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Research Papers

Control of Droplet Detachment Frequency in a GMAW Process by a Hybrid Model Predictive Control

[+] Author and Article Information
Hossein Sartipizadeh

Advanced Control System Lab,
Department of Electrical Engineering,
Sharif University of Technology,
Azadi Avenue 14584,
P.O. Box 11155-4363,
Tehran, Iran;
Department of Aerospace Engineering and
Engineering Mechanics,
University of Texas at Austin,
Austin, TX 78712
e-mail: hsartipi@utexas.edu

Mohammad Haeri

Professor
Department of Electrical Engineering,
Sharif University of Technology,
Azadi Avenue 14584,
P.O. Box 11155-4363,
Tehran, Iran
e-mail: haeri@sina.sharif.edu

1Present address: William E. Boeing Department of Aeronautics & Astronautics, University of Washington, Seattle, WA 98105.

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT,AND CONTROL. Manuscript received May 31, 2017; final manuscript received May 9, 2018; published online June 18, 2018. Assoc. Editor: Ardalan Vahidi.

J. Dyn. Sys., Meas., Control 140(11), 111008 (Jun 18, 2018) (10 pages) Paper No: DS-17-1283; doi: 10.1115/1.4040251 History: Received May 31, 2017; Revised May 09, 2018

Efficient control of a gas metal arc welding (GMAW) process enables one to obtain high quality products as a consequence of achieving a high quality weld. Although control of the droplet detachment frequency in the welding process would play a great role in improving the welding quality, measuring this variable is difficult and expensive. In this paper, we attempt to control the frequency of droplet detachments without directly measuring it. To this end, we utilize the hybrid property of the GMAW process to indirectly control the frequency. Specifically, a mixed logical dynamical (MLD) model is obtained by considering the hybrid act of the process during droplet detachment. Then, a nonlinear model predictive controller with variable control and prediction horizons is designed incorporating the hybrid behavior of the process. The controller regulates the droplet detachment frequency without measuring this variable directly. Computer simulation results show that the proposed controller leads to a higher quality weld compared to the present approaches.

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Figures

Grahic Jump Location
Fig. 1

Electrical model of a GMAW process

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Fig. 2

The flowchart of the proposed method utilized variable horizons and the MLD model to control the GMAW process

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Fig. 3

Droplet detachment frequency approximation as a linear function of the welding current and wire speed

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Fig. 4

Inputs and outputs of the GMAW process controlled by EDMC (from 0.5 to 1 s) and the proposed hybrid controller (from 1 to 1.5 s): (a) measured welding current, (b) measured arc length, (c) open loop voltage, and (d) wire speed

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Fig. 5

The droplet detachment frequency of the GMAW process controlled by EDMC (from 0.5 to 1 s) and the proposed hybrid controller (from 1 to 1.5 s)

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Fig. 6

The control horizon variation during the control operation

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Fig. 7

The estimated frequency

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Fig. 8

The droplet size and mass when the GMAW process is controlled by EDMC (from 0.5 to 1 s) and the proposed hybrid controller (from 1 to 1.5 s)

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Fig. 9

System outputs in presence of measurement noise: (a) welding current, (b) arc length, and (c) droplet detachment frequency

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