An effective path planning approach for robot welding considering redundant kinematics

Robot welding with redundant kinematics demands precise coordination of the welding path and redundant axis motion for stable operation. This paper introduces an effective G³ continuous path planning approach for a 6-DOF friction stir welding robot, integrating redundant axis motion to enhance welding stability and quality. The method encompasses a two-pronged strategy: a five-axis path corner smoothing technique and a motion synchronization strategy. Initially, a robust toolpath preprocessing algorithm is presented to mitigate curvature extremities of the inserted smoothing curves within predefined error limits. Subsequently, leveraging G³ continuity criteria, a B-spline-based smoothing method is advanced for refining tool position and orientation paths, with an analytical determination of spline control points facilitated by an explicit smoothing error expression. An effective motion synchronization technique is then proposed, which formulates the tool position, tool orientation, and redundant axis path as explicit functions of the position path arc length. The effectiveness of the proposed method is demonstrated through simulations and experiments on a robot welding platform, with the integration of a jerk-continuous feedrate profile for smooth motion execution. The findings indicate a significant improvement in robotic welding quality by integrating the proposed path planning method with existing workpiece posture optimization techniques.