CN104070267B - Forward type dual probe currents sensing automatic weld tracking control method - Google Patents
Forward type dual probe currents sensing automatic weld tracking control method Download PDFInfo
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- 239000000523 sample Substances 0.000 title claims abstract description 151
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- 238000000034 method Methods 0.000 title claims abstract description 59
- 238000003466 welding Methods 0.000 claims abstract description 96
- 230000008569 process Effects 0.000 claims abstract description 37
- 238000005476 soldering Methods 0.000 claims abstract description 10
- 230000008859 change Effects 0.000 claims description 27
- 238000003032 molecular docking Methods 0.000 claims description 11
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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 kind of forward type dual probe currents sensing automatic weld tracking control method, it mainly solves the control system complex that existing conventional weld tracking transducer exists, computing is numerous and diverse, control accuracy is low, volume is numerous and jumbled, noise is big, easy to wear, and cost is high, the technical problems such as narrow application range, and can eliminate or weaken the misalignment impact in welding process。Its drip irrigation device is: when the input current of dual probe eddy current sensor is after the process in advance of circuit each in preprocessor, arrive dual probe eddy current sensor head coil impedance Z, a voltage value signal U output it is made up of, thus obtaining the linear relationship of voltage value signal U and metallic plate spacing H and voltage value signal U and relative area S in welding process to realize soldering joint automatic tracking control the changing value of the measured value of this coil Yu metallic plate spacing H and relative area S。It is mainly used for the soldering joint automatic tracking of welding process automatic control system。
Description
Technical field
The present invention relates to a kind of welding control method, carry out the dual probe eddy current sensor type automatic weld tracking control method of soldering joint automatic tracking particularly for welding procedure。
Background technology
Welding process automatic control system subject matter to be solved is automatically controlling of soldering joint automatic tracking and welding torch。Soldering joint automatic tracking sensor relatively common at present has laser vision formula, mechanical contact and arc type sensor etc., and employing mechanical touch sensors simple in construction, but poor real, easy to wear, precision is difficult to ensure that；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 less high, and volume is big, and noise is big。Although adopting laser type sensor control accuracy higher, but its cost is high, and narrow application range in some cases, also is difficult to meet requirement even laser is followed the tracks of。
Summary of the invention
It is an object of the invention to provide a kind of forward type dual probe currents sensing automatic weld tracking control method, it is simple in construction both, 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, it is simple to penetration and promotion。
The technical solution adopted for the present invention to solve the technical problems is: adopt the dual probe eddy current sensor including being installed on welding gun, welding performs the control system of device and welding controller, welding in its control system performs device and includes the source of welding current and be connected to the welding gun 5 of welding controller, welding controller mainly includes dual probe eddy current sensor, preprocessor, welding tractor and crosshead shoe, dual probe eddy current sensor is preposition is placed in groove side in welding gun, dual probe eddy current sensor has two probes, pop one's head in I 1 by height distance change collection voltage signal, pop one's head in II 2 by left and right area change collection voltage signal, two probes of this eddy current sensor can mutually compensate for, when the input current of probe I 1 and probe II 2 is after the process in advance of circuit each in preprocessor, arrive dual probe eddy current sensor probe I 1 and probe II 2 head coil impedance Z, a voltage value signal U is constituted with the changing value docking metallic plate 4 spacing H by the measured value of probe I 1 head coil impedance Z1Output, compensates the distance H of acquisition to probe II 2 simultaneously, eliminates the distance H impacts on probe II 2 output, and is constituted a voltage value signal U with the changing value docking 4 relative area S of metallic plate by the measured value of II 2 head coil impedance Z of popping one's head in2Output, thus obtaining in welding process voltage value signal U and dock metallic plate 4 spacing H and the linear relationship of relative area S, show that adjustment signal is through drive control circuit welding execution device, it is achieved soldering joint automatic tracking control。
Described preprocessor is provided with signal processing circuit, A/H change-over circuit, single-chip microcomputer process circuit and drives control circuit, input current is processed in advance。
Two probes of eddy current sensor can mutually compensate for, the change in voltage of the probe I 1 of dual probe eddy current sensor and probe II 2 is carried out surface fitting by lstopt, choose suitable surface equation, carry out separating variables again, probe II 2 is given by the altimetric compensation of probe I 1, eliminate the distance H impact on probe II 2, catch the height right position information of welding gun 5 and weld seam, after sampled signal is first converted to digital signal, input single-chip microcomputer processes circuit, departure further according to weld seam uses Fuzzy PID control Butt welding gun 5 to be adjusted, realize welding gun 5 automatic tracking welding seam。
