水轮机叶片修复专门机器人系统
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水轮机过流部件磨蚀问题的研究与防护小水电2006年第1期(总第127期)技术交流水轮机过流部件磨蚀问题的研究与防护熊茂涛卢池杨昌明(西华大学能源与环境学院四川成都610039)陈次昌(西南石油学院四川成都610500)【摘要】针对我国高含沙水流中运行的水轮机组的过流部件的磨蚀这个长期存在的疑难问题,开展研究工作,在分析水轮机过流部件泥沙磨损,空化破坏各自的磨损机理,特点,影响因素,预测模型等的基础上,总结出水轮机过流部件的磨蚀主要是泥沙磨损,空化破坏及它们的联合作用,提出水轮机过流部件磨蚀的主要防护措施,为最终解决水轮机过流部件磨蚀问题提供了理论依据.图6幅,表1个.【关键词1泥沙水轮机磨蚀机理磨损空化l引言我国水能资源丰富,据2000年的数据,我国可开发水能资源为4.1324亿kW,2000年末我国水电装机总量达到75OO万kW,占全国总装机容量的24%_1】.同时我国河流的特点之一是含沙量大,年平均输沙量在1000万t以上的河流就有115条,每年直接人海泥沙总量达到19.4亿t[2】.因此在我国的水电开发中,存在着突出的泥沙问题.据不完全统计,在我国建成的装机7500kW以上的各类型大中小水电站中,有泥沙磨损的约占4o%[3J,由此产生的磨损,空化破坏严重,不仅影响了水电机组的安全经济运行,造成巨大的经济损失,而且威胁电网的安全运行,成为水电生产中急待解决的难题.表1为我国部分大型水电站水轮机磨蚀情况,其他河流上的水电站也存在着严重的磨蚀问题(见表1).表1我国部分大型水电站水轮机磨蚀简况河名,水电站名水轮机泥沙磨蚀情况90%的泥沙通过机组下泄,过机含沙量多年平均值为1.60ks/m3,汛期多年平黄河,刘家峡箬车翁簇赣嘉篷l泥沙大增,磨损,空化破坏空前加剧….多年平均含沙量为1.2kg/m~,最大含沙.…量1O.5kg,m3,水轮机转轮采用长江,葛洲坝0Crl3Ni4Mo和0Crl3Ni5Mo不锈钢铸造. 首台机组运行两个汛期就发现明显的磨损,空化破坏….1983年汛期后,沉沙库容所剩无几,过大渡河/龚嘴机泥沙数量猛增,水轮机开始进入严重的磨蚀损坏期.基金项目:国家自然基金项目资助(NO.90410013)由于磨蚀问题的复杂性和研究手段的制约,磨蚀的破坏机理至今看法不一.有鉴于此,通过分析水轮机泥沙磨损,空化各自的破坏机理,总结出高含沙水流中水轮机过流部件磨蚀机理及主要防护措施,为解决水轮机过流部件的磨蚀问题提供理论依据,对于提高水电站的经济效益和延长机组寿命,促进国民经济的发展有着极其重要的意义.2水轮机磨蚀破坏特征2.1水轮机的泥沙磨蚀携带泥,沙,石的高速水流,在通过水轮机流道时,对水轮机过流表面产生的破坏称之为磨蚀.通常情况下水轮机某一过流表面局部的破坏,往往不是单一因素造成的,多数情况下,它包括泥沙磨损和空化破坏及其联合作用.2.2水轮机过流部件的磨蚀部位及其特点1)混流式水轮机:叶片正面磨蚀表现为上轻下重,叶片正面靠进水边的边缘磨蚀一般较严重;下部靠出水边出现沟槽和锯齿状;叶片背面亦是普遍磨蚀,尤其是叶片下部靠近下环处和叶片出水边靠下环转弯处,均出现针孔,鱼鳞状凹坑等.图1为轴流式水轮机转轮叶片磨损情况示意图(见图1).圈1轴流式水轮机转轮叶片磨损情况示意图3l?技术交流SMAILHn)R0POWER2006Nol.TotalNo127 图2混流式水轮机转轮磨损部位示意图2)轴流式水轮机:叶片正面靠出水边缘特别是叶片外边缘,叶片背面亦严重磨蚀;转轮室下部半球形部分,转轮体及泄水锥的外表面等出现磨损.图2为混流式水轮机转轮磨损部位示意图(见图2).3)冲击式水轮机:引水管道,针阀,水斗内表面和喷嘴环等处容易受到泥沙磨蚀.3磨损破坏机理研究3.1磨损理论水轮机工作水流中含有泥沙颗粒时,具有一定动能的坚硬沙粒将有可能垂直冲击水轮机部件的过流表面的金属材料,材料在沙粒的冲击压力下,产生弹性变形,进入塑性流动状态.此后,表面弹性变形部分将恢复,而塑性变形被保留,形成冲击凹坑.在凹坑边缘有塑性变形中挤出的材料堆积物在沙粒不断冲击下,堆积物将重新受挤压变形和移位而有可能从材料表面剥落.同时,在合适的沙粒冲击角度下,堆积物易受剪切折断,形成材料的磨损量.某些金属有很强的冷作硬化能力,具有较高的硬度和脆性,可能产生变形裂纹.在足够的冲击能量下,冲击凹坑边缘和坑壁就常可能存在径向裂纹,即使沙粒冲击能量较小,不足以直接产生材料剥落,但经过长期反复冲击,也会导致材料的疲劳剥落.上述即为金属表面受沙粒冲击后,因弹一塑性变形引起的微体积损失过程,称之为变形磨损. 当沙粒以小冲角撞击材料表面,接触点很小的面积上将集中很高的压力.此冲击压力的垂直分量使沙粒压人材料表面.同时,沙粒在小冲角下有较大的水平动能分量,将使其沿大致水平于材料表面的方向移动.材料在沙粒尖角水平移动时.产生接触点的横向塑性流动,切出一定量的微体积材料. 这种材料的微体积损失称为微切削磨损.高含沙水流中含有不同形状的沙粒,流动也表-32-现为紊流形态,沙粒颗粒群体的运动方向可能是任意的,因此,高含沙水流中水轮机过流表面的实际磨损过程为上述变形磨损和微切削磨损的复合作用引.3.2泥沙磨损的破坏形态破坏轻微处有沿水流方向的划痕和麻点;严重时,表面呈波纹状或沟槽状,并常形成鱼鳞状凹坑;磨损强烈发展时,可使过流部件穿孔,成块崩落.磨损有明显的方向性,与水流特征一致;磨损表面密实,呈金属阴暗光泽L4J.3.3水轮机泥沙磨损的影响因素泥沙对磨损的影响因素:沙粒的特征,包括颗粒尺寸,硬度,形状等;含沙水流的特征,包括相对速度,冲击角等;金属材料的特征,包括硬度,韧性,破断强度等;水轮机的设计,如负荷选择,水头变化频率等等(见图3-5).圈3水轮机磨损的影响因素3.4水轮机泥沙磨损的预测水轮机过流表面的磨损行为十分复杂,到目前为止还没有一个公认的,普遍适用的机理和公式可以预}贝5水轮机材料的抗磨损性能.其中Finnie的微切削模型在验证塑性材料的冲蚀磨损规律方面有较好的效果L6】.cM厂(D)-r.式中:为冲蚀磨损量(kn);M为沙粒颗粒的质量(kg);U为沙粒的速度(rrds);P为金属材料的屈服应力;c为经验系数;a为入射角.国外,已有水轮机制造厂(如伏依特公司)利用TASCflow等商用软件计算泥沙颗粒运动轨迹,并预测泥沙磨损.但是,其颗粒运动轨迹计算量有限,不能得出分散相运动特性,预测泥沙磨损还需小水电2006年第1期(总第127期)大量经验数据.4空化破坏机理研究4.1空化理论空化存在两种物理变化过程:水流在流道里高速运动过程中,速度和压力都会变化.当速度增加压力降低时,水流中就会产生气泡,气泡集中的区域叫空穴,这种变化叫空化;挟带气泡的水流在高速流动过程中当速度降低压力增加时,气泡就会溃. 灭,气泡溃灭时会产生高温高压的微射流,靠近流道边壁的微射流长期对边壁作用,就会使边壁的固体物质产生疲劳破坏,使材料大量流失,这种变化过程叫空化.对流道边壁产生破坏作用的是后一种物理变化….图4为微射流引起的空化示意图(见图4).圈4微射流引起的空化示意图4.2空化的部位与特点空化破坏常常会出现在叶片的背面等低压区.轻微的空化使过流表面失去光泽而变暗,进而发展为麻点,麻面,针孔状等;较重的空化使表面变得十分疏松成为蜂窝状;空化严重时转轮叶片出水边较薄的地方就会穿孔,甚至整块脱落,过流部件很快就破坏失效.4.3空化的影响因素影响空化的因素主要是:硬度,断裂应变能,韧性及材料的抗腐蚀性能,流体速度,工件的表面粗糙度,流体的温度和气体含量等.但由于目前尚没有完全掌握空化机理,还不能准确预测各类材料耐空化性能.4.4水轮机空化的预测目前仍没有一种非常完善的评判水轮机空化状态的标准,尤其水轮机在实际运行过程中,无法直接确定其叶片的空化破坏程度,极大地制约了水轮机状态检修技术的发展.通常水电厂都是根据水轮技术交流机实际运行吸出高度的大小,能量特性的变化及振动状况来判断水轮机的空化状态,但这仅仅是一种趋势性分析,并没有确定的标准可依哺].5泥沙磨损,空化联合作用泥沙磨损和空化联合作用,就是含沙掺气高速水流产生的复合磨损破坏(即为磨蚀),其原理是:高含沙水流以混合体(压力水携带泥沙颗粒)高速冲击水轮机过流部件,其冲击强度随气泡大小可达上千个大气压,造成复合形式的磨损.其中,有气泡的空化,也有高速水滴和泥沙颗粒的冲蚀磨损及其交互作用.在水轮机过流部件的磨蚀破坏过程中,当水流中气泡爆裂产生的带有巨大冲击波的微射流射到泥沙颗粒上时,就使得泥沙颗粒从微射流上得到了速度.受到微射流冲击的泥沙颗粒由于微射流的速度远大于悬移质的速度,所以泥沙颗粒一般是以旋转状态沿着接近微射流的方向高速前进,旋转着的高速沙粒与边壁相遇时,金属材料除了受空化产生的脉冲式法向应力的重复作用外,还受泥沙颗粒的非法向力的切削作用.材料表面气泡溃灭时产生的微射流除直接蚀损材料外.还以冲击波的形式作用于泥沙颗粒上,极大地增加了泥沙颗粒的冲击速度,提高了对材料的切削作用,致使材料表面出现麻点,麻面,凹坑,甚至使泥沙颗粒嵌入材料表面形成凹凸不平,从而改变材料表面的平整度.当沙粒有锐利的棱角时,其切削作用则更加明显.这种切削作用使得金属表面的氧化膜不断受到冲击而产生崩落,既而引起水中腐蚀性介质对金属表面的进一步侵蚀.大量试验表明,含沙水流由于泥沙裂隙挟带气泡进入水流中,增加了水中气核,促使气泡初生提前发生.但气泡初生后,含沙水流对从气泡生长,溃灭到对过流表面的破坏机理,尚存在较大分歧.一般认为磨损促进了空化,空化又促进了磨损,但哪一个起主导作用尚未完全搞清楚.图5,图6即为葛洲坝水电站水轮机叶片典型的磨蚀表面,显示出分布规则的鱼鳞坑[6].这种磨蚀表面形貌与纯泥沙磨损和纯空化破坏得到的磨损表面有非常巨大的差别.说明我国高含沙水流中水轮机的磨蚀机理既不是简单的泥沙磨损也不是纯粹的空化破坏,而是泥沙磨损和空化联合作用对水轮机过流部件的破坏作用.33?技术交流SMAIHu)R()POWF~2O06Ⅳ0,TotalNo127 图5被严重磨损的叶片边缘6泥沙磨蚀防护措施6.1水电站的排沙措施与运行方式合理排沙,减少过机沙量是有效减轻水轮机泥沙磨蚀的重要措施.水库在设计时,就应该做好枢纽布置及科学调度的规划,以减少通过水轮机的泥沙.我国已总结出许多减少水库淤积,延长水库寿命的措施,包括在流域内大力开展水土保持工作; 合理布置电站取水口;设置导沙坝,冲沙闸,沉沙池等排沙设施.另外,利用水库采取调水调沙,蓄清排浑,泄洪排沙,异重流排沙等方式,都是行之有效的.6.2水轮机设计参数的合理选择水轮机设计参数选择时应考虑适当降低参数水平,特别注意控制降低水轮机转轮出lZl的相对流速,以达到最优比转速.同时采取水轮机转轮叶片的优化设计,考虑加大导叶分布圆的直径,选择合理导叶翼型,转轮叶片外缘加装裙边等措施.在转轮结构设计中,应注意提高部件的互换性,保证部件容易拆卸,修理和更换,以提高工作效率.6.3水轮机的制造和防护水轮机转轮采用0Crl3Ni4Mo,0Crl3Ni5Mo和0Crl3Ni6Mo等抗磨蚀性好的高强度不锈钢铸造, 特别是提高制造水平和质量,保证加工精度和表面光洁度.水轮机的防护采取材料表面物理强化技术,改性环氧金刚砂涂层,聚氯酯涂层,金属陶瓷涂层,喷涂超高音速WC,喷焊SPHG1焊条,堆焊GB1,A132焊条等先进技术和材料.6.4电站的检测,维修手段水电站要加强各种技术资料的收集和积累,加强水电站检修手段的研究和配置,提高检修质量, 采用叶型测绘修形,智能专家系统,坑内水轮机修复机器人等先进设备和措施.7结束语由于水轮机过流表面的磨蚀机理复杂,影响因素众多和研究手段的制约,目前对磨损,空化双重34?图6水轮机磨损表面的鱼鳞坑作用下的过流表面快速损坏机理的认识还不足以得到实用性强的水力抗磨耐蚀优化设计方法,有待于深入研究.近年来随着扫描电镜,电子探针,x射线衍射和能谱分析等现代化测试手段的出现,磨蚀问题的研究进入到微观程度,把磨蚀的宏观形貌和微观过程相联系,通过微观破坏形貌判定磨蚀机理,使人们对磨蚀机理的认识又推进到了新的高度.通过对水轮机过流部件表面的磨蚀机理研究,认识磨蚀损坏本质,进行水轮机泥沙磨蚀的预估和防护.可以对水轮机进行水力抗磨耐蚀优化设计提供依据和手段,对于最终解决水轮机过流表面磨蚀问题具有重要的意义.参考文献:[1]段生孝.我国水轮机空蚀磨损破坏状况与对策[A].天津:水机磨蚀论文集.2001,11—15.[2]王志高.我国水机腐蚀的现状和防护措施的进展[J].水利水电工程设计,2O02,21(3):1.[3]顾四行.我国水轮机泥沙磨损问题回顾[A].天津:水机磨蚀论文集.2001,20—21.[4]段昌国.水轮机沙粒磨损[M].北京:清华大学出版社.1981,9—14.【5]GreinH,Sehac~nmamA+SolarProblemofAbrasionin HydmclccmcMachinery[J].WaterPower&DamConstrue- tion,1992,(8):19.[6]李健,彭恩高,白秀琴,周燕,孙家峰.水轮机过流部件的磨损问题[J].材料保护,2004,37(7): 44—46.[7]薛伟,陈昭运.水轮机空蚀和磨蚀理论研究[J].大电机技术,l996,(6):46—47.[8]徐朝晖,陈乃祥,吴玉林,周兵.水轮机空蚀破坏估算法[J].华东电力,2002,(8):75.■熊茂涛(1976一),男,硕士研究生,工程师,主要从事水轮机空化与泥沙磨损理论和数值模拟研究工作. Dnail:********************陈次昌(1948一),男,工学博士,教授,博士生导师,主要从事流体机械研究工作.。
