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Chapter 4 describes the on-line positional and process control strategies. Chapter 5 presents the experimental materials and equipment used. Chapter 6 describes the modelling work and the integration of the control system proposed in Chapter 4, showing the results of the welding trials carried out during its commissioning. Chapter 7 shows the results obtained with the control system developed. Chapter 8 discusses the proposed system, the results obtained and possible industrial exploitation. Chapter 9 concludes and suggests further work that could be carried out to enhance the work done. Appendices A to K show details about the off-line programming module developed, description of electronic circuits built, description of the monitoring and control software developed and welding data collected during this research work. 3
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 22 and 23: NOTATION A, Electrode sectional are
Page 24 and 25: Pr(ign) Possibility measure of proc
Page 26 and 27: 1. Introduction Welding is the thir
Page 30 and 31: 2. Literature Review Robotic weldin
Page 32 and 33: generally accepted that far from th
Page 34 and 35: electrode, and a stiff arc (i. e. f
Page 36 and 37: Needham [ref. 36] stated that in or
Page 38 and 39: PR =r 1 bkVbk A mean meat where Ibk
Page 40 and 41: implements through variable program
Page 42 and 43: Figure 2.11 shows a typical volt-am
Page 44 and 45: There is also another classificatio
Page 46 and 47: however, developed for general robo
Page 48 and 49: According to the British Standards
Page 50 and 51: and kinematic model mismatch and th
Page 52 and 53: As a general rule, the welding proc
Page 54 and 55: parts, thereby making available for
Page 56 and 57: Concerning the time when the sensor
Page 58 and 59: eceptor. The sensors can also be bu
Page 60 and 61: 129] modes of metal transfer. Howev
Page 62 and 63: experimental trials, Ogunbiyi propo
Page 64 and 65: elatively low cost but can be affec
Page 66 and 67: The same approaches used for seam t
Page 68 and 69: Chawla [ref. 161] utilised statisti
Page 70 and 71: experimental conditions and are not
Page 72 and 73: where y is the dependent variable,
Page 74 and 75: for selecting indirect weld paramet
Page 76 and 77: The aim of this work, therefore, is
Page 78 and 79:
00 Globular transfer AL-ý -Z ýO..
Page 80 and 81:
tZ N IP tý. Pzh. s Pv Figure 2.7 -
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LLS > CONSTANT VOLTAGE POWER SOURCE
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1c 30 2.0- 1.5 1 0.8 0.6 0. L 0.2 0
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Probe JM (a) output v (b) Y H 2..,.
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3. Proposed Strategy for Off-line P
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of error was classified into this g
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aims at fine tuning the welding par
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Expected mean current from transien
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Table 3.1 - Ogunbiyi's model coeffi
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Step 5 Step 6 Step 7 Step 8 Step 9
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Step 16 Step 17 Step 18 Step 19 Ste
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treated as weld joints, however oth
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In the off-line programming module,
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m23 =z- mi1m32 (3.31) rn33 = mmu -
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Hence, the X-axis and the Y-axis of
Page 110 and 111:
3.3.3 Control module In the control
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Ts i 1 T, 1T pZ Leg Leg required r
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TABULATION OF POSITIONS OF FILLET W
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ot Word WCF : World Co-ordinates Fr
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93 o` 10 en 0 u . ii .. n H .. n 10
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.x 1 ý. X `f N TX r+- 1j X 1j ýN
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(xmin_ymin_zmin); lxmin 'clearance,
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4. On-line Control Strategy In this
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4.1.3.1 Adjustment before welding B
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considered as unstable and, therefo
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Table 4.4 - Control rules based on
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The addition of these rules improve
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stable arc condition for dip mode m
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certain level of process stability
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from three previously estimated val
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5. Experimental Equipment, Material
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mounting fixture. The voltage signa
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Linear resistive transducer: " Manu
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Workpiece " Material: " Plate thick
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Figure 5.2 - Implemented 1 degree-o
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M MEi 100 - r-O 50 -100 Demanded di
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6. System Commissioning Trials This
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Table 6.2 - Welding trials carried
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where Fen ss° _1974. Pe, 2 ä 32°
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6.2 Development of stand-off estima
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data. Measurements of resistance be
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Table 6.7 - Dip resistance dispersi
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parameter generator and five levels
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contact tip and the weld pool and c
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movements, in which the robot and t
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new control cycle would occur only
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500 450 1 400 d Imax 320 V Imax 550
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Welding torch \ ý- 60.0 mm Welding
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cm p 30 C 10 d5 (a) 15 Vmean 0,11 3
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Welding Power Source Power cable Ha
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38 33 28 III i SO-act [mm] DipR [mo
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38 33 28 23 18 13 0.00 2.52 5.32 8.
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22 20 18 -SO act [mm] 16 14 12 10 0
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30 25 20 15 10 5 0.00 1.72 3.67 5.6
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34 33 E 32 w 31 30 Ö > 29 28 27 Sp
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7. Experimental Results This chapte
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Table 7.2 - Bead geometry along the
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during the controlled welding trial
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2 ----- -- ------------------------
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FE N0 24- 22 20 18 250 240 230 220
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34 n. m Viewing direction Flange3 I
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22 20 18 220 200 180 14 12 vl 10 V:
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^ Z 33 d tu 31 29 Vewing direction
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23 22 21 20 19 210 200 190 180 18 1
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33 31 Viewing direction 1 Flange $,
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c 27 0 25 Viewing direction / Flang
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8. Discussion 8.1 Introduction The
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8.2.2 Integration between geometric
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orientation can be modified to impr
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Appendix J), it was observed that t
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It should be noted, however, that t
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profile to a more uniform profile.
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9. Conclusions and Recommendations
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References [1] LLOYD, B. Robot Fact
Page 228 and 229:
[27] HUTT, G. A. , LUCAS, W. Arc di
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[51] OGUNBIYI, T. E. B. Process mon
Page 232 and 233:
[74] KORTUS, M., WARD, T., WU, M. H
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[97] OWENS, J. and PIATKOWSKI, K. S
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[120] FUKUOKA, H. Application of to
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[140] SICARD, P., LEVINE, M. D. Joi
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[164] RICHARDS, R. J. An introducti
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[189] BROWN, M. , HARRIS, C. Neurof
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Further Reading [1] AutoCAD Release
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Appendices Appendix Description Pag
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Appendix A This appendix shows the
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offset2: "WPARAMS": distance betwee
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Appendix B This appendix shows the
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Appendix C This appendix shows the
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Once modified, the new ACAD. MNU mu
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Figure CA - Off-line programming mo
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Wrlciiuy Setup Ti ipt of Joint iip
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Appendix D This Appendix shows a fi
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Appendix E This Appendix describes
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Appendix F This Appendix gives the
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ýv ýý ,ý Appendix G This Append
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Touch sensor output type selection
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Appendix H Table H. 1 Technical spe
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Appendix I Table L1 Welding data us
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Appendix J This appendix shows the
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I ,. i Table J. 3 - Welding data co
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Table J. 6 - Welding data collected
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10.00 5.00- 0.00 y=x -5.00 1000 150
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15.00 10.00 5.00 0.00 sm y=0.00ý9B
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25.00- 20.00 y= O. C387k - Q5405 R2
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25.00- 20.00 15.00 y=0.0046k-0.265
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50.00- 40.00-- 30.00-- 20.00 y=0.01
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Appendix K This appendix shows the
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Table K. 1- continuation Set-up par
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Table K. 2 - Welding data used to d
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Table K. 2 - Continuation Set-up pa
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Table K3 - Welding data used to dev
Page 302 and 303:
Table K. 3 - Continuation Set-up pa
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