• Journal of Welding and Joining
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• v.20 no.6
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• pp.776-782
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• 2002

The experimental model of arc sensor in $CO_2$ arc welding has been individually developed according to welding condition and welding procedure. Therefore, the development of new arc sensor having the features of all conventional arc sensor is important in point of its application to various welding environment. In this study, the arc sensor experimental models comprised of a regression model and noise term were formulated using conventional arc sensing algorithm such as current area difference, current integration difference and weaving end current difference method, and their features were observed. The new regression arc sensor model was suggested using multiple linear regression analysis using current variables as independent variables of regression analysis. The artificial neural network model was also suggested where current variables and offset distance was used input/out variables of input/output node.

• Journal of Welding and Joining
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• v.8 no.1
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• pp.31-42
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• 1990

Arc must be stable during welding first of all other factors for obtaining sound weldment, especially in the automation of welding process. Arc stability is somewhat sophisticated phenomenon which is not clearly defined yet. In consumable electrode welding, the voltage and current variation due to metal transfer enables to assess arc stability. Recently, statistical analyses of the voltage and current waveform factors are performed to assess the degress of arc stability which is assessed and controlled by operator's own experience by now. But, considering the increasing need and the trend of automation of welding process, it is necessary to monitor arc stability in real-time. In this sutdy, the modified stability index composed of two voltage and current wvaeform factors (arc time and short circuit time) reduced from four factors (arc time, short circuit time, average arc current and average short circuit current) in Mita's index by the welding electrical circuit modeling is proposed and verified by experiments to be well estimating arc stability in the static sense. Also, the recursive calculation form estimating present arc stability in the dynamic sense is developed for real-time estimation. The results of applying the recursive index during welding show good estimation of arc stability in real-time. Therefore, the results of this study offers the mean for real-time control arc stability.

• Journal of Welding and Joining
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• v.30 no.3
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• pp.66-70
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• 2012

Welding is an essential process in the automotive industry. Most welding processes that are used for auto body is spot welding. And $CO_2$ arc welding is used in a small part. In production field, $CO_2$ arc welding process is decreased and spot welding process is increased due to welding quality is poor and defects are occurred in $CO_2$ arc welding process frequently. But $CO_2$ arc welding process should be used at robot interference parts and closed parts where spot welding couldn't. $CO_2$ welding is divided into lap welding and plug arc spot welding. In case of plug arc spot welding, burn through and under fill were caused in various welding environment such as different thickness combinations of base metal, teaching point, over the two steps welding and inconsistent voltage/current. It makes some problem like poor quality of welding area and decrease the productivity. In this study, we will evaluate the effect of teaching point through the weld pool behavior and bead geometry in the arc spot welding at the plut hole. Welding position is horizontal position. And galvanized steel sheet of 2.0mm thickness that has plug hole of 6mm diameter was used. Teaching point was changed by center, top, bottom, left and right of the plug hole. At each condition, the phenomenon of weld pool behavior was confirmed using a high-speed camera. As the result, we find the center of plug hole is the most optimal teaching point. In the other teaching point, under fill was occurred at the plug hole. This phenomenon is caused by gravity and surface tension. For performance of arc spot welding at the plug hole, the teaching condition should be controlled at a center of plug hole.

• Journal of Welding and Joining
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• v.22 no.1
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• pp.71-76
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• 2004

In the standpoint of the arc pressure, the effects of the filler wire feed rate on the penetration was investigated in this study. The pure Ar gas was used as a shield gas and the parameters investigated were the welding current and the filler wire feed rate. By making the experiment on the arc pressure, we could know that the arc pressure was fluctuated as the depth-into-arc of the tungsten rod. Instead of the filler wire, the tungsten rod was supplied into the molten pool to make this experiment. Because the filler wire melted in arc and then we couldn't measure the arc pressure. So, the tungsten rod - the highest melting point - was used. According to the depth-into-arc of the tungsten rod, the arc pressure could be measured by using the manometer. It was proved that the arc pressure got higher as the wire feed rate was slow. It is reported the arc pressure is proportion to welding voltage and the square of welding current. But, in the filler wire TIG welding, we could blow that arc pressure was fluctuated as the depth-into-arc of filler wire was changed. We could measure the arc pressure by the variation of the filler wire feed rate and could verify that it affected bead shape and penetration.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.12
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• pp.152-160
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• 1999

