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
一种利用电阻点焊过程声发射信号能量当量定量检测焊接喷溅的方法，步骤如下：实时采集电阻点焊过程的结构负载声发射信号，绘制出动态波形图；提取出焊接喷溅的声发射信号；统计信号脉冲的幅度分布；将幅度大小分为若干等级Mi，并按超过各幅度等级的声发射信号振铃计数Ni分别进行累计；以X轴表示幅度等级值Mi，Y轴表示按超过各幅度等级值Mi累计得到的声发射信号振铃计数的对数值log10Ni，得到散点分布图；进行直线拟合；根据拟合直线与X轴和Y轴形成的直角三角形，三角形面积即为对应的电阻点焊过程焊接喷溅的能量当量。当量值越大，表明焊接喷溅越大，即焊接喷溅对熔核质量的影响越大。本发明可准确地量化评定焊接喷溅的大小级别及其模式，实现对电阻点焊过程焊接喷溅的快速、准确、定量检测。
A method for quantitatively detecting welding spatter by using the energy equivalent of the acoustic emission signal in the resistance spot welding process, the steps are as follows: collect the structural load acoustic emission signal in the resistance spot welding process in real time, draw a dynamic waveform diagram; extract the acoustic emission of the welding spatter Signal; statistics the amplitude distribution of the signal pulse; divide the amplitude into several levels M i , and accumulate the acoustic emission signal ringing count N i exceeding each amplitude level; the X axis represents the amplitude level value M i , and the Y axis Indicates the logarithmic value log 10 N i of the acoustic emission signal ringing count accumulated over each amplitude level value M i to obtain a scatter distribution diagram; perform straight line fitting; according to the right angle formed by the fitted straight line and the X-axis and Y-axis Triangle, the area of the triangle is the energy equivalent of welding spatter in the corresponding resistance spot welding process. The larger the equivalent value, the greater the welding spatter, that is, the greater the influence of welding spatter on the quality of the nugget. The invention can accurately quantitatively evaluate the size level and mode of the welding spatter, and realize the fast, accurate and quantitative detection of the welding spatter in the resistance spot welding process.
Description
技术领域technical field
本发明涉及一种利用实时检测得到的电阻点焊过程声发射信号能量当量定量评估焊接喷溅的检测方法，适用于常用金属薄板结构材料的电阻点焊质量快速检测。The invention relates to a detection method for quantitatively evaluating welding spatter by using the acoustic emission signal energy equivalent of the resistance spot welding process obtained by real-time detection, which is suitable for rapid detection of the resistance spot welding quality of commonly used metal thin plate structural materials.
背景技术Background technique
电阻点焊是一种广泛应用于作为汽车制造的焊接方法，一部现代轿车上大约有3000-6000个电阻点焊焊点。因此，电阻点焊焊点质量的检测非常重要，焊接过程中高效率的焊点质量传感及其检测评估对于优化生产工艺，提高生产效率和焊接质量具有重要意义。焊接喷溅是金属材料电阻点焊中常见的一种现象，其产生原因是由于焊接电流熔化材料使连接界面形核，熔核因熔化形核而产生体积的快速膨胀，当电极压力以及熔核塑性环不足以压制熔核的体积膨胀时，熔核内部的液态金属喷出，从而形成焊接喷溅。焊接喷溅造成了熔核金属的损失，从而影响熔核的形核质量。当焊接喷溅较小时，对焊点的承载能力几乎无影响，当焊接喷溅较大时，却能降低焊点的承载能力。因此，焊接过程中既需要减小喷溅，对常见的焊接喷溅，也需要一种容易实现的快捷的检测方法。然而，电阻点焊过程中，熔核的形核过程并不能直接观测到，这为判断焊接喷溅的影响，进而检测电阻点焊焊点质量带来了困难。尤其是对于焊接喷溅这一类常见的熔核形核过程中的现象，长期以来缺少可靠的量化检测、评估方法。因此，电阻点焊过程中熔核形核质量信息的传感及其分析对于评价电阻点焊焊点质量具有重要的意义。为此，研究者采用多种方法检测熔核形核过程以表征熔核形核质量。