Technology & Validation

From 3D vision to trial validation — the shared technology foundation.

The common engineering layer behind four product families: Robotic Welding Cells, High-Mix Robotic Welding Automation, Robotic Welding Lines, and Weld Preparation Automation. This page covers 3D vision, workpiece recognition, automated programming, path generation, sensing, fixtures, positioners, trials, and weld validation as shared capabilities across those products.

Robotic welding of thick-plate structural components
Technology themes

Shared technology across product families

We separate what each product family covers from the technology roles explained here. Each theme is used across more than one product.

From recognition to motion generation

Two-stage vision and trajectory generation

Rather than asking one sensor to do everything, we combine a wide-field 3D camera that captures the workpiece envelope with a torch-side proximity sensor that confirms the weld zone. For H-beam — a featured application of High-Mix Robotic Welding Automation — wide-field 3D recognition captures the full workpiece; after the operator sets weld targets, parameters, and sequence, software generates the robot program and motion trajectory. The proximity sensor precisely locates start and end points before welding and is used to correct the generated trajectory. It does not provide real-time tracking during the weld.

Stage 1

Wide-field 3D camera captures the full workpiece

Captures overall placement and establishes position, pose, and relationships between members. Placement changes are checked across a wide field of view.

Stage 2

Torch-side proximity sensor precisely locates the weld line

Before welding, start and end points of the weld line are confirmed precisely and used to correct the generated trajectory. The proximity sensor itself does not track in real time during welding. Where needed, arc tracking corrects deviation during the weld.

01

Recognize the workpiece

Confirm workpiece position and pose from wide-field vision data.

02

Set weld targets and parameters

The operator selects targets from candidate weld lines and sets the required welding sequence and parameters.

03

Generate trajectory and simulate

Software calculates intermediate trajectories and generates robot motion. Interference is checked on a PC.

04

Locate start/end points and execute

The torch-side proximity sensor corrects weld-line start and end points before welding. The operator then confirms the corrected path and starts the welding cycle.

Preparation differences

Input and preparation approaches

Preparing data in advance and recognizing the workpiece on the shop floor follow different input and preparation models.

Advance preparation

Teaching / offline / CAD & dimension input

  • Conventional point-by-point teaching
  • Offline programming
  • Preparation that assumes 3D CAD
  • Advance input of workpiece dimensions
Shop-floor recognition

AGR recognition-based approach

  • Recognize the workpiece on the shop floor
  • Extract member relationships
  • Operator sets weld targets, parameters, and sequence
  • Path generation, simulation, and precise positioning
Delivered as a system

Designed as an integrated system — not a sensor alone

AGR does not offer vision sensors in isolation. We integrate robot, vision, welding equipment, control software, fixtures, and safety, then validate, design, and commission around the target workpiece.

Robot & control

Robot and controller are configured to process conditions.

Vision sensors

Wide-field 3D recognition and torch-side precise positioning are combined according to role.

Welding & processing equipment

Welding power sources and torches, or cutting and bevel equipment, are integrated as required.

Control software, fixtures & safety

Recognition and trajectory software, fixtures, and safety equipment are included in the system.

View High-Mix Robotic Welding Automation · View Weld Preparation Automation · View technology FAQ

01 3D vision & workpiece recognition

Capture position, pose, and geometry

Confirm variation in position, pose, and geometry to establish the basis for path generation. For H-beam applications, wide-field 3D recognition captures member layout and extracts candidate weld lines. Where recognition cannot be established, we treat the case as out of scope or revisit fixture design.

Go to two-stage vision and trajectory generation

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02 Automated programming & path generation

Generate weld and cut paths automatically

Paths are generated for the joint and access conditions. For H-beam, software calculates intermediate trajectories between start and end points from the operator-selected weld lines, welding sequence, and parameters, then generates the robot program and motion trajectory. After generation, simulation checks interference and reachability.

See the flow from recognition to motion generation

03 Simulation

Pre-execution checks

Generated robot motion is simulated on a PC to confirm interference, reachability, and torch orientation before execution. For H-beam applications, this is a fixed confirmation step before running the weld.

04 Sensing

Correct to the actual workpiece

On large thick-plate workpieces, tolerances from cutting, bending, and tack assembly stack up, producing variation in joint location and root gap. In addition to basic fixture location, sensing corrects to the actual workpiece.

  • H-beam torch-side proximity sensor — Precisely locates weld-line start and end points before welding and corrects the generated trajectory. The proximity sensor itself does not track in real time during welding.
  • Arc sensing / seam tracking — Where needed, corrects joint deviation during the weld. Short weld lines and some other cases may not use it.
  • Touch sensing / wire touch sensing — In other robotic welding cell configurations, used to find the actual weld start or joint location and, when needed, to measure root gap.

See H-beam precise positioning · See actual-workpiece correction in Robotic Welding Cells

05 Welding parameters

Parameter design

Welding parameters are designed for material, plate thickness, joint preparation, and welding position. Parameters are validated per project and are not finalized from general guidance alone. Measured root gap can inform parameter selection.

06 Fixtures & positioners

Design restraint, welding position, and reachability

Fixtures establish basic workpiece location; positioners establish the required welding position. Both are designed individually for workpiece shape, weight, center of gravity, and required welding position. Accuracy is not assumed from fixtures alone — it is balanced with actual-workpiece correction.

Read fixture and positioner basics

07 Trials & weld tests

Validate quality

Trial welds, test coupons, and process tests are used to review appearance, internal quality, and distortion.

Example themes: thick-plate joint test planning, distortion management, rework policy.

08 Quality confirmation

Inspection readiness

When inspection requirements such as UT / TOFD apply, they are considered from the weld-process design stage. Inspection acceptance is evaluated from parameter confirmation and trial/validation results.

Example themes: joint design with ultrasonic inspection in view; organizing visual inspection and process records.

09 Delivery record

Commissioned systems

Materials based on actual delivery and production operation are shared according to project conditions. They are presented separately from exhibition demos and reference 3D concepts.

10 Automation development

Automated programming for H-beam welding

We work on parametric programming that generates robot programs efficiently according to H-beam geometry and welding conditions. Combined with workpiece recognition and trajectory generation, this reduces setup and program-creation burden and strengthens fit for high-mix, low-volume production.

How evidence is presented

Review by validation stage

Delivery & production operation

Materials based on delivery and operation

Weld tests & validation

Materials based on trials and tests

Live equipment & venue demos

Demo and live-equipment confirmation

Live weld video & real workpieces

Video and photos based on real workpieces

Reference 3D & proposal drawings

Reference figures at proposal stage

Simulation

Analysis and simulation materials

Automation technology

Automated programming for H-beam welding

Demos and delivery records are presented separately.

Technology information hub · Case list · Quality confirmation including ultrasonic testing (UT)

Related links

Related reading

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