Change search
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf
Simulation-based feedback control of welding processes
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0001-5734-294X
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. , p. 109
Series
Technical report / Department of Signals and Systems, Automation Research Group, Chalmers University of Technology, ISSN 1403-266X ; 2008:013
Keywords [en]
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: urn:nbn:se:hv:diva-2409OAI: oai:DiVA.org:hv-2409DiVA, id: diva2:315390
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
List of papers
1. Simulation for Design of Automated Welding
Open this publication in new window or tab >>Simulation for Design of Automated Welding
2007 (English)In: EUROCON, 2007. The International Conference on "Computer as a Tool": Warsaw, Poland, 2007, IEEE Explore , 2007, p. 2263-2270Conference 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
Keywords
Welding, simulation, control engineering
National Category
Materials Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-204 (URN)10.1109/EURCON.2007.4400404 (DOI)1-4244-0813-X (ISBN)978-1-4244-0813-9 (ISBN)
Conference
EUROCON 2007
Available from: 2009-04-23 Created: 2009-04-23 Last updated: 2014-05-09Bibliographically approved
2. Integration of finite element analysis and computer aided robotics for advanced programming of robotized welding
Open this publication in new window or tab >>Integration of finite element analysis and computer aided robotics for advanced programming of robotized welding
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, p. 454-460Conference 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
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Mechatronics
Identifiers
urn:nbn:se:hv:diva-2232 (URN)978-1-61503-002-6 (ISBN)
Conference
1-6 june 2008, Pine Mountain, Georgia
Available from: 2010-02-22 Created: 2010-02-22 Last updated: 2016-02-09Bibliographically approved
3. Tools for simulation based fixture design to reduce deformation in advanced fusion welding
Open this publication in new window or tab >>Tools for simulation based fixture design to reduce deformation in advanced fusion welding
2008 (English)In: Intelligent Robotics and ApplicationsLecture Notes in Computer Science Volume 5315,  2008: First International Conference, ICIRA 2008 Wuhan, China, October 15-17, 2008 Proceedings, Part II / [ed] Youlun Xioun, Springer, 2008, Vol. 5315 LNAI, no PART 2, p. 398-407Conference paper, Oral presentation only (Refereed)
Abstract [en]

The traditional fusion welding and fixture simulations are performed using advanced finite element simulation tools, commonly used are e.g. MSC.Marc, ANSYS, ABACUS and COMSOL Multiphysics. These simulations are made one at a time and separately due to heavy calculation load for each case. Such an approach does not give a full description of the integrated work piece and fixture behaviour. We propose a strategy to decrease the computational time and solve the problem accurately enough for industrial needs. Focus of the simulation result is on residual deformation. The work piece is a simplified component composed by metal sheets, and rigid and loose clamping was investigated. Simulation results give the size of forces and deformations in the clamped edge. Deformation measurements are performed using 3D-scanning of the work piece after cooling and released from fixture, same situation as in the FE-simulations. The proposed strategy has shown to be useful and is industrially competitive due to reduced engineering manpower, computation time, and need for practical experiments. The strategy is to use full off-line programming where computer aided robotics for weld sequencies is integrated with finite element modelling in order to obtain weld parameters and fixture design.

Place, publisher, year, edition, pages
Springer, 2008
Series
Lecture Notes in Computer Science, ISSN 0302-9743 ; 5315
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-1514 (URN)10.1007/978-3-540-88518-4_43 (DOI)
Conference
1st International Conference on Intelligent Robotics and Applications, ICIRA 2008; Wuhan; China; 15 October 2008 through 17 October 2008
Available from: 2009-05-11 Created: 2009-05-11 Last updated: 2016-02-11Bibliographically approved
4. 3D-Scanning for Weld Distortion Measuring
Open this publication in new window or tab >>3D-Scanning for Weld Distortion Measuring
2006 (English)In: Instrumentation and Measurement Technology Conference, 2006. IMTC 2006. Proceedings of the IEEE, IEEE conference proceedings, 2006, p. 2132-2137Conference paper, Published paper (Refereed)
Abstract [en]

Optical three dimensional scanning for weld distortion measurements have been performed for validation, inspection, general visualization and documentation of a robotized welding process. The planning, preparing and processing of the weld is done in a simulation-based concept where computer aided robotics software simulations are integrated with finite element analysis simulations with the objective to reduce global geometrical deformation during welding. The off-line programmed robot paths were used as an input for finite element calculations of temperature fields and distortion in the work piece. In order to validate the finite element model 3D-scannings have been performed before and after every single welding sequence. This paper describes a validation experiment with non-contact measurements of weld distortion and discusses limitations in optical 3D-scanning techniques used for this purpose

Place, publisher, year, edition, pages
IEEE conference proceedings, 2006
Series
Conference proceedings - IEEE Instrumentation/Measurement Technology Conference, ISSN 1091-5281
Keywords
computer aided manufacturing, deformation, finite element analysis, mechanical variables measurement, optical scanners, robotic welding, welds, computer aided robotics software simulations, finite element analysis simulations, global geometrical deformation reduction, offline programmed robot paths, optical 3D scanning, robotized welding, temperature fields, weld distortion measurement, 3D-scanning, distortion, model validation, robotics, welding
National Category
Electrical Engineering, Electronic Engineering, Information Engineering Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Mechatronics; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-1795 (URN)10.1109/IMTC.2006.328524 (DOI)0-7803-9360-0 (ISBN)0-7803-9359-7 (ISBN)
Conference
2006 IEEE Instrumentation and Measurement Technology Conference
Available from: 2009-10-07 Created: 2009-10-06 Last updated: 2015-03-17Bibliographically approved

Open Access in DiVA

No full text in DiVA

Authority records BETA

Sikström, Fredrik

Search in DiVA

By author/editor
Sikström, Fredrik
By organisation
Division of Electrical and Automation Engineering
Control Engineering

Search outside of DiVA

GoogleGoogle Scholar

urn-nbn

Altmetric score

urn-nbn
Total: 345 hits
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf