Abstract
Arc sensing plays a significant role in the control and monitoring of welding quality for aluminum alloy pulsed gas touch argon welding (GTAW). A method for online quality monitoring was proposed based on the analysis of acquired arc voltage signal, through which two algorithms of feature extraction were developed in time and frequency domain, respectively. In time domain,the wavelet packet transform was carried out to eliminate the pulse interference of the feature parameter curve. In frequency domain, the other new algorithm was proposed based on the voltage power spectrum density (PSD) which was calculated by using the improved Welch algorithm and divided into five frequency bands before the statistic parameters were extracted. The correlation between the feature parameters in different frequency bands and welding defects were carefully analyzed to select a more sensitive one as the monitoring parameters. The proposed algorithms on this paper were verified to be capable of detecting lack of penetration, burn through, and the defect caused by lack of gas.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Chen SB, Wu J (2008) Intelligentized methodology for arc welding dynamical processes: visual information acquiring, knowledge modeling and intelligent control, vol. 29. Springer Verlag
Chen SB, Wu J (2009) Introduction. Intelligentized methodology for arc welding dynamical processes, p. 1–33
Chen SB (2007) Visual information acquirement and real-time control methodologies for weld pool dynamics during pulsed GTAW. Trans Tech Publ
Fan C, Lv FL, Chen SB (2009) Visual sensing and penetration control in aluminum alloy pulsed GTA welding. Int J Adv Manuf Technol 42(1):126–137
Wang J, Lin T, Chen SB (2005) Obtaining weld pool vision information during aluminium alloy TIG welding. Int J Adv Manuf Technol 26(3):219–227
Chen S, Zhao DB, Wu L, Lou YJ (2000) Intelligent methodology for sensing, modeling and control of pulsed GTAW: Part 1. Bead-on-plate welding. Weld J (USA) 79(6):151
Chen S, Zhao DB, Wu L, Lou YJ (2000) Intelligent methodology for sensing, modeling and control of pulsed GTAW: Part 2. Butt joint welding. Weld J (USA) 79(6):164
Zhang Y, Kovacevic R (1997) Real time image processing for monitoring of free weld pool surface. Trans ASME J Manuf Sci Eng 191:119
Zhang WJ, Liu YK, Wang XW, Zhang YM (2012) Characterization of three-dimensional weld pool surface in gas tungsten arc welding. Weld J 91:195s–203s
Zhang WJ, Zhang YM (2012) Modeling of human welder response to 3D weld pool surface: Part II. Results and analysis. Weld J 91:329s–353s
Zhang WJ, Zhang YM (2012) Modeling of human welder response to 3D weld pool surface: Part I. Principles. Weld J 91:310s–318s
Christner BR, Lovell M (1998) Campbell, Developing a GTAW penetration control system for the Titan IV Program. Weld Met Fabr 66(3):33–34
Duley W, Mao Y (1994) The effect of surface condition on acoustic emission during welding of aluminium with CO2 laser radiation. J Phys D Appl Phys 27:1379
Chen W, Chin B (1990) Monitoring joint penetration using infrared sensing techniques. Weld J 69:181s–185s
Cook GE (1983) Robotic arc welding: research in sensory feedback control. IEEE Trans Ind Electron IE-30(3):252–268
Thomsen JS (2005) Feedback linearization based arc length control for gas metal arc welding. In: Proceedings of the 2005 American Control Conference, vol 5. Electrical Engineering/Electronics, Computer, Communications and Information Technology Association, pp 3568–3573
Xu YL, Lv N, Zhong JY, Chen HB,Chen SB (2012) Research on the real-time tracking information of three-dimension welding seam in robotic GTAW process based on composite sensor technology. J Intell Robot Syst, pp 1–15
Chen B, Wang JF, Chen SB (2010) A study on application of multi-sensor information fusion in pulsed GTAW. Ind Rob 37(2):168–176
Quinn TP, Smith C, Mccowan CN, Blachowiak E, Madigan RB (1999) Arc sensing for defects in constant-voltage gas metal arc welding. Weld J New York 78:322
Burrus CS, Gopinath RA, Guo H (1998) Introduction to wavelets and wavelet transforms: a primer. Recherche 67:02. Prentice Hall, Upper Saddle River, NJ, USA
Misiti M, Misiti Y, Oppenheim G, Poggi JM (2004) Matlab wavelet toolbox user's guide, version 3
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhang, Z., Chen, X., Chen, H. et al. Online welding quality monitoring based on feature extraction of arc voltage signal. Int J Adv Manuf Technol 70, 1661–1671 (2014). https://doi.org/10.1007/s00170-013-5402-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-5402-2