Resistance spot welding is a welding method widely used in automobile manufacturing. There are about 3000-6000 resistance spot welding spots on a modern car. Therefore, the detection of the quality of resistance spot welding solder joints is very important. High-efficiency solder joint quality sensing and its detection and evaluation during the welding process are of great significance for optimizing the production process, improving production efficiency and welding quality. Welding spatter is a common phenomenon in resistance spot welding of metal materials. It is caused by the nucleation of the connection interface due to the melting of the material by the welding current, and the rapid expansion of the nugget due to the melting nucleation. When the electrode pressure and the nugget When the plastic ring is not enough to suppress the volume expansion of the nugget, the liquid metal inside the nugget is ejected, thus forming welding spatter. Weld spatter causes the loss of nugget metal, which affects the nucleation quality of the nugget. When the welding spatter is small, it has almost no effect on the bearing capacity of the solder joints, but when the welding spatter is large, it can reduce the bearing capacity of the solder joints. Therefore, it is necessary to reduce spatter during the welding process, and an easy-to-implement and quick detection method is also required for common welding spatter. However, in the process of resistance spot welding, the nucleation process of the nugget cannot be directly observed, which makes it difficult to judge the influence of welding spatter and then detect the quality of resistance spot welding joints. Especially for welding spatter, a common phenomenon in nugget nucleation process, there has been a lack of reliable quantitative detection and evaluation methods for a long time. Therefore, the sensing and analysis of nugget nucleation quality information during resistance spot welding is of great significance for evaluating the quality of resistance spot welding joints. To this end, researchers use a variety of methods to detect the nucleation nucleation process to characterize the quality of nuclei nucleation.
中国专利文献CN1609622A公开的点焊熔核直径的实时检测方法采用如下步骤：取与焊接件相同厚度的焊接试样进行多点点焊，通过测量与计算获得每点的动态电阻曲线；进而获得每点的准稳态电阻值rD；沿贴合面剖开焊接试样，测量每个焊点的熔核直径d核；根据每个焊点熔核直径d核与准稳态电阻值rD的对应关系，绘制出准稳态电阻值rD与熔核直径d核关系曲线；将不同厚度材料的rD-d核曲线存储在计算机系统中，当点焊某种材料时，计算机系统先获得该焊点的准稳态电阻值rD，再与相同厚度材料的rD-d核曲线进行比较可获得对应的熔核直径，当熔核直径小于设定的标准值时，判定焊点质量不合格，实现实时检测。The real-time detection method of spot welding nugget diameter disclosed in Chinese patent document CN1609622A adopts the following steps: take a welding sample with the same thickness as the weldment and carry out multi-point spot welding, and obtain the dynamic resistance curve of each point through measurement and calculation; The quasi-steady-state resistance value r D ; cut the welding sample along the joint surface, and measure the nugget diameter d core of each solder joint; according to the relationship between the nugget diameter d core of each solder joint and the quasi-steady-state resistance value r D According to the corresponding relationship, the relationship curve between the quasi-steady-state resistance value r D and the nugget diameter d core is drawn; the r D -d core curves of materials with different thicknesses are stored in the computer system. When spot welding a certain material, the computer system first obtains The quasi-steady-state resistance value r D of the solder joint is compared with the r D -d nuclear curve of the same thickness material to obtain the corresponding nugget diameter. When the nugget diameter is smaller than the set standard value, the quality of the solder joint is judged Unqualified, realize real-time detection.
