• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 2005년도 ICCAS
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• pp.626-630
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• 2005

This paper presents a novel Intelligent-Welding-Carriage (IWC) for automation of curved block in shipbuilding. The curved block is usually used in both front and back side of the ship. In curved block root gap is big, $1{\sim}7$ [mm] and inclination, $0{\sim}30$ [deg]. Since available conventional carriage type is limited to use below root gap of 3 [mm], only manual welding is employed in curved block. To adopt an IWC in curved block, it requires control of the welding conditions, i.e., voltage, current and travel speed, with respect to root gap and inclination to achieve good welding quality. In this paper, an IWC is developed for automization of welding operation to accommodate gap and inclination. Kinematics model and dynamics using Lagrangian formulation of the manipulator is introduced. IWC utilizes a database to perform accurate welding. The database is programmed based on numerous experimental test results with respect to gap, inclination, material, travel speed, weaving condition, voltage, and current. Finally, experimental result using PID control is addressed for verify the trajectory tracking accuracy of end-effector.

• 대한조선학회 특별논문집
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• 대한조선학회 2005년도 특별논문집
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• pp.171-176
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• 2005

This paper presents a novel Intelligent-Welding-Carriage (IWC) for automation of curved block in shipbuilding. The curved block is usually used in both front and back side of the ship. In curved block root gap is big, 1-7 (mm) and inclination, 0-30 (deg). Since available conventional carriage type is limited to use below root gap of 3 (mm), only manual welding is employed in curved block. To adopt an IWC in curved block, it requires control of the welding conditions, i.e., voltage. current, weaving speed, dwell time and travel speed, with respect to root gap and inclination to achieve good welding qualify. In this paper, an IWC is developed for automization of welding operation to accommodate gap and inclination. Kinematics model and dynamics using Lagrangian formulation of the manipulator is introduced. IWC utilizes a database to perform accurate welding. The database is programmed based on numerous experimental test results with respect to gap, inclination, material, travel speed, weaving condition, voltage, and current. Finally, experimental result using PID control is addressed for verifying the trajectory tracking accuracy of end-effector.

• 한국해양공학회지
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• 제27권5호
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• pp.77-81
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• 2013

The effects of the welding parameters, contact tip-to-workpiece distance (CTWD), current, and voltage on the diffusible hydrogen content in weld metal deposited by self-shielded flux cored arc welding were investigated and rationalized by comparing the amount of heat generated in the extension length of the wire. This showed that as CTWD increased from 15mm to 25mm, the amount of heat generated was increased from 71.1J to 174.8J, and the hydrogen content was decreased from 11.3mL/100g to 5.9mL/100 g. Even if little difference was observed in the amount of heat generated, the hydrogen content was increased with an increase in voltage because of the longer arc length. A regression analysis showed that the regression coefficient of voltage in self-shielded flux cored arc welding is greater than that in $CO_2$ arc welding. This implies that voltage control is more important in self-shielded flux cored arc welding than in $CO_2$ arc welding.

• Journal of Welding and Joining
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• 제29권6호
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• pp.77-81
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• 2011

In most industry, manual GTAW welding is preferred for formation of stable back bead in root weld of butt joint. However, manual GTAW welding has low productivity as compared with GMAW, also it has unstable bead quality which depend on skilled workers. So it is necessary to develop process of root pass welding by using automation GMAW that have stable back bead formation and high productivity. In this paper, the design of U-groove with 3mm root face was applied to extend the tolerance of misalignment in condition of standard root gap 1.5mm. Consequently, for the formation of stable back bead in root pass of butt welding, in case of the narrow root gap(0.5mm) the large arc force was applied by increasing the current and voltage. In case of the large root gap(2.5mm), the small arc force was applied by decreasing the current and voltage. Considering the various root gap, the required deposited metal was controlled by welding speed only.

• 한국산업융합학회 논문집
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• 제14권1호
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• pp.15-21
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• 2011

Welding variables and conditions in gas metal arc welding (GMAW) effect on the quality and productivity of the weld, extensive research efforts have been made to analyze the effect of the welding variables and conditions. In this study dynamic behavior of GMAW system is investigated using the characteristics of the power supply, wire and welding arc. Characteristic equation of wire is modified to include the effect of droplets attached at the electrode tip. The dynamic characteristics of arc length, current, voltage with respect to the step, ramp inputs of CTWD was simulated. From results of simulation, some predictions about dynamic characteristics of GMAW and welding process are available. The proposed simulator and results appear to be utilized to determine the proper welding conditions, to be improved by considering power supply dynamic characteristics.

