A Study on Arc Sensor Algorithm for Weld Seam Tracking in Gas Metal Arc Welding of Butt Joints

1991 ◽  
Vol 205 (4) ◽  
pp. 247-255 ◽  
Author(s):  
J-W Kim ◽  
S-J Na
Keyword(s):  
Arc Welding ◽  
Weld Seam ◽  
Gas Metal Arc Welding ◽  
Seam Tracking ◽  
Butt Joints ◽  
Metal Arc Welding ◽  
Weld Seam Tracking ◽  
Arc Sensor

Vision-based weld seam tracking in gas metal arc welding

2007 ◽  
Vol 1 (3) ◽  
pp. 268-273 ◽  
Author(s):  
Jinqiang Gao ◽  
Chuansong Wu ◽  
Xizhang Liu ◽  
Dianxiu Xia
Keyword(s):  
Arc Welding ◽  
Weld Seam ◽  
Gas Metal Arc Welding ◽  
Seam Tracking ◽  
Metal Arc Welding ◽  
Weld Seam Tracking

Investigation on arc light intensity in gas metal arc welding. Part 2: Application to weld seam tracking

1997 ◽  
Vol 211 (5) ◽  
pp. 355-363 ◽  
Author(s):  
C D Yoo ◽  
H-K Sunwoo ◽  
K-I Koh
Keyword(s):  
Signal Processing ◽  
Light Intensity ◽  
Arc Welding ◽  
Weld Seam ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Seam Tracking ◽  
Processing Methods ◽  
Metal Arc Welding ◽  
Signal Processing Methods

The arc sensor has been widely used to detect the weld seam by monitoring welding current or voltage variation during weaving in gas metal arc welding (GMAW). In this work, the arc light intensity and welding resistance are utilized as the seam tracking sensor. Signal characteristics of the arc light intensity and welding resistance are compared when argon and CO2 gas are used for shielding. The performance of signal processing methods such as the least squares and integration methods is evaluated experimentally. It is found that the arc light intensity provides higher quality signals than welding resistance with CO2 gas. While both signal processing methods demonstrate almost equal seam tracking capabilities, the integration method appears to be more efficient because of the short computation time.

scholarly journals An adaptive approach to compensate seam tracking error in robotic welding process by a moving fixture

2018 ◽  
Vol 15 (6) ◽  
pp. 172988141881620
Author(s):  
Reza Ebrahimpour ◽  
Rasul Fesharakifard ◽  
Seyed Mehdi Rezaei
Keyword(s):  
Weld Pool ◽  
Arc Welding ◽  
Sliding Mode ◽  
Gas Metal Arc Welding ◽  
Tracking Error ◽  
Welding Process ◽  
Seam Tracking ◽  
Ball Screw ◽  
Robotic Welding ◽  
Metal Arc Welding

Welding is one of the most common method of connecting parts. Welding methods and processes are very diverse. Welding can be of fusion or solid state types. Arc welding, which is classified as fusion method, is the most widespread method of welding, and it involves many processes. In gas metal arc welding or metal inert gas–metal active gas, the protection of the molten weld pool is carried out by a shielding gas and the filler metal is in the form of wire which is automatically fed to the molten weld pool. As a semi-metallic arc process, the gas metal arc welding is a very good process for robotic welding. In this article, to conduct the metal active gas welding torch, an auxiliary ball screw servomechanism is proposed to move under a welder robot to track the welded seam. This servomechanism acts as a moving fixture and operates separately from the robot. At last, a decentralized control method based on adaptive sliding mode is designed and implemented on the fixture to provide the desired motion. Experimental results demonstrate an appropriate accuracy of seam tracking and error compensation by the proposed method.

Noncontact Ultrasonic Sensing for Seam Tracking in Arc Welding Processes

1998 ◽  
Vol 120 (3) ◽  
pp. 600-608 ◽  
Author(s):  
S. B. Zhang ◽  
Y. M. Zhang ◽  
R. Kovacevic
Keyword(s):  
Arc Welding ◽  
Focal Length ◽  
Tracking System ◽  
Gas Metal Arc Welding ◽  
Transmission Efficiency ◽  
Seam Tracking ◽  
High Frequency Ultrasound ◽  
Tracking Accuracy ◽  
Metal Arc Welding ◽  
Welding Processes

A novel seam tracking technology based on high frequency ultrasound is developed in order to achieve high accuracy in weld seam identification. The transmission efficiency of the ultrasound is critical for obtaining a sufficient echo amplitude. Since the transmission efficiency is determined by the difference in impedance between the piezoelectric ceramic and air, match layers are designed to optimize the transmission efficiency by matching impedance. Since the air impedance depends on the density and velocity of the ultrasound, which both depend on the temperature, the optimization has been done for a wide bandwidth. Also, the receiving circuit is designed so that its resonance frequency matches the frequency of the ultrasound. As a result, the sensitivity of the noncontact ultrasonic sensor is improved 80-fold. By properly designing the focal length of the transducer, a high resolution ultrasound beam, 0.5 mm in diameter, is achieved. Based on the proposed sensing technology, a noncontact seam tracking system has been developed. Applications of the developed system in gas tungsten arc welding (GTAW) and CO2 gas metal arc welding (GMAW) processes show that a tracking accuracy of 0.5 mm is guaranteed despite the arc light, spatter, high temperature, joint configuration, small gap, etc.

A study of a dual-electromagnetic sensor system for weld seam tracking of I-butt joints

2003 ◽  
Vol 217 (9) ◽  
pp. 1305-1313 ◽  
Author(s):  
J-W Kim ◽  
J-H Shin
Keyword(s):  
Sheet Metal ◽  
Arc Welding ◽  
Weld Seam ◽  
Welding Process ◽  
Seam Tracking ◽  
Sensor System ◽  
Displacement Sensor ◽  
Butt Joints ◽  
Current Variation ◽  
Electromagnetic Sensor

Seam tracking systems for the arc welding process use various kinds of sensor including the arc sensor, vision sensor and laser displacement sensor. Among the various sensors available, the electromagnetic sensor is one of the most useful methods, especially in sheet metal butt-joint arc welding, primarily because it is hardly affected by the intense arc light and fumes generated during the welding process, or by the surface conditions of the weldment such as paint marks and scratches. In this study, a dual-electromagnetic sensor, which utilizes the induced current variation in the sensing coil due to the eddy current variation in the metal near the sensor, was developed for the arc welding of sheet metal I-butt joints. The dual-electromagnetic sensor thus detects the offset displacement of the weld line from the centre of the sensor head, even when there is no gap in the joint. A set of design variables for the sensor was examined to determine the maximum sensing capability through repeated experiments. Seam tracking was performed by correcting the position of the sensor to the amount of offset displacement determined during each sampling period. From the experimental results, the developed sensor system showed an excellent capability for weld seam detection and tracking when the sensor-to-workpiece distance was less than 5mm.

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