Design of a Control System for Welding Robot with Tracking Simulation

2008 ◽  
Vol 580-582 ◽  
pp. 251-258
Author(s):  
Jin Seok Oh ◽  
Jong Do Kim ◽  
Jun Ho Kwak ◽  
Ji Young Lee
Keyword(s):  
Control System ◽  
Welding Process ◽  
Simulation Method ◽  
Seam Tracking ◽  
High Rate ◽  
Welding Parameters ◽  
Welding Robot ◽  
Robot System ◽  
Closed Area ◽  
Welding Procedure

Welding tasks in shipbuilding create great problems for a manual welder since welding takes place in closed area with associated work environmental problems. This paper addresses the problems involved in the welding robot with control algorithm and system. The control system may similarly be modified as a tracking simulation test. The performance of the control system is assessed through the use of field data. The aim of this paper is to determine feasible parameters for a welding procedure with simulation for seam tracking of welding robot system. The main advantage of tracking simulation is its flexibility in that as the welding parameters are modified at a sufficiently high rate. Tracking simulation showed that the development of robot control algorithms should be performed by simulation, since it saves time, expenses and efforts. This paper will contribute to an increased use of automated welding technology with tracking simulation methods. Also, this paper’s results can be used for the optimization of welding process using simulation method with LabVIEW.

Welding robot system applied in sub-sea pipeline-installation

2015 ◽  
Vol 42 (1) ◽  
pp. 83-92
Author(s):  
Luo Yu ◽  
Jiao Xiangdong ◽  
Zhou Canfeng ◽  
Chen Jiaqing ◽  
Han Suxin
Keyword(s):  
Control System ◽  
System Design ◽  
Heterogeneous Network ◽  
Welding Process ◽  
Control System Design ◽  
Welding Robot ◽  
Submarine Pipeline ◽  
Robot System ◽  
Content Type ◽  
Offshore Pipeline

Purpose – The aim of this study was to develop a new generation of automatic systems based on cutting-edge design and practical welding physics to minimize downtime caused by defects and machine faults on the barges. Automatic welding has been used frequently on offshore pipeline projects. Design/methodology/approach – An automated welding robot system for sub-sea pipeline installation was constructed. The system utilized the double-car double-torch welding, which is light-weight and compact, suited for offshore applications. Several state-of-the-art technologies were integrated into the control system design, including a heterogeneous network based on EtherCAT technology, network communications based on CANopen, motor synchronization, all-position welding, etc. In addition, the utilization of the CAN bus reduced the number of cable lines and increased the extensibility of the proposed welding robot system. An internal clamp with copper shoes assured a nice root weld and narrow bevel design and the welding efficiency was improved accordingly. Findings – The trial was carried out to verify the rationality and effectiveness of the proposed automated system. The deposition rate of the backing welding could reach 17.78 kg/h; the average time for each welding was 340 s. This system was unique in that it features a dual-torch welding head that allowed for the deposition of one run with twice as much material as a single torch head. The experiment showed that the double-vehicle double-torch mode can greatly improve the welding efficiency of pipeline installation during the welding process. Research limitations/implications – The automated welding robot system will be applied to offshore pipeline projects. Originality/value – This robot is the first submarine pipeline installation welding robot to use a heterogeneous network based on EtherCAT technology. Various aspects of the submarine pipeline installation welding robot’s design and performance were discussed, including mechanical body design, control system design and welding process specification.

Design and experimental verification of an intelligent wall-climbing welding robot system

2014 ◽  
Vol 41 (6) ◽  
pp. 500-507 ◽  
Author(s):  
Zhongcheng Gui ◽  
Yongjun Deng ◽  
Zhongxi Sheng ◽  
Tangjie Xiao ◽  
Yonglong Li ◽  
...  
Keyword(s):  
Control System ◽  
Large Scale ◽  
Steel Structure ◽  
Steel Structures ◽  
Seam Tracking ◽  
Automatic Welding ◽  
Welding Robot ◽  
Robot System ◽  
Content Type ◽  
Robot Body

