Improving the Use of Robotic Welding of Aluminum Boats through Modularization

Abstract Full-Text HTML XML Download Download as PDF (Size:670KB) PP. 42-49
DOI: 10.4236/eng.2014.61007    4,472 Downloads   6,794 Views   Citations

ABSTRACT

The level of automation in the manufacture of recreational aluminum boats is very low. Robotized welding is rarely utilized, although it is commonly considered as the most effective way to reduce costs and increase competitiveness. A reason for the under-exploitation of robotics can be found in the construction of aluminum boats; boat models and their detailed structures are almost without exception individual pieces. A new stiffener structure for an aluminum recreational boat hull is developed in this work. Construction of the stiffener as a module allows exploitation of the advantages of modularization. The number of different parts is reduced and the structure simplified improves the applicability of robotic welding and provides benefits accruing from mass production. The same module can be used in several boat models. The modularity also makes it possible to use the same advanced robot welding fixture for a variety of boat models.

Cite this paper

P. Kah, E. Hiltunen and J. Martikainen, "Improving the Use of Robotic Welding of Aluminum Boats through Modularization," Engineering, Vol. 6 No. 1, 2014, pp. 42-49. doi: 10.4236/eng.2014.61007.

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1] D. T. Miller and P. Elgard, “Defining Modules, Modularity and Modularization—Evolution of the Concept in a Historical Perspective,” Proceedings of the 13th IPS Research Seminar, Fuglsoe, 1998, 19 p.
[2] J. N. Pires, A. Loureiro and G. Bolmsjo, “Welding Robots: Technology, System Issues and Application,” Springer, London, 2006.
[3] J. Aarnio, “Modularization by Integration: Creating Modular Concepts for Mechatronic Products,” Ph.D. Thesis, Tampere University of Technology, Tampere, 2003.
[4] M. Hellstrom, “Business Concepts Based on Modularity: A Clinical Inquiry into the Business of Delivering Projects,” Ph.D. Thesis, Abo Akademi University, Turku, 2006.
[5] T. Blecker, G. Friedrich, B. Kaluza, N. Abdelkafi and G. Kreutler, “Information and Management Systems for Product Customization,” Springer, Boston, 2004.
[6] L. Fleming and O. Sorenson, “The Dangers of Modularity,” Harvard Business Review, Vol. 79, No. 8, 2001, pp. 20-21.
[7] G. Erixon, “Modular Function Deployment—A Method for Product Modularization,” Ph.D. Thesis, The Royal Institute of Technology, Stockholm, 1998.
[8] A. Ericsson and G. Erixon, “Controlling Design Variants —Modular Product Platforms,” Society of Manufacturing Engineers, Dearborn, 1999.
[9] J. Lukkari, “Weld Deposition Rate and Its Uses,” Welding News, 2008, pp. 10-13.
[10] E. Craig, “The Plasma Arc Process—A Review,” Welding Journal, Vol. 2, 1988, pp. 19-25.
[11] W. Tuttle, “Understanding Aluminum Welding,” Welding Journal, Vol.70, 1991, pp. 43-46.
[12] H. Ahola, “Automated Arc Welding Taking into Account the Design of the Product,” Technical Information 16/88. 1988, pp. 13-28.
[13] J. Hoffman, “The Challenges of Robotic Aluminum Gas Metal Arc Welding,” Weldingmag.com, 2007.
[14] H. Tong, T. Ueyama, S. Harada and M. Ushio, “Quality and Productivity Improvement in Aluminium Alloy Thin Sheet Welding Using Alternating Current Pulsed Metal Inert Gas Welding System,” Science and Technology of Welding and Joining, Vol. 6, No. 4, 2001, pp. 203-208.
http://dx.doi.org/10.1179/136217101101538776
