• Proceedings of the KWS Conference
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• 1999.05a
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• pp.233-236
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• 1999

The welding residual stress should be considered in fatigue stress analysis because it develope during the process of the electric resistance spot welding and it causes bad affect on the fatigue crack initiation and growth at nugget edge of spot welded points. Therefore the accurate estimation of residual stress is crucial. In this study, nonlinear finite element analysis on welding residual stress generated during the process of the spot welding was conducted, and their results were compared with the experimental data measured by X-ray diffraction method. From the results, it was found that welding residual stress existed as tension in the nugget center and as compression around the nugget edge.

• 제어로봇시스템학회:학술대회논문집
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• 1992.10b
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• pp.382-387
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• 1992

In order to obtain desired arc welding performance, we already developed an arc welding robot system that enabled coordinated motions of dual arm robots. In this system one robot arm holds a welding target as a positioning device, and the other robot moves the welding torch. Concerning to such a dual arm robot system, the positioning accuracy of robots is one important problem, since nowadays conventional industrial robots unfortunately don't have enough absolute accuracy in position. In order to cope with this problem, our robot system employed teaching playback method, where absolute error are compensated by the operator's visual feedback. Due to this system, an ideal arc welding considering the posture of the welding target and the directions of the gravity has become possible. Another problem still remains, while we developed an original teaching method of the dual arm robots with coordinated motions. The problem is that manual teaching tasks are still tedious since they need fine movements with intensive attentions. Therefore, we developed a 3-dimensional vision guided robot control method for our welding robot system with coordinated motions. In this paper we show our 3-dimensional vision sensor to guide our arc welding robot system with coordinated motions. A sensing device is compactly designed and is mounted on the tip of the arc welding robot. The sensor detects the 3-dimensional shape of groove on the target work which needs to be weld. And the welding robot is controlled to trace the grooves with accuracy. The principle of the 3-dimensional measurement is depend on the slit-ray projection method. In order to realize a slit-ray projection method, two laser slit-ray projectors and one CCD TV camera are compactly mounted. Tactful image processing enabled 3-dimensional data processing without suffering from disturbance lights. The 3-dimensional information of the target groove is combined with the rough teaching data they are given by the operator in advance. Therefore, the teaching tasks are simplified

• Journal of Welding and Joining
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• v.28 no.6
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• pp.76-83
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• 2010

The purpose of this study is to propose a method to decide near-optimal settings of the constant current fuzzy control parameters using a controlled random search. This method tries to find the near-optimal settings of the constant current fuzzy control parameters through experiments. It has an advantage of being able to carry out searches in the search domain which includes some irregular points. The method suggested in this study was used to determine the fuzzy control parameters by which the desired welding current were formed during inverter DC resistance spot welding. The output variable was the ITAE (integral of time multiplied by the absolute error). This output variable was determined according to the input variables, which are the GE, GDE, and GDU. This study described how to obtained near-optimal welding current condition over a wide search space conducting a relatively small number of experiments.

• International Journal of Korean Welding Society
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• v.1 no.1
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• pp.23-30
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• 2001

Among the various welding conditions, the welding current that is inversely proportional to the tip-to-work-piece distance is an essential parameter as to monitor the GMAW process and to implement the welding automation. Considering the weld pool surface geometry including weld defects, it should modify the signal processing method for automatic seam tracking in horizontal fillet welding. To meet the above necessities, a mathematical model related with the weld pool geometry was proposed as in a conjunction with the two-dimensional heat flow analysis of the horizontal fillet welding. The signal processing method based on the artificial neural network (Adaptive Resonance Theory) was proposed for discriminating the sound weld pool surface from that with the weld defects. The reliability of the numerical model and the signal processing method proposed were evaluated through the experiments of which showed that they are effective for predicting the weld bead shape with or without the weld defects in a horizontal fillet welding.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.657-660
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• 2002

In this paper, a study on the residual stress of plate with longitudinal stiffeners is explained in terms of the welding sequences. In order to verify the results of numerical analysis, the hole drilling method (HDM) is performed, to measuring the residual stresses of the test plates in $CO_2$ Flux Cored Arc Welding (FCAW) under various welding conditions. The non-linear transient analysis technique for the numerical analysis in a large and complicate structure is considered. The residual stress of plate in consideration of the welding sequences and directions is evaluated by some numerical simulations and also by experiments. Comparison of numerical analysis results with experimental data shows the accuracy and validity of the proposed method.

• Proceedings of the KIPE Conference
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• 1999.07a
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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.

• International Journal of Automotive Technology
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• v.8 no.1
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• pp.83-91
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• 2007

Nowadays, the increasing global competition forces manufacturing enterprises to apply new technologies such as laser welding to manufacturing of their products. In case of automotive industries, they interest in assembly system for BIW (Body in White) carrying out laser welding. In this paper, the method of implementation for digital laser welding assembly system is proposed. Based on the requirements of assembly tasks obtained through product analysis, process modeling is executed by using the IDEF0 and UML model. For digital assembly system, the selected components are modeled by using 3D CAD tools. According to the system configuration strategy, lots of the alternative solutions for the assembly system of welding side panels are generated. Finally, the optimal laser welding system is chosen by the evaluation of the alternative solutions with TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) method.

• Journal of Power System Engineering
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• v.4 no.4
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• pp.54-58
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• 2000

The complete joining method for dissimilar hot die punch materials and its real-time evaluation method are not available at present. Brazing method has been used for joining them, but it is known that the welded joint by the brazing has the lower bonding efficiency and reliability than the diffusion welding. The friction welding with a diffusion mechanism in bonding was applied in this study. So, this work was carried out to determine the optimal friction welding conditions and to analyze mechanical properties of friction welded joints of hot die punch materials (STD61 for the blade part of hot die punch) to alloy steel (SCM440 for the shank part of hot die punch) such as plunger. In addition, acoustic emission test was carried out during friction welding to evaluate the weld quality.

• Journal of Welding and Joining
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• v.20 no.1
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• pp.26-33
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• 2002

This study was undertaken to obtain the fundamental knowledges on the weld deflects and it's realtime monitoring method. The paper describes the results of high speed photography, acoustic emission (AE) detection and plasma light emission (LE) measurements during $CO_2$ laser welding of STS 304 stainless steel and A5083 aluminum alloy in different welding condition. The characteristic frequencies of plasma and keyhole fluctuations at different welding speed and shield gases were measured and compared with the results of Fourier analyses of temporal AE and LE spectra, and they had considerably good agreement with keyhole and plasma fluctuation. Namely, the low frequency peaks of AE and LE shifted to higher frequency range with the welding speed increase, and leer the argon shield gas it was higher than that in helium and nitrogen gases. The low frequencies dominating in fluctuation spectra of LE probably reflect keyhole opening instability. It is possible to monitor the weld bead deflects by analyzing the acoustic and/or plasma light emission signals.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.652-656
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• 2002

The HDM(Hole Drilling Method) is a relatively simple and accurate method in measuring residual stress of welded metal. Various methods of evaluating residual stress are studied in welding field. The method of cutting holes on the plate much affects the accuracy of result. Especially for the hard material like stainless steel difficult to cut preciously is difficult to measure residual stress on welded metal. Because heat conduction of stainless steel is lower than other general steel, the magnitude of residual stress might be different as to changing of welding conditions. Therefore, The distribution of residual stress on the STS304 steel after welding using HDM is evaluated in this paper.