Torque-based adaptive temperature control in friction stir welding: a feasibility study
Torque-based adaptive temperature control in friction stir welding: a feasibility study
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DOI：
10.1007/s11740-018-0798-z
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发表时间：
2018-01
期刊：
影响因子：
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通讯作者：
A. Bachmann;M. Roehler;S. J. Pieczona;M. Kessler;M. F. Zaeh
中科院分区：
文献类型：
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作者：
A. Bachmann;M. Roehler;S. J. Pieczona;M. Kessler;M. F. Zaeh
搅拌摩擦焊是一种新型的焊接技术。由于不超过工件的固相线温度，因此它具有独特的优势。搅拌摩擦焊通常应用于连接质量至关重要的轻质铝结构。由于焊接温度是决定焊接质量的主要因素，为保证焊接质量均匀，研制了一套焊接温度控制系统。在这项研究中，解决了两个挑战。首先介绍了一种新型的温度测量系统。为此，焊接温度和过程扭矩之间的经验关系的建议。其次，自适应控制器结合输入线性化方法，开发了基于转矩的温度控制系统。选择这种控制结构是因为它的鲁棒性和快速的自适应速度。需要足够的鲁棒性，以解决使用工业机器人进行焊接时发生的机械振动。这些振动可以被检测为扭矩信号中的振荡。所开发的控制系统已成功地集成到搅拌摩擦焊接机和可实现的控制质量以及测量方法的绝对精度进行了研究，在实验中。
Friction stir welding (FSW) is an innovative welding technology. It offers unique advantages due to the fact that the solidus temperatures of the workpieces are not exceeded. FSW is typically applied to lightweight aluminum structures where the joint quality is crucial. As the weld quality is mainly governed by the welding temperature, a temperature control system was developed to ensure homogeneous weld properties. In this study, two challenges were addressed. First, a novel temperature measuring system was introduced. For this purpose, an empirical correlation between the welding temperature and the process torque was suggested. Second, aadaptive controller combined with an input linearization method was used to develop a torque-based temperature control system. This control structure was selected due to its robustness and fast adaption rates. Sufficient robustness was required, to account for the mechanical vibrations that occur when using industrial robots for welding. These vibrations can be detected as oscillations in the torque signal. The developed control system was successfully integrated into to an FSW machine and the achievable control quality as well as the absolute accuracy of the measuring method were investigated in experiments.