A new kind of control system for keyhole plasma arc welding （K-PAW） was developed based on the computer and the Graphics Language--LabVIEW. It can set and output the required current waveforms with desired decreasin...A new kind of control system for keyhole plasma arc welding （K-PAW） was developed based on the computer and the Graphics Language--LabVIEW. It can set and output the required current waveforms with desired decreasing slopes so that the corresponding ＂opening and closing＂ of keyhole can occur periodically. With this control strategy of welding current waveforms, the workpiece is fully penetrated while no burn-through Occurs. Keyhole plasma arc welding experiments were conducted to verify the stability and reliability of the developed system.展开更多
The controlled pulse waveform is newly applied in keyhole plasma arc welding process. Two additional descending slopes can guarantee stable and smooth transition of keyhole closing and opening periodically. To develop...The controlled pulse waveform is newly applied in keyhole plasma arc welding process. Two additional descending slopes can guarantee stable and smooth transition of keyhole closing and opening periodically. To develop a closed-loop control system for this special welding process, the key point is the determination of system input and output variables. The averaged efflux plasma voltage during a pulse cycle is defined as the characteristic variable reflecting the real keyhole dimension. Research and experiments are conducted to explore the relationship between the characteristic variable and weld pe^Cormance. Results show that alternated peak current can significantly change the keyhole dimension and the penetration. It is proposed that the keyhole average dimension is taken as the controlled variable, and the peak pulse current value and slopes are taken as control variables.展开更多
The development of closed-loop control systems is one of the most effective ways to improve the stability of the keyhole status during keyhole plasma arc welding （K-PAW）. Due to the disadvantages of the ＂one-pulse-...The development of closed-loop control systems is one of the most effective ways to improve the stability of the keyhole status during keyhole plasma arc welding （K-PAW）. Due to the disadvantages of the ＂one-pulse-one-keyhole＂ technology based on the conventional square current waveform, the controlled pulse welding current waveform is newly applied to control the keyhole open and close periodically. In order to realize the real-time control on the keyhole behavior with this advanced current waveform, welding experiments and system identification are conducted based on the classical control theory. One complete welding cycle can be divided into 3 periods. The keyhole establishing time is the most important time variable, which determines the keyhole behavior and welding process stability. At the same time, the averaged effiux plasma arc voltage during one pulse cycle can reflect the real keyhole dimension and status in a real-time manner. Therefore, two single-input-single-output （SISO） systems are proposed, in which keyhole establishing time and keyhole average dimension are taken as the system controlled variables respectively. Welding experiments are designed with the peak current varying randomly. Experiments show that the keyhole establishing time changes in an opposite direction to the varied peak current, and the averaged efflux plasma arc voltage varies with the same trend as the peak current. Based on the least squares technique and F test of classical system identification, second order difference equation for keyhole establishing time/peak current system and first order difference equation for keyhole average dimension/peak current system are obtained. It is proved that the calculated data by the two mathematical expressions are well matched with the measured data. The proposed research provides mathematical expressions and theoretical analysis to develop closed-loop systems for the controlled pulse K-PAW.展开更多
A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V al...A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V alloy sheets.The microstructures,facture surfaces and microhardness of the welded joints were characterized by using optical microscope,scanning electron microscope （SEM） and Vickers microhardness tester.Comparing with welds such as gas tungsten arc and conventional plasma arc processes,the experimental results revealed the improvements when using the present process including：1） reducing prior-beta （β） grain size and prohibiting formation of hard martensite phases in the fusion zone due to the decreased heat input;and 2） better toughness and higher hardness.展开更多
Methods of arc length control and visual image based weld detection for precision pulse TIG welding were investigated. With a particular all hardware circuit, arc voltage during peak current stage is sampled and inte...Methods of arc length control and visual image based weld detection for precision pulse TIG welding were investigated. With a particular all hardware circuit, arc voltage during peak current stage is sampled and integrated to indicate arc length, deviation of arc length and adjusting parameters are calculated and output to drive a step motor directly. According to the features of welding image grabbed with CCD camera, a special algorithm was developed to detect the central line of weld fast and accurately. Then an application system were established, whose static arc length error is ±0.1 mm with 20 A average current and 1 mm given arc length, static detection precision of weld is 0.01 mm , processing time of each image is less than 120 ms . Precision pulse TIG welding of some given thin stainless steel components with complicated curved surface was successfully realized.展开更多
