Automated edge welding based on edge recognition using separate positioning and welding robots

One or more non-transitory computer-readable media storing program instructions that, when executed by one or more processors, cause the one or more processors to fabricate a structure by performing the steps of:

• processing, using an edge detection algorithm, first optical data related to a first structural element to identify a set of feature data, wherein the first structural element is positioned proximate to a second structural element, and the feature data includes:
• a first geometrical feature that comprises a first edge of the first structural element, and
• a first structural variation of the first structural element;
• generating, based on the set of feature data, a strategy for affixing the first structural element to the second structural element, including:
• generating a welding geometry for a first material that is to be deposited on the first geometrical feature, wherein:
• the welding geometry is separate from the first structural element and the second structural element,
• the welding geometry compensates for the first structural variation,
• the first material occupies the welding geometry, and
• the first material bonds the first structural element to the second structural element,
• generating, based on the welding geometry, a first toolpath for manipulating the first structural element relative to the second structural element,
• generating a second toolpath for welding the first structural element to the second structural element by forming the welding geometry, and
• generating a first set of welding parameters corresponding to the second toolpath that compensate for the first structural variation;
• causing, based on the first toolpath, a first robot to manipulate the first structural element;
• and
• causing, based on the second toolpath and the welding geometry, a second robot to deposit the first material on the first geometrical feature using the first set of welding parameters to form the welding geometry with the first material.

A system for fabricating a structure, comprising:

• a memory storing a control application;
• a processor that executes the control application to perform the steps of:
• processing, using an edge detection algorithm, first optical data related to a first structural element to identify a set of feature data, wherein the first structural element is positioned proximate to a second structural element, and the feature data includes:
• a first geometrical feature that comprises a first edge of the first structural element, and
• a first structural variation of the first structural element,
• generating, based on the set of feature data, a strategy for affixing the first structural element to a second structural element including:
• generating a welding geometry for a first material that is to be deposited on the first geometrical feature, wherein (i) the welding geometry is separate from the first structural element and the second structural element, (ii) the welding geometry compensates for the first structural variation, (iii) the first material occupies the welding geometry, and (iv) the first material bonds the first structural element to the second structural element,
• generating, based on the welding geometry, a first toolpath for manipulating the first structural element relative to the second structural element,
• generating a second toolpath for welding the first structural element to the second structural element by forming the welding geometry, and
• generating a first set of welding parameters corresponding to the second toolpath that compensate for the first structural variation;
• a first robot that, based on the first toolpath, positions a first structural element proximate to the second structural element;
• and
• a second robot that, based on the second toolpath and the welding geometry, deposits the first material on the first geometrical feature using the first set of welding parameters to form the welding geometry with the first material.