International Journal of Pure and Applied Mathematics

Volume 119 No. 12 2018, 10243-10255

ISSN: 1314-3395 (on-line version)
url: http://www.ijpam.eu
Special Issue
ijpam.eu
SIMULATION OF SPOT WELDING ROBOT FOR AUTOMOTIVE
MANUFACTURING APPLICATION

Karthickraj N1, C.Thamotharan2, P.Naveenchandran3

1
B.Tech Student, 2,3Professor,DepartmentofAutomobile Engineering,
BIST, BIHER, Bharath University,Chennai. – 73.
[email protected]
A standout amongst the most essential utilizations of mechanical robots is spot welding
which is utilized as a part of high generation applications for the most part in car
enterprises where large scale manufacturing is required. The speed, accuracy, productivity
and the subsequent cost decrease because of large scale manufacturing are all around
acknowledged and all around recorded focal points of mechanization of spot welding
process utilizing robots. With a specific end goal to meet the new difficulties of expanded
worldwide rivalry, makers are compelled to look for new advancements for enhanced
creation and cost diminishment. Such cost cutting endeavors must be accomplished by
enhancing the disconnected programming strategy. Disconnected writing computer
programs is a standout amongst the most urgent parts of present day car producing process.
The entire procedure plan of the automated spot welding is not straightforward and
incorporates CAD outline of the part, shape and multifaceted nature of the parts which
should be spot weld, plan of the robot work cell, outline and choice of spot weld firearm,
required creation rate, disconnected programming instrument, robot adjustment, work cell
alignment, work piece positioner outline and so on. In this report a way to deal with
execute the disconnected programming of robot in light of reproduction programming with
the procedure information of auto body in white was proposed and in part created. Some
basic issues, for example, movement reproduction, impact discovery and alignment can be
mostly comprehended by this approach. The outcomes from disconnected programming
(mechanical reproduction) demonstrate that the new welding design is fit for
accomplishing the producer's objective. The usage of RSWS for car application is sensible
in view of proficiency, precision and practical.

Catchphrases: Robotic spot welding; robot reproduction; producing computerization

1.INTRODUCTION Notwithstanding, the most concerning issue that

SMEs are going up against is the nonattendance
Routine gathering structures (consistently of skilled workers, especially authorities in robot
considering adjusted computerization) are being programming and meanwhile specifically
supplanted by versatile and adaptable amassing amassing methodology, for instance[1-9],
systems. Due to its flexibility, programmability welding and painting. Thusly, new and more
and adequacy, mechanical robots are viewed as a intuitive courses for people to interface with
key segment of current versatile collecting robots are required to make robot programming
structures. Regardless, there are still a couple less requesting. The goal is to make strategies
issues that baffle the use of robots in industry, that help customers to program a robot with a
especially in the little and medium-sized attempts strange condition of reflection from the robot
(SMEs) . Programming a mechanical robot by the specific tongue. Another crucial segment is the
typical demonstrating procedure, through the ability to program a robot logged off, without
usage of the robot indicate pendant, is still a stop robot creation. Different courses of action
repetitive and dreary task that requires some have been proposed in keeping in touch with
specific capacity. Really, manual show systems make common HRIs; through the change and
are consistently monotonous and free. execution of straightforward programming

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International Journal of Pure and Applied Mathematics Special Issue

interfaces focused on a specific cutting edge untrained customer (without programming

