CN103487136B - A kind of method utilizing resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect welding splash - Google Patents
A kind of method utilizing resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect welding splash Download PDFInfo
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Abstract
Utilize resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect a method for welding splash, step is as follows: the structural load acoustic emission signal of Real-time Collection resistance spot welding process, draws out dynamic waveform figure; Extract the acoustic emission signal of welding splash; The amplitude distribution of statistical signal pulse; Amplitude size is divided into some grade M
i, and by exceeding the acoustic emission signal Ring-down count N of each amplitude levels
iadd up respectively; Amplitude levels value M is represented with X-axis
i, Y-axis represents by exceeding each amplitude levels value M
ithe logarithm value log of the accumulative acoustic emission signal Ring-down count obtained
10n
i, obtain scatter diagram; Carry out fitting a straight line; According to the right-angle triangle that fitting a straight line and X-axis and Y-axis are formed, triangle area is the energy equivalence of corresponding resistance spot welding process welding splash.Equivalent value is larger, and show that welding splash is larger, namely the impact of welding splash on nugget quality is larger.The present invention can the quantization assessment welding size rank of splash and pattern thereof exactly, realize to resistance spot welding process welding splash quick, accurate, quantitatively detect.
Description
Technical field
The present invention relates to a kind of utilization and detect the detection method that the resistance spot welding process Acoustic Emission Signal Energy equivalent qualitative assessment obtained welds splash in real time, the resistance spot welding quality being applicable to common metal thin-plate structure muterial detects fast.
Background technology
Resistance spot welding is a kind of welding method be widely used in as automobile making, nearly 3000-6000 resistance spot welding solder joint in a Modern Car.Therefore, the detection of resistance spot welding quality of welding spot is extremely important, and in welding process, high efficiency quality of welding spot sensing and check and evaluation thereof are for optimized production process, enhances productivity significant with welding quality.Welding splash is a kind of phenomenon common in metal material resistance spot welding, its producing cause is because welding current molten material makes linkage interface forming core, nugget produces the rapid expanding of volume because of melting nucleation, when welding foroe and nugget plastic area are not enough to the volumetric expansion suppressing nugget, the liquid metal ejection of nugget inside, thus form welding splash.Welding splash causes the loss of nugget metal, thus affects the forming core quality of nugget.When welding splash and being less, the load-bearing capacity of butt welding point, almost without impact, when welding splash and being larger, but can reduce the load-bearing capacity of solder joint.Therefore, both needed in welding process to reduce splash, to common welding splash, also needed a kind of detection method efficiently of easy realization.But in resistance spot welding process, the nucleation process of nugget can not directly observe, this is the impact judging welding splash, and then detection resistance spot welding quality of welding spot brings difficulty.Especially for the phenomenon of welding in the common nugget nucleation process of this class of splash, lack for a long time and quantize detection, appraisal procedure reliably.Therefore, in resistance spot welding process, the sensing and analyzing of nugget forming core quality information has great importance for evaluation resistance spot welding quality of welding spot.For this reason, researcher adopts multiple method to detect nugget nucleation process to characterize nugget forming core quality.
The real-time detection method of dot weld nugget diameter disclosed in Chinese patent literature CN1609622A adopts following steps: get and carry out multiple spot welding with the welded specimen of weldment same thickness, obtained the dynamic resistance curve of often by surveying and calculating; And then obtain the metastable state resistance value r of often
d; Cut welded specimen open along binding face, measure the nugget size d of each solder joint
core; According to each nugget diameter d
corewith metastable state resistance value r
dcorresponding relation, draw out metastable state resistance value r
dwith nugget size d
corerelation curve; By the r of different-thickness material
d-d
corein computer systems, which, when certain material of spot welding, computer system first obtains the metastable state resistance value r of this solder joint to profile memory
d, then with the r of same thickness material
d-d
corecurve compares and can obtain corresponding nugget size, when nugget size is less than the standard value of setting, judges that quality of welding spot is defective, realizes detecting in real time.
