Multisensor Data Fusion Multisensor Data Fusion Multisensor Data Fusion Multisensor Data Fusion for for for for the the the the Control System Control System Control System Control System of of of of an an an an Dottorato di Ricerca in Ingegneria Elettronica, Automatica e del Controllo dei Sistemi Complessi for for for for the the the the Control System Control System Control System Control System of of of of an an an an Arc Arc Arc Arc Welding Robot Welding Robot Welding Robot Welding Robot Filippo Bonaccorso Tutor Prof. G. Muscato
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Arc Welding Robot Arc Welding Robot - phd.dees.unict.it · Arc Welding RobotArc Welding Robot ... depositing weld material without the need for tooling. ... Arc Length Weld pool geometry
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Multisensor Data FusionMult isensor Data FusionMult isensor Data FusionMult isensor Data Fusionfor for for for the the the the Control System Control System Control System Control System of of of of an an an an
Dottorato di Ricerca in Ingegneria Elettronica,
Automatica e del Controllo dei Sistemi Complessi
for for for for the the the the Control System Control System Control System Control System of of of of an an an an Arc Arc Arc Arc Welding RobotWelding RobotWelding RobotWelding Robot
Filippo Bonaccorso Tutor Prof. G. Muscato
RAPOLAC clusters expertise and resources from 8participants, including 4 SMEs and 4 universities.The partners are drawn from member states of EU and oneother country, Argentina, and includes specialists in theareas of part manufacturing, microstructural analysis,modelling and control, and environmental specialists.
OUTLINEOUTLINEOUTLINEOUTLINE
• RAPOLACRAPOLACRAPOLACRAPOLAC• SMD PROCESSSMD PROCESSSMD PROCESSSMD PROCESS• WELDINGWELDINGWELDINGWELDING• WELDINGWELDINGWELDINGWELDING• EXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BED• USER INTERFACEUSER INTERFACEUSER INTERFACEUSER INTERFACE
INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION
RAPOLAC is focussed on the Shaped Metal Deposition (SMD)process which is ideal for use in prototype production as well as inmanufacturing, eliminating the need for tooling and shorteningmanufacturing, eliminating the need for tooling and shorteningdevelopment lead-times. It uses no tooling and has low to zeroharmful emissions.
RAPOLAC will carry out research on process automation and willconcentrate on documenting and controlling the material propertiesthrough the development of process models. Process parameters willbe developed for many materials and the cost and environmental
SMD PROCESSSMD PROCESSSMD PROCESSSMD PROCESSSMD PROCESSSMD PROCESSSMD PROCESSSMD PROCESS
Shaped Metal Deposition (SMD) is a near-net shape prototypingsystem patented by Rolls-Royce, licensed to the University ofSheffield and operated in collaboration with Footprint Tools.
• The process allows complex parts to be built directly from the CAD• The process allows complex parts to be built directly from the CADmodel with minimum finishing.• The system creates components from the base up in a layer-wise
fashion, depositing weld material without the need for tooling.• Complex parts can be made with improved material properties, and
it is possible for hybrid components to be created.• The main uses of SMD are one off parts, rapid prototyping, repair
The innovative aspect of the SMD process consists of reversing theproduction philosophy actuated up to now, by the traditionalmanufacturing methods, such as machining, where the material isremoved from the work piece to obtain a desired final shape.
DrawbacksDrawbacksDrawbacksDrawbacks::::DrawbacksDrawbacksDrawbacksDrawbacks::::• Large waste of material in scraps• Large prototyping time• High energy required.
All this costs increase depending of thematerial used.
EXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BEDEXPERIMENTAL TEST BED
SM
DS
MD
SM
DS
MD
PR
OC
ES
SP
RO
CE
SS
PR
OC
ES
SP
RO
CE
SS
AmperageAmperageAmperageAmperage
Wire Feed RateWire Feed RateWire Feed RateWire Feed Rate1) Torch Height from the Bead1) Torch Height from the Bead1) Torch Height from the Bead1) Torch Height from the Bead
2) Bead width and height2) Bead width and height2) Bead width and height2) Bead width and heightC
Desired Mechanical Desired Mechanical Desired Mechanical Desired Mechanical Properties of the Properties of the Properties of the Properties of the final work piecefinal work piecefinal work piecefinal work piece
PROCESS FEEDBACKPROCESS FEEDBACKPROCESS FEEDBACKPROCESS FEEDBACK
SOUNDSOUNDSOUNDSOUND
LIGHTLIGHTLIGHTLIGHT
VOLTAGEVOLTAGEVOLTAGEVOLTAGE
CCD CameraCCD CameraCCD CameraCCD Camera
WorkpieceWorkpieceWorkpieceWorkpiece
SOUNDSOUNDSOUNDSOUND
Thermal CameraThermal CameraThermal CameraThermal Camera
Torch Torch Torch Torch Height from the Height from the Height from the Height from the BeadBeadBeadBead====
Arc LengthArc LengthArc LengthArc Length
Weld pool geometryWeld pool geometryWeld pool geometryWeld pool geometry====
Bead Width and HeightBead Width and HeightBead Width and HeightBead Width and Height
Kuka Robot
Tig
Torch Torch Torch Torch HeightHeightHeightHeightfrom from from from the Beadthe Beadthe Beadthe Bead
Bead Bead Bead Bead widthwidthwidthwidthand and and and heightheightheightheight
•Each module is identified as an elementary unit or as avirtual machine that communicates with the other modulesto assure a good process control.• Several algorithms were designed and developed to obtain
this result.this result.•The proposed interface has been adopted in many different
trials to get the best working conditions and the tuningparameters for the controller.•The interface has been also really useful to monitor the
process during the experiments, allowing to check in realtime most of the parameters and to monitor the outputs.