Seam tracking and gap bridging during robotic laser beam welding via grayscale imaging and wobbling

The use of laser beam welding with robotic manipulators is expanding towards wider industrial applications as the system availability increases with reduced capital costs. Conventionally, laser welding requires high positioning and coupling accuracy. Due to the variability in the part geometry and positioning, as well as the thermal deformation that may occur during the process, joint position and fit-up are not always acceptable nor predictable a-priori if simple fixtures are used. This makes the passage from virtual CAD/CAM environment to real production site not trivial, limiting applications where short part preparations are a need like small-batch productions. Solutions that render the laser welding operations feasible for production series with non-stringent tolerances are required to serve a wider range of industrial applications. Such solutions should be able to track the seam as well as tolerating variable gaps formed between the parts to be joined. In this work, an online correction for robot trajectory based on a greyscale coaxial vision system with external illumination and an adaptive wobbling strategy are proposed as means to increase the overall flexibility of a manufacturing plant. The underlying vision algorithm and control architectures are presented; the robustness of the system to poor illumination conditions and variable reflection conditions is also discussed. The developed solution employed two control loops: the first is able to change the robot pose to follow varying trajectories; the second, able to vary the amplitude of circular wobbling as a function of the gap formed in butt-joint welds. Demonstrator cases on butt-joint welds with AISI 301 stainless steel with increased complexity were used to test the efficacy of the solution. The system was successfully tested on 2 mm thick, planar stainless-steel sheets at a maximum welding speed of 25 mm/s and yielded a maximum positioning and yaw-orientation errors of respectively 0.325 mm and 4.5°. Continuous welds could be achieved with up to 1 mm gaps and variable seam position with the developed control method. The acceptable weld quality could be maintained up to 0.6 mm gap in the employed autogenous welding configuration

High speed videography of gap bridging with beam oscillation and wire feeding during the laser welding of stainless steel and aluminum alloys

Laser beam welding is known for its quality and speed. Given its susceptibility to gaps, the technology is applied in the industrial field with hard automation and dedicated fixtures rather than small-batch production. The latter cannot always guarantee the strict conditions on the fit-up of joints, especially with complex geometries. Gap-bridging techniques may be exploited to overcome these inaccuracies. The present work investigates the simultaneous use of low frequency circular beam oscillation and wire feeding as means to produce a continuous weld seam in the presence of constant air gaps. Lap joint welding of 2 mm-thick AISI301LN and butt joint welding of 3 mm-thick AW6005A-T6 alloy were conducted with gaps up to 1mm. High-speed imaging at 10kHz provided an insight in the dynamics of the oscillating weld pool and spatter formation. Optical inspection and metallographic analyses were used to verify the gap-bridging capability as well as the resulting seam quality

Overview of the RFX-mod fusion science activity

This paper reports the main recent results of the RFX-mod fusion science activity. The RFX-mod device is characterized by a unique exibility in terms of accessible magnetic con gurations. Axisymmetric and helically shaped reversed- eld pinch equilibria have been studied, along with tokamak plasmas in a wide range of q(a) regimes (spanning from 4 down to 1.2 values). The full range of magnetic con gurations in between the two, the so-called ultra-low q ones, has been explored, with the aim of studying speci c physical issues common to all equilibria, such as, for example, the density limit phenomenon. The powerful RFX-mod feedback control system has been exploited for MHD control, which allowed us to extend the range of experimental parameters, as well as to induce speci c magnetic perturbations for the study of 3D effects. In particular, transport, edge and isotope effects in 3D equilibria have been investigated, along with runaway mitigations through induced magnetic perturbations. The rst transitions to an improved con nement scenario in circular and D-shaped tokamak plasmas have been obtained thanks to an active modi cation of the edge electric eld through a polarized electrode. The experiments are supported by intense modeling with 3D MHD, gyrokinetic, guiding center and transport codes. Proposed modi cations to the RFX-mod device, which will enable further contributions to the solution of key issues in the roadmap to ITER and DEMO, are also brie y presented