WO2013061518A1 - Welding skill evaluation device and weld quality evaluation device - Google Patents
Welding skill evaluation device and weld quality evaluation device Download PDFInfo
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- WO2013061518A1 WO2013061518A1 PCT/JP2012/006337 JP2012006337W WO2013061518A1 WO 2013061518 A1 WO2013061518 A1 WO 2013061518A1 JP 2012006337 W JP2012006337 W JP 2012006337W WO 2013061518 A1 WO2013061518 A1 WO 2013061518A1
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Classifications
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/006—Safety devices
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
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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
- B23K9/0953—Monitoring or automatic control of welding parameters using computing means
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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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
- B23K9/32—Accessories
Definitions
- the present invention can obtain detailed knowledge of the molten pool by welding training while visually observing the molten pool as an image, and can improve the welding skill in a shorter time.
- the present invention relates to a weld quality evaluation apparatus that enables welding work while detecting quality (complete penetration during welding and incomplete penetration) in real time during welding.
- a manual welding support device when a manual welding operation is performed, a welding environment measuring device and a welding environment measuring device for measuring data related to the welding environment including the welding target and the behavior of the welder during the welding operation.
- An arithmetic processing device that extracts the feature value of the welding state during welding from these measurement data, a welding state determination device that determines the quality of the manual welding state based on the feature amount extracted thereby,
- Manual welding support device (Patent Document 1) including a welding state presentation device that presents information regarding the transition of the welding state including the determination result to the welder who is performing welding, and two base materials to be welded
- a visual sensor such as a CCD camera attached to a welding torch, and a visual sensor for a welding work support device for supporting backside welding during gap welding and insert ring welding
- Image analysis means for processing the image information captured and measuring the molten pool state and comparing the result with past data to estimate the back wave state.
- the back wave estimated by the image analysis means There is known a welding work support
- the welded part quality evaluation apparatus is an apparatus for evaluating the quality during welding, which is a part outside the part where the metal is melted by heating, and is a heat-affected part that has been heated to a predetermined temperature.
- a manual welding work analysis device for analyzing and processing information an image pickup device integrated with a manual welding machine in which a surveillance camera is integrally connected to a manual welding torch, and image data for processing and recording digital signals from the image pickup device.
- a manual welding operation analyzer (Patent Document 4) characterized by comprising a recording device, a data processing device that processes the recorded image as data, and a display device that displays the processed information.
- a welding quality evaluation apparatus for evaluating the welding quality of a welded member that is made of a material that softens or melts at a predetermined temperature lower than the melting point of the welded member, and is installed at a predetermined position of the welded member.
- Patent Document 5 a welding quality evaluation device characterized by comprising an evaluation means for evaluating welding quality based on the above.
- the welded part has a wide variety of shapes and structures.
- the current weld inspection includes non-destructive inspection (X-ray inspection, ultrasonic inspection, penetrant inspection, etc.) and destructive inspection. Even in ISO, the weld is defined as a special process that cannot be fully verified because it is a subsequent inspection. In particular, in manual welding, confirmation of quality cannot be obtained even with a welded product of a skilled welder.
- the present inventors have the following technical knowledge for determining whether or not the resin is completely dissolved up to the back. 1) There is a stable bottom in the state where it is not completely melted to the back (hereinafter referred to as incomplete melt), and the molten metal hangs down on the back when it completely falls back (hereinafter referred to as complete melt) (supporting force is on the surface) (Tension only), the liquid level on the surface also decreases. 2) The melted metal part flows inside, and there are upper and lower liquid level vibrations. The vibration period and vibration height differ between complete penetration and the previous incomplete penetration state.
- the position of the molten metal is often slightly lower than the surface of the weld material in the front of the weld pool near the front of the weld line (there may be almost the same height).
- the surface position of the molten metal often falls below the surface of the welding material. The difference is greater as the thickness of the base material plate increases.
- the arc portion of the welding material is completely melted, it is slightly lowered. Although it can be detected as an increase in arc voltage, in the case of a skilled person, the torch is often lowered as the liquid level decreases, and it is difficult to recognize complete penetration as a voltage signal.
- the welding torch nozzle (ceramic insulating member) is lightly brought into contact with the welding material, and the arc is kept as close as possible with a distance of about 1 to 2 mm within a range where the electrode and the welding material do not short-circuit.
- the nozzle can be lifted from the welding material while keeping the electrode height unchanged so that the arc can be stably changed to the optimal nozzle orientation for stable welding.
- the temperature of the material to be welded is low, and it takes 3 to 5 seconds (depending on the thickness of the plate) to completely melt it to the back, but during this time it is lightly moved back and forth so that the width of the molten pool does not become too large.
- the arc is maintained while being moved to and that it completely melts to the back.
- the welded part is in the dark at the start of welding, it is easy to keep track of the position of the electrode and the welding material via a nozzle, etc. Able to understand how to contact the most suitable welding material.
- the nozzle and the welding material are separated from each other. It is possible to weld with the nozzle lightly in contact with the welding material, but the direction of the torch (the direction of arc flow) can be adjusted according to the flow and state of the molten metal inside the molten pool.
- the welding training device while visually observing the image projected on.
- the device is used as a support signal for welding penetration detection.
- a training apparatus that can obtain knowledge of a back-surface situation when a back-wave occurs and a synchronized surface condition, and enables estimation of the back-side condition from surface image observation.
- An apparatus that can improve the skill efficiently and in a short time while finding the improvement point while recognizing the welding skill of the welding trainer.
- a device that makes it possible to find a different point while comparing with the image of a welding expert and take measures to improve the skill at an early stage. By comparing with the above image, it is easy to understand the person's faults and to improve the skill in a short time.
- a device installed on the protective surface to check the surface condition while confirming the backside wave condition, and to allow welding training while recognizing complete penetration. It is possible to check the status of the surface molten pool while confirming that there is a back wave on the back of the weld with a small monitor, and to acquire knowledge that a back wave has occurred from the state of the molten pool surface in the future And
- the welded part quality evaluation device acquires the weld pool surface image in real time during welding, evaluates the quality from the obtained image, conveys the situation to the welder in real time, and issues a warning if a defect occurs.
- the following 1) to 6) were developed based on the development concept. 1) At the end of the welding work, the inspection is completed at the same time, and the device has a function that confirms the good quality. 2) A device that acquires a metal molten pool image formed at the tip of the torch during welding with a camera attached to the welding torch.
- An apparatus that enables a welding operation to be performed while performing a real-time inspection from the weld pool image during welding and confirming complete penetration.
- a device having a function of issuing a warning (pitch or rhythm of several stages according to the degree of defect) and prompting correction when a quality defect occurs.
- the present invention provides a molten pool observation camera for observing a torch behavior and a molten pool surface behavior, which is movably fixed to a welding apparatus and moves with the progress of welding, and a molten pool behind the molten pool moving together with the molten pool observation camera.
- Image taken by these four cameras a back-wave observation camera that measures the state
- a torch camera that is attached to the welding torch and monitors the melted state and the arc state
- a whole behavior photographing camera that photographs the welder's posture and the large state of the weld.
- a monitor that displays the recorded image together with a welding current / voltage signal obtained from the welding current / welding voltage measuring device, and image information captured by the four cameras is a welding current obtained from the welding current / welding voltage measuring device.
- the present invention also relates to a torch camera that is attached to a welding torch and monitors a molten state and an arc state, processes image information captured by the torch camera, measures a molten pool state and an arc state, and uses the image information as a welding current.
- -Judgment / evaluation device that determines and evaluates weld quality compared to the accumulated weld quality evaluation data together with the welding current / voltage signal obtained from the welding voltage measuring device, and welds in real time from the judgment / evaluation device
- a welding part quality evaluation apparatus equipped with a transmission means for performing quality evaluation and transmitting the situation to a welder, wherein the welding part quality evaluation data is movably fixed to the welding apparatus and moves with the progress of welding.
- the image information captured by the torch camera that is attached to the welding torch and monitors the molten state and the arc state is stored in a storage device for storing and analyzing together with the welding current / voltage signal obtained from the welding current / welding voltage measuring device.
- the present invention relates to a welded part quality evaluation apparatus that can complete quality confirmation at the same time when welding is completed, which is data in a database.
- the back surface penetration state can be confirmed in real time. Since the camera moves as welding progresses, the state of the molten pool can be analyzed on a large screen. 2) The status of the molten pool and arc can be checked in real time with a camera attached to the torch. This is an image of a camera fixed to the torch, the electrode tip position is always constant, and the variation of the arc length due to the variation of the torch can be measured. The size of the molten pool varies depending on the height of the torch (camera).
- Image information and audio signals displayed and transmitted during welding can be reproduced at any time, and the weld pool size (width, length, and area), backside bead size, and average voltage / current signal for a short time It has a function to clarify the characteristics of the skill of the welder by displaying macro information such as standard deviation. 7) Information necessary for improving the person's skills during welding by arbitrarily selecting an image on the back or a screen displayed on the PC monitor with a monitor attached to the helmet of the welder during welding. Is displayed. 8) By reproducing various kinds of information on the monitor attached to the welder's helmet after welding, the same situation can be reproduced while actually welding the situation, so that good and bad points can be learned repeatedly.
- the welded part quality evaluation apparatus of this invention there can exist the following effects. 1) With the ultra-small camera attached to the torch, it is possible to record the state of arc generation during welding, the behavior of the weld pool and the torch behavior as an image record, and record the voltage and current signal in synchronization, and externally if necessary. The welding situation can be reproduced by a monitor. 2) When the image and the voltage / current signal are analyzed in real time and the welding state tends to deteriorate, the welder can be notified in real time by an audio signal or an image signal.
- the light receiving element when converting an image into an electrical signal, the light receiving element is referred to as a charge coupled device (Charge Coupled Device) to read out the electric charges generated from the light.
- a CCD camera capable of performing transfer using circuit elements can be suitably exemplified.
- a welding torch equipped with a torch camera is used for manual welding where the distance between the electrode and the base metal is always constant, even if it is for an automatic welding machine where the distance between the electrode and the base material is constant. In the case of a welded part quality evaluation apparatus, it is preferably for manual welding.
- welding work is performed based on image information and welding current / voltage signals from the weld pool observation camera, the back wave observation camera, and the torch camera.
