CN104070267A - Method for eddy current sensing welding seam automatic following control of front dual probes - Google Patents
Method for eddy current sensing welding seam automatic following control of front dual probes Download PDFInfo
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- 238000012545 processing Methods 0.000 claims description 16
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
- B23K9/1272—Geometry oriented, e.g. beam optical trading
- B23K9/1276—Using non-contact, electric or magnetic means, e.g. inductive means
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Abstract
A method for eddy current sensing welding seam automatic following control of front dual probes mainly solves the technical problems that a control system of an existing traditional welding seam tracking sensor is complex and the existing traditional welding seam tracking sensor has complexity in calculation, is low in control precision, huge in size and large in noise, abrades easily and is high in cost and narrow in applied range, and misalignment influence in the welding process can be eliminated or weakened. The technical scheme is that after an input current of a dual probe eddy current sensor is subject to early treatment of each circuit in a preprocessor, the input current reaching a head coil impedor Z of the dual probe eddy current sensor, a measured value of a coil, the distance H between metal plates and a variation value of the relative area S form a voltage value signal U to be output, and accordingly linear relations between U and H and between U and S in the welding process are obtained to achieve welding seam automatic following control. The method is mainly used for welding seam automatic following of an automatic control system in the welding process.
Description
Technical field
The present invention relates to a kind of welding control method, relate in particular to the two probe eddy current sensor type automatic weld tracking control methods that carry out soldering joint automatic tracking for welding procedure.
Background technology
Welding process automatic control system subject matter to be solved is the automatic control of soldering joint automatic tracking and welding torch.More common soldering joint automatic tracking sensor has laser vision formula, mechanical contact and arc type sensor at present, adopt mechanical contact sensor construction simple, but real-time is poor, easy to wear, and precision is difficult to guarantee; In the Weld Seam Tracking Control system of arc type sensor, utilize electric arc self as sensor, real-time, low cost of manufacture, but control accuracy is not too high, and volume is large, and noise is large.Although adopt laser type sensor control accuracy higher, its cost is high, narrow application range, under some occasion, is also difficult to meet the demands even laser is followed the tracks of.
Summary of the invention
The object of this invention is to provide the two probe of a kind of forward type currents sensing automatic weld tracking control method, it is both simple in structure, adaptability is good, has again higher sensitivity and Weld seam quality control precision, and without contacting with test specimen, detection speed is fast, easy and simple to handle, stable, the life-span is long, cost is low, is convenient to penetration and promotion.
The technical solution adopted for the present invention to solve the technical problems is: adopt and comprise the two probe eddy current sensors that are installed on welding gun, the control system of welding actuating unit and welding controller, welding actuating unit in its control system comprises the source of welding current and is connected in the welding gun 5 of welding controller, welding controller mainly comprises two probe eddy current sensors, preprocessor, welding tractor and crosshead shoe, two probe eddy current sensors are prepended to welding gun and are placed in groove one side, two probe eddy current sensors have two probes, probe I 1 gathers voltage signal by height change of distance, probe II 2 is changed and is gathered voltage signal by left and right area, two probes of this eddy current sensor can compensate mutually, when the input current of probe I 1 and probe II 2 is after the processing in advance of each circuit in preprocessor, arrive two probe eddy current sensor probe I 1 and probe II 2 head coil impedance Z, measured value by probe I 1 head coil impedance Z is formed a voltage value signal U with the changing value that docks metallic plate 4 spacing H
1output compensates the distance H of acquisition to probe II 2 simultaneously, eliminates the impact of distance H on 2 outputs of probe II, and is formed a voltage value signal U by the measured value of probe II 2 head coil impedance Z with the changing value that docks 4 relative area S of metallic plate
2output, thus voltage value signal U and the linear relationship of docking metallic plate 4 spacing H and relative area S in welding process obtained, show that adjusting signal welds actuating unit through drive control circuit, realizes soldering joint automatic tracking and controls.
In described preprocessor, be provided with signal processing circuit, A/H change-over circuit, single-chip microcomputer treatment circuit and Drive and Control Circuit, input current is processed in advance.
