CONTROL OF MACHINE OF WELDING MIG USING CONTROLLER FUZZY

PETRNIO VIEIRA JUNHOR*, DENIS MARCELO BOLHOSA DA SILVA*, MARCOS VINICIUS SADALA BARRETO**, ALDO CESAR PEREIRA*

Federal University of Par * DEEC-CT-UFPA, Street Augusto Corra, 01 C.E.P. 8619, 66075-970, Belm PA - Brazil Center Federal of Technological Teaching of Par ** Av. Almirante Barroso, SN - CEP 66000-000, Belm PA - Brazil ABSTRACT - This work presents the development of a welding machine current MIG pulsed that it uses a

mathematical model. Initially the control model is developed with theories and applications PID which should be adjusted in agreement with the operation points stipulated by the variation of the stick out. That process becomes disadvantageous in a real process due to you continue changes of the points of operation of the welding machine. Being used of control techniques FUZZY the problem of controller's PID syntony can be eliminated and turning the most robust system the inherent disturbances of the process. Tends as main objective the comparison of controllers' PID results and Fuzzy that at once know that Fuzzy doesn't present the syntony problem for several operation points.
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INTRODUCTION The welding equipment, that uses the process MIG (Metal Inert Gs)/MAG (Metal Active Gs), it should supply fast answers for the adjustment in the length of the arch form voltaico to minimize the effects provoked by disturbances. The pressed current allows a control of the formation of the solder puddle, reducing the drainage for the spray production, like this the quality of the solder depends on the control of the current. The control of the process is accomplished by a microcontroller that implements a control algorithm that acts in the manipulation of the speed of feeding of the wire and in the adjustment of the current supplied by the source of energy. The controller that it manipulates the dynamic mistake of the process is implemented usually in PID. That implementation requests an effort of I make calculations for the non continuous of the model, and that, therefore it needs to tune in the controller's constants for each operation point. That work proposes a controller FUZZY that reduces the calculation need through their linguistic rules. For so much a mathematical model of the welding process is presented MIG of pressed current. That model initially is controlled by a controller PID. Then a controller FUZZY that is applied on the same model is developed. The simulations indicate better results with the smallest effort of I make calculations, proving a larger efficiency and the controllers' effectiveness with technology fuzzy. To prove the mathematical modeling and the found results, a source of current of pressed energy of 400A was implemented.
Wire Sensor of the Current Sensor of the power

CC - Motor

Control of mC the Process

Control of current pulse

Source of power

Figure 1. Schematic of the welding process MIG.

MATHEMATICAL MODELLING OF THE PROCESS OF WELDING PRESSED MIGMAG The model was developed to operate the welding in pressed current, ideally square. The motor is of continuous current (motor CC) with speed controlled through a converter CC-CC. The models of the welding source and of the motor they are developed separately and together they represent the welding process mathematically MATHEMATICAL MODEL OF THE SOURCE OF WELDING The used converter is of the type buck that allows conditioning the current CC in pr-established levels. For this reason it is adapted to produce currents pulsed in the welding process. The mathematical model is, therefore based on this operation beginning that can be represented by two circuits, with two operation stages, as cultured in the figure 2. A stage is defined with the key closed S when the potency is supplied by the source CC. The other operation stage happens in the opening of the key S when the current settles down for the capacitor C. the resistance R and the Inductance L represent the characteristics of calorific energy and

0-7803-8987-5/05/$20.00 2005 IEEE.

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the inductive effect of the electric arch. Like this, the increase of the stickout corresponds to the increase of the value of R.
Ii Vi

S
D C

L R

Io Vo
Vi

S
D C

L R

Io Vo

(a) Stage 1 of operation (b) Stage 2 of operation figure 2. stages of operation of the converter Buck Figure 4. Form of wave of the current.

To implement the operation of the opening commands and closing of the key of the converter Buck it is used of a sign PWM (it Presses Width Modulation). MATHEMATICAL MODEL OF THE FEEDER OF WIRE The drive of the feeder of the wire is accomplished by an electric motor. This way it can be considered that the model of the Feeder of the Wire understands the drive of the motor exclusively CC. INTEGRATION OF THE MODELS OF THE SOURCE AND OF THE FEEDER OF THE WIRE FOR MODELLING OF THE PROCESS OF WELDING The representative model of the welding process is constituted of the Source of Potency (Investor) and of the wire feeder (Motor CC), included the control of the process, shown in blocks in the figure 3.
Arame Motor CC

Tab. 1. Data obtained experimentally.

