Sensor-Driven Automated Weld Control

传感器驱动的自动焊接控制

• 批准号: 2894854
• 金额: --
• 依托单位: University of Strathclyde
• 依托单位国家: 英国
• 项目类别: Studentship
• 财政年份: 2023
• 资助国家: 英国
• 起止时间: 2023 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=studentship-2894854
• 关键词: Sensor; Driven; Automated; Weld; Control

Traditionally, welding and inspection of high-integrity joints are separate, sequential, often manual processes in manufacturing and repair. Ultimately, these limitations reduce productivity, throughput, schedule certainty and increase rework if defects are detected at weld completion. Furthermore, a shrinking and ageing skilled workforce, along with a desire to reduce hazardous working, drives process automation. Current state-of-the-art automated welding systems deploy optical and tactile sensors for process feedback, which are naturally limited to surface mapping, while ultrasonic inspection systems only examine completed fully-filled welds once cooled. As welding is a dynamic volumetric process, fusing joints of depth and width, this fellowship seeks to exploit the volumetric imaging capability of ultrasonics, and introduce this inspection modality directly into the welding process control loop. By investigating automated in-process ultrasonic inspection and control, this fellowship aims to deliver high-integrity welds right, first time, every time and overcome current technical and process limitations.Babcock undertake large numbers of complex high-integrity fusion welds on structural components in sectors such as Nuclear, Defence and Energy including Carbon Capture and Hydrogen. In-process ultrasonic-enabled welding control will offer Babcock significant reductions, estimated from current operational data of:> 55% in weld process time> 50% in overall weld cost> 75% in man hoursThese significant technical, commercial and safety benefits underpin long-term research sustainability and empower Babcock for future contract awards and repatriation. The establishment of a new globally-unique "Sensor Enabled Automation" research group ensures the UK remains at the forefront of international manufacturing innovation.

传统上，高完整性接头的焊接和检查在制造和维修中是独立的、连续的、通常是手动的过程。最终，如果在焊接完成时检测到缺陷，这些限制会降低生产率、吞吐量、进度确定性并增加返工。此外，熟练劳动力的减少和老龄化，以及减少危险工作的愿望，推动了流程自动化。当前最先进的自动化焊接系统部署光学和触觉传感器来进行过程反馈，这自然仅限于表面测绘，而超声波检测系统仅在冷却后检查已完成的完全填充的焊缝。由于焊接是一个动态体积过程，融合了深度和宽度的接头，因此该研究金旨在利用超声波的体积成像能力，并将这种检查方式直接引入焊接过程控制回路。通过研究自动化过程中超声波检测和控制，该奖学金的目标是每次都能正确地进行高完整性焊接，并克服当前的技术和工艺限制。Babcock 在结构部件上进行了大量复杂的高完整性熔焊。核、国防和能源等领域，包括碳捕获和氢。过程中超声波焊接控制将显着减少 Babcock 的成本，根据当前的运营数据估计：焊接工艺时间减少 55% > 焊接总成本减少 50% > 工时减少 75% 这些重大的技术、商业和安全优势支撑了长期发展长期研究的可持续性，并赋予巴布科克未来合同授予和遣返的权力。全球独一无二的“传感器自动化”研究小组的成立确保英国始终处于国际制造创新的前沿。