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Robotic arc welding and plasma arc cutting, in general, require precise positioning of the torch relative to the workpiece. To this end, a 1-dimensional non-contact sensor was applied to two assembly plant tasks and found to perform to requirements while maintaining the system's cost effectiveness. This paper first presents a comparative overview of sensor technology typically used for arc welding. 1,2, and 3-D sensors are briefly compared in terms of functionality, operational complexity, and cost. Two plant applications are discussed to substantiate the conclusions. The first is an A-Pillar reinforcement MIG welding job. The second is a sunroof opening plasma cutting operation. This latter application requires part location in the absence of typical weld joints. In both instances, a robot mounted 1-D laser sensor was used to locate the part prior to the welding/cutting operation.

The evolution of Robotics Technology has made the automatic application of sealants a reality and thus a necessity to maintain a competitive edge. Justification was made to design and install automated systems to account for nearly 70% of the sealing requirement for the General Motors new C/K Truck. A CAD/CAM simulation was completed generating an optimum robot layout as well as system design requirements. One of the innovations implemented as a part of this system was a robotically-applied cosmetic bead of sealant. To insure quality application to 100% of the truck box seams, techniques such as: analog sealant flow control, compliant sealant gun nozzles, and computer vision location of box corners were developed.