• Journal of Welding and Joining
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• 제16권4호
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• pp.39-46
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• 1998

$CO_2$ gas shielded arc welding has been characterized with its harsh arc compared to Ar-based shielding gases and with its high level of spattere specially in welding current range of 250~300 amperes. In this range of welding current, the metal transfer mode showed to be changed from short circuit to globular with the increase of welding voltage resulting in so-called the transitional mode in which both modes of transfer appeared together. To characterize the transitional mode, the short circuit events were divided into two groups, i.e. normal short circuit (N.S.C) which has short circuit time $(t_s)$ over 2msec and instantaneous short circuit (I.S.C) of $t_s$$\leq$2msec. The experimental results showed that the number of N.S.C decreased almost linearly with the increase of welding voltage and appeared to be not related with spatter generation rate. However I.S.C became to be pronounced in the transitional condition and its number reached the maximum value at around 29.0 volts. Considering the relation with the spatter generation rate, it was found that the number of I.S.C had a very strong correlation with the spatter generation rate of the transitional condition. It was further demonstrated that spatter generation rate decreased quite linearly with the decrease of I.S.C frequency. It implies that I.S.C is the most important waveform factor controlling the spatter generation of the transitional mode, i.e. in the middle range of welding current. Based on these results, It was discussed that in the transitional mode the basic concept of waveform control for suppressing spatter generation would be different from the one applied for typical short circuit transfer mode of low welding current.

• Journal of Welding and Joining
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• 제21권3호
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• pp.51-57
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• 2003

The metal transfer in $CO_2$ welding shows the transition of transfer mode from short-circuiting to repelled transfer will the increase of welding current. While the short-circuiting mode in $CO_2$ welding has been studied very extensively relating with droplet formation and spatter generation, the repelled transfer has little been understood. In this study, high current $CO_2$ welding has been performed with bead-on-plate welds along with the waveform analyzer and high speed camera. The image of high speed camera was synchronized with its waveform so that the moment of spatter generation could be realized during drop detachment. As a results of this study, it was found that welding arc changes its location either once or three times and thus single or double pulse signals were developed in the voltage waveform. Whenever the arc moved its location, new arc was developed in a explosive way and thus it caused spatter generation. Specially severe spattering took place when the waveform showed a double-peak pattern. As a consequence of these results, new waveform control techniques could be suggested for suppressing the spatter generation in the high-current $CO_2$ welding.

• Journal of Welding and Joining
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• 제25권5호
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• pp.58-63
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• 2007

The relationship between GMA welding conditions and the bead shape of overlay weld was studied by using ${\Phi}1.6mm$ hypo-eutectic metal-cored wire designed for hardfacing against the severe metal-to-metal wear. As the welding voltage increased, the dilution also increased but the sudden drop of dilution was observed at $30{\sim}33V$. It was considered to be due to the decrease of penetration resulting from the change of transfer mode, from short circuit to spray. It was also found that the behavior of penetration with welding current was dependant on the transfer mode. The short circuit mode exerted the penetration to decrease while the spray mode did it to increase with increase of welding current. The former was considered to be responsible for the remarkable decrease in dilution at low welding voltage region. The change of transfer mode also had an effect on the behavior of bead width with welding current but it did not on the bead spreadability defined as W/H ratio. It was considered that the optimal welding conditions for multi-pass overlay welding could be obtained from the bead spreadability suitable for bead lapping and the dilution as low as possible in the spray transfer mode.

• 전력전자학회:학술대회논문집
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• 전력전자학회 1999년도 전력전자학술대회 논문집
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• pp.563-568
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• 1999

Generally the control method of wire feeding motor in welding machine has been used full-wave phase control method. The fire-angle control generates low frequency speed ripple, and it causes the output current ripple. So it results in the variation of welding condition and low welding performances such as spatter generation and bead state. For the purpose of welding performances improvement by speed controller in wire feeding motor, in this paper the constant speed control method for welding machine is proposed. The proposed system is composed of speed control loop and current control loop. As a result of experiment by using proposed constant wire feed experiment by using proposed constant wire feed speed controller, the output voltage and current waveform and metal transfer are maintained stably. And moreover the number of instantaneous short circuit occurrence is reduced remarkably.

• Journal of Welding and Joining
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• 제17권1호
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• pp.116-123
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• 1999

The $CO_2$ welding with 100% $CO_2$ shielding gas is commonly used because of its cost and efficiency. Arc phenomena of the $CO_2$ welding is influenced by various factors such as chemical compositions of welding wire, shielding gas, welding condition and welding power source etc. In this study, arc phenomena is investigated by using two type of FCW(titania type, semi-metal type). Then, the welding quality and optimum welding condition can be selected. From this study, the following results were obtained; 1) In low current range(140A), FCW up to welding voltage(22V) resulted in a typical short circuit transfer. 2) In high current range(320A), the arc stability in titania FCW of a typical globular transfer is better than that of semi-metal FCW.