Virtual numerical control: an approach towards autonomous manufacturing with a case study in welding

Abstract Today’s customer lifestyles have reshaped their expectations and preferences, driving a growing demand for tailor-made products. While current conventional manufacturing (MNF) systems are robust, they often lack the flexibility needed to accommodate customization. Most MNF systems, despite advances in technology and machinery, still rely on executing predefined instructions, limiting their flexibility. In contrast, human workers excel at handling product variations due to their cognitive abilities, which allow them to perceive, analyze, and make appropriate decisions to adapt to changing conditions. This study introduces virtual numerical control (VNC) as a solution to upgrade MNF systems and overcome these limitations. VNC aims to transform MNF systems into cognitive entities capable of autonomous decision-making, enabling greater flexibility to meet customization demands. To demonstrate the potential of VNC, we implemented it in a welding system as a practical case study. The results showed that VNC enabled the system to operate autonomously. It accurately identified the shape of the objects to be welded, determined the appropriate welding paths, and executed them with high precision, all without human intervention. This highlights the significant potential of VNC technology for broader applications in industrial automation in welding and beyond.