An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove ...An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove before welding, and then adjust itself posture to the desired status preparing for welding, namely, it is a process that the robot autonomously aligns itself to the center of welding seam. Firstly, the configuration of welding mobile robot with the function of auto-searching weld line is introduced, then the algorithm and implementation of auto-searching weld line are presented on the basis of kinematics model of the robot, at last trajectory planning among auto-searching weld line is investigated in detail. The experiment result shows that the developed welding mobile robot can successfully implement the task of auto-searching weld line before welding, tracking error precision can be controlled to approximate ±1.5 mm, and satisfy the requirement of practical welding project.展开更多
In order to reduce the "trial-mold" risk and cost,numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 ...In order to reduce the "trial-mold" risk and cost,numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm(depth) ×0.4 mm(width) ×12 mm(length) in test area was selected as the objective part,and polypropylene(PP) as the experimental material. Respectively with specific commercial software(Mold Flow) and general computational fluid dynamic(CFD) software(Comsol Multiphysics) ,the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process,the specific commercial software for normal injection molding process is not valid to describe the micro flow process,the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle due to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development,the general CFD software,which is more flexible in user defining function,is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion,as for weld line forming process,the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process;but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.展开更多
The development of welding robots suitable for specially unstructured working enviroments has been become an important development direction of industrial robot application because large-scale welding structures have ...The development of welding robots suitable for specially unstructured working enviroments has been become an important development direction of industrial robot application because large-scale welding structures have been used more and more widely in modern industry. In this paper, an intelligent mobile robot for welding of ship deck with the function of autosearching weld line was presented. A wheeled motion mechanism and a cross adjustment slider are used for the welding robot body. A sensing system based on laser-PSD （position sensitive detector） displacement sensor was developed to obtain two dimensional deviation signals during seam tracking. A full-digital control system based on DSP and CPLD has also been realized to implement complex and high-performance control algorithms. Furthermore, the system has still the function of auto-searching weld line according to the characteristics information of weld groove and adjusting posture itself to the desired status preparing for welding. The experiment of auto-searching welding line shows that the robot has high tracing accuracy, and can satisfy the requirement of practical welding project.展开更多
The FEM technology is used to analyze the welding line movement behavior of deep drawing TWB sheet with different thickness. It is found that high stress fields are concentrated around the welding line and large resid...The FEM technology is used to analyze the welding line movement behavior of deep drawing TWB sheet with different thickness. It is found that high stress fields are concentrated around the welding line and large residual stresses are left. The effect of the welding line movement is like a rigid string and the selected nodes of the thin part near the welding line show the related larger strain.展开更多
Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of...Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of the most typical workcells. The inverse kinematics of robot and positioner is the foundation of the off line programming system. The previous researchers only focused on a special solution of the positioner inverse kinematics, which is the solution at down hand welding position. In this paper, we introduce a method for representing welding position. Then a general algorithm of rotating/tilting positioner inverse kinematics is presented, and an approach to find the unique solution of the inverse kinematics is discussed. The simulation experiment results show that the general algorithm can improve the ability of robotic arc welding off line programming system to program all types of welding positions.展开更多
Working principle for a four-axis oblique intersection line welding robot is analyzed. A mathematical model for welding torch orientation angle is established, and an interpolation algorithm based on time division is ...Working principle for a four-axis oblique intersection line welding robot is analyzed. A mathematical model for welding torch orientation angle is established, and an interpolation algorithm based on time division is proposed. The algorithm makes all interpolation points fall on a required curve in theory with no accumulated errors and a direct interpolation control on the saddle-shaped curve trajectory and space orientation angle can be achieved. It is shown by MATLAB simulation that the algorithm is real-time and fully meets the precision requirement. The algorithm has been applied to real robots.展开更多
