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Linear Mathematical Model for Seam Tracking with an Arc Sensor in P-GMAW Processes
Wenji Liu1, Liangyu Li2, Ying Hong3
1School of Mechanical Engineering, Tianjin Polytechnic University, No. 399 Bin Shui Xi Road, Xi Qing District, Tianjin 300387, China. liuwenji1981@126.com.
Sensors (Basel, Switzerland)
|March 25, 2017
Summary
This study introduces a linear mathematical model for pulse gas metal arc welding (P-GMAW) arc sensing, enhancing accuracy in narrow gap welding. Experimental validation confirms the model
Area of Science:
- Welding Engineering
- Robotics and Automation
- Sensing Technology
Background:
- Traditional arc sensors face limitations in narrow gap welding due to arc instability and poor sensing accuracy.
- Pulse gas metal arc welding (P-GMAW) shows promise for narrow gap and all-position welding, necessitating advanced arc sensing.
- Existing commercial arc sensing products are not optimized for challenging narrow gap configurations.
Purpose of the Study:
- To develop and validate a linear mathematical model for P-GMAW arc sensing.
- To investigate the linear characteristics of P-GMAW arc signals under various welding conditions.
- To improve seam tracking accuracy in narrow gap welding applications.
Main Methods:
- Derivation of a linear mathematical model for P-GMAW arc sensing.
- Experimental verification of model assumptions using controlled welding tests.
- Finite element method (FEM) analysis to support experimental findings.
- Systematic testing including torch height, uphill, and groove angle variations.
Main Results:
- P-GMAW arc signals demonstrated consistent linear behavior across different experimental conditions.
- Increased welding speed led to higher arc signal sensitivities.
- Smaller groove angles resulted in greater arc sensitivities, indicating enhanced responsiveness.
- Arc signal variation rate is dependent on welding power, groove angles, and weaving/rotation speed.
Conclusions:
- The derived linear mathematical model accurately describes P-GMAW arc sensing behavior.
- The findings provide a foundation for developing more precise arc sensing systems for narrow gap welding.
- The study highlights the need to adjust arc signal variation rates based on specific welding parameters for optimal performance.
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