水下机器人推进系统综述水下机器人是一种在水下进行任务的无人机器人系统,它可以应用于海洋科学研究、水下勘探、深海探测、水下维修等领域。
水下机器人的推进系统是其最关键的部件之一,它直接影响到水下机器人的性能和运行能力。
本文将对水下机器人推进系统进行综述,包括水下机器人推进系统的类型、工作原理、发展现状及未来发展方向等内容,以期为水下机器人的研究和应用提供参考。
水下机器人推进系统通常可以分为螺旋桨推进系统、水下喷射推进系统和水下旋翼推进系统三种类型。
螺旋桨推进系统是最常见的水下机器人推进系统,它通过螺旋桨的旋转来产生推进力,实现水下机器人的运动。
水下喷射推进系统则是通过喷射高压水流来产生推进力,从而推动水下机器人进行运动。
水下旋翼推进系统则类似于直升机的工作原理,通过旋翼的旋转来产生推进力,实现水下机器人的运动。
二、水下机器人推进系统的工作原理目前,水下机器人推进系统的发展已经取得了一定的成就,各种类型的推进系统在水下机器人中得到了广泛的应用。
螺旋桨推进系统因其简单、稳定、高效的特点,是目前应用最广泛的水下机器人推进系统。
水下喷射推进系统由于其高速、灵活、可在狭窄空间中操作的特点,得到了在水下作业、水下勘探和水下搜救等领域的广泛应用。
水下旋翼推进系统则因其可以实现多方向的自由运动,目前在水下机器人中也得到了一定程度的应用。
随着水下机器人应用领域的不断拓展和水下任务需求的增加,水下机器人推进系统也需要不断进行创新和改进。
未来,水下机器人推进系统的发展方向可能包括以下几个方面:首先是推进系统的高效性和节能性,可以通过提高推进系统的效率和降低能源消耗,实现水下机器人的长时间工作和远距离行驶。
其次是推进系统的智能化和自主化,可以通过引入智能控制算法和传感器技术,实现水下机器人的智能导航、避障和自主作业。
推进系统的多样化和模块化也将成为未来的发展趋势,可以通过多种推进系统的组合和模块化设计,实现水下机器人在不同任务中的灵活应用和快速转换。
水轮机叶片裂纹原因分析及现场修复措施摘要:近年来,华能雨汪电厂在长底水电站水轮机大修中发现水轮机转轮的叶片频繁发生裂纹,严重威胁水电站的安全经济运行,本文对长底水电站水轮机转轮叶片裂纹产生的原因进行分析及并对其进行现场处理,消除事故隐患,保证了机组安全稳定运行。
关键词:裂纹转轮叶片水轮机坡口一、引言华能雨汪电厂长底水电站长底水电站装机规模4×4.5MW,水轮机型号为ZDJP502~LH~250(0°),设计参数:水头15m,额定转速214.3r/min,飞逸转速472r/min,额定出力 4737kW,额定流量 34.61m3/s,2010年1月份投产,在历次大修中发现每台水轮机转轮叶片根部均存在裂纹现象,1号机组有3只叶片根部发现裂纹,2号机组、3号机组、4号机组有1只叶片根部焊缝发现裂纹。
二、裂纹产生原因分析通过对比每台机组叶片根部焊缝裂纹,裂纹分布在距叶片上冠约220mm处,长200~400mm,该位置正处于转轮叶片应力集中区。
一般转轮叶片存在四个高应力区,它们的位置在叶片进水边正面(压力分布面)靠近上冠处;叶片出水边正面的中部;叶片出水边背面靠近上冠处;叶片与下环连接区内。
对裂纹打磨发现,焊缝内部存在条状缺陷,有的约3mm左右气孔、夹渣缺陷,在外部应力的作用下可能会成为裂纹源,造成裂纹的产生。
转轮结构图(图1)裂纹示意图(图2)三、修复方案1、焊材的确定转轮材质为ZG230-450,叶片材质为0Cr13Ni4Mo,转轮直径800mm,长1200mm,叶片根部厚度75mm,转轮为铸钢材料,焊缝为异种钢焊接,根据一般异种焊接匹配原则,选择焊材为A102,A102是钛钙型药皮的Cr19Ni10不锈钢焊条。
熔敷金属具有良好的力学性能及抗晶间腐蚀性能。
有优良的焊接工艺性能和抗气孔性能,药皮耐发红、抗开裂。
2、裂纹的清除受现场条件限制,为避免碳弧气刨方法使用不当,引起裂纹再延伸扩展,裂纹清除采用机械打磨的方式进行清除,在挖磨过程中,边挖磨边观察裂纹走向、宏观检查裂纹消除后再用着色探伤方法确认裂纹彻底消除。
风电机组叶片维护装备的设备升级与改造方法随着全球对可再生能源的需求日益增长,风能作为一种清洁、可持续的能源来源,正受到越来越多的关注。
在风能的利用过程中,风电机组的叶片起着至关重要的作用。
然而,由于受到恶劣天气和长期使用的影响,叶片容易受损,需要进行定期的维护和修复。
为了提高效率和安全性,对风电机组叶片维护装备进行设备升级与改造具有重要的意义。
一、设备升级与改造的意义风电机组的叶片维护装备是保证风电机组正常运行的重要设备。
传统的叶片维护装备存在一些问题,如操作不便、维护效率低、安全性不足等。
设备升级与改造可以解决这些问题,提高叶片维护的效率和质量,降低维护成本,延长风电机组的使用寿命。
二、设备升级与改造的方法1. 引入先进技术目前,先进的技术如无人机、机器人等在叶片维护领域得到了广泛应用。
通过引入这些技术,可以实现叶片的快速检测和维护,大幅度提高工作效率,减少人力成本和时间。
无人机可以轻松地对叶片进行全面检测,发现潜在问题并及时处理。
机器人可以替代人工进行维护工作,避免了操作人员的危险和疲劳。
2. 加强监测系统建立高效可靠的叶片监测系统,对叶片进行实时监测和数据分析,有助于快速发现叶片的故障和损伤。
通过安装传感器,可以监测叶片的振动、温度、位移等参数,及时预警并采取相应的维修措施。
监测系统还可以收集大量的数据,为维护过程中的决策提供依据,提高叶片的维护效果。
3. 提高维护装备的适应性叶片维护装备的适应性是设备升级与改造的重点。
将叶片维护装备与自动化控制技术相结合,实现对叶片维护装备的远程监控和控制,提高其适应各种工作环境的能力。
此外,还可以增加装备的多功能性,使其能够适应不同类型和规格的叶片维护工作。
4. 提高维护装备的安全性叶片维护装备的安全性是设备升级与改造的首要考虑因素。
在设备设计和制造过程中,要注重提高装备的稳定性和承载能力,确保在恶劣天气条件下仍能正常工作。
此外,还应加强对操作人员的培训,确保其熟练掌握操作技能,提高工作安全性。
马氏体不锈钢水轮机叶片补焊修复工艺苟维杰;胡伟;王丽红【摘要】以水轮机的典型修复方案为背景,分析水轮机叶片空蚀补焊修复的技术要求,试验中以马氏体不锈钢为母材的水轮机叶片钢作为试验材料,采用熔滴高速摄影技术,研究不同焊接工艺及焊接参数对立焊焊缝成形的影响.结果表明,采用下向立焊、改变焊枪上仰角度、采用熔滴短路过渡、使用Ar+O2混合保护气体,得到成形良好的立焊焊缝.【期刊名称】《电焊机》【年(卷),期】2016(046)007【总页数】4页(P79-82)【关键词】立焊技术;熔滴过渡;水轮机叶片修复;马氏体钢【作者】苟维杰;胡伟;王丽红【作者单位】北京电子科技职业学院,北京100176;天津职业技术师范大学,天津300222;北京电子科技职业学院,北京100176;北京电子科技职业学院,北京100176【正文语种】中文【中图分类】TG457.11马氏体不锈钢(0Cr13Ni5Mo)广泛用于制造大型水轮机叶片。
水轮机运行过程中,水流中泥沙的磨蚀和高速水流的空蚀严重损伤水轮机叶片,被空蚀的叶片机组会产生剧烈震动和噪声。
空蚀磨损和叶片震动的存在降低了发电效率,严重威胁着水电站的运行安全。
针对空蚀磨损部位的补焊是水轮机叶片修复重要手段。
大型水轮机叶片的补焊作业主要有坑内修复和坑外修复。
坑内修复即原位修复,在不拆除、不挪动水轮机叶片的前提下进行修复,这种方法因检修周期短,效率高而被广泛采用。
修复过程分为三阶段:空蚀部位进行焊接前清底—补焊修复作业—焊后磨削喷涂[1-2]。
大型混流式水轮机的叶轮由于其自身工作需求以及条形空蚀方向的特点,停机检修时空蚀部位(叶片表面)处于垂直位置,因此,补焊焊缝类型为立焊位或横焊位,结合空蚀条形的形成方向与焊接机器人修复的施焊方向,在水轮机补焊过程中采用立焊姿进行补焊作业,有利于补焊修复及焊后磨削修形[3-4]。
水轮机叶片空蚀原形如图1所示。
水轮机叶片材质为马氏体不锈钢(0Cr13Ni5Mo),在此以马氏体不锈钢的水轮机叶片为试验材料,对水轮机的空蚀补焊工艺过程进行研究。
1Abstract -- This article presents an ongoing R&D project aiming at designing and constructing a specialized welding robotic system for repairing hydraulic turbine blades eroded by cavitation pitting, reducing human risks and increasing the efficiency of the process. The robotic system has a spherical topology with 5 degrees of freedom, electric stepper motors and a 2.5m-diameter workspace. The system has an embedded measurement system with a vision sensor built to produce range images by scanning laser beams on the blade surface. The range images are used to construct 3-D models of the blade surface and locate the damaged spots to be recorded into the robot controller in 3-D coordinates, enabling the robot to repair the flaws automatically by welding in layers. The robot controller and measurement system are built in an FPGA based reconfigurable system. The welding process is the GMAW with a tubular metal cored electrode with a pulsed GMA welding machine.Keywords – FPGA Applications, Robot Modeling, Robot Vision, Special Robots, Turbine Blade Defects, Welding Robots.I. I NTRODUCTIONHIS work presents the steps of a R&D project aiming at