• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.3 no.4
• /
• pp.73-80
• /
• 2004

A dual purpose robot automation system is developed for both arc welding and spot welding by one robot within a cell. The need for automation of both arc welding and spot welding processes is urgent while the production volume is not so big as to accommodate separate station for the two processes. Also, space is too narrow for separate station to be settled down in the factory. A spot welding robot is chosen and the function for arc welding are implemented in-house at cost of advanced functions. For the spot welding, a single pole type gun is used and the robot has to push down the plate to be welded, which causes the robot positioning error. Therefore, position error compensation algorithm is developed. The basic functions for the arc welding processes are implemented using the digital I/O board of robot controller, PLC, and A/D conversion PCB. The weaving pattern is taught in meticulously by manual teach. A fixture unit is also developed for dual purpose. The main aspects of the system is presented in this paper especially in the design and implementation procedure. The signal diagrams and sequence logic diagrams are also included. The outcome of the dual purpose welding cell is the increased productivity and good production stability which is indispensable for production volume prediction. Also, it leads to reduction of manufacturing lead time.

• Proceedings of the KWS Conference
• /
• 2003.11a
• /
• pp.150-152
• /
• 2003

This simulation was carried out to estimate the process time and to improve the operation efficiency. The subassembly process consists of piece arrangement, tack welding, robot welding, manual welding and the robot welding of them was the focus of the simulation. Robot welding stage was analyzed by UML and IDEFø method, and then it was represented as the three-dimensional model(simulator) based on the analysis. The output of this simulation was the cycle time for one day's work. The cycle time for the different torch and the different piece arrangement was investigated by the 3-dimensional simulation.

• 제어로봇시스템학회:학술대회논문집
• /
• 1993.10a
• /
• pp.270-275
• /
• 1993

In this paper, the arc welding robot controller using a touch sensor and a arc sensor is presented. The controller is composed of robot controller parts for moving torch, and arc welding controller for welding and tracking. In the controller, an compensated data is generated to control robot trajectory and seam tracking by the arc sensor function. The data is obtained by integration of arc current. Experimental results are presented confirming the controller performance.

• 제어로봇시스템학회:학술대회논문집
• /
• 1992.10a
• /
• pp.797-800
• /
• 1992

Much experience and knowledge is needed in welding because there are many working parameters and quantitative description is difficult. Therefore, introduction of expert system based on such data base has been required. In this study, welding heat and shape of bead was controlled by fuzzy inference with the welding condition, position error and voltage and current error of robot. For this, torch trajectory of robot was generated by modeling the working data with CAD and then welding was carried out through down loading to robot. And working error was controlled by on-line communication.

• Proceedings of the KIEE Conference
• /
• 1993.07a
• /
• pp.376-379
• /
• 1993

GoldStar Industrial Systems Co. R & D center successfully developed the inverter for welding under the support of GoldStar Electric Machinery Co. Now, we are currently working on the mechanical part of articulated robot and a high-performance general purpose motion controller. By combining the above three items, we will be able to constitute the complete welding robot system on our own. In this article. the welding robot system currently under developing is introduced. The main focus will be placed on the development of general purpose motion controller with welding control module. Therefore, the architecture of welding robot controller where the general purpose motion controller is combined with the welding controller module will be explained. Here, the software system will be explained with regard to the hardware system.

• Proceedings of the KSME Conference
• /
• 2003.04a
• /
• pp.917-922
• /
• 2003

In this paper, a high speed rotating arc sensor for automatic fillet welding is introduced. In order to track the welding seam, The high speed rotating arc sensor is used. The welding tip of a high speed rotating arc sensor rotates about 3000 rpm using DC motor. The rotating torch is driven by gear between welding torch body and wire guide. The welding current is measured by using the current sensor and rot at ing position sensor. To realize the welding seam tracking algorithm with accuracy, a software filter algorithm using the moving average method is applied to the measured welding current in the microprocessor. The welding mobile robot with two wheels and two sliders is developed for fillet welding. The welding mobile robot can control its traveling direction and turn itself around the corner. The effectiveness is proven through the experimental results conducted with varied fillet tracking patterns.

