Generation of rule-adhering robot programs for aluminium welding automatically from CAD

This paper presents a method to automatically generate robot welding programs from CAD to address the ever-constant demand for product customisation. Furthermore, to ensure that proper welding operations and structural integrity are met, the generated programs also consider the welding conditions and requirements. These welding conditions and requirements are defined by the weld direction and face relative to gravity and surrounding geometry, which has not been observed in the present research sphere. To achieve this, the approach leverages information that can be extracted from a topological analysis of tessellated geometry local to the weld joint in conjunction with available CAD API functions. Finally, an implementation of the method using Siemens NX and the Robotics Toolbox for Python is presented and tested on three geometrically different node configurations and a stiffener piece provided by industrial collaborators. In all, the proposed system was able to correctly generate programs adhering to allowed welding operations as long as a solution existed. For the more complex node configurations (which require reorientation when welded by humans), 32 weld path programs out of 42 were generated based on the given criteria. For the least complex node, a total of 20 out of 24 were generated with the same criteria. All 14 weld programs were generated for the stiffener representation.