designing and constructing a specialized welding robotic system for recovering material damage on hydraulic turbine blades. The current project proposes a methodology and presents the construction steps of a robotic prototype to automate the welding process with the purpose of repairing hydraulic turbine blades eroded by cavitation pitting and/or cracked by cyclic loading, reducing human risks and increasing the efficiency of the process.Hydraulic turbines installed in hydroelectric plants are subject to several types of mechanical wearing. The sources of mechanical straining can range from operational conditions of the hydro generator, poor design characteristics, properties of the blade material employed and operation points out of specification as a consequence of overloading [1]-[2].II. THE PROBLEM CHARACTERIZATIONThe most common cause of rotor wearing is the erosion by This work has been supported by ELETRONORTE (Electrical PowerPlants of the North of Brazil) and FINATEC (Foundation for Scientific and Technological Enterprises).J. M. S. T. Motta is with University of Brasilia, Brasilia-DF, 70910-900 Brazil(e-mail: jmmotta@unb.br). C. H. Llanos is with University of Brasilia, Brasilia-DF, 70910-900Brazil(e-mail: llanos@unb.br).G. C. Carvalho is with University of Brasilia, Brasilia-DF, 70910-900 Brazil(e-mail: gccarval@unb.br). S. C. A. Alfaro is with University of Brasilia, Brasilia-DF, 70910-900 Brazil(e-mail: sadek@unb.br).cavitation pitting [3]-[4]. This is a highly undesirable phenomenon in the operation of a turbine. The water that flows through the turbine ducts during operation generates pressure fields on the blade surface that can be below the water vapor pressure in the operation temperature. This extreme operation condition generates vapor bubbles that can be collapsed when they reach regions of abrupt changes in pressure and flow conditions. When such bubbles collapse, they produce high shock pressures, which cause tearing out of bits of metal when the collapse occurs in adjacent regions of the runner blades. This cyclical loading of high amplitude produces fatigue erosion on the blade surface, causing substantial loss of material. Fatigue cracks are more rarely found, but the phenomenon can happen in hardened steels, such as martensitic stainless steels.An established process for repairing the surface of turbine blades eroded by cavitation or damaged by fatigue cracks is to recover the material flaws by using electric arc welding. The welding process is carried out manually after visual inspection of the blade surface, requiring a halt of the turbine. This is a very harsh human labor condition, in air temperatures around 40°C and 99% of air humidity for tenths of hours.III. PROJECT GOALSThis project is intended to improve the quality of cavitation damage repairs in hydraulic turbine blades using robotic welding, reducing welding defect rates, material consumption, time-to-repair and overall repairing costs. Besides, the technology proposed can remove weld personnel from harsh environment, achieve a better blade profile and improve weld consistency.IV. ROBOT DESIGN AND CONSTRUCTIONA. Design RequirementsFor a robot to perform all tasks needed in the application proposed it has to be able to fulfill the requirements below:a) capacity to operate in any position: horizontal, vertical or inverted; b) low weight: portability and fixation to the blades; c) rigidity to deflection: load on wrist occurs in any directionand arm extension; d) high motion accuracy: capacity to reach accurately welding regions from the mapped geometry; e) availability of parts in the market; f) control with component interfacing capability; g) topology making feasible to measure large areas with laser scanning and 3D geometry mapping; h) large workspace; i) easiness to be fixed to the turbine blades. The robotic system proposed has a spherical topology with 5 degrees of freedom, electric stepper motors, rotary and linear A Prototype of a Specialized Robotic System forRepairing Hydraulic Turbine BladesJ. M. S. T. Motta, C. H. Llanos, G. C. Carvalho and S. C. A. AlfaroT2010 1st International Conference on Applied Robotics for the Power Industry Delta Centre-VilleMontréal, Canada, October 5-7, 2010978-1-4244-6635-1/10/$26.00 ©2010 IEEEactuators and a 2.5m-diameter workspace. The system has an embedded measurement system with a vision sensor especially built to produce range images by scanning laser beams on the blade surface. The range images are used to construct 3-D models of the blade surface and the location of the damaged spots are recorded into the robot controller in 3-D coordinates, thus enabling the robot to repair the flaws automatically by welding in layers. The robot controller and measurement system are built in FPGA-based reconfigurable microprocessors (Field Programmable Gate Arrays). The welding process is the GMAW (Gas Metal Arc Welding) using a composite GMAW electrode (tubular metal cored electrode) carried out with a pulsed arc welding machine. The robotic system was designed to have high rigidity mechanics, easy assembly and fixing on the blade surface (the fixing system is still to