• Journal of Welding and Joining
• /
• v.14 no.6
• /
• pp.68-80
• /
• 1996

When a workpiece is to be arc welded around the outside corner, continuous welding without welding seam in the neighborhood of comer still remains a very difficult technique. Skilled welders weld comers by delicate“hand-eye coordination”while turning the workpiece manually, However, there is not a very clear solution to this problem in robotized arc welding process. In order to solve this problem, the coordination of a robot and a positioner with one or two axes is necessary. This paper presents a method of continuous welding around the corner of workpiece using the coordinated motion of a robot and a positioner. The positioner is either revolute jointed or prismatic jointed. In this paper, a clothoid curve is chosen for welding trajectory. The clothoid curve is excellent in connecting straight and curved weld-lines with good continuity and accommodates various welding conditions. By using this welding trajectory, the deceleration, which leads to widening of the melt and the heat affected zone, at comer area is reduced with strategic rotation of robot torch in coordination with a positioner providing smooth transition of welding torch orientation. Two types of special clothoid curves are developed for different weld slope conditions. These clothoid curves are applied to the case of linear and rotary Positioners at arc welding robot work-cell.

• Journal of Welding and Joining
• /
• v.34 no.1
• /
• pp.54-58
• /
• 2016

In this research paper, suggest method of generate same bead as an actual measurement data in virtual welding conditions, exploit morphology information of the bead that acquired through robot welding. It has many multiple risk factors to Beginners welding training, by we make possible to train welding in virtual reality, we can reduce welding training risk and welding material to exploit bead visualization algorithm that we suggest so it will be expected to achieve educational, environmental and economical effect. The proposed method is acquire data to each case performing robot welding by set the voltage, current, working angle, process angle, speed and arc length of welding condition value. As Welding condition value is most important thing in decide bead form, we would selected one of baseline each item and then acquired metal followed another factors change. Welding type is FCAW, SMAW and TIG. When welding trainee perform the training, it's difficult to save all of changed information into database likewise working angle, process angle, speed and arc length. So not saving data into database are applying the method to infer the form of bead using a neural network algorithm. The way of bead's visualization is applying the spline algorithm. To accurately represent Morphological information of the bead, requires much of morphological information, so it can occur problem to save into database that is why we using the spline algorithm. By applying the spline algorithm, it can make simplified data and generate accurate bead shape. Through the research paper, the shape of bead generated by the virtual reality was able to improve the accuracy when compared using the form of bead generated by the robot welding to using the morphological information of the bead generated through the robot welding. By express the accurate shape of bead and so can reduce the difference of the actual welding training and virtual welding, it was confirmed that it can be performed safety and high effective virtual welding education.

• Journal of Advanced Marine Engineering and Technology
• /
• v.33 no.2
• /
• pp.313-321
• /
• 2009

The construction of fiber-reinforced plastic (FRP) boats is decreasing trend since the application of international regulations on the control of marine environmental pollution, which recommended the use of environmentally friendly materials. The aluminum alloy used with material for ship is a superior to FRP. It is environmental friendly, easy to recycle, and provides a high added value to fishing boats. However, the welding for Al alloy materials have many problems, such as deformation by welding heat and effect of the working environment. In this paper, it was carried out welding by robot with welding material of ER5183 and ER5556 on 6061-T6 Al alloy for ship. The mechanical and electrochemical characteristics evaluated for specimen welded by robot. The cathodic polarization trend for the base metal and welding metal showed the effects of concentration polarization due to oxygen reduction and activation polarization due to hydrogen generation. The hardnesses of welding zone and heat affected zone are lower than that of base metal. At the result of tensile test, the specimen welded with ER5183 presented excellent property compared with ER5556.

• International Journal of Precision Engineering and Manufacturing
• /
• v.4 no.2
• /
• pp.30-38
• /
• 2003

This paper proposed PID controller for torch slider and PD controller for motor right wheel. to control the motion of two-wheeled welding mobile robot with seam tracking sensor touched on welding line. The motion control is realized in the view of keeping constant welding velocity and precise seam tracking even though the target welding line is on straight line or curved line. The position and direction of the body of the mottle robot are controlled by using signal errors between seam tracking sensor and body positioning sensor attached on the end of torch slider and body side of the mobile robot, respectively. In turning motion, the body and the torch slider are controlled by using the kinematic model related with two motions of body turning and torch sliding. The straight locomotion is controlled according to eleven control patterns obtained from displacements between two sensors of the seam tracking sensor and the body positioning sensor. The effectiveness is proven through the experimental results fur lattice type welding line. Through the experimental results, we can see that the position value of the electrode end point and the welding velocity are controlled almost constantly both in straight and turning locomotion.