• Journal of Welding and Joining
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• v.16 no.3
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• pp.55-63
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• 1998

Among the position sensing methods available, the arc sensor which utilizes the electrical signal obtained from the welding arc itself is one of the most prevalently used methods, because it has an advantage that no particular sensing device is necessary and real-time sensing of a groove position is possible directly under the arc. The authors have already developed a seam tracking system that contains a new arc sensor algorithm, which uses the relative welding current variation according to the tip-to-workpiece distance in GMA welding. In this study a torch height control algorithm for automatic weld seam tracking was proposed for completing the previous system, which uses an on-off control technique. To implement the torch height control algorithm during weld seam tracking the system parameters which include 2nd averaging range, weighting factor for 2nd moving averaging, and Z-directional basic compensation distance were determined by experimental analysis. Finally the two different height control methods, one is simple on-off control and the other on-off control using a reference current value , were compared in their tracking abilities.

• Journal of Welding and Joining
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• v.26 no.2
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• pp.92-97
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• 2008

In welding of thin plate, some defects such as melt through and unmelted zone occur easily at welding start, however there is a limited study on those problems. Therefore the effects of start block and arc length on melt through and unmelted zone at start were investigated in this study. When start block height was lower than base metal, there was melt through at start. And when the height was even with base metal, no unmelted zone existed. Unmelted zone was increased as start block height increased from 0mm to 0.5mm. However unmelted zone was not much changed as the height increasing from 0.5mm to 1.0mm. When gap existed between start block and base metal, melt through occurred. However, unmelted zone was increased as the contact force of start block on base metal was increased from 0kgf to 7.5kgf. And when arc length was decreased from 3.8mm to 3.0mm, unmelted zone was decreased. It was concluded that the optimum condition to prevent melt through and to minimize unmelted zone would be with start block height 0.25mm, contact force 3.0kgf, and arc length 3.4mm. This optimum condition was applied to the mass production line and resulted in satisfied outcome.

• Proceedings of the KSME Conference
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• 2001.06a
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• pp.477-482
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• 2001

A study was performed to determine the optimum height for an arc air gouging of temporary attachments, which were attached at the pressure vessel made of low alloy steel. Frequently, the crack occurred in the base metal by the excessive heat input during an arc air gouging process to remove the temporary attachments. A numerical analysis by 2-dimensional finite element method was performed to calculate the temperature distribution in the base metal during the removal of temporary attachments. And then the mock-up test was performed to verify the numerical results. Numerical values showed good agreement with the experimental results. These results indicated that the defects due to the excessive heat input during an arc air gouging were dependent on the height of temporary attachments remained above hie main products.

• Journal of the Korean Society for Railway
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• v.13 no.1
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• pp.37-43
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• 2010

Catenary (Overhead Contact Lines) and Pantograph are used to transmit electrical energy to electric railways. An Arc occurs by unstable contact between catenary and pantograph during electric railways operation, which causes malfunctioning or even an accident. Therefore, to prevent a arc or electric contact loss are required arc detection systems with catenary maintenance capability. This paper describes developing of catenary arc detection system using photo detector in order to detect arc incidence in a indirect way. This developed system can also achieve Video-recordings and environmental conditions such as wire voltage/current, pantograph height, speed, position of electric railways, and temperature/humidity. This system have been evaluated at the section that bounds for dongdaegu from seoul. From the experimental results, the occurrence of arc and intensity of arc are mainly effected by wire voltage/current, pantograph height and speed of electric railways.

• Journal of Welding and Joining
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• v.30 no.2
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• pp.54-58
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• 2012

Al-coated steel sheets with excellent heat and corrosion resistance are widely used in various applications. In welding of thin plate, some defects such as unmelted zone and metal-through occur easily in the beginning and ending of welding line. In the study, the welding defects in Al-coated steel sheets were investigated with respect to plasma arc current, height between Cu block and base metals, and using a roller to align the height of the base metal. Full penetration and voids free welds were obtained with a plasma arc current 52A and weld speed 2.3m/min. An unmelted zone increased and Ericshen rate decreased as the height between Cu block and base metal increased from 0 to 0.6mm. Using a roller moving ahead of the plasma arc, the length of unmelted zone decreased from 1.7mm to 0.5mm.

