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15.00 10.00 5.00 0.00 sm y=0.00ý9Bx + 0.0025 RZ = 0.9676 c EM y= -0.001 ac 0 500 1000 1500 2000 2500 3000 3500 4000 Time [ms] f dSO [mm] M Sum{I(k)-I(k-1)) [A) -Linear (Sum(I(k)-I(k-1)} [A]) Linear (dSO [mm]) Figure J. 11 - Plot of stand-off variation and cumulative changes in welding current for welding trial "s151001" Table J. 12 - Welding data collected from stand-off slope trial "s151002" Time [ms] so [mm] 'mean, k [A] ASO mm E[Imean, k- 0 15.00 163.5 0.00 0.0 512 14.26 164.9 1024 13.52 169.4 1536 12.78 173.4 2048 12.04 176.6 2560 11.30 177.1 3072 10.56 180.6 WFS = 6.0 m/min Vset = 21.5 V 20.00 15.00 10.00 5.00 0.00 rm Sw = 0.7 m/min Vreq = 19.6 V y=0.0068x - 0.1543 R2 = 0.9721 y= -O. 14x -0.74 -1.48 -2.22 -2.96 -3.70 -4.45 o 5M 1000 1500 2000 2500 3000 3500 Time [ms] dSO [mm) A 1.4 5.9 10.0 13.2 13.6 17.1 Imean, (k-1)] u Sum(I(k)-I(k-1)} [A) -Linear (Sum(I(k)-I(k-1)} [A]) -Linear (dSO [mm)) Figure J. 12 - Plot of stand-off variation and cumulative changes in welding current for welding trial "s15 1002" 259
Table J. 13 - Welding data collected from stand-off slope trial "s15100311 Time [ms] so [mm] Imean, k [A] ASO [mm] E[Imcan, k- 0 15.00 184.0 0.00 0.0 512 14.15 184.9 1024 13.31 188.2 1536 12.46 193.1 2048 11.61 197.1 2560 10.77 200.3 3072 9.92 204.6 wry = i. u nvnun Vset = 21.8 V 25.00 20.00 15.00 10.00 5.00 0.00 5.00 -0.85 -1.69 -2.54 -3.39 -4.23 -5.08 -10.00 0 500 1000 1500 2000 2500 3000 3600 Time [ms] f dSO [mm] [A] 0.8 4.1 9.1 13.1 16.3 20.6 If Sum{I(k)-I(k-1)} [A] Imcan, (k. l)] Linear (Sum{I(k)-I(k-1)} [A]) -Linear (dSO [mm]) Figure J. 13 - Plot of stand-off variation and cumulative changes in welding current for welding trial "s151003" Table J. 14 - Welding data collected from stand-off slope trial "s15 1004" Time [ms] SO (mm] Jw= U. ö rn/nun Vreq=19.9V I, Q, , k [A] A SO mm I[1mcao. k -1, x. 0. (k->)] [A] 0 15.00 199.5 0.00 0.0 256 14.52 202.5 -0.48 3.0 512 14.05 201.9 -0.95 2.4 768 13.57 208.7 -1.43 9.2 1024 13.09 200.0 -1.91 1280 12.62 211.6 -2.38 1536 12.14 213.3 -2.86 1792 11.67 216.9 -3.33 2048 11.19 217.5 -3.81 2304 10.71 218.2 -4.29 2560 10.24 220.6 -4.76 WFS = 8.0 m/min Sw = 0.9 rn/min Vset = 22.1 V Vreq = 20.2 V 260 0.5 12.1 13.8 17.4 18.0 18.7 21.1
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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
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[38] D1LTHEY, U. , REICHELL, T. , S
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[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 and 280: 5.00- 0.00 y=0.0019x 1000 1500 2000
Page 281 and 282: Table J. 7 - Welding data collected
Page 283: Table J. 10 - Welding data collecte
Page 287 and 288: 20.00- 15. M y=0.0047x - 1.7922 10.
Page 289 and 290: Table J. 18 - Welding data collecte
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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