Advanced Automation Techniques in Adaptive Material Processing

by Chen, Xiaoqi; Devanathan, Rajagopalan; Fong, Aik Meng

• ISBN13: 9789810249021
• ISBN10: 9810249020
• Format: Hardcover
• Copyright: 2002-11-01
• Publisher: WORLD SCIENTIFIC PUB CO INC

Summary

Presents the editor's research as well as related recent findings on the applications of modern technologies in electrical and electronic engineering to the automation of some of the common manufacturing processes that have traditionally been handled within the mechanical and material engineering disciplines.

Table of Contents

Overview of Material Processing Automation	1	(19)
Constrained and Non-Constrained Material Processing	1	(1)
Multi-Facet Mechatronic Automation	2	(2)
Sensors for Material Processing	4	(6)
Measurands in Material Processing	4	(3)
Types of Sensors	7	(1)
Microsensors and Soft Sensors	8	(2)
Intelligent Control Techniques	10	(9)
Conventional Computer Numerical Control	10	(2)
Sensor Based Machine Tool Control	12	(1)
Open Architecture and Distributed Control	13	(2)
Intelligent Control and Computing Techniques	15	(1)
Human-Machine Interface	16	(1)
References	17	(2)
Process Development and Approach for 3D Profile Grinding/Polishing	19	(36)
Introduction	19	(2)
Profile Grinding and Polishing of Superalloys	21	(8)
Superalloy Components and Manual Blending	21	(4)
CNC Milling	25	(2)
Wheel Grinding	27	(2)
Force Control in Material Removal	29	(6)
Robot Holding Tool	30	(1)
Robot Holding Workpiece	31	(4)
Model-Based Robotic Machining	35	(2)
Part Variations and Process Dynamics	37	(3)
System Concept of Adaptive Robotic Blending System	40	(5)
A Mechatronic Approach	40	(1)
Device and Process	41	(1)
Knowledge-Based Process Control (KBPC)	42	(1)
Data-Driven Supervisory Control (DDSC)	43	(1)
System Layout and Working Cycle	43	(2)
Process Optimisation	45	(6)
Grinding/Polishing Process Parameters	45	(1)
Tool Path Optimisation	46	(3)
Tool Wear Compensation	49	(2)
Concluding Remarks	51	(4)
References	52	(3)
Adaptive Robotic System for 3D Profile Grinding/Polishing	55	(36)
Introduction	55	(2)
Finishing Robot and Control Interface	57	(3)
Finishing Robot	57	(1)
Self-Aligned End Effector	57	(2)
Control Interface	59	(1)
In-Situ Profile Measurement	60	(5)
Off-Line versus In-Situ Approach	60	(1)
Sensor Techniques	61	(3)
Coordinate Transform	64	(1)
Template-Based Optimal Profile Fitting	65	(11)
Template Generation	65	(2)
Profile Fitting Requirements	67	(3)
A Fast Converging Minimisation Algorithm	70	(3)
Software Development	73	(3)
Adaptive Robot Path Planner	76	(5)
Definition of Tool Path	76	(1)
Derivation of End-Effector Orientation	77	(2)
Generation of Tool Path	79	(2)
Implementation of SMART 3D Blending System	81	(2)
Results	83	(5)
Dimension of Finish Profile	83	(2)
Surface Roughness and Finish Quality	85	(2)
Wall Thickness	87	(1)
Concluding Remarks	88	(3)
References	89	(2)
Acoustic Emission Sensing and Signal Processing for Machining Monitoring and Control	91	(34)
Introduction	91	(2)
Sensors in Machining Process Monitoring	93	(6)
Motor Current & Power	94	(1)
Force/Torque	95	(2)
Vibration/Acceleration Signals	97	(1)
Optical and Vision System	98	(1)
Acoustic Emission Sensing	99	(8)
Acoustic Emission Mechanism	100	(1)
Acoustic Emission in Machining	101	(3)
Acoustic Emission Sensors	104	(3)
Advanced Signal Processing Techniques	107	(14)
Time Domain Analysis	109	(3)
Time Series Modelling	112	(1)
Frequency Domain Analysis	113	(1)
Time-Frequency Domain Analysis	114	(2)
Wavelet Analysis	116	(5)
Conclusions	121	(4)
References	122	(3)
Techniques of Automatic Weld Seam Tracking	125	(42)
Introduction to Weld Seam Tracking	125	(3)
The Importance of Welding	125	(1)
What is Welding?	125	(2)
Automated Welding	127	(1)
Need for Seam Tracking	127	(1)
Through-the-Arc Sensing	128	(15)
Survey of Existing Methods	128	(4)
System Overview	132	(1)
Data Acquisition	133	(2)
Signal Processing	135	(1)
Robotic Welding System	136	(2)
Implementation of Seam Tracking Controller	138	(1)
The Algorithm	138	(1)
The PID Controller	139	(1)
Plant Identification and Control	139	(4)
Vision-Based Seam Tracking	143	(21)
The Technology	143	(2)
Triangulation Techniques	145	(1)
Measurement Range and Accuracy	145	(1)
The Principle of Laser Triangulation	146	(1)
Vision Based Seam Tracking Systems	146	(1)
System Architecture	147	(1)
Vista Weld Laser Camera	148	(1)
Two Beam Laser Camera	148	(1)
Laser 3D Vision Sensor	148	(1)
Point Laser Scanner	149	(1)
Laser Camera	149	(1)
Fanuc's MIG EYE	150	(1)
System Description	151	(1)
Hardware-System Layout	151	(1)
Sensor Hardware	152	(1)
Mounting of Sensor Head	153	(2)
