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ACKNOWLEDGEMENTS I would like to express my thanks to my supervisor Robert McMaster for his continuing guidance and encouragement. I am also very greatful to Babatunde Ogunbiyi, Robert Apps, John Norrish, John Nixon and John Savill for their very supportive technical assistance during this project. I acknowledge the financial support of the National Research Council (CNPq) of the Brazilian Ministry for Science and Technology, without which this project would not have been possible. I would also like to thank Sadek Alfaro for his support and encouragement. Finally, I am greatful and indebted to all members of my immediate and extended family for their support, especially my mother Cremilda and my wife Giovana.
I dedicate this work to the memory of my .. ýfý a 6a/va (1927-1996) and my late grandfather oe &wu2 110 - oal Yý4,6 (1907-1996) late father _O e& I praise God for their life and achievements
Page 1 and 2: CRANFIELD UNIVERSITY GC CARVALHO AN
Page 3: ABSTRACT The aim of this work was t
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 28: Chapter 4 describes the on-line pos
Page 31 and 32: In pulse transfer, the welding curr
Page 33 and 34: Pd = Pv - pzh-s (2.1) where Pd is t
Page 35 and 36: the bridge. Another factor that ind
Page 37 and 38: establish the stable conditions for
Page 39 and 40: Philpott [ref. 21] developed an on-
Page 41 and 42: current peak at the moment the tip
Page 43 and 44: obot on the line must be individual
Page 45 and 46: collision detection capabilities wh
Page 47 and 48: cause dynamic variation in the seam
Page 49 and 50: Another type of robot static calibr
Page 51 and 52: spatter the gas nozzle is particula
Page 53 and 54: Table 2.1: Joint positioning tolera
Page 55 and 56:
In order to minimise the undesirabl
Page 57 and 58:
c) Ultrasonic sensors; d) Through-t
Page 59 and 60:
where K,, K2, K3 and K4 are constan
Page 61 and 62:
Philpott [refs. 21,131], based on t
Page 63 and 64:
centre. This is attributed to the m
Page 65 and 66:
technique must be employed to preve
Page 67 and 68:
" digital hardware, which is basica
Page 69 and 70:
" Maximum value, W.: Wmý = max(W )
Page 71 and 72:
process studied over a small range.
Page 73 and 74:
In-process welding control is a muc
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volume caused by the presence of a
Page 77 and 78:
SHIELDING GAS IN CONSUMABLE ELECTRO
Page 79 and 80:
Arc voltage Anode Arc length I Anod
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computed ideal procedure optimisnti
Page 83 and 84:
CONSTANT CURRENT POWER SOURCE `j' O
Page 85 and 86:
Original Surface New Surface Electr
Page 87 and 88:
otating welding wire direction weld
Page 89 and 90:
3.1.1.1 Robot errors A robot arm is
Page 91 and 92:
3.2.2 Programming error correction
Page 93 and 94:
3.3.2 Off-line programming module I
Page 95 and 96:
Pen is the weld penetration (side p
Page 97 and 98:
a. 2) Geometrical constraints from
Page 99 and 100:
Step 11 Step 12 Step 13 Step 14 Ste
Page 101 and 102:
Step 21 Step 22 If the wire feed sp
Page 103 and 104:
the Y'-axis results in a positive "
Page 105 and 106:
_ p1e0a - pORoba m31 Ilp! - poll (3
Page 107 and 108:
of a robot in its zero position12 w
Page 109 and 110:
frame points to the front of the ro
Page 111 and 112:
CAD Off-line (AutoCAD) programming
Page 113 and 114:
Z Surface 4 A Y 7 M2 Open Edge Join
Page 115 and 116:
WCF World Co-ordinates Frame 2a = J
Page 117 and 118:
x Torch Co-ordinates Frame o Indica
Page 119 and 120:
vo Ö 't7 Y7 't O m O 'S O O S O S
Page 121 and 122:
ýý aý 0 oA aW ö A O Zt A OO 't
Page 123 and 124:
Ti 9ý-! i4 *Tx t ap31 jx ý- ymin
Page 125 and 126:
errors', (i. e. joint positioning,
Page 127 and 128:
was considered to be outside the sc
Page 129 and 130:
Table 4.3 - Linguistic representati
Page 131 and 132:
The introduction of such a reduced
Page 133 and 134:
Table 4.8 - Final welding process c
Page 135 and 136:
the collection of welding data corr
Page 137 and 138:
Step 4- Calculate the confidence of
Page 139 and 140:
Z Table Co-ordinates Frame Y X Robo
Page 141 and 142:
5.3 Monitoring system The monitorin
Page 143 and 144:
the torch end. Only one degree of f
Page 145 and 146:
Current: 500 Position: 234.5 5.7.3
Page 147 and 148:
I" va JI ºr ö C 3 r" r" rl f_ £-
Page 149 and 150:
IgurC a. H -I UI qur vCiSUJ JpCCU C
Page 151 and 152:
126
Page 153 and 154:
Table 6.1 - Welding trials carried
Page 155 and 156:
Table 6.3 - Coefficients of Ogunbiy
Page 157 and 158:
Note that the calibration model sho
Page 159 and 160:
Table 6.6 - Welding parameters used
Page 161 and 162:
constant set-up welding parameters
Page 163 and 164:
stickout lengths and the temperatur
Page 165 and 166:
of the dip mode of metal transfer.
Page 167 and 168:
which would become active by settin
Page 169 and 170:
In section 4.2.5 it has been mentio
Page 171 and 172:
300 280 260 240 rd 35- 3D 25 20 15
Page 173 and 174:
Figure 6.5 - Measured "versus" Pred
Page 175 and 176:
i S 0 -0.1 -0.2 -0.3 -0.7- 68 10 12
Page 177 and 178:
32.0 E 31.5 y 31.0 30.5 30.0 j 29.5
Page 179 and 180:
35 - 30 p 15 10 0.00 2.60 5.42 8.23
Page 181 and 182:
40 35 30 25 20 15 10 A+iIII+F0.17 2
Page 183 and 184:
30 28 26 24 22 SO_act [mm] DipR [mo
Page 185 and 186:
22 20 18 SO_act [mm] DipR [ohm/100]
Page 187 and 188:
!: 30 25 20t 10 5-- 0 Dip Transfer
Page 189 and 190:
0.430- - 0.380- - :r 0.330 fPR L- 0
Page 191 and 192:
7.2 Tests with varying stand-off an
Page 193 and 194:
Table 7.3 - Bead geometry along the
Page 195 and 196:
ö a2 ., u" u,.., g .,. aucyuaac VI
Page 197 and 198:
0 24-- 22-- 18 210 1 90 0 v 170 mm
Page 199 and 200:
Q 34 32 3o mIm Viewing direction Fl
Page 201 and 202:
ýa 34 mm JO a .. ý nn ýr "u 00 M
Page 203 and 204:
22 20 18 Viewing direction Flange W
Page 205 and 206:
36 33 31 o 29 t 350 310 o 290 U due
Page 207 and 208:
I C, x -i 23 21 j 19 Q 240c WFS =10
Page 209 and 210:
en 34 32 - vsec 30- 26- 24 + .. ++
Page 211 and 212:
186
Page 213 and 214:
" to design and build the hardware
Page 215 and 216:
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
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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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248
Page 275 and 276:
Table 1.1 - continuation Run Vpk M
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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 285 and 286:
Page 287 and 288:
20.00- 15. M y=0.0047x - 1.7922 10.
Page 289 and 290:
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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