- Status record keeping, management, signal processing, judgment, etc. can be performed online, preferably based on the means with arithmetic processing function and welding condition judgment function and the image information of the whole behavior shooting camera. Measures information related to various movements and postures, and records, maintains, manages, processes and signals signals the welder's construction status, such as the position and movement of the head and hands, as well as the posture of the welder, based on this measurement signal.
- An apparatus having a means capable of performing such as online can be cited.
- the criteria for determining that the state has reached complete penetration are as follows: molten pool sag, liquid side surface descent at solid interface, liquid surface area decrease, liquid surface temperature increase rate, liquid surface part There are various factors such as changes in hot water flow, slag amount change rate at the liquid surface, slag behavior change, and liquid surface frequency cycle extension. Individual values vary greatly depending on the welding speed, and it is difficult to give an absolute value.
- the welding of each individual welder The following numerical values in the state of being completely melted up to the back surface fluctuate as follows with respect to the numerical values in the limit condition that is not melted up to the back by the conditions.
- the drop of the molten pool surface from the base metal surface is 0.2 to 1.0 mm
- the interface drop at the front of the weld pool is 0.05 to 0.3 mm
- the surface area of the molten pool cannot be detected within the variation error range.
- the hot water flow state of the part is also in a quantitative fluctuation error range and is difficult to detect.
- the amount of slag at the liquid surface depends greatly on the material and the state of the back surface, and a significant difference may be detected depending on the results of some trials.
- the liquid surface frequency can be detected with a value of about 10 seconds, but it is not practical for use in quality evaluation during actual welding work because of a large time delay.
- the weld pool observation camera and the back wave observation camera in the welding skill evaluation apparatus of the present invention are installed above and below the base material, and move integrally along the groove as welding progresses.
- the moving speed of the molten pool observation camera and the back wave observation camera can be set to a predetermined model speed, or a welding torch analyzed based on image information from the whole behavior imaging camera that images the posture of the welder.
- the speed can be synchronized with the movement speed of
- the welding skill evaluation apparatus of the present invention can select and display in real time an image on the back surface or a screen displayed on a PC monitor on a small monitor attached to the welder's weld protection surface during welding.
- a transmission means in the welded part quality evaluation apparatus of the present invention image analysis, welding state determination, and welding behavior / condition improvement based on image data captured by a torch camera that is attached to a welding torch and monitors a molten state and an arc state
- the instructions are transmitted as visual or auditory information via a cable to a small monitor attached to the welding protective surface, and in particular, as a danger signal when abnormal (such as poor weld penetration).
- FIG. 1 is a schematic diagram of the welding skill evaluation apparatus of the present invention
- FIG. 2 is a side view of an embodiment of the welding skill evaluation apparatus of the present invention
- FIG. 3 is a front view thereof.
- 1 is a welding torch
- 2 is a torch camera
- 3 is a back wave observation camera
- 4 is a molten pool observation camera
- 5 is a whole behavior imaging camera
- 6 is a work table
- 7 is a monitor
- 8 is a molten pool observation camera.
- 9 is a motor for synchronous movement of the molten pool observation camera and the back wave observation camera
- M is a molten pool
- B is a base material.
- the back wave observation camera 3 is provided on the groove back side of a pair of base materials B juxtaposed on the work table 6 via the groove. It is possible to move in the direction orthogonal to the groove via the wave observation camera 3 and the connecting body 8 and to tilt the groove obliquely upward so that the torch behavior and the molten pool M surface behavior can be observed. Is provided.
- the weld pool observation camera 4 and the back wave observation camera 3 are moved along the groove as the welding progresses by driving the synchronous movement motor 9 (see FIG. 3).
- the welding technique of the present invention can be widely used in industries such as shipbuilding, machinery, automobiles, construction, bridges and filling tanks.
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Abstract
The present invention addresses the problem of providing a welding skill evaluation device which enables the acquisition of detailed knowledge of a molten pool by welding training under the visual observation of the molten pool as an image to thereby enable improvement in welding skill in a short time, and a weld quality evaluation device which enables a welding operation while the quality (complete penetration and incomplete penetration during welding) of a weld is detected in real time during welding. The present invention is designed to solve the problem by a welding skill evaluation device equipped with: a molten pool observation camera for observing a torch behavior and a molten pool surface behavior; a reverse side observation camera that moves integrally with the molten pool observation camera in order to measure the molten state of the reverse side of the molten pool; a torch camera that is mounted to a welding torch in order to monitor a molten state and an arc state; a whole behavior photographing camera for photographing the posture of a welder; a monitor for displaying images captured by the four cameras together with a welding current/voltage signal; a storage unit for storing and analyzing image information relating to the images captured by the four cameras together with the welding current/voltage signal obtained from a welding current/welding voltage measurement unit; and a welding face shield to which a small monitor for displaying any of the images captured by the four cameras is attached.
Description
本発明は、溶融池を画像として目視しながらの溶接訓練により、溶融池の詳細な知見を得ることができ、より短時間での溶接技量向上を可能とした溶接技量評価装置や、溶接部の品質（溶接途上完全溶け込みと不完全溶け込み）を溶接途上リアルタイムに検知しながらの溶接作業を可能とした溶接部品質評価装置に関する。
The present invention can obtain detailed knowledge of the molten pool by welding training while visually observing the molten pool as an image, and can improve the welding skill in a shorter time. The present invention relates to a weld quality evaluation apparatus that enables welding work while detecting quality (complete penetration during welding and incomplete penetration) in real time during welding.
従来、手溶接支援装置としては、手溶接施工が行われる際にその溶接対象を含む溶接環境およびその溶接施工作業中の溶接士の挙動に関するデータを計測する溶接士動作計測装置および溶接環境計測装置と、これらの計測データから溶接施工中の溶接状態の特徴量を抽出する演算処理装置と、これにより抽出された特徴量に基づいて手溶接状態の良否を判定する溶接状態判定装置と、ここでの判定結果を含む溶接状態の推移に関する情報を溶接施工中の溶接士に認知可能に提示する溶接状態提示装置とを備える手溶接支援装置（特許文献１）や、溶接対象となる２つの母材のギャップ溶接やインサートリング溶接時の裏波溶接を支援する溶接作業支援装置において、溶接トーチに取付けたＣＣＤカメラなどの視覚センサと、この視覚センサにより撮像された画像情報を処理して溶融池状態を計測し、その結果を過去のデータと比較して裏波状態を推定する画像解析手段とを備え、この画像解析手段により推定された裏波情報の推測情報を溶接士へ伝達する溶接支援情報伝達手段からなる溶接作業支援装置（特許文献２）が知られている。
Conventionally, as a manual welding support device, when a manual welding operation is performed, a welding environment measuring device and a welding environment measuring device for measuring data related to the welding environment including the welding target and the behavior of the welder during the welding operation. An arithmetic processing device that extracts the feature value of the welding state during welding from these measurement data, a welding state determination device that determines the quality of the manual welding state based on the feature amount extracted thereby, Manual welding support device (Patent Document 1) including a welding state presentation device that presents information regarding the transition of the welding state including the determination result to the welder who is performing welding, and two base materials to be welded A visual sensor such as a CCD camera attached to a welding torch, and a visual sensor for a welding work support device for supporting backside welding during gap welding and insert ring welding Image analysis means for processing the image information captured and measuring the molten pool state and comparing the result with past data to estimate the back wave state. The back wave estimated by the image analysis means There is known a welding work support device (Patent Document 2) comprising welding support information transmission means for transmitting information estimation information to a welder.
また、溶接部品質評価装置としては、溶接中において、その品質を評価する装置であって、加熱により金属が溶融した部分の外側の部分であって、所定の温度まで昇温した熱影響部の分布に基づく情報を取得する手段と、正常な溶接が行われた場合の熱影響部の分布に基づく参照情報を記憶する手段と、前記取得された情報と前記参照情報を比較し、これらの情報が不一致の場合、溶接品質を不良とする手段と、を有する溶接の品質評価装置（特許文献３）や、手溶接作業対象周辺に設置した監視カメラで撮影した溶接施工中の溶融池周辺の画像情報を分析、処理する手溶接作業分析装置において、手溶接トーチに監視カメラを一体接続させる手溶接機一体型撮像装置と、この撮像装置からの画像のデジタル信号を処理、収録する画像データ収録装置と、収録された画像をデータとして情報処理するデータ処理装置と、処理した情報をディスプレイするディスプレイ装置とを備えたことを特徴とする手溶接作業分析装置（特許文献４）や、互いに溶接された被溶接部材の溶接品質を評価する溶接品質評価装置であって、被溶接部材の融点よりも低い所定の温度で軟化または溶融する材料からなり、前記被溶接部材の所定位置に設置される溶接品質評価用要素と、該溶接品質評価用要素の軟化または溶融を検知する検知手段と、該検知手段によって検知された溶接品質評価用要素の設置された位置における軟化または溶融したか否かに基づいて溶接品質を評価する評価手段とを備えたことを特徴とする溶接品質評価装置（特許文献５）が知られている。
The welded part quality evaluation apparatus is an apparatus for evaluating the quality during welding, which is a part outside the part where the metal is melted by heating, and is a heat-affected part that has been heated to a predetermined temperature. Means for acquiring information based on the distribution, means for storing reference information based on the distribution of the heat affected zone when normal welding is performed, comparing the acquired information with the reference information, and these information If there is a discrepancy, the welding quality evaluation apparatus (Patent Document 3) having means for making the welding quality defective, and an image of the periphery of the weld pool during welding construction taken by a monitoring camera installed around the object of manual welding work In a manual welding work analysis device for analyzing and processing information, an image pickup device integrated with a manual welding machine in which a surveillance camera is integrally connected to a manual welding torch, and image data for processing and recording digital signals from the image pickup device. A manual welding operation analyzer (Patent Document 4) characterized by comprising a recording device, a data processing device that processes the recorded image as data, and a display device that displays the processed information. A welding quality evaluation apparatus for evaluating the welding quality of a welded member that is made of a material that softens or melts at a predetermined temperature lower than the melting point of the welded member, and is installed at a predetermined position of the welded member. Whether or not the welding quality evaluation element, detection means for detecting softening or melting of the welding quality evaluation element, and whether or not the welding quality evaluation element detected by the detection means has been softened or melted There is known a welding quality evaluation device (Patent Document 5) characterized by comprising an evaluation means for evaluating welding quality based on the above.
