Improving Robotic Continuous Ultrasonic Welding Performance Through Sensor-Driven Path Correction

Robotic Continuous Ultrasonic Welding (cUSW) provides significant advantages, including efficiency, flexibility, and the capability to weld complex geometries with high repeatability. These features make it an ideal solution for industries like aerospace and automotive. However, it presents challenges due to complex interactions between the welding process and robot dynamics. Deflections caused by both dynamic and static forces on the robot and end effector result in deviations from the intended weld path. These deflections, in turn, disrupt the transmission of ultrasonic energy and consistent force application during welding, leading to reduced weld quality and consistency. This paper presents a novel approach to enhance the robustness and accuracy of robotic cUSW by integrating force sensor data with laser scanning technology. The proposed system compensates for path deviations in real time, improving process stability and weld quality. A force-control loop monitors and adjusts welding forces, while laser scanners measure and correct the position and orientation of the sonotrode. Experimental results demonstrate that the fusion of sensor data significantly reduces path deviations and improves overall weld precision.