Skip to main content
SpringerLink
Log in

Study on automatic control of arc gap in robotic TIG welding

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presents a method for automatic control of arc length in tungsten inert gas (TIG) welding process using the arc voltage. By using this method, the role of operator in arc length control is played by an automatic control system based on a predefined arc voltage value for any special welding operation. A dynamic model for feed-rate mechanism and the relation between variations of arc length and voltage are described in details. Using a proportional-integral controller, variations of arc length in welding path is compensated with an automatic feed-rate mechanism in a normal direction to the welding path. By keeping the voltage constant during the process, a stable weld with higher quality and better appearance is obtained specially in welding of uneven surfaces. Theoretical and practical investigations show that the suggested method is able to control the TIG welding process successfully. Test results show that an accurate weld is obtained without the interference of the operator, and by comparing the predefined values of arc voltage with what is practically obtained, the welding gap is automatically adjusted.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Yi X, Shan P, Hu S, Luo Z (2002) A numerical model of wire melting rate in CO2 gas-shielded welding. Mater Des 23:501–504

    Google Scholar 

  2. Li YC, Ushio M, Tanaka M (2000) Effect of surface active flux on welding-pool depth and arc phenomena in TIG welding. Chinese J Mech Eng 36(12):43–44

    Article  Google Scholar 

  3. Grosdidier T, Liao HL, Tidu A (2000) Proceedings of NTSC 2000, p 1341

  4. Zhang YM, Liguo E, Walcott BL (1998) Interval model based control of Gas metal arc welding. IEEE International Conference, American Control Conference 3:1752–1756

    Google Scholar 

  5. Narita K, Takagi K, Kimura T, Mitsui A (1975) Automatic welding of pipeline in Japan: part 1—some experiences with site applications. Int J Press Vessels Piping 3(3):175–194

    Article  Google Scholar 

  6. Tsai C-H, Houb K-H, Chuanga H-T (2006) Fuzzy control of pulsed GTA welds by using real-time root bead image feedback. J Mater Process Technol 176:158–167

    Article  Google Scholar 

  7. Li Z, Wang B, Ding J (2009) Detection of GTA welding quality and disturbance factors with spectral signal of arc light. J Mater Process Technol 209:4867–4873. doi:10.1016/j.jmatprotec.2009.01.010

    Article  Google Scholar 

  8. Mirapeix J, Garciá-Allende PB, Cobo A, Conde OM, Lopez-Higuera JM (2007) Real-time arc-welding defect detection and classification with principal component analysis and artificial neural networks. NDT&E International 40:315–323

    Article  Google Scholar 

  9. Mishra S, Lienert TJ, Johnson MQ, DebRoy T (2008) An experimental and theoretical study of gas tungsten arc welding of stainless steel plates with different sulfur concentrations. Acta Mater 56:2133–2146

    Article  Google Scholar 

  10. Lindgren L-E (2006) Numerical modeling of welding. Comput Methods Appl Mech Engrg 195:6710–6736

    Article  MATH  Google Scholar 

  11. Zhang G-J, Leng X-S, Wu L (2006) Physics characteristic of coupling arc of twin-tungsten TIG welding. Trans Nonferrous Met SOC China 16:813–817

    Article  Google Scholar 

  12. Zhang H, Zhanga G, Caib C, Gaoa H, Wua L (2008) Fundamental studies on in-process controlling angular distortion in asymmetrical double-sided double arc welding. J Mater Process Technol 205:214–223

    Article  Google Scholar 

  13. Gilles P, El-Ahmar W, Jullien J-F (2009) Robustness analyses of numerical simulation of fusion welding NeT-TG1 application: “single weld-bead-on-plate”. Int J Press Vessels Piping 86:3–12

    Article  Google Scholar 

  14. Bose BK (1985) Sliding mode control of induction motor. IEEE/IAS Conference Record 479–486

  15. Utkin VI (1993) Sliding mode control design principles and applications to electric devices. IEEE Trans Ind Electron 40(1):23–36

    Article  Google Scholar 

  16. Institute of Welding (1962) Physics of the welding arc, a symposium. Institute of Welding, London

    Google Scholar 

  17. The Welding Institute (1979) Arc physics and weld pool behavior, an international conference. The Welding Institute, London

    Google Scholar 

  18. Bose BK (1986) Power electronics and AC drives. Prentice-Hall, Englewood Cliffs

    Google Scholar 

  19. Chu W-H, Tung P-C (2005) Development of an automatic arc welding system using a sliding mode control. Int J Mach Tool Manuf 45:933–939

    Article  Google Scholar 

  20. Ferjutz K, Davis JR (1993) ASM handbook, volume 6: welding, brazing, and soldering. ASM International, Materials Park, 10 editions, ISBN-10: 0871703823

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, Tarbiat Modares University, Tehran, Iran

    Mohammad Reza Karafi, Yousef Hojjat & Mojtaba Gheybi

  2. Mechanical Engineering Department, University of Science and Technology, Arak, Iran

    Ramin Narimani

Authors
  1. Mohammad Reza Karafi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ramin Narimani
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yousef Hojjat
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Mojtaba Gheybi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mohammad Reza Karafi.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Karafi, M.R., Narimani, R., Hojjat, Y. et al. Study on automatic control of arc gap in robotic TIG welding. Int J Adv Manuf Technol 50, 953–960 (2010). https://doi.org/10.1007/s00170-010-2564-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-010-2564-z

Keywords

Search

Navigation