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The aim of this work, therefore, is to develop the integration concept between an adaptive control system, off-line programming and a robotic welding system and to build and test the integrated system for robotic welding of sheet steel. The concept developed is fully described in chapter 3. 51
SHIELDING GAS IN CONSUMABLE ELECTRODE BASE METAL SOLID ELECTRODE WIRE CURRENT CONDUCTOR WIRE GUIDE AND CONTACT DIRECTION TUBE OF TRAVEL ARC GAS NOZZLE GASEOUS SHIELD WELD METAL Figure 2.1 Gas Metal Arc Welding Process [ref. 2] % Oz 10 (A) Q VýQ4 (A) Best area for spatter, fumes, appearance (B) Best area for weld integrity 12 Area for optimum versatility ýBý Y" gPýä 10 20 % CO= Figure 2.2 - Guide for the choice of Ar+O2+CO= mixtures [ref. 4] 52
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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
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
Page 75: volume caused by the presence of a
Page 79 and 80: Arc voltage Anode Arc length I Anod
Page 81 and 82: 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
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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
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[86] CARGNELLI, M. and ROGOWSKI, A.
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[109] KURKIN, N. S. and DRIKKER, V.
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[130] USHIO, M. , LIU, W. , MAO, W.
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[151] DAVIS, A. R. Orr-line gap det
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[177] COOK, G. E. Feedback and adap
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[201] WON, Y. J. and CHO, H. S. A f
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220
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222
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wnum: local variable which defines
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Table A. 1 - continuation List item
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Imean = a2 + b2*WFS + c2*SO + d2*SO
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TCP2 number are also defined. The o
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f ROBSET. DAT: This file is created
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Figure C. 3 - Main dialogue box of
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Choose the set of welding parameter
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Water Cooling optic fibre bundle 0
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Figure E. 1 - Main graphical screen
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242
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Table G. 2 - Interface box external
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Robot ii Controller +24W CO . +24Vd
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248
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Table 1.1 - continuation Run Vpk M
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10- y =0.001ac 0 r. dSO [mm] $0 '10
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5.00- 0.00 y=0.0019x 1000 1500 2000
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Table J. 7 - Welding data collected
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Table J. 10 - Welding data collecte
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20.00- 15. M y=0.0047x - 1.7922 10.
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266
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Table K. 1- continuation Set-up par
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Table K. 1 - continuation Set-up pa
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Table K. 2 - continuation Set up pa
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Table K. 2 - Continuation Set-up pa
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Table K. 3 - Continuation Set-up pa
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Table K. 3 - Continuation Setup par
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