Motion Signal Processing for a Remote Gas Metal Arc Welding Application

Abstract

This article covers the signal processing for a human–robot remote controlled welding application. For this purpose, a test and evaluation system is under development. It allows a skilled worker to weld in real time without being exposed to the associated physical stress and hazards. The torch movement of the welder in typical welding tasks is recorded by a stereoscopic sensor system. Due to a mismatch between the speed of the acquisition and the query rate for data by the robot control system, a prediction has to be developed. It should generate a suitable tool trajectory from the acquired data, which has to be a C 2 -continuous function. For this purpose, based on a frequency analysis, a Kalman-Filter in combination with a disturbance observer is applied. It reproduces the hand movement with sufficient accuracy and lag-free. The required algorithm is put under test on a real-time operating system based on Linux and Preempt_RT in connection to a KRC4 robot controller. By using this setup, the welding results in a plane are of good quality and the robot movement coincides with the manual movement sufficiently.