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Ts i 1 T, 1T pZ Leg Leg required r Leg specried on drawing -=-ºý ----ý Leg specfied and required T Leg specified Leg required Root opening (gap) Concavity . -Vat Throat Specification for Automotive Frame Weld Quality - Arc Welding - AWSD8: 8-79 SAE HS J1196 Fillet Welds Minimum Leg Length = 70% min(T1, T2) for C02 welding Throat Thickness >- 60% min(T1, T2) = 90% min(T1, T2) for non-CO2 welding If gap is present then Leg required = Leg specified + gap Maximum allowable gap = min (2.3mm, min(T1, T2) ) Figure 3.4 - AWS Specification for Automotive Frame Weld Quality - Fillet Weld [ref. 107] Z World x z. Robot Table Figure 3.5 - Co-ordinate frames used for off-line programming Y x 87 Z Tool zY 2y Wo piece x x
Z Surface 4 A Y 7 M2 Open Edge Joint edge CAD World lop, x o-ordinate Frame n3 n1 Surface 3 C4 y. ý G n2 p1: Joird edge middle poird p2: Open edge middle point Figure 3.6 - Joint geometrical definitions Transversal out A-A P: point -n3 n: normal vector n4 Joint included angle Edge adjacent surface I n1: Vector normal to edge adjacerl solace I of pouf p1 n2: Vector normal to edge edjacerd surface 2 et point p1 n3: Vector normal to surface 3 at point p2 n4: Vector normal to surface 4 at point p2 n3 vA Surface 3 P2 r 0 ni Tp\ni pi n2 S,, rfaceº1 Figure 3.7 - Method for determining if surface intersection is a valid joint (Transversal cut A-A shown in Figure 3.6) 88
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CRANFIELD UNIVERSITY GC CARVALHO AN
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ABSTRACT The aim of this work was t
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I dedicate this work to the memory
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FIGURES TABLES APPENDICES NOTATION
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3.3.2.1 Welding parameters generato
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References Further reading Appendic
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Figure 3.12 Offsets for weld start
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Figure 6.31 Voltage step input test
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Figure J. 2 Plot of stand-off varia
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Table A. 1 Welding extended entity
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NOTATION A, Electrode sectional are
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Pr(ign) Possibility measure of proc
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1. Introduction Welding is the thir
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Chapter 4 describes the on-line pos
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In pulse transfer, the welding curr
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Pd = Pv - pzh-s (2.1) where Pd is t
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the bridge. Another factor that ind
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establish the stable conditions for
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Philpott [ref. 21] developed an on-
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current peak at the moment the tip
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obot on the line must be individual
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collision detection capabilities wh
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cause dynamic variation in the seam
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Another type of robot static calibr
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spatter the gas nozzle is particula
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Table 2.1: Joint positioning tolera
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In order to minimise the undesirabl
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c) Ultrasonic sensors; d) Through-t
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where K,, K2, K3 and K4 are constan
Page 61 and 62: Philpott [refs. 21,131], based on t
Page 63 and 64: centre. This is attributed to the m
Page 65 and 66: technique must be employed to preve
Page 67 and 68: " digital hardware, which is basica
Page 69 and 70: " Maximum value, W.: Wmý = max(W )
Page 71 and 72: process studied over a small range.
Page 73 and 74: In-process welding control is a muc
Page 75 and 76: volume caused by the presence of a
Page 77 and 78: SHIELDING GAS IN CONSUMABLE ELECTRO
Page 79 and 80: Arc voltage Anode Arc length I Anod
Page 81 and 82: computed ideal procedure optimisnti
Page 83 and 84: CONSTANT CURRENT POWER SOURCE `j' O
Page 85 and 86: Original Surface New Surface Electr
Page 87 and 88: otating welding wire direction weld
Page 89 and 90: 3.1.1.1 Robot errors A robot arm is
Page 91 and 92: 3.2.2 Programming error correction
Page 93 and 94: 3.3.2 Off-line programming module I
Page 95 and 96: Pen is the weld penetration (side p
Page 97 and 98: a. 2) Geometrical constraints from
Page 99 and 100: Step 11 Step 12 Step 13 Step 14 Ste
Page 101 and 102: Step 21 Step 22 If the wire feed sp
Page 103 and 104: the Y'-axis results in a positive "
Page 105 and 106: _ p1e0a - pORoba m31 Ilp! - poll (3
Page 107 and 108: of a robot in its zero position12 w
Page 109 and 110: frame points to the front of the ro
Page 111: CAD Off-line (AutoCAD) programming
Page 115 and 116: WCF World Co-ordinates Frame 2a = J
Page 117 and 118: x Torch Co-ordinates Frame o Indica
Page 119 and 120: vo Ö 't7 Y7 't O m O 'S O O S O S
Page 121 and 122: ýý aý 0 oA aW ö A O Zt A OO 't
Page 123 and 124: Ti 9ý-! i4 *Tx t ap31 jx ý- ymin
Page 125 and 126: errors', (i. e. joint positioning,
Page 127 and 128: was considered to be outside the sc
Page 129 and 130: Table 4.3 - Linguistic representati
Page 131 and 132: The introduction of such a reduced
Page 133 and 134: Table 4.8 - Final welding process c
Page 135 and 136: the collection of welding data corr
Page 137 and 138: Step 4- Calculate the confidence of
Page 139 and 140: Z Table Co-ordinates Frame Y X Robo
Page 141 and 142: 5.3 Monitoring system The monitorin
Page 143 and 144: the torch end. Only one degree of f
Page 145 and 146: Current: 500 Position: 234.5 5.7.3
Page 147 and 148: I" va JI ºr ö C 3 r" r" rl f_ £-
