Apparatus and method of automated manufacturing

A method of automating the determination of, and assuring the realization of optimal weld gun orientations and robot paths in a robotic welding system having a weld gun and at least one predetermined weld point, comprising:

• initializing a plurality of feasible configuration points;
• initializing a first plurality of sample points located in a free space;
• initializing a second plurality of sample points not located in said free space;
• determining an initial goodness rating of said first and second pluralities of sample points and said plurality of feasible configuration points;
• generating a plurality of new candidate points using an optimization methodology;
• determining if each of said new candidate points is a feasible configuration point;
• adding respective ones of said new candidate points to said plurality of feasible configuration points if said respective ones are feasible configuration points;
• determining if said respective ones of said new candidate points are located in said free space if said respective ones are not feasible configuration points;
• adding said respective ones to said first plurality of sample points if said respective ones are located in said free space and are not feasible configuration points;
• adding said respective ones to said second plurality of sample points if said respective ones are not located in said free space and are not feasible configuration points;
• determining an updated goodness rating of said first and second pluralities of sample points and said plurality of feasible configuration points;
• updating a probabilistic roadmap path planner;
• determining if a termination criteria has been met;
• reporting one of a best solution and no solution as the optimal weld gun orientations and robot paths if said termination criteria has been met;
• and
• repeating said generating a plurality of new candidate points and determining if each of said new candidate points is a feasible configuration point if said termination criteria has not been met;
• wherein said termination criteria is one of an optimized goal configuration, an optimized home configuration, an optimized weld gun orientation, an optimized collision free path, and a predetermined threshold number of iterations;
• and
• wherein a controller is operatively connected to the robotic welding system and the method is programmed into and is executed by the controller.

An apparatus for welding at least one work piece at one or more weld points, comprising:

• a weld gun configured to selectively complete a welding operation at the one or more weld points;
• an automated support arm operatively connected to said weld gun and configured to reposition said weld gun;
• a controller operatively connected to said support arm and weld gun and configured to control said repositioning and said selective welding of said weld gun;
• wherein said controller is programmed and configured to determine an optimization parameter via:
• initializing a plurality of feasible configuration points;
• initializing a first plurality of sample points located in a free space;
• initializing a second plurality of sample points not located in said free space;
• determining an initial goodness rating of said first and second pluralities of sample points and said plurality of feasible configuration points;
• generating a plurality of new candidate points using an optimization methodology;
• determining if each of said new candidate points is a feasible configuration point;
• adding respective ones of said new candidate points to said plurality of feasible configuration points if said respective ones are feasible configuration points;
• determining if said respective ones of said new candidate points are located in said free space if said respective ones are not feasible configuration points;
• adding said respective ones to said first plurality of sample points if said respective ones are located in said free space and are not feasible configuration points;
• adding said respective ones to said second plurality of sample points if said respective ones are not located in said free space and are not feasible configuration points;
• determining an updated goodness rating of said first and second pluralities of sample points and said plurality of feasible configuration points;
• updating a probabilistic roadmap path planner;
• determining if a termination criteria has been met;
• reporting one of a best solution and no solution if said termination criteria has been met;
• and
• repeating said generating a plurality of new candidate points if said termination criteria has not been met.