methodology ; using sensors joined to the human aptitudes) can set up the system and make a robot
body to catch arm improvements and along these program for a specific undertaking. The time
lines educate the robot by performing movements spent in the robot programming task (using the
; using vision-based interfaces ; and talk . Since structure here proposed) is stood out from the
over the span of late years, PC bolstered layout time carried with play out a similar errand
(CAD) packs are ending up being all the more however using the robot demonstrate pendant as
compelling and accessible, CAD-based game interface. Tests were performed with a six-rotate
plans related to the HRI issue have been typical current robot in lab environment, accommodating
(see zone II). In spite of the above, as a result of the peruser a not too bad information into the
the specific properties of a mechanical area it issue. Finally, results are inspected and a couple
remains hard to apply such structures in industry of thoughts about future work heading are
(various systems have not yet came to advanced made[10-16].
usage). Thusly, the show pendant continues being
the essential robot data contraption that offers Motivation Of the Research Work
access to all functionalities gave by the robot In this present work the paper is centeredaround
(running the controller, conveying and adjusting one of the sub-get together procedures required in
projects, et cetera.). In the latest couple of years, the spot welding procedure of car industry. This
the robot creators have endeavored remarkable sub-get together process is disconnected
attempts to make straightforward show pendants, programming (OLP) of spot welding robots. This
completing ergonomic arrangement thoughts, venture tries to advance the mix of CAD
more instinctual customer interfaces, shading Software, 3D Robotic Simulation Software and
touch screens with graphical interfaces, a 3D Robotic Spot Welding assignment in car industry
joystick, a 6D mouse and adding to a remote train so that distinctive CAD programming, 3D
pendant. Things being what they are, it is still Robotic Simulation Software and diverse Robots
troublesome for an untrained worker to work can trade data with each other for outlining the
with a robot teach pendant. The show pendants spot welding sequential construction system in
are not intuitive to use and require an extensive car industry. The venture can in this way be
measure of customer experience, other than being expressed as upgraded the OLP strategy for spot
colossal and significant. In this paper is welding process in car industry[17-21].
acquainted a CAD-based structure with program
a robot from a 3D CAD show, allowing Objective of the Project
customers with crucial CAD capacities to make As indicated by insights about portion of the
robot programs logged off. Besides, the 3D CAD modern robots around the globe are locked in
package (Autodesk Inventor) that interfaces with with different types of welding occupation. This
the customer is a most likely comprehended CAD has decreased the high danger of radiation and
package, extensive in the business part at a risk environment because of manual welding by
relative straightforwardness. This structure fills gifted welders and expanded the working
in as a veritable HRI where, through the CAD, condition and welding quality and productivity.
the customer works in the bona fide robot. The Robot innovation is a cutting edge coordinated
techniques used to focus information from the multidisciplinary of PC[22-26], computerized,
CAD (position and presentation of unyielding system, data and sensor innovation, manmade
bodies in space) and strategies to treat/change brainpower and bionics. There are two methods
over it into robot requests will be shown in for programming mechanical robots. One is
purpose of intrigue. A couple of trials were *Online programming and another is *Offline
directed to evaluate the structure execution. The programming (OLP). Web based programming
results exhibited that the proposed structure is comprises of Teach pendant, Playback or Manual
definitely not hard to use and within minutes an programming. Disconnected programming

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International Journal of Pure and Applied Mathematics Special Issue

comprises of Textual programming, CAD

programming, Macro programming or Acoustic
programming. The greater part of the aggregate
mechanical robots connected in manufacturing
plants over the world are in car businesses and
among them the greater part of the robot's are in
spot welding operation. The goal of this venture
work was to locate a quicker and more flexible
OLP strategy for the car business. Today
disconnected programming and recreation
programming are the conclusive and significant
instruments of generation arranging and process A methodology for robotic work cell modeling
in car industry. Car makers are confronting wild
rivalry from their rivals and dependably on the For this exploration work CAD based OLP
look for better and more effective answers for the strategy was chosen as the objective is to propose
generation procedure. a superior technique for the Virtual
Manufacturing Process in the automated spot
Mechanical robots utilize exclusive programming welding application. The venture work was done
and control frameworks. In future more designers on the Factory Simulation and OLP programming
are spanning up the hindrances of process from Visual Components. The advantages of
reproduction and OLP by progress advanced CAD based strategies are check of the
assembling arrangements empowering multi accompanying actualities –
seller frameworks. Today's modern automated
sys-tem all in all can be named open and shut. An  Components demeanor in space.
open framework[36-41].  Movement of segments and apparatuses.
 Are working focuses reachable?
alludes to the automated sys-tem which is  Time required for development.
adaptable and simple to grow encourage  Collision with environment.
arrangements on its stage, as a shut framework  Checking for options.
alludes to the exclusive arrangements where just  OLP with era of robot program
constrained assignments should be possible and
advancement of the framework is unrealistic 2. Offline Programming (OLP)
without the producers assent. ROS (Robot OLP (Offline Programming) is the best approach
Operating System) or RRS (Realistic Robot to educate a robot its assignments with no
Simulation) are cases of the exertion towards association with the robot or ceasing its present
more adaptable and open structures. However the undertaking. It permits growing new outline,
region of this venture work is centeredaround car speedier and entrusting creation, making
spot welding use of modern robots. Much sooner convoluted assignments in a simple manner,
than an auto is being produced the congregations enhancing process duration without removing the
are de-marked in CAD programming and a genuine robot from generation [37-41].
virtual duplicate of the robot and its surroundings
in made in the reproduction programming where The reproduction programming gives a virtual
the robots projects are made, altered, mimicked situation of the genuine robot work cell. In this
and confirmed before they are exchanged to the virtual world the client can import outer CAD
physical robot. Mechanical work cell recreation documents, demonstrate parts and apparatuses.
is a demonstrating based critical thinking At that point the client can make the assignments
approach and the system comprises of 6 stages, for welding, palletizing, material taking care of or
as demonstrated as follows[27-35]. painting with the robot. The achieve capacity and

