VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belagavi-590018

A TECHNICAL SEMINAR REPORT

ON

“ROBOTIC WELDING SYSTEM IN

MANUFACTURING”
Submitted in the partial fulfillment for the award of the Bachelor Degree
in
MECHANICAL ENGINEERING
Submitted By:
PRAVEEN M JALIHAL
[2KA21ME006]
UNDER THE GUIDANCE OF:

Prof. RAVI S. DURAGANNAVAR

Asst. Professor, Mechanical Department

Department of Mechanical Engineering

SMT. KAMALA & SRI VENKAPPA M. AGADI COLLEGE OF

ENGINEERING & TECHNOLOGY, LAKSHMESHWAR-582116

2024-25
 DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
Certified that the technical seminar entitled

“ROBOTIC WELDING SYSTEM IN

MANUFACTURING”
Is a bonafied work carried out by,

Praveen M Jalihal (2KA21ME006), bonafied student of Smt. Kamala & Sri Venkappa
M. Agadi College of Engineering & Technology, Lakshmeshwar in partial fulfillment for the
award of the Degree of Bachelor of Engineering in Mechanical Engineering of Visvesvaraya
Technological University, Belagavi during the year 2024-25. The technical seminar has been
approved as it satisfies the requirements in respect of technical seminar prescribed for the said
degree.

Mr. Ravi S. Duragannavar Dr. Sreenivasa R Dr. Parashuram Baraki

Guide Head of Department Principal

EXAMINERS

Name of the Examiner Signature with date

1. 1.

2. 2.
 AKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mention of people who made it possible, whose constant
guidance and encouragement crowned out efforts with success.

We would like to take this opportunity to thank our seminar Guide Prof. Ravi S.
Duragannavar, Professor, Department of Mechanical Engineering, without his immense
guidance and support the work would have been unthinkable. Also, he helped us in the
completion of project work.

We express our deep sense of gratitude to our HOD Dr. Sreenivasa R, Department
of Mechanical Engineering, for his unstinted support. We extend our gratitude to the Principal
Dr. Parashuram Baraki, SKSVMACET, Laxmeshwar who have helped us directly or
indirectly. We are very much indebted to our parents and friends for their unquestioning best
cooperation and help.

Regards,
PRAVEEN M JALIHAL
[2KA21ME006]
 ABSTRACT

Robotic welding systems have revolutionized manufacturing by enhancing precision,

efficiency, and consistency in welding processes. These systems utilize automated robotic
arms equipped with welding tools to perform high-quality welds with minimal human
intervention. They improve productivity by reducing cycle times and ensuring uniform weld
quality across large-scale production. Advanced robotic welding systems integrate AI,
sensors, and machine learning to optimize weld parameters in real time. They enhance
workplace safety by minimizing exposure to hazardous fumes and high temperatures.
Industries such as automotive, aerospace, and construction benefit from their high-speed
operation and repeatability. Robotic welding reduces material waste, lowers operational costs,
and increases overall efficiency. Integration with CAD and CAM software allows for seamless
programming and execution of complex welding tasks. These systems support various
welding techniques, including MIG, TIG, and spot welding. As automation advances, robotic
welding continues to play a crucial role in modern smart manufacturing.
 TABLE OF CONTENT:
Chapter No Content Page No
CHAPTER 1
1.1: Introduction 1
1.2: Literature Survey 2-3
CHAPTER 2
2.1: Evolution of Robotic Welding 4-5
2.2: Components of Robotic Welding System 5-8
2.3: Advantages of Robotic Welding 8-9
2.4: Challenges and Limitations 9-10
2.5: Applications in Various Industries 10-12
2.6: Future Trends and Innovations 12-13
CHAPTER 3
3.1: Conclusion 14
References 15

LIST OF FIGURES:

Figure No. Name of the figure Page No.

2.1 Structure of Robot Welding System 4
2.2 Robotic Welding Configuration 6
2.3 Automated Robot Welding System 12
ROBOTIC WELDING SYSTEMS IN MANUFACTURING

CHAPTER 1
1.1 INTRODUCTION
In modern manufacturing, automation plays a crucial role in enhancing productivity,
precision, and efficiency. Among various automated processes, robotic welding has
emerged as a game-changing technology, revolutionizing industries such as automotive,
aerospace, shipbuilding, and construction. Robotic welding refers to the use of
programmable machines to perform welding tasks with minimal human intervention. These
systems integrate industrial robots, welding equipment, sensors, and software to deliver
consistent, high-quality welds at high speeds.