Dual probe eddy current sensor is placed in welding gun front and is offset on the left of welding gun or right side, wherein probe II 2 is near welding gun, popping one's head in I 1 against probe II 2, probe I 1 gathers voltage signal by height distance change, and probe II 2 gathers voltage signal by left and right area change；Height direction voltage signal by I 1 acquisitions of popping one's head in, left and right directions voltage signal by II 2 acquisitions of popping one's head in, obtain the linearity curve of U-H and U-S with method of least square in conjunction with Fibonacci method matching, judge the position of welding gun 5 according to the voltage signal gathered simultaneously and make adjustment and realize weld joint tracking。
Signal processing circuit is use hardware filtering to add the mode that software filtering is superimposed。
The invention has the beneficial effects as follows: (1) adopts the dual probe eddy current sensor including being installed on welding gun, welding performs the control system of device and welding controller, and the non-contacting linearisation meter characteristic of connected applications dual probe eddy current sensor, it is achieved that a kind of new dual probe eddy current sensor type automatic weld tracking control method；(2) the non-contacting linearisation meter characteristic of dual probe eddy current sensor it is combined with, the change information of the coil impedance Z of dual probe eddy current sensor collection with sensor and metallic plate spacing H and relative area S is converted to voltage value signal output, treated and computing, reach to implement the position control between welding gun and weld seam, and control stable, reliably, it is achieved that soldering joint automatic tracking；(3) adopt welding to perform device to separate with welding controller, the excellent properties of existing manual welding machine and the excellent properties of dual probe eddy current sensor is made to combine together, both combinations drastically increase the system accuracy from motion tracking, reliability and weldquality；(4) because the characteristic of sensor has been regulated, the output characteristic curve causing the change of voltage signal and following distance and relative area approaches a curve, therefore sensor characteristic can be demarcated, linearization process, so that calculating process and circuit structure in computing greatly simplify, reduce system cost；(5) dual probe eddy current sensor simple in construction, control accuracy is high, it is not necessary to contact with test specimen, and detection speed is quick, and subject range expands；(6) this dual probe eddy current sensor can weaken or eliminate the misalignment impact in welding process；(7) dual probe eddy current sensor type automatic weld tracking control method is simple to operation, and welding process is good, and systematic tracking accuracy is high, practical, it is simple to penetration and promotion。
Accompanying drawing explanation
Fig. 1 is the Control system architecture schematic diagram of the present invention。
Fig. 2 is the dual probe eddy current sensor fundamental diagram of the present invention。
In figure: 1-dual probe eddy current sensor probe I, 2-dual probe eddy current sensor probe II, 3-welding tractor, 4-metallic plate, 5-welding gun, 6-crosshead shoe。
Detailed description of the invention
Below in conjunction with drawings and Examples, the present invention is described in further details。
Embodiment 1, the present invention adopts the dual probe eddy current sensor including being installed on welding gun, welding performs the control system of device and welding controller, and the non-contacting linearisation meter characteristic of connected applications dual probe eddy current sensor, realize a kind of dual probe eddy current sensor type automatic weld tracking control method, welding in its control system performs device and includes the source of welding current and be connected to the welding gun 5 of welding controller, welding gun 5 is directed at butt weld, i.e. docking metallic plate 4, welding controller mainly includes dual probe eddy current sensor, preprocessor, welding tractor 3 and crosshead shoe 6, dual probe eddy current sensor is preposition is placed in groove side in welding gun 5, dual probe eddy current sensor has two probes, pop one's head in I 1 by height distance change collection voltage signal, pop one's head in II 2 by left and right area change collection voltage signal, two probes of this eddy current sensor can mutually compensate for, when the input current of probe I 1 and probe II 2 is after the process in advance of circuit each in preprocessor, arrive dual probe eddy current sensor probe I 1 and probe II 2 head coil impedance Z, a voltage value signal U is constituted with the changing value docking metallic plate 4 spacing H by the measured value of probe I 1 head coil impedance Z1Output, compensates the distance H of acquisition to probe II 2 simultaneously, eliminates the distance H impacts on probe II 2 output, and is constituted a voltage value signal U with the changing value docking 4 relative area S of metallic plate by the measured value of II 2 head coil impedance Z of popping one's head in2Output, thus obtaining in welding process voltage value signal U and dock metallic plate 4 spacing H and the linear relationship of relative area S, show that adjustment signal is through drive control circuit welding execution device, it is achieved soldering joint automatic tracking control。Consult Fig. 1 to Fig. 2。