[15] H. Tong, “Study on the Mechanism of Fume Formation in Pulsed MIG Welding of Al-Mg Alloy,” MEng Thesis, Welding Research Institute, Osaka University, Osaka, 1995.
[16] H. Tong, T. Ueyama, S. Harada and M. Ushio, “High Speed Welding of Aluminium Alloy Sheets with Using the Laser/AC Pulsed MIG Hybrid Process,” Science and Technology of Welding and Joining, Vol. 8, 2003, pp. 229-234.
http://dx.doi.org/10.1179/136217103225010853
[17] G. Mathers, “Welding of Aluminum and Its Alloys,” Woodhead Publishing, Sawston, 2002.
[18] B. Zheng, “The Discontinuous Pilot Power Source for AC PAW,” China Weld, Vol. 6, 1995, pp. 1-6.
[19] B. Zheng, Q. L. Wang and R. Kovacevic, “Arc Interference and a Unique Push-Pull-Arc Solution in Alternating Current Plasma Arc Welding of Aluminum Alloys,” Journal of Engineering Manufacture, Vol. 213, No. 1, 1999, pp. 69-76.
[20] H. D. Steffens, Welding Journal, Vol. 6, 1972, pp. 40-45.
[21] B. Zheng, Q. L. Wang and R. Kovacevic, “Parameters Optimization for the Generation of a Keyhole Weld Pool during the Start-Up Segment in Variable-Polarity Plasma Arc Welding of Aluminium Alloys,” Journal of Engineering Manufacture, Vol. 214, No. 5, 2000, pp. 393-400.
[22] B. Mannion and J. Heinzman, “Plasma Arc Welding Brings Better Control,” Tooling and Production, Vol. 5, 1999, pp. 29-30.
[23] C. A. Huntington and T. W. Eagar, “Laser Welding of Aluminum and Aluminum Alloys,” Welding Research Supplement, Vol. 62, 1983, pp. 105-107.
[24] M. A. Bramson, “In Infrared Radiation,” Handbook for Applications, Plenum Press, New York, 1968, p. 107
[25] J. Weston, J. W. Yoon and E. R. Wallach, “Laser Welding of Aluminum Alloy using different Laser Sources,” TWI, 2003.
[26] A. Ascari, A. Fortunato and G. C. Leonardo Orazi, “The Influence of Process Parameters on Porosity Formation in Hybrid LASER-GMA Welding of AA6082 Aluminum Alloy,” Optics & Laser Technology, Vol. 44, No. 5, 2012, pp. 1485-1490.
http://dx.doi.org/10.1016/j.optlastec.2011.12.014
[27] H. Shen, J. Wu, T. Lin and S. Chen, “Arc Welding Robot System with Seam Tracking and Weld Pool Control Based on Passive Vision,” The International Journal of Advanced Manufacturing Technology, Vol. 39, No. 7-8, 2008, pp. 669-678.
http://dx.doi.org/10.1007/s00170-007-1257-8
[28] J. Mortiner, “Jaguar Uses Adaptive MIG Welding to Join C-Pillars to an Aluminium Roof Section in a New Sports Car,” Sensor Review, Vol. 26, No. 4, 2006, pp. 272-276.
http://dx.doi.org/10.1108/02602280610691971
[29] X. Chen, S. Chen and T. Lin, “Practical Method to Locate the Initial Weld Position Using Visual Technology,” The International Journal of Advanced Manufacturing Technology, Vol. 30, No. 7-8, 2006, pp. 663-668.
[30] C. Fan, F. Lv and S. Chen, “Visual Sensing and Penetration Control in Aliminum Alloy Pulsed GTA Welding,” International Journal of Manufacturing Technology, Vol. 42, No. 1-2, 2009, pp. 126-137.
[31] E. O’Shea, “Comparing Intelligent Robotic Arc-Sensing Technologies,” Penton's Welding Magazine, Vol. 82, No. 6, 2009, pp. 14-17.
[32] J. J. Wang, T. Lin and S. B. Chen, “Obtaining Weld Pool Vision Information during Aluminum Alloy TIG Welding,” International Journal of Manufacturing Technology, Vol. 26, No. 3, 2005, pp. 219-227.

  
comments powered by Disqus

Copyright © 2020 by authors and Scientific Research Publishing Inc.

Creative Commons License

This work and the related PDF file are licensed under a Creative Commons Attribution 4.0 International License.