Research on adaptive adjustment of welding torch pose in wire and arc additive remanufacturing of hot-forging dies

• Published in: International journal of advanced manufacturing technology Vol. 121; no. 5-6; pp. 3499 - 3510
• Main Authors: Shen, Yonghua, Wei, Yanhong, Du, Xinwei, Liu, Renpei
• Format: Journal Article
• Language: English
• Published: London Springer London 01.07.2022; Springer Nature B.V
• Subjects: Adaptive algorithms; Algorithms; CAE) and Design; Collision avoidance; Computer-Aided Engineering (CAD; Cylinder liners; Die forging; Engineering; Forging dies; Industrial and Production Engineering; Intersections; Mechanical Engineering; Media Management; Motion planning; Original Article; Quaternions; Remanufacturing; Robot dynamics; Welding; Wire; Welding torch pose; Collision detection; Hot-forging die; Additive remanufacturing
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-022-09548-8

Robot automatic motion planning is a significant issue in wire and arc additive remanufacturing (WAAR) of hot-forging dies. In order to realize collision-free robot motions in the WAAR process, this paper proposes a series of algorithms for the adaptive adjustment of welding torch pose. The collision detection between the welding torch and the die is divided into two phases: preliminary detection and precise detection. In the preliminary detection phase, spatial partitioning and bounding volumes are adopted to reduce the number of intersection tests between primitives. The intersection test between the line segment and the cylinder is performed in the precise detection phase. Subsequently, based on the results of collision detection, the corresponding adaptive adjustment algorithms for the welding torch pose are developed for the contour paths and the zigzag paths, respectively. In addition, the solution process of the quaternion representing the pose of the welding torch is designed. At last, the comparison tests of the three algorithms and the remanufacturing experiment of four dies verify that the proposed collision detection algorithm has great advantages in efficiency and the effectiveness of the adaptive adjustment algorithm of welding torch pose.