中国专利文献CN101241001A公开的铝合金电阻点焊熔核直径实时检测方法采用如下步骤：采集点焊过程中的电极位移信号，并绘制出电极位移信号曲线图；从所得的电极位移信号曲线上提取出膨胀位移和锻压位移两个特征值；将铝合金焊接试板撕开，对电阻点焊熔核直径进行实测，建立所提取的特征值与实测的熔核直径相对应的样本对，并形成训练集；建立人工神经网络模型，并用所得样本对对模型依据BP算法进行训练，实现从特征值到熔核直径的映射；人工神经网络模型是两个输入、一个输出，中间一个隐层，隐层结点的数目是5的结构，隐层的转移函数为Sigmoid函数，输出层的转移函数为线性函数；将训练好的模型用于铝合金电阻点焊熔核直径的在线实时检测。The disclosed aluminum alloy resistance spot welding nugget diameter real-time detection method of Chinese patent document CN101241001A adopts the following steps: collect the electrode displacement signal in the spot welding process, and draw the electrode displacement signal curve; Two eigenvalues of expansion displacement and forging displacement; the aluminum alloy welding test plate is torn apart, the diameter of the resistance spot welding nugget is measured, and a sample pair corresponding to the extracted eigenvalue and the measured nugget diameter is established, and a training set; establish an artificial neural network model, and use the obtained sample pairs to train the model according to the BP algorithm to realize the mapping from the feature value to the diameter of the nugget; the artificial neural network model has two inputs, one output, a hidden layer in the middle, and a hidden layer The number of nodes is a structure of 5, the transfer function of the hidden layer is a Sigmoid function, and the transfer function of the output layer is a linear function; the trained model is used for online real-time detection of aluminum alloy resistance spot welding nugget diameter.
中国专利文献CN1220034C公开的多信息融合技术确定铝合金板材电阻点焊熔核面积的方法采用如下步骤：依据小波包变换及其能量谱原理、依据信息熵原理、依据模态分析原理，计算出点焊过程中电极电压、电流、电极位移和声音信号的特征量，建立神经网络模型，由特征量和熔核面积对神经网络模型进行训练。神经网络模型计算出的熔核面积与实测熔核面积对照，确定误差值，调整神经网络模型，直至达到误差要求范围。The multi-information fusion technology disclosed in Chinese patent document CN1220034C adopts the following steps to determine the nugget area of resistance spot welding of aluminum alloy plates: according to the principle of wavelet packet transform and its energy spectrum, according to the principle of information entropy, and according to the principle of modal analysis, calculate the point The characteristic quantities of electrode voltage, current, electrode displacement and sound signal in the welding process are used to establish a neural network model, and the neural network model is trained by the characteristic quantities and nugget area. The nugget area calculated by the neural network model is compared with the measured nugget area, the error value is determined, and the neural network model is adjusted until the required error range is reached.
在电阻点焊过程中，随着电阻点焊工艺、材料属性发生变化，能量转换的规律将发生相应的变化。尤其是熔核形核过程中发生的焊接喷溅，也是材料内部积蓄的能量的一种瞬间释放形式。可表现为按照一定规律释放出的不同能量当量的结构负载声发射信号，且焊接喷溅大小不同时，释放出的结构负载声发射喷溅信号能量当量会有相应区别，这为电阻点焊过程喷溅信息的实时传感及快速检测、评估提供了可能。In the resistance spot welding process, as the resistance spot welding process and material properties change, the law of energy conversion will change accordingly. In particular, the welding spatter that occurs during the nucleation nucleation process is also a form of instantaneous release of the energy accumulated in the material. It can be expressed as structural load acoustic emission signals with different energy equivalents released according to certain rules, and when the size of welding spatter is different, the energy equivalent of the structural load acoustic emission spatter signal released will be correspondingly different, which is the resistance spot welding process. Real-time sensing and rapid detection and evaluation of splash information provide the possibility.
发明内容Contents of the invention
为了更加快捷地对电阻点焊过程中产生的焊接喷溅进行检测，并量化评估，本发明针对常用金属薄板结构材料的电阻点焊，提供一种利用电阻点焊过程声发射信号能量当量定量检测焊接喷溅的方法，该方法容易实施，便于评估判断，无损检测，具有检测灵敏度高，检测结果可靠，检测方法快捷，检测成本消耗低等优点。In order to detect and quantitatively evaluate the welding spatter generated in the resistance spot welding process more quickly, the present invention provides a quantitative detection of the energy equivalent of the acoustic emission signal in the resistance spot welding process for the resistance spot welding of commonly used metal sheet structural materials. The method of welding spatter is easy to implement, convenient for evaluation and judgment, non-destructive testing, and has the advantages of high detection sensitivity, reliable detection results, fast detection method, and low detection cost consumption.