Purpose – This paper aims to present a new intelligent wall-climbing welding robot system for large-scale steel structure manufacture, which is composed of robot body, control system and welding system. Design/methodology/approach – The authors design the robot system according to application requirements, validate the design through simulation and experiments and use the robot in actual production. Findings – Experimental results show that the robot system satisfies the demands of automatic welding of large-scale ferromagnetic structure, which contributes much to on-site manufacturing of such structures. Practical implications – The robot can work with better quality and efficiency compared with manual welding and other semi-automatic welding devices, which can much improve large-scale steel structure manufacturing. Originality/value – The robot system is a novel solution for large-scale steel structures welding. There are three major advantages: the robot body with reliable adsorption ability, large payload capability and good mobility which meet the requirements of welding; the control system with good welding seam tracking accuracy and intelligent automatic welding ability; and friendly human – computer interface which makes the robot easy to use.

GTAW Procedure Expert System Based on Neural Network

2013 ◽  
Vol 455 ◽  
pp. 425-430 ◽  
Author(s):  
Xue Wu Wang ◽  
Shang Yong Yang
Keyword(s):  
Neural Network ◽  
Expert System ◽  
Expert Knowledge ◽  
Welding Process ◽  
Learning Ability ◽  
Welding Parameters ◽  
Neural Network Learning ◽  
The Neural Network ◽  
Function Design ◽  
Welding Procedure

Intelligent procedure expert system was developed to select appropriate GTAW procedure in this paper. First, the function design and implementation methods of the welding procedure expert system were introduced. The expert system can present the welding procedure card, multimedia display of welding process, and output function to makes the data sharing more convenient. Then, the database design of the welding procedure expert system based on C/S mode was presented where the expert knowledge was stored. At last, the neural network model was established to realize procedure selection based on the neural network learning ability and the welding case from the database. With the BPNN model, the welding parameters can be obtained based on the input welding conditions.

scholarly journals Research on the Deviation Sensing of V-groove Weld Seam based on a Novel Two Channel Acoustic Sensor

2021 ◽  
Author(s):  
Yanfeng Gao ◽  
Jianhua Xiao ◽  
Genliang Xiong ◽  
Hua Zhang
Keyword(s):  
Weld Seam ◽  
Welding Process ◽  
Simulation Method ◽  
Seam Tracking ◽  
Acoustic Sensor ◽  
Robotic Welding ◽  
Weld Seam Tracking ◽  
Novel Method ◽  
Linear Property ◽  
Sensing Performance

Abstract It is essential to sense the deviation of weld seam real-timely in robotic welding process. However, welding process always accompanied with high temperature, strong arc light and background noises, which significantly affects the application of sensors. In this study, a novel acoustic sensor was developed. This sensor consists of two microphones. Based on the sound signals collected by these two microphones, the deviation of weld seam was detected. The frequency response of the developed acoustic sensor was studied through simulation method firstly, and then the sensing performance of it was analyzed with experiments. The experimental results show that the developed acoustic sensor has a linear property for the deviation detection of V-groove weld seam. This research provides a novel method for weld seam tracking.

Develop an Excel-Based Modeling Tool to Predict Weld and HAZ Cooling Rate and Hardness for Pipeline Welding

2015 ◽  
Author(s):  
Yu-Ping Yang ◽  
Zhenning Cao ◽  
Jerry Gould ◽  
Tom McGaughy ◽  
Jon Jennings
Keyword(s):  
Heat Source ◽  
Cooling Rate ◽  
Screening Tool ◽  
Plate Thickness ◽  
Welding Process ◽  
Thickness Effect ◽  
Welding Parameters ◽  
Microstructure Model ◽  
Pipeline Welding ◽  
Welding Procedure