Aluminium alloy resistance spot welding nugget size real-time detection method disclosed in Chinese patent literature CN101241001A adopts following steps: gather the electrode displacement signals during resistance in pinpoint welding procedure, and draw out electrode displacement signals during resistance curve map; Expansion displacement and forging and stamping displacement two eigenwerts are extracted from the electrode displacement signals during resistance curve of gained; Welded test plate (panel) is torn, nugget formation in resistance spot welding diameter is surveyed, set up the sample pair that the eigenwert extracted is corresponding with the nugget size of actual measurement, and form training set; Set up artificial nerve network model, and train according to BP algorithm to model with gained sample, realize the mapping from eigenwert to nugget size; Artificial nerve network model is two inputs, an output, a middle hidden layer, and the number of hidden layer node is the structure of 5, and the transfer function of hidden layer is Sigmoid function, and the transfer function of output layer is linear function; The model trained is used for the on-line real-time measuremen of aluminium alloy resistance spot welding nugget size.
The method of multi-information merging technology determination aluminum alloy plate materials nugget formation in resistance spot welding area disclosed in Chinese patent literature CN1220034C adopts following steps: according to wavelet package transforms and energy spectrum principle, foundation information entropy principle, foundation model analysis principle, calculate the characteristic quantity of electrode voltage in pinpoint welding procedure, electric current, electrode displacement and voice signal, set up neural network model, by characteristic quantity and nugget area, neural network model is trained.The nugget area that neural network model calculates contrasts with actual measurement nugget area, determines error amount, and adjustment neural network model, until reach error requirements scope.
In resistance spot welding process, along with resistance spot welding process, material properties change, will there is corresponding change in the rule of energy conversion.Especially the welding splash occurred in nugget nucleation process is also a kind of immediate release form of the energy of material internal savings.The structural load acoustic emission signal of the different-energy equivalent discharged according to certain rule can be shown as, and welding splash is when varying in size, the structural load acoustic emission splash signal energy equivalent discharged has corresponding difference, this be the real-time sensing of resistance spot welding process splash information and detect fast, assessment provides possibility.
Summary of the invention
In order to detect the welding splash produced in resistance spot welding process more quickly, and quantitative evaluation, the present invention is directed to the resistance spot welding of common metal thin-plate structure muterial, provide a kind of method utilizing resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect welding splash, the method is easily implemented, be convenient to assessment judge, Non-Destructive Testing, has detection sensitivity high, and testing result is reliable, detection method is quick, and testing cost consumes the advantages such as low.
The present invention takes following technical scheme:
A kind of method utilizing resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect welding splash, the method detects the splash information of resistance spot welding by the structural load acoustic emission signal detected in real time in resistance spot welding process, and the step of described detection method is as follows:
(1) the structural load acoustic emission signal of Real-time Collection resistance spot welding process, and draw out the dynamic waveform figure of signal;
(2) acoustic emission signal of welding splash is extracted by the structural load acoustic emission signal dynamic waveform of resistance spot welding process;
(3) amplitude distribution of statistics welding sputter transmit signal pulse;
(4) according to the amplitude distribution of welding sputter transmit signal pulse, amplitude size is divided into some grade M
i(number of degrees is at least more than five), and by exceeding the acoustic emission signal Ring-down count N of each amplitude levels
iadd up respectively, obtain welding sputter and to transmit Ring-down count N
iadd up with signal pulse changes in amplitude;
(5) amplitude levels value M is represented with X-axis
i, Y-axis represents by exceeding each amplitude levels value M
ithe logarithm value log of the accumulative acoustic emission signal Ring-down count obtained
10n
i, obtain scatter diagram;
(6) carry out fitting a straight line according to scatter diagram, obtain fitting a straight line equation;
(7) according to the right-angle triangle that fitting a straight line and X-axis and Y-axis are formed, obtain the area of this right-angle triangle, be the energy equivalence of corresponding resistance spot welding process welding splash.
Described resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively detects the method for welding splash, to the judgment principle of welding splash size quantitative assessment be: welding splash energy equivalence value is larger, show that welding splash is larger, namely the impact of welding splash on nugget quality is larger.
