Analysis of Robotic Arm for Friction Stir Welding Application

Balaji, V. Ajaye; Ajay, G.; Doss, Arockia Selvakumar Arockia; Schilberg, Daniel

doi:10.1007/978-981-19-3895-5_29

Cited by 2 publications

(4 citation statements)

References 10 publications

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“…Based on Equation (6), by substituting the spindle speeds before and after adjustment and the welding speed before adjustment into the formulas, the welding speed after adjustment can be calculated.…”

Section: Constant Heat Input Controlmentioning

confidence: 99%

“…Assuming the total heat generation power at the stirring tool before adjustment is 𝑊 with a welding speed of 𝑣 , and after adjustment, the total heat generation power is 𝑊 with a welding speed of 𝑣 , to maintain constant heat input per unit area, the heat input balance equation is established as shown in Equation (6).…”

Section: Simulation Modelsmentioning

confidence: 99%

“…Traditional FSW equipment, such as gantry and bench types, can perform two-dimensional planar welding; however, they are less effective for complex spatial curve welding tasks [ 5 ]. To meet the requirements for greener, lighter, and more flexible development, Robotic Friction Stir Welding (RFSW) has emerged [ 6 ]. Nonetheless, the relatively low stiffness of serial industrial robots can lead to deviations and vibrations at the end-effector during the welding, thereby imposing higher demands on the control and optimization of the robotic systems [ 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

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Active Vibration Avoidance Method for Variable Speed Welding in Robotic Friction Stir Welding Based on Constant Heat Input

Zong,

Kang,

Chen

2024

Materials

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Robotic Friction Stir Welding (RFSW) technology integrates the advantages of friction stir welding and industrial robots, finding extensive applications and research in aerospace, shipbuilding, and new energy vehicles. However, the high-speed rotational process of friction stir welding combined with the low stiffness characteristics of serial industrial robots inevitably introduces vibrations during the welding process. This paper investigates the vibration patterns and impacts during the RFSW process and proposes an active vibration avoidance control method for variable speed welding based on constant heat input. This method utilizes a vibration feedback strategy that adjusts the spindle speed actively if the end-effector’s vibration exceeds a threshold, thereby avoiding the modal frequencies of the robot at its current pose. Concurrently, it calculates and adjusts the welding speed of the robot according to the thermal equilibrium equation to maintain constant heat input. A simplified dynamic model of the RFSW robot was established, and the feasibility of this method was validated through simulation experiments. This study fills the gap in vibration analysis of RFSW and provides new insights into control strategies and process optimization for robotic friction stir welding.

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Section: Constant Heat Input Controlmentioning

confidence: 99%

Section: Simulation Modelsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Active Vibration Avoidance Method for Variable Speed Welding in Robotic Friction Stir Welding Based on Constant Heat Input

Zong,

Kang,

Chen

2024

Materials

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“…Industrial robots, with their strong versatility, large working space, and low development costs, have already been widely applied in the welding field [5]. The integration of general industrial robots with FSW equipment has become an inevitable trend in the development of FSW [6]. However, due to the high welding force in FSW and the limited end stiffness of serial industrial robots, stability during FSW decreases, leading to welding errors from excessive end displacement and reduced welding quality due to vibration [7][8][9].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Installation Position for Complex Space Curve Weldments in Robotic Friction Stir Welding Based on Dynamic Dual Particle Swarm Optimization

Zong,

Kang,

Chen

et al. 2024

Processes

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Robotic friction stir welding (RFSW), with its wide application range, ample working space, and task flexibility, has emerged as a vital development in friction stir welding (FSW) technology. However, the low stiffness of serial industrial robots can lead to end-effector deviations and vibrations during FSW tasks, adversely affecting the weld quality. This paper proposes a dynamic dual particle swarm optimization (DDPSO) algorithm through a new comprehensive stability index that considers both the stiffness and vibration stability of the robot to optimize the installation position of complex space curve weldments, thereby enhancing the robot’s stability during the FSW process. The algorithm employs two independent particle swarms for exploration and exploitation tasks and dynamically adjusts task allocation and particle numbers based on current results to fully utilize computational resources and enhance search efficiency. Compared to the standard particle swarm optimization (PSO) algorithm, the DDPSO approach demonstrated superior search capabilities and stability of optimization results. The maximum fitness value improved by 4.2%, the average value increased by 12.74%, and the concentration level of optimization results rose by 72.91% on average. The new optimization method pioneers fresh perspectives for optimizing the stability of RFSW, providing significant grounds for the process optimization and offline programming of complex spatial curve weldments.

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Analysis of Robotic Arm for Friction Stir Welding Application

Cited by 2 publications

References 10 publications

Active Vibration Avoidance Method for Variable Speed Welding in Robotic Friction Stir Welding Based on Constant Heat Input

Active Vibration Avoidance Method for Variable Speed Welding in Robotic Friction Stir Welding Based on Constant Heat Input

Optimization of Installation Position for Complex Space Curve Weldments in Robotic Friction Stir Welding Based on Dynamic Dual Particle Swarm Optimization

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