Sensor-Driven Automated Weld Control

传统上，在制造和维修过程中，高完整性接头的焊接和检查是分开的、连续的、通常是手动的过程。最终，如果在焊接完成时检测到缺陷，这些限制会降低生产率、吞吐量、进度确定性并增加返工。此外，不断萎缩和老龄化的熟练劳动力，以及减少危险工作的愿望，推动了流程自动化。目前最先进的自动化焊接系统部署了用于过程反馈的光学和触觉传感器，这自然仅限于表面映射，而超声波检测系统只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，融合了深度和宽度的接头，该协会致力于开发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。通过研究自动化的在线超声波检测和控制，该协会的目标是每次都能正确地提供高完整性焊接，并克服当前的技术和工艺限制。Babcock在核能、国防和能源等部门的结构部件上承担大量复杂的高完整性融合焊接，包括碳捕获和氢气。过程中的超声波焊接控制将为Babcock提供显著的减少，从当前的运营数据估计：焊接过程时间&gt；55%&gt；50%，焊接总成本&gt；75%，工时。这些显著的技术、商业和安全效益为长期研究的可持续性奠定了基础，并使Babcock能够在未来的合同授予和遣返中使用。一个新的全球独一无二的“传感器使能自动化”研究小组的成立，确保了英国保持在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.