16-second cycle time, a 74% reduction versus jig welding. 

This demonstrates the methodology's potential to systematically design optimized jigless robotic welding cells customized for a range of parts. Further physical prototyping is needed to quantify accuracy and productivity gains versus jig welding. The research provides a promising structured approach to achieve the benefits of adaptable and efficient automation.