Search results

The purpose of this paper is to analyze the characteristics of sound during gas tungsten argon welding (GTAW), which is very important to effectively monitor the welding quality in future by using the information extracted from sound.

The hardware used in the experiment is described. Then the paper researches the influence of welding techniques (gas flow, welding speed, welding current, and arc length) on arc sound and the distribution of the welding sound field. Finally, the relation between welding power and sound are studied based on Fourier transforms and recursive least square methods.

The sound pressure is affected greatly by gas flow, arc length, and current; welding sound source obeys the dipole model; the sound can be better predicted when the three orders derivative of the welding power are combined together.

This paper provides a new insight into welding sound resource model and a detailed analysis of the influence of the welding sound caused by welding techniques.

The purpose of this paper is to provide a modified welding image feature extraction algorithm for rotating arc narrow gap metal active-gas welding (MAG) welding, which is significant for improving the accuracy and reliability of the welding process.

An infrared charge-coupled device (CCD) camera was utilized to obtain the welding image by passive vision. The left/right arc position was used as a triggering signal to capture the image when the arc is approaching left/right sidewall. Comparing with the conventional method, the authors’ sidewall detection method reduces the interference from arc; the median filter removes the welding spatter; and the size of the arc area was verified to reduce the reflection from welding pool. In addition, the frame loss was also considered in the authors’ method.

The modified welding image feature extraction method improves the accuracy and reliability of sidewall edge and arc position detection.

The algorithm can be applied to welding seam tracking and penetration control in rotating or swing arc narrow gap welding.

The modified welding image feature extraction method is robust to typical interference and, thus, can improve the accuracy and reliability of the detection of sidewall edge and arc position.

Describes the use of welding robots for making bridge panels. The system uses a total of 14 sets of High Speed Rotating Arc welding robots and newly‐developed arc sensor techniques are used with both joint end and bead end sensors. A teaching‐less direct CADCAM system was developed to control the robots. The welding robot system is now in commercial operation with welding efficiencies that are twice those possible with conventional processes.

Whilst robots are of benefit in gas metal arc welding process parameters are the critical factors. Vernon Mangold of Kohol Systems discusses their influence on cell design.

This paper aim to build an information fusion model that can predict the bottom shape of welding groove for better welding quality control. Arc sensor is widely used in seam tracking due to its simplicity and good accessibility, but it heavily relies on the bottom shape of the groove. It is necessary to identify the welding groove bottom state. Therefore, arc sensor information and vision sensing information were fused by the rough set (RS) method to predict the groove state, which will lay the foundation for better welding quality control.

First, a multi-sensor information system was established, which included an arc sensing component and a vision sensing component. For the arc sensing system, the current waveform in each rotating period was obtained and divided into 12 parts to calculate variables representing the variation of arc length. For the vision sensing system, images were obtained by passive vision when the arc was near the groove sidewall. The positions of the sidewall and the arc were calculated to get the weld deviation which was unrelated with the bottom groove state. Second, experimental data were generated by workpiece with various bottom shapes. At last, the RS method was adopted to fuse the arc sensing and the vision information, and a rule-based model with good prediction ability was obtained.

By fusing arc sensing and vision sensing information, an RS-based model was built to predict the welding groove state.

The RS modeling method was used to fuse arc sensing information and vision sensing information to build a model that predicts groove bottom state. The arc sensing information represented the arc length variation, while the vision sensing information contains the seam deviation which was unrelated with the bottom groove state. The RS model gives satisfactory prediction results and can be applied to weld quality control.

Shielded metal arc welding (SMAW) is a typical manual process with many important but dangerous applications for the welder. The purpose of this paper is to present a methodology developed for execution time trajectory generation for robotic SMAW which offers greater safety and improved weld quality and repeatability.

The study presents a methodology developed for execution time trajectory generation for the robotic SMAW. In this methodology, while the electrode is melted the robot makes the diving movement, keeping the electric arc length constant. The trajectory is generated during execution time as a function of melting rate and independent of the welding speed, given by the welding parameters. The proposed methodology uses a variable tool center point (TCP) model where the covered electrode is considered a prismatic joint, whose displacement is determined by the melting rate.

The proposed methodology was implemented in a KUKA robot. The electrode melting rate was determined by measuring the arc voltage and the electrode holder trajectory was determined during the weld, keeping the arc length and the welding speed constant. All the obtained weld beads have the same aspect, showing the process repeatability.

Owing to its low productivity, robotic SMAW is only suitable to certain applications.

With this methodology, the TCP will always be located at the tip of the electrode (melting front), allowing one to program the welding speed independently of the electrode diving speed. The diving movement is automatically performed by the robot during the welding.

Robotic SMAW allows dangerous applications such as underwater welding and hot tapping of pipes without human intervention during the weld.

Welding sensor technology is the key technology in welding process, but a single sensor cannot acquire adequate information to describe welding status. This paper addresses arc sensor and sound sensor to acquire the voltage and sound information of pulsed gas tungsten arc welding (GTAW) simultaneously, and uses multi‐sensor information fusion technology to fuse the information acquired by the two sensors. The purpose of this paper is to explore the feasibility and effectiveness of multi‐sensor information fusion in pulsed GTAW.

The weld voltage and weld sound information are first acquired by arc sensor and sound sensor, then the features of the two signals are extracted, and the features are fused by weighted mean method to predict the changes of arc length. The weights of each feature are determined by optional distribution method.

The research findings show that multi‐sensor information fusion technology can effectively utilize the information of different sensors and get better result than single sensor.

The arc sensor and sound sensor are first used at the same time to get information about pulsed GTAW and the fusion result shows its advantages over single sensor; this reveals that multi‐sensor fusion technology is a valuable research area in welding process.

This paper outlines the range of robots available and in use in Britain for arc welding, and gives examples of typical current industrial applications. Work at the National Engeering Laboratories and the Welding Institute has the objective of increasing the range and ease of robot arc welding, and recent developments in this area are introduced.

By implementing a high‐speed welding system with a new arc welding robot, researchers have far exceeded current welding speeds. The heat warp of the work piece and adhesion of spatter onto the workpiece has been decreased, reducing the cycle time, and total heat input.

Initially, we reviewed the robot welding equipment in terms of its purpose: greatly improved arc welding quality and reliability, and stimulation of the arc welding market. We then discussed the arc welding package, with its advanced ability to perform work tasks. This equipment also results in a noticeable improvement in welding speed (4m/min). This is possible due to a welding power supply specially developed for robots and wire feeding equipment run by the servo drive so tasks that were previously not possible are now. In this article, we introduce the MOTOPAC‐WS100 (standard arc welding package), the MOTOPAC‐WH200 (high‐speed arc welding package), and the MOTOEYE‐LT, MOTOEYE‐LF (unique laser sensor tools), and the MOTOMAN‐ET (teach procedure support tool).