Abstract
The welding of intersecting structures requires multi-layer multi-pass welding. Manual welding of intersecting curves is being replaced by robotic welding due to its low efficiency and poor consistency. To enhance weld accuracy in intersecting structures and optimize multi-layer multi-pass planning in robot welding of large components, a realistic groove model is devised to address discrepancies between theoretical and actual groove surfaces. This include determining the size of the actual error angle, and the modeling of the actual groove in the intersecting structure. A method for groove error correction is then proposed based on this model. Firstly, the total and the error areas of the actual groove are calculated. Subsequently, the errors for each layer of the groove are computed from the total error area of the groove. Error correction for the groove layout is implemented layer by layer, resulting in an algorithm for multi-layer multi-pass groove layout correction. Additionally, a fitting function that closely approximates the groove profile is derived. This procedure finalizes the groove error correction, and through MATLAB simulation, the corrected intersecting structure groove is modeled, with results aligning with the error correction algorithm. Finally, further simulation and experimentation validate the feasibility, accuracy and effectiveness of the error correction algorithm for multi-layer multi-pass weld planning the actual intersecting structure groove, offering a theoretical foundation for the intricate weld planning required in robotic welding of intersecting components.