Project Title:

Feasibility Study of a Next Generation VPPA Welding Control System

04.08-8305
Feasibility Study of a Next Generation VPPA Welding Control System
General Digital Industries, Inc.
7702 Governors Drive
Huntsville
AL
35805
Vora
Dipak V.
36267

MSFC

Abstract:

New approaches to automatic control are needed if Variable Polarity Plasma ARC (VPPA)
welding is to realize its full potential as a reliable, repeatable, cost effective
process. Present VPPA control systems are first generation, elementary computer-based
systems that depend on programs which are experimentally derived, and do not compensate
for anomolies injected by tooling, part, and other independent variables.
	This SBIR effort will investigate the feasibility of using real-time measures of
joint quality to control all aspects of welder operation.  The key determinants of
joint quality will be established, the ability to sense each quality determinant
using available technology will be investigated, and an estimate of control ability
will be made for each determinant.  In Phase II, a set of requirements for this next
generation control system will be derived, and a prototype will be designed and implemented.
	If successful, this innovation will transform an expensive, sensitive, and human-error-prone
process into a reliable and easy to use process that can produce significant productivity
gains in the manufacture of aerospace structures.