Model Predictive Control of GTAW Weld Pool Penetration

Weld pool penetration is a major indicator of weld integrity but it is not directly measurable. The key to solving this issue is to find or create observable phenomena that can be used to derive the penetration. An innovative method has recently been proposed/developed to derive the penetration from the reflection of projected laser from an oscillating weld pool surface. However, in addition to the penetration, the oscillation, thus the reflection determined by it, also depends on the pulse amplitude of the current, which needs to be adjusted as the control variable to feedback control the penetration as the output. This dependence imposes a constraint on the control algorithm such that the adjustment of the control variable must be relatively slow to minimize additional sources that affect the oscillation/sensor. This restriction on the control variable adjustment also brings challenges to the identification of the dynamic model of the weld process to be controlled, which has to apply a varying control signal to stimulate the dynamics. To solve these issues, this letter proposes using a low order model to catch the dominant dynamics such that a high speed variation in the control signal can be avoided when choosing the model predictive control algorithm. This allows use of relatively poor models to determine the adjustment on the pulsing amplitude, and still achieves relatively accurate control. Experimental results verified the effectiveness of the resultant penetration control system despite the restrictions imposed by the penetration sensor, which affect the identification of high order dynamics and free adjustments of control variables.