Robotic Welding, Intelligence and Automation (eBook)

Preface 5
Contents 7
Part I: Intelligent Techniques for Robotic Welding 13
Research Evolution on Intelligentized Technologies for Robotic Welding at SJTU 14
Introduction 14
Characteristics Extraction of Multi-sensing Information During Arc Welding Process 15
Multi-information Acquirement of Arc Welding Process 15
Extraction of Multi-information Characteristics During Arc Welding Process 16
Information Fusion Algorithms for Prediction of Weld Penetration by Neural Network and DS Evidence Theory 17
Intelligent Modeling of Welding Process and Robot System 18
Knowledge Extraction of Arc Welding Dynamics by SVM Method 18
Knowledge Model of Al Alloy GTAW Welding Process by the RS Method 19
Mixed Logical Dynamical (MLD) Modeling of Pulsed GTAW During Robotic Welding 19
Intelligent Control Strategies for Welding Pool and Penetration Process 20
The Adaptive Inverse Control Scheme Based on SVM-FRDS for Pulsed GTAW 20
Closed Control Schemes Based-on the Knowledge Model by the RS Ttheory 20
The Model-Free Adaptive Control of Pulsed GTAW 22
The 3-D Seam Tracking During Robotic Welding by Combining Arc Sensing and Visual Sensing 22
Some Applications of Intelligentized Robotic Welding 23
An Autonomous Welding Robot System for Whole Position Motion and Across Obstacle 23
Conclusion Remarks 24
References 24
Image Processing for Automated Robotic Welding 26
Introduction 26
Refitting of an Existing Micro Panel Line by Image Processing 28
Advantages of the New Installed 3 D Image Processing System 32
Conclusions 32
Automatic Seam Detection and Path Planning in Robotic Welding 33
Introduction 33
Methodology 34
Boundary Detection 35
Corner/Curve Detection 35
Determine Seam Edges 37
Initial and Final Position Selection and Seam Point Reduction 37
Final Seam Points Input to the Robot 38
Results 39
Seam Detection and Reduction Results 39
Experimental Results 40
Conclusions 41
References 41
Error Compensation and Calibration of Inter-section Line Welding Robot Based on a Wavelet Neural Network 43
Introduction 43
Saddle-Back Coping Welding Robot Framework and Error Analysis 44
Algorithm of Intersection Line Welding Robot Error Compensation 44
Model of Error Compensation and Calibration 44
Design of a Robot Error Compensation Algorithm 46
Experiment of Error Compensation and Calibration 46
Experiment of Torch Point Error Compensation and Calibrate 46
Error Compensation and Calibration of Each Axis 48
Conclusions 49
References 50
Autonomous Seam Acquisition and Tracking for Robotic Welding Based on Passive Vision 51
Introduction 51
Experiment System 52
Image Process and Seam Extraction 53
Seam Deviation Definition 54
Seam Tracking Controller 55
Experiments and Results Analysis 56
Conclusions 58
References 58
A Framework of Intelligent Remanufacturing System Based on Robotic Arc Welding 59
Introduction 59
The Intelligent Remanufacturing System Design 60
Composition of System 60
System Description 60
Experiment and Analysis 61
Modeling 62
Slicing 62
Path Plan 63
Summary 65
References 65
A Fast GPI Line Detection Method for Robot Seam Tracking 66
Introduction 66
GPI Method 66
GPI Method with a Circular Sub-window 68
MSGPI Method 69
The Fast GPI Method 69
Principle of Fast GPI Algorithm 69
Specific Algorithm 70
Experimental Results 70
Conclusions 72
References 72
Mechanism Design and Kinematics Modeling of Irregular Cross-Section Pipeline Welding Robot 74
Introduction 74
Mechanism Design of the Special Pipe Welding Robot 75
Kinematics Modeling for the Special Pipe 77
Kinematics Modeling 77
Kinematics Modelling Verification 79
Simulation Verification 80
Conclusions 81
References 81
Combined Planning between Welding Pose and Welding Parameters for an Arc Welding Robot 82
Introduction 82
Weld Position and Welding Torch Posture 83
Welding Process Experiments 84
Construction of the Combined Planning Data Sheet 85
Typical Workpiece Welding Test 87
Conclusions 88
References 88
Optimal Digital Filtering for Tremor Suppression in a Master-Slave Robot Remote Welding System 90
Introduction 90
The Master-Slave Robot System 91
Welding Seam Tracking Experiment 91
Equalizer Design 92
Conclusions 94
References 94
Coordinated Motion of Different Weld Robots Based on User Coordinates 95
Introduction 95
Double Different Robots System 96