be designed) and hassle-free operation. Low cost, light weight, portability, high positioning accuracy and repeatability are also characteristics of the resulting robotic system.B. Robot PrototypeThe robot was assembled using off-the-shelf parts found in the international market and each part was selected according to the needs and design criteria related to high rigidity to deflection, high positioning accuracy, low weight, large workspace but with short dimensions vertically to be easily inserted between blades. All parts were constructed and assembled using CAD software and the drawings can be viewed in Fig. 1.Fig. 1. Robot prototype assembled and compared with the turbine model inCAD drawings.The robot constructed has a weight of 30kg, a ring-shaped workspace of 2.5m outer diameter x 60cm height and dimensions of (30 x 25 x 100cm), without the welding torch (Fig. 2).The manipulator is conceived to carry an integrated control system to manage various tasks and may be considered an autonomous robot, since those tasks can be executed without human action. The control system is designed such that, after receiving from the operator the delimitation of the surface area to work, it manages the robot actions to recognize the environment, to extract the location and the volume of material to be filled, to determine the strategies for slicing the volume into a sequence of weld beads, to generate trajectories to be followed by the welding torch, and to control the robot motion during the welding tasks and during the change of torch positions defined by the slicing strategy.Fig. 2. Robot prototype.All of these actions are carried out without further external commands. Fig. 3 presents a simplified block diagram of the modules of the robot control system.The modules are:1) Vision system module: it is responsible for mapping the surface geometry on which the robot is to weld. The vision sensor scans the turbine blade surface and generates cloud points in 3D coordinates [5] that have to be represented further in robot coordinates, recognizing by image processing and pattern recognition algorithms which parts are damaged and the original blade profile to be recovered.2) Welding Management Module: this module receives data from the vision sensor with areas to be welded as well as their 3D geometry. With the areas and volumes to be welded and knowing the expected geometry of the welding beads, which have been previously modeled as a function of the welding parameters, this module calculates the correct slicing strategy to recover the original geometry by welding parallel weld beads in each plan to be superimposed. This module is also responsible for selecting a welding procedure, from a previously defined data base, as a result of the measured relative direction between the gravity vector and the average normal vector to the original surface, thus setting the welding parameters on the welding power source, as well as defining the start and end points of each weld bead.3) Motion Control Module: controls the motion of the electric motors according to the robot kinematic model. The welding manager sends the list of the target positions to be welded through a RS232 interface to the motion controller, which is responsible to generate the right commands to the power drivers in order to move the manipulator. The implementation of the motion control model in an FPGA embedded microprocessor allows more flexibility andefficiency in it, as well as allowing rapid changes in the motion control hardware, as for example, the addition of more processors, hardware accelerators or modules for arithmetic operations. The motion control is based on an open loop feedforward speed control strategy with encoder position feedback for the wrist axes. A block diagram for the control strategy can be viewed in Fig. 4.4) Communication Module: For the communication between the control module and the electric motors, two communication lines were implemented, one using digital signals for controlling the first 3 robot axes, which are driven by step frequency and direction signals, and the other based on a standard RS485 network, which is used to transmit movement commands and data to and from the driver that controls the 2 orientation axes at the robot wrist. The control module sends the motion commands to the wrist motors via a RS232 port, which is connected to the network by a RS232-RS485 converter, whereas the motion commands to the first three axes are sent via dedicated FPGA digital output lines. This strategy was adopted since it would guarantee the necessary synchronism among the first three axes, which do not have position feedback. The synchronism of these and the two orientation wrist axes is attained by using a position feedback from encoders installed in each wrist axis and a different control cycle frequency. Such a strategy also facilitates the communication between the robot controller and other controllers present on the site, such as the welding power source. Each controller associated to a network node has an identification address, allowing commands to be sent to all nodes by broadcasting. Each controller identifies its specific commands by analyzing the address associated with each command launched on the network.5) Motors and Drivers Module: This module includes the five electric motors, their controllers and drivers.Fig. 4. Complete robot control scheme._