CN105750694B - Based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath - Google Patents
Based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath Download PDFInfo
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- CN105750694B CN105750694B CN201610335117.4A CN201610335117A CN105750694B CN 105750694 B CN105750694 B CN 105750694B CN 201610335117 A CN201610335117 A CN 201610335117A CN 105750694 B CN105750694 B CN 105750694B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
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- Mechanical Engineering (AREA)
- Arc Welding Control (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses it is a kind of based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath.The cardinal principle of this method is to utilize magnetic control rotary arc sensor sweep surface, sampled point current signal is collected through Hall sensor, divide to interval sensor and the division of interval and direction is carried out to the sampled point of each swing circle, arithmetic processor calculates each interval average current and carries out determining the minimum direction of sampling period average current after filtering process, position compensation controller will contrast reference cycle average current value adjust automatically welding gun height the sampling period simultaneously, stable to avoid current interruption and hit rifle；Pass through the four-axle linked welding machine of multiaxis driver control, ensure welding direction towards the minimum set of samples correspondence direction of current average current, welding is set to be carried out all the time in curved surface level height lower, when sampling period each interval average current change fluctuation very little, judge that the built-up welding of curved surface is completed when front curve has tended to be smooth.
Description
Technical field
The present invention relates to automatic field, be it is a kind of based on magnetic control rotating arc sensor from the complex-curved built-up welding in pathfinding footpath
Method.
Background technology
Welding is a kind of conventional manufacturing process and technology, and built-up welding is quick as one kind economy of material surface modifying
Process, the manufacture, reparation and process for modifying surface applied to each industrial department parts more and more widely.In reality
In the weld deposit process of border, require that workpiece portion faces to be welded are smooth substantially, when workpiece surface is complex-shaped, when such as there is curved surface,
Traditional bead-welding technology can not be directly applicable, and the automaticity of weld deposit process is relatively low, it is necessary to which artificial adjustment in real time could be protected
Demonstrate,prove the progress of built-up welding work.For the technological difficulties of solution built-up welding under the conditions of complex-curved, propose a kind of based on magnetic control rotating the arc
Sensing from the complex-curved overlaying method in pathfinding footpath, have positive role to the automation for further promoting bead-welding technology.
The content of the invention
In order to solve the deficiency of prior art presence, the automation development of bead-welding technology is preferably promoted, for current heap
Weld production line on, exist complex curved surface part built-up welding can only by way of manual operation so that produce built-up welding effect compared with
The problems such as difference, surfacing layer quality thickness do not reach requirement, propose a kind of complicated from pathfinding footpath based on magnetic control rotating arc sensor
Curved surface overlaying method, its system control block figure is as shown in Figure 1：The system authority of this method sampling includes：Magnetic control rotating the arc is passed
Sensor, point to interval sensor, arithmetic and control unit, position compensation controller, four-axle linked welding machine；This method is by dividing to interval
Sensor divides sampling interval and locality, and welding current is gathered according to magnetic control arc sensor, and arithmetic and control unit is calculated
The minimum corresponding direction of set of samples of average current, four-axle linked welding machine control welding gun is all the time curve water along average current minimum
The process of flat highly relatively low direction welding, following cycle sampling and positioning, when the average current change fluctuation of sampling interval is small
When reference interval, when the built-up welding of front curve is completed.Filled up by constantly welding at the out-of-flatness of curved surface until whole
The complete built-up welding of curved surface is smooth；Position compensation controller ensures not existing together arc stability to have realized again in curved surface height simultaneously
The automatic surfacing of miscellaneous curve surface work pieces, specifically includes following steps：
The first step：Divide sampling interval and determine direction signal, and gather the welding current signal of reference position
Magnetic control rotary arc sensor is arranged on welding gun, and 64 index point is provided with the motor shaft for driving magnetic pole rotation
Optical code disk, the characteristics of motion of electric arc is controlled according to magnetic field, one sampling period is divided into 8 samplings point to interval sensor
Interval and 8 interval directions, concurrently set per two neighboring interval as a set of samples, and each set of samples is a direction letter
Number, the position of the signal is in two interval centre positions.8 optocouplers are set to position this 8 direction signals.When reparation work
Work is when starting, first curved surface smooth station acquisition one or more sampling periods welding current signal as reference data,
Reference cycle average current and sampling interval average current standard deviation are determined after data processing, is believed as with follow-up welding current
Number processing standard reference data.
Second step：The high and low position of welding gun is determined according to the average current signal in reference cycle
Position compensation controller is according to the sampling period average current value analogy reference sample in each sampling period of receiving
The average current value in cycle, in the case where dry extension of electrode is constant, is calculated according to rotating the arc arc length and electric current classical formulas
Processing, is converted into equivalent arc length difference to control welding gun high and low position, to prevent when curved surface elevational change is larger,
Occur to hit rifle when current interruption and curved protrusion during such as curve recess, it is ensured that the stabilization of welding arc during automatic surfacing
Property.
3rd step：Welding direction is determined according to the welding arc signal of the different set of samples of current sample period
The average welding current value of different sampling intervals in Hall sensor collection current sample period, using interval variance
Analytic approach, when calculating current sample period average current variance more than reference cycle average current variance, it is determined that average weldering
The minimum set of samples of current value is connect, this corresponding direction signal in sampling class interval is positioned, according to welding current and pair of arc length
Formula is answered, this direction is assert towards the relatively low position of curved surface level height, drives four-axle linked welding machine to control welding gun along this direction
Carry out the welding sampling in next cycle, it is ensured that welding direction is all the time towards curved surface level height lower；Only work as the sampling period
When each interval average current value variance is less than or equal to reference cycle interval average current variance, assert that now curved surface is approximately smooth
Face.As welding sampling is carried out to curve recess direction all the time, the position of the out-of-flatness of curved surface is compensated always, a range of
Curved surface tends to be smooth, and this technical process of following cycle is until complex-curved smooth by whole built-up welding.
The beneficial effects of the invention are as follows：Propose it is a kind of based on magnetic control rotating arc sensor from the complex-curved built-up welding in pathfinding footpath
Method, this method is by the signal detection curved surface out-of-flatness position of welding itself, by constantly filling up complex-curved out-of-flatness
Place, is finally reached the complete built-up welding of whole curved surface；Using the signal of welding arc in itself, real-time is good, and multiple sensors are coordinated
Work, the stability of a system is high, and the intelligence degree of technique is high, and the automaticity for solving complex-curved built-up welding is not high, production
Inefficiency, surfacing quality be general and the problems such as larger cost of labor, is laid a good foundation for the development that automates technique for overlaying.
Brief description of the drawings
Fig. 1 is automatic surfacing system block diagram
Fig. 2 is automatic surfacing process chart
Fig. 3 is point to interval sensor operation principle schematic diagram
Fig. 4 is system motion illustraton of model
Case study on implementation
In order to preferably express the technical scheme and beneficial effect entirely invented, with reference to the accompanying drawings and examples to this hair
It is bright to be described in further details.But, the implementation of the present invention is not limited to this.
The present invention of embodiment 1 based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath as shown in figure 1,
Including magnetic control rotary arc sensor, divide to interval sensor, arithmetic and control unit, position compensation controller, four-axle linked welding machine；
Wherein divide to interval sensor operation principle as shown in figure 3, a rotation sampling period is divided into 8 sampling intervals and 8 areas
Between direction, concurrently set per two neighboring interval as a set of samples, each set of samples is a direction signal, the signal
Position is in two interval centre positions.8 optocouplers are installed to position each direction signal on optical code disk；Work as shown in Figure 2
Make in flow, magnetic control arc sensor first gathers the welding current signal in reference cycle during start-up operation, arithmetic and control unit is calculated
Go out the interval average current of all directions correspondence, four-axle linked welding machine control welding gun is along the less direction of set of samples average current all the time
Curved surface level height lower position direction is welded, and fluctuates very little until each interval average current changes, now current region curved surface
It is approximate smooth, continue to weld sampling process if it also there is other region curved surface；As shown in Figure 4 by constantly filling up curved surface
Out-of-flatness is in the surface topography that certain limit changes curved surface, finally makes the whole built-up welding of whole curved surface smooth, and position compensation
Controller can ensure curved surface height do not exist together arc stability so as to realize it is complex-curved under the conditions of automatic surfacing.
The present invention is as follows from the complex-curved overlaying method specific implementation step in pathfinding footpath based on magnetic control rotating arc sensor：
The first step：Divide sampling interval and determine direction signal, and gather the welding current signal of reference position
As shown in Figure 3：Magnetic control rotary arc sensor is arranged on welding gun, is provided with the motor shaft for driving magnetic pole rotation
The optical code disk of 64 index point, the characteristics of motion of electric arc is controlled according to magnetic field, divides to interval position sensor that one sampling is all
Phase is divided into 8 sampling intervals such as a, b, c, d, e, f, g and h, signal period, for zone leveling electric currentX values
a:H, then be represented by：
In formula：C is the data number in a sampling period；N is the revolution number of magnetic pole；S=c/8.
It is a set of samples to concurrently set per two neighboring interval, and each set of samples is a direction signal, the signal
Position sets direction signal of 8 optocouplers to position 1-8 in two interval centre positions.The average weldering of each set of samples
Connect electric current useRepresent, it is known that：
8 sampled datas when the sampled data in reference cycle is exactly n=0, the average welding current in reference cycle is averaged
Value I0Represent,
Second step：The high and low position of welding gun is determined according to the average current signal in reference cycle
As shown in figure 4, first take the sampling period in the smooth position of curved surface, position compensation controller is by each sampling period
Average current value contrasts the average current value in reference sample cycle, in the case where dry extension of electrode is constant, according to rotating the arc
GMAW welding systems arc length and electric current classical formulas calculating processing,
In formula：vnRepresent current change rate in the sampling period
It is converted into equivalent arc length difference e=Ln-L0, to control welding gun high and low position, to prevent in curved surface level height
Occur to hit rifle when current interruption and curved protrusion when changing greatly, such as during curve recess, it is ensured that weld during automatic surfacing
The stability of electric arc.