Master-Slave Coordinated Models 97
User Coordinates Establishment 97
Modeling Inferential Reasoning 98
Modeling Verification 101
Coordinated Motion Experiment 101
Conclusions 103
References 103
Research on Information Transmission of a Welding Robot Based on Network 104
Introduction 104
Communication System 105
Hardware 105
Software 105
Communication Method Design 107
C/S Communication Mode 107
Transmission Control Algorithm 107
Video Transmission Method 109
Test 110
The Environment of the Test 110
Experiments 110
Conclusions 111
References 112
Survey on Modeling and Controlling of Welding Robot Systems Based on Multi-agent 113
Introduction 113
The Modeling of Welding Robot System Based on Multi-agent 114
Modeling Based on BDI Model 114
Modeling Based on Petri Net 115
The Controlling of Welding Robot System Based on Multi-agent 116
The Application of Welding Robot System Based on Multi-agent 117
Conclusions 117
References 118
Research on the Robotic Arc Welding of a Five-Port Connector 120
Introduction 120
Deformation Prediction and Fixture Design for a Five-Port Connector 121
Deformation Prediction for a Five-Port Connector 121
Fixture Design of a Five-Port Connector 121
Welding Quality Control System for Robotic Arc Welding of Five-Port Connector 123
Acquisition and Processing of Welding Seam and Weld Pool Image Information 123
Three Dimensional Seam Tracking of the Five-Port Connector Welding 124
Plane Seam Tracking 124
Seam Height Tracking 124
Weld Formation Control Methods 125
Conclusions 125
References 126
Mixed Logical Dynamical Model for Robotic Welding System 128
Introduction 128
Mixed Logical Dynamical Model 129
Modeling of the Robotic Welding System 130
Conclusions 132
References 133
Part II: Sensing of Arc Welding Processing 134
A Method of Seam Tracking Based on Passive Vision 135
Introduction 135
Experiment Setup 135
Seam Image Processing 136
Image Segmentation 136
Wave Filtering 137
Edge Detection 139
Feature Extraction 139
Seam Adjusting 140
Conclusions 141
References 141
Research on a Trilines Laser Vision Sensor for Seam Tracking in Welding 143
Introduction 143
TLVS System 144
Basic Principles of TLVS 144
Seam Tracking System Structure 145
Image Preprocessing and Acquisition of Range Data 146
Image Preprocessing 146
Results of Seam Tracking 147
Conclusions 148
References 148
An Optimal Design of Multifunctional Vision Sensor System for Welding Robot 149
Introduction 149
The Design Principle and Structure of Vision Sensor System 150
The Multi-functional Optimal Design of a Vision Sensor 151
The Design of Automation Control over Long Distance 151
The Design for Resisting Disturbance from Arc 152
The Design of Guiding of the Initial Welding Position 152
Design of Seam Tracking and Weld Penetration Control 153
Experiment and Results 153
Conclusions 155
References 156
Wire Extension Control Based on Vision Sensing in Pulsed MIG Welding of Aluminum Alloy 157
Introduction 157
Experiment System Composition 158
Wire Extension Signal Extraction 159
Design of Fuzzy PID Controller 159
Wire Extension Control Experiment 161
Conclusions 162
References 163
Research on Track Fitting of Big Frame Intersection Line Seams 164
Introduction 164
Analysis on Errors Produced in Intersection Line Structural Assemblies 165
Research on Intersection Line Track Fitting 165
Ellipse Fitting Method 165
Three-Coordinate Separation and Least Square Algorithm Method 167
Comparison of Simulations of the Two Fitting Methods 169
Conclusions 171
References 171
A Hybrid Approach for Robust Corner Matching 172
Introduction 172
Background 173
Overview 173
Initial Corner Matching by SIFT Information 173
Refined Corner Matching 175
Localization of Stable Sub-pixel Corner Pairs 175
Similarity Measurement of Corner Region 176
Experimental Results and Discussion 177
Conclusions 179
References 179
Depth Extraction by Simplified Binocular Vision 181
Introduction 181
Image Processing 181
Matching Mechanism 182
Experiment 183
Conclusions 185
References 185
Comparison of Calibration Methods for Image Center 186
Introduction 186
The Camera Model 187
Calibration of Image Center 188
Category . 189
Direct Optical Method 189
Method of Varying Focal Length 190
Radial Alignment Method 191
Category . 191
Comparison and Discussion 192
References 193
Seam Tracking and Dynamic Process Control for High Precision Arc Welding 194