溶接部は形状、構造等多種多用である。現在の溶接部検査は非破壊検査（Ｘ線検査、超音波検、浸透探傷検査等）と破壊検査があるが共に事後の検査であり充分な検査はできない。ＩＳＯにおいても溶接部は事後の検査であり充分な検証はできない特殊工程として定義されている。特に手動溶接においては熟練溶接士の溶接施工品であっても品質に関する確証は得られない。
溶 接 The welded part has a wide variety of shapes and structures. The current weld inspection includes non-destructive inspection (X-ray inspection, ultrasonic inspection, penetrant inspection, etc.) and destructive inspection. Even in ISO, the weld is defined as a special process that cannot be fully verified because it is a subsequent inspection. In particular, in manual welding, confirmation of quality cannot be obtained even with a welded product of a skilled welder.
また本発明者らは、裏まで完全に溶け込んでいるか否かを判断する以下の技術的知見を有している。
１）裏まで完全には溶け込んでいない状態（以下不完全溶け込みと称す）では安定な底があり、完全に裏まで抜ける（以下完全溶け込みと称す）と裏面で溶融金属は垂れ下がり（支える力は表面張力のみ）、表面の液位も下がる。
２）溶けた金属部分は内部で流動するとともに、上下の液面振動も存在する。完全溶け込みとその前の不完全溶け込み状態とでは、振動周期と振動高さが異なる。ティグ溶接では電極先端部と液面の高さが変動すると、溶接電圧も変動する（近づくと電圧は短くなり、離れると電圧は高くなる）。このため、電圧信号を解析することにより、溶け込みを判断できる可能性がある。自動溶接機では、電極と溶接材料との距離が常に一定になるため、ある程度の判断は可能であるが、手動溶接では、高さはかなり変動するため、電圧信号のみで判断するのは難しい。特に、非熟練者ではトーチの動きによる電圧変動が高く電圧電流信号のみで判断することは不可能に近い。
３）不完全溶け込みの場合にも、溶接線前方付近の溶融池前面部では溶けた金属の位置は溶接材料表面より若干下側に下がっている場合が多い（ほとんど等しい高さの場合もある）が、完全に溶け込むと溶融金属表面位置が溶接材料表面より多く下がる場合が多い。母材の板の厚さが厚いほどこの違いは大きい。また、溶接材料のアークがあたっている部分も完全に溶け込むと若干低下する。アーク電圧の増加として検知は可能であるが、熟練者の場合には液面の低下にあわせてトーチを下げる場合も多く、電圧信号として完全溶け込みを認識するのは難しい。
４）裏側のシールド状態が悪いと、裏面での酸化反応が活発となり比較的軽いスラグが裏から表面に出てきて、溶融池表面のスラグ（＝酸化物、酸化物の種類により異なるが、ステンレスより溶融温度が高いものが多い）が増加することも多い。 Moreover, the present inventors have the following technical knowledge for determining whether or not the resin is completely dissolved up to the back.
1) There is a stable bottom in the state where it is not completely melted to the back (hereinafter referred to as incomplete melt), and the molten metal hangs down on the back when it completely falls back (hereinafter referred to as complete melt) (supporting force is on the surface) (Tension only), the liquid level on the surface also decreases.
2) The melted metal part flows inside, and there are upper and lower liquid level vibrations. The vibration period and vibration height differ between complete penetration and the previous incomplete penetration state. In TIG welding, when the height of the electrode tip and the liquid level fluctuates, the welding voltage also fluctuates (the voltage decreases as it approaches, and the voltage increases as it moves away). Therefore, there is a possibility that the penetration can be determined by analyzing the voltage signal. In the automatic welding machine, since the distance between the electrode and the welding material is always constant, a certain degree of determination is possible. However, in manual welding, the height varies considerably, so that it is difficult to determine only by the voltage signal. In particular, it is almost impossible for an unskilled person to make a determination based only on the voltage / current signal because the voltage fluctuation due to the movement of the torch is high.
3) In the case of incomplete penetration, the position of the molten metal is often slightly lower than the surface of the weld material in the front of the weld pool near the front of the weld line (there may be almost the same height). However, when completely melted, the surface position of the molten metal often falls below the surface of the welding material. The difference is greater as the thickness of the base material plate increases. In addition, when the arc portion of the welding material is completely melted, it is slightly lowered. Although it can be detected as an increase in arc voltage, in the case of a skilled person, the torch is often lowered as the liquid level decreases, and it is difficult to recognize complete penetration as a voltage signal.
4) If the shield on the back side is poor, the oxidation reaction on the back side becomes active, and relatively light slag comes out from the back to the surface, and the slag on the molten pool surface (= varies depending on the type of oxide and oxide, but stainless steel) In many cases, the melting temperature is higher).
１）裏まで完全には溶け込んでいない状態（以下不完全溶け込みと称す）では安定な底があり、完全に裏まで抜ける（以下完全溶け込みと称す）と裏面で溶融金属は垂れ下がり（支える力は表面張力のみ）、表面の液位も下がる。
２）溶けた金属部分は内部で流動するとともに、上下の液面振動も存在する。完全溶け込みとその前の不完全溶け込み状態とでは、振動周期と振動高さが異なる。ティグ溶接では電極先端部と液面の高さが変動すると、溶接電圧も変動する（近づくと電圧は短くなり、離れると電圧は高くなる）。このため、電圧信号を解析することにより、溶け込みを判断できる可能性がある。自動溶接機では、電極と溶接材料との距離が常に一定になるため、ある程度の判断は可能であるが、手動溶接では、高さはかなり変動するため、電圧信号のみで判断するのは難しい。特に、非熟練者ではトーチの動きによる電圧変動が高く電圧電流信号のみで判断することは不可能に近い。
３）不完全溶け込みの場合にも、溶接線前方付近の溶融池前面部では溶けた金属の位置は溶接材料表面より若干下側に下がっている場合が多い（ほとんど等しい高さの場合もある）が、完全に溶け込むと溶融金属表面位置が溶接材料表面より多く下がる場合が多い。母材の板の厚さが厚いほどこの違いは大きい。また、溶接材料のアークがあたっている部分も完全に溶け込むと若干低下する。アーク電圧の増加として検知は可能であるが、熟練者の場合には液面の低下にあわせてトーチを下げる場合も多く、電圧信号として完全溶け込みを認識するのは難しい。
４）裏側のシールド状態が悪いと、裏面での酸化反応が活発となり比較的軽いスラグが裏から表面に出てきて、溶融池表面のスラグ（＝酸化物、酸化物の種類により異なるが、ステンレスより溶融温度が高いものが多い）が増加することも多い。 Moreover, the present inventors have the following technical knowledge for determining whether or not the resin is completely dissolved up to the back.
1) There is a stable bottom in the state where it is not completely melted to the back (hereinafter referred to as incomplete melt), and the molten metal hangs down on the back when it completely falls back (hereinafter referred to as complete melt) (supporting force is on the surface) (Tension only), the liquid level on the surface also decreases.
2) The melted metal part flows inside, and there are upper and lower liquid level vibrations. The vibration period and vibration height differ between complete penetration and the previous incomplete penetration state. In TIG welding, when the height of the electrode tip and the liquid level fluctuates, the welding voltage also fluctuates (the voltage decreases as it approaches, and the voltage increases as it moves away). Therefore, there is a possibility that the penetration can be determined by analyzing the voltage signal. In the automatic welding machine, since the distance between the electrode and the welding material is always constant, a certain degree of determination is possible. However, in manual welding, the height varies considerably, so that it is difficult to determine only by the voltage signal. In particular, it is almost impossible for an unskilled person to make a determination based only on the voltage / current signal because the voltage fluctuation due to the movement of the torch is high.
3) In the case of incomplete penetration, the position of the molten metal is often slightly lower than the surface of the weld material in the front of the weld pool near the front of the weld line (there may be almost the same height). However, when completely melted, the surface position of the molten metal often falls below the surface of the welding material. The difference is greater as the thickness of the base material plate increases. In addition, when the arc portion of the welding material is completely melted, it is slightly lowered. Although it can be detected as an increase in arc voltage, in the case of a skilled person, the torch is often lowered as the liquid level decreases, and it is difficult to recognize complete penetration as a voltage signal.
4) If the shield on the back side is poor, the oxidation reaction on the back side becomes active, and relatively light slag comes out from the back to the surface, and the slag on the molten pool surface (= varies depending on the type of oxide and oxide, but stainless steel) In many cases, the melting temperature is higher).
他方、近年の人口減少、少子高齢化から将来世代への溶接技量伝承が困難になってきている。本発明の課題は、溶融池を画像として目視しながらの溶接訓練により、溶融池の詳細な知見を得ることができ、より短時間での溶接技量向上を可能とした溶接技量評価装置や、溶接部の品質（溶接途上完全溶け込みと不完全溶け込み）を溶接途上リアルタイムに検知しながらの溶接作業を可能とした溶接部品質評価装置を提供することにある。
On the other hand, it has become difficult to pass on welding skills to future generations due to the recent decline in population and declining birthrate and aging population. It is an object of the present invention to obtain a detailed knowledge of the molten pool by welding training while visually observing the molten pool as an image, and a welding skill evaluation device that enables improvement of the welding skill in a shorter time, welding It is an object of the present invention to provide a weld quality evaluation apparatus that enables welding work while detecting the quality of a weld (complete penetration during welding and incomplete penetration) in real time during welding.
より具体的には、以下の１）～８）を課題とした。
１）裏面まで確実に溶け込んでいるか否かを溶接施工中に確認できること。
２）３０ｃｍ程度以上の長さの溶接を、安定に（溶け込み幅一定で、裏面まで確実に溶け込ませ、溶接部の垂れ下がりを極力少なくした状態を保って）溶接できること。具体的には、
３）溶接中に電極先端位置、溶融池（溶接中に金属が溶けている部分）、溶接線（溶接する２枚の部材の継ぎ目線）を確認することができること。
４）電極先端部と溶接する部材との高さ（距離）をほとんど変動させずに、溶接トーチを自由に移動させることができること。
５）アーク開始時のみ、溶接トーチのノズル（セラミックスの絶縁部材）を溶接材料に軽く接触させ、電極と溶接材料とが短絡しない範囲で、距離が１～２ｍｍ程度とできるだけ接近した状態に保ちアークを始動させ、アークが安定した状態を見極め、電極高さが変動しないように保ちながらノズルを溶接材料から浮かして、溶接を安定に行うために最適なノズルの向きに変更できること。
６）最初は溶接する材料の温度が低く、裏まで完全に溶け込ませるのに３～５秒（板の厚みで異なる）かかるが、この間に溶融池の幅があまり大きくなりすぎないように軽く前後に移動させながらアークを維持し、裏まで完全に溶け込むことが確認できること。
７）溶接開始時点では、溶接する部分は暗闇の中にある状態なので、手探りとなるため、ノズルなどを介して電極と溶接材料との位置を一定に保つのが最も容易であり、アーク開始に最も適した溶接材料への接し方を理解することができること。
８）アークが発生すると溶接部の監視が可能になるため、アークを見ながらトーチの向きや高さの調節ができる。トーチ操作の自由度を高くするためには、ノズルと溶接材料は離れていることが好ましい。ノズルを溶接材料に軽く接触したまま溶接することは可能であるが、溶融池内部の溶融金属の流れ方や状態に応じてトーチの向き（アークの流れる方向）を調節できること。 More specifically, the following 1) to 8) were set as problems.
