Productive Robotics
Live Weld Speed Control
Built a real-time process parameter adjustment system allowing operators to modify weld speed while the robot is actively welding — changes propagate from the operator UI through the executive layer to the real-time control layer, with trajectory filtering that ensures only the active weld segments are modified.
Implemented a trajectory-filtering approach in the Python executive that isolates which trajectory segments are safe to modify during live execution. Approach, retract, and non-weld move segments are explicitly excluded — only the currently-active weld segments receive the new parameter. The filtering handles edge cases around step boundaries to avoid modifying the wrong scope.
Built a setter on the active spline in the real-time control layer that modifies in-flight trajectory parameters during execution, with the operator request routed through the executive layer's service gateway. The recipe is updated in parallel so the change persists for subsequent runs.
Diagnosed a subtle production bug where pausing and resuming a weld could cause travel speed to revert to a stale value from a prior preview run, leading to process defects. The fix replaced a multiplier-based scheme with absolute speed values stored in the recipe, eliminating the dependency on transient UI state.
Implemented torch delay logic for weld resume after pause — a safety requirement because the robot must rejoin the weld path before the arc can be restarted. The arc is held off until trajectory feedback confirms the robot has returned to the weld path.