3rd step：Welding direction is determined according to the welding arc signal of the different set of samples of current sample period
The average welding current value of different sampling intervals in Hall sensor collection current sample period, arithmetic and control unit is adopted
Interval method of analysis of variance is used, by average current I in the single sampling periodnRepresent, average current variance D (In) be represented by：
When sampling interval average current value variance more than reference cycle average current variance is D (In) ＞ D (I0) when, determine 8
Individual set of samplesMinimum value, obtains the minimum set of samples correspondence of average current
Direction signal, according to welding current and the corresponding formula of arc length, assert this direction towards curved surface level height lower position, drive
The welding that dynamic four-axle linked welding machine controls welding gun to carry out the next cycle along this direction is sampled, it is ensured that welding is high in curved surface level all the time
Spend lower；Only it is when each interval average current value variance of calculating is less than or equal to reference cycle interval average current variance
D(In)≤D(I0) when, assert the now approximate burnishing surface of curved surface, whole process side welding edge sampling, as welding is all the time to curved surface
Level height is relatively low to be carried out, and the position of curved surface out-of-flatness is compensated always, and a range of curved surface tends to be smooth, circulates this technique
Process is until complex-curved smooth by whole built-up welding.
The present disclosure applies equally to the automatic processing of the workpiece surface heap welding coat of complicated shape for case study on implementation 2.
Described above is only the preferred embodiment of the present invention, it is noted that under the premise without departing from the principles of the invention
Made some improvement, are all considered as protection scope of the present invention.
Claims (4)
1. based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath, the automatic heap for complex curved surface part
Weldering, it is characterized in that：The system of this method includes：Magnetic control rotary arc sensor, point to interval sensor, arithmetic and control unit, position
Put compensating controller, four-axle linked welding machine；This method divides sampling interval and locality, magnetic control by dividing to interval sensor
Rotary arc sensor gathers welding current, and arithmetic and control unit calculates the interval average current of all directions correspondence, four-axle linked weldering
Machine control welding gun is welded along the relatively low direction of the smaller i.e. curved surface level height of average current all the time, and position compensation controller ensures
Curved surface height is not existed together arc stability, and when each interval average current change fluctuation very little, the built-up welding of curved surface is completed.
2. according to claim 1 based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath, its feature
It is：Point include the direction locating module, data sampling and the signal transacting mould that are made up of optical code disk and 8 optocouplers to interval sensor
Block is constituted, and will be divided into 8 sampling intervals and 8 interval directions the sampling period by direction locating module, per two neighboring interval
As a set of samples, one direction signal of each set of samples correspondence, this direction is the direction of motion of welding gun.
3. according to claim 1 based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath, its feature
It is：The average current value in each sampling period is contrasted to the average current value in reference sample cycle, according to rotating the arc arc length and
The calculating of electric current classical formulas is handled, and is converted into equivalent arc length difference to control welding gun high and low position, is prevented in curve recess
Rifle is hit at place's current interruption and curved protrusion, to ensure the stability of welding arc during automatic surfacing.
4. according to claim 1 based on magnetic control rotating arc sensor from the complex-curved overlaying method in pathfinding footpath, its feature
It is：When sampling starts, a cycle welding current signal first is sampled as the reference cycle in the smooth position of curved surface, passes through Hall
Sensor receives the welding current signal of sampling interval, and each interval average electricity is calculated after the filtered processing of arithmetic and control unit
Flow valuve, using interval method of analysis of variance, when sampling period each interval average current variance is more than reference cycle interval average current
During variance, the minimum corresponding direction of set of samples of average current is selected in contrast, according to electric current arc length corresponding relation, assert this direction
Curved surface level height it is relatively low, four-axle linked welding machine to the direction feedback control welding gun of range restraint device according to point advancing；Constantly
Fill up at curved surface out-of-flatness, until sampling period average current variance is less than or equal to reference cycle interval average current variance
When, assert now curved surface convergence burnishing surface, the automatic surfacing under the conditions of completion is complex-curved.
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| US9599461B2 (en) | 2010-11-16 | 2017-03-21 | Ectoscan Systems, Llc | Surface data acquisition, storage, and assessment system |
| US11880178B1 (en) | 2010-11-16 | 2024-01-23 | Ectoscan Systems, Llc | Surface data, acquisition, storage, and assessment system |
| BR102018005422A2 (en) * | 2017-03-21 | 2019-02-05 | Lincoln Global, Inc. | welding system |
| CA3084951A1 (en) | 2017-12-06 | 2019-06-13 | Ectoscan Systems, Llc | Performance scanning system and method for improving athletic performance |
| CN109226936B (en) * | 2018-09-14 | 2022-02-01 | 湘潭大学 | Rotary arc type self-adaptive complex curved surface surfacing method |
| CN112658444B (en) * | 2020-12-15 | 2022-03-25 | 唐山松下产业机器有限公司 | Arc sensing control method and system for welding robot |
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