A novel synergetic arc control method was used to control twin-electrode alternating current （ AC） to direct current （DC） pulsed arc welding and the mechanism of poor sidewall fusion in narrow gap welding was inve...A novel synergetic arc control method was used to control twin-electrode alternating current （ AC） to direct current （DC） pulsed arc welding and the mechanism of poor sidewall fusion in narrow gap welding was investigated. The synergetic arc control method easured that the arc voltage of DC welding source could switch in phase with the AC welding source. To test the reliability and operability of this method, a twin-electrode AC to DC pulsed arc welding system was set up and data was acquired through high-speed photography and electrical signal measurement system. The results show that the interactions between the two arcs can be controlled effectively and the control method is a sensitive and efficient control method.展开更多
A fuzzy logic intelligent control system of pulsed MAG welding inverter based on digital signal processor （DSP） is proposed to obtain the consistency of arc length in pulsed MAG welding. The proposed control system ...A fuzzy logic intelligent control system of pulsed MAG welding inverter based on digital signal processor （DSP） is proposed to obtain the consistency of arc length in pulsed MAG welding. The proposed control system combines the merits of intelligent control with DSP digital control. The fuzzy logic intelligent control system designed is a typical two-input-single-output structure, and regards the error and the change in error of peak arc voltage as two inputs and the background time as single output. The fuzzy logic intelligent control system is realized in a look-up table （LUT） method by using MATLAB based fuzzy logic toolbox, and the implement of LUT method based on DSP is also discussed. The pulsed MAG welding experimental results demonstrate that the developed fuzzy logic intelligent control system based on DSP has strong arc length controlling ability to accomplish the stable pulsed MAG welding process and controls pulsed MAG welding inverter digitally and intelligently.展开更多
Based on the analysis of three-dimensional power conductor for DC arcfurnace, the electric arc deflection model was set up and the control system of the arc directionwas configured. According to the bus bar distributi...Based on the analysis of three-dimensional power conductor for DC arcfurnace, the electric arc deflection model was set up and the control system of the arc directionwas configured. According to the bus bar distribution at the bottom electrodes cooled by water, thearc direction control principle and its configuration were described. The simulation results showthat the control system can restrain the electric arc deflection and control the arc direction.展开更多
Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controll...Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.展开更多
This paper presents an integrated simulation model for full digital controlled PMIG/MAG welding system with Matlab/Simulink, and it consists of power inverter, digital control system and dynamic arc-load model. An int...This paper presents an integrated simulation model for full digital controlled PMIG/MAG welding system with Matlab/Simulink, and it consists of power inverter, digital control system and dynamic arc-load model. An integrated simulation study was done for full digital PMIG/MAG welding, and a method of connecting dynamic arc-load model to the system with controlled current source was presented, in addition, the simulation results were utilized to study the issues of digital control PMIG/MAG welding in this paper. The experimental results validated the developed simulation model, and this simulation study can be applied in implementation of the full digital PMIG/MAG welding and analysis of system dynamic process.展开更多
In order to improve the utilization rate of foam,an arc jet nozzle was designed for precise dust control.Through theoretical analysis,the different demands of foam were compared amongst arc jets,flat jets and full con...In order to improve the utilization rate of foam,an arc jet nozzle was designed for precise dust control.Through theoretical analysis,the different demands of foam were compared amongst arc jets,flat jets and full cone jets when the dust source was covered identically by foam.It is proved that foam consumption was least when an arc jet was used.Foam production capability of an arc jet nozzle under different conditions was investigated through experiments.The results show that with the gas liquid ratio(GLR)increasing,the spray state of an arc jet nozzle presents successively water jet,foam jet and mist.Under a reasonable working condition range of foam production and a fixed GLR,foam production quantity increases at first,and then decreases with the increase of liquid supply quantity.When the inner diameter of the nozzle is 14 mm,the best GLR is 30 and the optimum liquid supply quantity is0.375 m^3/h.The results of field experiments show that the total dust and respirable dust suppression efficiency of arc jet nozzles is 85.8%and 82.6%respectively,which are 1.39 and 1.37 times higher than the full cone nozzles and 1.20 and 1.19 times higher than the fiat nozzles.展开更多
文摘A new kind of control system for keyhole plasma arc welding （K-PAW） was developed based on the computer and the Graphics Language--LabVIEW. It can set and output the required current waveforms with desired decreasing slopes so that the corresponding ＂opening and closing＂ of keyhole can occur periodically. With this control strategy of welding current waveforms, the workpiece is fully penetrated while no burn-through Occurs. Keyhole plasma arc welding experiments were conducted to verify the stability and reliability of the developed system.
