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References [1] LLOYD, B. Robot Facts 1994: Annual report of UK investment in robot automation in manufacturing industry. BRA report, 1995. [2] O'BRIEN, R. L. (ed. ) Welding Handbook. 8th ed. Miami: American Welding Society, 1991, vol. 2,109-154. [3] NORRISH, J. Advanced Welding Processes. Bristol: Institute of Physics, 1992. [4] BLOT, R. A guide to shielding gases for gas metal arc welding. Welding Quarterly, September, 1988,12-15. [5] NORRISH, J. AND RICHARDSON, I Metal transfer mechanisms. Welding and Metal Fabrication, 56(1), Jan/Feb. 1988,17-22. [6] LANCASTER, J. F. (ed. ) The physics of welding. Oxford: Pergamon Press, 1984, Chapter 7. [7] USHIO, M. et al. Effects of shielding gas composition on metal transfer phenomena in high current GMA welding. Transactions of Japan Welding Research Institute, 20(1), 1993,7-12. [8] COOKSEY, C. J. and MILNER, D. R Metal transfer in gas shielded arc welding. IN: "Physics of the Welding Arc", Institute of Welding Symposium. 29 Oct. to 2 Nov., 1962,123-132. [9] MA, J. and APPS, R. L. Analysing metal transfer during MIG welding. Welding and Metal Fabrication, 51(3), April 1983,119-128. [10] MA, J. and APPS, R. L. New MIG process results from metal transfer mode control. Welding and Metal Fabrication, 51(4), May 1983,168-175. [11] SICARD, P. and LEVINE, M. D. An approach to an expert robot welding system. IEEE Transactions on Systems, Man and Cybernetics, 18(2), March/April 1988,204-222. (12] DYURGEROV, N. G. Causes of periodic short-circuiting of the arc gap during welding with a short arc. Welding Production, 21(9), 1974,1-4. [13] HAMI Y, E. Wire melting rate, droplet temperature, and effective anode melting potential. IN: Arc physics and weld pool behaviour. . an international conference, 8-10 May 1979, London. Cambridge: Welding Institute, 1980, Vol. 1,49-57. 201
[14] NEMCHINSKY, V. A. The effect of the type of plasma gas on current constriction at the molten tip or an arc electrode. Journal of Physics D: Applied Physics, 29(5), 1996,1202-1208. [15] RHEE, S. and KANNATEY-ASIBU, JR. Observation of metal transfer during gas metal arc welding. Welding Journal, 71(10), October 1992, 381s-386s. [16] PATON, B. E., MANDEL'BERG, S. L., SIDORENKO, B. G. Certain special features of the formation of welds made at high speeds. Automatic Welding, 24(8), 1971,1-6. [17] LEBEDEV, V. K. Stability of the metal pool when thin metal is welded. Automatic Welding, 28(6), 1975,57-58. [18] STOLBOV, V. I. and MASAKOV, V. V. The formation of burn-through in the fusion welding of thin sheets. Welding Production, 24(10), 1977,26- 28. [19] PATON, B. E. and ZARUBA, I. I. Peculiarities of arc discharge when welding with a short circuiting arc gap. IN: "Physics of the Welding Arc", Institute of Welding Symposium, 29 Oct. to 2 Nov. 1962, London, 102-107. [20] LAHNSTEINER, R et al. State of the art and definitions of the notions arc- stability, spattering and arc-striking characteristics. IIW Document XII- 1364-94. [21] PHILPOTT, M. L. Direct arc sensing for robotic MIG welding. <strong>Cranfield</strong> Institute of Technology, PhD thesis, 1986. [22] MODENESI, P. J. and NIXON, J. H. Arc instability phenomena in GMA welding. Welding Journal, 73(9), September 1994,219s-224s. [23] ZARUBA, I. I. Condition for stability of processes in which welds are made with short-circuiting. Automatic Welding, 24(2), 1971,1-4. [24] ZARUBA, I. I. et al. The effects of current supply source dynamic properties on CO2 welding using 2 mm diameter electrode wire. Automatic Welding, 14(8), 1961,28-37. [25] ZARUBA, I. I. Electrical explosions as the cause of metal spatter. Automatic Welding, 23(3), 1970,12-17. [26] ZARUBA, I. I. Factors governing metal spatter during welding with short- circuiting. Automatic Welding, 27(8), 1974,68. 202
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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
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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
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
Page 221 and 222: satisfy the required quality criter
Page 223 and 224: 198
Page 225: types of joints and multi-pass weld
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
Page 245 and 246: 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
Page 253 and 254: Imean = a2 + b2*WFS + c2*SO + d2*SO
Page 255 and 256: TCP2 number are also defined. The o
Page 257 and 258: 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
Page 263 and 264: 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
Page 271 and 272: Robot ii Controller +24W CO . +24Vd
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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
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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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