本发明采取以下技术方案：The present invention takes the following technical solutions:
一种利用电阻点焊过程声发射信号能量当量定量检测焊接喷溅的方法，该方法借助电阻点焊过程中实时检测到的结构负载声发射信号检测电阻点焊的喷溅信息，所述检测方法的步骤如下：A method for quantitatively detecting welding spatter using the energy equivalent of an acoustic emission signal in a resistance spot welding process, the method detects spatter information of resistance spot welding by means of structural load acoustic emission signals detected in real time during resistance spot welding, the detection method The steps are as follows:
（1）实时采集电阻点焊过程的结构负载声发射信号，并绘制出信号的动态波形图；(1) Real-time acquisition of structural load acoustic emission signals during the resistance spot welding process, and draw a dynamic waveform diagram of the signals;
（2）由电阻点焊过程的结构负载声发射信号动态波形提取出焊接喷溅的声发射信号；(2) The acoustic emission signal of welding spatter is extracted from the dynamic waveform of the structural load acoustic emission signal in the resistance spot welding process;
（3）统计焊接喷溅声发射信号脉冲的幅度分布；(3) Statistics of the amplitude distribution of welding spatter acoustic emission signal pulses;
（4）根据焊接喷溅声发射信号脉冲的幅度分布，将幅度大小分为若干等级Mi（等级数至少为五个以上），并按超过各幅度等级的声发射信号振铃计数Ni分别进行累计，得到焊接喷溅声发射信号振铃计数Ni随信号脉冲幅度变化统计；(4) According to the amplitude distribution of the welding spatter acoustic emission signal pulse, the amplitude is divided into several levels M i (the number of levels is at least five), and the ringing count N i of the acoustic emission signal exceeding each amplitude level is respectively Carry out accumulation, obtain welding spatter acoustic emission signal ringing count Ni changes statistics with signal pulse amplitude;
（5）以X轴表示幅度等级值Mi，Y轴表示按超过各幅度等级值Mi累计得到的声发射信号振铃计数的对数值log10Ni，得到散点分布图；(5) The X-axis represents the amplitude level value M i , and the Y-axis represents the logarithmic value log 10 N i of the acoustic emission signal ringing count accumulated over each amplitude level value M i to obtain a scatter distribution diagram;
（6）按照散点分布图进行直线拟合，得到拟合直线方程；(6) Perform straight line fitting according to the scatter distribution diagram to obtain the fitted straight line equation;
（7）根据拟合直线与X轴和Y轴形成的直角三角形，求出该直角三角形的面积，即为对应的电阻点焊过程焊接喷溅的能量当量。(7) According to the right-angled triangle formed by the fitting line and the X-axis and Y-axis, the area of the right-angled triangle is calculated, which is the energy equivalent of welding spatter in the corresponding resistance spot welding process.
所述电阻点焊过程声发射信号能量当量定量检测焊接喷溅的方法，对焊接喷溅大小定量评定的判断原则为：焊接喷溅能量当量值越大，表明焊接喷溅越大，即焊接喷溅对熔核质量的影响越大。The method for quantitatively detecting welding spatter by the energy equivalent of the acoustic emission signal in the resistance spot welding process, the judgment principle for the quantitative assessment of the size of the welding spatter is: the larger the energy equivalent value of the welding spatter, the larger the welding spatter, that is, the welding spatter The greater the impact of splatter on the quality of the nugget.
本发明的创新在于以实时监测到的电阻点焊过程中的结构负载声发射信号作为信息源，通过检测焊接喷溅的结构负载声发射信号，提取焊接喷溅信号的幅度、振铃计数等特征参数，并利用能量当量法量化评定焊接喷溅的大小级别及其模式，实现对电阻点焊过程焊接喷溅的快速、准确、定量检测。The innovation of the present invention is to use the structure-loaded acoustic emission signal in the resistance spot welding process monitored in real time as the information source, and extract the amplitude, ringing count and other characteristics of the welding spatter signal by detecting the structure-loaded acoustic emission signal of welding spatter parameters, and use the energy equivalent method to quantitatively evaluate the size level and mode of welding spatter, so as to realize the rapid, accurate and quantitative detection of welding spatter in the resistance spot welding process.