______________________________________________________________________________________________________V. MEASUREMENT VISION SENSORThe built-in vision sensor is based on laser scanning and active triangulation for dense surface acquisition and construction of 3-D models of the blade surface. In order to design a vision sensor capable of mapping the blade surface with high speed and accuracy, three main aspects were considered: a) sensor structure, b) image processing and c) calibration. The sensor structure defines the triangulation parameters and equations; the image processing detects the laser stripes and sample them, thus generating the input data for the triangulation equations; and the calibration solves the sensor parameters and is a critical procedure for the measurement accuracy.Fig. 5. Vision sensor prototype.The vision system (Fig. 5) is composed by a high resolution camera (1616x1216), 2 laser diodes (7mW) with stripe projection lens and a controlled rotary actuator for one laser diode (stepper motor). The system does not need any angular position encoder. An assessment of the first prototype of the vision system accuracy compared to the distance from the sensor to the turbine surface was reported to be 1:500.VI. KINEMATIC MODEL AND CALIBRATIONA robot can be modeled as a series of links connecting its end-effector to its base, with each link connected to the next by an actuated joint.Robot construction by assembling modular off-the-shelf parts brings about flexibility in manufacturing and allows the construction of several prototypes in the shop-floor, but also produces many sources of assembling inaccuracies. So, model calibration shows up as a very important step in order to achieve the desired accuracy. Besides, it is never possible to measure distances and angles between joints when there is no access to internal parts where the joint coordinate frames have to be assigned to represent the robot actual motion.Robot calibration procedures are an integrated process of modeling, measurement, numeric identification of actual physical characteristics of a robot, and implementation of a new model that describes more precisely the robot [6].The joint coordinate frames have to be assigned by using a rational convention, associated to a zero position (where all joint variables are set to zero). So, it is assumed that fortheassignment of coordinate frames to each link the manipulator has to be moved to its zero position. The zero position of the manipulator is the position where all joint variables are zero. This procedure may be useful to check if the zero positions of the model constructed are the same as those used by the controller, avoiding the need of introducing constant deviations to the joint variables (joint positions).Subsequently the z-axis of each joint should be made coincident with the joint axis. This convention is used by many authors and in many robot controllers [7]-[8]). For a prismatic joint, the direction of the z-axis is in the direction of motion, and its sense is away from the joint. For a revolute joint, the sense of the z-axis is towards the positive direction of rotation around the z-axis. The positive direction of rotation of each joint can be easily found by moving the robot and reading the joint positions on the robot controller display. The coordinate frames of the robot nominal kinematic model can be seen in Fig. 6.Fig. 6. Schematics of the robot kinematic model.There are many desirable characteristics for a kinematic model, but when considering kinematic models constructed aimed at using in robot calibration procedures three are mostly important: completeness, continuity and minimality [9]-[10]. Completeness is the ability of a kinematic model to describe all possible spatial geometric joint configurations of a robot. Continuity and minimality influence directly robot calibration, since they are related to model smoothness and to parameter redundancies in the model respectively.Robot kinematic models are generally based on the Denavit-Hartemberg convention [7] because of its simplicity and easiness to be geometrically represented. The elementary transformations can be formulated as (D-H convention):)()()()(),,,(αθαθX X Z Z R l T d T R l d f T == (1), where T represents position and orientation coordinates of a link frame related to a previous one, where θ and α are the rotation parameters, d and l are translation parameters.However, when considering an error parameter model for robot calibration a single minimal modeling convention that can be applied uniformly to all possible robot geometriescannot exist owing to fundamental topological reasons concerning mappings from Euclidean vectors to spheres [6]. However, after investigating many topological problems in robots, concerning inverse kinematics and singularities, [11] suggested that the availability of an assortment of methods for determining whether