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<p> Current research on the precision of large-diameter pipeline welding robot predominantly relies on passive post-process algorithmic compensation, which fails to fundamentally resolve geometric and deformation errors introduced during manufacturing. Moreover, conventional uniform tolerance allocation frequently leads to "over-design" and prohibitive costs for heavy-duty equipment. To overcome these limitations, this study proposes an "active," sensitivity-driven synergistic precision design paradigm. First, a highly coupled, nonlinear kinematic model incorporating position-dependent deformation curves is constructed based on screw theory. Given the complex parameter interactions, Sobol global sensitivity analysis is employed to quantitatively identify the structure-dominant influence weights of each motion axis. Subsequently, a probabilistic system-level constrained optimization framework driven by an improved GA-PSO algorithm is established. This framework achieves a differentiated tolerance allocation strategy—imposing strict pre-manufacturing constraints strictly on high-sensitivity axes (e.g., radial and axial) while cost-effectively relaxing the circumferential base axis. Comprehensive experimental validation along a full-scale continuous welding trajectory confirms the strategy’s robustness. The results quantitatively decouple error concentration from overall reliability: actual spatial errors are highly concentrated (90% within 9 μm), and the overall tolerance compliance rate exceeds 97%, strongly aligning with the 99.76% theoretical reliability prediction. This predictive approach effectively resolves the Pareto trade-off between precision and cost, realizing a fundamental paradigm shift from passive compensation to active design and providing a highly robust physical baseline for real-world industrial implementation.</p>

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Geometric Precision Design for Large-Diameter Pipeline Welding Robots

  • 期刊论文

  • 发表日期：

    2026年4月14日

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  • Zhou Tan,
  • Chunping Liang,
  • GuangShuai Liu,
  • Jianheng Zhang,
  • Honghui Yu,
  • Chaoming He

摘要

Current research on the precision of large-diameter pipeline welding robot predominantly relies on passive post-process algorithmic compensation, which fails to fundamentally resolve geometric and deformation errors introduced during manufacturing. Moreover, conventional uniform tolerance allocation frequently leads to "over-design" and prohibitive costs for heavy-duty equipment. To overcome these limitations, this study proposes an "active," sensitivity-driven synergistic precision design paradigm. First, a highly coupled, nonlinear kinematic model incorporating position-dependent deformation curves is constructed based on screw theory. Given the complex parameter interactions, Sobol global sensitivity analysis is employed to quantitatively identify the structure-dominant influence weights of each motion axis. Subsequently, a probabilistic system-level constrained optimization framework driven by an improved GA-PSO algorithm is established. This framework achieves a differentiated tolerance allocation strategy—imposing strict pre-manufacturing constraints strictly on high-sensitivity axes (e.g., radial and axial) while cost-effectively relaxing the circumferential base axis. Comprehensive experimental validation along a full-scale continuous welding trajectory confirms the strategy’s robustness. The results quantitatively decouple error concentration from overall reliability: actual spatial errors are highly concentrated (90% within 9 μm), and the overall tolerance compliance rate exceeds 97%, strongly aligning with the 99.76% theoretical reliability prediction. This predictive approach effectively resolves the Pareto trade-off between precision and cost, realizing a fundamental paradigm shift from passive compensation to active design and providing a highly robust physical baseline for real-world industrial implementation.