本发明适用于实时、快速检测和评定电阻点焊过程焊接喷溅对熔核形核质量的影响。与现有技术相比，本发明具有以下优点：The invention is suitable for real-time and rapid detection and evaluation of the influence of welding spatter on nuclei nucleation quality in the resistance spot welding process. Compared with the prior art, the present invention has the following advantages:
（1）仅需要采集电阻点焊过程的结构负载声发射一种信号，采集系统容易实现，采集系统设计制造成本较为低廉；(1) Only one signal of structural load acoustic emission in the resistance spot welding process needs to be collected, the collection system is easy to implement, and the design and manufacture cost of the collection system is relatively low;
（2）提取的焊接喷溅时的结构负载声发射喷溅信号幅度、振铃计数等特征参数都是与焊接喷溅变化关系密切的关键参数，使检测结果可靠性高；(2) The extracted structural load acoustic emission spatter signal amplitude, ringing count and other characteristic parameters during welding spatter are key parameters closely related to the change of welding spatter, which makes the detection results highly reliable;
（3）能够比较快捷地定量检测和评定焊接喷溅的大小级别、模式及其影响，有利于完善对电阻点焊熔核质量的评价；(3) It can quantitatively detect and evaluate the size level, mode and influence of welding spatter relatively quickly, which is conducive to improving the evaluation of resistance spot welding nugget quality;
（4）检测效率高，评定方法简单，适用于电阻点焊过程的实时质量检测和快速质量评定，适用的材料范围较广，实用性较强。(4) High detection efficiency, simple evaluation method, suitable for real-time quality inspection and rapid quality evaluation of resistance spot welding process, applicable to a wide range of materials, and strong practicability.
附图说明Description of drawings
图1是实施例1检测到的镀锌钢板电阻点焊过程的结构负载声发射信号波形。Fig. 1 is the structure-loaded acoustic emission signal waveform of the resistance spot welding process of galvanized steel sheet detected in Example 1.
图2是图1所示结构负载声发射信号中提取出的喷溅声发射信号波形。Fig. 2 is the splash acoustic emission signal waveform extracted from the structural load acoustic emission signal shown in Fig. 1 .
图3是图2所示喷溅信号的脉冲幅度与分段振铃计数对数值对应的散点分布及拟合直线。Fig. 3 is the scatter point distribution and the fitting line corresponding to the pulse amplitude of the spatter signal shown in Fig. 2 and the logarithmic value of the segmented ringing count.
图4是实施例2检测到的镀锌钢板电阻点焊过程的结构负载声发射信号波形。Fig. 4 is the structural load acoustic emission signal waveform of the resistance spot welding process of galvanized steel plate detected in Example 2.
图5是图4所示结构负载声发射信号中提取出的喷溅声发射信号波形。Fig. 5 is the splash acoustic emission signal waveform extracted from the structural load acoustic emission signal shown in Fig. 4 .
图6是图5所示喷溅信号的脉冲幅度与分段振铃计数对数值对应的散点分布及拟合直线。FIG. 6 is the scatter point distribution and the fitting line corresponding to the pulse amplitude of the spatter signal shown in FIG. 5 and the logarithm value of the segmented ringing count.
图7是实施例3检测到的镀锌钢板电阻点焊过程的结构负载声发射信号波形。Fig. 7 is the structural load acoustic emission signal waveform of the galvanized steel sheet resistance spot welding process detected in Example 3.
图8是图7所示结构负载声发射信号中提取出的喷溅声发射信号波形。Fig. 8 is the waveform of the splash acoustic emission signal extracted from the structural load acoustic emission signal shown in Fig. 7 .