Two probes of eddy current sensor can compensate mutually, the voltage change of the probe I of two probe eddy current sensors 1 and probe II 2 is carried out to surface fitting by lstopt, choose suitable surface equation, carry out again variable separation, by the altimetric compensation of probe I 1, give probe II 2, eliminate the impact of distance H on probe II 2, catch the height left and right positional information of welding gun 5 and weld seam, after first sampled signal being converted to data signal, input single-chip microcomputer treatment circuit, according to the departure of weld seam, using Fuzzy-PID to control Butt welding gun 5 again regulates, realize welding gun 5 automatic tracking welding seams.
Two probe eddy current sensors are placed in welding gun the place ahead and are offset to welding gun left side or right side, the II of wherein popping one's head in 2 is near welding gun, probe I 1 is near probe II 2, and probe I 1 gathers voltage signal by height change of distance, and probe II 2 is changed and gathered voltage signal by left and right area; The height direction voltage signal obtaining by probe I 1, the left and right directions voltage signal obtaining by probe II 2, with least square method, in conjunction with Fibonacci method matching, obtain the linearity curve of U-H and U-S, according to the voltage signal gathering, judge the position of welding gun 5 and make adjustment and realize weld joint tracking simultaneously.
In signal processing circuit, be to use hardware filtering to add the superimposed mode of software filtering.
The invention has the beneficial effects as follows: (1) adopts and comprises the two probe eddy current sensors that are installed on welding gun, the control system of welding actuating unit and welding controller, and in conjunction with the non-contacting linearisation meter characteristic of application two probe eddy current sensor, a kind of new two probe eddy current sensor type automatic weld tracking control methods have been realized; (2) in conjunction with utilizing the non-contacting linearisation meter characteristic of two probe eddy current sensor, convert the change information of the coil impedance Z of two probe eddy current sensor collection and sensor and metallic plate spacing H and relative area S to voltage value signal output, treated and computing, reach the Position Control of implementing between welding gun and weld seam, and controlling run is stable, reliably, realized soldering joint automatic tracking; (3) adopt welding actuating unit separated with welding controller, the excellent properties of existing manual welding machine is combined together with the excellent properties of two probe eddy current sensors, both combinations have greatly improved the accuracy of system from motion tracking, reliability and weldquality; (4) because the characteristic to sensor regulates, cause the output characteristic curve of the variation of voltage signal and following distance and relative area to approach curve one time, therefore can demarcate sensor characteristics curve, linearization process, thereby computational process and circuit structure in computing are greatly simplified, reduced system cost; (5) two probe eddy current sensors are simple in structure, and control accuracy is high, and without contacting with test specimen, detection speed is quick, and accommodation expands; (6) this pair of probe eddy current sensor can weaken or eliminate the misalignment impact in welding process; (7) two probe eddy current sensor type automatic weld tracking control methods are simple to operation, and welding process is good, and systematic tracking accuracy is high, practical, is convenient to penetration and promotion.
Accompanying drawing explanation
Fig. 1 is control system structural representation of the present invention.
Fig. 2 is two probe eddy current sensor fundamental diagram of the present invention.
In figure: the two probe of 1-eddy current sensor probe I, the two probe of 2-eddy current sensor probe II, 3-welding tractor, 4-metallic plate, 5-welding gun, 6-crosshead shoe.
The specific embodiment
Below in conjunction with drawings and Examples, the present invention is described in further details.
