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Appendix J This appendix shows the welding data collected from the stand-off slope trials carried out with the welding parameters shown in Table 6.6 to measure the proportionality constant, 4), which is used in the stand-off estimation model shown in equations 2.22 and 2.23. The constant value is obtained by dividing the slope of the linear function' that fits the points ESOk by the slope of the linear function that best fits the cumulative differences in welding current, E(Im ,, k- Imean, (k. 1)) (see equation 6.6). Note that the intercept of the latter will not be taken into account due to the fact that it corresponds to an offset which is probably caused by random noise present in the measurement of the initial value of welding current, I.,,, o. The following tables and graphs show the welding data collected from the trials and the fitted lines from which the value of 0 was calculated. The 0 values obtained in this Appendix are shown in the Table 6.6 and are compared with the corresponding 0 values estimated using equation 6.5. The results are plotted in Figure 6.9. Table J. 1 - Welding data collected from stand-off slope trial "s15 2001" Time [ms] SO [mm] I.. [A] ASO [mm] E[Imcan, k-1Ica,,. (W)] A 0 15 148.6 0 0 512 15.63506 144.9 0.635059 1024 16.27012 143.2 1.270118 1536 16.90518 142.3 1.905178 2048 17.54024 139.9 2.540237 2560 18.1753 138.2 3.175296 3072 18.81036 136.4 3.810355 3584 19.44541 134.5 4.445414 4096 20.08047 132.3 5.080474 WFS =5 m/min Vset = 21.3 V --- --------- ' y(x) = ax+b, a= slope, b= intercept Sw = 0.6 m/min Vreq = 19.4 V 251 -3.7 -5.4 -6.3 -8.7 -10.4 -12.2 -14.1 -16.3
10- y =0.001ac 0 r. dSO [mm] $0 '10 y= -0. 0037x - 0.96 -15 R2 = 0.98.97 -20 1500 2000 2500 3000 3500 4000 4E Mf Sum(1(k)-I(k-1)) [A] Time (ms) Linear (dSO [mm]) Linear (Sum(I(k)-1(k-1)) [A]) Figure J. 1 - Plot of stand-off variation and cumulative changes in welding current for welding trial "s15 2001" Table J. 2 - Welding data collected from stand-off slope trial "15_2002" time [ms] so [mm] Imean [A] ASO mm E[Imean, k- Imean, (k')] A] 0 15 162.8 0 0 512 15.74 161.7 0.74 1024 16.48 156.7 1.48 1536 17.22 156.6 2.22 -1.1 -6.1 -6.2 2048 17.96 155.7 2.96 -7.1 2560 18.70 150.4 3.70 -12.4 3072 19.44 150.7 4.45 -12.1 3584 20.19 149.5 5.19 -13.3 WFS =6 m/min Sw = 0.7 m/min Vset = 21.5 V Vreq = 19.6 V 10 5 y=0.0014x p 1 A6 dSO [mm] 1) 39-ft 1000 1500 2000 2500 3000 3500 4C 00 f Sum(I(k)-I(k-1)) [A] -5 f y= -0.003ýc 0,2917 f Linear (Sum(I(k)-I(k-1)) [A]) Linear (dSO [mm)) -10 R2=0.935 -15 Time [ms] Figure J. 2 - Plot of stand-off variation and cumulative changes in welding current for welding trial "s15 2002" 252
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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
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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
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
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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: Table 1.1 - continuation Run Vpk M
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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