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

这个项目是开发一个新的机器人平台，具有新颖的3D建模和可视化算法。现有的“哑”焊接机器人将被增强传感器，以观察工件及其周围环境。将开发新的算法来记录和重建三维焊接过程。重建的数据被传输到控制室，并通过增强现实技术实现可视化：熟练的焊工可以从不同的角度观察焊接过程，就好像他/她就在实际的焊接系统旁边。焊接参数可由人（智能）调整，由机器人（精密）执行。更重要的是，调整后的焊接过程将被记录和分析。系统建模技术将被开发，以关联人类调整与焊接过程的三维重建。通过这种方式，焊接机器人可以“以身作则”学习人类焊工的知识和经验，并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。本课题的成功完成为实现具有闭环智能控制的智能焊接机器人奠定了基础。这种机器人系统可以执行高速和高精度焊接，同时允许在工件和环境中有更多的变化。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类焊工的地方进行焊接。提出的焊接延伸平台将大大扩大焊接机器人的使用，并降低制造成本。代表性不足的学生将通过现有的机构项目被招募参与研究。还将寻求额外的资金和工业合作，以将技术从研究实验室转移到工业。

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.