图9是图8所示喷溅信号的脉冲幅度与分段振铃计数对数值对应的散点分布及拟合直线。FIG. 9 is a scatter point distribution and a fitting line corresponding to the pulse amplitude of the spatter signal shown in FIG. 8 and the logarithm value of the segmented ringing count.
图中：1实施例1波形中的焊接喷溅信号、2实施例1波形中的焊接喷溅信号、3实施例1波形中的焊接喷溅信号。In the figure: 1 welding spatter signal in the waveform of embodiment 1, 2 welding spatter signal in the waveform of embodiment 1, 3 welding spatter signal in the waveform of embodiment 1.
具体实施方式detailed description
下面结合具体实施例，进一步阐述本发明。Below in conjunction with specific embodiment, further illustrate the present invention.
实施例1：Example 1:
待焊接的工件为两块厚度1mm的镀锌钢板薄板结构的搭接。采用的主要焊接工艺参数为：焊接电流为10000A，焊接电流持续时间为8周波，电极压力为0.15MPa。The workpiece to be welded is the overlapping joint of two galvanized steel sheet structures with a thickness of 1 mm. The main welding process parameters used are: welding current is 10000A, welding current duration is 8 cycles, and electrode pressure is 0.15MPa.
焊接中，实时采集电阻点焊过程的结构负载声发射信号，由分析软件绘出结构负载声发射信号动态曲线图，如图1所示。During welding, the structural load acoustic emission signal of the resistance spot welding process is collected in real time, and the analysis software draws the dynamic curve of the structural load acoustic emission signal, as shown in Figure 1.
由波形图可以辨识出焊接过程不同阶段，提取出焊接喷溅信号1，如图2所示。可以看出，该焊接喷溅的模式为单声发射事件的焊接喷溅事件。Different stages of the welding process can be identified from the waveform diagram, and the welding spatter signal 1 can be extracted, as shown in Figure 2. It can be seen that the mode of the welding spatter is a welding spatter event of a single acoustic emission event.
统计焊接喷溅声发射信号脉冲的幅度分布。根据该分布，将幅度大小分为10个等级，即M1=0.3，M2=0.6，M3=0.9，M4=1.2，M5=1.5，M6=1.8，M7=2.1，M8=2.4，M9=2.7，M10=3.0。按超过各幅度等级的声发射信号振铃计数Ni分别进行累计，得到焊接喷溅声发射信号振铃计数Ni随信号脉冲十个幅度值变化的统计：N1=286，N2=80，N3=53，N4=45，N5=39，N6=33，N7=27，N8=24，N9=22，N10=19。Statistics the amplitude distribution of welding spatter acoustic emission signal pulse. According to the distribution, the magnitude is divided into 10 grades, namely 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. According to the accumulation of the ringing count N i of the acoustic emission signal exceeding each amplitude level, the statistics of the ringing count N i of the welding spatter acoustic emission signal changing with the ten amplitude values of the signal pulse are obtained: 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.
以X轴表示十个幅度等级值Mi，Y轴表示与幅度等级值Mi对应的声发射信号振铃计数的对数值log10Ni，得到散点分布图，如图3所示。The X-axis represents ten amplitude level values M i , and the Y-axis represents the logarithmic value log 10 N i of the acoustic emission signal ringing count corresponding to the amplitude level value M i , and a scatter distribution diagram is obtained, as shown in FIG. 3 .
对散点分布图直线拟合，得到拟合直线如图3所示，其拟合方程为Y=2.19-0.34X。求出拟合直线与X轴和Y轴形成的直角三角形的面积值为：7.05，即焊接时产生的焊接喷溅的能量当量为7.05。Fitting the scatter distribution diagram to the straight line, the fitting line is shown in Figure 3, and the fitting equation is Y=2.19-0.34X. Calculate the area value of the right triangle formed by the fitting line and the X-axis and Y-axis: 7.05, that is, the energy equivalent of welding spatter generated during welding is 7.05.
该结果表明，利用本发明所述方法可以较为准确快捷地实现电阻点焊过程中产生的焊接喷溅的检测和定量评估。The result shows that the detection and quantitative evaluation of the welding spatter generated in the resistance spot welding process can be realized more accurately and quickly by using the method of the present invention.