Embodiment 2, is provided with signal processing circuit, A/H change-over circuit, single-chip microcomputer process circuit and drives control circuit, input current is processed in advance in described preprocessor。The signal of dual probe eddy current sensor collection is converted to voltage value signal output, in its processing procedure, first after signal processing circuit and A/H change-over circuit process, it is then fed into single-chip microcomputer process circuit and carries out software processes and computing, processed circuit by single-chip microcomputer and provide adjustment signal through drive control circuit welding execution device, reach the position control between enforcement welding gun 5 and workpiece-conductive surface and adjust in real time, thus realizing soldering joint automatic tracking。Consulting Fig. 1 to Fig. 2, all the other are with embodiment 1。
Embodiment 3, two probes of eddy current sensor can mutually compensate for, the change in voltage of the probe I 1 of dual probe eddy current sensor and probe II 2 is carried out surface fitting by lstopt, choose suitable surface equation, carry out separating variables again, probe II 2 is given by the altimetric compensation of probe I 1, eliminate the distance H impact on probe II 2, catch the height right position information of welding gun 5 and weld seam, after sampled signal is first converted to digital signal, input single-chip microcomputer processes circuit, departure further according to weld seam uses Fuzzy PID control Butt welding gun 5 to be adjusted, realize welding gun 5 automatic tracking welding seam。Consult Fig. 1 to 2, all the other same above-described embodiments。
Embodiment 4, dual probe eddy current sensor is placed in welding gun front and is offset on the left of welding gun or right side, it is installed in welding tractor 3 on crosshead shoe 6, wherein probe II 2 is near welding gun, pop one's head in I 1 against probe II 2, popping one's head in I 1 by height distance change collection voltage signal, probe II 2 gathers voltage signal by left and right area change；Height direction voltage signal by I 1 acquisitions of popping one's head in, left and right directions voltage signal by II 2 acquisitions of popping one's head in, obtain the linearity curve of U-H and U-S with method of least square in conjunction with Fibonacci method matching, judge the position of welding gun 5 according to the voltage signal gathered simultaneously and make adjustment and realize weld joint tracking。Consult Fig. 1 to 2, all the other same above-described embodiments。
Embodiment 5, is use hardware filtering to add the mode that software filtering is superimposed in signal processing circuit。Consult Fig. 1 to 2, all the other same above-described embodiments。
Referring to accompanying drawing 1, it is arranged on welding gun 5 front and is placed in groove side dual probe eddy current sensor, its control flow is: the two-way voltage value signal U simultaneously exported by dual probe eddy current sensor is carried out low-pass filtering by signal processing circuit after separating variables and power amplification processes, the process of signal adopts hardware filtering to add the superimposed method of software filtering, eliminate the noise jamming caused in welding process by factors such as electric arcs, hardware filtering adopts low-pass filter circuit filtering, and software filtering adopts medium filtering and arithmetic equal value to filter the method combined；Digital sampled signal is converted analog signals into subsequently into A/H change-over circuit, gained digital sampled signal enters single-chip microcomputer and processes circuit, single-chip microcomputer processes and adopts C51 series monolithic in circuit and by the process program of single-chip microcomputer, digital sampled signal compared, and judge: whether the relative position of welding gun 5 and weld seam changes, compound Fuzzy PID is adopted to control, the i.e. control model of fuzzy control and PID parallel connection, adopts fuzzy control, quickly responds adjustment when position deviation is bigger；Conventional linear PID is adopted to control when position deviation is less, details adjustment。After providing control signal, control signal enters and drives control circuit to drive motor Butt welding gun 5 position in welding tractor 3 and crosshead shoe 6 to make adjustment, owing to welding gun 5 and dual probe eddy current sensor relative position are fixed, then while adjusting welding gun 5, dual probe eddy current sensor probe I 1 have also been obtained adjustment with by distance H and the dual probe eddy current sensor probe II 2 of weldering metallic plate-conductor with by the relative area S of weldering metallic plate-conductor, the signal that after adjustment, dual probe eddy current sensor is sampled again is sent into single-chip microcomputer process circuit and is compared, so circulation achieves closed loop control, so that the voltage value signal U at dual probe eddy current sensor probe I 1 and dual probe eddy current sensor probe II 2 two ends1And U2Output maintains in the scope of restriction, namely realize dual probe eddy current sensor probe I 1 end faces to remain stable for respective the be directed at spacing by weldering metallic plate-conductor and dual probe eddy current sensor probe II 2 to by the relative area S of weldering metallic plate-conductor, thus realizing stablizing of welding gun 5 butt welded seam relative position, control welding gun 5 and be directed at weld seam, it is achieved that welding gun 5 and position while welding from motion tracking。