Introduction 194
The Robotic Welding Systems Description 195
Image Processing Algorithm 196
The Precise Control of the Arc Welding Robot 198
Seam Tracking Control Module 198
Control Scheme for the Face Flange 199
Conclusions 201
References 202
Feature Selection of Arc Acoustic Signals Used for Penetration Monitoring 203
Introduction 203
Experiment System and Signal Preprocessing 203
Experiment System 203
Welding Condition 204
Preprocessing of Acoustic Signal 205
Feature Selection 206
Evaluation Function 206
Feature Selection Based on Branch and Bound Method 207
Experimental Results 208
Conclusions 209
References 210
Rough Set-Based Model for Penetration Control of GTAW 211
Introduction 211
Experimental System 212
Proposed Method 213
Basic Concepts of Rough Set Theory 213
Approximations 214
Reduction of Attributes 215
Modeling Step 215
Experiment and Results 215
Data Preparation 215
Rules 216
Prediction Accuracy 217
The Stability of the Modeling Method 217
Conclusions 218
References 218
A Study of Arc Length in Pulsed GTAW of Aluminum Alloy by Means of Arc Plasma Spectrum Analysis 219
Introduction 219
Theoretical Background 220
Experimental Setup and Results 221
Conclusions 226
References 226
Arc Sound Recogniting Penetration State Using LPCC Features 228
Introduction 228
Experimental Setup 229
Model and Features of the Arc Sound 229
Results 230
Conclusions 232
References 232
Investigation on Acoustic Signals for On-line Monitoring of Welding 233
Introduction 233
Usefulness of Welding Acoustic Signals 233
Source of Welding Acoustic Signals 234
The Characteristic of Welding Sound 236
The Processing and Modeling of the Welding Sound 237
Reducing Noise 237
Processing of Welding Sound Signals 237
Modeling of Welding Sound 237
On-line Monitoring 239
Conclusions 239
References 239
A Study on Applications of Multi-sensor Information Fusion in Pulsed-GTAW 242
Introduction 242
Experimental System 243
A Brief Introduction about D-S Evidence Theory 243
Obtaining Basic Probability Assignment by Kohonen and Fuzzy Membership Function 244
Membership Functions and Basic Probability Assignment 244
Membership Functions Representation of BPA 245
Extracting Training Data by Kohonen Network 245
Constructing Membership Prediction Model 246
Multi-sensor Information Fusion Based on D-S Evidence Theory 247
Experimental Results 247
Conclusions 248
References 248
Research on Image Process and Tracing of a Welding Robot 250
Introductions 250
Hardware System 251
Image Pre-process 251
Image Information Extraction 252
Image Initial Process 252
Image Characteristics Extraction 253
Tracing Experiments 254
Conclusions 255
References 256
Part III: Modeling and Intelligent Control of Welding Processing 257
Predictive Control of Weld Penetration in Pulsed Gas Metal Arc Welding 258
Introduction 258
System Description 259
Step Experiments 259
Control Algorithm 260
Pre-filter 261
Predictive Control Algorithm 261
Results and Discussion 262
Simulation 262
Welding Experiments 263
Conclusions 264
References 264
Study on the MLD Modeling Method of Pulsed GTAW Process for Varied Welding Speed 265
Introduction 265
Pulsed GTAW Process 266
Mixed Logical Dynamical Model 267
Modeling of Pulsed GTAW with Varied Welding Speed 268
Conclusions 271
References 271
Simulation of Decoupling Control of Pulsed MIG Welding for Aluminum Alloy 273
Introduction 273
The Mathematical Description and Analysis for the Model 274
Simulation of Decoupling Control 275
Compensation Decoupling Control 275
Neural Network Object Inverse Model Decoupling Control 276
Conclusions 278
References 278
Modeling and Decoupling Control Analysis for Consumable DE-GMAW 279
Introduction 279
Consumable DE-GMAW 279
ARC Model of Consumable DE-GMAW 280
Coupling Relation Analysis of Parameters in Arc System 282
Decoupling Control Simulation and Discussion 284
Conclusions 286
References 286
The Structure Design and Kinematics Simulation for Rotating Arc Sensor of TIG Welding Based on Pro/E 3D Design 287
Introduction 287
Requirements 287
Basic Principle 288
Design Idea 288
3D-Modeling of Important Parts 289
Dynamic Balance of Rotating Parts 289
Dynamic Simulation Analysis 290
Dynamic Simulation Workflow 290
Analysis Results 291
Conclusions 291
References 292
Knowledge Model Building about a Motor Speed Regulation Fuzzy Control System 293
