Introduction
The career episode discusses the industrial experiment and practical aspects of “welding technology” and “welding inspection system” usefulness and is carried out during the Bachelor of Science and Industrial Engineering program at the University of Philippines situated at Diliman, Quezon City, Philippines. The project was conducted to demonstrate how the theoretical welding technology can be implemented in a practical aspect.
Background
The welding process is defined as the fundamental manufacturing process in which two similar or dissimilar metals are joined by filler metal. The welding process has been done by mainly three processes, which include joining by a filler material, inspection, and final finishing through grinding, polishing, etc. The testing and finishing is an essential process to justify that the approach and final finish have standard follows the procedure. The inspection procedure includes weld deformation, observation, impurities, and final inspection. The welding procedure can be performed through the automated or manual welding process, which includes cost, quality, and performance parameters. The manual welding process takes time, and it is not acceptable for the large production process. Therefore, it is essential to develop automatic welding technology that can provide accurate, fast, and cost-effective welding procedures. For that, computer applications, software, and programming are the key component that ensures accurate welding joints. For this project, I decided to use the MATLAB programming language, which works to make things easier. As it performs MATLAB programming and engages with the practical case, it will provide an accurate, cost-effective, and fast process.
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Personal engineering activity
When I was performing the project and collecting useful information regarding the project, I learned from two different areas, i.e., Mechanical and Electrical. From the latest thesis, research articles, and journals, I learned about the fundamental welding process, which includes laser welding, TIG welding, MIG welding, gas welding, and arc welding. For automatic operation, I learn laser sensors, laser-based technology, image processing, image capturing cameras, automatic weld seam tracking technology, and laser line projection.
To experiment, I set up the laser sensor and camera to illuminate the weld seam and the camera to get pictures or images of the weld seam. I developed a vision sensor that fused a structured light laser stripe generator, a GigE camera where I injected the CMOS image sensor and an optical channel that I set before the centering lens. I prepared the segment's geometrical plan by the utilization of CAD programming for geometric detail for the precise gathering of every sensor part. I made sure that only 650.7 nm wavelength reflected light stripe could pass through the optical channel to the place of an image sensor. I mounted the vision sensor in the light of a perpendicularly multipurpose slide over the abundant hub movement framework. I controlled the framework to get development in three dimensions, following the work of weld examining. I exchanged the image obtained with the vision sensor and a personal computer by the application of an Ethernet link.
Further, I did the remaining essential work, which included the processing arrangement and collecting images. For the welding process, I make a sufficient distance to ensure the projection encloses the portion of the base material and welded join. Also, ensure that the end goal was capable of locating the cross-segment of the material base at the time of picture examination. For that, I used the lines cross-section area that discourses to the material based as the new source of the forecast. I perform the task of projecting from the weld. I collected the picture through the laser line projection camera over the surface of the weld and projected it on the plan surface.
To make a completely automatic system, I prepare MATLAB programming and engage with the image processing technique. I performed an endeavor for using the edge identification, which results in a smooth control with the canny channel. To make a clearer picture, I increase the pixel size and vertical bearer to consolidate the pixel to the utilization of the enlargement device. Additionally, I handled all images through the simple channel. I also use different equipment and elements to fill the gaps that observe large pixel bunches. By using the MATLAB coding and graphic interface, I experiment.
Asan experiment with MATLAB, I plot the result to obtain accuracy and clarity of the process. In this case, I observe that the item size is smaller than 0.2 mm in the path of the z-axis. Throughout the process, I didn't use the filter to test and keep the individual threshold. The anticipated laser line has tackled the information obtained from the picture until the focuses were accustomed in framework direction to the y-hub and x-hub. I had to change the graphical interface prepared in MATLAB programming, which allows the images and details sent through ScanCONTROL. This way, I completed the welding process and inspection system of the project. The following demonstrates the defect that occurs and is observed during the welding process.
Difficulties during project progress and working
The difficulties arise during the setup and arrangement of the base metal or material that has been placed. It experiences when performing the test. The difficulty resulted in the insensitive situation for the usefulness of the cross-section area, which was the new projection root from welding. To solve the issues, I kept a distance between the weld element and the laser diode and ensured that the projection could cover the portion of the base terminal and weld. In solving the placement issues, it was found the new material base, was used as the advance and new projection direction.
Problem during performs MATLAB and image processing techniques.
I came across issues with image processing, which is accessed throthroughMATLAB application. The graphs, charts, and images were used and produced to minimize the information and edge identification. I performed and tried to use the edge identification that resulted in a smooth line with the canny channel. However, the lines were unacceptable for uniting the adjacent items to large devices. Therefore, I use the large device for the improvement level of the pixel and for the vertical bearing to consolidate all the pixels together. It observes that all the pictures were managed by the Sobel channel, which solves the problem of unrealistic lines. The entire picture was prepared with the Sobel channel application, and there occurred the widening of the apparatus for joining the item parts, this way, issues solved.
To access the operation, I prepared or designed the MATLAB coding and precede MATLAB graphic interface. At the same time, I changed the graphical interface prepared in MATLAB, which allows accessing the information sent from the ScanCONTROL. Further, I solved the issues by setup processing and image processing through engineering fundamental techniques.
After completing the experiment and obtaining the result, I arranged a meeting with the team and identified the study field and tasks. For planning purposes, I prepare a Gantt chart for a suitable section of working studies. I discuss the project's progress with my supervisor and collect more information regarding the project's aim point of view. Side by side, I constantly observed the development and produced results through analysis. Further, I engage with the supervisor for an effective analysis of those produced results. Lastly, I approved the result that I obtained and prepared the report. In the report, there is a discussion of the project aim, objectives, experiment, and how results are obtained. For this project, I have used the standard technique for the welding system by applying ISO 14732. Additionally, was applied IEC 61508 for using MATLAB in this project. The entire project had been completed with the awareness of welding technology rules and regulations.
Summary
The project aims to design an automated welding system that can perform the different operations of welding technology and work smoothly with accuracy. The project is also concerned about the welding quality and reducing defects. I prepared the automatic welding system, which can reduce overall defects and enhance the accuracy of the welding procedure with consistent results.
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