1) It should be possible to confirm whether or not it has melted to the back side during welding.
2) Welding with a length of about 30 cm or more can be welded stably (with a constant penetration width, with a reliable penetration to the back surface, and with the welding part kept in a state where sag is minimized). In particular,
3) It is possible to confirm the electrode tip position, the weld pool (the portion where the metal is melted during welding), and the weld line (the joint line between the two members to be welded) during welding.
4) The welding torch can be moved freely without substantially changing the height (distance) between the electrode tip and the member to be welded.
5) Only at the start of the arc, the welding torch nozzle (ceramic insulating member) is lightly brought into contact with the welding material, and the arc is kept as close as possible with a distance of about 1 to 2 mm within a range where the electrode and the welding material do not short-circuit. The nozzle can be lifted from the welding material while keeping the electrode height unchanged so that the arc can be stably changed to the optimal nozzle orientation for stable welding.
6) At first, the temperature of the material to be welded is low, and it takes 3 to 5 seconds (depending on the thickness of the plate) to completely melt it to the back, but during this time it is lightly moved back and forth so that the width of the molten pool does not become too large. It can be confirmed that the arc is maintained while being moved to and that it completely melts to the back.
7) Since the welded part is in the dark at the start of welding, it is easy to keep track of the position of the electrode and the welding material via a nozzle, etc. Able to understand how to contact the most suitable welding material.
8) Since welding can be monitored when an arc is generated, the direction and height of the torch can be adjusted while viewing the arc. In order to increase the degree of freedom of the torch operation, it is preferable that the nozzle and the welding material are separated from each other. It is possible to weld with the nozzle lightly in contact with the welding material, but the direction of the torch (the direction of arc flow) can be adjusted according to the flow and state of the molten metal inside the molten pool.
１）裏面まで確実に溶け込んでいるか否かを溶接施工中に確認できること。
２）３０ｃｍ程度以上の長さの溶接を、安定に（溶け込み幅一定で、裏面まで確実に溶け込ませ、溶接部の垂れ下がりを極力少なくした状態を保って）溶接できること。具体的には、
３）溶接中に電極先端位置、溶融池（溶接中に金属が溶けている部分）、溶接線（溶接する２枚の部材の継ぎ目線）を確認することができること。
４）電極先端部と溶接する部材との高さ（距離）をほとんど変動させずに、溶接トーチを自由に移動させることができること。
５）アーク開始時のみ、溶接トーチのノズル（セラミックスの絶縁部材）を溶接材料に軽く接触させ、電極と溶接材料とが短絡しない範囲で、距離が１～２ｍｍ程度とできるだけ接近した状態に保ちアークを始動させ、アークが安定した状態を見極め、電極高さが変動しないように保ちながらノズルを溶接材料から浮かして、溶接を安定に行うために最適なノズルの向きに変更できること。
６）最初は溶接する材料の温度が低く、裏まで完全に溶け込ませるのに３～５秒（板の厚みで異なる）かかるが、この間に溶融池の幅があまり大きくなりすぎないように軽く前後に移動させながらアークを維持し、裏まで完全に溶け込むことが確認できること。
７）溶接開始時点では、溶接する部分は暗闇の中にある状態なので、手探りとなるため、ノズルなどを介して電極と溶接材料との位置を一定に保つのが最も容易であり、アーク開始に最も適した溶接材料への接し方を理解することができること。
８）アークが発生すると溶接部の監視が可能になるため、アークを見ながらトーチの向きや高さの調節ができる。トーチ操作の自由度を高くするためには、ノズルと溶接材料は離れていることが好ましい。ノズルを溶接材料に軽く接触したまま溶接することは可能であるが、溶融池内部の溶融金属の流れ方や状態に応じてトーチの向き（アークの流れる方向）を調節できること。 More specifically, the following 1) to 8) were set as problems.
1) It should be possible to confirm whether or not it has melted to the back side during welding.
2) Welding with a length of about 30 cm or more can be welded stably (with a constant penetration width, with a reliable penetration to the back surface, and with the welding part kept in a state where sag is minimized). In particular,
3) It is possible to confirm the electrode tip position, the weld pool (the portion where the metal is melted during welding), and the weld line (the joint line between the two members to be welded) during welding.
4) The welding torch can be moved freely without substantially changing the height (distance) between the electrode tip and the member to be welded.
5) Only at the start of the arc, the welding torch nozzle (ceramic insulating member) is lightly brought into contact with the welding material, and the arc is kept as close as possible with a distance of about 1 to 2 mm within a range where the electrode and the welding material do not short-circuit. The nozzle can be lifted from the welding material while keeping the electrode height unchanged so that the arc can be stably changed to the optimal nozzle orientation for stable welding.
6) At first, the temperature of the material to be welded is low, and it takes 3 to 5 seconds (depending on the thickness of the plate) to completely melt it to the back, but during this time it is lightly moved back and forth so that the width of the molten pool does not become too large. It can be confirmed that the arc is maintained while being moved to and that it completely melts to the back.
7) Since the welded part is in the dark at the start of welding, it is easy to keep track of the position of the electrode and the welding material via a nozzle, etc. Able to understand how to contact the most suitable welding material.
8) Since welding can be monitored when an arc is generated, the direction and height of the torch can be adjusted while viewing the arc. In order to increase the degree of freedom of the torch operation, it is preferable that the nozzle and the welding material are separated from each other. It is possible to weld with the nozzle lightly in contact with the welding material, but the direction of the torch (the direction of arc flow) can be adjusted according to the flow and state of the molten metal inside the molten pool.
以下の１）～６）を開発コンセプトとすることとにより溶接技量評価装置を開発した。
１）接トーチに取り付けたカメラ、溶融池裏側（裏波）観察用カメラ、溶融池表側観察用カメラ、及び溶接士姿勢観察用カメラによる４方向からの画像と、更に保護面内に取り付けたモニターに映し出された画像を目視しながらの溶接訓練装置とする。
２）溶融池の状況（画像）と同期した溶接施工品実物の状況を目視比較しながら興味を持ち技量向上に効率的訓練が可能な装置、特に溶接電圧の変動、溶接電流の変動を検知し溶接溶け込み検知のサポート信号とする装置とする。
３）裏波が出た場合の裏波状況、同期した表面状況の知見が得られ、表面画像観察から裏側状況の推測を可能とする訓練装置とする。
４）溶接訓練士の溶接技量を認識しながら改良点を見つけ効率的、短時間での技量向上を可能とする装置とする。
５）溶接熟練士の画像と比較しながら異なる点を見つけ対策を講じ早期の技量向上を可能とする装置、すなわち、溶接訓練士は溶融池表面の状況、裏面の状況、溶接姿勢について熟練溶接士の画像と比較することにより本人の欠点が理解し易く短時間での技量向上を可能とした装置とする。
６）溶接保護面内に設置したモニターで裏波状況を確認しながら表状況を確認し、完全溶け込みを認識しながら溶接施工の訓練を可能とする装置、より具体的には、保護面に設置した小型モニターで溶接裏面に裏波が出ていることを確認しながらその時の表面溶融池状況チェックを可能とし、将来溶融池表面の状況から裏波が出たことの知見取得を可能とした装置とする。 We developed a welding skill evaluation device based on the following development concepts 1) to 6).
1) A camera attached to the contact torch, a weld pool back side (back wave) observation camera, a weld pool front side observation camera, and a welder posture observation camera, and a monitor attached in a protective surface. The welding training device while visually observing the image projected on.
2) A device that can be used for effective training to improve skill while visually comparing the actual state of the welded product in synchronism with the state of the weld pool (image), especially detecting fluctuations in welding voltage and welding current. The device is used as a support signal for welding penetration detection.
3) A training apparatus that can obtain knowledge of a back-surface situation when a back-wave occurs and a synchronized surface condition, and enables estimation of the back-side condition from surface image observation.
4) An apparatus that can improve the skill efficiently and in a short time while finding the improvement point while recognizing the welding skill of the welding trainer.
5) A device that makes it possible to find a different point while comparing with the image of a welding expert and take measures to improve the skill at an early stage. By comparing with the above image, it is easy to understand the person's faults and to improve the skill in a short time.
6) A device installed on the protective surface to check the surface condition while confirming the backside wave condition, and to allow welding training while recognizing complete penetration. It is possible to check the status of the surface molten pool while confirming that there is a back wave on the back of the weld with a small monitor, and to acquire knowledge that a back wave has occurred from the state of the molten pool surface in the future And
１）接トーチに取り付けたカメラ、溶融池裏側（裏波）観察用カメラ、溶融池表側観察用カメラ、及び溶接士姿勢観察用カメラによる４方向からの画像と、更に保護面内に取り付けたモニターに映し出された画像を目視しながらの溶接訓練装置とする。
２）溶融池の状況（画像）と同期した溶接施工品実物の状況を目視比較しながら興味を持ち技量向上に効率的訓練が可能な装置、特に溶接電圧の変動、溶接電流の変動を検知し溶接溶け込み検知のサポート信号とする装置とする。
３）裏波が出た場合の裏波状況、同期した表面状況の知見が得られ、表面画像観察から裏側状況の推測を可能とする訓練装置とする。
４）溶接訓練士の溶接技量を認識しながら改良点を見つけ効率的、短時間での技量向上を可能とする装置とする。
５）溶接熟練士の画像と比較しながら異なる点を見つけ対策を講じ早期の技量向上を可能とする装置、すなわち、溶接訓練士は溶融池表面の状況、裏面の状況、溶接姿勢について熟練溶接士の画像と比較することにより本人の欠点が理解し易く短時間での技量向上を可能とした装置とする。
６）溶接保護面内に設置したモニターで裏波状況を確認しながら表状況を確認し、完全溶け込みを認識しながら溶接施工の訓練を可能とする装置、より具体的には、保護面に設置した小型モニターで溶接裏面に裏波が出ていることを確認しながらその時の表面溶融池状況チェックを可能とし、将来溶融池表面の状況から裏波が出たことの知見取得を可能とした装置とする。 We developed a welding skill evaluation device based on the following development concepts 1) to 6).
