A Methodology for Transitioning from Jig-Based to Jigless MIG Welding Utilizing Articulated Robots

This thesis presents a methodology to replace jig-based welding systems with jigless solutions utilizing articulated robots. The goal is to reduce overall cycle time and increase flexibility to handle more product variations. The methodology entails setting the requirements first, followed by designing a robotic cell layout, selecting suitable grippers, defining required components, and experimental verification via simulation. It is applied to a case study of welding steel brackets. The application successfully designs customized solutions tailored to the bracket parameters. Simulation confirms the feasibility of the proposed cell layout and 21-second cycle time with a 74% reduction. Further prototyping is needed to quantify improvements versus jig welding. This research demonstrates the methodology's potential for flexible, automated jigless welding to improve productivity.