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An innovative sensing method for seam tracking based on the arc ‘jump sidewall’ behavior

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Abstract

To improve the reliability of the arc sensor in the application in the narrow gap welding process, a new method was provided in this paper. The special shape of the signal curve was used in this method to detect the torch deviation. Narrow gap seam tracking experiments showed that the new method displayed better reliability when the deviation was larger than 0.6 mm, and the sensing accuracy can meet the tracking requirements of the narrow gap P-GMAW. The sensing mechanism was studied, and it was found that under conditions of narrow gap and pulse welding mode, the arc ‘jump sidewall’ behaviour would lead to the change of heat transfer, which will cause the melting of the groove sidewall and the change of the signal curve. The change of the curve was found to be highly sensitive to the groove morphology but was less prone to arc interruption, molten pool disturbance and short circuit. Therefore, the sensing method base on the change of the signal curve exhibits high reliability especially when the arc stability was poor.

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Abbreviations

v :

Speed which the torch swings to the side wall

α :

Angle of the groove

Δu :

Increase in the welding wire combustion speed

Δt :

Time for arc to recover length

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Acknowledgments

This study was supported by National Natural Science Foundation of China (U1733125).

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Authors and Affiliations

  1. School of Mechanical Engineering, Tiangong University, Tianjin, 300387, China

    Wenji Liu, Yafeng Zhang, Lingze Meng & Jianfeng Yue

Authors
  1. Wenji Liu
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  2. Yafeng Zhang
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  3. Lingze Meng
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  4. Jianfeng Yue
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Corresponding author

Correspondence to Wenji Liu.

Additional information

Wenji Liu is a senior engineer in the School of Mechanical Engineering of Tiangong University where his research focuses on numerical simulation of welding process and seam tracking system in narrow gap. He received his Ph.D. degrees from Tiangong University in 2017, M.Sc. degree form Chongqing University in 2009, B.Sc. degree from Zhongbei University in 2006. He has published over 20 journal and conferences articles.

Yafeng Zhang is a graduate student within robotics laboratory at Tiangong University where his research focuses on seam tracking of narrow gap welding. He received his B.Sc. degree from Zhongyuan University of Technology in 2021.

Lingze Meng is a graduate student within robotics laboratory at Tiangong University where his research focuses on welding seam tracking in narrow gap. He received his B.Sc. degree from Tiangong University in 2019.

Jianfeng Yue is a Professor in Department of Mechanical Engineering at Tiangong University where his research focuses on Industrial robot technology and welding automation. He received his Ph.D. degree from Tiangong University in 2013, M.Sc. and B.Sc. degrees from Hebei University of Technology in 1997 and 2003, respectively. He has published over 30 journal and conferences articles.

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Liu, W., Zhang, Y., Meng, L. et al. An innovative sensing method for seam tracking based on the arc ‘jump sidewall’ behavior. J Mech Sci Technol 37, 2325–2332 (2023). https://doi.org/10.1007/s12206-023-0409-6

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  • DOI: https://doi.org/10.1007/s12206-023-0409-6

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