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NOTATION A, Electrode sectional area [mm'] a, ß, S, y Regression constants Conf Bad Ign Output from the confidence of bad ignition model DCJ/ Dip Consistency Index DipR Dip resistance [0] DipR; Dip resistance calculated for a sample of welding voltage and current [0] DipRmean The arithmetic average of the DipR; calculated in a fixed time period [S2] DipR, a Standard deviation of the dip resistances measured within a fixed [S2] time period ASO Variation in stand-off [mm] AV Variation in welding voltage [V] A-) Prediction percentage error Proportionality constant between variation in stand-off and resulting variation in welding current [Vol [mm/A] Calculated value of 4) [mm/A] Measured value of 4) [mm/A] Function G, GAP Gap size [mm] Imean , Imean Mean welding current: arithmetic average of the welding current [A] transient samples acquired in a fixed time pediod Imax_320 Maximum welding current produced by the Migatronic BDH320 [A] welding power source in dip mode of metal transfer Imax_550 Maximum welding current produced by the Migatronic BDH550 [A] welding power source in dip mode of metal transfer Imean_320 Mean welding current produced by the Migatronic BDH320 welding [A] power source Imean 550 Mean welding current produced by the Migatronic BDH550 welding [A] power source Ibk Background welding current: the arithmetic average of all the current [A] transient samples less than or equal to 'mean Maximum welding current: the maximum value in the welding current transient samples Minimum welding current: the minimum value in the welding current transient samples Peak welding current: the arithmetic average of all the current samples greater than Imean Ipred Expected welding current predicted by an empirical model Itbk Background current time: the arithmetic average of the time duration [ms] of the background periods in the welding current transient samples xi [A] [A] [A] [A]
Itpk Peak current time: the arithmetic average of the time duration of the [ms] peaks in the welding current transient samples j Current density JA/m'] KI, K2, ... A] , A, z, ... Regression constants Constants L. Arc length [mm] L, Electrode stickout [mm] Leg Leg length [mm] Leg«, Average leg length [mm] Legb Bottom leg length (horizontal-vertical fillet joint) [mm] Legpr, d Expected average leg length predicted by the welding parameters generator [mm] Legreq Minimum required leg length [mm] Leg, Side leg length (horizontal-vertical fillet joint) [mm] Leg, Leg length at the web side in a flat position fillet weld [mm] Leg: Leg length at the flange side in a flat position fillet weld [mm] 17 Resistivity [f2. m] Nb Number of transient samples with values equal or smaller than the No, p samples average Number of welding voltage transient samples complying with VS 6 bk N, Number of transient samples with values greater than the samples average Nn Number of periods in which the data samples are consecutively smaller than the samples average NT, Number of periods in which the data samples are consecutively greater than the samples average Nw Number of transient data samples acquired in a fixed time period (window) Pd Pressure exerted by the arc on the weld pool [Pa] Pen Weld penetration (depth of fusion) [mm] Pen, Weld penetration in the web plate in a flat position fillet weld [mm] Pent Weld penetration in the flange plate in a flat position fillet weld [mm] Pen,,. Average weld penetration [mm] Penb Bottom weld penetration (horizontal-vertical fillet joint) [mm] Pen,,, d Expected average weld penetration predicted by the welding [ mml parameters generator Pen, Side weld penetration (horizontal-vertical fillet joint) [mm] POS Binary operator which indicates if a weld is non-positional (0) or J PR positional (1) Power Ratio Pr(arc) Possibility measure of bad arc ignition X11
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 and 16: Figure 6.31 Voltage step input test
Page 17 and 18: Figure J. 2 Plot of stand-off varia
Page 19 and 20: Table A. 1 Welding extended entity
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
Page 69 and 70: " 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
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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
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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
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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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Page 291 and 292:
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
Page 303:
Table K. 3 - Continuation Setup par
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