Achieving Optimum Welding Performance Using Proactive Intelligent Process Control
- by Karl
The customer expects to receive a quality welded product on time. There are two ways for a supplier to achieve this – reactively or proactively. Reactively means not doing any preventative planning or analysis of what the true welding process capability is of each ship component welding system, be it man, machine or robot.
If you’re looking for a reliable welding inspection service in San Diego, look no further than Industrial Welding Inspection of San Diego. We have over 25 years of experience inspecting welds for compliance with national and international standards. Our team of experts will work with you to ensure that your welds are up to par. Contact us today for a free consultation!
The proactive approach means one designs for manufacturing, employs capable processes and works with intelligent systems which again can be man, machine or robot based. The level of intelligent processing and pro-activeness is shown below.
Level of intelligent automation Proactive/Reactive Level
Manual welding Could be both
Blind (no vision) machine or robot Reactive
Automated pre-check of joint fit-up Proactive
Real time seam tracking Proactive/Reactive
Real time seam tracking with adaptive control Proactive-Adaptive Correction
Laser vision system inspection Reactive but more accurate
Weld Inspection Measurement System Proactive
Closed loop control of process Proactive
Repair based on automated weld inspection Proactive & Reactive
Feed-forward ID of parts not to spec. from welding Proactive & Reactive
Let’s look at some specific applications of some of these systems starting with a manual portable weld inspection system (PWIMS).
Portable Weld Inspection Management System (PWIMS)
Presently there is a great deal of redundant and subjective inspection being done on all types of ship structures. It is not uncommon to see 400% inspection of some welds resulting in wasted time and unnecessary repairs.
An improvement to this situation is now possible to deploy for many applications.
The system consists of a portable handheld laser vision sensor combined with a database management tool. It provides objective weld feature measurements and SPC analysis tools.
When it comes to welding, safety is always the number one priority. That’s why you need a reliable welding inspection service to help keep your workplace safe and compliant. At Industrial Welding Inspection of San Diego, we have more than 20 years of experience in the industry, so you can trust us to get the job done right. We use the latest technology and equipment to ensure that your welds meet all safety standards, and we’re always available to answer any questions you may have. Contact us today for a free consultation!
Real Time Seam Tracking and Adaptive Processing
Typical stiffener welding machines consist of gantries, welding equipment and heavy duty clamping devices. Maintaining the wire position correctly in the joint has been done historically by manual jogging of the wire or using a probe seam follower. More intelligent welding can be done with a laser vision seam tracker capable of 1) qualifying the weld joint is within tolerance, 2) tracking the joint in real time and 3) adapting the weld process to optimize weld quality. To achieve precision welding results (minimum over welding) at maximum speed traditional methods will not work.
Closed Loop Control
The laser hybrid process consisting of a high power laser and Gas Metal Arc welding equipment is beginning to make inroads into ship component manufacturing. One of its big advantages is more precise welding resulting in reduced distortion. To achieve optimum control and quality, one manufacturer has deployed a closed loop control system that measures the weld shape just after the weld is solidified and then feeds this information back to give constant corrections. Travel speed and laser or GMAW parameters can be adjusted automatically as needed. See Figure 4 for an overview of this system.
Industrial Welding Inspection of San Diego
9914 Oak Grove Dr. San Diego, CA 91916
The customer expects to receive a quality welded product on time. There are two ways for a supplier to achieve this – reactively or proactively. Reactively means not doing any preventative planning or analysis of what the true welding process capability is of each ship component welding system, be it man, machine or robot. If…