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Modeling and simulation for welding automation
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0001-5734-294X
2010 (English)Doctoral thesis, comprehensive summary (Other academic)
Place, publisher, year, edition, pages
Göteborg: Chalmers , 2010. , p. 158
Series
Doktorsavhandlingar vid Chalmers tekniska högskola, ISSN 0346-718X ; 3132
Keywords [en]
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: urn:nbn:se:hv:diva-2870ISBN: 978-91-7385-451-1 (print)OAI: oai:DiVA.org:hv-2870DiVA, id: diva2:372836
Available from: 2010-12-03 Created: 2010-11-29 Last updated: 2016-02-09Bibliographically approved
List of papers
1. Sampled-data Hcontrol applied to the choice of controller order and sampling rate
Open this publication in new window or tab >>Sampled-data Hcontrol applied to the choice of controller order and sampling rate
2010 (English)Manuscript (preprint) (Other academic)
National Category
Other Engineering and Technologies not elsewhere specified
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2865 (URN)
Available from: 2010-11-26 Created: 2010-11-26 Last updated: 2016-02-09Bibliographically approved
2. Role of fixture forces on distortion in gas tungsten arc welding: An experimental and modelling approach
Open this publication in new window or tab >>Role of fixture forces on distortion in gas tungsten arc welding: An experimental and modelling approach
2011 (English)In: Proceedings of the Institution of mechanical engineers. Part B, journal of engineering manufacture, ISSN 0954-4054, E-ISSN 2041-2975, Vol. 225, no 1, p. 140-148Article in journal (Refereed) Published
Abstract [en]

Simulation and experiments show that the fixture clamping force has a significant influence on the structural integrity of a welded workpiece. This understanding is of great importance for the manufacture of aerospace components with tight tolerances in the specifications. The focus in the present study is on the temperature history during welding and residual deformation; its main contribution is a demonstrator designed for evaluation of the influence of fixture clamping forces and validation of the simulation results. The demonstrator concerns a simplified situation considering gas tungsten arc welding of a nickel-based metal plate fixed by a specially designed fixture, where one side of the plate was clamped with different levels of force. The temperature history was measured during the weld sequence and deformation measurements were performed after cooling and release of the workpiece from the fixture. The results from simulation and experimentation showed good agreement. The proposed strategy is industrially competitive and has shown that the looser the fixture clamps, the smaller the residual deformation. Furthermore, the study provides a knowledge base for selection of active fixture concepts in that the fixture clamping force can be determined in advance and possibly also be subject to force control.

Place, publisher, year, edition, pages
Sage Publications, 2011
Keywords
Finite element analysis; Fixture clamping force; Gas tungsten arc welding; Nickel-based steel; Residual deformation. Aerospace components; Clamping Force; Deformation measurements; Gas tungsten arc welding; Knowledge base; Metal plates; Nickel-based steel; Residual deformation; Simulation result; Temperature history; Tight tolerances; Work pieces
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2861 (URN)10.1177/09544054JEM2048 (DOI)
Available from: 2010-11-26 Created: 2010-11-26 Last updated: 2017-12-12Bibliographically approved
3. Modeling and simulation aspects of feedback control in gas tungsten arc welding: An experimental study
Open this publication in new window or tab >>Modeling and simulation aspects of feedback control in gas tungsten arc welding: An experimental study
2010 (English)Manuscript (preprint) (Other academic)
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2863 (URN)
Available from: 2010-11-26 Created: 2010-11-26 Last updated: 2016-02-09Bibliographically approved
4. Model order reduction methods applied to a welding model
Open this publication in new window or tab >>Model order reduction methods applied to a welding model
2012 (English)In: Proceedings of the Institution of mechanical engineers. Part I, journal of systems and control engineering, ISSN 0959-6518, E-ISSN 2041-3041, Vol. 226, no 7, p. 972-984Article in journal (Refereed) Published
Abstract [en]

A  finite element representation modelling transient heat conduction of gas tungsten arc welding of stainless steel is used to evaluate different methods for model order reduction. The focus is on establishing a linear low-order model of the dynamic  relation between the welding current and the temperature measured by a radiation pyrometer. The objective of this low-order model is to design a model-based feedback controller and to investigate the consequences of applying feedback control of the process. Three different approaches for model reduction have been evaluated, namely the Krylov subspace method for moment    matching, balanced truncation and parametric system identification. The study provides a knowledge base for the selection of model order reduction methods when dealing with large-scale systems like finite element models of transient heat conduction, and it recommends parametric system identification. It renders sufficient approximations for controller design, no linearization of the finite element model is required, and there is no limit on degrees of freedom of the finite element model.

Place, publisher, year, edition, pages
Sage Publications, 2012
Keywords
balanced truncation; Finite element modelling; model order reduction; moment matching; parametric system identification; welding.
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2864 (URN)10.1177/0959651812440910 (DOI)000309208800011 ()2-s2.0-84870437443 (Scopus ID)
Available from: 2010-11-26 Created: 2010-11-26 Last updated: 2017-12-12Bibliographically approved
5. 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
6. 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

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