or not inverse kinematic functions can be defined on various subsets of the operational spaces would be useful, but even more important, a collection of methods by which inverse functions can actually be constructed in specific situations. An insightful paper about robot topologies was published by [12], who noted that inverse functions can never be entirely successful in circumventing the problems of singularities when pointing or orienting.Mathematically, model-continuity is equivalent to continuity of the inverse function T -1, where T is the product of elementary transformations (rotation and translation) between joints. From this, the definition of parameterization's singularity can be stated as a transformation Ts ∈ E (parameterization's space of the Euclidean Group - 3 rotations and 3 translations), where the parameter vector p ∈ R 6 (p represents distance or angle) exists such that the rank of the Jacobian Js = dTs/dp is smaller than 6. In other way, each parameterization T can be investigated concerning their singularities detecting the zeroes of determinant det(J T .J) considered as a function of parameter p .The robot (Fig. 6) has perpendicular and parallel axes. However, the Denavit-Hartemberg convention, shown in (1), cannot be used in error parameter models when modeling parallel axes due to singularities that occur in the Jacobian matrix, as explained. This matrix will be described ahead in the text in Eq. (4). This issue is discussed in details in [9] and [13]. A possible convention for parallel axes is the Hayati-Mirmirani [14], which cannot be used in perpendicular axes for the same reason. The Hayati-Mirmirani is as four-parameter convention that describe the transformation between two parallel axes as shown in (2).()()()()()βαθβαθY X X Z R R l T R l f =,,, (2)Using the previous two conventions (Denavit-Hartenberg and Hayati-Mirmirani) and taking into account the requirements of a kinematic model (completeness, continuity and minimality), the singularity-free approach discussed was applied for the assignment of coordinate frames and for the definition of which error parameters should be included in the kinematic model [9]. Using this approach a kinematic model representing mathematically this robot was constructed. The parameters used are shown in Table I, where δ are the error variables between the nominal model and the actual robot model to be identified by the calibration system, and are initially set to null.From the mathematical point of view, robot calibration is a non-linear parameter estimation process. That means a mathematical model to identify unknown parameters from experimental data by using a proper cost function to minimize errors.Coincident OriginsTABLE IKINEMATIC MODEL PARAMETERS TO BE CALIBRATEDAND ERROR VARIABLESJointsParametersFrom (type of joint) To (type of joint)Tx Ty Tz Rx Ry Rz Base (Base)Joint 1(Rotation)0+δ 0+δ 0 0°+δ 0°+δ 0° Joint 1 (Rotation) Joint 2 (Rotation) 0+δ 0 110+δ90°+δ0° 0°+δ Joint 2 (Rotation) Joint 3 (Prismatic) 30−100 −90°+δ 0° 90°+δ Joint 3 (Prismatic) Joint 4 (Rotation) 0+δ 0+δ 570 0°+δ 0°+δ 0° Joint 4 (Rotation) Joint 5 (Rotation) 0+δ0+δ 90°+δ 0°0°+δJoint 5 (Rotation) TCP (TCP) 0+δ 0+δ 0+δ0°+δ0°+δ 0°+δTCP: Tool Center PointA robot kinematic model can be seen as a function that relates kinematic model parameters and joint variables to coordinate positions of the robot end-effector. As an example to present the mathematics involved, a kinematic model following the D-H convention can be derived as (from (1)):l lP d dP P P P ∆∂∂+∆∂∂+∆∂∂+∆∂∂=∆ααθθ(3), where P represents position and orientation coordinates of the manipulator end-effector (Tool Center Position – TCP) and θ, α, d and l are the four parameters that define the transformation from a robot joint frame to the next joint frame, where θ and α are the rotation parameters, d and l are translation parameters.The first derivative of (1) can be interpreted as the position and orientation error equation of the robot TCP coordinates [15], where ∆P is the pose error and it can be physically measured.Considering the manipulator transformation, P , from the robot’s base frame to the TCP-frame, the measured robot position, M , related to the measurement system coordinate frame and the transformation that locates the robot base frame to the measurement system, B , (the transformation B have to be considered as a link that makes part of the robot model) then ∆P is the vector to be calculated inP M P −=∆ (4)The transformation P is then iteratively modified when the error parameters of the robot model are updated, and by the end of the calibration process the transformation P represents the actual robot and its location in the measurement system coordinate frame.Rewriting (3) in a matricial form for various measured positions and orientations of the robot end-effector, (4) can be formulated as the Jacobian matrix containing the partial derivatives of P such as ∆x is the vector of the model parameter errors as in (5).Thus the calibration problem is reduced to the solution of a non-linear system of the type Ax = b .P J =∆ ∆= ∆∆∆∆∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂∂= ∆∆∆x