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Acoustic Sensing and Real-Time Control of Weld Penetration in Intelligentized Robotic Welding

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Transactions on Intelligent Welding Manufacturing

Part of the book series: Transactions on Intelligent Welding Manufacturing ((TRINWM))

Abstract

Real-time welding quality monitoring has been more important and difficult in automatic welding process than manual ones. Penetration state is the key judgment of welding quality monitoring. Arc sound signal is one of the associated signals of welding penetration state. It has been proved to be effective and essential information for weld quality control. In this paper, the author summarized all the recent research on welding arc sound in SJTU. First, the incentive mechanism of arc sound signal was observed when compared with the arc voltage and current signal frequency characteristic. The incentive sound source appeared periodically in 70 Hz, the same as the frequency of welding power source. A new method of time–frequency domain feature extraction of penetration state was proposed, including the auditory attention AC-ROI extraction preprocessing method and the maximum modulus threshold de-noising method. All these characters have good correspondence to the penetration state of weld seam. A new method of controlling the pulsed GTAW dynamic process was designed and verified. It contained two parts: one was the PID controller, that could achieve the real-time control of arc length and weld collapse during the welding process. The other is PW-BP controller, that could achieve the real-time closed-loop control of weld penetration welding experiment. The results showed that the weld quality was improved obviously and forming quality was good compared to constant welding parameter experiment.

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Acknowledgements

This work is supported by the National Natural Science Foundation of China (51575349, 61401275) and the Chine Postdoctoral Fund (No. 2016M601588 and 2017T100295) and the Startup Fund for Youngman Research at SJTU (SFYR at SJTU) (18X100040049).

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Authors and Affiliations

  1. Department of Information Detection and Instrument, Shanghai Jiao Tong University, Shanghai, 200240, China

    Na Lv, Wei Tao & Hui Zhao

  2. Intelligentized Robotic Welding Technology Laboratory, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Na Lv, Yanling Xu & Shanben Chen

Authors
  1. Na Lv
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  2. Yanling Xu
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  3. Wei Tao
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  4. Hui Zhao
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  5. Shanben Chen
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Corresponding author

Correspondence to Shanben Chen .

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Editors and Affiliations

  1. Shanghai Jiao Tong University, Shanghai, China

    Shanben Chen

  2. Department of Electrical and Computer Engineering, University of Kentucky, Lexington, KY, USA

    Yuming Zhang

  3. Oak Ridge National Laboratory, Oak Ridge, TN, USA

    Zhili Feng

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Lv, N., Xu, Y., Tao, W., Zhao, H., Chen, S. (2020). Acoustic Sensing and Real-Time Control of Weld Penetration in Intelligentized Robotic Welding. In: Chen, S., Zhang, Y., Feng, Z. (eds) Transactions on Intelligent Welding Manufacturing. Transactions on Intelligent Welding Manufacturing. Springer, Singapore. https://doi.org/10.1007/978-981-13-8192-8_2

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