Transactions on Intelligent Welding Manufacturing: Volume II No. 3 2018

173 Pages·2019·10.492 MB·English

by  Shanben Chen, Yuming Zhang, Zhili Feng

Transactions on
Intelligent Welding
Manufacturing
Volume II No. 3 2018
Transactions on Intelligent Welding
Manufacturing
Editors-in-Chief
ShanbenChen YumingZhang ZhiliFeng
ShanghaiJiaoTongUniversity UniversityofKentucky OakRidgeNationalLaboratory
PRC USA USA
HonoraryEditors
G.Cook,USA S.A.David,USA Y.Hirata,JAP T.Lienert,USA
K.L.Moore,USA S.J.Na,KOR J.Norrish,AUS T.J.Tarn,USA
Ji-LuanPan,PRC LinWu,PRC
GuestEditors
H.P.Chen,USA X.Q.Chen,NZL D.Du,PRC D.Fan,PRC
J.C.Feng,PRC D.Hong,USA X.D.Jiao,PRC I.Lopez-Juarez,MEX
H.J.Li,AUS W.Zhou,SGP
RegionalEditors
Asia:L.X.Zhang,PRC Australia:Z.X.Pan,AUS
America:Y.K.Liu,USA Europe:S.Konovalov,RUS
AssociateEditors
Q.X.Cao,PRC Y.Huang,USA PedroNeto,PRT S.Wang,PRC
B.H.Chang,PRC S.Konovalov,RUS G.Panoutsos,UK X.W.Wang,PRC
J.Chen,USA W.H.Li,PRC Z.X.Pan,AUS Z.Z.Wang,PRC
H.B.Chen,PRC X.R.Li,USA X.D.Peng,NL G.J.Zhang,PRC
S.J.Chen,PRC Y.K.Liu,USA Y.Shi,PRC H.Zhang,B,PRC
X.Z.Chen,PRC L.M.Liu,PRC J.Wu,USA H.Zhang,N,PRC
A.-K.Christiansson,SWE H.Lu,PRC J.X.Xue,PRC L.X.Zhang,PRC
Z.G.Li,PRC Z.Luo,PRC L.J.Yang,PRC W.J.Zhang,USA
X.M.Hua,PRC G.H.Ma,PRC M.Wang,PRC
AcademicAssistantEditors
J.Cao,PRC S.B.Lin,PRC S.L.Wang,PRC H.W.Yu,PRC
B.Chen,PRC Y.Shao,USA J.Xiao,PRC K.Zhang,PRC
Y.Luo,PRC Y.Tao,PRC J.J.Xu,PRC W.Z.Zhang,PRC
N.Lv,PRC J.J.Wang,PRC Y.L.Xu,PRC Z.F.Zhang,PRC
F.Li,PRC H.Y.Wang,PRC C.Yu,PRC
EditorialStaff
ExecutiveEditor(ManuscriptandPublication): Dr.YanZhang,PRC
ResponsibleEditors(AcademicandTechnical): Dr.NaLv,PRC
Dr.JingWu,USA
More information about this series at http://www.springer.com/series/15698
Shanben Chen Yuming Zhang Zhili Feng
(cid:129) (cid:129)
Editors
Transactions on Intelligent
Welding Manufacturing
Volume II No. 3 2018
123
Editors
Shanben Chen YumingZhang
ShanghaiJiao Tong University Department ofElectrical
Shanghai, China andComputer Engineering
University of Kentucky
Zhili Feng Lexington, KY,USA
Oak RidgeNational Laboratory
Oak Ridge,TN, USA
ISSN 2520-8519 ISSN 2520-8527 (electronic)
Transactions onIntelligent Welding Manufacturing
ISBN978-981-13-7417-3 ISBN978-981-13-7418-0 (eBook)
https://doi.org/10.1007/978-981-13-7418-0
LibraryofCongressControlNumber:2019936002
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Editorial
This issue of the Transactions on Intelligent Welding Manufacturing (TIWM) is a
collection of high-quality papers selected from “2018 International Conference on
Robotic Welding, Intelligence and Automation (RWIA’2018),” December 7–10,
2018, Guangzhou, China. They include two Feature Articles, eight full Research
Papers, and one Short Papers and Technical Notes contributing to intelligent
welding manufacturing through understanding, sensing, and control of welding
manufacturing processes.