The operation principle of the present invention: as shown in Figure 1, the preposition dual probe eddy current sensor being arranged on welding gun side is placed in docking metallic plate groove side, two probes are placed in sustained height, and dual probe eddy current sensor front end face with dock metallic plate 4 surface, namely keep vertical between workpiece-conductive surface, the high frequency oscillating current of input produces alternating magnetic field in the coil of probe head, when adjusting by weldering metallic plate position, i.e. workpiece-conductor position, make conductor when this magnetic field, conductive surface can produce faradic current, magnetic field and the alternating magnetic field of coil that this faradic current produces resist formation impedance Z mutually, simultaneously when conductor parallel double pops one's head in eddy current sensor transverse shifting time, the faradic current that conductive surface produces can change, the alternating magnetic field of its generation also can change accordingly。Now, when dual probe eddy current sensor probe I 1 input current after the process in advance of circuit each in preprocessor, arrive probe I 1 head coils, measure head coil impedance Z and with docking, metallic plate 4 is formed voltage value signal U export by the change of weldering metallic conductor spacing H。And will compensate to probe II 2 apart from H, when the input current of probe II 2 is after the process in advance of circuit each in preprocessor, arrive probe II 2 head coils, measure head coil impedance Z and with docking, metallic plate 4 is formed voltage value signal U export by the change of weldering metallic conductor relative area S。As shown in Figure 2, the interaction principle of coil and workpiece-conductor, when being placed in above metallic plate by eddy current sensor, when eddy current sensor head coil applies high frequency alternating current I1Time, the surrounding at coil will generate high-frequency alternating electromagnetic field H1The nearly surface of the workpiece-conductor being in this alternating magnetic field will produce the vortex flow i rotated, and in like manner, vortex flow also can produce high-frequency alternating electromagnetic field H1, H2Direction at any one time all with H2In opposite direction, workpiece-conductor can be reduced to a simple induction coil from electromagnetic angle。According to Ke Xihefu law, equation group can be listed:
(1)
The self-induction formula of solenoid inductor simultaneously,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 is zero), A is the length of coil, F byWithDetermine,,,For circular loop radius。When coil and loop distance areTime, there is below equation:
(2)
When coil is positioned at the situation of metal-sheet edges, according to Faraday law of electromagnetic induction it can be seen that the change of magnetic flux produces electromotive force, by(For the relative area of induction coil,Radius for coil) it can be seen that faradic size withIt is directly proportional。So there being below equation:
(3)
KeepingWhen constant, induction coil is reduced to a relative area isCoil, now mutual inductanceObtained by formula 1:
(4)
It is expression formula 5 that simultaneous formula 1,3,4 and equation group 2 can solve detection coil impedance:
(5)
Wherein:
In formula: R1 is coil resistance, L1 is the equivalent inductance of coil；R2 is metallic conductor equivalent resistance；L2 is metallic conductor equivalent inductanceFor the mutual inductance between coil and conductor；J is complex unit. keeps other parameter constants, has Z=f(s, h), whereinRight opposite for coil Yu workpieceFor lengthwise position。In lengthwise positionWhen fixing, mutual inductanceOnly and relative areaRelevant。According to Kirchhoff's law, can solve coil impedance withRelation, i.e. relative areaRelation with coil impedance。
When the measured value of dual probe eddy current sensor head coil impedance Z and the changing value of welded piece 4 spacing H and relative area S respectively constitute a voltage value signal output, dual probe eddy current sensor coil then has high frequency alternating current I1Input, just produces high-frequency alternating electromagnetic field H around coil1。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, thus causing that the parameter such as inductance value of dual probe eddy current sensor coil changes。Distance H and relative area S between the change of its parameter with dual probe eddy current sensor coil to measured conductor constitute the factor that is associated。If keeping other parameter constants. only changing the displacement of distance H, the inductance value of dual probe eddy current sensor probe I 1 coils is just the monotropic function of H。Now compensated by the distance H of collection to probe II 2, namely eliminate the distance H impact on probe II 2, then the inductance value of dual probe eddy current sensor probe II 2 coils is with regard to the monotropic function of simply S。By frequency modulation type resonance circuit, the change of inductance value is converted to the change of frequency of oscillation。Voltage signal, last amplified output is converted to through FIV。Within the scope of certain distance of reaction, output voltage U and dual probe eddy current sensor coil have good linear relationship to distance H and the relative area S between measured conductor。Namely eddy current sensor is obtained relative to the height right position by weldering metallic plate-conductor by the changing value of measurement output voltage U。