Embodiment 1, the present invention adopts and comprises the two probe eddy current sensors that are installed on welding gun, the control system of welding actuating unit and welding controller, and in conjunction with the non-contacting linearisation meter characteristic of application two probe eddy current sensor, realize a kind of two probe eddy current sensor type automatic weld tracking control method, welding actuating unit in its control system comprises the source of welding current and is connected in the welding gun 5 of welding controller, welding gun 5 is aimed at butt weld, dock metallic plate 4, welding controller mainly comprises two probe eddy current sensors, preprocessor, welding tractor 3 and crosshead shoe 6, two probe eddy current sensors are prepended to welding gun 5 and are placed in groove one side, two probe eddy current sensors have two probes, probe I 1 gathers voltage signal by height change of distance, probe II 2 is changed and is gathered voltage signal by left and right area, two probes of this eddy current sensor can compensate mutually, when the input current of probe I 1 and probe II 2 is after the processing in advance of each circuit in preprocessor, arrive two probe eddy current sensor probe I 1 and probe II 2 head coil impedance Z, measured value by probe I 1 head coil impedance Z is formed a voltage value signal U with the changing value that docks metallic plate 4 spacing H
1output compensates the distance H of acquisition to probe II 2 simultaneously, eliminates the impact of distance H on 2 outputs of probe II, and is formed a voltage value signal U by the measured value of probe II 2 head coil impedance Z with the changing value that docks 4 relative area S of metallic plate
2output, thus voltage value signal U and the linear relationship of docking metallic plate 4 spacing H and relative area S in welding process obtained, show that adjusting signal welds actuating unit through drive control circuit, realizes soldering joint automatic tracking and controls.Consult Fig. 1 to Fig. 2.
Embodiment 2, are provided with signal processing circuit, A/H change-over circuit, single-chip microcomputer treatment circuit and Drive and Control Circuit in described preprocessor, and input current is processed in advance.Convert the signal of two probe eddy current sensor collection to voltage value signal output, in its processing procedure, first after signal processing circuit and the processing of A/H change-over circuit, then send into single-chip microcomputer treatment circuit and carry out software processing and computing, by single-chip microcomputer treatment circuit, provide adjustment signal and weld actuating unit through drive control circuit, reach the Position Control of implementing between welding gun 5 and workpiece-conductive surface and adjust in real time, thereby realizing soldering joint automatic tracking.Consult Fig. 1 to Fig. 2, all the other are with embodiment 1.
Embodiment 3, two probes of eddy current sensor can compensate mutually, the voltage change of the probe I of two probe eddy current sensors 1 and probe II 2 is carried out to surface fitting by lstopt, choose suitable surface equation, carry out again variable separation, by the altimetric compensation of probe I 1, give probe II 2, eliminate the impact of distance H on probe II 2, catch the height left and right positional information of welding gun 5 and weld seam, after first sampled signal being converted to data signal, input single-chip microcomputer treatment circuit, according to the departure of weld seam, using Fuzzy-PID to control Butt welding gun 5 again regulates, realize welding gun 5 automatic tracking welding seams.Consult Fig. 1 to 2, all the other same above-described embodiments.
Embodiment 4, two probe eddy current sensors are placed in welding gun the place ahead and are offset to welding gun left side or right side, be installed in welding tractor 3 on crosshead shoe 6, the II of wherein popping one's head in 2 is near welding gun, probe I 1 is near probe II 2, probe I 1 gathers voltage signal by height change of distance, and probe II 2 is changed and gathered voltage signal by left and right area; The height direction voltage signal obtaining by probe I 1, the left and right directions voltage signal obtaining by probe II 2, with least square method, in conjunction with Fibonacci method matching, obtain the linearity curve of U-H and U-S, according to the voltage signal gathering, judge the position of welding gun 5 and make adjustment and realize weld joint tracking simultaneously.Consult Fig. 1 to 2, all the other same above-described embodiments.
Embodiment 5, are to use hardware filtering to add the superimposed mode of software filtering in signal processing circuit.Consult Fig. 1 to 2, all the other same above-described embodiments.
