CN104741802A - Welding quality monitoring system and method - Google Patents
Welding quality monitoring system and method Download PDFInfo
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- CN104741802A CN104741802A CN201510145918.XA CN201510145918A CN104741802A CN 104741802 A CN104741802 A CN 104741802A CN 201510145918 A CN201510145918 A CN 201510145918A CN 104741802 A CN104741802 A CN 104741802A
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding
Abstract
The invention provides a welding quality monitoring system and method. The welding quality monitoring system comprises a welding gun, a thermal infrared imager, an image capture card and an image processing computer. The welding gun is used for welding welding spots. The thermal infrared imager is used for recording molten bath infrared thermal imaging data of the welding spots. The image capture card is used for collecting the molten bath infrared thermal imaging data and sending the molten bath infrared thermal imaging data to the image processing computer. The image processing computer is used for analyzing the molten bath infrared thermal imaging data to obtain welding parameters, comparing the welding parameters with preset welding standards and obtaining a welding spot quality estimation result. In this way, by the adoption of the welding quality monitoring system and method, online monitoring of automatic welding quality can be achieved, the monitoring efficiency and monitoring quality are improved, and the missing inspection rate is reduced.
Description
Technical field
The invention belongs to petroleum works technical field, particularly relate to a kind of welding quality monitoring system and method.
Background technology
Laser/electric arc combined welding technology has that speed of welding is fast, welding penetration is large, bridging capability is good, weld properties is good, layer is thick, save the advantages such as wlding.But laser/electric arc combined weldering welding equipment system is huge, and complex structure, all multi-parameters such as arc voltage, wire feed rate, laser energy, laser defocusing amount, laser incident angle, chevilled silk spacing all can affect welding fabrication effect and welding quality.Therefore need to carry out on-line monitoring to welding process quality.
At present, automatic welding of pipelines equipment directly observes on-line monitoring welding quality by artificial, and this monitoring mode can not adapt to the higher speed of welding of laser/electric arc combined weldering on the one hand, cannot observe inner fusion situation, and can not record Monitoring Data; Superlaser also can damage the eyes of human body and skin on the other hand, although there is protective gear, should avoid as far as possible.
Summary of the invention
For prior art Problems existing, embodiments providing a kind of welding quality monitoring system and method, for solving manual observation welding quality inaccuracy of the prior art, and superlaser cannot be avoided the technical problem of human injury.
The invention provides a kind of welding quality monitoring system, described system comprises:
Welding gun, described welding gun is used for butt welding point and welds;
Thermal infrared imager, described thermal infrared imager is for shooting with video-corder the molten bath infrared thermal imaging data of described solder joint;
Image pick-up card, described molten bath infrared thermal imaging data, for gathering described molten bath infrared thermal imaging data, are sent to pattern process computer by described image pick-up card;
Pattern process computer, described pattern process computer, for analyzing described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtains quality of welding spot assessment result.
In such scheme, described pattern process computer comprises:
Image processor, described image processor is used for described molten bath infrared thermal imaging data analysis, obtains welding parameter;
Mass analyzer, described mass analyzer is used for, by described welding parameter compared with the welding standard preset, obtaining quality of welding spot assessment result;
Memory, described memory is for storing described molten bath infrared thermal imaging data.
In such scheme, described welding parameter comprises: the size in described molten bath, structure and thermograde.
In such scheme, described pattern process computer also for: when detecting that the welding parameter of described solder joint does not meet described welding standard, extract the weld interval of described solder joint, welding position information, analyze the defect of described weld interval and the existence of described welding position.
In such scheme, described welding gun comprises: laser welding gun and arc welding gun.
In such scheme, described pattern process computer also for:
Read the described molten bath infrared thermal imaging data stored in described memory, off-line analysis is carried out to described molten bath infrared thermal imaging data.