1) A camera attached to the contact torch, a weld pool back side (back wave) observation camera, a weld pool front side observation camera, and a welder posture observation camera, and a monitor attached in a protective surface. The welding training device while visually observing the image projected on.
2) A device that can be used for effective training to improve skill while visually comparing the actual state of the welded product in synchronism with the state of the weld pool (image), especially detecting fluctuations in welding voltage and welding current. The device is used as a support signal for welding penetration detection.
3) A training apparatus that can obtain knowledge of a back-surface situation when a back-wave occurs and a synchronized surface condition, and enables estimation of the back-side condition from surface image observation.
4) An apparatus that can improve the skill efficiently and in a short time while finding the improvement point while recognizing the welding skill of the welding trainer.
5) A device that makes it possible to find a different point while comparing with the image of a welding expert and take measures to improve the skill at an early stage. By comparing with the above image, it is easy to understand the person's faults and to improve the skill in a short time.
6) A device installed on the protective surface to check the surface condition while confirming the backside wave condition, and to allow welding training while recognizing complete penetration. It is possible to check the status of the surface molten pool while confirming that there is a back wave on the back of the weld with a small monitor, and to acquire knowledge that a back wave has occurred from the state of the molten pool surface in the future And
また、溶接部の品質評価装置を溶融池表面の画像を溶接途上リアルタイムに取得し、得た画像から品質を評価しながら溶接士へリアルタイムに状況を伝達し、不良が出た場合は警報を発する機能を備えた装置とするため、以下の１）～６）を開発コンセプトとすることとにより開発した。
１）溶接施工作業終了時には同時に検査終了であり品質良好が確認済となる機能を有する装置とする。
２）溶接トーチに取り付けたカメラで溶接時トーチ先端に形成される金属溶融池画像を取得する装置とする。
３）パソコンに設定された溶接部品質（完全溶け込みと不完全溶け込み）の判定基準とするデータベース（適正電流、適正電圧を含む）からリアルタイムに溶接部品質評価を行い溶接士へ状況を伝達する機能を有する装置とする。
４）溶接部完全溶け込みの判定基準として、溶融池の落ち込み、固液界面で液体側の挙動、液体表面部面積の変化、液体表面温度の変化、液体表面での湯流れ状態の変化、液体表面部でのスラグ量変化、スラグの挙動変化、液体表面の振動周期の変化とした装置とする。
５）溶接途上溶融池画像からリアルタイムに検査を実施し完全溶け込みを確認しながら溶接作業実行を可能とする装置とする。
６）品質不具合発生時には警報（不良程度にあわせて５段階数段階の音程あるいはリズム）を発し修正を促す機能を有する装置とする。 In addition, the welded part quality evaluation device acquires the weld pool surface image in real time during welding, evaluates the quality from the obtained image, conveys the situation to the welder in real time, and issues a warning if a defect occurs. In order to make the device equipped with functions, the following 1) to 6) were developed based on the development concept.
1) At the end of the welding work, the inspection is completed at the same time, and the device has a function that confirms the good quality.
2) A device that acquires a metal molten pool image formed at the tip of the torch during welding with a camera attached to the welding torch.
3) A function that evaluates weld quality in real time from a database (including proper current and proper voltage) that is used as a judgment standard for weld quality (complete penetration and incomplete penetration) set on a personal computer and transmits the situation to the welder It is set as the apparatus which has.
4) As criteria for determining the complete penetration of the weld zone, the molten pool falls, the liquid side behavior at the solid-liquid interface, the change in the liquid surface area, the change in the liquid surface temperature, the change in the hot water flow state at the liquid surface, the liquid surface The apparatus has a slag amount change at the part, a slag behavior change, and a change in the vibration cycle of the liquid surface.
5) An apparatus that enables a welding operation to be performed while performing a real-time inspection from the weld pool image during welding and confirming complete penetration.
6) A device having a function of issuing a warning (pitch or rhythm of several stages according to the degree of defect) and prompting correction when a quality defect occurs.
１）溶接施工作業終了時には同時に検査終了であり品質良好が確認済となる機能を有する装置とする。
２）溶接トーチに取り付けたカメラで溶接時トーチ先端に形成される金属溶融池画像を取得する装置とする。
３）パソコンに設定された溶接部品質（完全溶け込みと不完全溶け込み）の判定基準とするデータベース（適正電流、適正電圧を含む）からリアルタイムに溶接部品質評価を行い溶接士へ状況を伝達する機能を有する装置とする。
４）溶接部完全溶け込みの判定基準として、溶融池の落ち込み、固液界面で液体側の挙動、液体表面部面積の変化、液体表面温度の変化、液体表面での湯流れ状態の変化、液体表面部でのスラグ量変化、スラグの挙動変化、液体表面の振動周期の変化とした装置とする。
５）溶接途上溶融池画像からリアルタイムに検査を実施し完全溶け込みを確認しながら溶接作業実行を可能とする装置とする。
６）品質不具合発生時には警報（不良程度にあわせて５段階数段階の音程あるいはリズム）を発し修正を促す機能を有する装置とする。 In addition, the welded part quality evaluation device acquires the weld pool surface image in real time during welding, evaluates the quality from the obtained image, conveys the situation to the welder in real time, and issues a warning if a defect occurs. In order to make the device equipped with functions, the following 1) to 6) were developed based on the development concept.
1) At the end of the welding work, the inspection is completed at the same time, and the device has a function that confirms the good quality.
2) A device that acquires a metal molten pool image formed at the tip of the torch during welding with a camera attached to the welding torch.
3) A function that evaluates weld quality in real time from a database (including proper current and proper voltage) that is used as a judgment standard for weld quality (complete penetration and incomplete penetration) set on a personal computer and transmits the situation to the welder It is set as the apparatus which has.
4) As criteria for determining the complete penetration of the weld zone, the molten pool falls, the liquid side behavior at the solid-liquid interface, the change in the liquid surface area, the change in the liquid surface temperature, the change in the hot water flow state at the liquid surface, the liquid surface The apparatus has a slag amount change at the part, a slag behavior change, and a change in the vibration cycle of the liquid surface.
5) An apparatus that enables a welding operation to be performed while performing a real-time inspection from the weld pool image during welding and confirming complete penetration.
6) A device having a function of issuing a warning (pitch or rhythm of several stages according to the degree of defect) and prompting correction when a quality defect occurs.
すなわち本発明は、溶接装置に移動可能に固定され溶接の進行とともに移動する、トーチ挙動と溶融池表面挙動を観察する溶融池観察カメラ、前記溶融池観察カメラと一体で移動する溶融池裏側の溶融状態を計測する裏波観察カメラ、溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラ、溶接者の姿勢と溶接部の大きな状況を撮影する全体挙動撮影カメラ、これら４台のカメラにより撮像された画像を、溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに表示するモニター、前記４台のカメラにより撮像された画像情報を、溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに記憶・解析する記憶装置、及び、前記４台のカメラにより撮像された画像のいずれかを表示する小型モニターを装着した溶接保護面を装備した溶接技量評価装置に関する。
That is, the present invention provides a molten pool observation camera for observing a torch behavior and a molten pool surface behavior, which is movably fixed to a welding apparatus and moves with the progress of welding, and a molten pool behind the molten pool moving together with the molten pool observation camera. Image taken by these four cameras, a back-wave observation camera that measures the state, a torch camera that is attached to the welding torch and monitors the melted state and the arc state, a whole behavior photographing camera that photographs the welder's posture and the large state of the weld. A monitor that displays the recorded image together with a welding current / voltage signal obtained from the welding current / welding voltage measuring device, and image information captured by the four cameras is a welding current obtained from the welding current / welding voltage measuring device. A storage device that stores and analyzes together with voltage signals, and a small monitor that displays one of the images captured by the four cameras. Welding skill evaluation device equipped with a welding protective surface equipped with over.
また本発明は、溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラ、該トーチカメラにより撮像された画像情報を処理して溶融池状態とアーク状態を計測し、その画像情報を溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに、蓄積した溶接部品質評価データと比較して、溶接部品質を判定・評価する判定・評価装置、該判定・評価装置からリアルタイムに溶接部品質評価を行い溶接士へ状況を伝達する伝達手段を装備した溶接部品質評価装置であって、前記溶接部品質評価データが、溶接装置に移動可能に固定され溶接の進行とともに移動する、トーチ挙動と溶融池表面挙動を観察する溶融池観察カメラと、前記溶融池観察カメラと一体で移動する溶融池裏側の溶融状態を計測する裏波観察カメラと、溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラとにより撮像された画像情報を、溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに記憶・解析する記憶装置に蓄積されているデータベース中のデータである、溶接施工終了時には同時に品質確認も完了を可能とする溶接部品質評価装置に関する。
The present invention also relates to a torch camera that is attached to a welding torch and monitors a molten state and an arc state, processes image information captured by the torch camera, measures a molten pool state and an arc state, and uses the image information as a welding current. -Judgment / evaluation device that determines and evaluates weld quality compared to the accumulated weld quality evaluation data together with the welding current / voltage signal obtained from the welding voltage measuring device, and welds in real time from the judgment / evaluation device A welding part quality evaluation apparatus equipped with a transmission means for performing quality evaluation and transmitting the situation to a welder, wherein the welding part quality evaluation data is movably fixed to the welding apparatus and moves with the progress of welding. A molten pool observation camera for observing the molten pool surface behavior, and a back wave observation camera for measuring the molten state on the back side of the molten pool moving together with the molten pool observation camera The image information captured by the torch camera that is attached to the welding torch and monitors the molten state and the arc state is stored in a storage device for storing and analyzing together with the welding current / voltage signal obtained from the welding current / welding voltage measuring device. The present invention relates to a welded part quality evaluation apparatus that can complete quality confirmation at the same time when welding is completed, which is data in a database.
