Measurement and theoretical investigation of arc sensor sensitivity in dynamic state during gas metal arc welding

Mao, Wei Min; Ushio, Masao

doi:10.1179/stw.1997.2.5.191

Cited by 15 publications

(9 citation statements)

References 5 publications

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“…To compare the simulation and experimental results, experimental data of reference [6] are used, in which the amplitudes of welding current for sinusoidal variation of torch height were measured at various frequencies. The experimental results and two simulated results are shown in Fig.…”

Section: Simulation Of Arc Sensormentioning

confidence: 99%

A study of an arc sensor model for gas metal arc welding with rotating arc Part 1: Dynamic simulation of wire melting

2001

Proceedings of the Institution of Mechanical Engineers, Part B:

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A dynamic wire melting phenomenon is found in rotating arc welding since self-regulation of the arc length is not fully performed. Consequently welding current and electrode extension vary rapidly in high speed rotating arc operation. This paper presents the dynamic simulation of wire melting by using the variable space network method and by modelling the heat¯ux from the molten end of the wire into the electrode. The simulations are compared with experimental results from other references to show a fairly good agreement. By using simulation analyses, it is clari®ed how the characteristics of the welding power source aVect the sensitivity of the arc sensor.

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Section: Simulation Of Arc Sensormentioning

confidence: 99%

A study of an arc sensor model for gas metal arc welding with rotating arc Part 1: Dynamic simulation of wire melting

2001

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…When welding with a conventional CV power source, it is known that the dynamic performance of the arc sensor is determined by the power source characteristics, dynamic behavior of the wire melting, welding conditions, and so on. 19,20…”

Section: Resultsmentioning

confidence: 99%

“…the welding power source and welding cable). 19 In the design of the seam tracking arc sensor, the frequency characteristics, especially in high-frequency weaving, should be considered to prevent tracking error.…”

Section: Resultsmentioning

confidence: 99%

“…The sensitivity and reliability of the arc sensor in a dynamic state have been evaluated in experimental and theoretical investigations. 18–21 During a quasi-steady state, that is, when the weaving frequency is relatively low (≪1 Hz), the phase difference between the welding current waveform and the change in CTWDs is almost 180°. However, when the weaving frequency is relatively high (≥1 Hz), the phase difference between them varies in a dynamic manner, which can lead to poor joint tracking and sometimes a collision of the torch with the structure.…”

Section: Introductionmentioning

confidence: 99%

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Through arc sensing for reciprocating wire feed gas metal arc welding

Kim

2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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An arc sensor for reciprocating wire feed gas metal arc welding was developed to detect the torch height and track weld joints. The welding voltage waveform was adopted for the characteristic signal because the welding current remains almost constant with a change in the contact tip-to-workpiece distance. During reciprocating wire feed gas metal arc welding, the voltage waveform changes in an inherently complicated but periodic manner. After recognizing the voltage waveform pattern, the voltage characteristic for each phase was analyzed for arc sensing, and it was revealed that the short-circuit and cycle voltage characteristics were good estimators for torch height sensing. The dynamic arc sensing characteristics for reciprocating wire feed gas metal arc welding were investigated and found to be similar to those of a conventional constant voltage welding system. The seam tracking capability was evaluated by using the voltage integration difference method with transverse torch weaving. The voltage integration difference showed a linear relationship with the offset distance, and the reliability of the joint tracking sensor could be increased by using the moving average algorithm.

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“…The arc sensor characteristics have been discussed experimentally and theoretically in many previous studies. [6][7][8][9][10][11] For example, Ushio and Mao [6][7][8] proposed a mathematical model for spray transfer MAG welding and analysed the dynamic characteristics of the arc sensor at oscillation frequencies from 0 . 1 to 100 Hz.…”

Section: Introductionmentioning

confidence: 99%

Arc sensor sensitivity in short circuiting metal active gas welding with high speed torch oscillation

Kodama¹,

Ichiyama²,

Ikuno³

et al. 2006

Science and Technology of Welding and Joining

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The present paper describes the characteristics of the arc sensor, focusing on the sensitivity of the change in welding voltage and current to the torch oscillation frequency, in the low current and high speed torch oscillation metal active gas (MAG) process. First, a mathematical model of the short circuiting transfer welding is proposed, based on a previously reported model of spray transfer welding. Then, the relationship between the oscillation frequency and the rate of short circuiting was investigated using the proposed model. Numerical calculation results revealed that short circuiting regularly occurs at both oscillating edges at oscillation frequencies close to half the rate of short circuiting obtained under non-oscillating conditions. This finding agrees satisfactorily with the experimental results. Fast Fourier transformation analyses of the signals of welding voltage and current showed that the sensitivity of the change in the voltage and current is maximised at a frequency equal to about half the short circuiting rate obtained under nonoscillating conditions. It is considered that accurate seam tracking by arc sensors in short circuiting MAG welding can be achieved by setting the torch oscillation frequency to the above value.A arc heating coefficient of wire melting5 0 . 22 mm s 21 A 21 B Joule heating coefficient of wire melting5 6 . 3610 25 s 21 A 22 E a electric field intensity in arc column5 0 . 7 V mm 21 I welding current, A J z Joule heating weight at location z of wire extension, A 2 s K s slope of U-I characteristic of power source5 0 . 02 V[w5 L a arc length, mm L e wire extension length, mm L s inductance of circuit52 . 5610 24 H L t torch height (L e zL a ), mm P t ,P v ,P i peak strength at frequency of 2f for torch height, voltage, and current signals respectively R a electric resistance of arc column50 . 03 V R c resistance of welding power cable556 10 23 V R e resistance of wire extension, V r(J z ) resistance of unit length of wire extension as function of J z , r(J z )59610 28 J z z3 . 56 10 24 V mm 21 U a arc voltage, V U ao constant component of arc voltage516 V U e voltage drop across wire extension, V U s equivalent output voltage of power source in state when I50, V U t welding voltage (U a zU e ), V V f wire feeding rate, mm s 21 V m wire melting rate, mm s 21 z location of wire extension t time, s Symbols for short circuiting transfer condition B 1 Joule heating coefficient of wire melting at short circuiting53 . 8610 3 mm s 21 A 22 V 21 L em droplet length, mm L es wire extension length of unmelted part, mm N s rate of short circuiting with oscillation, s 21 N s0 rate of short circuiting without oscillation, s 21 R m radius of droplet having assumed spherical shape, mm S cross-sectional area of wire, mm 2 t ia time at start of droplet growth, s t is time at start of short circuiting, s a coefficient of droplet length53 b coefficient of short circuiting time5200

show abstract

Measurement and theoretical investigation of arc sensor sensitivity in dynamic state during gas metal arc welding

Cited by 15 publications

References 5 publications

A study of an arc sensor model for gas metal arc welding with rotating arc Part 1: Dynamic simulation of wire melting

A study of an arc sensor model for gas metal arc welding with rotating arc Part 1: Dynamic simulation of wire melting

Through arc sensing for reciprocating wire feed gas metal arc welding

Arc sensor sensitivity in short circuiting metal active gas welding with high speed torch oscillation

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