Interdisciplinary Treatment to Arc Welding Power Sources

Size: px
Start display at page:

Download "Interdisciplinary Treatment to Arc Welding Power Sources"

Transcription

1 Interdisciplinary Treatment to Arc Welding Power Sources

2 S. Arungalai Vendan Liang Gao Akhil Garg P. Kavitha G. Dhivyasri Rahul SG Interdisciplinary Treatment to Arc Welding Power Sources 123

3 S. Arungalai Vendan School of Electrical Engineering VIT University Vellore, Tamil Nadu India Liang Gao State Key Lab of Digital Manufacturing Equipment and Technology Huazhong University of Science and Technology Wuhan, Hubei China Akhil Garg Intelligent Manufacturing Key Laboratory of Ministry of Education Shantou University Shantou, Guangdong China P. Kavitha School of Electrical Engineering VIT University Vellore, Tamil Nadu India G. Dhivyasri School of Electrical Engineering VIT University Vellore, Tamil Nadu India Rahul SG School of Electrical Engineering VIT University Vellore, Tamil Nadu India ISBN ISBN (ebook) Library of Congress Control Number: Springer Nature Singapore Pte Ltd This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. Printed on acid-free paper This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore , Singapore

4 1 Welding an Overview Basics of Arc Welding Electric Charge Electric Current Voltage Electrical Resistance Heat Input Power Equivalent Electrical Analogous Representation of Arc Welding Arc Welding as a Confluence of Several Disciplines Applications of Arc Welding References Insight into Arc Welding Power Source Terminologies Critical Arc Power Source Terminologies for Welding Arc Plasma Arc Efficiency Arc Stability Arc Blow Pinch Effect Arc Shielding Influence of Power Source Parameters on Weldment Open-Circuit Voltage (OCV) Arc Voltage Welding Current Electrode Polarity Power Factor Duty Cycle and Current Rating Class of Insulation v

5 vi 2.3 Impact of Power Source Characteristics on Weldments Static Characteristics Dynamic Characteristics Classification of Arc Welding Power Sources Static Types Rotating Types Power Sources Components Briefing Diode BJT MOSFET Insulated Gate Bipolar Transistor (IGBT) Silicon-Controlled Rectifier (SCR) Pulse Width Modulators (PWM) Microprocessor Microcontroller Field-Programmable Gate Arrays (FPGAs) Evolution of Arc Welding Power Sources Switch-Based Techniques Adopted for Welding Power Sources Literature Addressing Power Source Parameters References Control Terminologies and Schemes for Arc Welding Processes Control System Terminologies Process System Control System Parameters/Variables Control Disturbances Setpoint Feedback Error Transfer Function Open Loop System Closed-Loop System Control System Analysis Order of the System Zeroth Order System First-Order System Second-Order System Linearity Sensitivity... 78

6 vii 3.3 Introduction to Fundamental Controllers Stability Analysis Significance of Control System Control System for Arc Welding Sensing System Control Strategy and Algorithms Desired Gating Signals Controller Schemes Adopted for Welding Power Sources Process Parametric Influences on Weld Quality Real-Time Sample Reports on Formulating Adaptive Control Scheme for Cold Metal Transfer for JoiningAA Objective Implementation Controller Results MRAC Controller Response References Power Sources and Challenges for Different Arc Welding Processes Power Sources in Manual Metal Arc Welding (MMA) Power Sources in Shielded Metal Arc Welding (SMAC) Power Sources in Gas Tungsten Arc Welding (GTAW)/Tungsten Inert Gas Arc Welding (TIG) Power Sources in Gas Metal Arc Welding/Metal Inert Gas Welding (GMAW/MIG) Power Sources in Submerged Arc Welding (SAW) Major Challenges in Power Sources Harmonics Effects of Magnetic Field in Arc Welding Protection of Power Sources Cooling System References Sensors for Welding Data Acquisition Data Acquisition System What Are Sensors and Transducers? Signals What Is a DAQ Hardware? Physical Principles of Sensing Characteristics of Different Sensor Types Basic Terminologies Choosing a Sensor Key Measurement Components of a DAQ Device Signal Conditioning

7 viii Analog-to-Digital Converter (ADC) Computer Bus Role of Computer in a DAQ System Application Software Driver Software Data Acquisition in Arc Welding Processes Measuring Current and Voltage Wire Feed Speed Shielding Gas Flow Temperature Sensors for Geometrical Parameters Arc Sensors Typical Sensors and Their Outputs Parameters of Arc Welding Sensors for Various Applications Data Acquisition Using LabVIEW Physical Input/Output Signals DAQ Device/Hardware Driver Software Application Software Measurement and Automation Explorer DAQ Assistant Case Study 1: Measurement of Temperature During Joining of 316L Stainless Steel by CMT Process Process Details Description of DAQ Unit Experimental Data Temperature Plots Case Study 2: Characterization of Gas Metal Arc Welding System Using DAQ Description Welding Procedure Results References Optimization in Arc Welding Process Introduction to Optimization Constructing a Model System Identification in Arc Welding Significance of Optimization in Welding

8 ix 6.3 ANN-Based Optimization Techniques to Arc Welding Processes Introduction to ANN Backpropagation Neural Network (BP-NN) Development of PSO-Based Backpropagation Neural Network Particle Swarm Optimization Development of BP-NN Using PSO Algorithm Development of Levenberg Marquardt (LM) Algorithm-Based Backpropagation Neural Network Introduction to LM Algorithm Computing the Jacobian Matrix Steps in Levenberg Marquardt Algorithm Genetic Algorithm for Tuning the Neural Network Case Study 1: Optimization of Flux Cored Arc Welding Parameters Using GA Objective Experimentation Optimization Case Study 2: Optimization and Prediction of Hardness and Shear Strength Using PSO Based ANN in FSW of AA6061 Alloys Objective Experimentation Implementation Case Study 3: LM Algorithm-Based ANN Model to Predict Strength and Joint Resistance of Al-Cu Alloys Joined by Ultrasonic Welding Process Objective Experimentation Implementation References Codes and Safety Standards During Welding Risk Management Process Identifying the Potential Hazards Assessment of Risk Risk Control Specific Hazards and Control Measures Airborne Contaminants Radiation Electrical Risks Risks Due to Electromagnetic Fields

9 x Exposure to Heat and Burns Compressed and Liquefied Gases Personal Protective Equipment (PPE) Health Monitoring Standard Operating Procedures During Arc Welding Engine Power Equipment In Presence of Electric and Magnetic Fields During Handling Cylinders While Handling Shielding Gases Welding Codes: American Welding Society (AWS) Quality Assurance and Quality Management En ISO En ISO EN ISO EN ISO EN ISO 5817 and ISO References