Abstract
Controlling the gas metal arc welding (GMAW) process is investigated utilizing feedback linearization with heat input, detaching droplet diameter and melting rate as controlled variables while accounting for actuator saturation. The control algorithm is employed using a state space model with eight dynamic states. Stability and internal dynamics of the process are studied thoroughly. Sliding mode state observers are implemented to determine the arc current and contact tip to work piece distance as well as the stick out length (which constitute the internal states of the system). Several simulation reports are provided to demonstrate successful regulation and tracking of detaching droplet diameter, heat input rate and melting rate. Finally, simulations indicate that the method is capable of overcoming parametric uncertainty.
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