Referring to accompanying drawing 1, be arranged on welding gun 5 the place aheads and be placed in the two probe of groove one side eddy current sensor, its control flow is: the two-way voltage value signal U that two probe eddy current sensors are exported simultaneously by signal processing circuit, carries out LPF after variable separation and power amplification is processed, the processing of signal adopts hardware filtering to add the superimposed method of software filtering, eliminate the noise jamming being caused by factors such as electric arcs in welding process, hardware filtering adopts low-pass filter circuit filtering, the method that software filtering adopts medium filtering and arithmetic equal value filtering to combine; Then enter A/H change-over circuit analog signal is converted to digital sampled signal, gained digital sampled signal enters single-chip microcomputer treatment circuit, in single-chip microcomputer treatment circuit, adopt C51 series monolithic and by the handling procedure of single-chip microcomputer, digital sampled signal compared, and judge: whether welding gun 5 changes with the relative position of weld seam, adopt compound Fuzzy-PID to control, it is the control model of fuzzy control and PID parallel connection, when position deviation is larger, adopt fuzzy control, response is adjusted fast; When position deviation is less, adopt conventional linear PID to control, details adjustment.Provide after control signal, control signal enters Drive and Control Circuit and drives stepper motor Butt welding gun 5 positions in welding tractor 3 and crosshead shoe 6 to make adjustment, because welding gun 5 and two probe eddy current sensor relative positions are fixed, so two probe eddy current sensor probe I 1 have also obtained adjustment with distance H and two probe eddy current sensor probe II 2 of welded metallic plate-conductor with the relative relative area S of welded metallic plate-conductor when adjusting welding gun 5, the signal that after adjusting, two probe eddy current sensors are sampled is again sent into single-chip microcomputer treatment circuit and is compared, so circulation has realized closed-loop control, thereby make the voltage value signal U at two probe eddy current sensor probe I 1 and two probe eddy current sensor probes II 2 two ends
1and U
2output maintains in the scope of restriction, realize pair probe eddy current sensors probe I 1 end face stable to the relative relative area S maintenance of welded metallic plate-conductor to distance between welded metallic plate-conductor of aiming at separately and two probe eddy current sensor probe II 2, thereby realize the stable of welding gun 5 butt welded seam relative positions, control welding gun 5 and aim at weld seams, realized welding gun 5 and position while welding from motion tracking.
Operation principle of the present invention: as shown in Figure 1, the preposition two probe eddy current sensors that are arranged on welding gun one side are placed in docking metallic plate groove one side, two probes are placed in sustained height, and two probe eddy current sensor front end faces with dock metallic plate 4 surfaces, be between workpiece-conductive surface, to keep vertical, the higher-order of oscillation electric current of input produces alternating magnetic field in the coil of probe head, when adjusting welded metallic plate position, it is workpiece-conductor position, while making conductor near this magnetic field, conductive surface can produce induced-current, the magnetic field that this induced-current produces and the alternating magnetic field of coil resist formation impedance Z mutually, simultaneously in the time of conductor parallel double probe eddy current sensor transverse shifting, the induced electricity that conductive surface produces fails to be convened for lack of a quorum and changes, the alternating magnetic field of its generation also can change accordingly.Now, when the input current of the probe I 1 of two probe eddy current sensors is after the processing in advance of each circuit in preprocessor, arrive probe I 1 head coil, the variation of welded metallic conductor spacing H on measuring head coil impedance Z and docking metallic plate 4 and form voltage value signal U and export.And distance H is compensated to probe II 2, when probe II 2 input current after the processing in advance of each circuit in preprocessor, arrive probe II 2 head coils, the variation of welded metallic conductor relative area S on measuring head coil impedance Z and docking metallic plate 4 and form voltage value signal U and export.As shown in Figure 2, the interaction principle of coil and workpiece-conductor, while being placed in metallic plate top by eddy current sensor, when eddy current sensor head coil applies high-frequency alternating electric current I
1time, in the surrounding of coil, will generate high-frequency alternating electromagnetic field H
1the nearly surface of the workpiece-conductor inside in this alternating magnetic field will produce the vortex flow i of rotation, and in like manner, vortex flow also can produce high-frequency alternating electromagnetic field H
1, H
2direction at any one time all with H
2opposite direction, from electromagnetic angle, workpiece-conductor can be reduced to a simple induction coil.According to Ke Xihefu law, can list equation group:
