NRI-Small: Virtualized Welding: A New Paradigm for Intelligent Welding Robots in Unstructured Environment

该项目旨在开发一种新的机器人平台，具有新颖的3D建模和可视化算法。现有的“哑巴”焊接机器人将增加传感器，以观察工件及其周围环境。将开发新的算法来记录和三维重建焊接过程。重建的数据被传输到控制室，并使用增强现实技术进行可视化：熟练的焊工可以从不同的角度查看焊接过程，就像他/她就在实际的焊接系统旁边一样。焊接参数可以由人(智能地)调整，并由机器人(精确地)执行。更重要的是，调整以及重建的焊接过程将被记录和分析。将开发系统建模技术，将人为调整与焊接过程的3D重建联系起来。如此一来，焊接机器人就可以将人类焊工的知识和经验，在未来自行进行类似的智能调整。这项新技术的主要用途是在制造业。该项目的顺利完成为智能焊接机器人实现闭环智能控制奠定了基础。这样的机器人系统可以进行高速和高精度的焊接，同时允许工件和环境有更多的变化。此外，虚拟焊接可以与移动平台集成，允许在危险或不适合人工焊接的地方进行焊接。拟议的焊接延伸平台将显著扩大焊接机器人的使用，并降低制造成本。代表不足的学生将通过退出机构项目被招募参与研究。还将寻求额外的资金和产业合作，将技术从研究实验室转移到产业。

This project is to develop a new robotic platform with novel 3D modeling and visualization algorithms. An existing "dumb" welding robot will be augmented with sensors to observe the work piece, as well as its surroundings. New algorithms will be developed to record and reconstruct in 3D the welding process. The reconstructed data are transmitted to a control room and visualized with augmented reality techniques: A skilled welder can look at the welding process from different angles, as if he/she was right next to the actual welding system. Welding parameters can be adjusted by the human (with intelligence) and executed by the robot (with precision). More importantly, the adjustment, together with the reconstructed welding process, will be recorded and analyzed. System modeling techniques will be developed to correlate the human adjustment with the 3D reconstruction of the welding process. In this way, a welding robot can "learn by examples" the knowledge and experiences of a human welder and make similar intelligent adjustments by itself in the future. The primary use for this new technology is in manufacturing. Successful completion of the proposed project paves the foundation for intelligent welding robots with closed-loop intelligent control. Such a robotic system can perform high-speed and high-precision welding while allowing more variations in the work pieces and environments. In addition, virtualized welding can be integrated with a mobile platform to allow welding in places that are hazardous or unsuitable for human welders. The proposed welding extension platform will significantly expand the use of welding robots as well as reduce manufacturing costs. Under-represented students will be recruited to participate in the research through exiting institutional programs. Additional funding and industrial collaboration to transfer technology from research labs to industry will also be pursued.