The present invention also provides a kind of welding quality monitoring method, and described method comprises:
Welding gun butt welding point is utilized to weld;
Shoot with video-corder the molten bath infrared thermal imaging data of described solder joint;
Gather and send described molten bath infrared thermal imaging data;
Analyze described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtain quality of welding spot assessment result.
In such scheme, described method also comprises: when detecting that the welding parameter of described solder joint does not meet described welding standard, extracts the weld interval of described solder joint, welding position information, analyzes the defect of described weld interval and the existence of described welding position.
In such scheme, described welding parameter comprises: the size in described molten bath, structure and thermograde.
In such scheme, described method also comprises: read described molten bath infrared thermal imaging data, carries out off-line analysis to described molten bath infrared thermal imaging data.
The invention provides a kind of welding quality monitoring system and method, described method comprises: utilize welding gun butt welding point to weld; Shoot with video-corder the molten bath infrared thermal imaging data of described solder joint; Gather and send described molten bath infrared thermal imaging data; Analyze described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtain quality of welding spot assessment result; So, the on-line monitoring of automatic welding quality can be realized, improve monitoring efficiency and quality, reduce loss, for welding quality provides reference data.
Accompanying drawing explanation
The welding quality monitoring system overall structure schematic diagram that Fig. 1 provides for the embodiment of the present invention one;
The structural representation of the deflector that Fig. 2 provides for the embodiment of the present invention one;
The structural representation of the protective plate that Fig. 3 provides for the embodiment of the present invention one;
The welding quality monitoring method schematic flow sheet that Fig. 4 provides for the embodiment of the present invention two.
Detailed description of the invention
In order to ensure the welding quality of laser/electric arc combined weldering, improve welding quality monitoring efficiency, the invention provides a kind of welding quality monitoring system and method, described method comprises: utilize welding gun butt welding point to weld; Shoot with video-corder the molten bath infrared thermal imaging data of described solder joint; Gather and send described molten bath infrared thermal imaging data; Analyze described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtain quality of welding spot assessment result.
Below by drawings and the specific embodiments, technical scheme of the present invention is described in further detail.
Embodiment one
The present embodiment provides a kind of welding quality monitoring system, and as shown in Figure 1, described system comprises: welding gun 1, thermal infrared imager 2, image pick-up card 3, pattern process computer 4; Wherein,
Described welding gun 1 welds for butt welding point; Described welding gun 1 comprises: laser welding gun 11 and arc welding gun 12.
Described thermal infrared imager 2, in welding gun 1 welding process, shoots with video-corder molten bath infrared thermal imaging data and the appearance of weld process of described solder joint;
After described molten bath infrared thermal imaging data and appearance of weld process have been shot with video-corder by described infrared thermography 2, described image pick-up card 3 specifically for: gather described molten bath infrared thermal imaging data and appearance of weld process, described molten bath infrared thermal imaging data appearance of weld process be sent to pattern process computer 4;
After described pattern process computer 4 receives described molten bath infrared thermal imaging data, specifically for: analyze described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtain quality of welding spot assessment result.Here, described welding parameter comprises: the size in described molten bath, structure and thermograde.
Particularly, described pattern process computer 4 comprises: image processor 41, mass analyzer 42 and memory 43; Wherein,
After described pattern process computer 4 receives described molten bath infrared thermal imaging data, described image processor 41 specifically for: to described molten bath infrared thermal imaging data analysis, obtain welding parameter, described welding parameter is sent to described mass analyzer 42.
When described mass analyzer 42 receives described welding parameter, specifically for: by described welding parameter compared with the welding standard preset, automatic acquisition quality of welding spot assessment result; And to detecting time of abnormal solder joint, coordinate carries out record, and the time of described abnormal solder joint, coordinate are sent to memory 43.
Described memory 43 is for storing time, the coordinate data of described molten bath infrared thermal imaging data, the view data of described welding fabrication process and described Abnormal welding point.
Here, when described pattern process computer 4 detects that the welding parameter of described solder joint does not meet described welding standard, also for: extract the weld interval of described solder joint, welding position information, analyze the weld interval of described solder joint and the defect of described welding position existence, for Welding quality test provides reference data.
