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new control cycle would occur only after three new non-filtered stand-off estimates were obtained. This strategy was adopted in order to eliminate from the estimation the effect of the stand-off estimates obtained before each control cycle, hence preventing the control system from responding to an error that has already been acted upon. In control terms, it could be called a "forgetting" property of the filter, without which an oscillatory behaviour would result, as observed in the tuning trials. 6.4.2 Dependency of Power Ratio reference range with wire feed speed According to the final form of the welding process controller described in section 4.2.1, the best performance for the dip mode of metal transfer was found to occur when the allowed range of variation of the power ratio was considered as a function of the wire feed speed. Figure 6.35 shows that this is in agreement with the actual behaviour of the power ratio when different wire feed speeds are used. Figure 6.36 shows the variation of the other monitoring indices with the wire feed speed for stable dip mode of metal transfer. Note that TSI is the most affected index, while TI and DCI remain fairly constant. Considering that TSI is used only for a minor voltage trimming rule, the allowed range of variation was kept constant, despite the observed dependency on the wire feed speed. No pronounced trends in the monitoring indices were observed when varying the wire feed speed in stable spray mode of metal transfer. 145
300 280 260 240 rd 35- 3D 25 20 15 Vmean = 0.9107Vset 10 10 15 20 25 30 35 Power source set-up voltage [volts] Figure 6.1 - Mean Voltage "versus" Set-up Voltage chart for the BDH 550 welding power source f Ipred 220 200 ,4 Imean 320 - Imean_550 t: 1 80 -' Ipred (Trendline) 0 160 140 120 ", 100 "- "- 2468 10 12 14 Wire feed speed [mhnin] --- (mean 320 (Trendline) Imean 560 (Trend line) Figure 6.2 - Comparison between predicted welding current and actual welding current delivered by BDH320 and BDH550 welding power sources 146
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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
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Philpott [refs. 21,131], based on t
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centre. This is attributed to the m
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technique must be employed to preve
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" digital hardware, which is basica
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" Maximum value, W.: Wmý = max(W )
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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
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SHIELDING GAS IN CONSUMABLE ELECTRO
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Arc voltage Anode Arc length I Anod
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computed ideal procedure optimisnti
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CONSTANT CURRENT POWER SOURCE `j' O
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Original Surface New Surface Electr
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otating welding wire direction weld
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3.1.1.1 Robot errors A robot arm is
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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
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the Y'-axis results in a positive "
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_ 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
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
Page 163 and 164: stickout lengths and the temperatur
Page 165 and 166: of the dip mode of metal transfer.
Page 167 and 168: which would become active by settin
Page 169: In section 4.2.5 it has been mentio
Page 173 and 174: Figure 6.5 - Measured "versus" Pred
Page 175 and 176: i S 0 -0.1 -0.2 -0.3 -0.7- 68 10 12
Page 177 and 178: 32.0 E 31.5 y 31.0 30.5 30.0 j 29.5
Page 179 and 180: 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
Page 185 and 186: 22 20 18 SO_act [mm] DipR [ohm/100]
Page 187 and 188: !: 30 25 20t 10 5-- 0 Dip Transfer
Page 189 and 190: 0.430- - 0.380- - :r 0.330 fPR L- 0
Page 191 and 192: 7.2 Tests with varying stand-off an
Page 193 and 194: Table 7.3 - Bead geometry along the
Page 195 and 196: ö a2 ., u" u,.., g .,. aucyuaac VI
Page 197 and 198: 0 24-- 22-- 18 210 1 90 0 v 170 mm
Page 199 and 200: Q 34 32 3o mIm Viewing direction Fl
Page 201 and 202: ýa 34 mm JO a .. ý nn ýr "u 00 M
Page 203 and 204: 22 20 18 Viewing direction Flange W
Page 205 and 206: 36 33 31 o 29 t 350 310 o 290 U due
Page 207 and 208: 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
Page 213 and 214: " to design and build the hardware
Page 215 and 216: Although only linear joints were im
Page 217 and 218: for predicting possibility of bad a
Page 219 and 220: 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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