Owing to process conditions such as uneven clearance of base metal assembly and welding deformation,it is difficult to obtain well-formed structural welds with robot constant specification parameters welding.Determini...Owing to process conditions such as uneven clearance of base metal assembly and welding deformation,it is difficult to obtain well-formed structural welds with robot constant specification parameters welding.Determining how to extract a structured,anti-interference,concise,and dynamic knowledge model from measurable data,and then adjust the welding parameters with corresponding control methods in real time is a central problem to be solved in welding formation control.Hence,this paper proposes a welding penetration control method based on a Neighborhood Rough Set-Adaptive Neuro-Fuzzy Inference System(NRS-ANFIS)to achieve effective penetration control for the GMAW welding process.In orthogonal experiments,the NRS algorithm,which is based on visual sensing to obtain the properties of the weld pool and gap changes,is used to reduce the established frontal weld pool feature information decision table,and the minimum feature set of the weld pool tail width WTand the tail area coefficient CTSis obtained.The minimum feature set of the effective frontal weld pool,real-time line laser distance change,and real-time current information are used as the input for the ANFIS control system.The experimental results for the two groups of time-varying gaps demonstrate that under the condition of no preheating of the base metal,the complete welding penetration rate of the adjusted welding process parameters output by the trained ANFIS model reaches 87%,and the backside melting width is uniform and consistent,which meets the welding specification requirements.展开更多
A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V al...A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V alloy sheets.The microstructures,facture surfaces and microhardness of the welded joints were characterized by using optical microscope,scanning electron microscope （SEM） and Vickers microhardness tester.Comparing with welds such as gas tungsten arc and conventional plasma arc processes,the experimental results revealed the improvements when using the present process including：1） reducing prior-beta （β） grain size and prohibiting formation of hard martensite phases in the fusion zone due to the decreased heat input;and 2） better toughness and higher hardness.展开更多
The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature...The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature gradients in the weld pool result in very intensive thermocapillary(Marangoni)convection.The weld pool surface width becomes very large and unstable.However,an externally applied oscillating magnetic field can stabilize the surface of the melt.In the present work this technology was used to stabilize the weld pool surface in partial penetration 4.4 kW Nd:YAG laser beam welding of AW-5754 aluminium alloy in PA position.An AC magnet was mounted on the laser welding head.The oscillating magnetic field was oriented perpendicular to the welding direction.It was found that the AC magnetic field can drastically reduce the surface roughness of welds.X-ray image analysis shows a drastic reduction of welds porosity.This effect can be explained as a result of electromagnetic rectification of the melt.展开更多
Realizing of weld penetration control in gas tungsten arc welding requires establishment of a model describing the relationship between the front-side geometrical parameters of weld pool and the back-side weld width w...Realizing of weld penetration control in gas tungsten arc welding requires establishment of a model describing the relationship between the front-side geometrical parameters of weld pool and the back-side weld width with sufficient accuracy. A neural network model is developed to attain this aim. Welding experiments are conducted to obtain the training data set （including 973 groups of geometrical parameters of the weld pool and back-side weld width） and the verifying data set （108 groups）. Two data sets are used for training and verifying the neural network, respectively. The testing results show that the model has sufficient accuracy and can meet the requirements of weld penetration control.展开更多
Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controll...Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.展开更多
The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust ...The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities （LMIs） and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design oarameter.展开更多
The purpose of computer-aided design of new adaptive pulsed arc technologies of welding is: to de- sign optimum algorithms of pulsed control over main energy parameters of welding.It permits:to in- crease welding ...The purpose of computer-aided design of new adaptive pulsed arc technologies of welding is: to de- sign optimum algorithms of pulsed control over main energy parameters of welding.It permits:to in- crease welding productivity, to stabilize the welding regime, to control weld formation,taking into ac- count its spatial position, to proveal specie strength of the welded and coatings. Computer- aided design reduces the time of development of new pulsed arc technology:provides the optimization of technological referes according to the operating conditions of welded joints,the prediction of the ser- vice life of the welds.The developed methodology of computer-aided design of advanced technologies, models, original software, adaptive algorithms of pulsed control, and spend equipment permits to regulate penetration,the weld shape, the sizes of heat - affected zone; to predict sired properties and quality of welded joints.展开更多
