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Appendix B This appendix shows the format in which the file containing the coefficients of the welding models must be written so that it can be correctly read by the off-line programming module. The file defined for power source used in this work (Migatronic BDH550) is shown below. The sintax used is explained in the header of the file, between the asterisk (*) lines. The file name extension defines the type of joint which the file corresponds to. The valid extension names are: "fil" for fillet joints, "lap" for lap joints and "but" for butt joints. The name of the file shown below was chosen to be "AR5MS 1 OA. FIL", "AR5" standing for Argonshield 5 shielding gas, "MS 10" standing for mild steel 1.0mm welding wire and "A" indicating that a power source other than the BDH320 was used. File start: ; Coefficients for models obtained from "cal" data series Welding models Coefficients obtained for 1 mm mild steel wire and BOC Argonshield 5 shielding gas in fillet joints. -Each line corresponds to a model, containing the respective coeficients. -Each number must be separated by a space, a comma or a tab. -Each line must finish with a #. -A line begining with a semi-colon is considered a comment. -A line begining with a colon indicates a label. An equal sign (_) indicates the end of the label and the begining of the label value. The valid labels are: Material: indicates the welded material. GasType: indicates the shielding gas. WireDiameter: indicates the wire diameter in mm. WPS: indicates the Welding Power Supply used to obtain the coeffitients -Observation: III It is mandatory that the four labels are defined III Material = Mild Steel GasType = BOC Argon-Shield 5 (Ar 5%C02 2%02) WireDiameter =1.0 WPS = BDH550 Coefficients of the regression models Leg length model coefficients Side leg (a1 1 b1 1) 1 0.561068# Bottom leg (al _2 b1 2) 1 0.592637# Off-line mean current model coefficients (a2 b2 C2 d2) (bead on plate) 227
Imean = a2 + b2*WFS + c2*SO + d2*SO*WFS, SE=9.933 R2=0.9830 53.64149 24.65153 0.0 -0.413273# TSI coefficients (a3 b3 c3 d3) TSI = a3 + b3*lmean + c2*SO + d2*SO*Imean, SE= 0.254314 R2=0.7585 3.455699 -0.006043 -0.034601 0.0# On-line mean current model coefficients (a4 b4) Imean = a4*lmax + b4*lmin, SE=15.8588 R2=0.9960 0.324805 0.693878# VbkNmean model coefficients (a5 b5 c5 d5) = a5 + b5*lmin + c5*SO + d5*SO*Imin, SE=0.1 12111 R2=0.8545 -0.335025 0.002398 0.040318 0.0# Vbk estimation model coefficients (a6 b6 c6) a6 + b6*lmean + c6*Vmean; SE=1.00907 R2=0.9921 -30.787835 -0.031138 2.265039# Imax estimation model coefficients (a7 b7 c7 d7) Imax = a7 + b7*lmean + c7*Vmean + d7*lmean*Vmean, SE=36.000 R2=0.9881 0.0 3.364032 0.0 -0.072541# Penetration models Side penetration model coefficients (a8, b8) 0.01782 -0.449818# Side penetration model coefficients (a9, b9) 0.019058 -0.639698# Undercut possibility measure model coefficients (a10 b10 c10) 0.0044 0.0265# -0.0982 Possibility measure for stable wire melting and ignition model ; (all b11) 13.519345 0.97619# PR model coefficients (a12 b12 c12 d12) a12 + b12*Vmean + cl2*lmean"2 + d12*Vmean*lmean, SE=0.0433, r2=0.9818 -0.92147 0.068592 -0.0000028511 0.0# Pr spray model coefficients (a13 b13 c13 d13 e13) Pr spray = I- Pr dip ; e13=SE Pr spray = a13 + b13*TSI + c13*DCI + d13*Tl SE=0.09532 r2=0.9650 1.379678 -0.294549 -0.807387 -0.763514 0.09532# Correction of average penetration model coefficients (a14 b14) -1.15857 2.114041# Correction of set up voltage model coefficients (al 5 b15 c15 dl 5) case el 5=0 then (Vmean = al 5+ b15*Vset + cl 5*WFS + d15*Vset*WFS) linear fit case e15=1 then (Vmean = a15*exp(b15*Vset)) exponential fit case el 5=2 then (Vmean = a15*Vset^bl5) logarithmic fit linear fit SE=0.354 R2=0.99604 0.00.9174310.00.00# ; Correction of average leg length model coefficients (a16 b16) 0.623039 0.880194# 228
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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
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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
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
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Page 225 and 226: 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
Page 245 and 246: 220
Page 247 and 248: 222
Page 249 and 250: wnum: local variable which defines
Page 251: Table A. 1 - continuation List item
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
Page 273 and 274: 248
Page 275 and 276: Table 1.1 - continuation Run Vpk M
Page 277 and 278: 10- y =0.001ac 0 r. dSO [mm] $0 '10
Page 279 and 280: 5.00- 0.00 y=0.0019x 1000 1500 2000
Page 281 and 282: Table J. 7 - Welding data collected
Page 283 and 284: Table J. 10 - Welding data collecte
Page 287 and 288: 20.00- 15. M y=0.0047x - 1.7922 10.
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
Page 297 and 298: 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
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Table K. 3 - Continuation Setup par
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