Single-chip microcomputer processes the control principle of circuit: the electric current of dual probe eddy current sensor is after the process in advance of electronic circuit in its fore-lying device, convert voltage value signal U to and export with by change and the head coil impedance Z of weldering metallic plate-distance between conductors H with the change by the relative area S between weldering metal-conductor again through head coil impedance Z, from the requirement improving welding quality, welding gun 5 error of centralization to be limited inWithin 1mm, and to ensure that welding gun 5 is stable, for the situation adopting complementary dual probe eddy current sensor butt welding weld seam, a kind of Special controlling method Fuzzy PID is adopted to control, that is: the magnitude of voltage of each deviation of height direction can be obtained according to the linear relationship of the U-H of dual probe eddy current sensor probe I 1 before welding, the linear relationship of the U-S of dual probe eddy current sensor probe II 2, the magnitude of voltage of each differential location of left and right directions can be obtained, dual probe eddy current sensor probe I 1 control welding gun is utilized to carry out height direction adjustment, dual probe eddy current sensor probe II 2 control welding gun is utilized to carry out left and right directions adjustment, first one scope of butt welded seam deviation setting, when weld seam deviation is more than 1mm, adopt fuzzy-adaptation PID control；Adopt PID to control when weld seam deviation is less than 1mm。First the magnitude of voltage of initial state is set respectively,。The two paths of signals collectedWith, carry out computing,, judge the departure of weld seam according to difference, whereinControl welding gun 5 to move up and down,Control welding gun about 5 to move。
C51 series monolithic is adopted to realize the horizontal and vertical step motor control of Butt welding gun 5 according to deviation signal。The deviation signal of weld seam is due to the uncertainty of welding process, time variation, and weld joint tracking process is difficult to describe with accurate mathematical model。One can be set up for thisThreshold values, adopt fuzzy control when large deviation, improve response speed, reduce regulating time。Adopt conventional linear PID to control when little deviation, details adjustment, to ensure the centering of welding gun 5。
Claims (4)
1. a forward type dual probe currents sensing automatic weld tracking control method, it is characterized in that: dual probe eddy current sensor has two probes, probe I (1) gathers voltage signal by height distance change, probe II (2) gathers voltage signal by left and right area change, two probes of this eddy current sensor can mutually compensate for, when the input current of probe I (1) and probe II (2) is after the process in advance of circuit each in preprocessor, arrive dual probe eddy current sensor probe I (1) and probe II (2) head coil impedance Z, a voltage value signal U is constituted with the changing value docking metallic plate (4) spacing H by the measured value of probe I (1) head coil impedance Z1Output, the distance H of acquisition is compensated to probe II (2) simultaneously, eliminate the distance H impact that probe II (2) is exported, and constituted a voltage value signal U by the measured value of probe II (2) head coil impedance Z with docking the changing value of relative area S between metallic plate (4)2Output, thus obtaining voltage value signal U and the linear relationship docking metallic plate (4) spacing H and relative area S in welding process, show that adjustment signal performs device through drive control circuit welding, it is achieved soldering joint automatic tracking controls。
2. forward type dual probe currents sensing automatic weld tracking control method according to claim 1, it is characterized in that: described preprocessor is provided with signal processing circuit, A/H change-over circuit, single-chip microcomputer process circuit and drives control circuit, input current is processed in advance。
3. forward type dual probe currents sensing automatic weld tracking control method according to claim 1, it is characterized in that: two probes of eddy current sensor can mutually compensate for, the change in voltage of the probe I (1) of dual probe eddy current sensor and probe II (2) is carried out surface fitting by lstopt, choose suitable surface equation, carry out separating variables again, the distance H of acquisition is compensated to probe II (2), eliminate the distance H impact on probe II (2), catch the height right position information of welding gun (5) and weld seam, after sampled signal is first converted to digital signal, input single-chip microcomputer processes circuit, departure further according to weld seam uses Fuzzy PID control Butt welding gun (5) to be adjusted, realize welding gun (5) automatic tracking welding seam。
4. forward type dual probe currents sensing automatic weld tracking control method according to claim 1, it is characterized in that: dual probe eddy current sensor is placed in welding gun front and is offset on the left of welding gun or right side, wherein pop one's head in II (2) near welding gun, probe I (1) is against probe II (2), probe I (1) gathers voltage signal by height distance change, and probe II (2) gathers voltage signal by left and right area change；By I (1) the height direction voltage signal obtained of popping one's head in, by II (2) the left and right directions voltage signal obtained of popping one's head in, obtain the linearity curve of U-H and U-S with method of least square in conjunction with Fibonacci method matching, judge the position of welding gun (5) according to the voltage signal gathered simultaneously and make adjustment and realize weld joint tracking。
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