GOALI: Enabling Friction Stir Welding in Unstructured Environments Through Process Identification and Shared Control

目标：通过过程识别和共享控制在非结构化环境中实现搅拌摩擦焊接

• 批准号: 0824879
• 负责人: Frank Pfefferkorn
• 金额: $ 30万
• 依托单位: University of Wisconsin-Madison
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2008
• 资助国家: 美国
• 起止时间: 2008-07-15 至 2012-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0824879&HistoricalAwards=false
• 关键词: GOALI; Enabling; Friction; Stir; Welding

The objective of this project is to determine how well a skilled human operator can share in the control of a robotic friction stir weld system. Friction stir welding has been called the most significant advance in joining technology in the last 20 years. It offers advantages in weld quality, consistency, energy consumption, and cost over traditional joining methods, yet its introduction has been hampered by a need for significant up-front effort in developing part-specific programs for machine control. To justify these up-front investments, production volumes must be sufficient to amortize the investment at a reasonable cost per part, precluding use of friction stir welding in low-volume and repair applications. In addition, large process uncertainties such as weld path deviation and widely varying gap conditions between plates arise in many manufacturing applications but cannot be addressed using traditional control techniques. Finally, the large forces required during friction stir welding prevent it from becoming a manual process. To realize the benefits of friction stir welding for low-volume and repair applications, it is our belief, that a tele-operated robotic system, employing shared human-computer control, offers the best chance to overcome the limitations. To accomplish this and evaluate its effectiveness, we have devised a three phase research approach. Phase1 will seek to understand how specific friction stir welding process parameters, such as feed rate, travel angle, and working angle, affect the quality of a friction stir weld. Phase 2 will determine the optimal method of controlling these parameters ? through direct computer control or through a shared-human control approach. In Phase 3, we will evaluate the performance of the shared-control architecture in a lab and production environment where large aluminum assemblies are fabricated. The benefits to society include the development of an enabling technology for on-site friction stir welding - giving this emerging solid-state welding process the same flexibility that current fusion processes enjoy. In addition, societal benefits arise from the application of shared control to a variety of manufacturing processes used in repair, one-off, and low-volume production. Further societal impact will result from integrating techniques and results into the engineering curriculum and training students in this interdisciplinary research. Close industrial collaboration will enhance technology transfer and the opportunity for students to receive diverse research experience, and to successfully make connections from basic science to important technological needs.

该项目的目标是确定熟练的人类操作员在机器人搅拌摩擦焊接系统的控制中的分担能力。 搅拌摩擦焊被认为是近20年来连接技术中最重要的进步。 与传统的连接方法相比，它在焊接质量、一致性、能耗和成本方面具有优势，但它的引入受到了在开发机器控制的特定零件程序方面需要大量前期工作的阻碍。 为了证明这些前期投资的合理性，生产量必须足以以合理的每部件成本摊销投资，排除在小批量和维修应用中使用摩擦搅拌焊接。 此外，大的过程不确定性，如焊接路径偏差和板之间的广泛变化的间隙条件出现在许多制造应用中，但不能使用传统的控制技术来解决。 最后，摩擦搅拌焊接过程中所需的大的力防止其成为手动过程。 为了实现小批量和修复应用的摩擦搅拌焊接的好处，我们相信，采用共享人机控制的远程操作机器人系统提供了克服限制的最佳机会。 为了实现这一目标并评估其有效性，我们设计了一个三阶段的研究方法。 第一阶段将试图了解特定的搅拌摩擦焊接工艺参数，如进给速度，行进角度和工作角度，如何影响搅拌摩擦焊接的质量。 第二阶段将确定控制这些参数的最佳方法？通过直接的计算机控制或通过共享的人类控制方法。 在第3阶段，我们将在制造大型铝组件的实验室和生产环境中评估共享控制架构的性能。 对社会的好处包括开发了一种用于现场搅拌摩擦焊的技术-使这种新兴的固态焊接工艺具有与当前熔合工艺相同的灵活性。 此外，社会效益来自于对维修、一次性和小批量生产中使用的各种制造过程应用共享控制。 将技术和成果整合到工程课程中并在这一跨学科研究中培养学生，将产生进一步的社会影响。 密切的工业合作将促进技术转让，并为学生提供获得多样化研究经验的机会，并成功地将基础科学与重要的技术需求联系起来。