Weld System - Blade Generation System

Vision: Smart Weld Data Generator

🎯 Goal

Auto-detect weld joints from CAD geometry, extract torch approach vectors, and export to neutral formats for offline robot programming.

✓ Detect weld joints from part/fixture intersection
✓ Extract torch approach vectors (default: Z+ approach)
✓ Union touching beads into continuous paths
✓ Export to neutral format (CSV/JSON/XML)
✓ Generate individual + combined STL for simulation

📅 Deadline: April 1, 2026

Weld export system with union, torch vectors, and multi-format export.

Weld Bead Detection

Detection Method

WELD DETECTION WORKFLOW Part Body + Fixture Blades │ ▼ ┌─────────────────────────┐ │ sld int (intersection) │ ◀── Find touching faces └───────────┬─────────────┘ │ ▼ ┌─────────────────────────┐ │ Extract edge curves │ ◀── Weld path = intersection edges └───────────┬─────────────┘ │ ▼ ┌─────────────────────────┐ │ Calculate face normals │ ◀── Torch approach direction └───────────┬─────────────┘ │ ▼ ┌─────────────────────────┐ │ Union touching beads │ ◀── Merge continuous paths └───────────────────────────┘

Torch Vector Calculation

Default approach: Z+ (from above). For angled welds, calculate bisector of adjacent face normals.

TORCH APPROACH OPTIONS 1. Z+ Default (vertical down) ↓ torch ═══════ weld bead 2. Bisector (angled joint) ↘ torch ╱═══════╲ face1 face2 3. User-specified override

Export Formats

Format	Use Case	Status
CSV	Simple import to spreadsheets, basic robots	TODO
JSON	Structured data with metadata, web integration	TODO
XML	Legacy systems, some robot controllers	TODO
STL	Individual beads + combined for simulation	TODO

CSV Output Structure

Weld_ID,Start_X,Start_Y,Start_Z,End_X,End_Y,End_Z,Torch_X,Torch_Y,Torch_Z,Length W001,100.0,50.0,0.0,200.0,50.0,0.0,0.0,0.0,1.0,100.0 W002,200.0,50.0,0.0,200.0,150.0,0.0,0.0,0.0,1.0,100.0

Robot Format Research

Future: Native export for specific robot brands

Nachi format
OTC Daihen format
FANUC LS format
ABB RAPID

Weld Cell Configuration

Fixture design must account for customer's welding equipment:

Configuration	Fixture Impact
Stationary Table	All welds accessible from above/sides. May need repositioning.
Single-Axis Positioner	Can rotate 360° around one axis. Design apertures for underside.
Trunnion / 2-Axis	Full orientation control. Maximum flexibility.

Implementation Status

○ Weld bead detection from intersection
○ Union touching beads (sld int)
○ Torch vector calculation (Z+ default)
○ CSV export
○ JSON export (structured with metadata)
○ XML export
○ STL export (individual + combined)
○ Nachi/OTC Daihen format research

📦 Deliverables

fxDetectWelds.ovm - weld bead identification

fxWeldUnion.ovm - merge touching beads

fxTorchVector.ovm - approach angle calculation

fxWeldExportCSV.ovm, fxWeldExportJSON.ovm, fxWeldExportSTL.ovm

fxWeldCellConfig.ovm - equipment type configuration