3D digital reconfiguration of an automated welding system for a railway manufacturing application

In the last years, efforts have been focused towards new approaches for the automation of gas metal arc welding process parameters. In this framework, an innovative welding system based on a 3-axis motion device and a vision system consisting of a video camera, a laser head and a band-pass filter has been developed and implemented to recognize the desired features of weld joints, such as geometry and dimensions, and automatically adapt the welding process parameters according to these features. This papers focuses on a real case study of the railway manufacturing industry related to the welding process of a bogie frame. Through the employment of 3D Motion Simulation, the identification of a suitable reconfiguration of the system through the substitution of the 3-axis motion device by means of an industrial robot is studied in a totally digital framework. Simulation of the welding process allows calculation of robot kinematics, collision detection and motion planning.