Modelling and Simulation for Feedback Control of Welding

F. Sikstrm, A.-K. Christiansson, and B. Lennartson (Sweden)


Weld simulation, modelling, model reduction and control.


This paper describes a promising strategy that makes use of modelling and simulation to support design of real time control in automated welding. A finite element method has been used for thermal modelling of gas tungsten arc welding on a simplified test object. Data for model calibration and validation was acquired through thermal imaging during weld experiments on test objects of the alloy SS316. An optimization scheme for inverse modelling was employed in the calibration of the distributed weld process model. Frequency weighted model reduction and parametric system identification were applied and evaluated to get a low order model of the single-input single-output dynamics between a simulated weld source (actuator) and a simulated sensor signal. This low order model was then successfully used for controller design and the closed-loop performance was evaluated by simulation of the weld process model.

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