🎯 Vision: Smart Weld Data Generator
Build a "smart weld data generator" that does 70% of the intellectual work - finding welds, calculating vectors, sequencing, exporting - and let dedicated robot simulation tools (RoboDK, OEMs' software) handle the kinematics. This is a HIGH PRIORITY initiative.
What We Can Build (Achievable 3-6 months)
- ✓ Identify weld seams automatically from part intersections
- ✓ Calculate torch approach vectors with accessibility scoring
- ✓ Sequence welds logically (minimize travel, thermal considerations)
- ✓ Export to neutral format (CSV/JSON/XML) that feeds robot simulation
What's Hard (Not in scope for v1)
- Full robot kinematics - every brand has different joint limits, reach envelopes, singularity zones
- True collision-free motion planning through the workspace
- Multi-pass welds, weave patterns
- Real-world calibration and TCP management
Leave this to dedicated OLP tools like OCTOPUZ or DELMIA - we provide the smart data.
Identify weld beads in the model and export for robotic welding systems.
Weld Bead Detection
Identify weld bead solids based on geometry characteristics or layer/attribute markers.
- ✓ Detection by solid body name/attribute
- ○ Detection by geometric signature (linear sweep, triangular cross-section)
- ○ Union touching/overlapping beads (
sld intproximity test) - ○ Extract weld path centerline
- ○ Calculate torch approach vector (default Z+, or face normal)
Export Formats
WELD EXPORT DATA STRUCTURE
{
"welds": [
{
"id": "W001",
"type": "fillet",
"path": [
{"x": 100.0, "y": 200.0, "z": 50.0},
{"x": 100.0, "y": 350.0, "z": 50.0}
],
"torch_vector": {"x": 0.707, "y": 0.0, "z": 0.707},
"parameters": {
"leg_size": 6.0,
"wire_speed": 300,
"travel_speed": 400
}
}
]
}
- ○ CSV export (simple point list)
- ○ JSON export (structured with metadata)
- ○ XML export (for legacy systems)
- ○ STL export - individual beads
- ○ STL export - combined/unioned beads
Robot Format Research
- ○ Research Nachi robot weld format
- ○ Research OTC Daihen format
- ○ Research Fanuc RJ3iC weld format
- ○ Create format conversion templates
📦 Deliverables
fxDetectWelds.ovm - weld bead identification
fxWeldUnion.ovm - merge touching beads
fxTorchVector.ovm - calculate approach vectors
fxWeldExportCSV.ovm, fxWeldExportJSON.ovm, fxWeldExportSTL.ovm