This report describes a Bachelor thesis work in which a robotised laser Welding cell has been modelled and simulated for the purpose of making a presentation movie. The report shows that the work has been concentrated on making the movie from the modelling phase through the recording of the movie and ending up with the editing of the final presentation movie. A pre-study was made prior the Bachelor thesis work. In the pre-study a literature study was conducted about measurement and calibration of a Welding cell. Measurement of almost all equipment in the entire cell was also conducted in the pre-study.

AbstractThis bachelor thesis has been assigned by the company ACG Nyström, Borås. ACG Nyström is working in cooperation with a Swiss company named Jentschmann AG. Jentschmann is a manufacturer of ultra sonic Welding machines which ACG Nyström is marketing in Scandinavia and the Baltic States. On behalf of Jentschmann AG the company has the aim to introduce the ultra sonic Welding technique to new companies.The aim of this thesis is to compare traditional sewing machines with ultra sonic Welding machines within two textile areas, protective clothing and outdoor living.Two investigative questions have been formulated for this purpose: what are the differences between a sewing machine and an ultra sonic Welding machine? Is it possible to replace the sewing technology with ultra sonic Welding? These stand as guidance for this paper.To gather knowledge interviews, literature studies, and tests on two different ultra sonic Welding machines were performed.

ESAB is a world leader in production of Welding consumables and equipment. The company manufactures, among other things, Welding electrodes. A roller straightening unit is used in the cutting process to straighten the wire, which the Welding electrode consists of, by adjusting some of the rollers during operation. According to ESAB?s standard and the European machinery directives, moving parts of machinery, such as rollers of the roller straightening unit, must be out of the operator?s reach.

ESAB is a world leader in production of Welding consumables and equipment. The company manufactures, among other things, Welding electrodes. A roller straightening unit is used in the cutting process to straighten the wire, which the Welding electrode consists of, by adjusting some of the rollers during operation. According to ESAB?s standard and the European machinery directives, moving parts of machinery, such as rollers of the roller straightening unit, must be out of the operator?s reach.

This Master of Science thesis was a part of Pharmadule Emtungas project to construct a mobile automated cell for Welding of carbon steel pipe (Heating, Ventilation and Sanitation). Pharmadule Emtunga is using a modular building concept for building pharmaceutical factories. The modules contain these pipes. The goal of the thesis was to present concepts for technical solutions regarding Welding methods and fixtures for the cell. Conceptual models for the cell were made with aid of CAD software.

The aim of this thesis was to investigate if the robotized Welding method FSW (Friction Stir Welding) could be applied for joining a rotating structure in an aero engine at Volvo Aero Corporation. FSW is expected to introduce less defects than today?s Welding methods and could therefore be suitable for critical aero components. The material is the nickel based alloy Inconel 718, however a material experimentation is outside the scope of this report.The main goal of this study is to verify if the ESAB ROSIO robot based FSW-system has a suitable work space to be able to weld the rotating structure, and if the Welding tool has accessibility to the joints. The FSW-process needs a rigid fixture, and a number of fix-ture concepts are presented based on a proposed weld sequence.

The aim of this thesis was to investigate if the robotized Welding method FSW (Friction Stir Welding) could be applied for joining a rotating structure in an aero engine at Volvo Aero Corporation. FSW is expected to introduce less defects than today?s Welding methods and could therefore be suitable for critical aero components. The material is the nickel based alloy Inconel 718, however a material experimentation is outside the scope of this report.The main goal of this study is to verify if the ESAB ROSIO robot based FSW-system has a suitable work space to be able to weld the rotating structure, and if the Welding tool has accessibility to the joints. The FSW-process needs a rigid fixture, and a number of fix-ture concepts are presented based on a proposed weld sequence.

This report describes the development process of a pipe clamp used on exhaust system for cars. It is made based on the manufacturers desire to improve and make the clamp easier to manufacture and to reduce its price to their customers. This should be done either by manufacturing the clamp in one piece without an expensive and work intensive Welding process, or by generating ideas of how to develop a brand new type of clamp. Investigating the market for similar products was done to eliminate intrusion of other manufacturers? patents but also to generate ideas.