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International Journal of Pure and Applied Mathematics Special Issue

availability of the end effectors of the robot can work piece geometry . The 3D scanner creates a
be checked in various positions and as well as point cloud and it is changed over to the surface
can be expected be alloted. This same model of the work piece. At the point when just
employment with the genuine robot would be 2D CAD is accessible the 3D model of the work
huge tedious undertaking. At that point the piece can be gotten in three ways a) mul-tiple
reproduction is run and checked 20 for achieve perspective of 2D drawing b) extra sensors or c)
capacity, impact location or whatever other basically programming the robot in 2D . There
mistakes which can be then settled. Movement are diverse sorts of CAD documents and current
way advancement and process duration is OLP programming can import all outstanding
investigated from the reenactment. At long last CAD records to their own particular good[42-46].
utilizing an interpreter the robot program is
created and downloaded straightforwardly to the Tag Creation
robot controller . The accompanying segments OLP programming has worked in capacities to
some reference to the examination works done on produce labels with a particular device focus
cutting edge movement arranging of mechanical point (TCP) from elements, for example, corners
robots and edges, casings or little geometry highlights.
In this proposition work the created Add On
Steps of OLP [Spot Welding] label focuses have been made
The initial step to OLP is to demonstrate the from a *.csv record and geometry highlights in
entire robot work cell in 3D. This is fundamental the CAD show. There are likewise right hand
to test the a) robot development b) achieve label focuses 24 e.g. home focuses, approach
capacity c) impact identification and d) handle focuses and withdraw focuses. The position and
related data for producing a mistake free introduction data of the TCP to achieve every
disconnected program in the robot. With OLP the label point is naturally made by the OLP
robot projects can be created before in the programming. Research is going ahead to
plan/generation cycle without hampering the naturally extricate robot movement data from the
present creation prepare. Also era of OLP is a CAD information[47-52].
considerable measure less demanding and Trajectory planning
proficient contrasted with run and instruct Opposite kinematics of mechanical enunciated
technique. As reproduction is joined with all OLP robots for the most part has numerous
strategies so a) robot development b) robot crash arrangements in the Cartesian space. Direction
c) profitability and d) wellbeing are pre-checked arranging incorporates a) movement sort
minimizing the possibility of blunder. (straight/joint) b) joint con-figuration c) joint
speed d) joint increasing speed/deceleration e)
achieve capacity and f) impact location. In this
proposal work the created Add On [Spot
Welding] the disconnected developer can dole
out withdraw separation to every spot welding
label point, likewise allocate approach and
Key steps of OLP withdraw by means of focuses for the begin and
end of a spot weld grouping. Likewise the
Generation of 3D CAD model introduction of a gathering of spot welding labels
Generally 3D models are produced by utilizing can be turned along X pivot, Y hub or Z hub to
diverse CAD programming. In the event of any required degree for the best design.
changing measurements there are a few
techniques to create the required 3D show. One Process planning
of them is utilizing a 3D scanner to catch the The necessities of a particular procedure should
be concentrated painstakingly first. It is

