Lightweight, durable textile-based inflatable soft actuators are widely used in soft robotics, particularly for wearable robots in rehabilitation and in enhancing human performance in demanding jobs. Fabricating these actuators typically involves multiple steps: heat-sealable fabrics are fused with a heat press, and non-stick masking layers define internal chambers. These layers must be carefully removed post-fabrication, often making the process labor-intensive and prone to errors. To address these challenges and improve the accuracy and performance of inflatable actuators, we introduce the Weld n'Cut platform-an open-source, automated manufacturing process that combines ultrasonic welding for fusing textile layers with an oscillating knife for precise cuts, enabling the creation of complex inflatable structures. We demonstrate the machine's performance across various materials and designs with arbitrarily complex geometries.

Ensuring consistent processing quality is challenging in laser processes due to varying material properties and surface conditions. Although some approaches have shown promise in solving this problem via automation, they often rely on predetermined targets or are limited to simulated environments. To address these shortcomings, we propose a novel real-time reinforcement learning approach for laser process control, implemented on a Field Programmable Gate Array to achieve real-time execution. Our experimental results from laser welding tests on stainless steel samples with a range of surface roughnesses validated the method's ability to adapt autonomously, without relying on reward engineering or prior setup information. Specifically, the algorithm learned the correct power profile for each unique surface characteristic, demonstrating significant improvements over hand-engineered optimal constant power strategies -- up to 23% better performance on rougher surfaces and 7% on mixed surfaces. This approach represents a significant advancement in automating and optimizing laser processes, with potential applications across multiple industries.

Ultrasonic Additive Manufacturing (UAM) employs ultrasonic welding to bond similar or dissimilar metal foils to a substrate, resulting in solid, consolidated metal components. However, certain processing conditions can lead to inter-layer defects, affecting the final product's quality. This study develops a method to monitor in-process quality using deep learning-based convolutional neural networks (CNNs). The CNN models were evaluated on their ability to classify samples with and without embedded thermocouples across five power levels (300W, 600W, 900W, 1200W, 1500W) using thermal images with supervised labeling. Four distinct CNN classification models were created for different scenarios including without (baseline) and with thermocouples, only without thermocouples across power levels, only with thermocouples across power levels, and combined without and with thermocouples across power levels. The models achieved 98.29% accuracy on combined baseline and thermocouple images, 97.10% for baseline images across power levels, 97.43% for thermocouple images, and 97.27% for both types across power levels. The high accuracy, above 97%, demonstrates the system's effectiveness in identifying and classifying conditions within the UAM process, providing a reliable tool for quality assurance and process control in manufacturing environments. Key Words: Machine Learning, Convolution Neural Network, Image Analysis, Ultrasonic Additive Manufacturing, In situ Monitoring, Anomaly Detection 1.0 Introduction Additive manufacturing (AM) refers to a set of computer-controlled techniques that create threedimensional objects by layering materials (Ansari et al., 2022; Saimon et al., 2024). Ultrasonic additive manufacturing (UAM) is a standout solid-state manufacturing method within this group, producing nearly finished metal parts without melting the materials.

Efficiently detecting target weld seams while ensuring sub-millimeter accuracy has always been an important challenge in autonomous welding, which has significant application in industrial practice. Previous works mostly focused on recognizing and localizing welding seams one by one, leading to inferior efficiency in modeling the workpiece. This paper proposes a novel framework capable of multiple weld seams extraction using both RGB images and 3D point clouds. The RGB image is used to obtain the region of interest by approximately localizing the weld seams, and the point cloud is used to achieve the fine-edge extraction of the weld seams within the region of interest using region growth. Our method is further accelerated by using a pre-trained deep learning model to ensure both efficiency and generalization ability. The performance of the proposed method has been comprehensively tested on various workpieces featuring both linear and curved weld seams and in physical experiment systems. The results showcase considerable potential for real-world industrial applications, emphasizing the method's efficiency and effectiveness. Videos of the real-world experiments can be found at https://youtu.be/pq162HSP2D4.

This article undertakes a comprehensive examination of two distinct robot morphologies: the PUMA-type arm (Programmable Universal Machine for Assembly) and the UR-type robot (Universal Robots). The primary aim of this comparative analysis is to assess their respective performances within the specialized domain of welding, focusing on predefined industrial application scenarios. These scenarios encompass a range of geometrical components earmarked for welding, along with specified welding paths, spatial constraints, and welding methodologies reflective of real-world scenarios encountered by manual welders. The case studies presented in this research serve as illustrative examples of Weez-U Welding practices, providing insights into the practical implications of employing different robot morphologies. Moreover, this study distinguishes between various base positions for the robot, thereby aiding welders in selecting the optimal base placement aligned with their specific welding objectives. By offering such insights, this research facilitates the selection of the most suitable architecture for this particular range of trajectories, thus optimizing welding efficiency and effectiveness. A departure from conventional methodologies, this study goes beyond merely considering singularities and also delves into the analysis of collisions between the robot and its environment, contingent upon the robot's posture. This holistic approach offers a more nuanced understanding of the challenges and considerations inherent in deploying robotic welding systems, providing valuable insights for practitioners and researchers alike in the field of robotic welding technology.