Page 149 and 150: IgurC a. H -I UI qur vCiSUJ JpCCU C
Page 151 and 152: 126
Page 153 and 154: Table 6.1 - Welding trials carried
Page 155 and 156: Table 6.3 - Coefficients of Ogunbiy
Page 157 and 158: Note that the calibration model sho
Page 159 and 160: Table 6.6 - Welding parameters used
Page 161 and 162: constant set-up welding parameters
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stickout lengths and the temperatur
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of the dip mode of metal transfer.
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which would become active by settin
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In section 4.2.5 it has been mentio
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300 280 260 240 rd 35- 3D 25 20 15
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Figure 6.5 - Measured "versus" Pred
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i S 0 -0.1 -0.2 -0.3 -0.7- 68 10 12
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32.0 E 31.5 y 31.0 30.5 30.0 j 29.5
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35 - 30 p 15 10 0.00 2.60 5.42 8.23
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40 35 30 25 20 15 10 A+iIII+F0.17 2
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30 28 26 24 22 SO_act [mm] DipR [mo
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22 20 18 SO_act [mm] DipR [ohm/100]
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!: 30 25 20t 10 5-- 0 Dip Transfer
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0.430- - 0.380- - :r 0.330 fPR L- 0
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7.2 Tests with varying stand-off an
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Table 7.3 - Bead geometry along the
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ö a2 ., u" u,.., g .,. aucyuaac VI
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0 24-- 22-- 18 210 1 90 0 v 170 mm
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Q 34 32 3o mIm Viewing direction Fl
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ýa 34 mm JO a .. ý nn ýr "u 00 M
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22 20 18 Viewing direction Flange W
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36 33 31 o 29 t 350 310 o 290 U due
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I C, x -i 23 21 j 19 Q 240c WFS =10
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en 34 32 - vsec 30- 26- 24 + .. ++
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186
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" to design and build the hardware
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Although only linear joints were im
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for predicting possibility of bad a
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8.4 Process monitoring and control
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satisfy the required quality criter
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198
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types of joints and multi-pass weld
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[14] NEMCHINSKY, V. A. The effect o
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[38] D1LTHEY, U. , REICHELL, T. , S
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[64] KING, F-J. and HIRSCH, P. Seam
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[86] CARGNELLI, M. and ROGOWSKI, A.
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[109] KURKIN, N. S. and DRIKKER, V.
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[130] USHIO, M. , LIU, W. , MAO, W.
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[151] DAVIS, A. R. Orr-line gap det
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[177] COOK, G. E. Feedback and adap
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[201] WON, Y. J. and CHO, H. S. A f
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220
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222
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wnum: local variable which defines
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Table A. 1 - continuation List item
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Imean = a2 + b2*WFS + c2*SO + d2*SO
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TCP2 number are also defined. The o
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f ROBSET. DAT: This file is created
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Figure C. 3 - Main dialogue box of
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Choose the set of welding parameter
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Water Cooling optic fibre bundle 0
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Figure E. 1 - Main graphical screen
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242
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Table G. 2 - Interface box external
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Robot ii Controller +24W CO . +24Vd
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248
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Table 1.1 - continuation Run Vpk M
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10- y =0.001ac 0 r. dSO [mm] $0 '10
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5.00- 0.00 y=0.0019x 1000 1500 2000
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Table J. 7 - Welding data collected
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Table J. 10 - Welding data collecte
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20.00- 15. M y=0.0047x - 1.7922 10.
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266
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Table K. 1- continuation Set-up par
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Table K. 1 - continuation Set-up pa
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Table K. 2 - continuation Set up pa
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Table K. 2 - Continuation Set-up pa
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Table K. 3 - Continuation Set-up pa
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Table K. 3 - Continuation Setup par
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