Innovation of the present invention is structural load acoustic emission signal in the resistance spot welding process real-time monitored as information source, by detecting the structural load acoustic emission signal of welding splash, extract the characteristic parameter such as amplitude, Ring-down count of welding splash signal, and utilize energy equivalence method quantization assessment to weld the size rank of splash and pattern thereof, realize to resistance spot welding process welding splash quick, accurate, quantitatively detect.
The present invention is applicable in real time, detect fast and evaluation resistance spot welding process welds splash to the impact of nugget forming core quality.Compared with prior art, the present invention has the following advantages:
(1) only need a kind of signal of structural load acoustic emission gathering resistance spot welding process, acquisition system easily realizes, and acquisition system design and manufacture cost is comparatively cheap;
(2) characteristic parameter such as structural load acoustic emission splash signal amplitude, Ring-down count during the welding splash of extracting is all the key parameter close with welding splash variation relation, makes testing result reliability high;
(3) quantitatively can detect and evaluate the size rank of welding splash, pattern and impact thereof in fast ground, being conducive to improving the evaluation to nugget formation in resistance spot welding quality;
(4) detection efficiency is high, and assessment method is simple, and the real-time quality being applicable to resistance spot welding process detects and fast mass evaluation, and the material ranges be suitable for is comparatively wide, and practicality is stronger.
Accompanying drawing explanation
Fig. 1 is the structural load acoustic emission signal waveform of the galvanized steel sheet resistance spot welding process that embodiment 1 detects.
Fig. 2 is that the sputter extracted in the acoustic emission signal of structural load shown in Fig. 1 transmits waveform.
Fig. 3 is that loose corresponding with segmentation Ring-down count logarithm value of the pulse height of the signal of splash shown in Fig. 2 distributes and fitting a straight line.
Fig. 4 is the structural load acoustic emission signal waveform of the galvanized steel sheet resistance spot welding process that embodiment 2 detects.
Fig. 5 is that the sputter extracted in the acoustic emission signal of structural load shown in Fig. 4 transmits waveform.
Fig. 6 is that loose corresponding with segmentation Ring-down count logarithm value of the pulse height of the signal of splash shown in Fig. 5 distributes and fitting a straight line.
Fig. 7 is the structural load acoustic emission signal waveform of the galvanized steel sheet resistance spot welding process that embodiment 3 detects.
Fig. 8 is that the sputter extracted in the acoustic emission signal of structural load shown in Fig. 7 transmits waveform.
Fig. 9 is that loose corresponding with segmentation Ring-down count logarithm value of the pulse height of the signal of splash shown in Fig. 8 distributes and fitting a straight line.
In figure: the welding splash signal in the welding splash signal in 1 embodiment 1 waveform, 2 embodiment 1 waveforms, the welding splash signal in 3 embodiment 1 waveforms.
Embodiment
Below in conjunction with specific embodiment, set forth the present invention further.
Embodiment 1:
Workpiece to be welded is the overlap joint of the galvanized steel plain sheet thin-slab construction of two pieces of thickness 1mm.The major weld process parameters adopted is: welding current is 10000A, and the welding current duration is 8 cycles, and welding foroe is 0.15MPa.
In welding, the structural load acoustic emission signal of Real-time Collection resistance spot welding process, draws structural load acoustic emission signal dynamic curve diagram by analysis software, as shown in Figure 1.
Welding process different phase can be picked out by oscillogram, extract welding splash signal 1, as shown in Figure 2.Can find out, the pattern of this welding splash is the welding splash event of monophone transmit events.
The amplitude distribution of statistics welding sputter transmit signal pulse.According to this distribution, amplitude size is divided into 10 grades, i.e. M
1=0.3, M
2=0.6, M
3=0.9, M
4=1.2, M
5=1.5, M
6=1.8, M
7=2.1, M
8=2.4, M
9=2.7, M
10=3.0.By the acoustic emission signal Ring-down count N exceeding each amplitude levels
iadd up respectively, obtain welding sputter and to transmit Ring-down count N
istatistics with signal pulse ten range value changes: N
1=286, N
2=80, N
3=53, N
4=45, N
5=39, N
6=33, N
7=27, N
8=24, N
9=22, N
10=19.
