Modeling, Sensing and Control of Gas Metal Arc Welding
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Table of contents
- Modeling, Sensing and Control of Gas Metal Arc Weldingiii
- Copyright Pageiv
- Contentsxi
- Dedicationv
- Prefacevii
- Acknowledgmentsix
- List of Figuresxvii
- Chapter 1. Introduction1
- 1.1 Introduction1
- 1.2 The Survey4
- References List for Chapter 17
- Chapter 2. Gas Metal Arc Welding: Modeling9
- 2.1 Gas Metal Arc Welding9
- 2.2 Physics of Welding14
- 2.3 Melting Rate22
- 2.4 Metal Transfer Characteristics23
- 2.5 Weld Pool31
- 2.6 Process Voltages35
- 2.7 Heat and Mass Transfer37
- 2.8 Process Variables38
- 2.9 INEEL/ISU Model43
- 2.10 Empirical and Statistical Models52
- 2.11 Modeling by System Identification and Estimation53
- 2.12 Intelligent Modeling53
- 2.13 Other Issues on Modeling55
- 2.14 Power Supplies61
- 2.15 Other Issues on Power Supplies65
- 2.16 Classification of References by Section66
- References List for Chapter 267
- Chapter 3. Gas Metal Arc Welding: Sensing95
- 3.1 Classification of Sensors95
- 3.2 Conventional Method99
- 3.3 Computer-Based Measurements99
- 3.4 Welding Parameters Monitoring100
- 3.5 Sensors for Line Following/Seam Tracking101
- 3.6 Arc Length Sensors103
- 3.7 Sensors for Weld Penetration Control105
- 3.8 Sensors for Weld Pool Geometry111
- 3.9 Optical Sensors113
- 3.10 Sensors for Quality Control114
- 3.11 Intelligent Sensing114
- 3.12 Other Issues on Sensing115
- 3.13 Classification of References by Section118
- References List for Chapter 3121
- Chapter 4. GMAW: Automatic Control147
- 4.1 Automatic Welding147
- 4.2 Control of Process Variables150
- 4.3 Classical Control: PI, PID and Others160
- 4.4 Multivariable Control161
- 4.5 Optimization and Optimal Control163
- 4.6 Adaptive Control164
- 4.7 Intelligent Control172
- 4.8 Statistical Process Control and Quality Control178
- 4.9 Other Control Methodologies and Issues179
- 4.10 Safety and Environmental Issues183
- 4.11 Classification of References by Section184
- References List for Chapter 4187
- Chapter 5. Control of GMAW: A Case Study219
- 5.1 Introduction219
- 5.2 Empirical Modeling of a GMAW Process222
- 5.3 SISO Current Control Using PI Controller235
- 5.4 Multi-Loop Control of the GMAW Process239
- 5.5 Adaptive Control of GMAW Process244
- 5.6 Control Strategy257
- 5.7 Summary268
- 5.8 Classification of References by Section270
- References List for Chapter 5271
- Chapter 6. Conclusions275
- 6.1 Control Technology and Automation in Welding275
- 6.2 Main Issues and Outlook276
- 6.3 Classification of References by Section278
- References List for Chapter 6279
- Bibliography281
- Index347
Arc welding is one of the key processes in industrial manufacturing, with welders using two types of processes - gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW). This new book provides a survey-oriented account of the modeling, sensing, and automatic control of the GMAW process.
Researchers are presented with the most recent information in the areas of modeling, sensing and automatic control of the GMAW process, collecting a number of original research results on the topic from the authors and colleagues.
Providing an overview of a variety of topics, this book looks at the classification of various welding processes; the modeling aspects of GMAW; physics of welding; metal transfer characteristics; weld pool geometry; process voltages and variables; power supplies; sensing (sensors for arc length, weld penetration control, weld pool geometry, using optical and intelligent sensors); control techniques of PI, PID, multivariable control, adaptive control, and intelligent control. Finally, the book illustrates a case study presented by the authors and their students at Idaho State University, in collaboration with researchers at the Idaho National Engineering and Environment Laboratory.