The first Feature Article entitled “Modeling and Optimization of Adjustment of
Human Welder on Weld Pool Dynamics for Intelligent Robot Welding” is con-
tributed by a joint research team from Lanzhou University of Technology and
UniversityofKentucky.Animproved machine–human cooperative control system
was developed in this article to obtain sufficient data pairs for modeling welder’s
adjustment on weld pool dynamics by the data-driven approach. The effect of
welding torch orientation on weld pool dynamics was numerically studied for
understandingthemechanismofhumanwelder’sadjustmentandprovidingthekey
data to optimize the control system. A gray multiple linear regression model
(GMLRM)wasemployedtoanalyzethecontributionandinteractivecompensation
of each adjusted parameter on the weld widths as the welding current randomly
changes in a given range. A nonlinear adaptive kernel radial basis function neural
network (AK-RBFNN) was also proposed to improve the model accuracy.
The second Feature Article entitled “Progress and Trend in Intelligent Sensing
and Control of Weld Pool in Arc Welding Process” is contributed by researchers
from Lanzhou University of Technology. In this article, the current progress in
sensing of arc welding pool is detailed and challenges in measuring the weld pool
are analyzed. The key factor that hinders the development of intelligent robotic
welding is identified, and approaches that realize intelligent welding are also dis-
cussed. Lastly, the trend of intelligent welding manufacturing is predicted.
The first Research Paper “Spectral Analysis of the Plasma Emission During
Laser WeldingofGalvanizedSteel with Fiber Laser”iscontributedby researchers
fromHarbinInstituteofTechnology.Spectralinformationduringthelaserwelding
ofgalvanizedsteelwasobtained.Theplasmaspectrawereanalyzedunderdifferent
v
vi Editorial
laser powers and sheet gaps. Signal filter and statistical method were used to
processtheobtainedspectralinformation.Itwasfoundthattheplasmatemperature
increases with the laser power, and plasma temperature and spectral intensity
demonstrate aminimumwiththesheet gap.Statistical processcontrol methodwas
used to analyze the relationship between the welding quality and the spectral
information. It was found that the welding defects, in laser welding of galvanized
steel, are detectible from the spectra.
The second Research Paper “A Method for Detecting Central Coordinates of
GirthWeldsBasedonInverseCompositionalAAMinTube-TubeSheetWelding”
studiesdetectingcentralcoordinatesofgirthweldsbasedoninversecompositional
AAM by using a triaxial flaw detection device for the tubular heat exchanger. It is
contributed by researchers from Shanghai Jiao Tong University and involves the
design of software, calibration algorithm, center detection algorithm, etc. The
accuracy of the developed algorithm was experimentally verified.
ResearchPaper“SpectralSignalAnalysisUsingVMDinPulsedGTAWProcess
of 5A06 Al Alloy” is also contributed by researchers from Shanghai Jiao Tong
University. It proposes an automatic discriminant criterion based on correlation
coefficienttoeliminateredundantwavelengthsignalsinspectraldomain(200–1100
nm), resulting in only a few spectral lines for further subsequent processing. To
overcomethelimitofEMD,thevariationalmodedecomposition(VMD)algorithm
is used to decompose the spectral signal into the determined number of intrinsic
signals with fewer modal aliasing in the time domain.
FollowingResearchPaper“NonlinearIdentificationofWeldPenetrationControl
System in Pulsed Gas Metal Arc Welding” is a contribution from researchers at
TianjinUniversity.Thepaperestablishedasingle-input,single-output(SISO)weld
penetrationcontrolsysteminpulsedgasmetalarcwelding(GMAW-P).According
to the nonlinear relationship between base current and arc voltage difference, a
Hammerstein model with residual, composed of the nonlinear static model and
linear dynamic model, was proposed to describe the nonlinear control system.
ResearchPaper“EffectofTransverseUltrasonicVibrationonMIGWeldedJoint
Microstructure and Microhardness of Galvanized Steel Sheet” is contributed by
joint researchers from School of Mechanical Engineering and School of
Environment and Chemical Engineering, Nanchang University. A comparison test
of conventional MIG welding and ultrasonic-MIG hybrid welding was carried out
inthispaper.Theeffectsoftransverseultrasonicvibrationonweldformation,weld
microhardness, andweldmicrostructures duringultrasonic-MIGhybridweldingof
1-mm-thick galvanized steel sheet were discussed.
FollowingResearchisentitled“EffectofScanningModeonMicrostructureand
Physical Property of Copper Joint Fabricated by Electron Beam Welding” con-
tributed by authors from Nanchang Hangkong University. Copper T2 thin sheet
with a thickness of 2 mm was vacuum electron beam welded. Scanning electron
microscopy, optical microscopy, microhardness tester, and tensile testing machine
were used to facilitate the investigation. The formation of the weld surface by
different scanning methods was also studied.