High-frequency pulsed(HFP)gas tungsten arc welding(GTAW)has shown excellent performance in welding of aluminum alloys in recent years,which makes itself a promisingly potential technique for part manufacturing in avia...High-frequency pulsed(HFP)gas tungsten arc welding(GTAW)has shown excellent performance in welding of aluminum alloys in recent years,which makes itself a promisingly potential technique for part manufacturing in aviation industry.However,existing researches generally focuses on the effect of a single parameter while lacks multivariable researches.Considering of the fact that gap and misalignment are inevitable in real part clamping,adaptive intelligent welding is usually used during automatic manufacturing,which means under the control of filler wire amount per length of a weld,other parameters including current,welding speed and wire feed speed during one single weld are changing according to the specific clamping situation.Therefore,the influence of specific energy input led by different welding parameters within one adaptive welding program on microstructure and mechanical property of the weld needs to be clarified.This study investigates the effect of welding heat input(ranging from 1048.3 J/mm to 825.6 J/mm within one adaptive welding program control)on the formation quality of 3.25 mm thick 6061 aluminum alloy joints fabricated by HFP-GTAW with 4043 filler wire.According to the obtained results,non-monotonic relationship between heat input and porosity,with an optimal minimum of 4.92%achieved at an intermediate heat input of 856.8 J/mm.The 21.2%decrease of energy input during welding process would reduce the average grain size in the weld center and adjacent to fusion line by 18.6%and 19.4%,respectively.The ratios between fluctuation range to minimum value in average yield and the relative ranges of yield strength and ultimate tensile strength across the tested heat inputs were 14.7%and 12.7%,respectively.The findings provide a general overview on how the microstructure and mechanical properties would fluctuate in an adaptively controlled HFP-GTAW fabricated aluminum alloy weld.展开更多
Today, automated robot welding of components with low tolerances in series production is state-of-the-art. But turning to small batch production particularly of parts with high tolerances, engineering and construction...Today, automated robot welding of components with low tolerances in series production is state-of-the-art. But turning to small batch production particularly of parts with high tolerances, engineering and construction of automated solutions is just at the beginning of providing economic efficiency. While weld seam tracking is well established for the described problem, geometric recognition of weldments is not yet solved satisfactorily. This paper will present an optimisation approach of a laser sensor guided and programmed robot welding system which was developed within the project ROPROF at the TU Dortmund. With this development, a working prototype of a robot weld system was built by a steel construction company as well as additional demonstration software showing the potential and transferability of adjusted geometric location of weldments for industrial applications.展开更多
基金Supported by National Natural Science Foundation of China(Grant Nos.52261044,51969001)the Guangxi Provincial Science and Technology Major Project(Grant No.Guike AA23062037)Research Foundation Ability Enhancement Project for Young and Middle Aged Teachers in Guangxi Universities of China(Grant No.2024KY0441)。
文摘Owing to process conditions such as uneven clearance of base metal assembly and welding deformation,it is difficult to obtain well-formed structural welds with robot constant specification parameters welding.Determining how to extract a structured,anti-interference,concise,and dynamic knowledge model from measurable data,and then adjust the welding parameters with corresponding control methods in real time is a central problem to be solved in welding formation control.Hence,this paper proposes a welding penetration control method based on a Neighborhood Rough Set-Adaptive Neuro-Fuzzy Inference System(NRS-ANFIS)to achieve effective penetration control for the GMAW welding process.In orthogonal experiments,the NRS algorithm,which is based on visual sensing to obtain the properties of the weld pool and gap changes,is used to reduce the established frontal weld pool feature information decision table,and the minimum feature set of the weld pool tail width WTand the tail area coefficient CTSis obtained.The minimum feature set of the effective frontal weld pool,real-time line laser distance change,and real-time current information are used as the input for the ANFIS control system.The experimental results for the two groups of time-varying gaps demonstrate that under the condition of no preheating of the base metal,the complete welding penetration rate of the adjusted welding process parameters output by the trained ANFIS model reaches 87%,and the backside melting width is uniform and consistent,which meets the welding specification requirements.
基金Project(2009CB939705) supported by the National Basic Research Program of ChinaProject(200233) supported by the Foundation for the Author of National Excellent Doctoral Dissertation of China (FANEDD)
文摘A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V alloy sheets.The microstructures,facture surfaces and microhardness of the welded joints were characterized by using optical microscope,scanning electron microscope （SEM） and Vickers microhardness tester.Comparing with welds such as gas tungsten arc and conventional plasma arc processes,the experimental results revealed the improvements when using the present process including：1） reducing prior-beta （β） grain size and prohibiting formation of hard martensite phases in the fusion zone due to the decreased heat input;and 2） better toughness and higher hardness.
基金Item Sponsored by the German Collaborative Industrial Research Program (IGF) and the German Welding Society (DVS) Under Grant Nr.IGF-17.265 N/DVS-06.078
文摘The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature gradients in the weld pool result in very intensive thermocapillary(Marangoni)convection.The weld pool surface width becomes very large and unstable.However,an externally applied oscillating magnetic field can stabilize the surface of the melt.In the present work this technology was used to stabilize the weld pool surface in partial penetration 4.4 kW Nd:YAG laser beam welding of AW-5754 aluminium alloy in PA position.An AC magnet was mounted on the laser welding head.The oscillating magnetic field was oriented perpendicular to the welding direction.It was found that the AC magnetic field can drastically reduce the surface roughness of welds.X-ray image analysis shows a drastic reduction of welds porosity.This effect can be explained as a result of electromagnetic rectification of the melt.
