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Table J. 6 - Welding data collected from stand-off slope trial "s15_2006" Time [ms) so [mm] Imean. k [A] ESO mm Z[Imeaq 0 15 217.2 0 0 512 15.53 212.0 0.53 1024 16.06 213.5 1.06 1536 16.59 211.9 1.59 2048 17.12 209.3 2.12 2560 17.65 207.6 2.65 3072 18.18 205.4 3.18 3584 18.70 204.2 3.70 4096 19.23 200.1 4.23 4608 19.76 200.9 4.76 WFS = 9.5 m/nun Jw = U. 5 m/min Vset = 22.7 V Vreq = 20.7 V 5.00- 0.00 $'ý A" -10.00 -15.00 -20.00- y =0.001x 10 2000 3000 4000 5C 30 E CISO [mm] y= -0.003x - 0.91 Time [ms] " k- [A] -5.2 -3.7 -5.4 -8.0 -9.6 -11.8 -13.0 -17.1 -16.3 Sum(I(k)-I(k-1)) [A] lmean, (k"1)] 'Linear (Sum(I(k)-I(k-1)) (A]) -Linear (dSO (mm]) Figure J. 6 - Plot of stand-oll variation and cumulative changes in welding current for welding trial "s15 2006" 255
Table J. 7 - Welding data collected from stand-off slope trial ßs15 2007" Time [ms] SD [mm] Imean. k [A] LSO [mm] E+[Imean, k- 0 15 279.1 0 0 512 15.64 269.9 0.64 1024 16.27 266.3 1.27 1536 16.91 262.0 1.91 2048 17.54 257.4 2.54 2560 18.18 254.1 3.18 3072 18.81 253.2 3.81 3584 19.45 247.3 4.45 4096 20.08 243.9 5.08 WFS = 11 m/min Vset = 33.1 V 10 5y=0.0012x 0' Sw=0.6m/min Vreq = 30.5 V [A] -9.2 -12.8 -17.1 -21.7 -25.0 -25.9 -31.8 -35.2 Imean, (k-1)] -5 1000 2000 3000 4000 SOpO ro dS0[mm] -10 " Sum(I(k)-I(k-1)) [A] -15 Linear (dSO [mm]) -20-- -25-- Linear (Sum(I(k}I(k-1)) [A]) - -40 y=-0. M -3.6756 Time [ms] Figure J. 7 - Plot of stand-off variation and cumulative changes in welding current for welding trial "s152007" Table J. 8 - Welding data collected from stand-off slope trial "s15 2008" Time [ms] so [mm] Imean, k [A] ASO mm 0 15 299.4 0 0 E[Imean, k- Imean, (k-1)] [A] 512 15.74 289.9 0.74 -9.5 1024 16.48 284.8 1.48 -14.6 1536 17.22 283.4 2.22 -16.0 2048 17.96 275.2 2.96 -24.2 2560 18.70 269.6 3.70 -29.8 3072 19.45 267.1 4.45 -32.3 3584 20.19 265.0 5.19 -34.4 WFS = 12.5 m/min Vset = 33.8 V Sw = 0.7 m/min Vreq = 31.1 V 256
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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
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types of joints and multi-pass weld
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[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
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: 5.00- 0.00 y=0.0019x 1000 1500 2000
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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