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Figure 7.21 Bead appearance and bead profiles along the weld for the stand-off controlled welding trial "S6". fillet 180 Figure 7.22 Welding data and bead geometry obtained from test S6 180 Figure 7.23 Bead appearance and bead profiles along the weld for the voltage and stand-off 181 controlled welding trial "SV2". Figure 7.24 Welding data and bead geometry obtained from test SV2 181 Figure 7.25 Bead appearance and bead profiles along the weld for the voltage and stand-off 182 controlled welding trial "SV3" Figure 7.26 Welding data and bead geometry obtained from test SV3 182 Figure 7.27 Bead appearance and bead profiles along the weld for the voltage and stand-off 183 controlled welding trial SV4. Figure 7.28 Welding data and bead geometry obtained from test SV4 183 Figure 7.29 Bead appearance and bead profiles along the weld for the voltage and stand-off 184 controlled welding trial "SV5" Figure 7.30 Welding data and bead geometry obtained from test SV5 184 Figure 7.31 Bead appearance and bead profiles along the weld for the voltage and stand-off 185 controlled welding trial "SV6". Figure 7.32 Welding data and bead geometry obtained from test SV6 185 Figure C. 1 Off-line programming module pull down menu 233 Figure C. 2 Dialogue box used to define the file containing the coefficients of the welding 233 models Figure C. 3 Main dialogue box of the welding procedure generator Figure C. 4 Dialogue box for defining the starting point of the weld Figure C. 5 Dialogue box for defining the required weld geometry Figure C. 6 Data input dialogue for defining the bead geometry in fillet joints 235 Figure C. 7 Welding parameters output dialogue 236 Figure C. 8 Input dialogue for defining the transformation matrix between the CAD co- 236 ordinates system and the Robot world co-ordinates system Figure D. 1 Fibre optic based sensor for seam tracking and gap detection 238 Figure E. 1 Main graphical screen of the monitoring and control software developed, in the 240 replay mode Figure G. 1 External connections of the Interface Box 245 Figure G. 2 Switch-type to 24 V output transformation circuit Figure G. 3 24 V to switch-type input transformation circuit Figure G. 4 Relay terminals as mounted in the relay board 246 Figure J. 1 Plot of stand-off variation and cumulative changes in welding current for welding 252 trial "s 15200 1" V 234 234 235 245 246
Figure J. 2 Plot of stand-off variation and cumulative changes in welding current for welding 252 trial "s 15 2002" Figure J. 3 Plot of stand-off variation and cumulative changes in welding current for welding 253 trial "s15 2003" Figure J. 4 Plot of stand-off variation and cumulative changes in welding current for welding 254 trial "s 15_2004" Figure J. 5 Plot of stand-off variation and cumulative changes in welding current for welding 254 trial "s15 2005" Figure J. 6 Plot of stand-off variation and cumulative changes in welding current for welding 255 trial "s15 2006" Figure J. 7 Plot of stand-off variation and cumulative changes in welding current for welding 256 trial "s15_2007" Figure J. 8 Plot of stand-off variation and cumulative changes in welding current for welding 257 trial "s15_2008" Figure J. 9 Plot of stand-off variation and cumulative changes in welding current for welding 257 trial "s15_2009" Figure J. 10 Plot of stand-off variation and cumulative changes in welding current for welding 258 trial "s15 2010" Figure J. 11 Plot of stand-off variation and cumulative changes in welding current for welding 259 trial "s15_1001" Figure J. 12 Plot of stand-off variation and cumulative changes in welding current for welding 259 trial "s15_1002" Figure J. 13 Plot of stand-off variation and cumulative changes in welding current for welding 260 trial "s15_1003" Figure J. 14 Plot of stand-off variation and cumulative changes in welding current for welding 261 trial "s15 1004" Figure J. 15 Plot of stand-off variation and cumulative changes in welding current for welding 262 trial "s15 1005" Figure J. 16 Plot of stand-off variation and cumulative changes in welding current for welding 263 trial "s15 1006" Figure J. 17 Plot of stand-off variation and cumulative changes in welding current for welding 263 trial "s15 1007" Figure J. 18 Plot of stand-off variation and cumulative changes in welding current for welding 264 trial "s 15 1008" Figure J. 19 Plot of stand-off variation and cumulative changes in welding current for welding 265 trial "s15_1009" Figure J. 20 Plot of stand-off variation and cumulative changes in welding current for welding 265 trial "s15 1010" vi
Page 1 and 2: CRANFIELD UNIVERSITY GC CARVALHO AN
Page 3 and 4: ABSTRACT The aim of this work was t
Page 5 and 6: I dedicate this work to the memory
Page 7 and 8: FIGURES TABLES APPENDICES NOTATION
Page 9 and 10: 3.3.2.1 Welding parameters generato
Page 11 and 12: References Further reading Appendic
Page 13 and 14: Figure 3.12 Offsets for weld start
Page 15: Figure 6.31 Voltage step input test
Page 19 and 20: Table A. 1 Welding extended entity
Page 22 and 23: NOTATION A, Electrode sectional are
Page 24 and 25: Pr(ign) Possibility measure of proc
Page 26 and 27: 1. Introduction Welding is the thir
Page 28: Chapter 4 describes the on-line pos
Page 31 and 32: In pulse transfer, the welding curr
Page 33 and 34: Pd = Pv - pzh-s (2.1) where Pd is t
Page 35 and 36: the bridge. Another factor that ind
Page 37 and 38: establish the stable conditions for
Page 39 and 40: Philpott [ref. 21] developed an on-
Page 41 and 42: current peak at the moment the tip
Page 43 and 44: obot on the line must be individual
Page 45 and 46: collision detection capabilities wh
Page 47 and 48: cause dynamic variation in the seam
Page 49 and 50: Another type of robot static calibr
Page 51 and 52: spatter the gas nozzle is particula
Page 53 and 54: Table 2.1: Joint positioning tolera
Page 55 and 56: In order to minimise the undesirabl
Page 57 and 58: c) Ultrasonic sensors; d) Through-t
Page 59 and 60: 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
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" Maximum value, W.: Wmý = max(W )
Page 71 and 72:
process studied over a small range.