Foreword 293
Fuzzy System Model of Knowledge 294
Definitions for Model 294
Categories and Knowledge in the Model 295
The Approximation and Measurement to Category in Model 295
Approximation and Measurement of Knowledge in the Model 296
The Consistency of the Model and the Decomposition of Maximum Consistency 297
The Building of Knowledge Model of AC Motor Speed Adjustment Fuzzy Control System 297
Conclusions 299
References 300
Research on Surface Recover of Aluminum Alloy PGTAW Pool Based on SFS 301
Introduction 301
Welding Pool Image of Aluminum Alloy Pulsed GTAW 302
Reflectance Map Model of Welding Pool Surface 302
Spherical Light Source Model of Aluminum Alloy PGTAW 302
Object Surface Reflectance Model 303
Camera Characteristics 303
Resolution of Reflectance Map Equation 304
Reflectance Map Model Discretization and Linearization 305
Reflectance Map Equation Resolution 305
Surface Height Calculation of Aluminum Alloy GTAW Welding Pool 306
Conclusions 307
References 307
Research on Fuzzy-Prediction-Control of GTAW Process Based on MLD Modeling 309
Introduction 309
System Modeling 310
MLD Model 310
MLD Modeling on the GTAW Welding System 311
MPC 312
Predictive Control of MLD Systems 312
Fuzzy -MLD-PC 313
Stability of MLD Systems 313
Simulation 314
Conclusions 315
References 315
Application of Fuzzy Edge Detection in Weld Seam Tracking System 317
Introduction 317
Weld Seam Tracking System 318
Edge Detection Principle 318
Edge Models 318
Fuzzification of Edge Detection 319
Parameter Choice of Membership Functions 321
Conclusions 323
References 323
Part IV: Welding Technics and Automations 325
Application and Research of Arc Welding Automation in Korea 326
Introduction 326
Welding Research Trend in Korea 327
Automation of GMAW Process with Controlled Arc 327
Automation and Monitoring with Vision Sensor 329
Welding Automation in Industry 331
Conclusions 331
References 332
Offline Programming for a Complex Welding System Using DELMIA Automation 333
Introduction 333
DELMIA for Offline Programming and Automation 335
Automatic Seam Extraction 335
Path Planning 337
Experimental Results 338
Conclusion and Future Work 340
References 341
Robot Path Planning in Multi-pass Weaving Welding for Thick Plates 342
Introduction 342
Establishment of Offline Simulation System 343
Relationship of Weld Shape and Welding Parameter 343
Self-defining Multi-pass Weaving Welding Layout Model 344
Position and Attitude of Welding Torch 345
Oscillation Displacement Determination 347
Multi-pass Welding Experiments 348
Conclusions 349
References 350
Influence of the Bar Shape on the Welding Quality of Friction Hydro Pillar Processing 351
Introduction 351
Experimental Procedures and Method 352
Results and Analyses 353
General Features of the Welded Joints 353
Microstructure Characterization 354
Static Stress Distribution of Different Shapes 355
Influence of Different Shapes on the Welding Temperature 356
Conclusions 356
References 357
Interference Analysis of Infrared Temperature Measurement in Hybrid Welding 358
Introduction 358
Experimental Setup 359
Interference Analysis 360
Arc Llight Interference 360
TIG Ceramic Nozzle Interference 360
Laser Nozzle Iinterference 361
The Method of Removing Interferences 361
Results 362
Calibration 362
Temperature Measurement in Hybrid Welding 362
Conclusions 363
References 363
Preliminary Investigation on Embedding FBG Fibre within AA6061 Matrices by Ultrasonic Welding 364
Introduction 364
Process Conditions and Experiments 365
Test Materials 365
Test Procedure 365
Results and Discussion 366
Conclusions 369
References 370
Thermal Process Analysis in Welding Prototyping of Metal Structures 371
Introduction 371
Mathematical Model 371
Thermal Analysis 372
Stress Analysis 372
The Physical Model and Mesh Division 373
The Results and Discussion 373
Temperature Field Distribution 373
Stress Analysis 374
The Effects of Welding Temperature Field on Weld Metal 375
Conclusions 377
References 377
Study on Sub-sea Pipelines Hyperbaric Welding Repair under High Air Pressures 379
Introduction 379
Hyperbaric Welding Equipments 380
The Hyperbaric Welding Chamber 380
The Hyperbaric Welding Test Chamber and Pipe Welding Machine 380
GTAW Arc under High Air Pressures 382
Testing Conditions 382
Arc Behavior and Static Characteristics 382
Girth Weld under High Air Pressures 383
