ABSTRACT Arc welding uses power sources of the constant current type having drooping characteristics or constant voltage characteristics. However, in reality, arc welding is a stochastic process due to random arc behaviour and metal transfer. The quality of a weld depends on the extent of these variations. The random signal amplitudes and time characteristics of the weldingsignal (voltage and current) allow a quality analysis of the welding process and disturbances. These random variations in current and voltage cannot be recorded with ordinary instruments. In the present work, a Programmable System on Chip based embedded Weld Monitoring System (WMS) with suitable software package was designed and developed to measure all the dynamic variations of welding voltage and current. Welding data were acquired using this WMS for the duration of 20 seconds at a sampling rate of 100,000 samples/s. The data obtained were filtered and subjected to the time domain and statistical analyses to evaluate various arc-welding parameters. The results obtained with WMS indicated that the same can be used for evaluating the welding consumables and assessing the skill of the welders. Thus, this work proposes a standalone, affordable, and an innovative tool for comprehensive on-line analysis of an arc-welding process.

中文翻译：

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基于芯片的焊缝监控系统可编程系统的弧焊工艺质量分析

摘要 弧焊使用具有下垂特性或恒压特性的恒流型电源。然而，实际上，由于电弧行为和金属转移的随机性，电弧焊是一个随机过程。焊接质量取决于这些变化的程度。焊接信号（电压和电流）的随机信号幅度和时间特性允许对焊接过程和干扰进行质量分析。这些电流和电压的随机变化无法用普通仪器记录。在目前的工作中，基于可编程芯片系统的嵌入式焊接监控系统 (WMS) 与合适的软件包被设计和开发，以测量焊接电压和电流的所有动态变化。使用此 WMS 以 100,000 个样本/秒的采样率在 20 秒的持续时间内获取焊接数据。对获得的数据进行过滤并进行时域和统计分析，以评估各种弧焊参数。使用 WMS 获得的结果表明，同样可用于评估焊接耗材和评估焊工的技能。因此，这项工作提出了一种独立的、负担得起的、创新的工具，用于对弧焊过程进行全面的在线分析。