 The purpose with this thesis was to develop a designguideline which will simplify the development of new products that will be laser welded. The need for this thesis has come forward from the quality problems that Volvo Construction Equipment, Components Division is having with their laser Welding manufacturing unit. The reason for the problems emerges from the bad communication between the development unit and the manufacturing unit within the company when the products produced today was developed. This resulted in products that were hard to and in some cases almost impossible to weld. To avoid these problems from occurring again it was needed to gather the experiences within this area and compile it and present in a brief a pedagogical manner. The information for the groundwork of our results has been gathered by interviews of several key persons in Volvo Construction Equipment, Components Division.

This master thesis deals with problems in the arc length control in Pulsed MIG/MAG Welding. The main problem is that it is not possible to measure the arc length. In the present solution the voltage over both the electrode and the arc represents the arc length. To improve the arc length control a model of the electrode melting has been built. One output from the model is the voltage over the electrode and with this voltage together with the measured voltage it is possible to calculate the voltage over just the arc.

Rapporten beskriver ett examensarbete genomfört på uppdrag av Motoman Robotics Europe AB i Torsås. Uppdraget gick ut på att hitta en lösning för att helautomatiskt kunna växla svetspistoler med en Motoman HP-20 industrirobot. Projektet har i första hand varit ett utvecklingsarbete med fokus på en fungerande praktisk lösning. Arbetet har fortskridit i nära samarbete med och handledning av konstruktörer på företaget samt stöd från vår lärare. Resultatet har blivit en kompakt och estetiskt tilltalande konstruktion som uppfyller kraven som uppdragsgivaren ställt..

Under början av 1990-talet inledde Volvo Personvagnar i Olofström en process där övervakning av robotiserad MIG/MAG-svetsning var i fokus. Det ledde fram till ett forskningsprojekt som resulterade i att Stefan Adolfsson, Lunds tekniska högskola/Blekinge tekniska högskola, 1998 presenterade avhandlingen Automatic Quality Monitoring in GMA Welding using Signal Processing Methods [5]. I den presenterades ett SPRT-baserat övervakningskoncept för övervakning av MIG/MAG-svetsning med kort- och spraybåge. För att få fram ett kostnadseffektivt övervakningssystem uppkom tanken att använda vanliga PC-datorer som plattform. De erbjuder hög beräkningskapacitet till förhållandevis låg kostnad.

This M.Sc. thesis is a material application evaluation commissioned by the advanced body engineering department at SAAB Automobile AB. The purpose of the thesis is to evaluate implementation of the innovative sandwich design material Hybrix into an automobile body. Today the most commonly material used in the body is galvanized steel sheets and by shifting material to Hybrix several problematic issues have to be dealt with. Hybrix is an innovative sandwich sheet that inherits thin stainless steel face sheets and a stainless steel fibrous core.

Welding is a common method for joining of metal or plastic construction parts. This report describes several different weld methods in general terms. The report focuses on the GMAW method, specifically MAG Welding.A case study has also been performed for the company Wenmec. The task received from the company was to compare the mechanical properties of joints welded with the tube electrode called Nittetsu SM-3A and joints welded with the homogenous electrode called ESAB Aristorod 12.63. Both types of weld joint were welded with the MAG method with an Argon based shielding gas with 18% CO2.

Under början av 1990-talet inledde Volvo Personvagnar i Olofström en process där övervakning av robotiserad MIG/MAG-svetsning var i fokus. Det ledde fram till ett forskningsprojekt som resulterade i att Stefan Adolfsson, Lunds tekniska högskola/Blekinge tekniska högskola, 1998 presenterade avhandlingen Automatic Quality Monitoring in GMA Welding using Signal Processing Methods [5]. I den presenterades ett SPRT-baserat övervakningskoncept för övervakning av MIG/MAG-svetsning med kort- och spraybåge. För att få fram ett kostnadseffektivt övervakningssystem uppkom tanken att använda vanliga PC-datorer som plattform. De erbjuder hög beräkningskapacitet till förhållandevis låg kostnad. Examensarbetets mål är att implementera det SPRT-baserade övervakningskonceptet i LabVIEW på en PC och utvärdera realtidsegenskaperna.