RCAM Presentationx

bijoufriesΤεχνίτη Νοημοσύνη και Ρομποτική

19 Οκτ 2013 (πριν από 3 χρόνια και 7 μήνες)

77 εμφανίσεις

1

Automated
Submerged Arc
Welding

Note: movies will can only be viewed in full presentation mode with an Internet connection.


By eliminating or minimizing


Lack of Fusion


Lack of Penetration


Undercuts


Slag Entrapment


Porosity


Repair or Re
-
Weld Cost


By improving


Seam Shape


Surface Finish


Weld Strength and Toughness


Bead Placement


http://met
-
tech.com/images/crane
-
failure
-
15.jpg

Objective is to achieve high
-
quality welds

This could be achieved by:



seam tracking



adaptive fill control




CMOS GigE with high resolution, high frame rate up to 200 fps


Directed streaming of image signal into network card ( no need for
dedicated frame grabber)


The distance to transfer data up to 100 m or 333 ft, especially


of importance in the case of welding large structures such as


wind turbine.


PC
-
based controller of a 3
-
axis positioning system (no need for a
proprietary integrated circuit board.


Software based on LabView


Characteristics of the developed laser
-
based

machine Vision System

4

Motion
Control
System

Automated Seam Tracking for Submerged
Arc Welding

Desired position
of

tracking point

Workpieces

with groove

Laser
Machine

Vision
System

Shape of groove

Width of groove

Depth of groove

Area of groove

Stand
-
off distance

Actual
position

of tracking point

Mismatch

5

Automated Fill Control for Submerged
Arc Welding

Weld Model

Arc Voltage

Current / WFS

SAW Machine

Geometry of
groove/bead

Travel Speed

Shape of groove/bead

Width of groove/bead

Depth of groove/bead

Area of groove/bead

Stand
-
off distance

Temperature
distribution



Laser

Machine
Vision System


Developed Laser
-
based Machine Vision System

at the Research Center for Advanced Manufacturing

(a)
Schematic presentation of

laser

machine vision system


(b)

Photo of

laser

machine vision
system installed at the 3
-
axis PC
-
based controlled positioning system

Control panel of the developed laser machine vision system

workpiece profile

3D profile

tracking error

w
idth : 25.4 mm

d
epth : 15.9 mm

Application of Laser Machine Vision System

as Measuring Instrument

(a) coupon

as measurement target
(b)

configuration of measurement process

(c) Movie
s recorded during

measurement process


Note: movies will can only be viewed in full presentation mode.


Results of Measurement

Seam Tracking Control

(a)

top and side view of the setup for seam tracking
both along X and Z direction

(b)

Flowchar
t of the close
-
loop controller for seam tracking along two axes

Movies of Laser Machine Vision System for Seam Tracking Control

(a)

when seam tracking is not activated (
click images to play
)

(b)
when seam tracking is
activated (
click images to play
)

The Results for Seam Tracking Control

(a) position error

of tracking point when seam tracking is not activated

(b) position error

of tracking point when seam tracking is activated

Laser Machine Vision System for Post
-
Weld Inspection

(a) coupon

for

post weld inspection
(b)

configuration of inspection system

(c) movie
s showing

inspection process (
click images to play
)

Note: movies will can only be viewed in full presentation mode.

Results of Post
-
Weld Inspection

(a) coupon

as post inspection target
(b)

3D
-
view of the profile of the coupon

(c)

top
-
view of the profile of the coupon (d) side
-
view of the profile of the coupon


A
1

A
2

A

A=A
1
+A
2

A
×

v
w

=
v
f

×

π
×
d
2
/4

A
-
cross
-
sectional area of the weld

d
-

diameter of filler wire

V
w
-
welding speed

V
f
-
wire feed rate

Width of weld

Weld

Height of clad

Weld cross
-
section calculation for adaptive fill control

Simulation of Adaptive Fill Control

scan “A”

scan “A”

Level of

current for

scan “A”

Modeled heat transfer in the

molten pool for scan “A”

Off
-
line Simulation of Heat Transfer in SAW Based On FEM

Simple Straight Butt Weld

Case Analysis 1

Circumferential Weld

Case Analysis 2

Case Analysis 2

(
click to play the movie above
)

Note: Movies can only be viewed in full presentation mode