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In-process welding control is a muc
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volume caused by the presence of a
Page 77 and 78:
SHIELDING GAS IN CONSUMABLE ELECTRO
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Arc voltage Anode Arc length I Anod
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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
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3.3.2 Off-line programming module I
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Pen is the weld penetration (side p
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a. 2) Geometrical constraints from
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Step 11 Step 12 Step 13 Step 14 Ste
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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
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of a robot in its zero position12 w
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frame points to the front of the ro
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CAD Off-line (AutoCAD) programming
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Z Surface 4 A Y 7 M2 Open Edge Join
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WCF World Co-ordinates Frame 2a = J
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x Torch Co-ordinates Frame o Indica
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vo Ö 't7 Y7 't O m O 'S O O S O S
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ýý aý 0 oA aW ö A O Zt A OO 't
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Ti 9ý-! i4 *Tx t ap31 jx ý- ymin
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errors', (i. e. joint positioning,
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was considered to be outside the sc
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Table 4.3 - Linguistic representati
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The introduction of such a reduced
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Table 4.8 - Final welding process c
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the collection of welding data corr
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Step 4- Calculate the confidence of
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Z Table Co-ordinates Frame Y X Robo
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5.3 Monitoring system The monitorin
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the torch end. Only one degree of f
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Current: 500 Position: 234.5 5.7.3
Page 147 and 148:
I" va JI ºr ö C 3 r" r" rl f_ £-
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IgurC a. H -I UI qur vCiSUJ JpCCU C
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126
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Table 6.1 - Welding trials carried
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Table 6.3 - Coefficients of Ogunbiy
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Note that the calibration model sho
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Table 6.6 - Welding parameters used
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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
Page 181 and 182:
40 35 30 25 20 15 10 A+iIII+F0.17 2
Page 183 and 184:
30 28 26 24 22 SO_act [mm] DipR [mo
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22 20 18 SO_act [mm] DipR [ohm/100]
Page 187 and 188:
!: 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
Page 193 and 194:
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
Page 201 and 202:
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
Page 209 and 210:
en 34 32 - vsec 30- 26- 24 + .. ++
Page 211 and 212:
186
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" to design and build the hardware
Page 215 and 216:
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
Page 223 and 224:
198
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types of joints and multi-pass weld
Page 227 and 228:
[14] NEMCHINSKY, V. A. The effect o
Page 229 and 230:
[38] D1LTHEY, U. , REICHELL, T. , S
Page 231 and 232:
[64] KING, F-J. and HIRSCH, P. Seam
Page 233 and 234:
[86] CARGNELLI, M. and ROGOWSKI, A.
Page 235 and 236:
[109] KURKIN, N. S. and DRIKKER, V.
Page 237 and 238:
[130] USHIO, M. , LIU, W. , MAO, W.
Page 239 and 240:
[151] DAVIS, A. R. Orr-line gap det
Page 241 and 242:
[177] COOK, G. E. Feedback and adap
Page 243 and 244:
[201] WON, Y. J. and CHO, H. S. A f
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220
Page 247 and 248:
222
Page 249 and 250:
wnum: local variable which defines
Page 251 and 252:
Table A. 1 - continuation List item
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Imean = a2 + b2*WFS + c2*SO + d2*SO
Page 255 and 256:
TCP2 number are also defined. The o
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f ROBSET. DAT: This file is created
Page 259 and 260:
Figure C. 3 - Main dialogue box of
Page 261 and 262:
Choose the set of welding parameter
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Water Cooling optic fibre bundle 0
Page 265 and 266:
Figure E. 1 - Main graphical screen
Page 267 and 268:
242
Page 269 and 270:
Table G. 2 - Interface box external
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Robot ii Controller +24W CO . +24Vd
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248
Page 275 and 276:
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
Page 281 and 282:
Table J. 7 - Welding data collected
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Table J. 10 - Welding data collecte
Page 285 and 286:
Page 287 and 288:
20.00- 15. M y=0.0047x - 1.7922 10.
Page 289 and 290:
Page 291 and 292:
266
Page 293 and 294:
Table K. 1- continuation Set-up par
Page 295 and 296:
Table K. 1 - continuation Set-up pa
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Table K. 2 - continuation Set up pa
Page 299 and 300:
Table K. 2 - Continuation Set-up pa
Page 301 and 302:
Table K. 3 - Continuation Set-up pa
Page 303:
Table K. 3 - Continuation Setup par
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