Editorial vii
The seventh Research entitled “Research on Virtual Reality Monitoring
Technology of Tele-operation Welding Robot” is contributed by researchers from
BeijingInstituteofPetrochemicalTechnology.Inthispaper,variousaspectsofthe
tele-operation of welding robot were discussed, such as robot construction, 3D
model building and application in Unity, network communication between the
virtual robot and the physical robot, and tele-operation welding test trial.
ThelastResearchPaperis“TheInfluenceofPowderLayersInterventiononthe
Microstructure and Property in Brazing Joints of Titanium/Steel,” by researchers
from Lanzhou University of Technology. In this paper, comparison tests, where
different types of metal powder layers were used in the brazing joints of
titanium/steel, were carried out. Mechanical properties and microstructures of the
joints were also analyzed against processing parameters and different powders.
The Short Paper “Process Research on Diode Laser-TIG Hybrid Overlaying
Welding Process” is a contribution from researchers at Lanzhou University of
Technology. A laser-TIG overlaying welding method is proposed to improve
forming quality and reduce equipment cost. An experiment system was set up to
study the influence of welding parameters on forming characteristics.
IamconfidentthattheabovepapersinthisTIWMissuesignificantlycontribute
tothe frontier ofintelligent welding manufacturing, aswellas thetopicsrelatedto
the conference RWIA’2018.
Yuming Zhang, Ph.D.
TIWM Editor-in-Chief
[email protected]
James R. Boyd
Professor of Electrical Engineering, University of Kentucky
Fellow, American Welding Society (AWS)
Fellow, American Society of Mechanical Engineers (ASME)
Fellow, Society of Manufacturing Engineers (SME)
Contents
Feature Articles
ModelingandOptimizationofAdjustmentofHumanWelderonWeld
Pool Dynamics for Intelligent Robot Welding . . . . . . . . . . . . . . . . . . . . 3
Gang Zhang, Yukang Liu, Yu Shi, Ding Fan and Yuming Zhang
Progress and Trend in Intelligent Sensing and Control of Weld Pool
in Arc Welding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ding Fan, Gang Zhang, Yu Shi and Ming Zhu
Research Papers
Spectral Analysis of the Plasma Emission During Laser Welding
of Galvanized Steel with Fiber Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Bo Chen, Zhiwei Chen, Han Cheng, Caiwang Tan and Jicai Feng
A Method for Detecting Central Coordinates of Girth Welds Based
on Inverse Compositional AAM in Tube-Tube Sheet Welding. . . . . . . . 65
Yu Ge, Yanling Xu, Huanwei Yu, Chao Chen and Shanben Chen
Spectral Signal Analysis Using VMD in Pulsed GTAW Process
of 5A06 Al Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Haiping Chen, Gang Li, Na Lv and Shanben Chen
NonlinearIdentificationofWeldPenetrationControlSysteminPulsed
Gas Metal Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Wandong Wang, Zhijiang Wang, Shengsun Hu, Yue Cao
and Shuangyang Zou
Effect of Transverse Ultrasonic Vibration on MIG Welded Joint
Microstructure and Microhardness of Galvanized Steel Sheet . . . . . . . . 109
Guohong Ma, Xiaokang Yu, Jian Li and Yinshui He
ix
x Contents
Effect of Scanning Mode on Microstructure and Physical Property
of Copper Joint Fabricated by Electron Beam Welding. . . . . . . . . . . . . 119
ZiyangZhang,ShanlinWang,JijunXin,YuhuaChenandYongdeHuang
ResearchonVirtualRealityMonitoringTechnologyofTele-operation
Welding Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Canfeng Zhou, Long Wang, Yu Luo, Hui Gao, Juan Li and Guoxue Gao
The Influence of Powder Layers Intervention on the Microstructure
and Property in Brazing Joints of Titanium/Steel . . . . . . . . . . . . . . . . . 147
Pengxian Zhang, Yibin Pang and Shilong Li
Short Papers and Technical Notes
Process Research on Diode Laser-TIG Hybrid Overlaying Welding
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Ming Zhu, Buyun Yan, Xubin Li, Yu Shi and Ding Fan
Information for Authors. .... ..... .... .... .... .... .... ..... .... 169
Author Index.. .... .... .... ..... .... .... .... .... .... ..... .... 171