D w tp Vp T (ms) 9,60 8,00 6,86 6,00 5,33 4,80 tb (Volts) 5,20 3,80 3,06 2,70 2,23 2,00 Im (A) 118,17 134,75 151,32 167,90 184,48 201,06 Ib (A) Ip (A) Vg (mm3)

(mm) (m/min) (ms) (Volts) 1,2 1,2 1,2 1,2 1,2 1,2 5 6 7 8 9 10 4,4 4,2 3,8 3,3 3,1 2,8 28,38 29,05 30,54 32,77 33,81 35,58

32,40 219,68 0,90 35,32 224,85 0,90 45,77 236,38 0,90 63,26 253,66 0,90 77,46 261,72 0,90 97,19 275,38 0,90

DETERMINATION OF THE POINT OF OPERATION OF THE WELDING A graph determining the representative resistance of the stickout for each pick current or speed in a stable welding can be elaborated with help of the table 2 as it illustrates the figure 5.

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Sensor de Velocidade

mC

Look Up Tabble

Controlador

Modelo do Motor

dio 1 1 = [ io R io dt ] dt L C Controlador dio 1 = [( E - VS ) - io R ] dt L Modelo do Conversor

Sensor de Tenso

(a) Determination using the pick current (b) Determination using the speed of the wire feeder
Sensor de Corrente

Figure 5. determination of the representative resistance of the stickout

Figure 3. Diagram of blocks of the model of the control of the welding process.

Tab. 2. it fixes for of values of R obtained by simulation

Nr. of the measure 1 2 3 4 5 6 R (stickout) 0,220 0,210 0,200 0,187 0,180 0,172 Pick current (A) 219 224 236 253 261 275 Speed of the wire feeder (m/min) 5 6 7 8 9 10

VALIDATION OF THE MODEL WITH EXPERIMENTAL DATA Experimentally they were obtained instantaneous data of current for welding pressed MIG-MAG, according to Tab 1. THE form of pressed wave can be observed in the figure 4.

SINTONIZAO OF THE CONTROLLERS During the welding process the stability of the arch determines an operation point, this point is obtained

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in function of the speed of the progress of the wire electrode that is consumed by the arch through where travels the pressed current where settling down tension and a stick specific out. When it happens a disturbance characterized by a projection, for instance, this stability is put in risk. It is like this necessary a controller to guarantee stable and safe operation of the process. Due to no continuous of the model of the welding process controller PID'S syntony for a certain operation point becomes very costly because yours makes calculations should be redone for each operation strip. The figure 6 illustrates the behavior of the current, in its change of operation point, for a speed of 5m/min and of the stick out of 0.21 for 0,172 with controller PID.

Figure 7 Behavior of the current with controller FUZZY.

For development and this controller's implantation was accomplished a study of the behavior of the process, resulting in strips of values and a linguistic table with rules, for any operation point wanted. Resulting in three sets, two which two of entrance and one of exit. The entrance sets are denominated of: "mistake" and "derived of the mistake". And the same ones were divided in seven subsets: very Negative, Negative, Small Negative, Zero, Small Positive, Positive and Very Positive (MN, PN, N, Zero, PP, P MP); and which are cultured in the figure 8 and 9. The exit set, that represents the control, figure 10, was woven in a similar way. The linguistic rules, involving the three sets will have a total of 48 rules, generated starting from you continuous observations in referred him process and based in the experimental data. See table 3. The methodology of used defuzzyficao hi the one of center of gravity, due to be a method easy implementation in the controller and not to present, in this case pertinent problems the not to put upon of groups. Table 3 - Group of rules of the control Fuzzy
Erro Derivada do erro DMN DN DPN Dzero DPP DP DMP EMN D GD GD GD GD GD GD EN BD D GD D D D GD EPN BA BD D BD D GD GD EZero GA A BA BD D GD EPP GA A A BA A BA BD EP GA A A A A BA BA EMP GA GA A GA GA GA A

Figure 6 Behavior of the current with controller PID

1 - CONTROLLER PID The controllers' PID technique was used as initial control of the welding process, figure 3, for the syntony of their parameters in a point of operation of the welding machine, however in a real process there will be variation of the operation point, having the need to calculate a new syntony for the controller turning the repetitive and costly process. Verified the figure 6 accordingly, in that the plant with controller PID gets to reach the necessary current for the first operation point, they put for the second, point of operation 0,172, the fact is not true as verified comparing the table of current(Tab1 values) with the figure 6. 5.2 CONTROLLER'S FUZZY PROJECT The techniques of control fuzzy allow a variation of the operation points without there being the need to calculate a new operation point, in this case in that no there is a mathematical continuity of the process. The technique fuzzy is quite adaptable should accept necessary linguistic rules for the perfect operation of the plant, which are implemented in this controller fuzzy. The figure 7 illustrates the behavior of the current pulsed for the same point of controller's PID operation, proving the largest efficiency and effectiveness of the controller fuzzy in relation to controller PID.

