The ultimate aim of this work “Vision Based Self Adaptive Algorithm for 6 Axis ABB Industrial Welding Robot” is to develop a self-adaptive RAPID algorithm based on the captured image of the work piece. The image of the work piece is captured using NI Guppy pro F031C camera which has 300 DPI with 120 FPS resolution. The captured image is transferred to the LabVIEW software for developing the self-adaptive algorithm through RS232 serial communication protocol. The LabVIEW vision assistant module is used to develop an algorithm based on the geometry of the captured image. The various image processing operations like Thresholding, Morphological operation (Thinning), and edge detection are carried out. The caliper tool is used to measure the distance between the coordinate points (welding distance). With the aid of Visual Basic, the measured values are converted into coordinates. The coordinates are used to develop a RAPID program with the aid of ABB Robot Studio library functions. The virtual server is established between the ABB Robot Studio and IRC5 Controller with the use of MOD-BUS protocol with VISA. After receiving the data from the MOD-BUS, the IRC5 controller moves the ABB Industrial Robot End effectors along with the welding gun for the welding purpose. The work piece is located on the designed jigs and fixtures. The different types of welding with different design can be incorporated with the Vision Assistant module for further development. To illustrate the developed algorithm, robot assisted MIG welding process is carried out. The welded work-pieces are tested for its strength quality and the results are verified. Optimal welding parameters for the good quality of weldment identified by using Taguchi method of optimization.

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