To reveal the reason of weld-line movement in hydroforming of a tailor-welded tube (TWT) with dissimilar thickness,the stress ratio of axial stress to circumferential stress is derived by mechanical analysis and analy...To reveal the reason of weld-line movement in hydroforming of a tailor-welded tube (TWT) with dissimilar thickness,the stress ratio of axial stress to circumferential stress is derived by mechanical analysis and analyzed between the thicker and thinner tubes,as well as the property of the axial strain. During TWT hydroforming,tensile strain along axial direction happens on the thinner tube. On the contrary,compressive strain happens on the thicker tube. Experiments are conducted to varify the weld-line movement regularity and strain distribution. It indicates that the weld-line moves from the thinner part to the thicker during TWT hydroforming. The thinning ratio of the thinner tube is bigger than that of the thicker tube,especially in the zone near weldline. Stress ratio difference between the thicker tube and the thinner tube is the main reason of weld-line movement and non-uniform thinning ratio distribution.展开更多
Zigzag line is a common defect in friction stir welding(FSW) joint.The formation mechanism of the zigzag line in Al-Cu alloy FSW joint and its influence on the microstructure and mechanical properties during post weld...Zigzag line is a common defect in friction stir welding(FSW) joint.The formation mechanism of the zigzag line in Al-Cu alloy FSW joint and its influence on the microstructure and mechanical properties during post weld heat treatment(PWHT) were studied by scanning electron microscopy(SEM),microhardness and tensile tests.It is found that the occurrence of zigzag line for PWHT joint is determined by PWHT process which in nature depends on residual stress and thermal stress of FSW joint.The optimization of PWHT process to reduce the residual and thermal stress can trigger for the deterioration of mechanical properties of PWHT joints with zigzag line.No obvious decrease of tensile properties is observed for T6-450 and T6-495 joints although zigzag line appears in the weld.PWHT determines the sizes of zigzag line cracks and consequently determines the fracture location and characteristics of FSW joint.展开更多
A study of the interference simulation based on robot welding of the radar pedestal was carried out by using the KUKA Sim Pro simulation software and off-line program technology. Compared with the actual robot welding...A study of the interference simulation based on robot welding of the radar pedestal was carried out by using the KUKA Sim Pro simulation software and off-line program technology. Compared with the actual robot welding process, it was found that the trajectory of the simulated robot welding process in line with that recorded in the actual welding process, and the actual limit and interference appeared at the same place as the simulation process. There was no interference phenomenon on the outside weld-seam; on the internal weld-seam, especially on the weld-joint of support plate connected to the cylinder, a phenomenon of interference appeared. It was helpful to use the simulation method to guide the actual robot welding so as to protect robot from impacting and reduce the weld defects.展开更多
Thick walled curve welding are usually joined by multi-layer and multi-pass welding, which quality and efficiency could be improved by off-line programming of robot welding. However, the precision of off-line programm...Thick walled curve welding are usually joined by multi-layer and multi-pass welding, which quality and efficiency could be improved by off-line programming of robot welding. However, the precision of off-line programming welding path was decreased due to the deviation between the off-line planned welding path and the actual welding path. A path planning algorithm and a path compensation algorithm of multi-layer and multi-pass curve welding seam for off-line programming of robot welding are developed in this paper. Experimental results show that the robot off-line programming improves the welding efftcieney and precision for thick walled curve welding seam.展开更多
This paper presents generalized CAPP （G-CAPP） method which deals with macro process planning for multiobjective in the planning stage of production line of accuracy welding （PLAW） based on the features of accuracy...This paper presents generalized CAPP （G-CAPP） method which deals with macro process planning for multiobjective in the planning stage of production line of accuracy welding （PLAW） based on the features of accuracy welding production （ AWP ）. G-CAPP offers foundations for prototype design and general equipment sorting, production capacity predication and production analysis by means of simulation and optimization. A synthetic hierarchy evaluation （SHE） model for G-CAPP established according to the planning objective is utilized to estimate the alternate processing plans by using membership function and analytic hierarchy process （AHP） of operational theory. The assembly welding line of hydraulic torque converter （HTC） is as an example of typical A WP to explicate G-CAPP and synthetic evaluating strategy of PLAW. The feasible and rational process configuration strategies of HTC assembly welding line are pointed oat under different planning objective.展开更多
The fractal dimension of the fusion line in different dissimilar welded joints is measured with Box Dimension Method.The non scale region of the fusion line with fractal character is calculated. The fusion line in th...The fractal dimension of the fusion line in different dissimilar welded joints is measured with Box Dimension Method.The non scale region of the fusion line with fractal character is calculated. The fusion line in the dissimilar welded joint is proved to be a fractal structure. The change and influence factors of the fractal dimension of the fusion line are studied.展开更多
A measurement system for high power electrical variables with ultrasonic frequency was established. It can measure the effective values of the voltage and the current, the active power, the phase difference of voltage...A measurement system for high power electrical variables with ultrasonic frequency was established. It can measure the effective values of the voltage and the current, the active power, the phase difference of voltage and current, the frequency of the transducer during ultrasonic welding and cutting. In sampling circuits of the system, the measured current is sensed by using a no capacitance and no inductance precision resistor and is treated with a difference amplifier, the measured voltage is processed by using a proportional amplifier. For achieving good amplitude frequency characteristics and rapid measurement of high frequency signals, the resistors, capacitors and amplifiers used in the system are rationally selected. Calibrating experiments show that relative errors are less than 1% for voltage and current effective values and less than 2.5% for active power, and absolute errors are ±1 Hz for frequency and ±1.7° for phase difference of voltage and current in the range of 17～23 kHz .展开更多