The mounted surface with the rules and the entrance groups and exit is illustrated in the illustration 11.

Figure 8 Behavior of the Derived of the Mistake with controller Fuzzy

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Incio

1. Definio de variveis e constantes do programa. 2. Configurao dos registradores do conversor A/D e do mdulo PWM.

Figure 9 Behavior of the Mistake with controller Fuzzy

Ler Vks na porta de entrada. Erro = Referencia - Vks.

Fuzzy

1. Rotina para gerar o sinal PWM.

Figure 10 Behavior of the exit with controller FUZZY

2. Envia o sinal para a porta de sda.

PWM

Fim

S
Fim

Figure 12. Flowchart of control digital.

IMPLEMENTATION AND EXPERIMENTAL VERIFICATION The implementation of the prototype is illustrated in the figure 13. All the experimental results were obtained starting from this prototype, where the digital program is being validated. Experimentally it was obtained the behavior of the pressed current shown in the figure 14 and 15. Theoretical results presented in the figure 6 and 7 could be validated by the comparison with the experimental ones, proving the model.

Figure 11 Behavior of the current with controller Fuzzy

CONTROLS DIGITAL

The program of digital control this based on the reading of the current signs and sensor originating from speed, when the process begins should be established an operation point (Reference). In the moment of the welding if there is some imperfection or relief in the work surface the characteristics of the current and (stickout) they change, as for each reference current a reference speed exists selected by the operator of the machine, the program will execute a consultation routine to a table (lookup Table), then the control will act to return to the operation point, the flowchart shown in the figure 12 describes the routines of the digital control.

Figure 13. Implementation of the welding source MIG.

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GRATITUDES The authors thank National Council of Technological Scientific Development - CNPq, entity Brazilian government promoter of technological scientific development, for the support the this research in the financing concession to the project EFFICIENT SOURCE FOR MACHINES OF SOLDER THE ELECTRIC ARCH through the process nr. 55.1463/01-5. he/she also thanks the Program of Academic Cooperation: PROCAD-CASTRATE with the partnership UFPA(PPGEE - Program of Masters degree in Electric Engineering) and UFCG (COPELE Coordinating of Masters degree in Electric Engineering) BIBLIOGRAPHICAL REFERENCE [1] Diefenderfer, A. JAMES, Principles of

Figure 14 Answer in closed mesh

Electronic

Instrumentation,

Saunders

College

Publishing, 1994 [2] Amin, M., Pulsed Current Parameters for Arc Stability and Controlled Metal Transfer in Arc Welding, Metal Construction, 1983.
Figure 15. Acquisition in the way of wave of the current of the arch of the solder MIG.

[3] J. Norrish, Advanced Welding Processes, Bristol, Philadelphia and New York. Institute of Physiscs Publishing, 1992. [4] Zafer Bingl, George E. Cook, Alvin M.

CONCLUSION A mathematical model for verification of the behavior of the welding process MIG-MAG in pressed current, for the control predicted of the process was developed. The model was simulated using the program MATLAB/Simulink. THE behavior of the current in function of the stickout was adapted, validating the model for transient in the welding process as, for instance, imperfections of the surface of the welded committee. Through experimental data it was obtained the validation of the model. Starting from the knowledge of operation points they can be determined characteristic curves where for a given welding current the speed of the wire can be defined using a representative variable of the stickout. Like this, for a given operation condition, they can be determined the current values and speed of the feeding of the wire to take to a stable operation. These results validate the model presented besides suggesting a methodology for analytical determination of the stickout facilitating the automated programming of machines of welding MIG/MAG.

Strauss, Application of Fuzzy Logic to Spatial Thermal Control in Fusion Welding, IEEE Trans. On Industry, 2000, pg. 1523-1530. [5] J. Hanright, (1986), Robotic Arc Welding

under Adaptive Control A Survey of Current Technology, Welding Journal. [5] S. Godoy, (1999), Controle e Modelagem

Fuzzy, Editora Edgard Blucher LTDA, 2001.

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