A NEURAL NETWORK FOR WELD PENETRATION CONTROL IN GAS TUNGSTEN ARC WELDING

Realizing of weld penetration control in gas tungsten arc welding requires establishment of a model describing the relationship between the front-side geometrical parameters of weld pool and the back-side weld width with sufficient accuracy. A neural network model is developed to attain this aim. Welding experiments are conducted to obtain the training data set （including 973 groups of geometrical parameters of the weld pool and back-side weld width） and the verifying data set （108 groups）. Two data sets are used for training and verifying the neural network, respectively. The testing results show that the model has sufficient accuracy and can meet the requirements of weld penetration control.

A high-precision control system for robotic welding positioner

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.

SPOT WELDING QUALITY FUZZY CONTROL SYSTEM BASED ON MULTISENSOR INFORMATION FUSION

The multisensor information fusion technology is adopted for real time measuring the four parameters which are connected closely with the weld nugget size（welding current, electrode displacement, dynamic resistance, welding time）, thus much more original information is obtained. In this way, the difficulty caused by measuring indirectly weld nugget size can be decreased in spot welding quality control, and the stability of spot welding quality can be improved. According to this method, two-dimensional fuzzy controllers are designed with the information fusion result as input and the thyristor control signal as output. The spot welding experimental results indicate that the spot welding quality intelligent control method based on multiscnsor information fusion technology can compensate the influence caused by variable factors in welding process and ensure the stability of welding quality.

ROBUST CONTROL OF GAS TUNGSTEN ARC WELDING SYSTEM

The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities （LMIs） and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design oarameter.

BASIC THEORY AND APPLICATIONS OF WELDING ARC SPECTRAL INFORMATION

Welding arc spectral information is a rising welding information source. In some occasion, it can reflect many physical phenomena of welding process and solve many problems that cannot be done with arc electric information, acoustic information and other arc information. It is of important significance in developing automatic control technique of welding process and other similar process. Many years study work on welding arc spectral information of the anthor are discussed from three aspects of theory, method and application. Basic theory, view and testing methods of welding arc spectral information has been put forward. In application aspects, many applied examples, for example, monitoring of harmful gases in arc （such as hydrogen and nitrogen） with the method of welding arc spectral information; welding arc spectral imaging of the welding pool which is used in automatic seam tracking; controlling of welding droplet transfer with welding arc spectral information and so on, are introduced. Especially, the successful application in real time controlling of welding droplet transfer in pulsed GMAW is introduced too. These application examples show that the welding arc spectral information has great applied significance and development potentialities. These .content will play an important role in applying and spreading welding arc spectral informarion technology.

COMPUTER-AIDED DESIGN OF ADAPTIVE PULSED ARC WELDING OF ROOT WELDS BY MELTING ELECTRODE

The purpose of computer-aided design of new adaptive pulsed arc technologies of welding is: to de- sign optimum algorithms of pulsed control over main energy parameters of welding.It permits:to in- crease welding productivity, to stabilize the welding regime, to control weld formation,taking into ac- count its spatial position, to proveal specie strength of the welded and coatings. Computer- aided design reduces the time of development of new pulsed arc technology:provides the optimization of technological referes according to the operating conditions of welded joints,the prediction of the ser- vice life of the welds.The developed methodology of computer-aided design of advanced technologies, models, original software, adaptive algorithms of pulsed control, and spend equipment permits to regulate penetration,the weld shape, the sizes of heat - affected zone; to predict sired properties and quality of welded joints.

Investigation of front pool width penetration control for application to varying plate thickness

The influence of plate thickness on the penetration in GTAW was investigated and a theoretical heat flow model for a plate of finite thickness has been utilized to investigate the relationship between front and back pool widths.Then,front pool width penetration control approach approach has been studied, which controls penetration under the variation of plate thickness.A penetration control system for autogenous GTA welding has been utilized which includes a coaxial weld pool imaging system and computer vision processing system to sense the front width of the GTA weld pool.Empirical results show the good performance of this penetration control approach in the presence of variations in joint plant thickness of 1 mm 0.04 inch) to 3 mm(0.125 inch)

Electromagnetic Control of the Weld Pool Dynamics in Partial Penetration Laser Beam Welding of Aluminium Alloys

The main characteristic feature of deep penetration laser beam welding is a large temperature difference between the plasma cavity(keyhole)in the weld pool centre and the melting/solidification front.Large temperature gradients in the weld pool result in very intensive thermocapillary(Marangoni)convection.The weld pool surface width becomes very large and unstable.However,an externally applied oscillating magnetic field can stabilize the surface of the melt.In the present work this technology was used to stabilize the weld pool surface in partial penetration 4.4 kW Nd:YAG laser beam welding of AW-5754 aluminium alloy in PA position.An AC magnet was mounted on the laser welding head.The oscillating magnetic field was oriented perpendicular to the welding direction.It was found that the AC magnetic field can drastically reduce the surface roughness of welds.X-ray image analysis shows a drastic reduction of welds porosity.This effect can be explained as a result of electromagnetic rectification of the melt.