Abstract
This paper proposes a new evaluation method for welder skill in Gas Metal Arc Welding (GMAW) process in term of studying the natural hand-movement that affect the signal processing. Weld quality of GMAW generally depends on welder skill to maintain the uniform of hand movement. Therefore, the welder skill is considered as the critical point to maintain the weld quality. Hence, welding current and voltage signal could be an alternative way for monitoring and assessing the skill of welder based on the signal variation of the welding process. This research defines in two stages, first is the physical-simulation using robot welding Fanuc Arc Mate 100iB and monitoring the signal using Cyclogram technique. Second is comparing the Cyclogram characteristic of robot welding and manual welder. By using the data acquired, the characteristic of Cyclogram was analyzed by varying Torch angle change (W1) and Torch-height change (W2) to investigate the signal processing. Furthermore, the data of current and voltage were generated as a quantitative method to determine the size of Cyclogram. The results show that the method capable of differentiating the two beginner welders compare to the robot welding performance based area of Cyclogram characteristic. Finally, the Cyclogram could be a novel tool for monitoring and evaluating the welder skill with high sensitivity to detect hand motion.
Highlights
The Gas metal arc welding (GMAW) process is widely used in the industrial welding process
The result shows two groups of Cyclogram: the first group is stable arc welding and the second group is unstable of arc welding by increasing the number amplitude which relates to the torch angle from 4.25mm to 6.35mm
It is possible that the data acquired from welding current and voltage to with only sampling rate 5000 to monitoring the arc stability
Summary
The Gas metal arc welding (GMAW) process is widely used in the industrial welding process. The signal current and voltage could become a tool for feedback to the welder to adjust handmovement during welding in real time by using mean and standard deviation, and control chart [5] This is the possible way to help the trainee welder to correct their travel angle, arc length, and travel speed properly. In the welding industry, Cyclogram was used to represent the arc stability of the current and voltage in the metal transfer This method can be more sensitive to observe the size of the region of the short-circuit area, arc extinction area and arc burning area. Some papers have been studied on Cyclogram characteristic in metal transfer for observing the arc stability, Cyclogram has not been applied for monitoring and evaluating the welding skill. The Cyclogram characteristic is used to distinguish the performance of the robot welding and manual welder
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