Adaptive Control of Back Bead and Bead Height under Gap Variation in Narrow Gap Robotic Welding

窄间隙机器人焊接间隙变化下后焊道和焊道高度的自适应控制

• 批准号: 15560621
• 负责人: KANEKO Yasuyoshi
• 金额: $ 2.24万
• 依托单位: Saitama University
• 依托单位国家: 日本
• 项目类别: Grant-in-Aid for Scientific Research (C)
• 财政年份: 2003
• 资助国家: 日本
• 起止时间: 2003 至 2004
• 项目状态: 已结题
• 来源: https://kaken.nii.ac.jp/en/grant/KAKENHI-PROJECT-15560621/
• 关键词: Switch back welding; Narrow gap welding; Welding condition control; CCD Camera; Back bead control; Feedforward control; Welding robot; Power source characteristic

If the amount of the deposited metal becomes big in the narrow gap, the bead height becomes high. In this case, the arc heat is given on the weld pool and is not given to the root edge. Lack of fusion takes place and cause the problem concerning the mechanical strength. Therefore, in general, the amount of the deposited metal is determined so that the bead height is less than 4mm. It takes more than three times of the torch traveling from the beginning to the end of the welding line, when the thickness of the metal plates is over 12mm. Moreover, the arc behavior depends on the welding power source characteristic ; the electrode wire feed rate and the welding torch motion. The short arc length is necessary to get a high quality of the welding.In order to control the bead height and the back bead, authors propose a cooperative control method of the welding equipments including the power source, the electrode wire feeder and the welding robot by using the computer network.Authors try to n … More ot only oscillate the welding torch on the groove at 10 Hz, but also move along the weaving centre back and forth like switch back, i.e., authors propose the switch back welding method.First, the authors move the weaving centre forward, to pre-heat the root edges of the base metal by the arc. The stable back bead is formed without the lack of fusion. The mentioned welding process is called forward process. Next, the authors move weaving centre backward to deposit droplets to the root edges and to the groove surface, so that the desired bead height is obtained. This is called backward process. If the arc length becomes long, it is difficult to give the heat to the root edge and a lack of fusion in the joint part takes place. In order to observe the weld pool, it is useful to use a CCD camera. But, it is difficult to apply the observation method of the weld pool, which is proposed for thin plate welding, i.e., it is important that the shutter of the CCD camera is synchronized with torch oscillating. In this paper, the shutter of the CCD camera is opened when the torch passes on the centre of the weaving. In the switch back welding, there are many parameters of welding conditions, such as traveling speed of the torch, the current, the wire feed rate and so on. To find the optimum parameters of the welding conditions, the numerical model of the weld pool is described by using an equation of heat conduction. It takes long time to solve the numerical model by applying the finite difference in a numerical analysis. In stead of the numerical model, the fuzzy model of the weld pool is proposed to save the calculation time. Its model is adjusted by using the numerical results. The optimum stroke length is estimated from 4 to 6mm gap. In order to verify the validity of the fuzzy model and the proposed welding method, the experiment is carried out under the variation of the gap. A good result of the welding can be obtained, i.e., the smooth surface bead and wide back bead are obtained. Less

如果在窄间隙中熔敷金属的量变大，则焊缝高度变高。在这种情况下，弧热提供给焊接熔池，而不是提供给根部边缘。熔合不足会导致机械强度方面的问题。因此，一般而言，熔敷金属的量被确定为使焊珠高度小于4 mm。当金属板厚度超过12 mm时，焊枪从焊接线的起点到终点需要三次以上的时间。此外，电弧行为取决于焊接电源特性、电极送丝速度和焊枪运动。为了获得高质量的焊接质量，需要较短的弧长。为了控制焊缝高度和背面焊缝，作者提出了一种利用计算机网络对焊接设备进行协调控制的方法，包括电源、送丝机和焊接机器人。作者尝试将…另外，焊枪不仅在坡口上以10赫兹的频率摆动，而且像开关一样沿编织中心来回移动，即提出了开关回焊的方法，首先将编织中心前移，通过电弧预热母材的根边。形成了稳定的背珠，没有熔合的缺陷。上述焊接工艺称为正向焊接工艺。其次，作者将织造中心向后移动，将液滴沉积到根部边缘和沟槽表面，从而获得所需的珠子高度。这被称为反向过程。如果弧长变长，则很难将热量传递到根部边缘，从而导致接头部分缺乏熔融。为了观察熔池，使用一台CCD摄像机是很有用的。但是，传统的薄板焊接熔池观测方法很难应用，即摄像机的快门必须与焊枪的摆动同步。在本文中，当火炬通过织造中心时，打开了CCD摄像机的快门。在开关反焊中，焊枪的行进速度、电流、送丝速度等焊接条件参数很多。为了找出最佳的焊接工艺参数，用热传导方程描述了熔池的数值模型。在数值分析中应用有限差分法求解数值模型需要较长的时间。为了节省计算时间，提出了熔池模糊模型来代替数值模型。利用数值计算结果对其模型进行了修正。最佳冲程长度为4~6 mm。为了验证模糊模型和所提出的焊接方法的有效性，在间隙变化的情况下进行了焊接实验。焊接效果良好，获得了表面光滑、背面宽大的焊缝。较少

项目成果

Control of Back Bead by Visual Robot in V-groove Welding without Backing Plate

无垫板V型坡口焊接中视觉机器人背焊道控制

• 发表时间: 2004
• 期刊: Proc.of IIW Commission XII
• 作者: Satoshi Yamane;山根 敏;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;金子 裕良;山根 敏;Yasuyoshi Kaneko;Satoshi Yamane;Satoshi Yamane
• 通讯作者: Satoshi Yamane

Effect of Power Source Characteristic on CO_2 Short Circuiting Arc Welding

电源特性对CO_2短路电弧焊的影响

• 发表时间: 2005
• 期刊: Science and Technology of Welding and Joining 10,3
• 作者: Satoshi Yamane;山根 敏;Satoshi Yamane
• 通讯作者: Satoshi Yamane

Neural network model and feed forward of weld pool in pulsed MIG welding.

脉冲 MIG 焊接熔池的神经网络模型和前馈。

• 发表时间: 2004
• 期刊: Preprints of national meeting of J.W.S No.74
• 作者: Satoshi Yamane;山根 敏;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;金子 裕良;山根 敏;Yasuyoshi Kaneko
• 通讯作者: Yasuyoshi Kaneko

複数ロボット環境下における溶接作業の最適化

多机器人环境中焊接工作的优化

• 发表时间: 2004
• 期刊: 溶接学会全国大会講演概要集 75集
• 作者: Satoshi Yamane;山根 敏;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;金子 裕良;山根 敏;Yasuyoshi Kaneko;Satoshi Yamane;Satoshi Yamane;金子 裕良
• 通讯作者: 金子 裕良

パルスMIG溶融池のニューラルネットワークモデルとフィードフォワード制御

脉冲MIG熔池神经网络模型及前馈控制

• 发表时间: 2004
• 期刊: 溶接学会全国大会講演概要集 74集
• 作者: Satoshi Yamane;山根 敏;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;Satoshi Yamane;金子 裕良
• 通讯作者: 金子 裕良