Ten amplitude levels value M are represented with X-axis
i, Y-axis represents and amplitude levels value M
ithe logarithm value log of corresponding acoustic emission signal Ring-down count
10n
i, obtain scatter diagram, as shown in Figure 3.
To scatter diagram fitting a straight line, obtain fitting a straight line as shown in Figure 3, its fit equation is Y=2.19-0.34X.The area value obtaining the right-angle triangle that fitting a straight line and X-axis and Y-axis are formed is: 7.05, and the energy equivalence of the welding splash namely produced during welding is 7.05.
This result shows, utilizes the method for the invention can realize detection and the qualitative assessment of the welding splash produced in resistance spot welding process comparatively accurately and quickly.
Embodiment 2:
Workpiece to be welded is the overlap joint of the galvanized steel plain sheet thin-slab construction of two pieces of thickness 1mm.The major weld process parameters adopted is: welding current is 11000A, and the welding current duration is 8 cycles, and welding foroe is 0.15MPa.
In welding, the structural load acoustic emission signal of Real-time Collection resistance spot welding process, draws structural load acoustic emission signal dynamic curve diagram by analysis software, as shown in Figure 4.
Welding process different phase can be picked out by oscillogram, extract welding splash signal 1, as shown in Figure 5.Can find out, the pattern of this welding splash is the welding splash event of alliteration transmit events composition.
The amplitude distribution of statistics welding sputter transmit signal pulse.According to this distribution, amplitude size is divided into 10 grades, i.e. M
1=0.3, M
2=0.6, M
3=0.9, M
4=1.2, M
5=1.5, M
6=1.8, M
7=2.1, M
8=2.4, M
9=2.7, M
10=3.0.By the acoustic emission signal Ring-down count N exceeding each amplitude levels
iadd up respectively, obtain welding sputter and to transmit Ring-down count N
istatistics with signal pulse ten range value changes: N
1=427, N
2=143, N
3=100, N
4=73, N
5=57, N
6=48, N
7=44, N
8=34, N
9=27, N
10=22.
Ten amplitude levels value M are represented with X-axis
i, Y-axis represents and amplitude levels value M
ithe logarithm value log of corresponding acoustic emission signal Ring-down count
10n
i, obtain scatter diagram, as shown in Figure 6.
To scatter diagram fitting a straight line, obtain fitting a straight line as shown in Figure 6, its fit equation is Y=2.46-0.40X.The area value obtaining the right-angle triangle that fitting a straight line and X-axis and Y-axis are formed is: 7.56, and the energy equivalence of the welding splash namely produced during welding is 7.56.
This result shows, utilizes the method for the invention can realize detection and the qualitative assessment of the welding splash produced in resistance spot welding process comparatively accurately and quickly.
Embodiment 3:
Workpiece to be welded is the overlap joint of the galvanized steel plain sheet thin-slab construction of two pieces of thickness 1mm.The major weld process parameters adopted is: welding current is 10000A, and the welding current duration is 8 cycles, and welding foroe is 0.15MPa.
In welding, the structural load acoustic emission signal of Real-time Collection resistance spot welding process, draws structural load acoustic emission signal dynamic curve diagram by analysis software, as shown in Figure 7.
Welding process different phase can be picked out by oscillogram, extract welding splash signal 1, as shown in Figure 8.Can find out, the pattern of this welding splash is the welding splash event of three acoustie emission event compositions.
The amplitude distribution of statistics welding sputter transmit signal pulse.According to this distribution, amplitude size is divided into 10 grades, i.e. M
1=0.3, M
2=0.6, M
3=0.9, M
4=1.2, M
5=1.5, M
6=1.8, M
7=2.1, M
8=2.4, M
9=2.7, M
10=3.0.By the acoustic emission signal Ring-down count N exceeding each amplitude levels
iadd up respectively, obtain welding sputter and to transmit Ring-down count N
istatistics with signal pulse ten range value changes: N
1=608, N
2=298, N
3=198, N
4=154, N
5=125, N
6=107, N
7=88, N
8=74, N
9=64, N
10=55.