X70 grade large diameter line pipe with helical and longitudinal seam SAW was developed and used in West-East Pipeline Project of Petrochina. The operation pressure of the pipeline was designed as 10 MPa, with diamete...X70 grade large diameter line pipe with helical and longitudinal seam SAW was developed and used in West-East Pipeline Project of Petrochina. The operation pressure of the pipeline was designed as 10 MPa, with diameter of 1016 mm OD. This project represents the first high-pressure, large diameter and high strength grade gas pipeline in China. All the factors affecting the safety of the pipeline shall be considered. The welds quality of line pipe is very important for safety of the pipeline. Acicular ferrite type X70 grade pipeline steel was adopted for the base material. The welds performances of X70 line pipes with 1016mm OD and 14.6-21.0 mm WT has reached a very high level, especially of low temperature Charpy V impact toughness of welds metal. Welding technique and quality status of X70 line pipe of China are investigated in this paper.展开更多
During the process of laying long-distance oil and gas transmission pipelines, the hot-induction-bend method is extensively used when the direction has to be changed. By considering the pipeline＇ s ongoing processing...During the process of laying long-distance oil and gas transmission pipelines, the hot-induction-bend method is extensively used when the direction has to be changed. By considering the pipeline＇ s ongoing processing and loading states during service, the pipeline that is generally used exhibits thicker walls than those that are observed in the line pipe. As such, during pipeline construction, hot-induction-bend and line pipes with different wall thickness are girth-welded. The chemical composition of hot-induction-bend and line pipes differs, with the carbon content being particularly higher in the hot-induction-bend pipe;it also depicts a higher carbon equivalent, which makes it possible to modify the girth of the pipe. In this study, using Baosteel＇ s standard X70M UOE hot- induction-bend and line pipes, solid-wire automatic gas-metal-arc girth welding was performed and the performance of the girth-welded joint was evaluated. Furthermore,the weldability of the pipeline girth and the microstructure of the girth-welded joint were analyzed. The results reveal that Baosteel＇ s standard UOE hot-induction-bend and line pipes exhibit good girth weldability, and their technical quality can be guaranteed in case of consumer field- construction applications.展开更多
基金This project is supported by Program of International Science and Technology Cooperation(No.2004 DFA02400).
文摘An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove before welding, and then adjust itself posture to the desired status preparing for welding, namely, it is a process that the robot autonomously aligns itself to the center of welding seam. Firstly, the configuration of welding mobile robot with the function of auto-searching weld line is introduced, then the algorithm and implementation of auto-searching weld line are presented on the basis of kinematics model of the robot, at last trajectory planning among auto-searching weld line is investigated in detail. The experiment result shows that the developed welding mobile robot can successfully implement the task of auto-searching weld line before welding, tracking error precision can be controlled to approximate ±1.5 mm, and satisfy the requirement of practical welding project.
基金Project(ZI648/13-1) supported by German Research FoundationProject(D/06/00373) supported by German Academic Exchange Service
文摘In order to reduce the "trial-mold" risk and cost,numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm(depth) ×0.4 mm(width) ×12 mm(length) in test area was selected as the objective part,and polypropylene(PP) as the experimental material. Respectively with specific commercial software(Mold Flow) and general computational fluid dynamic(CFD) software(Comsol Multiphysics) ,the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process,the specific commercial software for normal injection molding process is not valid to describe the micro flow process,the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle due to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development,the general CFD software,which is more flexible in user defining function,is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion,as for weld line forming process,the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process;but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.
文摘The development of welding robots suitable for specially unstructured working enviroments has been become an important development direction of industrial robot application because large-scale welding structures have been used more and more widely in modern industry. In this paper, an intelligent mobile robot for welding of ship deck with the function of autosearching weld line was presented. A wheeled motion mechanism and a cross adjustment slider are used for the welding robot body. A sensing system based on laser-PSD （position sensitive detector） displacement sensor was developed to obtain two dimensional deviation signals during seam tracking. A full-digital control system based on DSP and CPLD has also been realized to implement complex and high-performance control algorithms. Furthermore, the system has still the function of auto-searching weld line according to the characteristics information of weld groove and adjusting posture itself to the desired status preparing for welding. The experiment of auto-searching welding line shows that the robot has high tracing accuracy, and can satisfy the requirement of practical welding project.
