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Position gauging of welding joints with an FMCW-based mm-wave radar system

Published online by Cambridge University Press:  18 December 2015

Jochen O. Schrattenecker*
Affiliation:
Institute for Communication Engineering and RF-Systems, Johannes Kepler University, Linz, Upper Austria A-4040, Austria. Phone: +43 732 2468 6390
Stefan Schuster
Affiliation:
Voestalpine Stahl GmbH, Upper Austria, A-4020 Linz, Austria
Christian M. Schmid
Affiliation:
DICE, Upper Austria A-4040, Austria
Werner Scheiblhofer
Affiliation:
Institute for Communication Engineering and RF-Systems, Johannes Kepler University, Linz, Upper Austria A-4040, Austria. Phone: +43 732 2468 6390
Helmut Ennsbrunner
Affiliation:
Fronius International GmbH, Upper Austria, A-4600 Wels-Thalheim, Austria
Andreas Stelzer
Affiliation:
Institute for Communication Engineering and RF-Systems, Johannes Kepler University, Linz, Upper Austria A-4040, Austria. Phone: +43 732 2468 6390
*
Corresponding author: J.O. Schrattenecker Email: j.schrattenecker@nthfs.jku.at
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Abstract

This paper presents a position gauging system of welding joints. While the principle measurement concept was already introduced by Schrattenecker et al. in 2014, here it is focused on different types of practically used welding materials. The sensor used is based on the frequency-modulated continuous-wave principle operating in the W-band. Position estimation (PoE) of different welding geometries is carried out with polarimetric scattering effects introduced by geometrical discontinuities. For the real-time calculation of the signal models a field simulation tool we developed is used. Aside from a variety of geometries, we introduce a geometrical optimization approach that increases the achievable accuracy of the measurement concept. The optimization and PoE of the different welding materials were examined in various simulations and the results were verified by measurements in the laboratory and in an industrial environment. Simulation and measurement were in good agreement.

Information

Type
Industrial and Engineering Paper
Copyright
Copyright © Cambridge University Press and the European Microwave Association 2015 
Figure 0

Fig. 1. Schematic diagram of the simulation and measurement scenario. As a target a lap joint, V-butt joint, or a T-joint is used.

Figure 1

Fig. 2. Side and top view of a typical lap joint formed by a top and a bottom plate.

Figure 2

Fig. 3. Geometry of a typical V-butt joint in top, side, and isometric view. The left and the right plate form the geometrical arrangement.

Figure 3

Fig. 4. Geometry of a typical T-joint in top, side, and isometric view.

Figure 4

Fig. 5. Photograph of the FMCW prototype FE used for measurements at the welding test stand.

Figure 5

Fig. 6. Photograph of a complete 77 GHz radar TRX module with a WR12 transition on top of the packaged MMIC.

Figure 6

Fig. 7. Schematic diagram of the simulation and measurement scenario with the antenna system facing the step with the facing angle φF.

Figure 7

Fig. 8. Schematic block diagram of the range compression: the antenna system is facing the step of the lap joint or the T-joint.

Figure 8

Fig. 9. Absolute value of the range profile of a lap joint where the antenna system is facing the step at an angle of 45°. The dashed lines depict the search areas and the solid line the estimated ranges.

Figure 9

Fig. 10. Absolute value of the range profile of a lap joint after correction for range migration. The antenna system faces the step at an angle of 45°.

Figure 10

Table 1. Simulation parameters.

Figure 11

Fig. 11. Range profile of the measurement data of the V-butt joint.

Figure 12

Fig. 12. Range-compressed measurement data xcross(ux) and signal model scross(ux) for a V-butt joint. They are in good agreement.

Figure 13

Fig. 13. Cost function resulting from the position estimation (PoE) of the V-butt joint with the same measurement data as used for Fig. 12.

Figure 14

Fig. 14. Photograph of the measurement arrangement of the T-joint. The radar prototype is mounted on the welding robot, and the antenna system is focused in the direction of the T-Joint.

Figure 15

Table 2. Measurement parameters.

Figure 16

Fig. 15. Measured data xcross(ux) and signal model scross(ux) of a T-joint. The measurements were taken with the FMCW prototype introduced in Section III. The setup parameters are given in Section II.

Figure 17

Fig. 16. Cost function resulting from the position estimation (PoE) of the T-joint based on the same measurement data as used for Fig. 13.

Figure 18

Fig. 17. Photo of the measurement arrangement for verifying the improvements in the variance of the position estimation (PoE). The MMIC-based radar prototype depicted in Fig. 6 was used.

Figure 19

Fig. 18. CRLB of position estimation (PoE) for different facing angles. The CRLB was validated by MC simulations and measurements. The CRLB and the MC results are in good accordance. An improvement in the CRLB can be achieved when the antenna system faces the lap joint.