Ten amplitude levels value M are represented with X-axis
i, Y-axis represents and amplitude levels value M
ithe logarithm value log of corresponding acoustic emission signal Ring-down count
10n
i, obtain scatter diagram, as shown in Figure 9.
To scatter diagram fitting a straight line, obtain fitting a straight line as shown in Figure 9, its fit equation is Y=2.69-0.34X.The area value obtaining the right-angle triangle that fitting a straight line and X-axis and Y-axis are formed is: 10.64, and the energy equivalence of the welding splash namely produced during welding is 10.64.
This result shows, utilizes the method for the invention can realize detection and the qualitative assessment of the welding splash produced in resistance spot welding process comparatively accurately and quickly.
Relatively above three examples can be found out, present invention achieves the qualitative assessment to the detection of the welding splash in resistance spot welding process and pattern, rank size.Embodiment 1 and embodiment 3 contrast visible, although adopt identical welding parameter, Spray Mode in welding process is not identical with splash rank size, and embodiment 2 adopts the welding parameter different from above-mentioned two examples, there occurs welding splashes different with it, the present invention all can realize detecting and assessment to above-mentioned welding splash.This also show agility, sensitivity and reliability that the method for the invention has.
Claims (1)
1. the method utilizing resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect welding splash, the method detects the splash information of resistance spot welding by the structural load acoustic emission signal detected in real time in resistance spot welding process, and the step of described detection method is as follows:
(1) the structural load acoustic emission signal of Real-time Collection resistance spot welding process, and draw out the dynamic waveform figure of signal;
(2) acoustic emission signal of welding splash is extracted by the structural load acoustic emission signal dynamic waveform of resistance spot welding process;
(3) amplitude distribution of statistics welding sputter transmit signal pulse;
(4) according to the amplitude distribution of welding sputter transmit signal pulse, amplitude size is divided into and is at least more than five grade M
i, and by exceeding the acoustic emission signal Ring-down count N of each amplitude levels
iadd up respectively, obtain welding sputter and to transmit Ring-down count N
iadd up with signal pulse changes in amplitude;
(5) amplitude levels value M is represented with X-axis
i, Y-axis represents by exceeding each amplitude levels value M
ithe logarithm value log of the accumulative acoustic emission signal Ring-down count obtained
10n
i, obtain scatter diagram;
(6) carry out fitting a straight line according to scatter diagram, obtain fitting a straight line equation;
(7) according to the right-angle triangle that fitting a straight line and X-axis and Y-axis are formed, obtain the area of this right-angle triangle, be the energy equivalence of corresponding resistance spot welding process welding splash, welding splash welding splash size is detected according to energy equivalence, energy equivalence value is larger, show that welding splash is larger, namely the impact of welding splash on nugget quality is larger.
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| CN104007182B (en) * | 2014-06-12 | 2016-04-27 | 重庆理工大学 | A kind of method utilizing acoustic emission signal frequency spectrum quantitatively to detect nugget formation in resistance spot welding forming core quality |
| CN103994821B (en) * | 2014-06-12 | 2016-03-23 | 重庆理工大学 | A kind of method utilizing acoustic emission signal frequency spectrum real-time quantitative to assess resistance spot welding splash |
| CN106808063B (en) * | 2017-02-22 | 2018-04-03 | 重庆理工大学 | A kind of method based on electric arc acoustic emission signal sensor monitoring electric arc arc length |
| CN106881516B (en) * | 2017-02-22 | 2018-05-01 | 重庆理工大学 | A kind of method using arc voltage signal monitoring electric arc arc length |
| JP2019141851A (en) * | 2018-02-16 | 2019-08-29 | マツダ株式会社 | Method and device for detecting expulsion and surface flash in electric resistance welding |
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