实施例2：Example 2:
待焊接的工件为两块厚度1mm的镀锌钢板薄板结构的搭接。采用的主要焊接工艺参数为：焊接电流为11000A，焊接电流持续时间为8周波，电极压力为0.15MPa。The workpiece to be welded is the overlapping joint of two galvanized steel sheet structures with a thickness of 1mm. The main welding process parameters used are: welding current is 11000A, welding current duration is 8 cycles, and electrode pressure is 0.15MPa.
焊接中，实时采集电阻点焊过程的结构负载声发射信号，由分析软件绘出结构负载声发射信号动态曲线图，如图4所示。During welding, the structural load acoustic emission signal of the resistance spot welding process is collected in real time, and the analysis software draws the dynamic curve of the structural load acoustic emission signal, as shown in Figure 4.
由波形图可以辨识出焊接过程不同阶段，提取出焊接喷溅信号1，如图5所示。可以看出，该焊接喷溅的模式为双声发射事件组成的焊接喷溅事件。Different stages of the welding process can be identified from the waveform diagram, and the welding spatter signal 1 is extracted, as shown in Figure 5. It can be seen that the welding spattering mode is a welding spattering event composed of two acoustic emission events.
统计焊接喷溅声发射信号脉冲的幅度分布。根据该分布，将幅度大小分为10个等级，即M1=0.3，M2=0.6，M3=0.9，M4=1.2，M5=1.5，M6=1.8，M7=2.1，M8=2.4，M9=2.7，M10=3.0。按超过各幅度等级的声发射信号振铃计数Ni分别进行累计，得到焊接喷溅声发射信号振铃计数Ni随信号脉冲十个幅度值变化的统计：N1=427，N2=143，N3=100，N4=73，N5=57，N6=48，N7=44，N8=34，N9=27，N10=22。Statistics the amplitude distribution of welding spatter acoustic emission signal pulse. According to the distribution, the magnitude is divided into 10 grades, namely 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. According to the accumulation of the ringing count N i of the acoustic emission signal exceeding each amplitude level, the statistics of the ringing count N i of the welding spatter acoustic emission signal changing with the ten amplitude values of the signal pulse are obtained: 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.
以X轴表示十个幅度等级值Mi，Y轴表示与幅度等级值Mi对应的声发射信号振铃计数的对数值log10Ni，得到散点分布图，如图6所示。The X-axis represents ten amplitude level values M i , and the Y-axis represents the logarithmic value log 10 N i of the acoustic emission signal ringing count corresponding to the amplitude level value M i , and a scatter distribution diagram is obtained, as shown in FIG. 6 .
对散点分布图直线拟合，得到拟合直线如图6所示，其拟合方程为Y=2.46-0.40X。求出拟合直线与X轴和Y轴形成的直角三角形的面积值为：7.56，即焊接时产生的焊接喷溅的能量当量为7.56。Fitting the scatter distribution diagram to the straight line, the fitting straight line is shown in Figure 6, and the fitting equation is Y=2.46-0.40X. Calculate the area value of the right triangle formed by the fitting line and the X-axis and Y-axis: 7.56, that is, the energy equivalent of welding spatter generated during welding is 7.56.
该结果表明，利用本发明所述方法可以较为准确快捷地实现电阻点焊过程中产生的焊接喷溅的检测和定量评估。The result shows that the detection and quantitative evaluation of the welding spatter generated in the resistance spot welding process can be realized more accurately and quickly by using the method of the present invention.
实施例3：Example 3:
待焊接的工件为两块厚度1mm的镀锌钢板薄板结构的搭接。采用的主要焊接工艺参数为：焊接电流为10000A，焊接电流持续时间为8周波，电极压力为0.15MPa。The workpiece to be welded is the overlapping joint of two galvanized steel sheet structures with a thickness of 1 mm. The main welding process parameters used are: welding current is 10000A, welding current duration is 8 cycles, and electrode pressure is 0.15MPa.