x J J J l d l P dP P P l P d P P P l P d P P P P P P n n nnnn212222111121αθαθαθαθ (5)There are many different methods to solve this type of system and one of those that is widely used is the Squared Sum Minimization (SSM). Many authors [16]-[17] discuss extensively those methods and algorithms are easily found in the literature.One method to solve non-linear least-square problems which proved to be very successful in practice and thus recommended for general solutions, is the algorithm proposed by Levenberg-Marquardt (LM algorithm) [17]. Several algorithms versions of the L.M. algorithm have been proved to be successful (globally convergent). It turns to be an iterative solution method by introducing few modifications in the Gauss-Newton method in order to overcome some divergence problems [16].Since the geometric parameters of the robot model has been identified in the calibration model, two kinematic models are available, i.e. the nominal kinematic model and the calibrated model. The calibrated model cannot be inverted with explicit variables, since there are more geometric parameters (different of zero) than the nominal one. The solution for correcting the robot coordinates from a set of joint variables is position compensation.VII. THE ROBOT CONTROLLERThe robot controller is built with reconfigurable architectures based on FPGAs. The main advantage to use FPGAs is their capacity for embedding complex systems, including microprocessor and specific application hardware using only one device. This allows the system to improve its performance to execute complex algorithms. They provide arrays of configurable logical cells (CLBs) that can be configured to perform given functions by means of configuration bitstreams The bitstreams are generated by a software tool, and usually contains the configuration information for all the components. Configuration of the FPGA can be realized by using several design/synthesis tools provided by companies such as Altera [18] and Xilinx [19]. The circuit can be described using a high level description language such as VHDL or Verilog. The tool makes the synthesis of the description file producing a binary configuration file (bitstream file). This file is used to configure the FPGA device.FPGAs permit to implement algorithm directly in hardware instead of in software (for instance, using microcontrollers). Implementation in software has limitations due to the sequential nature of von Newmann architectures that run the software model. In contrast, in FPGA implementations the potential of parallelism of the algorithms can be explored in order to improve the performance of the system. Moreover, the flexibility of these devices permits to configure (reconfiguration operation) the system even in real time. Reconfigurable systems are composed of a microcontroller and a FPGA working jointly. In this case one part of thesystem can be running in software (in th whereas the other part can be implemented i FPGA). In general, reconfigurable systems using hardware-software co-design approac methodologies in order to determine the s implemented in software and hardware. Th be made taking into account a function optimize some circuit characteristic such as and power consumption of the system.VIII. CONCLUSIONS This article presented a research proj several topics related to mechanical mechatronics related to the design specialized welding robotic system re turbine blades eroded by cavitation pi kinematics and calibration, control systems,hardware implementation are discussed. The robot was designed to be used w control positioning system, relying on the ac sensor conceived to map the turbine blade detect their geometric defects for weldi positioning open controls require determination of the robot geometrical par coordinate systems of both sensor and referenced in a single system to allow autom programming based on 3D surface map operation is equivalent to off-line robot prog is not possible to correct robot positioning u on-line operation. However, the system operate automatically.IX. R EFERENCES[1] Parmar, R. S., 1997, “Welding Processes Khanna Publishers: Delhi.[2] Ecober, X., Egusquiza, E., Farhat, M., Avellan, F “Detection of Cavitation in Hydraulic Turbines and Signal Processing, Vol. 20, Issue 4, p.p.- 983[3] Hammit, F. G., 1979, “Cavitation erosion: t predicting capability”, Applied Mechanics Rev 665-675.[4] Arndt, R. E. A., 1981, “Recent Advances Ca Advances in Hydroscience, Vol. 12, Academis P 72.[5] Ginani, L. and Motta, J. M S. T.., 2007, “A Las 3D Modeling of Industrial Objects Based o Proceedings of 19th International Congress of M Vol. 1, Brasilia-DF, Brazil, 10 p.[6] Schröer, K., 1993, “Theory of Kinematic Mo Procedures for Robot Calibration”, In: Robot Ca & Hall, pp. 157-193.[7] McKerrow, P. J., 1991, "Introduction to Robotics Wesley, Singapore, 800 p.