When operating personnel need off-line analysis, described pattern process computer 4 also for:
Read the described molten bath infrared thermal imaging data stored in described memory 43, off-line analysis is carried out to described molten bath infrared thermal imaging data, obtain off-line analysis information; And play described molten bath infrared thermal imaging process and welding fabrication process by frame, the welding procedure for different materials, different parameters provides data reference.
In addition, in order to solve when high-speed welding, guarantee that described Combined Welding welding gun and described weld seam keep dynamically right precision, ensure appearance of weld effect and welding quality.The welding quality monitoring system that the present embodiment provides also comprises: laser sensor 5, controller 6, actuator 7, deflector 8 and protective plate 9.Wherein,
Described primary importance image information and second place image information, for gathering primary importance image information and the second place image information of weld seam, are sent to pattern process computer 4 by described laser sensor 5.Particularly, absorb by charge coupled cell (CCD, Charge-coupled Device) image-generating unit the image information comprising weld seam parameter after described laser sensor 5 projects the laser stripe of the CF on weld seam mating plate filters other frequency interferences light after filtration.Described weld seam parameter comprises: the lateral deviation of described weld seam, longitudinal bias, the alignment clearance of described weld seam and the unfitness of butt joint of described weld seam.
In welding process, when described pattern process computer 4 receives described primary importance image information and second place image information, first described image processor 41 calculates lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information; The alignment clearance of weld seam and the unfitness of butt joint of described weld seam according to described second place image information acquisition, according to described alignment clearance and described unfitness of butt joint the Fitting Calculation laser output power controlled quentity controlled variable.
Particularly, described image processor 41 utilizes laser power control Function Fitting to calculate laser output power controlled quentity controlled variable.
Because described Combined Welding has large fusion penetration, feature that bridging capability is good, therefore can adapt to larger unfitness of butt joint, the value of described unfitness of butt joint is specifically as follows: 0 ~ 2mm.If but described unfitness of butt joint is more than 2mm, just need the laser output power controlled quentity controlled variable increasing described Combined Welding.
In general, the two-sided 1mm root face of weldering needs the laser output power of 1KW thoroughly, therefore, when weld seam is inner shaping, and required first laser output power P
1can draw according to formula (1).
P
1＝P
0*(1+1/2*C) (1)
Wherein, in formula (1), described P
0based on power, described C is unfitness of butt joint.
Further, because the focal diameter of the laser beam of described Combined Welding is generally 0.33mm, when root face is less, the alignment clearance that described laser beam can adapt to is 0 ~ 0.3mm; And root face is when being the thicker root face of 4 ~ 10mm, the diameter of described laser beam at negative out of focus place becomes large, and the alignment clearance that can adapt to is 0 ~ 0.5mm.Wherein, described negative out of focus is the back side that the focus point of described laser beam is positioned at welding work pieces.
And alignment clearance excessive time, make laser-transmitting energy excessive, cause weld seam too high behind, therefore can adjust the second laser output power P according to formula (2) according to the alignment clearance of 0 ~ 0.5mm
2.
P
2＝P
0*(1-1/2*G) (2)
Wherein, in formula (2), described G is alignment clearance.
Therefore, the relational expression of described laser power control function can be drawn, as shown in formula (3):
P＝P
0*(1+1/2*C-1/2*G) (3)
Wherein, the corresponding 1v voltage of the 1mm of described unfitness of butt joint and described alignment clearance.
Here, described lateral deviation is described second place image information and described second place image information residual quantity in the horizontal direction; Described longitudinal bias is described second place image information and described primary importance image information residual quantity in vertical direction.Wherein,
Described primary importance image information specifically comprises: the initial weld positional information of described Combined Welding welding gun;
Described second place image information specifically comprises: in predetermined period, the welding position information that described Combined Welding welding gun arrives.The described default cycle is 1 ~ 3s.
