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Simulation for Design of Automated Welding
University West, Department of Technology, Mathematics and Computer Science, Division for Electrical Engineering and Land Surveying.ORCID iD: 0000-0001-5734-294X
University West, Department of Technology, Mathematics and Computer Science, Division for Electrical Engineering and Land Surveying.ORCID iD: 0000-0001-5608-8636
Chalmers University of Technology, Department of Signals and Systems.
2007 (English)In: EUROCON, 2007. The International Conference on "Computer as a Tool": Warsaw, Poland, 2007, IEEE Explore , 2007, 2263-2270 p.Conference paper, Published paper (Refereed)
Abstract [en]

This paper describes a promising approach where simulations were used in the design of real-time control for automated welding. A finite element method has been used for thermal modelling of gas tungsten arc welding on a simplified test object. Measurement data for model calibration and validation was acquired through thermal imaging during weld experiments on test objects of the alloy Fe-316. An optimisation scheme for inverse modelling was employed in the calibration of the distributed weld process model. Frequency weighted model reduction and parametric system identification were applied and evaluated to get a low order model of the single-input single-output dynamics between a simulated weld heat source (actuator) and a sensor. This low order model was then successfully used for controller design where the control signal was weld current and the measured output was a moving spot temperature. Finally, the closed-loop performance was evaluated by simulation of the weld process model showing improved temperature stability relative to open loop.

Place, publisher, year, edition, pages
IEEE Explore , 2007. 2263-2270 p.
Keyword [en]
Welding, simulation, control engineering
National Category
Materials Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-204DOI: 10.1109/EURCON.2007.4400404ISBN: 1-4244-0813-X (print)ISBN: 978-1-4244-0813-9 (print)OAI: oai:DiVA.org:hv-204DiVA: diva2:212672
Conference
EUROCON 2007
Available from: 2009-04-23 Created: 2009-04-23 Last updated: 2014-05-09Bibliographically approved
In thesis
1. Simulation-based feedback control of welding processes
Open this publication in new window or tab >>Simulation-based feedback control of welding processes
2008 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Fusion welding for joining of metals is an important manufacturing process widely used in industry, and very appreciated for its usefulness. This thesis presents a strategy dealing with the problem of designing feedback control for robotised welding. The idea is to use off-line programming where computer aided robotics for weld sequences is integrated with finite element modelling for simulations and analyses of weld processes. By this approach the design, evaluations, trials and visualisation can be made “off-line”, beside or prior to continuous production. The focus is to reduce the amount of manpower and need for physical experiments. Focuses on the results are to ensure a high quality weld with limited residual stress and deformation. Different models for two types of austenitic steels and two types of weld sources has been calibrated and validated to form a basis for this strategy. Suggestions for systematic model calibration methods have been proposed including global and local optimisation methods. Experimental work has been performed to support and verify the simulation results and the usefulness of the method. The simulation based strategy has been evaluated and proven to work successfully in two different types of applications. The method is not independent of physical experiments since it is based on models that have to be calibrated, but the experiments needed are assumed to be carried out in a simple and cost efficient way. The thesis suggests how these experiments can be performed. The use of all these technologies is assumed to form an efficient tool for the welding engineer in order to obtain high weld quality in robotised welding. The research presented indicates that the methods work well in real situations and that further work for more robust industrialisation will be beneficial for the welding community.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology, 2008. 109 p.
Series
Technical report / Department of Signals and Systems, Automation Research Group, Chalmers University of Technology, ISSN 1403-266X ; 2008:013
Keyword
Finite element modelling, Heat transfer, Model order reduction, Sensors, Weld simulation Controller design
National Category
Control Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2409 (URN)
Presentation
2008-10-03, C120, Gustava Melins gata 2, Trollhättan, 10:15 (English)
Opponent
Supervisors
Available from: 2010-04-29 Created: 2010-04-29 Last updated: 2016-02-09Bibliographically approved

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