Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Feedback Control of Melt Pool Temperature During Laser Cladding Process

Presented by VISAKH.V M2 AEI, ROLL NO:12

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Overview
1 2 3 4 5 6 7 8 9

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Pool Temperature Simulations Conclusions References
College of Engineering, Trivandrum

Feedback Control of Melt Pool Temperature During Laser Cladding Process

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Introduction
Laser Cladding Advantages
Rapid heating and cooling Well conned laser beam Minimal distortion

Disadvantage
Complex multi-parameter process

Nonintrusive sensors
CCD Cameras Photodiodes Pyrometers

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Laser Cladding System

MIMO High power laser Dual-colour pyrometer Identify state-space model Real time controller
GPC algorithm with input constraints

Reference temperature tracking

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Experimental Setup

Figure: Experimental setup of DMD process with a closed loop temperature controller

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

5-D adjustable CNC system Pyrometer connected to collecting lens Pyrometer monitors the melt pool temperature View of pyrometer to match laser beam on substrate H13 tool steel powder is used Real-time controller
samples melt pool temperature from pyrometer controls laser power through analog interface

Implements GPC algorithm with input constraints and sampling interval= 10 ms

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Melt Pool Temperature Dynamic

Analog modulation of pulse duration and laser power P = 1.5603V 0.8849 4th order state-space model x(k + 1) = Ax(k) + Bu(k) + Ke(k) y (k) = Cx(k) + Du(k) + e(k)

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Input output signals for model identication

Feedback Control of Melt Pool Temperature During Laser Cladding Process College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Predictive Control

Generalised predictive algorithm with input constraints, x (k + N) = AN x(k) + AN1 Bu(k) + ....... + Bu(k + N 1) y (k + N) = CAN x(k) + CAN1 Bu(k) + ..... + CBu(k + N 1)

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Augmented State-Space Matrix

x(k + 1) A B B = x(k) + u(k) u(k) 0 I I x(k) y(k)= c D +D u(k) u(k 1)

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

For Oset free tracking, -Cost function to be minimised,

N

Jk =

T y {( (k +j)w (k +j))T Qy Qy ( (k +j)w (k +j))} y

T T {uk+j1 Qu Qu uk+j1 }

j=N0 +1 Nu j=1

Model is valid for a certain input range umin u(k) umax umin u(k + 1) umax . . . . . . . . . umin u(k + Nu 1) umax
Feedback Control of Melt Pool Temperature During Laser Cladding Process College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

T-lter approach

T-lter is used in generalised predictive control. Hf = State Space Estimation x (k +1, k) = A(k, k 1)+AK (k)(y (k)C x (k, k 1))+Bu(k) x 1 1 q 1

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Tracking Melt Pool Temperature

Tuning GPC for better performance Noise is used to tune the controller and the parameters were tuned Tracking a sinusoidal and square temperature prole

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Tracking Temperature Prole

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Compensating Lack of Deposition

Lack of deposition and overbuilt Lower melt pool temperature Mismatch of temperature indicates Lack of deposition Closed loop controller increases laser power tom increase deposition

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Simulations

Figure: Deposition geometry

Figure: Detection of melt pool temperature for an uneven surface

Feedback Control of Melt Pool Temperature During Laser Cladding Process College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Melt pool temperature and laser action at 2nd and 3rd layer

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Melt pool temperature and laser action at 26th and 27th layer

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Melt pool temperature and laser action at 37th and 38th layer

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Pictures of deposition at (a) 10th layer (b) 20th layer(c) 30th layer and (d) 40th layer
Feedback Control of Melt Pool Temperature During Laser Cladding Process College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Deposition heights on and o the step at every tenth layer with and without GPC Controller

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Melt pool temperatures and laser actions at the second layer with and without controller

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Figure: Melt pool temperatures and laser actions at the second layer with and without controller
Feedback Control of Melt Pool Temperature During Laser Cladding Process College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

Conclusions

Melt pool temperature measured using pyrometer State-space model identied experimentally GPC algorithm implemented in real time Closed loop process tracked the melt pool temperature GPC compensated lack of deposition

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

References
1. Lijun. Song, and Jyoti. Mazumder., Feedback Control of Melt Pool Temperature During Laser Cladding Process ,IEEE Transactions on Control Systems Techonology, Volume 19, No. 6, Nov, 2011. 2. M. Asselin et al., Development of trinocular CCD-based optical detector for real-time monitoring of laser cladding , in Proceedings of IEEE International Conference on Mechatronics and Automation, volume 14, paper 11901196. 3. J. Koch and J. Mazumder, Apparatus and methods for monitoring and controlling multi-layer laser cladding, U.S. Patent 6 122 564, September 19, 2000. 4. E. Toyserkani and A. Khajepour, A mechatronics approach to laser powder deposition process, Mechatronics, volume 16, paper. 631641, December2006.
Feedback Control of Melt Pool Temperature During Laser Cladding Process College of Engineering, Trivandrum

Introduction Laser Cladding System Experimental Setup Melt Pool Temperature Dynamic Predictive Control Tracking Melt Poo

5. M. J. D. Powell, On the quadratic-programming algorithm of Goldfarb and Idnani, Math. Program. Study, volume 25, paper. 4661, October. 1985. 6. D. Goldfarb and A. Idnani, A numerically stable dual method for solving strictly convex quadratic programs, Math. Program., volume. 27, paper. 133, 1983.

Feedback Control of Melt Pool Temperature During Laser Cladding Process

College of Engineering, Trivandrum