• Journal of Welding and Joining
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• v.18 no.4
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• pp.82-86
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• 2000

Gas metal arc welding(GMAW) is regarded as one of the best candidate for welding automation in industrial joining application. It is important to monitor the weld quality for the high performance weld automation. In GMAW, weld quality is closely related to arc stability especially. In this paper, arc light signal is measured and spectrum analyzed to the detect the variation of the weld quality. The FFT of the signal showed that the amplitude variance of FFT power spectrum was very large in poor weld process such as the decrease of weld bead width and height. The results show that it is possible to detect the weld defect position in weld process.

• International Journal of Korean Welding Society
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• v.3 no.2
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• pp.15-23
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• 2003

A genetic algorithm was applied to an arc welding process to determine near optimal settings of welding process parameters which produce good weld quality. This method searches for optimal settings of welding parameters through systematic experiments without a model between input and output variables. It has an advantage of being able to find optimal conditions with a fewer number of experiments than conventional full factorial design. A genetic algorithm was applied to optimization of weld bead geometry. In the optimization problem, the input variables were wire feed rate, welding voltage, and welding speed, root opening and the output variables were bead height, bead width, penetration and back bead width. The number of level for each input variable is 8, 16, 8 and 3, respectively. Therefore, according to the conventional full factorial design, in order to find the optimal welding conditions, 3,072 experiments must be performed. The genetic algorithm, however, found the near optimal welding conditions from less than 48 experiments.

• Electrical & Electronic Materials
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• v.8 no.5
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• pp.564-571
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• 1995

This paper deals with the arc discharge characteristics of kerosene oil as a basic study on electrical discharge machine. Using needle electrode the discharge voltage, discharge current, discharge energy and the shape of discharge crater are measured. In consequence, it becomes clear that the discharge crater(depth, height, diameter) is depending on the discharge energy. Rapid increase in depth, height and diameter of discharge crater was observed during initial discharge, where discharge energy is large. However, rather slow decrease of those values was found when discharge energy is low or N is more than 3. As the ratio of $I_p$$T_on$ increase, the shape of discharge crater gets near circle. The protuberances of the discharge crater were not formed by the melted needle electrode but by the that of work piece.

• 제어로봇시스템학회:학술대회논문집
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• 2003.10a
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• pp.2701-2706
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• 2003

This paper describes weld seam tracking and error compensation methods of automatic plasma arc welding system designed for the corrugation panel that consists of a linear section and a curved section with various curvatures. Realizing automatic welding system, we are faced with two problems. One is a precise seam tracking and the other is an arc length control. Due to the complexity of the panel shape, it is difficult to find a seam and operate a torch manually in the welding process. So, laser vision sensor for seam tracking is equipped for sensing the seam position and controlling the height of a torch automatically. To attain more precise measurement of an arc length, we measure the 3D shape of the panel and analyze error factors according to the various panel states and caused errors are predicted through the welding process. Using that result, compensation algorithm is added to that of arc length control and real time error compensation is achieved. The result shows that these two methods work effectively.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.4
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• pp.132-139
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• 2002

In GMAW(Gas Metal Arc Welding) processes, bead geometry (penetration, bead width and height) is a criterion to estimate welding quality. Bead geometry is affected by welding current, arc voltage and travel speed, shielding gas, CTWD (contact-tip to workpiece distance) and so on. In this paper, welding process variables were selected as welding current, arc voltage and travel speed. And bead geometry was reasoned from the chosen welding process variables using neuro-fuzzy algorithm. Neural networks was applied to design FL(fuzzy logic). The parameters of input membership functions and those of consequence functions in FL were tuned through the method of learning by backpropagation algorithm. Bead geometry could be reasoned from welding current, arc voltage, travel speed on FL using the results learned by neural networks. On the developed inference system of bead geometry using neuro-furzy algorithm, the inference error percent of bead width was within $\pm$4%, that of bead height was within $\pm$3%, and that of penetration was within $\pm$8%. Neural networks came into effect to find the parameters of input membership functions and those of consequence in FL. Therefore the inference system of welding quality expects to be developed through proposed algorithm.