Software architecture for real-time sensor analysis and control of the friction stir welding process

The friction stir welding (FSW) process requires advanced automation to ensure consistent and reliable joints. This has been realized by the development of an experimental set-up by the integration and online monitoring of accurate sensors with reliable modular control software. With increasing productivity and quality requirements imposed by manufacturers, machine flexibility and scalability are becoming increasingly pertinent. On-line process monitoring facilitates the `adaption' of machines able to respond to changing process parameters and conditions. Modular open software architectures allow flexibility in machine application. This paper introduces a fresh approach for the integration of the latest automation technology into an experimental setup equipped with an advanced sensory system. A new method of capturing sensory data and the implementation aspects of the software architecture for a micro-kernel based real-time embedded operating system is introduced. Agile automation of the FSW process is thus realized by advanced monitoring and control