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International Journal of Pure and Applied Mathematics Special Issue

extremely basic as in the accomplishment of Spot welding is one kind of resistance welding
robotization of the procedure depends broadly on where two metal sheets are combined without
watchful investigation of the necessities of the applying in order to use any filler material weight
procedure advancement. Prepare arranging and warmth to the district to be welded. The
incorporates a) streamlining of asset b) robot technique uses copper amalgam terminals for
determination for the procedure c) figure the applying weight and power, the material between
quantity of robots required d) efficiency e) robot the cathodes yields, squeezed together, it shapes
workcell outline f) material taking care of process "piece" of mol-ten materials which when bonds
de-sign g) computation of process duration and outlines the welded joint.
so on. For procedures which includes substantial
number of spot welds in constrained process
duration can be dealt with as the "voyaging
salesperson problem"(TSP) an answer which
depends on a hereditary calculation.

Simulation
In this progression the reproduction of the
procedure is keep running in the reenactment
programming. The robot runs and does its acts as
customized by the disconnected developer. This
Figure1 Principal of resistance spot welding.
gives a reasonable representation of the
procedure, what will be actualized in this present
Spot Weld Gun
reality. From the running reenactment the
disconnected software engineer can see and
The algorithm for selecting a spot welding gun is
compute the defects all the while, and remedy
presented in figure .
them as vital. He can figure the procedure halts,
process duration, profitability, asset usage and
get every one of these information in a graphical
(diagram/outline) arrange or numerical
configuration (exceed expectations or *.csv). The
best advantage of reproduction is that all the
procedure can be checked heretofore without the
need of any physical robot or other machine's and
expels the danger of any wrong/wasteful usage of
robot's or machines in the last stage. Algorithm for selecting the spot welding gun
3.Spot Welding Process
Resistance spot welding is a proficient procedure In spot welding industry the occupation begins
to join vehicle body parts, by the method for with planning the correct weapon and right dance
solid communication between electrical, warm, for the parts which will be spot welded. The
metallurgical and mechanical marvels . Spot dance creator outlines the dances and the
welds are ordinarily used to join vehicle parts instrument architect plans the mechanical spot
upto 3 mm in thickness. There is a thickness welding devices.
proportion which ought to be additionally kept
up, normally which ought not be under 3:1. Spot Spot welding firearms are planned in view of
weld width ranges from 3mm upto 12.5 mm . utilization. The weapons can be sorted as taking
after:
Principle

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International Journal of Pure and Applied Mathematics Special Issue

a) C-sort (working chamber is associated

straightforwardly to the moving terminal)

b) X-sort (most regular sort)

c) D-sort (for the most part utilized for vertical

welds)

Additionally every firearm can be ordered in two

segments
a) Fixed jaw

b) Moving jaw
Figure4How spot weld gun is defined in the
simulation software
There is a settled jaw in most of the spot weld
Most of the spot weld guns have at least 3 home
guns. While separated programming at the tip of
positions:
the settled jaw, a packaging is portrayed and this
a. fully closed
is the contraption TCP for that spot weld gun.
b. semi opened
c. fully opened

Ordinarily the spot weld firearms are not servo

driven but rather pneumatic driven. In
disconnected ace gramming there are a few terms
to be considered for the spot weld firearm. There
Figure2 C type spot weld gun are two unique sorts of rates while spot welding,
i.e. move speed and welding speed. Weld-ing rate
is the speed by which the spot weld firearm is
playing out the spot weld operation (open/close)
and moving rate is the speed is the speed of the
robot in the middle of spot focuses.

So fundamentally what occurs in industry is that

every robot station has its own particular spot
weld apparatus. The stations are isolated in view
of the sort of operation going to be performed in
Figure3X type spot weld gun every station. Likewise there are arrangements
for instrument change (spot weld firearm) in
same station. In disconnected programming of
mechanical spot weld with the 3D Create
programming every spot point contains the data
of the apparatus definition that implies every spot
point is as-marked with the device name.