本発明の溶接技量評価装置によると、以下の効果を奏することができる。
１）裏面溶け込み状態をリアルタイムで確認できる。溶接の進行とともにカメラが移動するため、サイズの大きな画面で溶融池の状態を解析できる。
２）トーチにとりつけたカメラで溶融池とアークの状況をリアルタイムで確認できる。トーチ固定のカメラの画像であり、電極先端位置は常に一定となり、トーチの変動によるアーク長さの変動が計測できる。溶融池のサイズはトーチ（カメラ）高さにより変動する。
３）裏波観察カメラと同期して移動する溶融池観察カメラにより、溶接者の操作するトーチと溶融池を監視することにより、カメラを基準とした静止系の画像が撮影でき、トーチの変動や溶融池形状の変動を計測できる。
４）４台のカメラで取得した画像と電圧電流信号とをリアルタイムで画面に表示するとともに、溶接状況を溶接状態に応じた音声信号で発信できる。
５）画像信号および電圧電流信号は外部記録装置に記録され、必要に応じていつでも再現できる。
６）溶接中に表示発信する画像情報および音声信号とまったく同じ情報をいつでも再生できるとともに、溶融池のサイズ（幅や長さおよび面積）や裏面ビードのサイズと電圧電流信号の短時間の平均値や標準偏差などのマクロ情報を表示することにより溶接者の技能の特徴を明確にする機能を有する。
７）溶接中に溶接者のヘルメットに装着したモニタにより、裏面の画像あるいはＰＣモニターに表示される画面などを任意に選択してリアルタイム表示することにより、溶接中に本人の技能向上に必要な情報を表示する。
８）溶接後溶接者のヘルメットに装着したモニタに各種情報を再現することにより、実際に溶接している状況を同じ状況を再現することにより、良い点悪い点を注意しながら繰り返し学習できる。
９）本人の溶接結果のみでなく、模範とすべき熟練者の画像データも同様に繰り返し表示して再現することにより、効率的な学習が可能である。
１０）溶接中に記録・解析した情報は外部記録装置に記録され、溶接装置なしのＰＣなどで溶接中の装置と同等な画像および音声信号を再現させることにより、時間と場所に依存せずに必要に応じて学習できる。
１１）手動溶接技能のみでなく、溶接トーチおよび裏面ビードを撮影する駆動部に溶接トーチを固定することにより、自動溶接装置として新技術開発過程で用いることも可能であり、画像信号や電圧電流信号の解析により新技術開発時の問題点の把握と解決に有効な機能を有する。
１２）また、上記自動溶接機構を用いて溶接させ、溶接技能者に手動で溶加棒（溶接金属量を確保するための外部から添加する溶接金属）を送り込む訓練が可能であることから、溶加棒を送り込む訓練を独立して実施可能としたことにより溶融池の状態を冷静に確認しながら溶加棒を送り込むことにより、訓練の効率を飛躍的に増加させることができる。通常の状態では、うまく溶接できないことが溶接トーチの影響かあるいは溶加棒の送りが悪いのか判断できないことが多いのに対して、溶接自体は理想的な状態で自動で実施し訓練者は溶加棒の送りのみに専念して訓練することにより学習効率が向上する。
１３）溶加棒の送り方の相違による溶融池の状態変化について事前に多くの例を画像を見ながら学習することにより客観的な学習が可能であり、従来一方交通的な面も多く存在する熟練者からの教育がより具体的に理解できる。 According to the welding skill evaluation device of the present invention, the following effects can be obtained.
1) The back surface penetration state can be confirmed in real time. Since the camera moves as welding progresses, the state of the molten pool can be analyzed on a large screen.
2) The status of the molten pool and arc can be checked in real time with a camera attached to the torch. This is an image of a camera fixed to the torch, the electrode tip position is always constant, and the variation of the arc length due to the variation of the torch can be measured. The size of the molten pool varies depending on the height of the torch (camera).
3) By monitoring the torch and weld pool operated by the welder with a weld pool observation camera that moves in synchronization with the back-wave observation camera, it is possible to take a static image based on the camera, Measurement of molten pool shape fluctuation
4) The images and voltage / current signals acquired by the four cameras can be displayed on the screen in real time, and the welding status can be transmitted as an audio signal corresponding to the welding state.
5) The image signal and the voltage / current signal are recorded in an external recording device and can be reproduced whenever necessary.
6) Image information and audio signals displayed and transmitted during welding can be reproduced at any time, and the weld pool size (width, length, and area), backside bead size, and average voltage / current signal for a short time It has a function to clarify the characteristics of the skill of the welder by displaying macro information such as standard deviation.
7) Information necessary for improving the person's skills during welding by arbitrarily selecting an image on the back or a screen displayed on the PC monitor with a monitor attached to the helmet of the welder during welding. Is displayed.
8) By reproducing various kinds of information on the monitor attached to the welder's helmet after welding, the same situation can be reproduced while actually welding the situation, so that good and bad points can be learned repeatedly.
9) Efficient learning is possible by repeatedly displaying and reproducing not only the welding result of the person himself but also the image data of the expert who should serve as a model.
10) Information recorded / analyzed during welding is recorded in an external recording device, and images and audio signals equivalent to the device being welded can be reproduced on a PC without a welding device, making it independent of time and place. Learn as needed.
11) Not only manual welding skills, but also by fixing the welding torch to the drive part that photographs the welding torch and backside bead, it can be used in the process of developing new technology as an automatic welding device. It has an effective function for understanding and solving problems at the time of new technology development.
12) Also, it is possible to train using the above automatic welding mechanism and manually send a welding rod to the welding technician (welding metal added from the outside to secure the amount of weld metal). By making it possible to carry out the training for feeding the rod independently, the efficiency of the training can be dramatically increased by feeding the filler rod while confirming the state of the molten pool calmly. Under normal conditions, it is often impossible to judge whether welding is not successful or the effect of the welding torch or the feed of the filler rod is bad, whereas welding is performed automatically in an ideal state, and the trainer performs welding. Learning efficiency improves by training exclusively on the feeding of the bar.
13) Objective learning is possible by studying many examples of the state change of the molten pool due to the difference in the feeding method of the filler rod in advance while viewing the images. Can understand education from experts more specifically.
１）裏面溶け込み状態をリアルタイムで確認できる。溶接の進行とともにカメラが移動するため、サイズの大きな画面で溶融池の状態を解析できる。
２）トーチにとりつけたカメラで溶融池とアークの状況をリアルタイムで確認できる。トーチ固定のカメラの画像であり、電極先端位置は常に一定となり、トーチの変動によるアーク長さの変動が計測できる。溶融池のサイズはトーチ（カメラ）高さにより変動する。
３）裏波観察カメラと同期して移動する溶融池観察カメラにより、溶接者の操作するトーチと溶融池を監視することにより、カメラを基準とした静止系の画像が撮影でき、トーチの変動や溶融池形状の変動を計測できる。
４）４台のカメラで取得した画像と電圧電流信号とをリアルタイムで画面に表示するとともに、溶接状況を溶接状態に応じた音声信号で発信できる。
５）画像信号および電圧電流信号は外部記録装置に記録され、必要に応じていつでも再現できる。
６）溶接中に表示発信する画像情報および音声信号とまったく同じ情報をいつでも再生できるとともに、溶融池のサイズ（幅や長さおよび面積）や裏面ビードのサイズと電圧電流信号の短時間の平均値や標準偏差などのマクロ情報を表示することにより溶接者の技能の特徴を明確にする機能を有する。
７）溶接中に溶接者のヘルメットに装着したモニタにより、裏面の画像あるいはＰＣモニターに表示される画面などを任意に選択してリアルタイム表示することにより、溶接中に本人の技能向上に必要な情報を表示する。
８）溶接後溶接者のヘルメットに装着したモニタに各種情報を再現することにより、実際に溶接している状況を同じ状況を再現することにより、良い点悪い点を注意しながら繰り返し学習できる。
９）本人の溶接結果のみでなく、模範とすべき熟練者の画像データも同様に繰り返し表示して再現することにより、効率的な学習が可能である。
１０）溶接中に記録・解析した情報は外部記録装置に記録され、溶接装置なしのＰＣなどで溶接中の装置と同等な画像および音声信号を再現させることにより、時間と場所に依存せずに必要に応じて学習できる。
１１）手動溶接技能のみでなく、溶接トーチおよび裏面ビードを撮影する駆動部に溶接トーチを固定することにより、自動溶接装置として新技術開発過程で用いることも可能であり、画像信号や電圧電流信号の解析により新技術開発時の問題点の把握と解決に有効な機能を有する。
１２）また、上記自動溶接機構を用いて溶接させ、溶接技能者に手動で溶加棒（溶接金属量を確保するための外部から添加する溶接金属）を送り込む訓練が可能であることから、溶加棒を送り込む訓練を独立して実施可能としたことにより溶融池の状態を冷静に確認しながら溶加棒を送り込むことにより、訓練の効率を飛躍的に増加させることができる。通常の状態では、うまく溶接できないことが溶接トーチの影響かあるいは溶加棒の送りが悪いのか判断できないことが多いのに対して、溶接自体は理想的な状態で自動で実施し訓練者は溶加棒の送りのみに専念して訓練することにより学習効率が向上する。
１３）溶加棒の送り方の相違による溶融池の状態変化について事前に多くの例を画像を見ながら学習することにより客観的な学習が可能であり、従来一方交通的な面も多く存在する熟練者からの教育がより具体的に理解できる。 According to the welding skill evaluation device of the present invention, the following effects can be obtained.
1) The back surface penetration state can be confirmed in real time. Since the camera moves as welding progresses, the state of the molten pool can be analyzed on a large screen.
2) The status of the molten pool and arc can be checked in real time with a camera attached to the torch. This is an image of a camera fixed to the torch, the electrode tip position is always constant, and the variation of the arc length due to the variation of the torch can be measured. The size of the molten pool varies depending on the height of the torch (camera).
3) By monitoring the torch and weld pool operated by the welder with a weld pool observation camera that moves in synchronization with the back-wave observation camera, it is possible to take a static image based on the camera, Measurement of molten pool shape fluctuation
4) The images and voltage / current signals acquired by the four cameras can be displayed on the screen in real time, and the welding status can be transmitted as an audio signal corresponding to the welding state.
5) The image signal and the voltage / current signal are recorded in an external recording device and can be reproduced whenever necessary.
