6.4.1 Welding Tutorials

The Welding Tutorials section provides examples for controlling welding applications using the Doosan Robotics API. It covers both analog and digital interfaces, along with weaving (oscillation) motion, parameter adjustment, and TCP calibration.

These examples demonstrate how to integrate the welding interface with a real robot motion sequence to achieve synchronized weld control.

Tutorial Flow

  1. Analog Welding Control: Configure and adjust analog welding conditions.

  2. Digital Welding Control (EtherNet/IP): Set up digital interface and process mapping.

  3. Weaving Patterns: Apply trapezoidal, zigzag, circular, or sinusoidal weaving motion.

  4. Real-time Parameter Adjustment: Modify welding conditions dynamically during operation.

  5. Welding TCP Calibration: Calibrate the welding tool center point (TCP).

  6. Monitoring & Signal Output: Monitor welding data and control digital welding signals.

Analog Welding Control

Purpose
Enable analog welding control interface and set base welding conditions such as voltage, current, and wire feed speed.

CONFIG_ANALOG_WELDING_INTERFACE analog_if{};
CONFIG_ANALOG_WELDING_SETTING analog_set{};

// Enable analog interface. The configuration is passed by value.
Drfl.app_weld_enable_analog(analog_if);

// Set analog welding condition
analog_set._fTargetVoltage      = 22.5f;    // V
analog_set._fTargetCurrent      = 160.0f;   // A
analog_set._fTargetFeedingSpeed = 6.5f;
analog_set._fTargetVel          = 10.0f;    // travel speed, mm/s
Drfl.app_weld_set_weld_cond_analog(analog_set);

Check
Analog interface is activated successfully, and the configured parameters (voltage/current/feed) are applied to the external welder.

Digital Welding Control (EtherNet/IP)

Purpose
Establish communication with the welder through EtherNet/IP and configure both R2M (Robot-to-Machine) and M2R (Machine-to-Robot) signals.

CONFIG_DIGITAL_WELDING_INTERFACE_PROCESS    r2m_process{};
CONFIG_DIGITAL_WELDING_INTERFACE_MONITORING m2r_monitoring{};

// Set up the EtherNet/IP interface. Each direction and each group of
// signals has its own configuration type.
Drfl.app_weld_set_interface_eip_r2m_process(r2m_process);
Drfl.app_weld_set_interface_eip_m2r_monitoring(m2r_monitoring);

// Enable digital interface
Drfl.app_weld_enable_digital(1);

Check
Digital interface activates successfully and EtherNet/IP connection status is valid.

Weaving Patterns

Purpose
Configure and apply a weaving pattern (trapezoidal, zigzag, circular, or sinusoidal) to simulate weld bead oscillation.

// Zigzag and sinusoidal weaving take the pattern as arguments:
// offset Y, offset Z, gradient, weaving width, weaving cycle
Drfl.app_weld_weave_cond_zigzag(2.0f, 1.0f, 0.0f, 5.0f, 3.0f);

// Trapezoidal weaving takes a configuration structure instead
CONFIG_TRAPEZOID_WEAVING_SETTING weave{};
weave._fOffsetY  = 2.0f;
weave._fOffsetZ  = 1.0f;
weave._fGradient = 0.0f;
Drfl.app_weld_weave_cond_trapezoidal(weave);

Check
The robot follows the configured oscillation pattern and maintains consistent bead width across the welding path.

Real-time Parameter Adjustment

Purpose
Adjust welding parameters dynamically during operation for adaptive control.

unsigned char real_time = 1;
unsigned char reset     = 0;

float target_voltage = 23.0f;   // V
float feeding_speed  = 7.0f;    // wire feed
float travel_speed   = 10.0f;   // mm/s

// real-time flag, reset flag, voltage, feeding speed, travel speed,
// offset Y, offset Z, width rate
Drfl.app_weld_adj_welding_cond_analog(
    real_time, reset, target_voltage, feeding_speed, travel_speed,
    0.0f, 0.0f, 1.0f
);

Check
Voltage, wire feed and travel speed update in real time without interrupting the welding process.

Welding TCP Calibration

Purpose
Calibrate the TCP (Tool Center Point) for accurate weld torch alignment.

unsigned char mode = 0;          // measurement mode
float stickout     = 15.0f;      // torch stickout
float target_pos[9][6] = { };    // nine taught joint postures

LPMEASURE_TCP_RESPONSE result = Drfl.measure_welding_tcp(mode, stickout, target_pos);

Check
The call returns the measured TCP and the measurement error, and the calibrated position matches the torch tip location.

Monitoring & Signal Output

Purpose Monitor welding data and control digital outputs for arc start/stop signals.

// Start monitoring
Drfl.set_on_monitoring_welding_data(OnMonitoringWeldingData);

// Force a welding signal. The first argument selects the signal, as defined
// by the welding interface configuration; the second carries its value.
unsigned char command_type = 0;

Drfl.set_digital_welding_signal_output(command_type, 1.0f);  // Arc start
std::this_thread::sleep_for(std::chrono::seconds(2));
Drfl.set_digital_welding_signal_output(command_type, 0.0f);  // Arc stop

Check
Monitoring callback provides real-time welding feedback, and the digital output toggles the external welder correctly.

Note

  • The app_weld_* functions and measure_welding_tcp are compiled only when DRCF_VERSION is defined as 2. The header defaults to 3, so a default build does not expose them.

  • Welding tutorials require an external welding machine (analog or digital EtherNet/IP) configured with the correct parameters.

  • All welding operations must run under Auto Mode with Servo ON.