Study and implementation of an URCap for coordinated external axes in a Collaborative Robot

In modern welding applications, precision and efficiency are crucial to achieve high-quality welds. Many welding processes require complex, multi-axis movements, where external axes and control software play a vital role. External axes are robotic systems that extend the capabilities of a primary welding robot, improving weld quality, reducing defects, and allowing more precise torch movements. Software controlling these external axes also enables dynamic adjustments of welding parameters, improving efficiency, reducing cycle times, and increasing productivity. In hazardous work environments, external axes enhance safety by reducing operator exposure to risks, as the system can stop in case of danger. Additionally, using external axes allows more complex welding trajectories, adapting automatically to surfaces with varying angles and geometries, without the need for manual intervention. The internship was conducted at Carpano Equipment Srl, a company that collaborates with Universal Robots, a producer of Collaborative Robots (Cobots) for industrial automation. Cobots are appreciated for their innovative features, including reduced machine protections, easier operator access, intrinsic safety features, ease of programming, faster setup, and lower costs compared to traditional robots. However, for welding applications, Cobots need to be taught how to interface with welding machines, external axes, and control software for torch oscillation and arc voltage. This dissertation focuses on developing an URCap to initialize the welding environment with an intuitive interface for operators and a framework for programmers to collect data and generate a script. The collected data is used by Universal Robots' MotionPlus technology to coordinate robot and external axis movements during welding.