Welding Deposition Feedback Control for Layer Height Consistency
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Solution Overview
Problem
In robotic welding additive manufacturing, actual layer heights often deviate from expected heights due to surface conditions and control accuracy issues, leading to inconsistencies in the workpiece part.
Innovation Solution
A system that samples welding output current and wire feed speed in real time to determine instantaneous contact tip-to-work distances, calculates a running average, and generates a correction factor to adjust parameters such as travel speed, weld duration, or wire feed speed to compensate for height errors in the current and subsequent layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time sampling and adjustment of welding parameters is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system implements feedback by continuously monitoring welding parameters (current, wire feed speed) and using this information to dynamically adjust process variables. The controller samples instantaneous parameter pairs during welding, determines contact tip-to-work distance from these parameters, and uses the measured average CTWD to generate correction factors that are applied to subsequent welding operations, creating a closed-loop control system that improves layer height consistency.
Solution Approach 2:
The welding system performs self-correction by automatically adjusting its own parameters based on real-time measurements. The controller determines the actual CTWD during welding and uses this information to generate correction factors that modify welding parameters for the current and subsequent layers, enabling the system to self-correct height deviations without external intervention.
2Manufacturing precision
If real-time parameter adjustments are made during welding, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The system maintains continuous welding operation by performing all measurements and calculations during the welding process itself. The controller samples parameter pairs and determines CTWD values throughout the welding of each layer, then applies correction factors to the current and subsequent layers without interrupting the overall manufacturing flow. This continuous approach minimizes idle time while maintaining precision.
Solution Approach 2:
The system prepares correction factors in advance for subsequent layers based on measurements taken during the current layer welding. By determining the average CTWD and generating correction factors before the next layer begins welding, the system ensures that parameter adjustments are ready to be applied immediately, minimizing delays and maintaining continuous productive action.
3Manufacturing precision
If average contact tip-to-work distance is used to generate correction factors, then manufacturing precision is improved, but measurement precision requirements increase
Solution Approach 1:
The system uses multiple instantaneous CTWD measurements taken at different points during the welding of each layer and calculates an average value. By taking more measurements than a single point reading and averaging them, the system compensates for local variations and achieves more reliable overall CTWD data, reducing the burden on any single measurement while improving deposit level control.
Data Source
AI summary
A system and method to correct for deposition errors during a robotic welding additive manufacturing process. The system includes a welding power source to sample instantaneous parameter pairs of welding output current and wire feed speed in real time during a robotic welding additive manufacturing process while creating a current weld layer of a 3D workpiece part. An instantaneous ratio of welding output current and wire feed speed are determined for each instantaneous parameter pair. A short term running average ratio is determined based on the instantaneous ratios. A relative correction factor is generated based on at least the short term running average ratio and is used in real time while creating the current weld layer to compensate for deviations in a deposit level from a desired deposit level for the current weld layer.