Robust sensing and control of weld pool surface

Wei Lu, Yu Ming Zhang, Chuan Zhang, Bruce L. Walcott

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review


Gas tungsten arc welding is the primary process for precision joining of metals. To develop a simple yet durable sensing and control system for this process, a novel sensor which requires no additional attachment is proposed to sense the depth of the weld pool surface using a non-transferred arc. To assure its effectiveness and accuracy, a flat surface is periodically established to provide a real-time reference so that the weld pool surface depth can be accurately measured. Because of possible large process variations, an interval model control algorithm with adaptively updated intervals is adopted. Closed-loop experiments showed that the developed control system is capable of achieving quality welds and is robust with respect to different variations.

Original languageEnglish
Title of host publicationProceedings of the 16th IFAC World Congress, IFAC 2005
Number of pages6
StatePublished - 2005

Publication series

NameIFAC Proceedings Volumes (IFAC-PapersOnline)
ISSN (Print)1474-6670

Bibliographical note

Funding Information:
This work is funded by NSF under Grant DMI-0114982. Supplemental funding is provided by the Magnatech Limited Partnership, East Granby, Connecticut, and NSF GOALI Program.


  • Adaptive control
  • Manufacturing processes
  • Predictive control
  • Sensor system
  • Uncertainty

ASJC Scopus subject areas

  • Control and Systems Engineering


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