Intelligent thermal control of resistance welding of fiberglass laminates for automated manufacturing

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DOIResolve DOI: http://doi.org/10.1109/TMECH.2014.2366100
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TypeArticle
Journal titleIEEE/ASME Transactions on Mechatronics
ISSN1083-4435
Volume20
Issue3
Article number6966767
Pages10691078; # of pages: 10
SubjectAutomation; Composite materials; Controllers; Fuzzy control; Fuzzy logic; Intelligent control; Laser beam welding; Reinforced plastics; Resistance welding; Thermoplastics; Welding; Welds; Automated Manufacturing; Closed loop controllers; Fuzzy logic controllers; Intelligent Manufacturing; Intelligent thermal controls; Thermoplastic composite; Thermoplastic composite material; Welding automation
AbstractA novel approach to automate large-scale resistance welding of thermoplastic composite materials, based on real-time temperature control, is presented in this paper. Resistance welding, a kind of fusion bonding, is a widespread alternative process to mechanical fastening and adhesive bonding in joining thermoplastic composites. A second-order linear observer was identified to estimate the online temperature at the weld interface. A fuzzy logic controller (FLC) was designed to control the weld temperature using both process voltage and linear weld speed as the control inputs and using the temperature estimate as the feedback signal. The FLC was implemented in real time with the experimental setup using an industrial robot - KUKA KR 210. The closed-loop controller was capable of successfully controlling the weld temperature within 10% of the desired temperature, resulting in superior weld quality when compared to open-loop results. The results thus affirm the suitability of the control strategy for large-scale automated welding.
Publication date
PublisherIEEE
LanguageEnglish
AffiliationNational Research Council Canada (NRC-CNRC); Aerospace
Peer reviewedYes
NPARC number21275696
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Record identifierf41b69e9-1323-4c9e-b1e7-b17733aa0e44
Record created2015-07-14
Record modified2016-05-09
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