Particularly, image processor 41 carries out the image procossing such as filtering, binaryzation, Threshold segmentation and rim detection to the primary importance image information received and second place image information, Digital Image Processing algorithm is utilized to simulate the weld image with weld seam with proportionate relationship, according to longitudinal bias and the lateral deviation of structured light principle determination welding gun and weld seam centering, add longitudinal bias described in proportionality coefficient correction and described lateral deviation.
Here, the setting height(from bottom) and the proportionality coefficient that pass through the laser sensor 5 calculated have relation.Such as, the setting height(from bottom) preset is 100mm, then proportionality coefficient is 1.But can alignment error be there is in installation process, or due to the restriction of frame for movement can not accurately install vision sensor in 100mm height, now need to set proportionality coefficient, such as setting height(from bottom) is 90mm, and proportionality coefficient needs to be set to 0.9; Or when setting height(from bottom) is 110mm, proportionality coefficient needs to be set to 1.1, revise with this and obtain weld seam dimensional information accurately.In sum, described proportionality coefficient is generally about 1.In use, setting height(from bottom) as far as possible close to 100mm, otherwise can should be affected for the image quality of the laser sensor 5 focused.
Secondly, described lateral deviation is converted to lateral deviation voltage by described image processor 41, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to the advanced amount of delay pre-set, described lateral deviation voltage, described longitudinal bias voltage and described laser output power controlled quentity controlled variable are sent to controller 6.Here, described advanced amount of delay is determined according to the leading amount of described laser sensor 5 and the speed of welding of described Combined Welding.Such as, when described leading amount is 1m, when described speed of welding is 1m/s, can determine that described advanced amount of delay is 1s.
Particularly, described lateral deviation is converted to the first corresponding pixel according to the first conversion coefficient by described image processor 41, and described first pixel is converted to described lateral deviation voltage;
According to the second conversion coefficient, described longitudinal bias is converted to the second corresponding pixel, described second pixel is converted to described longitudinal bias voltage.Wherein,
Described first conversion coefficient is: corresponding 100 described first pixels of described lateral deviation of 1mm, lateral deviation voltage described in 100 corresponding 1V of described first pixel;
Described second conversion coefficient is: corresponding 100 described second pixels of described longitudinal bias of 1mm, longitudinal bias voltage described in 100 corresponding 1V of described second pixel.
Wherein, described first conversion coefficient and described second conversion coefficient are determined according to the setting height(from bottom) of laser sensor 5.
When described image processor 41 described lateral deviation is converted to described lateral deviation voltage, described longitudinal bias is converted to described longitudinal bias voltage time, described controller 6 specifically for: control actuator 7 lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage; Accurate Shaft alignment state is kept to make described Combined Welding welding gun and described weld seam.Regulate the output energy of described laser sensor 5 according to described laser output power controlled quentity controlled variable in real time, ensure mating of the alignment clearance of laser output power and described weld seam, unfitness of butt joint, and then guarantee welding quality.
In welding process, described deflector 8 for: change compressed-air actuated airflow direction, eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole.As shown in Figure 2, described deflector 8 is T-shape metallic plate, described deflector 8 is provided with first circular hole concentric with Laser Focusing point, is communicated with laser optical path.The diameter of described first circular hole can be calculated by the Gaussian beam energy dissipation of laser welding gun 11, makes described first circular hole assemble 86% of described Gaussian beam laser energy.
Here, the material of described deflector 8 comprises: copper coin, aluminium sheet.
One end of described deflector 8 is linear pattern, and the first width is 55mm, and the first length is 60mm; The other end of described deflector 8 is arc, and the second width is 90mm, and the second length is 150mm.The thickness of described deflector 8 is 0.1mm.
