Testing Simulators

Developed a suite of hardware-free simulation and testing tools that enabled software development without continuous access to a physical robot or welding equipment. Includes welder telemetry simulation, a standalone weld dashboard, a headless background recorder, kinematics testing tools, and a motor simulator.

Built a welding status simulator that emulates the welder's telemetry responses, allowing the welding software stack to run without a physical welder connected. The simulator accepts configuration for different welding scenarios — steady-state, arc transients with realistic ramp profiles, and fault injection for testing error-handling paths. A companion standalone dashboard runs the weld monitoring UI as a self-contained Python application with no robotics-framework dependency, launchable on any developer's laptop.

Developed a headless Python recorder that subscribes to welding telemetry and writes timestamped CSV files in the background — capturing arc parameters, travel speed, and position data at full rate, suitable for post-weld analysis and process development. Built kinematics testing tools that verify the robot's forward and inverse kinematic solutions against known reference poses — essential for validating kinematic parameter changes without needing to move the physical robot.

Created a motor simulator that emulates motor-controller responses for all joints — position, velocity, current, temperature, and fault status — using a simplified motor model. This enabled development of the C++ motor control layer (PID tuning, trajectory interpolation, fault detection) from a home office without access to the robot hardware. Together, these simulators substantially reduced the requirement for on-site development, enabling productive remote work.