（1）
The self-induction formula of while solenoid inductor
,
for the solenoidal number of turn,
for solenoid radius.The self-induction formula of circular loop is
.The mutual inductance formula of solenoid coil and circular loop is
(fore-and-aft distance in coil and loop be zero), the length that A is coil, F by
with
determine,
,
,
for circular loop radius.When coil and loop, distance is
time, there is following formula:
（2）
When coil is positioned at the situation of metal-sheet edges, known according to Faraday's electromagnetic induction law, the variation of magnetic flux produces electromotive force, by
(
for the relative area of induction coil,
radius for coil) known, faradic size with
be directly proportional.So there is following formula:
(3)
Keeping
in constant situation, induction coil is reduced to a relative area is
coil, now mutual inductance
by formula 1, obtained:
（4）
It is expression formula 5 that simultaneous formula 1,3,4 and equation group 2 can solve magnetic test coil impedance:
（5）
Wherein:
In formula:
r1for coil resistance,
l1 is the equivalent inductance of coil;
r2 is metallic conductor equivalent resistance;
l2 is metallic conductor equivalent inductance
for the mutual inductance between coil and conductor;
jfor complex unit. keep other parameter constants, have
z=
f(
s,
h), wherein
right opposite for coil and workpiece
for lengthwise position.In lengthwise position
in fixing situation, mutual inductance
only and relative area
relevant.According to Kirchhoff's law, can solve coil impedance with
relation, i.e. relative area
relation with coil impedance.
When the measured value of two probe eddy current sensor head coil impedance Z and the changing value of welded piece 4 spacing H and relative area S form respectively a voltage value signal output, in two probe eddy current sensor coil, there is high-frequency alternating electric current I
1input, coil just produces high-frequency alternating electromagnetic field H around
1.Now, workpiece-conductor is placed in this magnetic field range, in conductor, just produces current vortex, current vortex also will produce new induced field, two magnetic directions are contrary, and active force can weaken former magnetic field, thereby cause the parameters such as inductance value of two probe eddy current sensor coil to change.The variation of its parameter forms to the distance H between measured conductor and relative area S the factor that is associated with two probe eddy current sensor coil.If keep other parameter constants. only change the displacement of distance H, the inductance value of two probe eddy current sensor probe I 1 coil is just the monotropic function of H.Now the distance H of collection is compensated to probe II 2, eliminate the impact of H on the II 2 of popping one's head in, the inductance value of two probe eddy current sensors probe II 2 coils is just the monotropic function of S.By frequency modulation type resonance circuit, the variation of inductance value is converted to the variation of frequency of oscillation.Through FIV, be converted to voltage signal, finally by output after amplifying.Within the scope of certain distance of reaction, output voltage U and two probe eddy current sensor coil have good linear relationship to the distance H between measured conductor and relative area S.By measuring the changing value of output voltage U, obtain eddy current sensor with respect to the position, height left and right of welded metallic plate-conductor.
The control principle of single-chip microcomputer treatment circuit: the electric current of two probe eddy current sensors is after the processing in advance of electronic circuit in its fore-lying device, by head coil impedance Z, with the variation of welded metallic plate-distance between conductors H and head coil impedance Z, with the variation of the relative area S between welded metal-conductor, converting voltage value signal U to again exports, from improving the requirement of welding quality, welding gun 5 errors of centralization will be limited in
in 1mm, and guarantee that welding gun 5 is stable, for the situation that adopts complementary two probe eddy current sensor butt welding weld seams, adopt a kind of special control method Fuzzy-PID to control, that is: according to the linear relationship of the U-H of two probe eddy current sensors probe I 1 before welding, can obtain the just magnitude of voltage of each deviation of direction, the linear relationship of the U-S of two probe eddy current sensor probe II 2, can obtain the magnitude of voltage of each differential location of left and right directions, utilize two probe eddy current sensor probe I 1 to control welding gun and carry out the adjustment of height direction, utilize two probe eddy current sensor probe II 2 to control welding gun and carry out left and right directions adjustment, scope of first butt welded seam deviation setting, when weld seam deviation is greater than 1mm, employing fuzzy is controlled, when being less than 1mm, weld seam deviation adopt PID to control.First the magnitude of voltage of setting initial state is respectively
,
.The two paths of signals collecting
with
, carry out computing
,
, according to difference, judge the departure of weld seam, wherein
control welding gun 5 and move up and down,
controlling welding gun 5 left and right moves.