Particularly; below focusing lens one end of described deflector 8 being arranged on described laser welding gun 11; the other end is connected with one end of described laser sensor 5; in welding process, the high pressure air stream of horizontal air blowing curtain after the side blowout of laser welding gun 11, after the other end of described deflector 8 guides; be discharged to welding gun both sides remotely; eliminate the interference of high pressure air stream to Combined Welding shielding gas flow, effectively inhibit weld blowhole, improve welding quality.
Further, in welding process, described protective plate 9 specifically for: effectively avoid laser welding gun 11 focusing lens to be subject to the pollution of welding slag, eliminate described laser welding gun 11 and protect the impact of gas curtain air-flow on shielding gas flow, improve welding quality and welding efficiency; Wherein,
As shown in Figure 3, described protective plate 9 is " L " type metallic plate, and described protective plate 9 comprises: the first metallic plate 91 and the second metallic plate 92; Wherein,
Described first metallic plate 91 is rectangle, and described rectangular length is 100mm, described rectangular wide be 64mm.Described first metallic plate 91 is provided with installing hole, and described installing hole comprises three rows, to adjust the setting height(from bottom) of described first metallic plate 91.
Described second metallic plate 92 is square, and the described foursquare length of side is 64mm, described second metallic plate 92 is provided with second circular hole concentric with described laser welding gun 11 focus point.
Particularly, before welding, described protective plate 9 is arranged on the laser head place of laser welding gun 11, and calculates the setting height(from bottom) h of described protective plate 9 by formula h=d/D*H; Wherein,
Described d is the diameter of described second circular hole; Described H is the focal length of laser welding gun 11.The diameter d of described second circular hole is 7.3 ~ 7.5mm.
The welding quality monitoring system that the present embodiment provides, has the following advantages:
(1) can Real-Time Monitoring analyze molten bath and form situation and appearance of weld situation, the time of the bad solder joint of accurate recording and positional information, acquisition welding quality assessment result; With manually directly observe compared with high-speed welding, improve efficiency and the quality of quality of welding spot detection, avoid the injury of laser to human body.
(2) provide reference data for quality of welding spot detects, reduce loss.
Embodiment two
Corresponding to embodiment one, the present embodiment also provides a kind of welding quality monitoring method, and as shown in Figure 4, described method comprises following step:
Step 410, utilizes welding gun butt welding point to weld;
In this step, described welding gun comprises laser welding gun and arc welding gun.
Step 411, shoots with video-corder the molten bath infrared thermal imaging data of described solder joint;
In this step, in welding gun welding process, infrared thermoviewer is utilized to shoot with video-corder molten bath infrared thermal imaging data and the appearance of weld process of described solder joint.
Step 412, gathers and sends described molten bath infrared thermal imaging data;
After described molten bath infrared thermal imaging data and appearance of weld process have been shot with video-corder by described infrared thermography, utilize described image pick-up card to gather described molten bath infrared thermal imaging data and appearance of weld process, described molten bath infrared thermal imaging data appearance of weld process is sent to pattern process computer.
Step 413, analyzes described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtains quality of welding spot assessment result;
After described pattern process computer receives described molten bath infrared thermal imaging data, analyze described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtain quality of welding spot assessment result.Here, described welding parameter comprises: the size in described molten bath, structure and thermograde.
Particularly, described pattern process computer comprises: image processor, mass analyzer and memory; Wherein,
After described pattern process computer receives described molten bath infrared thermal imaging data, described molten bath infrared thermal imaging data are sent to described image processor, described image processor is to described molten bath infrared thermal imaging data analysis, obtain welding parameter, described welding parameter is sent to described mass analyzer.
When described mass analyzer receives described welding parameter, by described welding parameter compared with the welding standard preset, automatic acquisition quality of welding spot assessment result; And to detecting time of abnormal solder joint, coordinate carries out record, and the time of described abnormal solder joint, coordinate are sent to memory.
Described memory is for storing time, the coordinate data of described molten bath infrared thermal imaging data, the view data of described welding fabrication process and described Abnormal welding point.
