Welding big impellers and static parts

Hello there,
I have been welding big impellers and static parts ( up to 25 tons) with fanuc for the last 10 years. The problem with this products is that they are unique; i never manufacture 4 or 5 equal products. The programming of this parts is huge, i do use roboguide to reduce the setup time but i need to do something to reduce the lead time.
On my programs normally i use frames and touch sensing; but i think i need to explore more advanced techniques to reduce the programming; some fans have different sizes but they are similar. I am looking for advance TP programs or even Karel to get some ideas. I never got an advance training, i have the arc tool manual and hundreds of nights with roboguide without sleep Can anyone help me?

Btw, my roboguide is crashing all the time, it can be the GPU card? my pc is: AMD Ryzen 7 1700 ; GPU RX 560 ; 16 GB RAM 3200 MHZ ; SSD ; Win 10. Should i change the GPU for a Nvidea quadro?

Thank you

i have the last version of roboguide and it has cad to path. On all points, i still need to use touch sensing, because my parts have a lot of assembly "defects" (high thickness and big parts".
My products have between 2k and 20k lines of code, with thousands of points; i really need to make some kind of parametric and self learning program but i dont know where to start.

Hello Again,
I didn't mention that my cells has many big external axis as well. As for the frames, i have 1 frame for the entire piece and than other frames for small routines. I need the first frame to eliminate differences from the 3D to the real piece and assembling errors (the tolerances of my pieces are big). With this frame i can use other frames on it to use the same routine in similar joints, just changing the frame. For example, if the piece has 1 continuous weld where 3 points are enough, i have a routine with the points attached to a frame, moving the frame will move all the points and then i just need to correct them; in some cases i dont need to correct them because i the touch sensing in the 3 directions with big searching distances, sometimes 500 mm, so when the join is bigger, the robot always catch the beginning and the end.
I have routines for joint search as well with skips where i simulate the rotation of a frame to search for joints in different angles.
I read that amazing things can be made with karel, but where i can see examples? i dont even know what i can do with it.
Thank you in advance,

Hello Macru,
I did try TAST already but my parts are in high strength steel and CrMo steel so heat input must be very low, i cant use weaving.
I bought a laser from scansonic as well but it doesn't work; I need to grind 150mm on the welding surface to increase the visual aspect, reduce cracking and porosity as well and the laser doesn't really work with grinded surfaces. Also, most of the places are very tight and the laser doesn't fit. Another problem with the laser is that i use basic fluxed core bcuz of cold crack and the position to weld doesn't allow me to use laser track. Also, track only works with the robot axis and i use external axis as well. I had 3 years trying to use laser tracking but without success. I think the only solution is a self teaching program, but i don't even know how to start

Hello,
I actually do that with touch sensing, i touch on the edges and corners, etc to calibrate the frame, than i call the routine over that frame and with touch sensing again i re-calibrate the seam. Systems like I-cube are a problem for this pieces, my orientations and positions are crap. My idea of a program was with touch sensing the robot would build a virtual design of the piece or something like that. I dont mind having the robot searching for joints and do calculations for 1 entire day, my pieces has around 4-5 days of welding on the robot, so 1 day touching for me is nothing.

Quote from dha

I think there is a guy on forum from Inrotech. Maybe he has some good ideas. They made this one i think:

https://www.youtube.com/watch?v=pUgeLtNlE4U

I saw that video already, it's amazing! But i stay in the same position, how the robot teaches itself I assume that there is zero information and manuals to actually develop this right? I think i need some like of road map to start, and ofc some examples to start developing
Thank you

On example of a program that i would like to build.
Some part of my pieces has circular welding, however, the radius is not perfect and in fact it has many many radius so my only solution is to teach many points. Normally i teach the robot to the position and than the external axis moves, sometimes i have 100 points to have the welding perfect of the seam. What i want is for example:
- i teach the robot to the max dimension of the piece, or the limit of the robot
- with touch sensing the robot learn the piece location, return 10 mm after (in the bigger diameter to avoid a collision
- turning the external axis for positive and negative with touch sensing for the robot to learn the beginning and the end of the welding
- after it i can choose learn points every 2 degree of rotation or 10 degree of rotation
- rotate the external axis and store the position into a PR[R[10]] ; R[10]=[10]+1 ; PR[R10:grp2]=PR[R10:gpr2]+rotation (example)
- with a counter i can know how many PR it stored
- i wanted the program to create the arc start and arc end with the points it created or the number of points it created.

with this, all the circular welding will be calculated automatically with the program and will remove many points.

anyone?

Quote from dha

You could use KAREL to write temporary welding TP program out of your PRs.

I don't know to to write Arc Start and Arc End commands from KAREL.

You know how to write PR's with karel in the TP?

Thank you m8