4. Spot Welding Line Setup

Planning the Spot Welding Assembly Line

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International Journal of Pure and Applied Mathematics Special Issue

In this test seat an auto BIW spot welding line needs to enter the name of the station for which
was planned where there are three diverse spot the chose robot will create the RSL articulations
welding stations in arrangement. Every station for the spot welding operation. While the geo
was doled out with four spot welding robots. spots were made in the auto BIW CAD display it
Likewise a general control was accepted to was remembered that there are four robots in
recognize every robot in every individual station. every station and the spot welds were gathered in
In each station towards the bearing of a way so that the reachability of spot weld
development spot welding model (auto BIW for focuses in every robot in every station are
this situation) the robot on upper left side is advantageously dispersed.
viewed as the principal robot in the station. At
that point alternate robots are considered clock-
wise second, third and fourth robot of that station
continuously. In the test seat if the Station ID of a
gathering of spot weld is Station_3_1 that implies
this gathering of spot welds has a place with the
first robot in the third station. The screenshot of
figure 4-17 demonstrates the mechanical spot
welding line test seat all the more intricately:

Figure6Geometry feature pointing spot

location

Figure5Robotic spot welding line setup.

Features of the Add-On [Spot Welding]

In the assembling business CAD modelers Figure7Distribution of spot welds according to
generally models the CAD geometry with the robot position
spot welding focuses included as little geometry
highlights. This makes the OLP work a ton 5. Simulation Results
simpler as the label point for robot can be The experiments showed that the
effectively made from the CAD information generated program (off-line programming) works
specifically. Here in the auto BIW display there very well. Off-Line Programming (OLP) is the
are very nearly 150 spot weld focuses which are process of converting the “sequence of
spoken to by little roundabout geometry operations”, which is the result of the robot
highlights. simulation phase, and generating the robot
program in the native language of the robot
To run this AddOn a robot should be chosen first. manufacturer (FANUC). The OLPs which have
At the point when the client runs this AddOn the been so generated can be downloaded directly to
name of the chose robot flies up in the container the robot controller and tested. after simulation
[Selected Robot's Name]. At that point the client we can get the co-ordinates of the robot in the

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program through path editor ,which can be given

as input to robots, thus the path will be followed No of Stage
by robot on station same as in simulated in
15
process simulation environment.
10
Thus, the experiment (off-lime programming) 5 N0 Of stg
was conducted with one participant with basic 0
skills in CAD, simulation and 3D modeling. The 40 JPH 45 JPH
positions & significant factors in the variation
simulation, in order to achieve satisfactory
agreement between simulated results and reality.
Figure10 Proposed Plans for Robot Stages
30 (40JPH to 45JPH)
25 Table1 Proposed products to ZZ Stages for
Robot No
20 45JPH
15 No.Of.Spots
Robot Program
10 _ 40 jph Disconnected from the net Programming
5 No.Of.Spots_ (OLP) is the procedure of changing over the
45jph "arrangement of operations", which is the
0
consequence of the robot reproduction stage, and
1 2 3 4 5 6 7 8 9 10 creating the robot program in the local dialect of
the robot maker (FANUC, and so on). The OLPs
which have been so produced can be downloaded
Figure8Distribution of Weld Spots For robots straightforwardly to the robot controller and tried.
(40JPH & 45JPH) Disconnected from the net reducing so as to
programme advantages clients the on location
80
programming time (consequently authorizing the
70
No.Of.Sp robot to be utilized for generation, instead of
60
ots _ programming) and decreasing the downtime of
50
45jph gear while programming new work variations
40
30 Programming complex ways, after recreation we
20 No.Of.Sp can get the co-ordinates of the way.
10 ots _
0 40jph Robot Specification R-2000iB/210F
J1 95 °/ Axes 6 ±180°
ZZZ1
ZZZ3
ZZZ5
ZZZ7
ZZZ9