According to deviation signal, adopt C51 series monolithic to realize the horizontal and vertical step motor control of Butt welding gun 5.The deviation signal of weld seam is due to uncertainty, the time variation of welding process, and weld joint tracking process is difficult to describe by accurate Mathematical Modeling.Can set up one for this reason
threshold values
, when large deviation, adopt fuzzy control, improve response speed, reduce the adjusting time.When little deviation, adopt conventional linear PID to control, details adjustment, to guarantee the centering of welding gun 5.
Claims (4)
1. the two probe of forward type currents sensing automatic weld tracking control methods, it is characterized in that: two probe eddy current sensors have two probes, probe I (1) gathers voltage signal by height change of distance, probe II (2) is changed and is gathered voltage signal by left and right area, two probes of this eddy current sensor can compensate mutually, when the input current of probe I (1) and the II (2) of popping one's head in is after the processing in advance of each circuit in preprocessor, arrive two probe eddy current sensor probe I (1) and probe II (2) head coil impedance Z, measured value by probe I (1) head coil impedance Z is formed a voltage value signal U with the changing value that docks metallic plate (4) spacing H
1output, the distance H of acquisition is compensated to probe II (2) simultaneously, eliminate the impact of distance H on probe II (2) output, and formed a voltage value signal U by the measured value of probe II (2) head coil impedance Z with the changing value that docks relative area S between metallic plate (4)
2output, thus voltage value signal U and the linear relationship of docking metallic plate (4) spacing H and relative area S in welding process obtained, show that adjusting signal welds actuating unit through drive control circuit, realizes soldering joint automatic tracking and controls.
2. the two probe of forward type according to claim 1 currents sensing automatic weld tracking control methods, it is characterized in that: in described preprocessor, be provided with signal processing circuit, A/H change-over circuit, single-chip microcomputer treatment circuit and Drive and Control Circuit, input current is processed in advance.
3. the two probe of forward type according to claim 1 currents sensing automatic weld tracking control methods, it is characterized in that: two probes of eddy current sensor can compensate mutually, the voltage change of the probe I (1) of two probe eddy current sensors and probe II (2) is carried out to surface fitting by lstopt, choose suitable surface equation, carry out again variable separation, the altimetric compensation of the I of popping one's head in (1) is given probe II (2), eliminate the impact of distance H on probe II (2), catch the height left and right positional information of welding gun (5) and weld seam, after first sampled signal being converted to data signal, input single-chip microcomputer treatment circuit, according to the departure of weld seam, using Fuzzy-PID to control Butt welding gun (5) again regulates, realize welding gun (5) automatic tracking welding seam.
4. the two probe of forward type according to claim 1 currents sensing automatic weld tracking control methods, it is characterized in that: two probe eddy current sensors are placed in welding gun the place ahead and are offset to welding gun left side or right side, the II of wherein popping one's head in (2) is near welding gun, probe I (1) is near probe II (2), probe I (1) gathers voltage signal by height change of distance, and probe II (2) is changed and gathered voltage signal by left and right area; The height direction voltage signal obtaining by probe I (1), the left and right directions voltage signal obtaining by probe II (2), with least square method, in conjunction with Fibonacci method matching, obtain the linearity curve of U-H and U-S, according to the voltage signal gathering, judge the position of welding gun (5) and make adjustment and realize weld joint tracking simultaneously.
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| CN112317922A (en) * | 2020-11-17 | 2021-02-05 | 内蒙古北方重型汽车股份有限公司 | Automatic arc light tracking device for electric welding and use method thereof |
| CN114571167A (en) * | 2020-11-30 | 2022-06-03 | 大众汽车股份公司 | Method for producing a battery element |
| CN114535757A (en) * | 2022-03-29 | 2022-05-27 | 湘潭大学 | Multipolar magnetic control GTAW arc sensor with self-adaptation calibration function |
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