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ýv ýý ,ý Appendix G This Appendix shows the external connections of the interface box built in this work and gives information about its internal electronic circuits. Figure G. 1 shows the external view of the Interface Box. This box was primarily built to transform available robot inputs and outputs (I/Os) from switch-type to 24 Vdc I/Os, so that they could be connected to the table controller and the power source robot interface. It was designed to allow up to 8 robot inputs and up to 8 outputs to be used as 24 Vdc I/Os. The transformation between the robot I/Os and the 24V I/Os was provided by using an internally built 24 Vdc (800 mA) power supply and contact relays. The circuits for the outputs and the inputs are shown in Figure G. 2 and Figure G. 3, respectively. Table G. 1 gives the connections made in the Interface Box internal relay board and Table G. 2 gives the connections made in the 37-way D-connector. The touch sensor was also mounted inside the interface box and its circuit is shown in Figure 5.1. Table G. 1 - Relay board connector pin layout pIN Terminal input Relay A** B** C** D** I 1 com*** 2 3 2 5 com 6 7 3 10 com 8 9 4 13 com 11 12 5 15 com 14 16 6 22 com 20 21 7 23 com 24 25 8 28 com 26 27 9* 31 com 29 30 * This relay was mounted but aas not used ** See Figure G. 4 *** Pins 4 and 32 were connected to the common of the 24V power supply, which was also powering the table controller. Pins 17,18 and 19 were not connected. 243
Table G. 2 - Interface box external 37-way D-connector pin layout Connector pin Robot 1/O Connector pin Robot 1/0 1 output 1 9 output 5 2 output 1 10 output 5 3 output 2 11 output 6 4 output 2 12 output 6 5 output 3 13 output 7 6 output 3 14 output 7 7 output 4 15 output 8 8 output 4 16 output 8 17 input 1 22 input S 18 input 2 23 input 6 19 input 3 24 input 7 20 input 4 25 input 8 21 robot common* 26 robot common Obs.: Pins 27 to 37 were not connected. * See Figure G. 3 244
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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
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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
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 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 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: 242
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
Page 303: Table K. 3 - Continuation Setup par
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