Sensor-Driven Automated Weld Control

传统上，高完整性接头的焊接和检查是单独的、顺序的，通常是制造和维修中的手动过程。最终，这些限制会降低生产率、产量、进度确定性，并在焊接完成时检测到缺陷时增加返工。此外，技术劳动力的萎缩和老龄化，以及减少危险工作的愿望，沿着推动了过程自动化。目前最先进的自动化焊接系统部署了光学和触觉传感器用于过程反馈，这些传感器自然限于表面映射，而超声波检测系统仅在冷却后检查完成的完全填充的焊缝。由于焊接是一个动态的体积过程，融合深度和宽度的接缝，该奖学金旨在利用超声波的体积成像能力，并将这种检测方式直接引入焊接过程控制回路。通过研究自动化过程中超声波检测和控制，该奖学金旨在每次都提供正确的高完整性焊接，并克服当前的技术和工艺限制。Babcock在核能，国防和能源（包括碳捕集和氢气）等行业的结构部件上承担了大量复杂的高完整性熔焊。过程中的超声波焊接控制将为Babcock提供显著的减少，从目前的操作数据估计：> 55%的焊接过程时间> 50%的总焊接成本> 75%的工时这些显着的技术，商业和安全效益支持长期的研究可持续性，并使Babcock未来的合同授予和遣返。新的全球独特的“传感器启用自动化”研究小组的成立确保了英国仍然处于国际制造业创新的前沿。

Traditionally, welding and inspection of high-integrity joints are separate, sequential, often manual processes in manufacturing and repair. Ultimately, these limitations reduce productivity, throughput, schedule certainty and increase rework if defects are detected at weld completion. Furthermore, a shrinking and ageing skilled workforce, along with a desire to reduce hazardous working, drives process automation. Current state-of-the-art automated welding systems deploy optical and tactile sensors for process feedback, which are naturally limited to surface mapping, while ultrasonic inspection systems only examine completed fully-filled welds once cooled. As welding is a dynamic volumetric process, fusing joints of depth and width, this fellowship seeks to exploit the volumetric imaging capability of ultrasonics, and introduce this inspection modality directly into the welding process control loop. By investigating automated in-process ultrasonic inspection and control, this fellowship aims to deliver high-integrity welds right, first time, every time and overcome current technical and process limitations.Babcock undertake large numbers of complex high-integrity fusion welds on structural components in sectors such as Nuclear, Defence and Energy including Carbon Capture and Hydrogen. In-process ultrasonic-enabled welding control will offer Babcock significant reductions, estimated from current operational data of:> 55% in weld process time> 50% in overall weld cost> 75% in man hoursThese significant technical, commercial and safety benefits underpin long-term research sustainability and empower Babcock for future contract awards and repatriation. The establishment of a new globally-unique "Sensor Enabled Automation" research group ensures the UK remains at the forefront of international manufacturing innovation.