6) Image information and audio signals displayed and transmitted during welding can be reproduced at any time, and the weld pool size (width, length, and area), backside bead size, and average voltage / current signal for a short time It has a function to clarify the characteristics of the skill of the welder by displaying macro information such as standard deviation.
7) Information necessary for improving the person's skills during welding by arbitrarily selecting an image on the back or a screen displayed on the PC monitor with a monitor attached to the helmet of the welder during welding. Is displayed.
8) By reproducing various kinds of information on the monitor attached to the welder's helmet after welding, the same situation can be reproduced while actually welding the situation, so that good and bad points can be learned repeatedly.
9) Efficient learning is possible by repeatedly displaying and reproducing not only the welding result of the person himself but also the image data of the expert who should serve as a model.
10) Information recorded / analyzed during welding is recorded in an external recording device, and images and audio signals equivalent to the device being welded can be reproduced on a PC without a welding device, making it independent of time and place. Learn as needed.
11) Not only manual welding skills, but also by fixing the welding torch to the drive part that photographs the welding torch and backside bead, it can be used in the process of developing new technology as an automatic welding device. It has an effective function for understanding and solving problems at the time of new technology development.
12) Also, it is possible to train using the above automatic welding mechanism and manually send a welding rod to the welding technician (welding metal added from the outside to secure the amount of weld metal). By making it possible to carry out the training for feeding the rod independently, the efficiency of the training can be dramatically increased by feeding the filler rod while confirming the state of the molten pool calmly. Under normal conditions, it is often impossible to judge whether welding is not successful or the effect of the welding torch or the feed of the filler rod is bad, whereas welding is performed automatically in an ideal state, and the trainer performs welding. Learning efficiency improves by training exclusively on the feeding of the bar.
13) Objective learning is possible by studying many examples of the state change of the molten pool due to the difference in the feeding method of the filler rod in advance while viewing the images. Can understand education from experts more specifically.
また本発明の溶接部品質評価装置によると、以下の効果を奏することができる。
１）トーチに取り付けた超小型カメラにより全溶接中のアークの発生状況と溶融池の挙動およびトーチ挙動を画像記録として記録するとともに、電圧電流信号とを同期して記録でき、必要に応じて外部モニターにより溶接状況を再現できる。
２）画像および電圧電流信号をリアルタイムで解析し、溶接状態が悪化する傾向を示すときに、溶接者にリアルタイムで音声信号あるいは画像信号により通知可能である。
３）該当溶接作業において、その標準的な状態と異なる状況が発生した場合、その事象の発生した時刻およびそのときの画像の特徴（溶融池の形状、アーク長さ）と電圧電流信号の特徴（平均値とその時間帯の標準偏差など）を全体の平均値とともに別途記録保存すること、あるいは完成した装置仕様書にその情報を添付することにより、その装置の長時間稼動時になんらかの異常が発生したときに、原因究明の早期解決の情報として利用可能である。
４）画像および電圧電流信号とを標準化して記録保存し、出荷した装置の長時間経過による事故的事象の無発生あるいは発生記録と対比することが可能となり、評価精度向上に資する。 Moreover, according to the welded part quality evaluation apparatus of this invention, there can exist the following effects.
1) With the ultra-small camera attached to the torch, it is possible to record the state of arc generation during welding, the behavior of the weld pool and the torch behavior as an image record, and record the voltage and current signal in synchronization, and externally if necessary. The welding situation can be reproduced by a monitor.
2) When the image and the voltage / current signal are analyzed in real time and the welding state tends to deteriorate, the welder can be notified in real time by an audio signal or an image signal.
3) If a situation different from the standard state occurs in the welding operation, the time when the event occurred, the characteristics of the image (the shape of the molten pool, the arc length), and the characteristics of the voltage / current signal ( If the average value and the standard deviation of the time zone are recorded and saved separately together with the overall average value, or if the information is attached to the completed device specification, some abnormality occurred during long-term operation of the device. Sometimes it can be used as information for early resolution of cause investigation.
4) It is possible to standardize and store images and voltage / current signals and to compare them with the occurrence or no occurrence of accidents due to the long-term progress of the shipped equipment, which contributes to the improvement of evaluation accuracy.
１）トーチに取り付けた超小型カメラにより全溶接中のアークの発生状況と溶融池の挙動およびトーチ挙動を画像記録として記録するとともに、電圧電流信号とを同期して記録でき、必要に応じて外部モニターにより溶接状況を再現できる。
２）画像および電圧電流信号をリアルタイムで解析し、溶接状態が悪化する傾向を示すときに、溶接者にリアルタイムで音声信号あるいは画像信号により通知可能である。
３）該当溶接作業において、その標準的な状態と異なる状況が発生した場合、その事象の発生した時刻およびそのときの画像の特徴（溶融池の形状、アーク長さ）と電圧電流信号の特徴（平均値とその時間帯の標準偏差など）を全体の平均値とともに別途記録保存すること、あるいは完成した装置仕様書にその情報を添付することにより、その装置の長時間稼動時になんらかの異常が発生したときに、原因究明の早期解決の情報として利用可能である。
４）画像および電圧電流信号とを標準化して記録保存し、出荷した装置の長時間経過による事故的事象の無発生あるいは発生記録と対比することが可能となり、評価精度向上に資する。 Moreover, according to the welded part quality evaluation apparatus of this invention, there can exist the following effects.
1) With the ultra-small camera attached to the torch, it is possible to record the state of arc generation during welding, the behavior of the weld pool and the torch behavior as an image record, and record the voltage and current signal in synchronization, and externally if necessary. The welding situation can be reproduced by a monitor.
2) When the image and the voltage / current signal are analyzed in real time and the welding state tends to deteriorate, the welder can be notified in real time by an audio signal or an image signal.
3) If a situation different from the standard state occurs in the welding operation, the time when the event occurred, the characteristics of the image (the shape of the molten pool, the arc length), and the characteristics of the voltage / current signal ( If the average value and the standard deviation of the time zone are recorded and saved separately together with the overall average value, or if the information is attached to the completed device specification, some abnormality occurred during long-term operation of the device. Sometimes it can be used as information for early resolution of cause investigation.
4) It is possible to standardize and store images and voltage / current signals and to compare them with the occurrence or no occurrence of accidents due to the long-term progress of the shipped equipment, which contributes to the improvement of evaluation accuracy.
本発明の溶接技量評価装置や溶接部品質評価装置におけるカメラとしては、画像を電気信号に変換する際に、受光素子が光から発生した電荷を読み出すために電荷結合素子 (Charge Coupled Device) と呼ばれる回路素子を用いて転送を行うことができるＣＣＤカメラを好適に例示することができる。また、トーチカメラが取り付けられている溶接トーチは、溶接技量評価装置の場合、電極と母材との距離が常に一定になる自動溶接機用であっても、高さが変動する手動溶接用であってもよいが、溶接部品質評価装置の場合は手動溶接用であることが好ましい。
As a camera in the welding skill evaluation apparatus and welded part quality evaluation apparatus of the present invention, when converting an image into an electrical signal, the light receiving element is referred to as a charge coupled device (Charge Coupled Device) to read out the electric charges generated from the light. A CCD camera capable of performing transfer using circuit elements can be suitably exemplified. In addition, a welding torch equipped with a torch camera is used for manual welding where the distance between the electrode and the base metal is always constant, even if it is for an automatic welding machine where the distance between the electrode and the base material is constant. In the case of a welded part quality evaluation apparatus, it is preferably for manual welding.
また、本発明の溶接技量評価装置や溶接部品質評価装置における上記記憶装置としては、溶融池観察カメラと裏波観察カメラとトーチカメラとからの画像情報と溶接電流・電圧信号に基づき、溶接施工状態の記録保持・管理・信号処理・判定等をオンラインで行うことができ、好ましくは演算処理機能や溶接条件判定機能を有する手段と、全体挙動撮影カメラの画像情報に基づき、溶接者の連続的な動作や姿勢に関する情報を計測し、この計測信号に基づき、溶接者の姿勢の他、頭や手の位置と動き等の動作など、溶接者の施工状態の記録保持・管理・信号処理・判定等をオンラインで行うことができる手段を合わせもつ装置を挙げることができる。
In addition, as the storage device in the welding skill evaluation device and welded part quality evaluation device of the present invention, welding work is performed based on image information and welding current / voltage signals from the weld pool observation camera, the back wave observation camera, and the torch camera. Status record keeping, management, signal processing, judgment, etc. can be performed online, preferably based on the means with arithmetic processing function and welding condition judgment function and the image information of the whole behavior shooting camera. Measures information related to various movements and postures, and records, maintains, manages, processes and signals signals the welder's construction status, such as the position and movement of the head and hands, as well as the posture of the welder, based on this measurement signal. An apparatus having a means capable of performing such as online can be cited.
上記溶接条件判定において、完全溶け込みに達した状況と判定する基準としては、溶融池の落ち込み、固腋界面で液体側表面の下降、液体表面部面積低下、液体表面温度の増加率、液体表面部での湯流れの変化、液体表面部でのスラグ量変化率、スラグの挙動変化、液体表面振動数周期延長という諸要素が考えられ、これら判定要素の数値化は、溶接者の技量及び要求される溶接速度により個々の値は大幅に異なり、絶対値で与えることは困難であるが、例えば材質をＳＵＳ３０４、板厚を３ｍｍ、電流を１００Ａ、アーク長を３ｍｍとした場合、個々溶接者の溶接条件で裏まで溶けていない限界条件での数値に対して裏面まで完全に溶け込んだ状態での以下の数値は次のように変動する。溶融池表面の母材表面に対する落ち込みは０．２～１．０ｍｍ、溶接池前方部の界面落ち込み０．０５～０．３ｍｍ、溶融池表面積は変動の誤差範囲で変化は検出できず、液体表面部の湯流れ状態も定量的な変動誤差範囲となり検出は難しい。液体表面部でのスラグ量は材質や裏面の状態に大きく依存し、ある程度の試行の結果により、有意な差が検出できる場合もある。液体表面振動数は１０秒程度値で有意さが検出できるが、実際の溶接作業中に品質評価判定に用いるには時間の遅れが大きく実用的ではない。
In the above welding condition determination, the criteria for determining that the state has reached complete penetration are as follows: molten pool sag, liquid side surface descent at solid interface, liquid surface area decrease, liquid surface temperature increase rate, liquid surface part There are various factors such as changes in hot water flow, slag amount change rate at the liquid surface, slag behavior change, and liquid surface frequency cycle extension. Individual values vary greatly depending on the welding speed, and it is difficult to give an absolute value. For example, when the material is SUS304, the plate thickness is 3 mm, the current is 100 A, and the arc length is 3 mm, the welding of each individual welder The following numerical values in the state of being completely melted up to the back surface fluctuate as follows with respect to the numerical values in the limit condition that is not melted up to the back by the conditions. The drop of the molten pool surface from the base metal surface is 0.2 to 1.0 mm, the interface drop at the front of the weld pool is 0.05 to 0.3 mm, and the surface area of the molten pool cannot be detected within the variation error range. The hot water flow state of the part is also in a quantitative fluctuation error range and is difficult to detect. The amount of slag at the liquid surface depends greatly on the material and the state of the back surface, and a significant difference may be detected depending on the results of some trials. The liquid surface frequency can be detected with a value of about 10 seconds, but it is not practical for use in quality evaluation during actual welding work because of a large time delay.