Here, when described pattern process computer detects that the welding parameter of described solder joint does not meet described welding standard, also extract the weld interval of described solder joint, welding position information, analyze the weld interval of described solder joint and the defect of described welding position existence, for Welding quality test provides reference data.
When operating personnel need off-line analysis, described pattern process computer reads the described molten bath infrared thermal imaging data stored in described memory, carries out off-line analysis to described molten bath infrared thermal imaging data, obtains off-line analysis information; And play described molten bath infrared thermal imaging process and welding fabrication process by frame, the welding procedure for different materials, different parameters provides data reference.
In addition, the present embodiment also utilizes laser sensor, controller, actuator, deflector and protective plate, guarantees when high-speed welding, and described Combined Welding welding gun and described weld seam keep dynamically right precision, ensures appearance of weld effect and welding quality.Wherein,
Described primary importance image information and second place image information, for gathering primary importance image information and the second place image information of weld seam, are sent to pattern process computer by described laser sensor.Particularly, described laser sensor absorbs by charge coupled cell CCD image-generating unit the image information comprising weld seam parameter after projecting the laser stripe of the CF on weld seam mating plate filtering other frequency interferences light after filtration.Described weld seam parameter comprises: the lateral deviation of described weld seam, longitudinal bias, the alignment clearance of described weld seam and the unfitness of butt joint of described weld seam.
In welding process, when described pattern process computer receives described primary importance image information and second place image information, first described image processor calculates lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information; The alignment clearance of weld seam and the unfitness of butt joint of described weld seam according to described second place image information acquisition, according to described alignment clearance and described unfitness of butt joint the Fitting Calculation laser output power controlled quentity controlled variable.
Particularly, described image processor utilizes laser power control Function Fitting to calculate laser output power controlled quentity controlled variable.
Because described Combined Welding has large fusion penetration, feature that bridging capability is good, therefore can adapt to larger unfitness of butt joint, the value of described unfitness of butt joint is specifically as follows: 0 ~ 2mm.If but described unfitness of butt joint is more than 2mm, just need the laser output power controlled quentity controlled variable increasing described Combined Welding.
In general, the two-sided 1mm root face of weldering needs the laser output power of 1KW thoroughly, therefore, when weld seam is inner shaping, and required first laser output power P
1can draw according to formula (1).
P
1＝P
0*(1+1/2*C) (1)
Wherein, in formula (1), described P
0based on power, described C is unfitness of butt joint.
Further, because the focal diameter of the laser beam of described Combined Welding is generally 0.33mm, when root face is less, the alignment clearance that described laser beam can adapt to is 0 ~ 0.3mm; And root face is when being the thicker root face of 4 ~ 10mm, the diameter of described laser beam at negative out of focus place becomes large, and the alignment clearance that can adapt to is 0 ~ 0.5mm.Wherein, described negative out of focus is the back side that the focus point of described laser beam is positioned at welding work pieces.
And alignment clearance excessive time, make laser-transmitting energy excessive, cause weld seam too high behind, therefore can adjust the second laser output power P according to formula (2) according to the alignment clearance of 0 ~ 0.5mm
2.
P
2＝P
0*(1-1/2*G) (2)
Wherein, in formula (2), described G is alignment clearance.
Therefore, the relational expression of described laser power control function can be drawn, as shown in formula (3):
P＝P
0*(1+1/2*C-1/2*G) (3)
Wherein, the corresponding 1v voltage of the 1mm of described unfitness of butt joint and described alignment clearance.
Here, described lateral deviation is described second place image information and described second place image information residual quantity in the horizontal direction; Described longitudinal bias is described second place image information and described primary importance image information residual quantity in vertical direction.Wherein,
Described primary importance image information specifically comprises: the initial weld positional information of described Combined Welding welding gun;
Described second place image information specifically comprises: in predetermined period, the welding position information that described Combined Welding welding gun arrives.The described default cycle is 1 ~ 3s.