基金Acknowledgement The authors would like to thank the financial support for this research from the National Natural Science Foundation of China （ Key Program Grant No. 50936003）.
文摘The controlled pulse waveform is newly applied in keyhole plasma arc welding process. Two additional descending slopes can guarantee stable and smooth transition of keyhole closing and opening periodically. To develop a closed-loop control system for this special welding process, the key point is the determination of system input and output variables. The averaged efflux plasma voltage during a pulse cycle is defined as the characteristic variable reflecting the real keyhole dimension. Research and experiments are conducted to explore the relationship between the characteristic variable and weld pe^Cormance. Results show that alternated peak current can significantly change the keyhole dimension and the penetration. It is proposed that the keyhole average dimension is taken as the controlled variable, and the peak pulse current value and slopes are taken as control variables.
基金supported by National Natural Science Foundation of China(Grant No. 50936003)
文摘The development of closed-loop control systems is one of the most effective ways to improve the stability of the keyhole status during keyhole plasma arc welding （K-PAW）. Due to the disadvantages of the ＂one-pulse-one-keyhole＂ technology based on the conventional square current waveform, the controlled pulse welding current waveform is newly applied to control the keyhole open and close periodically. In order to realize the real-time control on the keyhole behavior with this advanced current waveform, welding experiments and system identification are conducted based on the classical control theory. One complete welding cycle can be divided into 3 periods. The keyhole establishing time is the most important time variable, which determines the keyhole behavior and welding process stability. At the same time, the averaged effiux plasma arc voltage during one pulse cycle can reflect the real keyhole dimension and status in a real-time manner. Therefore, two single-input-single-output （SISO） systems are proposed, in which keyhole establishing time and keyhole average dimension are taken as the system controlled variables respectively. Welding experiments are designed with the peak current varying randomly. Experiments show that the keyhole establishing time changes in an opposite direction to the varied peak current, and the averaged efflux plasma arc voltage varies with the same trend as the peak current. Based on the least squares technique and F test of classical system identification, second order difference equation for keyhole establishing time/peak current system and first order difference equation for keyhole average dimension/peak current system are obtained. It is proved that the calculated data by the two mathematical expressions are well matched with the measured data. The proposed research provides mathematical expressions and theoretical analysis to develop closed-loop systems for the controlled pulse K-PAW.
基金Project(2009CB939705) supported by the National Basic Research Program of ChinaProject(200233) supported by the Foundation for the Author of National Excellent Doctoral Dissertation of China (FANEDD)
文摘A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V alloy sheets.The microstructures,facture surfaces and microhardness of the welded joints were characterized by using optical microscope,scanning electron microscope （SEM） and Vickers microhardness tester.Comparing with welds such as gas tungsten arc and conventional plasma arc processes,the experimental results revealed the improvements when using the present process including：1） reducing prior-beta （β） grain size and prohibiting formation of hard martensite phases in the fusion zone due to the decreased heat input;and 2） better toughness and higher hardness.