J2 90 °/Payload 210kg (462.97lbs) +75°,-60°

J3 95 °/s H-Reach 2655mm (104.53in) +230°,-
132°
Figure9 Comparisons for Weld spots & Cycle
time (sec) (40JPH & 45JPH) J4 120 °/s ±360°
J5 120 °/s Robot Mass 1240kg ±125°
J6 190 °/s ±360°
Table2 Specification of R2000 ib-210 Fanuc
Robot

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International Journal of Pure and Applied Mathematics Special Issue

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30. Saritha, B., Chockalingam, M.P., Technology, V-8, I-3, PP-17182-17187,
Synthesis of photocatalytic composite Fe- 2016
C/TiO2 for degradation of malachite green 39. Shanthi, E., Nalini, C., Rama, A.,
dye from aqueous medium, International Autonomous epistemologies for 802.11
Journal of Pure and Applied Mathematics, mesh networks, International Journal of
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31. Saritha, B., Chockalingam, M.P., Removal 40. Sharavanan, R., Golden Renjith, R.J.,
of heavy X`X`l from aqueous medium Design and analysis of fuel flow in bend
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Mathematics, V-116, I-13 Special Issue, Issue, PP-59-64, 2017
PP-205-210, 2017 41. Sharavanan, R., Jose Ananth Vino, V.,
32. Saritha, B., Chockalingam, M.P., Emission analysis of C.I engine run by
Degradation of malachite green dye using diesel,sunflower oil,2 ethyl hexyl nitrate
a semiconductor composite, International blends, International Journal of Pure and
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2017 42. Sharavanan, R., Sabarish, R., Design of
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Photocatalyticdecolourisationoftextileindu vehicles, International Journal of Pure and
strywastewaterby TiO2, International Applied Mathematics, V-116, I-17 Special
Journal of Pure and Applied Mathematics, Issue, PP-457-460, 2017
V-116, I-18 Special Issue, PP-221-224, 43. Sharavanan, R., Sabarish, R., Design and
2017 fabrication of aqua silencer using charcoal
34. Sartiha, B., Chockalingam, M.P., Study on and lime stone, International Journal of
photocatalytic degradation of Crystal Pure and Applied Mathematics, V-116, I-
Violet dye using a semiconductor, 14 Special Issue, PP-513-516, 2017
International Journal of Pure and Applied 44. Sharmila, G., Thooyamani, K.P.,
Mathematics, V-116, I-18 Special Issue, Kausalya, R., A schoolwork on customer
PP-209-212, 2017 relationship management with special
35. Shanthi, E., Nalini, C., Rama, A., The reference to domain 2 host, International
effect of highly-available epistemologies Journal of Pure and Applied Mathematics,
on hardware and architecture, International

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2017
45. Sharmila, S., Jeyanthi Rebecca, L.,
Anbuselvi, S., Kowsalya, E., Kripanand,
N.R., Tanty, D.S., Choudhary, P.,
SwathyPriya, L., GC-MS analysis of
biofuel extracted from marine algae, Der
Pharmacia Lettre, V-8, I-3, PP-204-214,
2016
46. Sidharth Raj, R.S., Sangeetha, M., Data
embedding method using adaptive pixel
pair matching method, International
Journal of Pure and Applied Mathematics,
V-116, I-15 Special Issue, PP-417-421,
2017
47. Sidharth Raj, R.S., Sangeetha, M.,
Android based industrial fault monitoring,
International Journal of Pure and Applied
Mathematics, V-116, I-15 Special Issue,
PP-423-427, 2017
48. Sidharth Raj, R.S., Sangeetha, M., Mobile
robot system control through an brain
computer interface, International Journal
of Pure and Applied Mathematics, V-116,
I-15 Special Issue, PP-413-415, 2017
49. Sivaraman, K., Sundarraj, B., Decisive
lesion detection in digital fundus image,
International Journal of Pure and Applied
Mathematics, V-116, I-10 Special Issue,
PP-161-164, 2017
50. Sridhar, J., Sriram, M., Cloud privacy
preserving for dynamic groups,
International Journal of Pure and Applied
Mathematics, V-116, I-8 Special Issue,
PP-117-120, 2017

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