كتاب Welding Robots Technology, System Issues and Applications

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Welding Robots Technology, System Issues and Applications
J Norberto Pires

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List of Figures xv
1 Introduction and Overview1
11 Introduction 1
111 Why Robotic Welding and a CAD Programming Interface?3
12 Historical Perspective6
121 Welding 7
122 Robotics 13
13 Why to Automate Welding?17
131 Example of an SME Based Industrial Robotic System17
132 Are Robots Adapted to Robotic Welding? 22
14 Objectives and Outline of the Book 23
15 References 24
2 Welding Technology27
21 Gas Tungsten Arc Welding (GTAW)27
211 Introduction27
212 Welding Equipment 28
2121 Power Sources 28
2122 Welding Torch29
2123 Non-consumable Electrodes 29
2124 Arc Striking Techniques30
2125 Shielding Gas Regulator31
213 Process Parameters 31
2131 Current31
2132 Welding Speed33
2133 Arc Length33
2134 Shielding Gases 33
2135 Filler Metals34
2136 Electrode Vertex Angle 34
2137 Cast-to-cast Variation 34
xii Contents
214 Process Variants35
22 Gas Metal Arc Welding (GMAW)36
221 Introduction37
222 Welding Equipment 38
2221 Power Source38
2222 Electrode Feed Unit 39
2223 Welding Torch40
223 Process Parameters 40
2231 Current41
2232 Voltage 42
2233 Welding Speed42
2234 Electrode Extension42
2235 Shielding Gas42
2236 Electrode Diameter 43
224 Process Variants43
23 Laser Beam Welding (LBW)45
231 Introduction45
232 Welding Equipment 47
2321 Solid-state Lasers47
2322 Gas Lasers 48
233 Process Parameters 49
2331 Beam Power and Beam Diameter50
2332 Focus Characterization 50
2333 Travel Speed51
2334 Plasma Formation 51
2335 Welding Gases52
2336 Absorptivity52
234 Process Variants53
24 Resistance Spot Welding (RSW)54
241 Introduction55
242 Welding Equipment 56
2421 Power Sources 56
2422 Electrodes 58
243 Process Parameters 58
2431 Welding Current and Time 59
2432 Welding Force 60
244 Process Variants61
25 Friction Stir Welding (FSW)62
251 Introduction63
252 Welding Equipment 64
253 Process Parameters 65
254 Process Variants66
26 Health and Safety 67
27 References 68
3 Sensors for Welding Robots73
31 Introduction 73
Contents xiii
31 Sensors for Technological Parameters 75
311 Arc Voltage75
312 Welding Current 76
3121 Hall Effect Sensor76
3122 Current Shunt76
313 Wire Feed Speed76
32 Sensors for Geometrical Parameters77
321 Optical Sensors 78
322 Through-arc Sensing84
33 Monitoring87
34 Pulsed GMAW89
341 Synergic Control90
35 Short-circuit GMAW92
36 Spray GMAW 93
37 Fault Detection Using Monitoring94
38 Design of a Monitoring System for Quality Control 96
39 Monitoring System Development – An Example99
391 Short-circuiting GMAW99
392 Spray GMAW100
310 Discussion 101
311 References 102
4 Robotic Welding: System Issues105
41 Introduction 105
41 Modeling the Welding Process106
411 Definition and Detection of the Process Parameters106
42 Control of the Welding Process112
421 Knowledge Base 113
422 Sensors and Interfaces 113
44 Programmable and Flexible Control Facility 116
45 Application to Robot Manipulators 118
451 Using RPC – Remote Procedure Calls120
452 Using TCP/IP Sockets 123
46 Simple Welding Example131
47 Semi-autonomous Manufacturing Systems 139
48 Chapter Final Notes142
49 References 143
5 Robotic Welding: Application Examples147
51 Introduction 147
52 A Robotic Welding System148
521 Overview of the system 148
522 CAD Interface152
523 WeldPanel157
524 WeldAdjust159
525 File Explorer 159
526 Robot Control Panel and RPC Server to Receive Events 159
xiv Contents
53 Test Cases160
531 Test Case 1 – Multi-layer Welding161
532 Test Case 2 – Multiple Welding Paths161
54 Discussion 162
541 IO and Memory Remote Access163
542 Software Components167
543 CAD Interface167
5431 Parameterization Approach 168
5432 Code Generation Approach 173
544 Low-level Interfaces for Sensors 174
55 References 175
6 What’s Next?177
Index 179

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