文摘The FEM technology is used to analyze the welding line movement behavior of deep drawing TWB sheet with different thickness. It is found that high stress fields are concentrated around the welding line and large residual stresses are left. The effect of the welding line movement is like a rigid string and the selected nodes of the thin part near the welding line show the related larger strain.
基金ThispaperissupportedbyNationalNatureScienceFoundation (No .5 96 35 16 0 )AdvancedUniversityDoctoralSubjectFoundation (No .980 2 1311)
文摘Off line programming provides an essential link between CAD and CAM, whose development will result in greater use of robotic arc welding. An arc welding system with a robot and a rotating/tilting positioner is one of the most typical workcells. The inverse kinematics of robot and positioner is the foundation of the off line programming system. The previous researchers only focused on a special solution of the positioner inverse kinematics, which is the solution at down hand welding position. In this paper, we introduce a method for representing welding position. Then a general algorithm of rotating/tilting positioner inverse kinematics is presented, and an approach to find the unique solution of the inverse kinematics is discussed. The simulation experiment results show that the general algorithm can improve the ability of robotic arc welding off line programming system to program all types of welding positions.
文摘Working principle for a four-axis oblique intersection line welding robot is analyzed. A mathematical model for welding torch orientation angle is established, and an interpolation algorithm based on time division is proposed. The algorithm makes all interpolation points fall on a required curve in theory with no accumulated errors and a direct interpolation control on the saddle-shaped curve trajectory and space orientation angle can be achieved. It is shown by MATLAB simulation that the algorithm is real-time and fully meets the precision requirement. The algorithm has been applied to real robots.
基金Sponsored by the National Natural Science Foundation of China(Grant No 50575051)Program for New Century Excellent Talents in University(Grant No NCET-07-0237)
文摘To reveal the reason of weld-line movement in hydroforming of a tailor-welded tube (TWT) with dissimilar thickness,the stress ratio of axial stress to circumferential stress is derived by mechanical analysis and analyzed between the thicker and thinner tubes,as well as the property of the axial strain. During TWT hydroforming,tensile strain along axial direction happens on the thinner tube. On the contrary,compressive strain happens on the thicker tube. Experiments are conducted to varify the weld-line movement regularity and strain distribution. It indicates that the weld-line moves from the thinner part to the thicker during TWT hydroforming. The thinning ratio of the thinner tube is bigger than that of the thicker tube,especially in the zone near weldline. Stress ratio difference between the thicker tube and the thinner tube is the main reason of weld-line movement and non-uniform thinning ratio distribution.
基金financially supported by the National Natural Science Foundation of China(Nos.51775397 and 51405358)the China Automobile Industry Innovation and Development Joint Fund(No.U1564202)+1 种基金the Program of the Ministry of Education of China for Introducing Talents of Discipline to Universities(No.B17034)the Open Fund of Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures(No.2017002)
文摘Zigzag line is a common defect in friction stir welding(FSW) joint.The formation mechanism of the zigzag line in Al-Cu alloy FSW joint and its influence on the microstructure and mechanical properties during post weld heat treatment(PWHT) were studied by scanning electron microscopy(SEM),microhardness and tensile tests.It is found that the occurrence of zigzag line for PWHT joint is determined by PWHT process which in nature depends on residual stress and thermal stress of FSW joint.The optimization of PWHT process to reduce the residual and thermal stress can trigger for the deterioration of mechanical properties of PWHT joints with zigzag line.No obvious decrease of tensile properties is observed for T6-450 and T6-495 joints although zigzag line appears in the weld.PWHT determines the sizes of zigzag line cracks and consequently determines the fracture location and characteristics of FSW joint.
基金Funded by Anhui Provincial Natural Science Foundation of China(GFKJ2015B002)Quality Engineering Project of Anhui province(2014zy122)
文摘A study of the interference simulation based on robot welding of the radar pedestal was carried out by using the KUKA Sim Pro simulation software and off-line program technology. Compared with the actual robot welding process, it was found that the trajectory of the simulated robot welding process in line with that recorded in the actual welding process, and the actual limit and interference appeared at the same place as the simulation process. There was no interference phenomenon on the outside weld-seam; on the internal weld-seam, especially on the weld-joint of support plate connected to the cylinder, a phenomenon of interference appeared. It was helpful to use the simulation method to guide the actual robot welding so as to protect robot from impacting and reduce the weld defects.