The demand for robotic welding has increased significantly due to the growing need for
cost-effective and high-quality production. Traditional manual welding processes, while
effective, are often labor-intensive, time-consuming, and prone to human error. In contrast,
robotic welding systems offer precise control, repeatability, and enhanced safety, making
them an ideal solution for mass production environments. With the ability to operate
continuously without fatigue, robotic welders improve overall manufacturing efficiency
and reduce downtime.

Over the years, advancements in artificial intelligence (AI), machine learning, and sensor
technology have further improved the capabilities of robotic welding systems. These
systems can now adapt to real-time changes in welding parameters, detect defects, and
optimize welding paths automatically. Vision-based robotic welding, for instance, uses
cameras and sensors to adjust welding operations based on workpiece variations, ensuring
superior weld quality.

Different types of robotic welding processes are employed depending on the application,
including arc welding, spot welding, laser welding, friction stir welding, and plasma
welding. Each method offers distinct advantages, catering to specific industrial
requirements. For example, spot welding is widely used in the automotive industry for
assembling vehicle bodies, while laser welding is preferred for high-precision applications
in aerospace and electronics.

Despite its numerous benefits, robotic welding comes with challenges such as high initial
investment costs, complex programming, and the need for skilled operators. However, with
continuous technological advancements, the adoption of robotic welding is becoming more

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widespread across industries. The integration of collaborative robots (cobots) is further

bridging the gap between human workers and automation, enabling flexible and efficient
manufacturing solutions.

In the future, robotic welding systems will continue to evolve, driven by innovations in AI,
IoT-based monitoring, and adaptive welding techniques. These advancements will further
enhance productivity, reduce material waste, and contribute to sustainable manufacturing
practices. As industries move towards smart factories and Industry 4.0, robotic welding will
remain a key component in shaping the future of automated manufacturing.

1.2 LITERATURE SURVEY

1.2.1 Evolution of Robotic Welding

Early research in robotic welding focused on automating repetitive welding tasks to

improve efficiency and reduce human intervention. According to a study by Groover
(2010), the introduction of industrial robots in welding began in the 1960s, primarily in the
automotive sector. The study highlights the transition from manual to robotic welding,
emphasizing the need for higher precision and repeatability.

1.2.2 Advancements in Welding Automation

Recent literature explores advancements in robotic welding technologies, including AI-

based adaptive welding and real-time quality monitoring. Zhang et al. (2018) investigated
the integration of machine learning in robotic welding, which enables the system to
optimize welding parameters dynamically. Similarly, Tan et al. (2020) discussed the role
of computer vision and sensor-based adaptive control in improving weld accuracy and
reducing defects.

1.2.3 Applications in Manufacturing

Several studies have examined the widespread use of robotic welding in various industries.
Chen and Li (2017) conducted an industrial case study on the implementation of robotic
welding in automobile production, demonstrating significant improvements in productivity
and consistency. In aerospace applications, Patel et al. (2019) highlighted the benefits of
laser-based robotic welding in achieving high-strength and precision joints.

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1.2.4 Challenges and Limitations

Despite its advantages, robotic welding faces challenges such as high setup costs, complex
programming, and limited adaptability to custom welding tasks. Ramesh et al. (2021)
explored the limitations of robotic welding in small-scale industries, emphasizing the need
for flexible and cost-effective robotic systems. The study suggests the use of collaborative
robots (cobots) to address these challenges and enhance human-robot interaction in welding
processes.

1.2.5 Future Trends and Innovations

Emerging trends in robotic welding include AI-driven autonomous welding, IoT-enabled

monitoring, and cloud-based data analytics. Singh et al. (2022) discussed the impact of
Industry 4.0 on robotic welding, predicting a rise in intelligent and self-learning robotic
welders. The study also emphasizes the role of sustainable welding techniques in reducing
material waste and energy consumption.