Particularly, image processor 41 carries out the image procossing such as filtering, binaryzation, Threshold segmentation and rim detection to the primary importance image information received and second place image information, Digital Image Processing algorithm is utilized to simulate the weld image with weld seam with proportionate relationship, according to longitudinal bias and the lateral deviation of structured light principle determination welding gun and weld seam centering, add longitudinal bias described in proportionality coefficient correction and described lateral deviation.
Here, the setting height(from bottom) and the proportionality coefficient that pass through the laser sensor 5 calculated have relation.Such as, the setting height(from bottom) preset is 100mm, then proportionality coefficient is 1.But can alignment error be there is in installation process, or due to the restriction of frame for movement can not accurately install vision sensor in 100mm height, now need to set proportionality coefficient, such as setting height(from bottom) is 90mm, and proportionality coefficient needs to be set to 0.9; Or when setting height(from bottom) is 110mm, proportionality coefficient needs to be set to 1.1, revise with this and obtain weld seam dimensional information accurately.In sum, described proportionality coefficient is generally about 1.In use, setting height(from bottom) as far as possible close to 100mm, otherwise can should be affected for the image quality of the laser sensor 5 focused.
Secondly, described lateral deviation is converted to lateral deviation voltage by described image processor, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to the advanced amount of delay pre-set, described lateral deviation voltage, described longitudinal bias voltage and described laser output power controlled quentity controlled variable are sent to controller.Here, described advanced amount of delay is determined according to the leading amount of described laser sensor and the speed of welding of described Combined Welding.Such as, when described leading amount is 1m, when described speed of welding is 1m/s, can determine that described advanced amount of delay is 1s.
Particularly, described lateral deviation is converted to the first corresponding pixel according to the first conversion coefficient by described image processor, and described first pixel is converted to described lateral deviation voltage;
According to the second conversion coefficient, described longitudinal bias is converted to the second corresponding pixel, described second pixel is converted to described longitudinal bias voltage.Wherein,
Described first conversion coefficient is: corresponding 100 described first pixels of described lateral deviation of 1mm, lateral deviation voltage described in 100 corresponding 1V of described first pixel;
Described second conversion coefficient is: corresponding 100 described second pixels of described longitudinal bias of 1mm, longitudinal bias voltage described in 100 corresponding 1V of described second pixel.
Wherein, described first conversion coefficient and described second conversion coefficient are determined according to the setting height(from bottom) of laser sensor.
When described image processor described lateral deviation is converted to described lateral deviation voltage, described longitudinal bias is converted to described longitudinal bias voltage time, described controller specifically for: control actuator lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage; Accurate Shaft alignment state is kept to make described Combined Welding welding gun and described weld seam.Regulate the output energy of described laser sensor according to described laser output power controlled quentity controlled variable in real time, ensure mating of the alignment clearance of laser output power and described weld seam, unfitness of butt joint, and then guarantee welding quality.
In welding process, utilize deflector to change compressed-air actuated airflow direction, eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole.As shown in Figure 2, described deflector is T-shape metallic plate, described deflector is provided with first circular hole concentric with Laser Focusing point, is communicated with laser optical path.The diameter of described first circular hole can be calculated by the Gaussian beam energy dissipation of laser welding gun, makes described first circular hole assemble 86% of described Gaussian beam laser energy.
Here, the material of described deflector comprises: copper coin, aluminium sheet.
One end of described deflector is linear pattern, and the first width is 55mm, and the first length is 60mm; The other end of described deflector is arc, and the second width is 90mm, and the second length is 150mm.The thickness of described deflector is 0.1mm.
Particularly; below focusing lens one end of described deflector being arranged on described laser welding gun; the other end is connected with one end of described laser sensor; in welding process, the high pressure air stream of horizontal air blowing curtain after the side blowout of laser welding gun, after the other end of described deflector guides; be discharged to welding gun both sides remotely; eliminate the interference of high pressure air stream to Combined Welding shielding gas flow, effectively inhibit weld blowhole, improve welding quality.