文摘Methods of arc length control and visual image based weld detection for precision pulse TIG welding were investigated. With a particular all hardware circuit, arc voltage during peak current stage is sampled and integrated to indicate arc length, deviation of arc length and adjusting parameters are calculated and output to drive a step motor directly. According to the features of welding image grabbed with CCD camera, a special algorithm was developed to detect the central line of weld fast and accurately. Then an application system were established, whose static arc length error is ±0.1 mm with 20 A average current and 1 mm given arc length, static detection precision of weld is 0.01 mm , processing time of each image is less than 120 ms . Precision pulse TIG welding of some given thin stainless steel components with complicated curved surface was successfully realized.
基金Supported by National Natural Science Foundation of China （Grant No. 51175374）, the Application of Basic ＆ Frontier Technology Program of Tianjin （Grant No. 09JCYBJC05000） and the Science ＆ Technology Pillar Program of Tianjin（ Grant No. 10ZCKFSF00200）.
文摘A novel synergetic arc control method was used to control twin-electrode alternating current （ AC） to direct current （DC） pulsed arc welding and the mechanism of poor sidewall fusion in narrow gap welding was investigated. The synergetic arc control method easured that the arc voltage of DC welding source could switch in phase with the AC welding source. To test the reliability and operability of this method, a twin-electrode AC to DC pulsed arc welding system was set up and data was acquired through high-speed photography and electrical signal measurement system. The results show that the interactions between the two arcs can be controlled effectively and the control method is a sensitive and efficient control method.
基金supported by National Natural Science Foundation of China(No.50375054)China Postdoctoral Science Foundation (No.20060400745).
文摘A fuzzy logic intelligent control system of pulsed MAG welding inverter based on digital signal processor （DSP） is proposed to obtain the consistency of arc length in pulsed MAG welding. The proposed control system combines the merits of intelligent control with DSP digital control. The fuzzy logic intelligent control system designed is a typical two-input-single-output structure, and regards the error and the change in error of peak arc voltage as two inputs and the background time as single output. The fuzzy logic intelligent control system is realized in a look-up table （LUT） method by using MATLAB based fuzzy logic toolbox, and the implement of LUT method based on DSP is also discussed. The pulsed MAG welding experimental results demonstrate that the developed fuzzy logic intelligent control system based on DSP has strong arc length controlling ability to accomplish the stable pulsed MAG welding process and controls pulsed MAG welding inverter digitally and intelligently.
文摘Based on the analysis of three-dimensional power conductor for DC arcfurnace, the electric arc deflection model was set up and the control system of the arc directionwas configured. According to the bus bar distribution at the bottom electrodes cooled by water, thearc direction control principle and its configuration were described. The simulation results showthat the control system can restrain the electric arc deflection and control the arc direction.
文摘Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.
文摘This paper presents an integrated simulation model for full digital controlled PMIG/MAG welding system with Matlab/Simulink, and it consists of power inverter, digital control system and dynamic arc-load model. An integrated simulation study was done for full digital PMIG/MAG welding, and a method of connecting dynamic arc-load model to the system with controlled current source was presented, in addition, the simulation results were utilized to study the issues of digital control PMIG/MAG welding in this paper. The experimental results validated the developed simulation model, and this simulation study can be applied in implementation of the full digital PMIG/MAG welding and analysis of system dynamic process.
基金supported by the National Natural Science Foundation of China(No.51474216)
文摘In order to improve the utilization rate of foam,an arc jet nozzle was designed for precise dust control.Through theoretical analysis,the different demands of foam were compared amongst arc jets,flat jets and full cone jets when the dust source was covered identically by foam.It is proved that foam consumption was least when an arc jet was used.Foam production capability of an arc jet nozzle under different conditions was investigated through experiments.The results show that with the gas liquid ratio(GLR)increasing,the spray state of an arc jet nozzle presents successively water jet,foam jet and mist.Under a reasonable working condition range of foam production and a fixed GLR,foam production quantity increases at first,and then decreases with the increase of liquid supply quantity.When the inner diameter of the nozzle is 14 mm,the best GLR is 30 and the optimum liquid supply quantity is0.375 m^3/h.The results of field experiments show that the total dust and respirable dust suppression efficiency of arc jet nozzles is 85.8%and 82.6%respectively,which are 1.39 and 1.37 times higher than the full cone nozzles and 1.20 and 1.19 times higher than the fiat nozzles.
