TY - JOUR A1 - Ebert-Spiegel, M. A1 - Goecke, S.-F. A1 - Rethmeier, Michael T1 - Possibilities for compensating a higher heat input, in particular by the torch offset relative to the top sheet at the fillet weld on a lap joint JF - Welding in the world N2 - This paper deals with the use of an adaptive control system for compensating the variation in the gap height of a fillet welded lap joint. Gap bridging requires the input of additional filler material and is related to an increased energy input. Hence, the aim was a compensation of the effect of an increased heat input, in order to maintain the weld pool and excessive penetration, which can prevent consequently root reinforcement and burn-through. The findings achieved in this work show possibilities for a real-time controlled adjustments of the welding parameters in automated metal active gas (MAG) welding for compensating a higher heat input, in particular by means of the torch offset relative to the top sheet at the fillet weld on a lap joint. KW - MAG welding KW - Adaptive control KW - High strength steels KW - Gap KW - Energy input KW - Mathematical models PY - 2015 DO - https://doi.org/10.1007/s40194-015-0220-9 SN - 0043-2288 SN - 1878-6669 VL - 59 IS - 3 SP - 443 EP - 453 PB - Springer CY - Oxford AN - OPUS4-33079 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ebert-Spiegel, M. A1 - Goecke, S.-F. A1 - Rethmeier, Michael T1 - Efficient gap filling in MAG welding using optical sensors JF - Welding in the world N2 - MAG welding is widely used for thin sheet metal applications such as car body structures due to its ability to tolerate a fair amount of deviation of the components from the ideal shape. In MAG welding, the process window is sufficiently large to accommodate the expected component tolerances. In practice, however, quality control is an issue since most welds are produced with parameters outside of the optimum range, especially in the case of automated MAG welding. To ensure best performance, a robust real-time control law is needed that adapts critical process parameters to the changing conditions, most notably the variation in gap height. Here, the gap-dependent adaptive control algorithm for the deposition of filler material and the related energy input comes into play. With an optical sensor that is mounted in front of the torch, the system measures the actual position of the two components in real-time during the entire welding process and the controller adapts the relevant parameters accordingly using a dynamic process model. This optimization ensures that only the required filler material is used and the associated energy input is tightly controlled to assure best quality even in a fully automated welding process. KW - MAG welding KW - Sheet KW - Robots KW - Automation KW - Sensors KW - Adaptive control PY - 2014 DO - https://doi.org/10.1007/s40194-014-0145-8 SN - 0043-2288 SN - 1878-6669 VL - 58 IS - 5 SP - 637 EP - 647 PB - Springer CY - Oxford AN - OPUS4-31438 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -