Simulation-Based Optimization of Robotic Weld Seam Tracking Using Fuzzy C-Means Clustering and PID Control

Year 2025, Volume: 13 Issue: 4, 1758 - 1781, 30.10.2025

Adem Dilbaz , İlker Ali Ozkan , Ziya Özçelik

https://doi.org/10.29130/dubited.1724335

Abstract

Today, welding automation is a vital technology that boosts efficiency in manufacturing processes while enhancing weld quality by minimizing human intervention. However, deformations caused by high heat and deviations from programming errors in robotic welding can negatively impact welding quality. Existing camera and laser-based seam tracking systems are insufficient in certain scenarios due to factors such as highly reflective surfaces, intense arc radiation, or uneven surface conditions. This article presents a weld seam tracking system based on an angle sensor, called Weld Guide, developed to address the limitations of existing systems. The proposed system features angle sensors that utilize a Contact-based sensor principle to improve the accuracy of the robotic welding torch. The Weld Guide system was designed using SolidWorks software, simulated in RoboDK simulation software, and validated through experimental tests. The prototype was tested on both linear and curved weld seams, and its performance under different control systems was evaluated using an optical microscope. Results from the experiments showed that the Weld Guide system successfully tracked weld seams with a deviation of less than 0.6 mm. The comparison between the trajectories obtained from simulated and actual field tests exhibited a similarity exceeding 97%, demonstrating a high level of accuracy in trajectory-tracking performance. Furthermore, a hybrid approach combining Fuzzy C-Means (FCM) clustering with Proportional Integral Derivative (PID) control was implemented to enable automatic tuning of the PID parameters. By incorporating oscillation levels into the fuzzy logic rules, the optimization was enhanced against sudden changes, thereby preventing error accumulation and excessive oscillations. These findings indicate that the proposed system provides a reliable and cost-effective alternative when optical-based tracking methods fall short.

Keywords

Angle Sensors , Contact-Based Sensor , FCM-PID , Robodk , Robotic Welding , Simulation , SolidWorks , Weld Seam Tracking

Ethical Statement

This study does not involve human or animal participants. All procedures followed scientific and ethical principles, and all referenced studies are appropriately cited.

Thanks

The authors would like to express their sincere thanks to the editor and the anonymous reviewers for their helpful comments and suggestions. The authors also acknowledge the support of ZETEST Quality Control Laboratory in Ankara for providing facilities for microstructural examinations. This study was conducted as part of a doctoral thesis entitled “Mechanical Feedback and Artificial Intelligence-Based Optimization in Robotic Welding

Bulanık C-Means Kümeleme ve PID Kontrolü Kullanılarak Robotik Kaynak Dikişi Takibinin Simülasyon Tabanlı Optimizasyonu

Abstract

Günümüzde kaynak otomasyonu, imalat süreçlerinde verimliliği artırırken, insan müdahalesini en aza indirerek kaynak kalitesini iyileştiren hayati bir teknolojidir. Ancak, robotik kaynaktaki yüksek ısı kaynaklı deformasyonlar ve programlama hatalarından kaynaklanan sapmalar, kaynak kalitesini olumsuz etkileyebilir. Mevcut kamera ve lazer tabanlı dikiş takip sistemleri, yüksek yansıtıcı yüzeyler, yoğun ark ışınımı veya düzensiz yüzey koşulları gibi faktörler nedeniyle bazı senaryolarda yetersiz kalmaktadır. Bu makalede, mevcut sistemlerin sınırlamalarını aşmak amacıyla geliştirilen, açı sensörüne dayalı bir kaynak dikişi takip sistemi olan Weld Guide sunulmaktadır. Önerilen sistem, robotik kaynak meşalesinin doğruluğunu artırmak için temas bazlı ölçüm prensibini kullanan açı sensörleri içermektedir. Weld Guide sistemi SolidWorks yazılımı ile tasarlanmış, RoboDK simülasyon yazılımında modellenmiş ve deneysel testlerle doğrulanmıştır. Prototip, hem doğrusal hem de eğrisel kaynak dikişlerinde test edilerek çeşitli kaynak koşulları altında performansı değerlendirilmiştir. Deney sonuçları, Weld Guide sisteminin kaynak dikişlerini 0,6 mm’den daha az sapma ile başarılı bir şekilde takip ettiğini göstermiştir. Simülasyon analizlerinin gerçek saha testleriyle karşılaştırılması ise %97’den fazla benzerlik oranı ortaya koymuştur. Ayrıca, Fuzzy C-Means (FCM) kümeleme ve PID kontrolünü birleştiren hibrit bir yöntem uygulanarak PID parametrelerinin otomatik ayarlanması sağlanmış ve ani hata değişikliklerine karşı optimizasyon iyileştirilmiş, böylece hata birikimi ve salınımlar önlenmiştir. Bu bulgular, önerilen sistemin optik tabanlı takip yöntemlerinin yetersiz kaldığı durumlarda güvenilir ve ekonomik bir alternatif sunduğunu göstermektedir.

Keywords

Açı sensörleri , FCM-PID , Kaynak dikiş takibi , RoboDK , Robotik kaynak , Simülasyon , SolidWorks

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