Abstract
Combining human welder (with intelligence and sensing versatility) and automated welding systems (with precision and consistency) can lead to next generation intelligent welding systems. This paper aims to present a data-driven approach to model human welder hand movement in 3-D, and use the learned model to control automated Gas Tungsten Arc Welding (GTAW) process. To this end, an innovative virtualized welding platform is utilized to conduct teleoperated training experiments: the welding current is randomly changed to generate fluctuating weld pool surface and a human welder tries to adjust the torch movements in 3-D (including welding speed, arc length, and torch orientations) based on the observation on the real-time weld pool image feedback. These torch movements together with the 3-D weld pool characteristic parameters are recorded. The weld pool and human hand movement data are off-line rated by the welder and a welder rating system is trained, using an Adaptive Neuro-Fuzzy Inference System (ANFIS), to automate the rating. Data from the training experiments are then automatically rated such that top rated data pairs are selected to model and extract “good response” minimizing the effect from “bad operation” made during the training. ANFIS model is then utilized to correlate the 3-D weld pool characteristic parameters and welder’s torch movements. To demonstrate the effectiveness of the proposed model as an effective intelligent controller, automated control experiments are conducted. Experimental results verified that the controller is effective under different welding currents and is robust against welding speed and measurement disturbances. A foundation is thus established to learn human welder intelligence, and transfer such knowledge to realize intelligent welding robot.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
O’Brien R (ed) (1998) Welding handbook, vol 2, 8th edn. Welding Processes, AWS, Miami FL
Renwick R, Richardson R (1983) Experimental investigation of GTA weld pool oscillations. Weld J 62(2):29s–35s
Matsui H, Chiba T, Yamazaki K (2014) Detection and amplification of the molten pool natural oscillation in consumable electrode arc welding. Weld Int 28(1):5–12
Carlson N, Johnson J (1988) Ultrasonic sensing of weld pool penetration. Weld J 67(11):239s–246s
Guu AC, Rokhlin SI (1992) Arc weld process control using radiographic sensing. Mater Eval 50(11):1344
Song JB, Hardt DE (1993) Closed-loop control of weld pool depth using a thermally based depth estimator. W J 72(10):471s–478s
Pietrzak KA, Packer SM (1994) Vision-based weld pool width control. J Eng Ind Trans ASME 116(1):86–92
Chen H, Lv F, Lin T et al (2009) Closed-loop control of robotic arc welding system with full-penetration monitoring. J Intell Rob Syst 56(5):565–578
Liu YK, Zhang YM (2013) Model-based predictive control of weld penetration in gas tungsten arc welding. IEEE Trans Control Syst Technol 22(3):955–966
Liu YK, Zhang YM (2013) Control of 3D weld pool surface. Control Eng Pract 21(11):1469–1480
Zhang WJ, Liu YK, Wang X, Zhang YM (2012) Characterization of three dimensional weld pool surface in GTAW. Weld J 91(7):195s–203s
Liu YK, Zhang WJ, Zhang YM (2015) Nonlinear modeling for 3d weld pool characteristic parameters in GTAW. Weld J 94:231s–240s
Liu YK, Zhang WJ, Zhang YM (2015) Dynamic neuro-fuzzy based human intelligence modeling and control in GTAW. IEEE Trans Autom Sci Eng 12(1):324–335
Liu YK, Zhang YM, Kvidahl L (2014) Skilled human welder intelligence modeling and control: part I—modeling. Weld J 93:46s–52s
Liu YK, Zhang YM, Kvidahl L (2014) Skilled human welder intelligence modeling and control: part II—analysis and control applications. Weld J 93:162s–170s
Uttrachi GD (2007) Welder shortage requires new thinking. Weld J 86(1):6
Cary HB, Helzer SC (2005) Modern welding technology. Pearson/Prentice Hall
Liu YK, Zhang YM (2014) Control of human arm movement in machine-human cooperative welding process. Control Eng Pract 32:161–171
Liu YK, Zhang YM (2015) Controlling 3d weld pool surface by adjusting welding speed. Weld J 94:125s–134s
Liu YK, Zhang YM (2015) Iterative local anfis based human welder intelligence modeling and control in pipe GTAW process: a data-driven approach. IEEE/ASME Trans Mechatron 20(3):1079–1088
Liu YK, Zhang YM (2017) Supervised learning of human welder behaviors for intelligent robotic welding. IEEE Trans Autom Sci Eng 14(3):1532–1541
Liu YK, Zhang YM (2017) Fusing machine algorithm with welder intelligence for adaptive welding robots. J Manuf Processes 27:18–25
Liu YK (2016) Toward intelligent welding robots: virtualized welding based learning of human welder behaviors. Weld World 60(4):719–729
Liu YK, Shao Z, Zhang YM (2014) Learning human welder movement in pipe GTAW: a virtualized welding approach. Weld J 93:388s–398s
Liu YK, Zhang YM (2015) Toward welding robot with human knowledge: a remotely-controlled approach. IEEE Trans Autom Sci Eng 12(2):769–774
Daniel T (2012) Leap motion: 3D hands-free motion control, unbound, http://news.cnet.com/8301-11386_3-57437404-76/leap-motion-3d-hands-free-motion-control-unbound/ Accessed 20 May 2012
Liu YK, Zhang WJ, Zhang YM (2013) Estimation of weld joint penetration under varying GTA pools. Weld J 92(11):313s–321s
Tanaka K, Sano M, Watanabe H (1995) Modeling and control of carbon monoxide concentration using a neuro-fuzzy technique. IEEE Trans Fuzzy Syst 3(3):271–279
Jang JSR (1993) ANFIS: Adaptive-network-based fuzzy inference systems. IEEE Trans Syst Man Cybern 23(3):665–685
Zhao L et al (2014) Data-based modeling of vehicle crash using adaptive neural-fuzzy inference system. IEEE/ASME Trans Mechatron 19(2):684–696
Druitt CM, Alici G (2014) Intelligent control of electroactive polymer actuators based on fuzzy and neurofuzzy methodologies. IEEE/ASME Trans Mechatron 19(6):1951–1962
Acknowledgements
This work is funded by the National Science Foundation (IIS-1208420). The authors thank the assistance from Mr. Ning Huang on the experiments.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2019 Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Liu, Y., Zhang, Y. (2019). Human Welder 3-D Hand Movement Learning in Virtualized GTAW: Theory and Experiments. In: Chen, S., Zhang, Y., Feng, Z. (eds) Transactions on Intelligent Welding Manufacturing. Transactions on Intelligent Welding Manufacturing. Springer, Singapore. https://doi.org/10.1007/978-981-10-8740-0_1
Download citation
DOI: https://doi.org/10.1007/978-981-10-8740-0_1
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-10-8739-4
Online ISBN: 978-981-10-8740-0
eBook Packages: Intelligent Technologies and RoboticsIntelligent Technologies and Robotics (R0)