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Visual feed-back for operator interaction in robotized laser metal deposition
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för elektro- och automationsteknik. (PTW)
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för elektro- och automationsteknik. (PTW)ORCID-id: 0000-0001-7935-7974
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för industriell produktion. (PTW)ORCID-id: 0000-0002-0234-3168
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för elektro- och automationsteknik. (PTW)ORCID-id: 0000-0001-5608-8636
2008 (engelsk)Inngår i: Proceedings of the 22nd International Conference on Surface Modification Technologies SMT22: Held at University West, Trollhättan, Sweden September 22-24, 2008 / [ed] T.S. Sudarshan & Per Nylen, 2008, s. 297-304Konferansepaper, Publicerat paper (Annet vitenskapelig)
sted, utgiver, år, opplag, sider
2008. s. 297-304
Serie
Surface Modification Technologies ; 22
HSV kategori
Forskningsprogram
TEKNIK, Mekatronik; TEKNIK, Produktions- och materialteknik
Identifikatorer
URN: urn:nbn:se:hv:diva-2249ISBN: 978-0-9817065-1-1 (tryckt)OAI: oai:DiVA.org:hv-2249DiVA, id: diva2:301393
Konferanse
Surface Modification Technologies SMT22
Tilgjengelig fra: 2010-03-03 Laget: 2010-03-03 Sist oppdatert: 2018-07-25bibliografisk kontrollert
Inngår i avhandling
1. Towards full Automation of Robotized Laser Metal-wire Deposition
Åpne denne publikasjonen i ny fane eller vindu >>Towards full Automation of Robotized Laser Metal-wire Deposition
2009 (engelsk)Licentiatavhandling, med artikler (Annet vitenskapelig)
Abstract [en]

Metal wire deposition by means of robotized laser welding offers great saving potentials, i.e. reduced costs and reduced lead times, in many different applications, such as fabrication of complex components, repair or modification of high-value components, rapid prototyping and low volume production, especially if the process can be automated. Metal deposition is a layered manufacturing technique that builds metal structures by melting metal wire into beads which are deposited side by side and layer upon layer. This thesis presents a system for on-line monitoring and control of robotized laser metal wire deposition (RLMwD). The task is to ensure a stable deposition process with correct geometrical profile of the resulting geometry and sound metallurgical properties. Issues regarding sensor calibration, system identification and control design are discussed. The suggested controller maintains a constant bead height and width throughout the deposition process. It is evaluated through real experiments, however, limited to straight line deposition experiments. Solutions towards a more general controller, i.e. one that can handle different deposition paths, are suggested.

A method is also proposed on how an operator can use different sensor information for process understanding, process development and for manual on-line control. The strategies are evaluated through different deposition tasks and considered materials are tool steel and Ti-6Al-4V. The developed monitoring system enables an operator to control the process at a safe distance from the hazardous laser beam.

The results obtained in this work indicate promising steps towards full automation of the RLMwD process, i.e. without human intervention and for arbitrary deposition paths.

Publisher
s. 82
Serie
Technical Report, ISSN 1403-266X ; R002/2009
Emneord
Laser metal wire deposition, process control, process development, optical sensors, robotic weld equipment
HSV kategori
Forskningsprogram
TEKNIK, Produktions- och materialteknik
Identifikatorer
urn:nbn:se:hv:diva-2148 (URN)
Presentation
2009-03-13, C120, Högskolan Väst, Trollhättan, 10:15 (engelsk)
Opponent
Veileder
Prosjekter
RMS
Tilgjengelig fra: 2010-03-03 Laget: 2010-01-19 Sist oppdatert: 2020-04-01bibliografisk kontrollert
2. Monitoring and Control of Robotized Laser Metal-Wire Deposition
Åpne denne publikasjonen i ny fane eller vindu >>Monitoring and Control of Robotized Laser Metal-Wire Deposition
2012 (engelsk)Doktoravhandling, med artikler (Annet vitenskapelig)
Abstract [en]

The thesis gives a number of solutions towards full automation of the promising manufacturing technology Robotized Laser Metal-wire Deposition (RLMwD). RLMwD offers great cost and weight saving potentials in the manufacturing industry. By metal deposition is here meant a layered manufacturing technique that builds fully-dense structures by melting metal wire into solidifying beads, which are deposited side by side and layer upon layer. A major challenge for this technique to be industrially implemented is to ensure process stability and repeatability. The deposition process has shown to be extremely sensitive to the wire position and orientation relative to the melt pool and the deposition direction. Careful tuning of the deposition tool and process parameters are therefore important in order to obtain a stable process and defect-free deposits. Due to its recent development, the technique is still manually controlled in industry, and hence the quality of the produced parts relies mainly on the skills of the operator. The scientific challenge is therefore to develop the wire based deposition process to a level where material integrity and good geometrical fit can be guaranteed in an automated and repeatable fashion. This thesis presents the development of a system for on-line monitoring and control of the deposition process. A complete deposition cell consisting of an industrial robot arm, a novel deposition tool, a data acquisition system, and an operator interface has been developed within the scope of this work. A system for visual feedback from the melt pool allows an operator to control the process from outside the welding room. A novel approach for automatic deposition of the process based on Iterative Learning Control is implemented. The controller has been evaluated through deposition experiments, resembling real industrial applications. The results show that the automatic controller increases the stability of the deposition process and also outperforms a manual operator. The results obtained in this work give novel solutions to the important puzzle towards full automation of the RLMwD process, and full exploitation of its potentials.

sted, utgiver, år, opplag, sider
Göteborg: Chalmers University of Technology, 2012. s. 186
Serie
Doktorsavhandlingar vid Chalmers tekniska högskola, ISSN 0346-718X ; 3336
Emneord
Laser Metal Wire Deposition, Additive Layer Manufacturing, Robotic Weld Equipment, Optical Sensors, Process Control, Process Development, Process Stability, Iterative Learning Control
HSV kategori
Forskningsprogram
TEKNIK, Produktions- och materialteknik
Identifikatorer
urn:nbn:se:hv:diva-4206 (URN)978-91-7385-655-3 (ISBN)
Disputas
2012-03-23, F123, Högskolan Väst, Trollhättan, 10:00 (engelsk)
Opponent
Tilgjengelig fra: 2012-03-26 Laget: 2012-03-14 Sist oppdatert: 2023-04-05bibliografisk kontrollert

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