A Microsoft Excel-based screening tool was developed to allow an engineer with weld process knowledge to predict cooling rate and hardness during welding procedure qualifications to screen a combination of materials and welding process parameters quickly to meet requirements of fabrication and design codes. The material properties for commonly used pipeline steels have been built into a database coupled with the screening tool. The Excel-based tool includes a physics-based laser and arc welding solution which was developed based on Rosenthal’s mathematical equations for a point heat source to predict thermal cycles by inputting welding parameters. A reflecting heat source scheme was adapted to model the boundary conditions and plate thickness effect on cooling rate. The Excel-based tool also includes a microstructure model which was developed based on the Ashby model. The microstructure model can be used to predict the distributions of individual phases such as ferrite, bainite, and martensite along with a hardness map across the weld and heat-affected-zone (HAZ) regions by integrating with the thermal model.

scholarly journals A Mobile Robotic Welding Robot will be Verified both Theoretically and Empirically using AWS and ASTM Standards

2020 ◽  
Vol 8 (5) ◽  
pp. 5246-5251
Keyword(s):  
Weld Joint ◽  
Vertical Section ◽  
Welding Process ◽  
Movement Control ◽  
Cutting Edge ◽  
Welding Robot ◽  
Robotic Welding ◽  
Weld Joints ◽  
Welding Procedure ◽  
Welding System

Customary automated welding, basic in ventures, for example, car creation, gets unfeasible in enterprises that utilization unstructured assembling systems, for example, shipbuilding. This is expected to some extent to the size of the made frameworks and the size and areas of the weld. In these unstructured assembling conditions, the cutting edge for automated welding has generally comprised of a fixed-track framework with a mechanical welding carriage that works along the track. In any case, elective automated welding approaches that utilize advancements from the field of versatile mechanical autonomy are being sought after. One such model is the semiautonomous Versatile Robotic Welding System (MRWS). The MRWS is a lightweight versatile controller comprising of a two-degrees-of-opportunity portable stage and a threedegrees-of-opportunity burn controller. The MRWS is equipped for climbing ferrous surfaces by the utilization of changeless magnet tracks and situating the welding light along a weld joint. This framework is intended to automate the welding procedure for an assortment of weld joints with insignificant arrangement time. Arrangement comprises of putting the MRWS superficially to be welded and heading to the expected weld joint. So as to be used in a producing condition, such a framework must be confirmed for the welding procedure it is performing. This paper exhibits and confirms the MRWS as a legitimate other option for automated welding in unstructured situations. The confirmation procedure comprises of two parts: plan approval dependent on hypothetical investigation of the MRWS framework models to demonstrate the weld procedure necessities can be met, trailed by an exact confirmation dependent on AWS weld test particulars for a particular, normally utilized welding process. The plan approval centers around the two essential contrasts between the MRWS and demonstrated fixed-track motorized welding frameworks, burn movement control on a portable stage, and effect of the MRWS attractive feet on the weld process. The observational confirmation was performed on a vertical section weld on gentle steel with tough movement, 3G-PF

Applications of Robotics in Welding

2018 ◽  
Vol 7 (3) ◽  
pp. 30
Author(s):  
Tanveer Majeed ◽  
Mohd Atif Wahid ◽  
Faizan Ali
Keyword(s):  
Control System ◽  
Industrial Robot ◽  
Seam Tracking ◽  
Effective Control ◽  
Welding Parameters ◽  
Profile Measurement ◽  
Robotic Welding ◽  
Intelligent Control System ◽  
Joint Location ◽  
Welding Processes

An Industrial robot is reprogrammable, automatically controlled, multifunctional manipulator programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications. Technical innovations in robotic welding has facilitated manual welding processes in sever working conditions with enormous heat and fumes to be replaced with robotic welding. The robotic welding has greater capability to control robot motion, welding parameters and enhanced wrong detection and wrong correction. Major difficulties in robotic welding are joint edge inspection, weld penetration control, seam tracking of joints, and width or profile measurement of a joint. These problems can be more easily solved by use of sensory feedback signals from weld joint.  Robotic welding system has intelligent and effective control system that can track the joint, monitor the joint in process and accounts for variation in joint location. Sensors play an important role in robotic welding systems with adaptive and intelligent control system features that can track the joint, account for variation in joint location and geometry monitor in-process quality of the weld. In this paper various aspects of robotic welding, robot programming, and problems associated with robot welding are undertaken.