文摘Thick walled curve welding are usually joined by multi-layer and multi-pass welding, which quality and efficiency could be improved by off-line programming of robot welding. However, the precision of off-line programming welding path was decreased due to the deviation between the off-line planned welding path and the actual welding path. A path planning algorithm and a path compensation algorithm of multi-layer and multi-pass curve welding seam for off-line programming of robot welding are developed in this paper. Experimental results show that the robot off-line programming improves the welding efftcieney and precision for thick walled curve welding seam.
文摘This paper presents generalized CAPP （G-CAPP） method which deals with macro process planning for multiobjective in the planning stage of production line of accuracy welding （PLAW） based on the features of accuracy welding production （ AWP ）. G-CAPP offers foundations for prototype design and general equipment sorting, production capacity predication and production analysis by means of simulation and optimization. A synthetic hierarchy evaluation （SHE） model for G-CAPP established according to the planning objective is utilized to estimate the alternate processing plans by using membership function and analytic hierarchy process （AHP） of operational theory. The assembly welding line of hydraulic torque converter （HTC） is as an example of typical A WP to explicate G-CAPP and synthetic evaluating strategy of PLAW. The feasible and rational process configuration strategies of HTC assembly welding line are pointed oat under different planning objective.
文摘The fractal dimension of the fusion line in different dissimilar welded joints is measured with Box Dimension Method.The non scale region of the fusion line with fractal character is calculated. The fusion line in the dissimilar welded joint is proved to be a fractal structure. The change and influence factors of the fractal dimension of the fusion line are studied.
基金This work has been carried out with the support of National Natural Science Foundation(No.59675054)
文摘A measurement system for high power electrical variables with ultrasonic frequency was established. It can measure the effective values of the voltage and the current, the active power, the phase difference of voltage and current, the frequency of the transducer during ultrasonic welding and cutting. In sampling circuits of the system, the measured current is sensed by using a no capacitance and no inductance precision resistor and is treated with a difference amplifier, the measured voltage is processed by using a proportional amplifier. For achieving good amplitude frequency characteristics and rapid measurement of high frequency signals, the resistors, capacitors and amplifiers used in the system are rationally selected. Calibrating experiments show that relative errors are less than 1% for voltage and current effective values and less than 2.5% for active power, and absolute errors are ±1 Hz for frequency and ±1.7° for phase difference of voltage and current in the range of 17～23 kHz .
文摘X70 grade large diameter line pipe with helical and longitudinal seam SAW was developed and used in West-East Pipeline Project of Petrochina. The operation pressure of the pipeline was designed as 10 MPa, with diameter of 1016 mm OD. This project represents the first high-pressure, large diameter and high strength grade gas pipeline in China. All the factors affecting the safety of the pipeline shall be considered. The welds quality of line pipe is very important for safety of the pipeline. Acicular ferrite type X70 grade pipeline steel was adopted for the base material. The welds performances of X70 line pipes with 1016mm OD and 14.6-21.0 mm WT has reached a very high level, especially of low temperature Charpy V impact toughness of welds metal. Welding technique and quality status of X70 line pipe of China are investigated in this paper.
文摘During the process of laying long-distance oil and gas transmission pipelines, the hot-induction-bend method is extensively used when the direction has to be changed. By considering the pipeline＇ s ongoing processing and loading states during service, the pipeline that is generally used exhibits thicker walls than those that are observed in the line pipe. As such, during pipeline construction, hot-induction-bend and line pipes with different wall thickness are girth-welded. The chemical composition of hot-induction-bend and line pipes differs, with the carbon content being particularly higher in the hot-induction-bend pipe;it also depicts a higher carbon equivalent, which makes it possible to modify the girth of the pipe. In this study, using Baosteel＇ s standard X70M UOE hot- induction-bend and line pipes, solid-wire automatic gas-metal-arc girth welding was performed and the performance of the girth-welded joint was evaluated. Furthermore,the weldability of the pipeline girth and the microstructure of the girth-welded joint were analyzed. The results reveal that Baosteel＇ s standard UOE hot-induction-bend and line pipes exhibit good girth weldability, and their technical quality can be guaranteed in case of consumer field- construction applications.