[8] Paul, R. P., 1981, "Robot Manipulators - Math and Control", Boston, MIT Press, Massachusetts,[9] Motta, J.M.S.T., 2005, “An Investigation Kinematic Chains Aiming at Building Robot C Off-line Programming”, Journal of the Brazilian Sciences and Engineering, Vol. 2, No. 2, pp. 200[10] Albright, S.L., 1993, “Calibration System for Ro and Accuracy”, In : Robot Calibration, Bernhard 56, Chapman & Hall, ISBN 0 412 49140 0, Cam [11] Baker, D.R., 1990, “Some topological proble Mathematical Intelligencer, Vol.12, No.1, pp. 66[12] Gottlieb, D.H., 1986, “Robots and Topology”,International Conference on Robotics and Autom in the microcontroller)nted in hardware (in the stems can be designed pproach which specifies system parts being e. This partitioning can ction cost that tries to ch as area, performanceproject that involves ical engineering and and construction of afor repairing hydraulicon pitting. The robottems, vision sensor and ed with an open loopthe accuracy of a visionlade 3-D surface and to welding tasks. Robots high accuracy in theal parameters, since theand robot must be automatic joint position maps. This type ofot programming, since itning using the sensor in stem was designed to and Technology”, 2nd Ed.llan, F., Coussirat, M., 2006,bines”, Mechanical Systems 983-1007. on: the state-of-the-art ands Reviews, Vol. 32, 6, p.p. in Cavitation Research”, In:mis Press, New York, p.p. 1-A Laser Scanning System forsed on Computer Vision”, of Mechanical Engineering, c Modelling and Numericalot Calibration, Ed. Chapman obotics", 1st ed., Ed. AddisonMathematics, Programming,usetts, USA, 279 p. n of Singularities in Robotobot Calibration Models for zilian Society of Mechanical . 200-204. or Robot Production Controlrnhardt and Albright, pp. 37- Cambridge, UK. problems in robotics”, Thep. 66-76. gy”, Proceedings of the IEEEAutomation, pp. 1689-1691.[13] Schröer, K., Albright, S. an Minimal and Model-Continuo Calibration”, Robotics & Comput No. 1, pp. 73-85.[14] Hayati, S. and Mirmirani, M.Positioning Accuracy of Robots Systems, Vol. 2, No.4, 397-413.[15] Hollerbach, J. M., Benett, Calibration”, Robotics Review, pp [16] Jacoby, S.L.S, Kowalik, J.S. and for Nonlinear Optimization Proble 274 p.[17] Dennis JE, Schnabel RB. Num Optimisation and Non-linear Equa [18] Altera: (accessed [19] Xilinx: (accessed X. B IOG J. M. S. T. M 1963. gr Brazil, received his from the sam Ph.D. R University, S Science, UK Professor in Mechatronic Brasilia. His interests include Roboti design of robot cells and machine visionC.H. Llanos 1958. gra Colombia, received his M the Federal 1990 and rec Engineering fr 1998. Current Department Engineering a include Em Computing and their applications in AuG.C.Carvalh He graduate Technology Mechanical E degree in Me of Brasília, Br Welding Tec School In UK, in 199in the Departm Engineering a include Weld Automation, mainly on control of robotS. C. A. Alfar He graduated Brazil, 19Manufacturing Minas Gerais, in Welding T School In UK, in 1989. C Department Engineering a include Weldi control and welding automation.L. and Grethlein, M., 1997, “Complete,tinuous Kinematic Models for Robot omputer-Integrated Manufacturing, Vol. 13, i, M. (1985). “Improving the AbsoluteRobots Manipulators”. Journal of Robotic 413. , D. J., 1988, “A Survey of Kinematicew, pp. 207-242. . and Pizzo, J.T., 1972, “Iterative MethodsProblems”, Prentice Hall, New Jersey, USA, . Numerical Methods for UnconstrainedEquations, New Jersey:Prentice-Hall, 1983. cessed in May 2009). cessed in June of 2008).IOGRAPHIESS. T. Motta was born in Brazil, on Sept. 17,He graduated from University of Brasilia, in Mechanical Engineering, in 1986,d his M. S. degree in Mechanical Systems he same university in 1990 and received his in Robotics Technology from Cranfieldsity, School of Industrial and Manufacturing e, UK, in 1999. Currently, he is an Associateor in the Department of Mechanical and tronics Engineering at University ofRobotics and Computer Vision, mainly onvision. lanos was born in Colombia, on Jun. 06, He graduated from Universidad del Valle, , in Electrical Engineering, in 1983,his M. S. degree in Computer Science from eral University of Minas Gerais, Brazil, ind received his Doctoral degree in Electrical ring from University of São Paulo, Brazil, inurrently, he is an Associate Professor in the ment of Mechanical and Mechatronics ring at University of Brasilia. His interests Embedded Systems, Reconfigurablein Automation, Control and Robotics.rvalho was born in Brazil, on Apr. 22, 1967.duated from Aeronautical Institute of ogy, São Paulo, Brazil, in Aeronautical- ical Engineering in 1989, received his M. S. n Mechanical Systems from the University lia, Brazil, in 1993 and received his Ph.D. in Technology from Cranfield University, of Industrial and Manufacturing Science, 1997. Currently, he is an Associate Professor epartment of Mechanical and Mechatronics ring at University of Brasilia. His interests Welding, Instrumentation, Robotics androbotic welding operations. Alfaro was born in Peru, on Jan. 27, 1957. uated from University of Rio Grande do Sul, in 1979, received his M. S. degree in turing Processes from Federal University of erais, Brazil, in 1983 and received his Ph.D. ing Technology from Cranfield University, of Industrial and Manufacturing Science, 989. Currently, he is a Full Professor in the ent of Mechanical and Mechatronics ing at University of Brasilia. His interests Welding, Sensors and Robotics, mainly on。