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CHAPTER 2

2.1 EVOLUTION OF ROBOTIC WELDING

Fig 2.1 Structure of Robot Welding System

2.1.1 Early Developments in Welding Automation

The journey of robotic welding began in the 1960s when the first industrial robots were
introduced to automate welding tasks. The Unimate, developed by George Devol and
Joseph Engelberger, was one of the first robotic systems used in manufacturing, particularly
in the automotive industry for spot welding. Early welding robots were primarily designed
for repetitive and high-volume production tasks, improving efficiency and reducing human
labour. However, these early systems lacked flexibility, as they relied on hard-coded
programming with minimal adaptability to changes in workpiece variations.

2.1.2 Advancements in Industrial Robotics

With advancements in sensor technology, microcontrollers, and CNC programming,

robotic welding systems became more sophisticated in the 1980s and 1990s. The
introduction of articulated robotic arms with multi-axis movement significantly improved
the precision and flexibility of welding operations. Developments in motion control and
feedback systems enabled robots to handle complex weld paths with higher accuracy. The

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use of servo motors, force sensors, and vision-guided systems further enhanced their
capabilities, making them suitable for industries such as aerospace, shipbuilding, and
construction.

2.1.3 Integration of AI and Machine Learning in Welding

Recent advancements in artificial intelligence (AI) and machine learning (ML) have
transformed robotic welding into an intelligent and adaptive process. AI-powered robots
can now analyse welding parameters in real-time, adjust their operations based on material
properties, and detect defects automatically. Machine learning algorithms help optimize
weld quality by learning from previous weld data and making predictive adjustments.
Additionally, AI-driven vision systems use cameras and sensors to improve weld accuracy
and consistency. These innovations have led to the development of smart welding robots
that can operate with minimal human intervention and self-correct errors, paving the way
for fully autonomous welding systems in Industry 4.0.

2.2 COMPONENTS OF A ROBOTIC WELDING SYSTEM

2.2.1 Industrial Robots: Types and Configurations

Industrial robots are the core component of any robotic welding system, designed to
automate the movement of the welding tool along predefined paths. These robots can be
classified based on their structure and the degree of flexibility they offer:

• Articulated Robots: These robots have multiple rotating joints (typically 6),
offering a high range of motion, making them suitable for complex welding tasks.

• Cartesian Robots: These have linear movements along X, Y, and Z axes, offering
precise control, typically used for repetitive tasks.

• SCARA Robots: With two arms that move in parallel, SCARA robots are
commonly used in simpler welding tasks requiring high speed and precision.

• Delta Robots: These are lightweight robots with a high-speed motion, often used
for spot welding or smaller components.

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Fig 2.2 Robot Welding Configuration

The configuration of these robots is chosen based on the workpiece size, task complexity,
and the desired flexibility of the system.

2.2.2 Welding Equipment: MIG, TIG, Laser, Spot Welding Setups

The welding equipment in robotic systems depends on the type of welding process being
used. Each method has its own advantages for specific applications:

• MIG (Metal Inert Gas) Welding: Also known as Gas Metal Arc Welding
(GMAW), MIG welding is a versatile, high-speed welding technique suitable for
thick materials and a wide range of metals. It uses a continuous wire feed as the
electrode.

• TIG (Tungsten Inert Gas) Welding: Known for its precision, TIG welding
(GTAW) is used for welding thin materials or when high-quality, clean welds are
required. It uses a non-consumable tungsten electrode and a separate filler material.

• Laser Welding: A high-precision technique that uses a focused laser beam to create
deep welds with minimal heat input, reducing thermal distortion. It is particularly
effective in industries that require high-quality joints such as aerospace.

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• Spot Welding: This is used mainly in the automotive industry for joining sheet
metal. Electrodes apply pressure and current to the workpieces, creating localized
welds at specific points.

2.2.3 Sensors and Vision Systems: Adaptive Control Mechanisms

Sensors and vision systems play a critical role in robotic welding systems by providing
real-time feedback and ensuring precise weld placement and quality.

• Position Sensors: These are used to track the robot's position and adjust the welding
path as needed to ensure accuracy.

• Vision Systems: Cameras and imaging systems are used to inspect the workpieces
for alignment, defects, and surface conditions. These systems help in adaptive
control by adjusting parameters such as weld speed and heat input based on the
detected variations.