The weld quality of $CO_2$ arc welding is closely related to the arc stability. As the characteristics of the arc are excessively complex and nonlinear, it is not easy to make the arc model as mathematical form and to control the arc state to be stabilized. This paper was aimed to estimate the arc stability and to control for stabilizing the arc state in short circuit metal transfer mode of $CO_2$ arc welding. For these purposes, the behaviors of arc stability was investigated at different welding conditions using Mita's arc stability index, and the fuzzy control algorithm which uses the arc stability index as control imput and the arc voltage as control output was developed. In the control of the arc stability, the experiments of two cases were performed; the case of setting an initial welding voltage arbitrarily, the case of the step change in workpiece shape. Obtained results were as follows; Mita's arc stability index was able to be estimated qualitatively in the case of using the inverter type welding power source and the control performance for stabilizing the arc status was excellent in the case of existing step change disturbance.

• Journal of Welding and Joining
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• v.16 no.3
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• pp.44-54
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• 1998

In this study a new arc sensor algorithm for automatic weld seam tracking was proposed, which uses the relative welding current variation according to the tip-to-workpiece distance in GMA welding. Since the new developed arc sensor algorithm is not sensitive to unstable factors of arc signal, the system is expected to get rid of the problems of already existing arc sensor system which include the difficulty of modeling the process for various welding conditions and limitation of application to thick plate welding. Thus the system is applicable not only to thick plate welding but also to thin plate welding. To implement the new arc sensor algorithm the system parameters which include sampling time, averaging range, weighting factor of moving averaging, basic compensation time, and basic compensation distance were determined by experimental analysis. Consequently this system has shown the successful tracking capability for the various welding conditions.

• Proceedings of the KWS Conference
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• 2001.05a
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• pp.65-68
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• 2001

The application of a feedback control system in robotic arc welding is becoming more and more demanding than ever before. This requirement arises from the fact that robotic arc welding process needs no manual operator to monitor and manipulate the process parameters and hence a means of controlling the quality of the robotic arc welding process becomes apparent. Arc force sensor employed in this research to monitor the bead geometry of the arc welding process, A relationship between the bead dimension and the arc force distributions was established. Experimental configuration for measurement of arc force was used to quantify the changes in the arc force distributions of the plate being welded. Arc force sensor mounted at the end of the robot wrist was employed to measure the arc force applied to the weld. The sensor information was the used to establish a relationship between welding current and arc force. Arc force sensor have shown to be on of the most sophisticated technique to monitor perturbations that occurred during arc welding process.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.5
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• pp.110-117
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• 2004

In automatic welding process using a robot, seam tracking is one of the important parts. Sensor for seam tracking is divided broadly into two categories as non contact sensor and contact sensor. The arc sensor is one of the non contact sensors, and it can be applied in weaving arc and rotating arc welding process. In such the arc sensors, rotating arc sensor can be applied to high speed welding over tens of Hz. The decrease of self regulation by high rotating speed causes to improve accuracy and response of sensor. In this study, fuzzy controller was used to track the seam for the $CO_2$ arc welding which had unstable arc. It could be shown that the rotating arc sensor was better than the weaving arc sensor.

• Journal of the Korean Society of Safety
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• v.13 no.2
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• pp.65-75
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• 1998

The cases of welders illness by welding fume generated during arc welding are recently reported, which makes the legal regulation in the welding work place. Also, this situation makes the employers and welders be concerned about the welding fume seriously. At this point of time it is necessary that a standard testing method is developed as a fundamental tool for the evaluation of Fume Generation Rate(FGR) required for making progress in the development of low fume electrodes and welding process technology and also constructing the ventilation system in welding area. However, the current standard(KS D 0062) is only applicable to the manual covered electrode arc welding. In this study the evaluation procedure for the FGR is established by developing the fume collection chamber which can be applicable to semiautomatic and automatic arc welding as well as manual arc welding. This evaluation system and procedure can be used as a tool not only to develop the low fume welding electrode and welding process technology but also to construct the equipment controlling the welding workshop atmosphere.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.170-173
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• 2002

The object of this study is to investigate the effect of compounded welding through the AE (Acoustic Emission) characteristics on static tensile test. This study was carried out a SM 490A, high tension steel using the low hydrogen type E4316 of electronic shield metal arc welding and compound wire of $CO_2$gas arc welding. $CO_2$welding, weak in the intensity of HAZ (Heat Affected Zone), can be improved by being combined with coated arc welding, Coated arc welding, weak in the intensity of the bead, can be improved by being combined with $CO_2$welding. Especially, electronic coated arc welding and $CO_2$welding complement the mechanical intensity of HAZ and the bead with each other. So, compounded welding increases the intensity in the special parts and enhances the quality of goods.