焊接中，实时采集电阻点焊过程的结构负载声发射信号，由分析软件绘出结构负载声发射信号动态曲线图，如图7所示。During welding, the structural load acoustic emission signal of the resistance spot welding process is collected in real time, and the dynamic curve of the structural load acoustic emission signal is drawn by the analysis software, as shown in Figure 7.
由波形图可以辨识出焊接过程不同阶段，提取出焊接喷溅信号1，如图8所示。可以看出，该焊接喷溅的模式为三个声发射事件组成的焊接喷溅事件。Different stages of the welding process can be identified from the waveform diagram, and the welding spatter signal 1 is extracted, as shown in Figure 8. It can be seen that the weld spatter pattern is a weld spatter event composed of three acoustic emission events.
统计焊接喷溅声发射信号脉冲的幅度分布。根据该分布，将幅度大小分为10个等级，即M1=0.3，M2=0.6，M3=0.9，M4=1.2，M5=1.5，M6=1.8，M7=2.1，M8=2.4，M9=2.7，M10=3.0。按超过各幅度等级的声发射信号振铃计数Ni分别进行累计，得到焊接喷溅声发射信号振铃计数Ni随信号脉冲十个幅度值变化的统计：N1=608，N2=298，N3=198，N4=154，N5=125，N6=107，N7=88，N8=74，N9=64，N10=55。Statistics the amplitude distribution of welding spatter acoustic emission signal pulse. According to the distribution, the magnitude is divided into 10 grades, namely 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. According to the accumulation of the ringing count N i of the acoustic emission signal exceeding each amplitude level, the statistics of the ringing count N i of the welding spatter acoustic emission signal changing with the ten amplitude values of the signal pulse are obtained: 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.
以X轴表示十个幅度等级值Mi，Y轴表示与幅度等级值Mi对应的声发射信号振铃计数的对数值log10Ni，得到散点分布图，如图9所示。The X-axis represents ten amplitude level values M i , and the Y-axis represents the logarithmic value log 10 N i of the acoustic emission signal ringing count corresponding to the amplitude level value M i to obtain a scatter distribution diagram, as shown in FIG. 9 .
对散点分布图直线拟合，得到拟合直线如图9所示，其拟合方程为Y=2.69-0.34X。求出拟合直线与X轴和Y轴形成的直角三角形的面积值为：10.64，即焊接时产生的焊接喷溅的能量当量为10.64。Fitting the scatter distribution diagram to a straight line, the fitting line is shown in Figure 9, and the fitting equation is Y=2.69-0.34X. Calculate the area value of the right triangle formed by the fitting line and the X-axis and Y-axis: 10.64, that is, the energy equivalent of welding spatter generated during welding is 10.64.
该结果表明，利用本发明所述方法可以较为准确快捷地实现电阻点焊过程中产生的焊接喷溅的检测和定量评估。The result shows that the detection and quantitative evaluation of the welding spatter generated in the resistance spot welding process can be realized more accurately and quickly by using the method of the present invention.
比较以上三个实例可以看出，本发明实现了对电阻点焊过程中的焊接喷溅的检测和模式、级别大小的定量评估。实施例1和实施例3对比可见，尽管采用相同的焊接参数，焊接过程中的喷溅模式和喷溅级别大小并不相同，而实施例2采用与上述两例不同的焊接参数，发生了与之不同的焊接喷溅，本发明对上述焊接喷溅均能实现检测和评估。这也表明了本发明所述方法所具有的快捷性、灵敏性与可靠性。Comparing the above three examples, it can be seen that the present invention realizes the detection of welding spatter in the resistance spot welding process and the quantitative evaluation of the pattern and level. It can be seen from the comparison between embodiment 1 and embodiment 3 that although the same welding parameters are used, the spattering mode and spattering level in the welding process are not the same, while embodiment 2 adopts welding parameters different from the above two examples, and the same phenomenon occurs. For different welding spatters, the present invention can detect and evaluate all the above welding spatters. This also shows the quickness, sensitivity and reliability of the method of the present invention.
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