Development of Welding Procedures for X90-Grade Seamless Pipes for Riser Applications

2012 ◽  
Author(s):  
Hiroyuki Nagayama ◽  
Masahiko Hamada ◽  
Mark F. Mruczek ◽  
Mark Vickers ◽  
Nobuyuki Hisamune ◽  
...  
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Mechanical Test ◽  
Welding Process ◽  
High Strength ◽  
Submerged Arc Welding ◽  
Welding Parameters ◽  
Flux Cored Arc Welding ◽  
Welding Procedure ◽  
Submerged Arc

Ultra-high strength seamless pipes of X90 and X100 grades have been developed for deepwater or ultra-deepwater applications. Girth welding procedure specifications (WPSs) should be developed for the ultra-high strength pipes. However, there is little information for double jointing welding procedure by using submerged arc welding process for high strength line pipes. This paper describes mechanical test results of submerged arc welding (SAW) and gas shielded flux cored arc welding (GSFCAW) trials with various welding consumables procured from commercial markets. Welds were then made with typical welding parameters for riser productions using high strength X90 seamless pipes. The submerged arc weld metal strength could increase by increasing alloy elements in weld metal. The weld metal with CE (IIW) value of 0.74 mass% achieved fully overmatching for the X90 pipe. The weld metal yield strength (0.2% offset) was 694 MPa, and the ultimate tensile strength was 833 MPa. It was also confirmed that the reduction of boron in weld metal can improve low temperature toughness of high strength weld metal. Furthermore, it was confirmed that the HAZ has excellent mechanical properties and toughness for riser applications. In this study GSFCAW procedures were also developed. GSFCAW can be used for joining pipe and connector material for riser production welding. The weld metal with a CE (IIW) value of 0.54 mass% could meet the required strength level for X90-grade pipe as specified in ISO 3183. Cross weld tensile testing showed that fractures were achieved in the base metal. Good Charpy impact properties in weld metal and HAZ were also confirmed.

scholarly journals Fatigue Life Enhancement of Transverse and Longitudinal T-Joint on Offshore Steel Structure HSLAS460G2+M using Semi-automated GMAW and HFMI/PIT

2019 ◽  
Vol 269 ◽  
pp. 06001 ◽  
Author(s):  
Dahia Andud ◽  
Muhd Faiz Mat ◽  
Yupiter HP Manurung ◽  
Salina Saidin ◽  
Noridzwan Nordin ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Oil And Gas ◽  
Welding Process ◽  
Steel Structure ◽  
Raw Material ◽  
Welding Parameters ◽  
Weld Toe ◽  
Life Enhancement ◽  
Welding Procedure ◽  
Fatigue Life Enhancement

This research deals with a method and procedure for enhancing the structural life of the commonly used steel structure in oil and gas industries HSLA S460G2+M with a thickness of 10 mm. The type of joint and welding process is T-joint with transverse and longitudinal attachment welded using semi-automated GMAW. Filler wire ER80S-Ni1 and mixed shielding gas (80% Ar / 20% CO2) is used as material consumables. At first, the best suitable welding parameters are comprehensively investigated, prepared, tested and qualified according to welding procedure specification (WPS) qualification requirements. Further, the weld toe is treated by using HFMI/PIT with a frequency of 90Hz, 2 mm pin radius and air pressure of 6 bars. In accordance with the recommendation of the International Welding Institute (IIW), fatigue test is conducted using constant amplitude loading with the stress ratio of 0.1 and loading stresses from 55% to 75% of the yield strength of the material. Finally, the results of the fatigue experimental are compared with the fatigue recommendation of as-welded and HFMI/PIT of IIW as well as the untreated raw material. As a conclusion, it is observed that the fatigue life is increased up to 300% compared to IIW and 70% to as-welded. It is also obvious that treated transverse T-joint shows significant improvement than the longitudinal attachment.

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