Data Acquisition System	155	(1)
Software Overview	156	(1)
Image Acquisition and Processing	157	(1)
Structured Light Approach	157	(1)
Capturing the Image	158	(1)
Image Preprocessing	159	(1)
Erosion	160	(1)
Blobs Tool Control	160	(1)
Seam Detection Algorithms	161	(1)
Implementation and Experimental Results	162	(1)
Evaluating Accuracy of Seam Tracking	162	(2)
Evaluating the Overall Accuracy	164	(1)
Concluding Remarks	164	(3)
References	165	(2)
Weld Pool Geometry Sensing and Control in Arc Welding	167	(34)
Introduction	167	(2)
Survey of Weld Pool Inspection	169	(14)
Weld Pool Oscillation	169	(1)
Sensing Principle	169	(1)
Theoretical Models	169	(2)
Pool Oscillation Detection	171	(1)
Results	172	(1)
Disadvantages	172	(1)
Ultrasound	173	(1)
Contact Transducer	173	(1)
Laser Array and EMAT Ultrasonic Measurement	174	(3)
Infrared Sensing	177	(1)
Theoretical Foundations	177	(1)
Infrared Sensing Technology	178	(1)
Results	178	(2)
Limitation	180	(1)
Surface Depression Sensing	180	(1)
Background	180	(1)
Sensing Technology	180	(1)
Image Processing	181	(1)
Results	182	(1)
Disadvantages	182	(1)
Weld Pool Vision and Control System	183	(3)
Controlled Welding Process	183	(1)
Weld Pool Vision System	184	(1)
Set-Up of Weld Pool Vision and Control System	184	(2)
Weld Pool Geometry Extraction	186	(3)
Real-Time Weld Pool Geometry Extraction	186	(1)
Edge Detection	186	(1)
Connectivity Analysis	187	(1)
Relationship between Weld Pool Dimensions and Welding Parameters	188	(1)
Neurofuzzy Logic Control	189	(5)
Fuzzy Logic Control	189	(1)
Neurofuzzy Logic System	190	(3)
System Optimisation and Integration	193	(1)
Results	194	(3)
Simulation Results of Neurofuzzy Logic Control System	194	(1)
Closed-Loop Control of Welding Speed	194	(3)
Conclusions	197	(4)
References	197	(4)
Automatic GTAW System Control and Teleoperation	201	(42)
Introduction - The Automatic Welding of High Performance Alloys	201	(1)
Special Considerations for Welding Titanium	202	(5)
GTAW for Titanium	202	(2)
Features of an Intelligent Welding System	204	(2)
Subsystems and Components	206	(1)
Manipulator Configuration	207	(12)
Selection of Axes	207	(2)
The Experimental and Demonstration Welding Manipulator	209	(1)
Machine Kinematics	210	(1)
Assigning Coordinate Frames	210	(3)
Kinematic Simulation	213	(3)
Inverse Kinematics	216	(1)
Trajectory by Decomposition of Tool Transformation Matrix	217	(2)
Process Control	219	(8)
Critical Process Parameters	220	(2)
Inert Gas Shielding	222	(1)
Other Procedures	222	(1)
Sensing and Monitoring	223	(2)
Schemes for Process Control	225	(1)
Use of AI in Automatic Welding	225	(2)
CNC and Low-Level Control	227	(2)
Interactive and Tele-Operated Welding System	229	(10)
Visual Monitoring	229	(2)
Computer Enhanced Vision	231	(1)
Modelling of Camera Views	231	(2)
Modelling of Solid Objects	233	(1)
Implementation in Simulation Software	234	(4)
Integration of Models and Welding Workpiece Images	238	(1)
Conclusions	239	(4)
References	240	(3)
Laser Material Processing and Its Quality Monitoring and Control	243	(54)
Introduction	243	(7)
Laser Equipment	243	(2)
Applications of Laser Material Processing	245	(1)
Automation of Laser Material Processing	246	(1)
In-Process Monitoring	247	(2)
In-Process Control	249	(1)
Survey of Real-Time Laser Welding Quality Monitoring	250	(7)
Acoustic Emission	251	(1)
Audible Sound	252	(1)
Infrared Sensing	253	(1)
Ultraviolet Sensing	254	(1)
Ultraviolet Spectroscopic Analysis	255	(1)
Ultraviolet Signal Analysis	255	(2)
Analysis of Optical and Acoustic Signals Emitted from Plasma and Sensor Design	257	(7)
Laser-Induced Plasma During Welding of Thin Metal Sheets	258	(2)
Optical Emission from Laser-Induced Plasma	260	(1)
Waves in Plasma	261	(2)
Design of Optical and Acoustic Sensors	263	(1)
Signal Processing through FFT and Wavelet Analysis	264	(21)
FFT Analysis	265	(1)
Frequency Characteristics of Optical and Acoustic Signals Using Magnetically Restrained Discharge Laser	265	(2)
Frequency Characteristics of Optical and Acoustic Signals of Different Defects	267	(8)
Wavelet Analysis of Audible Acoustic Emission Signals	275	(1)
Wavelet Decomposition of AE Signals	276	(2)
Results of Wavelet Analysis of AE Signal	278	(2)
Definition and Applications of Detection Curve	280	(1)
Definition of Detection Curve	280	(1)
Example	281	(4)
Real-Time Monitoring of Laser Welding by ANN	285	(8)
Structure of the Neural Network	285	(1)
Construction of Features	285	(2)
Improvement of Features	287	(1)
BP Network Parameters and Effect of Different Features	288	(3)
Performance of the Neural Network	291	(2)
Discussion	293	(1)
Conclusions	293	(4)
References	294	(3)
Index	297