Further, in welding process, utilize protective plate to eliminate described laser welding gun protection gas curtain air-flow to the impact of shielding gas flow, effectively avoid laser welding gun focusing lens to be subject to the pollution of welding slag, improve welding quality and welding efficiency; Wherein,
As shown in the figure, described protective plate is " L " type metallic plate, and described protective plate comprises: the first metallic plate and the second metallic plate; Wherein,
Described first metallic plate is rectangle, and described rectangular length is 100mm, described rectangular wide be 64mm.Described first metallic plate is provided with installing hole, and described installing hole comprises three rows, to adjust the setting height(from bottom) of described first metallic plate.
Described second metallic plate is square, and the described foursquare length of side is 64mm, described second metallic plate is provided with second circular hole concentric with described laser welding gun focus point.
Particularly, before welding, described protective plate is arranged on the laser head place of laser welding gun, and calculates the setting height(from bottom) h of described protective plate by formula h=d/D*H; Wherein,
Described d is the diameter of described second circular hole; Described H is the focal length of laser welding gun.The diameter d of described second circular hole is 7.3 ~ 7.5mm.
The above, be only preferred embodiment of the present invention, be not intended to limit protection scope of the present invention, and all any amendments done within the spirit and principles in the present invention, equivalent replacement and improvement etc., all should be included within protection scope of the present invention.
Claims (10)
1. a welding quality monitoring system, is characterized in that, described system comprises:
Welding gun, described welding gun is used for butt welding point and welds;
Thermal infrared imager, described thermal infrared imager is for shooting with video-corder the molten bath infrared thermal imaging data of described solder joint;
Image pick-up card, described molten bath infrared thermal imaging data, for gathering described molten bath infrared thermal imaging data, are sent to pattern process computer by described image pick-up card;
Pattern process computer, described pattern process computer, for analyzing described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtains quality of welding spot assessment result.
2. the system as claimed in claim 1, is characterized in that, described pattern process computer comprises:
Image processor, described image processor is used for described molten bath infrared thermal imaging data analysis, obtains welding parameter;
Mass analyzer, described mass analyzer is used for, by described welding parameter compared with the welding standard preset, obtaining quality of welding spot assessment result;
Memory, described memory is for storing described molten bath infrared thermal imaging data.
3. the system as claimed in claim 1, is characterized in that, described welding parameter comprises: the size in described molten bath, structure and thermograde.
4. the system as claimed in claim 1, it is characterized in that, described pattern process computer also for: when detecting that the welding parameter of described solder joint does not meet described welding standard, extract the weld interval of described solder joint, welding position information, analyze the defect of described weld interval and the existence of described welding position.
5. the system as claimed in claim 1, is characterized in that, described welding gun comprises: laser welding gun and arc welding gun.
6. the system as claimed in claim 1, is characterized in that, described pattern process computer also for:
Read the described molten bath infrared thermal imaging data stored in described memory, off-line analysis is carried out to described molten bath infrared thermal imaging data.
7. a welding quality monitoring method, is characterized in that, described method comprises:
Welding gun butt welding point is utilized to weld;
Shoot with video-corder the molten bath infrared thermal imaging data of described solder joint;
Gather and send described molten bath infrared thermal imaging data;
Analyze described molten bath infrared thermal imaging data acquisition welding parameter, by described welding parameter compared with the welding standard preset, obtain quality of welding spot assessment result.
8. method as claimed in claim 7, it is characterized in that, described method also comprises: when detecting that the welding parameter of described solder joint does not meet described welding standard, extracts the weld interval of described solder joint, welding position information, analyzes the defect of described weld interval and the existence of described welding position.
9. method as claimed in claim 7, it is characterized in that, described welding parameter comprises: the size in described molten bath, structure and thermograde.
10. method as claimed in claim 7, it is characterized in that, described method also comprises: read described molten bath infrared thermal imaging data, carries out off-line analysis to described molten bath infrared thermal imaging data.
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