This paper presents a novel approach for seam tracking using
ultrasonics. An ultrasonic seam tracking system has been developed for robotic
welding which tracks a seam that curves freely on a two-dimensional surface. The
seam is detected by scanning the area ahead of the torch and monitoring the
amplitude of the waves received after reflection from the workpiece surface.
Scanning is accomplished by using two ultrasonic sensors (a transmitter and a
receiver) mounted on a stepper motor such that the transmitter angle is the same
as the receiver angle. The motor is mounted on the end-effector just ahead of
the welding torch and covers a ninety degree arc in front of the torch. If there
is no seam then the receiver receives most of the transmitted waves after
reflection, but if there is a seam then most of the transmitted waves are
dispersed in directions other than that of the receiver. The system has been
tested and is very robust in the harsh environments generated by the arc welding
process. The robustness of the system stems from using various schemes such as
time windowing, a waveguide, air and metal shields, and an intelligent sensor
manager. This ultrasonic system offers some distinct advantages over traditional
systems using vision and other sensing techniques. It can be used to weld very
shiny surfaces, and is a very economical method in terms of cost as well as
computational intensity. The system can be used to detect seams less than 0.5 mm
wide and 0.5 mm deep.