• Arc Sensors: These sensors monitor the welding arc’s stability, ensuring consistent
weld bead formation. If any disturbance is detected, the system can adjust the
robot’s movement or welding parameters automatically.

• Temperature Sensors: These ensure optimal heat distribution during welding,

preventing overheating or underheating that may lead to defects.

2.2.4 Software and Programming: CNC and AI-Driven Systems

Robotic welding systems rely on sophisticated software for programming, control, and
optimization:

• CNC (Computer Numerical Control) Systems: CNC-based programming allows

precise control over the robot’s movements along complex paths. It generates the
welding trajectory based on design data (CAD files), ensuring high accuracy in
repetitive tasks.

• AI-Driven Systems: Artificial intelligence is increasingly used in robotic welding

to enable adaptive learning. AI systems can optimize the welding process by
analyzing real-time feedback from sensors and vision systems. They can adjust the
welding parameters dynamically for different materials, geometries, or welding
conditions.

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• Simulation Software: Before actual production, robotic welding programs are

often simulated to predict potential issues and optimize the paths, speeds, and
welding parameters. This software reduces errors and ensures smooth operation
during real-world application.

2.3 ADVANTAGES OF ROBOTIC WELDING

• Increased Precision and Repeatability: Robotic welding systems are designed to

perform highly precise welding tasks with minimal variation between each weld.
Unlike human welders, who may experience fatigue or inconsistency over time,
robots can deliver consistent and accurate welds across a production run. This high
precision ensures uniformity, reduces errors, and meets strict quality standards.

• Higher Productivity and Efficiency: Robotic welders are capable of working

continuously without the need for breaks, unlike human workers. They can perform
welding tasks at much faster speeds, increasing the overall throughput in
manufacturing processes. This continuous operation and faster cycle times
significantly improve productivity and reduce lead times, contributing to more
efficient production lines.

• Reduced Labor Costs and Human Fatigue: By replacing manual labor with
robotic systems, companies can reduce the need for skilled workers to perform
repetitive and physically demanding tasks. This not only cuts labor costs but also
prevents the physical strain and fatigue that human welders might face during long
working hours. It also frees up human workers to focus on more complex tasks,
improving workforce utilization.

• Enhanced Workplace Safety: Robotic welding systems minimize the exposure of

human workers to dangerous conditions associated with welding, such as high
temperatures, intense light, fumes, and molten metal splashes. Robots can work in
hazardous environments without risking injury, leading to a safer workplace.

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Additionally, robots can be equipped with safety features like sensors and barriers
to further protect workers.

• Consistent Weld Quality and Reduced Material Wastage: Robotic welders use
advanced sensors and control systems to optimize welding parameters, ensuring
that the weld quality remains consistent throughout the production process. This
consistency helps in meeting high-quality standards and reduces defects.
Furthermore, the precise control over welding speed, temperature, and material
usage minimizes material wastage, leading to cost savings and better resource
utilization.

2.4 CHALLENGES AND LIMITATIONS

1. High Initial Investment Costs

The cost of implementing robotic welding systems is a significant barrier for many
companies. These systems involve not only the expense of the robots themselves but also
the associated equipment, software, sensors, and integration into existing production lines.
The upfront capital required for purchasing and setting up robotic welding systems can be
high, making it difficult for small or medium-sized enterprises (SMEs) to adopt this
technology without significant financial investment.

2. Complex Setup and Maintenance

Setting up robotic welding systems requires a careful, precise integration of various

components, including robotic arms, welding equipment, sensors, and controllers. The
installation and calibration process can be complex, often requiring specialized knowledge.
Additionally, maintaining robotic welding systems involves ongoing monitoring, regular
maintenance of robotic components, welding equipment, and software updates. Failure to
properly maintain these systems can lead to costly downtime and production delays.

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3. Skilled Workforce Requirement for Programming and Troubleshooting

While robotic welding systems are designed to reduce the need for human labor in welding
tasks, they still require skilled personnel to program and troubleshoot. These robots need
to be configured, programmed, and maintained by trained engineers or technicians who
understand the nuances of welding processes, robotics, and software systems. The shortage
of such skilled workers can be a limitation for some industries, especially as the technology
becomes more advanced and specialized.