基金the Shandong Provincial Natural Science Foundation of China （No. Z2003F05 ）.
文摘Realizing of weld penetration control in gas tungsten arc welding requires establishment of a model describing the relationship between the front-side geometrical parameters of weld pool and the back-side weld width with sufficient accuracy. A neural network model is developed to attain this aim. Welding experiments are conducted to obtain the training data set （including 973 groups of geometrical parameters of the weld pool and back-side weld width） and the verifying data set （108 groups）. Two data sets are used for training and verifying the neural network, respectively. The testing results show that the model has sufficient accuracy and can meet the requirements of weld penetration control.
文摘Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.
基金This project is supported by Doctor's Research Fund of Science Education Ministry of China(No.20060214004)Scientific Research Fund Education Ministry of China(No.206041)Scientific Research Fund of Harbin Sci-ence Bureau China(No.20051AAICG037).
文摘The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities （LMIs） and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design oarameter.
文摘The purpose of computer-aided design of new adaptive pulsed arc technologies of welding is: to de- sign optimum algorithms of pulsed control over main energy parameters of welding.It permits:to in- crease welding productivity, to stabilize the welding regime, to control weld formation,taking into ac- count its spatial position, to proveal specie strength of the welded and coatings. Computer- aided design reduces the time of development of new pulsed arc technology:provides the optimization of technological referes according to the operating conditions of welded joints,the prediction of the ser- vice life of the welds.The developed methodology of computer-aided design of advanced technologies, models, original software, adaptive algorithms of pulsed control, and spend equipment permits to regulate penetration,the weld shape, the sizes of heat - affected zone; to predict sired properties and quality of welded joints.
基金supported by the Commercial Aircraft Corporation of China Ltd.(Grant No.COMAC-SFGS-2024–569)Fundamental Research Funds for the Central Universities and Institute of Marine Equipment,Shanghai Rising-Star Program of Science and Technology Commission of Shanghai Municipality(Grant No.23QA1404700)+1 种基金National Natural Science Foundation of China(Grant No.52475384,52505409)China Postdoctoral Science Foundation(Grant No.2024M761963)。
文摘High-frequency pulsed(HFP)gas tungsten arc welding(GTAW)has shown excellent performance in welding of aluminum alloys in recent years,which makes itself a promisingly potential technique for part manufacturing in aviation industry.However,existing researches generally focuses on the effect of a single parameter while lacks multivariable researches.Considering of the fact that gap and misalignment are inevitable in real part clamping,adaptive intelligent welding is usually used during automatic manufacturing,which means under the control of filler wire amount per length of a weld,other parameters including current,welding speed and wire feed speed during one single weld are changing according to the specific clamping situation.Therefore,the influence of specific energy input led by different welding parameters within one adaptive welding program on microstructure and mechanical property of the weld needs to be clarified.This study investigates the effect of welding heat input(ranging from 1048.3 J/mm to 825.6 J/mm within one adaptive welding program control)on the formation quality of 3.25 mm thick 6061 aluminum alloy joints fabricated by HFP-GTAW with 4043 filler wire.According to the obtained results,non-monotonic relationship between heat input and porosity,with an optimal minimum of 4.92%achieved at an intermediate heat input of 856.8 J/mm.The 21.2%decrease of energy input during welding process would reduce the average grain size in the weld center and adjacent to fusion line by 18.6%and 19.4%,respectively.The ratios between fluctuation range to minimum value in average yield and the relative ranges of yield strength and ultimate tensile strength across the tested heat inputs were 14.7%and 12.7%,respectively.The findings provide a general overview on how the microstructure and mechanical properties would fluctuate in an adaptively controlled HFP-GTAW fabricated aluminum alloy weld.
文摘Today, automated robot welding of components with low tolerances in series production is state-of-the-art. But turning to small batch production particularly of parts with high tolerances, engineering and construction of automated solutions is just at the beginning of providing economic efficiency. While weld seam tracking is well established for the described problem, geometric recognition of weldments is not yet solved satisfactorily. This paper will present an optimisation approach of a laser sensor guided and programmed robot welding system which was developed within the project ROPROF at the TU Dortmund. With this development, a working prototype of a robot weld system was built by a steel construction company as well as additional demonstration software showing the potential and transferability of adjusted geometric location of weldments for industrial applications.
