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Research Papers

Dynamic Model of Consumable Double-Electrode Submerged Arc Welding Process

[+] Author and Article Information
Yi Lu

Adaptive Intelligent Systems, LLC,
1500 Bull Lea Road,
Lexington, KY 40511;
Department of Electrical and
Computer Engineering and
Institute for Sustainable Manufacturing,
College of Engineering,
University of Kentucky,
Lexington, KY 40506

Jinsong Chen

Adaptive Intelligent Systems, LLC,
1500 Bull Lea Road,
Lexington, KY 40511

YuMing Zhang

Adaptive Intelligent Systems, LLC,
1500 Bull Lea Road,
Lexington, KY 40511;
Department of Electrical and
Computer Engineering and
Institute for Sustainable Manufacturing,
College of Engineering,
University of Kentucky,
Lexington, KY 40506
e-mail: ymzhang@engr.uky.edu

1Corresponding author.

Manuscript received January 17, 2012; final manuscript received August 1, 2013; published online December 12, 2014. Assoc. Editor: Wei Li.

J. Manuf. Sci. Eng 137(2), 021001 (Apr 01, 2015) (6 pages) Paper No: MANU-12-1018; doi: 10.1115/1.4025580 History: Received January 17, 2012; Revised August 01, 2013; Online December 12, 2014

Double-electrode submerged arc welding (DE-SAW) is a new variant of the innovative double-electrode gas metal arc welding (DE-GMAW) process. In order to control this process, its dynamic model needs to be established. To this end, this paper analyzes the melting physical process of the consumable DE-SAW to derive its dynamic model. To identify the parameters in the dynamic model, a series of experiments are designed and performed. Least-squares technique has been used to identify the parameters from the experimental data.

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Figures

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Fig. 1

Consumable DE-GMAW process

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Fig. 2

Wire extensions and arc lengths in consumable DE-SAW process. E1, extension of the main wire; l1, length of the main arc; E2, extension of the bypass wire; l2, length of the bypass arc; CTWD, contact tip to work distance.

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Fig. 3

dynamic model of consumable DE-SAW

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Fig. 4

Experimental system: (a) Lincoln LT-7 tractor [22] and (b) main torch and bypass torch

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Fig. 5

Step input signals

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Fig. 6

Step response of base metal current

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Fig. 7

Step response of bypass current

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Fig. 8

Random input signals

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Fig. 9

The response of the random signals

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