4. Adaptability for Custom and Small-Scale Productions

Robotic welding systems excel in high-volume production settings where the welding tasks
are repetitive and standardized. However, for small-scale or custom production runs,
adapting robotic systems to different products or welding scenarios can be challenging. The
flexibility of robotic welding systems is limited when the design or geometry of the
workpieces changes frequently. Reprogramming the system for each new design can be
time-consuming and costly, limiting the appeal of robotic welding for small-batch
production.

2.5 APPLICATIONS IN VARIOUS INDUSTRIES

1. Automotive Industry: Car Body and Chassis Welding

Robotic welding is extensively used in the automotive industry, particularly for welding
car bodies and chassis. Robots are employed for high-speed, high-precision spot welding
and arc welding processes. The automation of these tasks ensures consistent, repeatable
welds across millions of vehicles, improving both quality and productivity. Robotic
systems can also handle intricate designs and complex geometries, reducing the time
required for assembly. Key tasks include welding body panels, door frames, and structural
components, significantly enhancing manufacturing efficiency and reducing human error.

2. Aerospace Industry: High-Precision Structural Welding

In aerospace, the need for precision and high-strength materials makes robotic welding
crucial. Robotic systems are used for welding structural components, such as aircraft

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frames, engine parts, and landing gear assemblies. Advanced welding methods, including
laser welding and friction stir welding, are often employed for their ability to produce
strong, lightweight joints. Robotic welding in aerospace ensures that parts meet strict
quality standards and can withstand extreme conditions, while also speeding up the
production process for complex components.

3. Shipbuilding: Large-Scale Automated Welding

Shipbuilding benefits from robotic welding through the automation of large-scale, heavy-
duty welding tasks. Robots are used to weld ship hulls, decks, and other large metal
structures, where the scale and weight of materials would make manual welding difficult.
Robotic systems in shipbuilding allow for faster production times, more consistent welds,
and the ability to work in hard-to-reach areas. The precision and durability of robotic welds
are particularly essential in ensuring the safety and longevity of vessels exposed to harsh
marine environments.

4. Construction and Infrastructure: Prefabricated Steel Structures

Robotic welding plays a vital role in the construction and infrastructure sectors, particularly
in the fabrication of steel structures used in buildings, bridges, and other infrastructure
projects. Robots are used to weld steel beams, columns, and framework components in
prefabrication plants, which are then transported and assembled on-site. The use of robotic
welding ensures that these components are fabricated to exact specifications, improving the
quality and stability of the final structure. Furthermore, robotic welding enhances the speed
and safety of large-scale construction projects.

5. Electronics Industry: Micro-Welding for Circuit Boards

In the electronics industry, robotic welding is employed for micro-welding tasks, especially
in the assembly of circuit boards and electronic components. Techniques such as laser
welding and resistance welding are used to create precise, small welds on delicate parts like
connectors, resistors, and microchips. These methods are critical in ensuring that
components are securely connected without damaging sensitive electronic parts. Robotic
systems offer high repeatability and accuracy, essential for producing high-quality
electronic devices used in everything from smartphones to medical equipment.

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Fig 2.3 Automated Robot Welding System

2.6 FUTURE TRENDS AND INNOVATIONS

2.6.1 AI and Machine Learning Integration

Artificial intelligence (AI) and machine learning (ML) are revolutionizing robotic welding
by enabling systems to make real-time decisions and optimize welding processes
autonomously. AI algorithms can analyze large datasets generated by sensors and cameras,
allowing robots to predict optimal welding parameters based on variables like material
type, thickness, and environmental conditions. Machine learning can help the robotic
system adapt to changes in the workpiece, automatically adjusting speed, power, and other
parameters to ensure consistent weld quality. Over time, the system "learns" from past data,
improving its welding strategies and minimizing defects.

2.6.2 Collaborative Robotic Welding (Cobots)

Collaborative robots, or cobots, are designed to work alongside human operators in a shared
workspace, enhancing the flexibility of robotic welding systems. Unlike traditional
industrial robots, which often operate in isolation for safety reasons, cobots are equipped
with advanced sensors and safety features to interact directly with humans without posing
risks. This enables manufacturers to deploy robotic welding in smaller production runs and
in environments where human supervision or adjustments are required. Cobots can assist

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with tasks like handling parts, adjusting welding parameters, or providing maintenance,
improving productivity without completely replacing human labor.