Sea-Trial of The Welding Repair System 384
Conclusions 385
References 385
Part V: Special Robot Technology and Systems 386
The Mechanism Design of a Wheeled Climbing Welding Robot with Passing Obstacles Capability 387
Introduction 387
Objectives and Challenge 389
Concept Structure of the Robot 389
The Mechanism Design of the Robot 390
The Design of the Manipulator 390
The Design of the Wheeled and Lifting Mechanism 391
Optimal Design of the Adhesion Unit 392
Experiment of Passing Obstacles 393
Conclusion and Future Work 394
References 394
Anytime Ant System for Manipulator Path Planning 396
Introduction 396
Ant System with Negative Feedback 397
Ant Colony Optimization 397
Ant System with Negative Feedback 398
Anytime Ant System for Manipulator Path Planning 401
Case Studies 401
Conclusions and Future Work 403
References 404
Path Planning and Computer Simulation of a Mobile Welding Robot 406
Introduction 406
Robot Kinematic Modeling 407
Mathematical Model 407
The Method of Choosing Geometric Structure 408
Inverse Kinematics Problem 408
Trajectory Planning Method 409
CP Trajectory Planning 409
PTP Trajectory Planning With Obstacles 411
Conclusions 412
References 412
The Control System Design of a Climbing Welding Robot Based on CAN Bus 414
Introduction 414
Climbing Welding Robot Structure 415
Control System Design 415
Hardware 416
CAN Network 417
Robot Motion Control 417
Multi-sensor Network Design 418
Conclusions 419
References 419
An Implementation of Seamless Human-Robot Interaction for Pipeline Welding Telerobotics 420
Introduction 420
Task Planning 421
Seamless HRI Algorithm 423
Experiment and Results 425
Conclusions 426
References 427
Design and Experiment of a Novel Portable All-Position Welding Robot 428
Introduction 428
Preliminaries 429
Task Analysis 429
Motion Analysis 429
Construction of Performance Index 430
Type Synthesis of Mechanism 432
Dimension Synthesis of Mechanism 433
Motor Layout Optimization Design 434
Virtual Prototype Simulations and Experiment 434
Conclusions 435
References 435
The Power and Propulsion of Medical Microrobots 436
Introduction 436
Issues Facing the Medical Microrobots 436
The Power and Propulsion of Medical Microrobots 437
Microrobot Driven by GMA 437
Microrobot Driven by Piezoelectric Element 438
Microrobot Driven by Cell Battery 439
Microrobot Driven by Magnetic Field 439
Microrobot Driven by Biotic Energy 441
Microrobot Driven by PDMS Microbial Fuel Cell 441
Other Relevant Issues 442
Conclusions 443
References 444
Mechanical Design and Analysis of an Articulated-Tracked Robot for Pipe Inspection 445
Introduction 445
Pipe Inspection Robot System 445
Locomotion Analysis for Obstacle-Negotiation 446
Actuation System Description 447
Actuation System Dimensioning 448
Robot Motivation Requirement and Motor Selection 448
Mechanical Dimensioning 449
Conclusions 451
References 451
Part VI: Intelligent Control and Its Applications in Engineering 452
A Construction Method of Rational Approximation Model for Fractional Calculus Operators in Frequency Domain 453
Introduction 453
The Construction Method of Rational Approximation Model in Frequency 454
Construction Method 454
Error Analysis 458
Frequency Characteristic Analysis for an Example 458
Conclusions 460
References 460
Research of Direct Discretization Method of Fractional Order Differentiator/Integrator Based on Rational Function Approximation 461
Introduction 461
Origin of the Best Approximation Problem 461
Rational Remez Approximation Algorithm 462
Remez Approximation Algorithm Validations 464
Conclusions 467
References 467
Blind Source Separation of Vibration Signal of Electric Motor Velocity Modulation System 468
Introduction 468
Blind Source Separation Principle and Fast ICA Algorithm 469
The Principle of Blind Source Separation 469
Fast ICA Algorithm 469
Separating Source Vibration Signal of Motor Velocity Modulation System 472
Collecting Data of Vibration Signal of Motor Velocity Modulation System 472
Isolation and Analysis of the Vibration Source Signals 473
Conclusions 475
References 476
A Survey on Artificial Intelligence Algorithm for Distribution Network Reconfiguration 477
Introduction 477
The Mathematical Model of DNRC 478
Fuzzy Control Algorithm 480
Artificial Neural Network Algorithm 480
Genetic Algorithm 481
Conclusions 482
References 483
Author Index 485