The visual sensing system is one of the most important parts of the welding robots to realize intelligent and autonomous welding. The active visual sensing methods have been widely adopted in robotic welding because of their higher accuracies compared to the passive visual sensing methods. In this paper, we give a comprehensive review of the active visual sensing methods for robotic welding. According to their uses, we divide the state-of-the-art active visual sensing methods into four categories: seam tracking, weld bead defect detection, 3D weld pool geometry measurement and welding path planning. Firstly, we review the principles of these active visual sensing methods. Then, we give a tutorial of the 3D calibration methods for the active visual sensing systems used in intelligent welding robots to fill the gaps in the related fields. At last, we compare the reviewed active visual sensing methods and give the prospects based on their advantages and disadvantages.

The industry of the future, also known as Industry 5.0, aims to modernize production tools, digitize workshops, and cultivate the invaluable human capital within the company. Industry 5.0 can't be done without fostering a workforce that is not only technologically adept but also has enhanced skills and knowledge. Specifically, collaborative robotics plays a key role in automating strenuous or repetitive tasks, enabling human cognitive functions to contribute to quality and innovation. In manual manufacturing, however, some of these tasks remain challenging to automate without sacrificing quality. In certain situations, these tasks require operators to dynamically organize their mental, perceptual, and gestural activities. In other words, skills that are not yet adequately explained and digitally modeled to allow a machine in an industrial context to reproduce them, even in an approximate manner. Some tasks in welding serve as a perfect example. Drawing from the knowledge of cognitive and developmental psychology, professional didactics, and collaborative robotics research, our work aims to find a way to digitally model manual manufacturing skills to enhance the automation of tasks that are still challenging to robotize. Using welding as an example, we seek to develop, test, and deploy a methodology transferable to other domains. The purpose of this article is to present the experimental setup used to achieve these objectives.

Ultrasonic welding machines play a critical role in the lithium battery industry, facilitating the bonding of batteries with conductors. Ensuring high-quality welding is vital, making tool condition monitoring systems essential for early-stage quality control. However, existing monitoring methods face challenges in cost, downtime, and adaptability. In this paper, we present WeldMon, an affordable ultrasonic welding machine condition monitoring system that utilizes a custom data acquisition system and a data analysis pipeline designed for real-time analysis. Our classification algorithm combines auto-generated features and hand-crafted features, achieving superior cross-validation accuracy (95.8% on average over all testing tasks) compared to the state-of-the-art method (92.5%) in condition classification tasks. Our data augmentation approach alleviates the concept drift problem, enhancing tool condition classification accuracy by 8.3%. All algorithms run locally, requiring only 385 milliseconds to process data for each welding cycle. We deploy WeldMon and a commercial system on an actual ultrasonic welding machine, performing a comprehensive comparison. Our findings highlight the potential for developing cost-effective, high-performance, and reliable tool condition monitoring systems.

The automation of key processes in metal cutting would substantially benefit many industries such as manufacturing and metal recycling. We present a vision-based control scheme for automated metal cutting with oxy-fuel torches, an established cutting medium in industry. The system consists of a robot equipped with a cutting torch and an eye-in-hand camera observing the scene behind a tinted visor. We develop a vision-based control algorithm to servo the torch's motion by visually observing its effects on the metal surface. As such, the vision system processes the metal surface's heat pool and computes its associated features, specifically pool convexity and intensity, which are then used for control. The operating conditions of the control problem are defined within which the stability is proven. In addition, metal cutting experiments are performed using a physical 1-DOF robot and oxy-fuel cutting equipment. Our results demonstrate the successful cutting of metal plates across three different plate thicknesses, relying purely on visual information without a priori knowledge of the thicknesses.

Establishing a communication bridge by transferring data driven from different embedded sensors via internet or reconcilable network protocols between enormous number of distinctively addressable objects or "things", is known as the Internet of Things (IoT). IoT can be amalgamated with multitudinous objects such as thermostats, cars, lights, refrigerators, and many more appliances which will be able to build a connection via internet. Where objects of our diurnal life can establish a network connection and get smarter with IoT, robotics can be another aspect which will get beneficial to be brought under the concept of IoT and is able to add a new perception in robotics having "Mechanical Smart Intelligence" which is generally called "Internet of Robotic Things" (IoRT). A robotic arm is a part of robotics where it is usually a programmable mechanical arm which has human arm like functionalities. In this paper, IoRT will be represented by a 5 DoF (degree of freedoms) Robotic Arm which will be able to communicate as an IoRT device, controlled with heterogeneous devices using IoT and "Cloud Robotics".