Among the variety of welding processes available, the flux cored arc welding is one of the most frequently used recently, because of its wide range of application and high productivity. The weld joint tracking is indispensable to improve the flexibility of the arc welding robot application for the flux cored arc welding(FCAW) process.
In this study, an arc sensor which utilizes the electrical signal obtained from the welding arc itself was developed for weld joint tracking in FCAW. Because a model of the welding arc in flux cored arc welding was required to develop the arc sensor, a mathematical model was developed by analysing the welding arc behaviour, and experimental model by using the factorial experiment and least square method. For overcoming the fluctuation in the welding current signal during tracking the weld joint, it was fitted to a curve which is inversely proportional to a trace of tip-to-workpiece distance by using the quadratic curve-fitting method. Interfacing to the arc welding robot of the developed arc sensor was carried out successfully.