2.6.3 IoT-Based Real-Time Monitoring

The Internet of Things (IoT) allows robotic welding systems to be connected to a network
of sensors and devices that monitor every aspect of the welding process in real time. This
connectivity enables remote monitoring and predictive maintenance, ensuring the system
operates at peak performance. IoT integration can track weld quality, detect anomalies, and
alert operators to potential failures before they occur. Additionally, the data collected by
IoT-enabled systems can be analyzed for further optimization of the welding process,
leading to improved product quality and reduced downtime.

2.6.4 Advanced Adaptive Welding Techniques

Advanced adaptive welding techniques involve using feedback loops, sensors, and real-
time data to automatically adjust welding parameters to changing conditions. For instance,
robots can use vision systems and laser sensors to measure joint geometry and
automatically adjust the welding path and speed to accommodate slight variations in the
material or position. This adaptability improves weld quality and minimizes human error,
making robotic welding suitable for highly variable or custom applications. Techniques like
adaptive control in laser welding or friction stir welding are particularly valuable in
industries where precision is critical, such as aerospace and automotive.

2.6.5 Sustainable and Eco-Friendly Welding Processes

Sustainability is becoming an increasing focus in the manufacturing sector, and robotic

welding systems are evolving to support more eco-friendly practices. Innovations in
welding processes aim to reduce energy consumption, minimize waste, and lower
emissions. For example, laser welding and friction stir welding are more energy-efficient
compared to traditional arc welding methods. Additionally, there is growing interest in the
use of environmentally friendly materials and gases in welding processes. As industries
push toward greener practices, robotic systems are being designed to optimize energy use
and reduce the carbon footprint of manufacturing processes, aligning with global
sustainability goals.

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CHAPTER 3

3.1 CONCLUSION

Robotic welding systems have transformed manufacturing by improving precision,

consistency, and productivity. These systems reduce labor, enhance safety, and minimize
human error, making them ideal for high-volume industries like automotive and aerospace.
The integration of AI, machine learning, and sensors allows for real-time adjustments,
optimizing weld quality. While the high initial investment and complex setup pose
challenges for smaller enterprises, the benefits—such as reduced labor costs and greater
efficiency—often outweigh the costs in large-scale production. Collaborative robots
(cobots) are offering more flexibility and enabling safer interaction with human workers.
As Industry 4.0 evolves, robotic welding systems will become smarter, more adaptable, and
cost-effective. Future innovations will focus on real-time monitoring, predictive
maintenance, and sustainability, including reducing material waste and energy
consumption. Overall, robotic welding will continue to shape the future of smart
manufacturing, improving efficiency and flexibility in production.

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REFERENCES

Groover, M. P. (2010). Automation, Production Systems, and Computer-Integrated

Manufacturing. Pearson.

Zhang, L., Shi, Y., & Jiang, S. (2018). "Machine learning in robotic welding." J.
Manufacturing Processes, 34, 23-34.

Tan, W., et al. (2020). "Vision-based adaptive welding." Robotics and Computer-
Integrated Manufacturing, 63, 101908.

Chen, Z., & Li, S. (2017). "Robots in automotive welding." J. Manufacturing Science
and Engineering, 139(4), 040904.

Patel, H., et al. (2019). "Laser robotic welding in aerospace." Aerospace Sci. and Tech.,
87, 1-12.

Ramesh, S., & Kumar, R. (2021). "Challenges in small-scale robotic welding." Int. J.
Adv. Manufacturing Tech., 112(5), 1234-1245.

Singh, A., & Soni, S. (2022). "Industry 4.0 and welding robots." Procedia CIRP, 106,
17-22.

Zhang, Y., & Li, D. (2018). "Real-time quality control in welding." J. Manufacturing
Sci. and Eng., 140(9), 091009.

Kuo, H., & Chang, S. (2020). "Collaborative robots in welding." J. Robotics and
Automation, 35(7), 543-556.

Wang, F., & Yang, L. (2021). "Sustainability in robotic welding." Sustainable

Manufacturing, 5(1), 1-14.

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