本発明の溶接技量評価装置における溶融池観察カメラと裏波観察カメラは、母材の上方と下方に設置され、溶接の進行とともに開先に沿って一体的に移動するようになっている。これら溶融池観察カメラと裏波観察カメラの移動速度は、所定のモデル速度とすることもできるし、また、溶接者の姿勢を撮影する全体挙動撮影カメラからの画像情報に基づき解析された溶接トーチの移動速度と同期した速度とすることができる。また、本発明の溶接技量評価装置には、溶接中に溶接者の溶接保護面に装着した小型モニターに、裏面の画像あるいはＰＣモニターに表示される画面などを任意に選択してリアルタイム表示することに加え、溶接状況を溶接状態に応じた音声信号で発信できる機構を備えるものが好ましい。
The weld pool observation camera and the back wave observation camera in the welding skill evaluation apparatus of the present invention are installed above and below the base material, and move integrally along the groove as welding progresses. The moving speed of the molten pool observation camera and the back wave observation camera can be set to a predetermined model speed, or a welding torch analyzed based on image information from the whole behavior imaging camera that images the posture of the welder. The speed can be synchronized with the movement speed of In addition, the welding skill evaluation apparatus of the present invention can select and display in real time an image on the back surface or a screen displayed on a PC monitor on a small monitor attached to the welder's weld protection surface during welding. In addition, it is preferable to have a mechanism capable of transmitting a welding state with an audio signal corresponding to the welding state.
本発明の溶接部品質評価装置における伝達手段としては、溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラで撮像された画像データに基づき、画像解析、溶接状態判定及び溶接挙動・条件改善指示を、ケーブルを介して、溶接保護面に装着した小型モニターに視覚情報又は聴覚情報として伝達、特に異常時（溶接溶け込み不良など）には危険シグナルとして伝達するようにしたものである。
As a transmission means in the welded part quality evaluation apparatus of the present invention, image analysis, welding state determination, and welding behavior / condition improvement based on image data captured by a torch camera that is attached to a welding torch and monitors a molten state and an arc state The instructions are transmitted as visual or auditory information via a cable to a small monitor attached to the welding protective surface, and in particular, as a danger signal when abnormal (such as poor weld penetration).
本発明の溶接技量評価装置の模式図を図１に、本発明の溶接技量評価装置の一態様の側面図を図２に、正面図を図３にそれぞれ示す。図中、１は溶接トーチ、２はトーチカメラ、３は裏波観察カメラ、４は溶融池観察カメラ、５は全体挙動撮影カメラ、６は作業台、７はモニター、８は溶融池観察カメラと裏波観察カメラの連結体、９は溶融池観察カメラと裏波観察カメラの同期移動用モータ、Ｍは溶融池、Ｂは母材をそれぞれ示す。
FIG. 1 is a schematic diagram of the welding skill evaluation apparatus of the present invention, FIG. 2 is a side view of an embodiment of the welding skill evaluation apparatus of the present invention, and FIG. 3 is a front view thereof. In the figure, 1 is a welding torch, 2 is a torch camera, 3 is a back wave observation camera, 4 is a molten pool observation camera, 5 is a whole behavior imaging camera, 6 is a work table, 7 is a monitor, and 8 is a molten pool observation camera. A coupled body of back wave observation cameras, 9 is a motor for synchronous movement of the molten pool observation camera and the back wave observation camera, M is a molten pool, and B is a base material.
図１～３において、裏波観察カメラ３は、作業台６上に開先を介して並置された一対の母材Ｂの開先裏面側に設けられており、溶融池観察カメラ４は、裏波観察カメラ３と連結体８を介して開先に対して直交する方向に移動可能で、かつトーチ挙動と溶融池Ｍ表面挙動を観察することができるように、開先斜め上方に傾斜させて設けられている。溶融池観察カメラ４と裏波観察カメラ３は同期移動用モータ９の駆動により、溶接の進行とともに開先に沿って移動する（図３参照）。
1 to 3, the back wave observation camera 3 is provided on the groove back side of a pair of base materials B juxtaposed on the work table 6 via the groove. It is possible to move in the direction orthogonal to the groove via the wave observation camera 3 and the connecting body 8 and to tilt the groove obliquely upward so that the torch behavior and the molten pool M surface behavior can be observed. Is provided. The weld pool observation camera 4 and the back wave observation camera 3 are moved along the groove as the welding progresses by driving the synchronous movement motor 9 (see FIG. 3).
本発明の溶接技術は、造船、機械、自動車、建設、橋梁、充填タンクなどの産業界に広く利用できる。
The welding technique of the present invention can be widely used in industries such as shipbuilding, machinery, automobiles, construction, bridges and filling tanks.
１ 溶接トーチ
２ トーチカメラ
３ 裏波観察カメラ
４ 溶融池観察カメラ
５ 全体挙動撮影カメラ
６ 作業台
７ モニター
８ 溶融池観察カメラと裏波観察カメラの連結体
９ 溶融池観察カメラと裏波観察カメラの同期移動用モータ
Ｍ 溶融池
Ｂ 母材 1 Welding torch
2 Torch camera
3 Back-wave observation camera
4 molten pool observation camera
5 Overall behavior photography camera 6 Work table 7Monitor 8 Connected body of molten pool observation camera and back wave observation camera 9 Motor M for synchronized movement of molten pool observation camera and back wave observation camera M molten pool B Base material
２ トーチカメラ
３ 裏波観察カメラ
４ 溶融池観察カメラ
５ 全体挙動撮影カメラ
６ 作業台
７ モニター
８ 溶融池観察カメラと裏波観察カメラの連結体
９ 溶融池観察カメラと裏波観察カメラの同期移動用モータ
Ｍ 溶融池
Ｂ 母材 1 Welding torch
2 Torch camera
3 Back-wave observation camera
4 molten pool observation camera
5 Overall behavior photography camera 6 Work table 7
Claims (2)
- 溶接装置に移動可能に固定され溶接の進行とともに移動する、トーチ挙動と溶融池表面挙動を観察する溶融池観察カメラ、前記溶融池観察カメラと一体で移動する溶融池裏側の溶融状態を計測する裏波観察カメラ、溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラ、溶接者の姿勢と溶接部の大きな状況を撮影する全体挙動撮影カメラ、これら４台のカメラにより撮像された画像を、溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに表示するモニター、前記４台のカメラにより撮像された画像情報を、溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに記憶・解析する記憶装置、及び、前記４台のカメラにより撮像された画像のいずれかを表示する小型モニターを装着した溶接保護面を装備した溶接技量評価装置。 A weld pool observation camera that observes the torch behavior and the molten pool surface behavior that is movably fixed to the welding apparatus and moves with the progress of welding, and a back surface that measures the molten state on the back side of the molten pool moving together with the molten pool observation camera. A wave observation camera, a torch camera that is attached to a welding torch and monitors the melted state and the arc state, an overall behavior photographing camera that photographs the welder's posture and the large state of the welded portion, images captured by these four cameras, Monitor displaying with welding current / voltage signal obtained from welding current / welding voltage measuring device, and storing image information taken by the four cameras together with welding current / voltage signal obtained from welding current / welding voltage measuring device -Welding protection equipped with a storage device for analysis and a small monitor that displays one of the images captured by the four cameras. Welding skill evaluation device equipped with a surface.
- 溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラ、該トーチカメラにより撮像された画像情報を処理して溶融池状態とアーク状態を計測し、その画像情報を溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに、蓄積した溶接部品質評価データと比較して、溶接部品質を判定・評価する判定・評価装置、該判定・評価装置からリアルタイムに溶接部品質評価を行い溶接士へ状況を伝達する伝達手段を装備した溶接部品質評価装置であって、前記溶接部品質評価データが、溶接装置に移動可能に固定され溶接の進行とともに移動する、トーチ挙動と溶融池表面挙動を観察する溶融池観察カメラと、前記溶融池観察カメラと一体で移動する溶融池裏側の溶融状態を計測する裏波観察カメラと、溶接トーチに取り付けて溶融状態とアーク状態を監視するトーチカメラとにより撮像された画像情報を、溶接電流・溶接電圧測定装置から得られる溶接電流・電圧信号とともに記憶・解析する記憶装置に蓄積されているデータベース中のデータである、溶接施工終了時には同時に品質確認も完了を可能とする溶接部品質評価装置。 A torch camera that is attached to a welding torch and monitors a molten state and an arc state, processing image information captured by the torch camera to measure a molten pool state and an arc state, and measuring the image information as a welding current / weld voltage measuring device Compared with the welding current and voltage signals obtained from the welding quality assessment data accumulated, the judgment / evaluation device for judging / evaluating the quality of the welded portion, welding quality evaluation in real time from the judgment / evaluation device and welding Welding device quality evaluation device equipped with a transmission means for transmitting the situation to a welder, wherein the weld quality evaluation data is movably fixed to the welding device and moves with the progress of welding and the weld pool surface behavior A welding pool observation camera, a back wave observation camera for measuring the molten state behind the molten pool moving together with the molten pool observation camera, and a welding torch A database that is stored in a storage device that stores and analyzes image information captured by a torch camera that monitors the melted state and the arc state together with a welding current / voltage signal obtained from a welding current / welding voltage measuring device. This is a weld quality evaluation device that can complete quality confirmation at the same time when welding is completed.
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| JP2011-235415 | 2011-10-26 | ||
| JP2011235415A JP2013091086A (en) | 2011-10-26 | 2011-10-26 | Welding skill evaluation device and weld zone quality evaluation device |
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