Automated bead layout methodology for robotic multi-pass welding

An automated bead layout methodology is proposed for multi-pass welding on varying seam angle. This methodology will replace the tedious process of `teaching and playback' in the current line of robotic welding. To develop the proposed method, manual flux cored arc welding has been conducted on several workpieces. It is then ascertained that the bead size varies from 25 to 30 mm2 in a more ideal welding zone. Therefore, this leads to the assumption of a constant bead size for automated welding. Based on the results from this experiment, the bead layout and welding parameters for new workpiece with different seam angles can be determined. The simulation result show that a uniform bead layout is achieved.