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Integration of finite element analysis and computer aided robotics for advanced programming of robotized welding
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0001-5734-294X
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0002-4329-418X
2009 (English)In: ASM Proceedings of the International Conference: Trends in Welding Research / [ed] S.A. David, T. DebRoy, J.N. DuPont, T. Koseki, and H.B. Smartt, ASM International, 2009, 454-460 p.Conference paper, Published paper (Refereed)
Abstract [en]

This paper describes a promising approach where finite element analysis is combined with computer aided robotics in off-line programming of advanced robotized welding. Finite element analysis is used to find an optimized weld power signal based on weld trajectories obtained from computer aided robotic simulations. The weld power signal is calculated by applying feedback control in the finite element simulation. This optimization ensures a full penetration weld while the total specific thermal energy input is minimized in order to mitigate unwanted residual stress and distortion. The objective with this approach is to support the design of robotized welding and significantly reduce the number of costly trials in physical implementations. The relevance of this paper is a useful method for off-line optimization of robot trajectories and varying process parameters.

Place, publisher, year, edition, pages
ASM International, 2009. 454-460 p.
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Mechatronics
Identifiers
URN: urn:nbn:se:hv:diva-2232ISBN: 978-1-61503-002-6 (print)OAI: oai:DiVA.org:hv-2232DiVA: diva2:298994
Conference
1-6 june 2008, Pine Mountain, Georgia
Available from: 2010-02-22 Created: 2010-02-22 Last updated: 2016-02-09Bibliographically 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
2. Modeling and simulation for welding automation
Open this publication in new window or tab >>Modeling and simulation for welding automation
2010 (English)Doctoral thesis, comprehensive summary (Other academic)
Place, publisher, year, edition, pages
Göteborg: Chalmers, 2010. 158 p.
Series
Doktorsavhandlingar vid Chalmers tekniska högskola, ISSN 0346-718X ; 3132
Keyword
welding automation, fixturing, finite element modeling, heat conduction, model order reduction, sensors, welding simulation, controller design
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2870 (URN)978-91-7385-451-1 (ISBN)
Available from: 2010-12-03 Created: 2010-11-29 Last updated: 2016-02-09Bibliographically approved

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