CN104858559A - Device for measuring dripping speed of molten drop in consumable electrode pulsed argon arc welding and analysis method thereof - Google Patents
Device for measuring dripping speed of molten drop in consumable electrode pulsed argon arc welding and analysis method thereof Download PDFInfo
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- CN104858559A CN104858559A CN201510229590.XA CN201510229590A CN104858559A CN 104858559 A CN104858559 A CN 104858559A CN 201510229590 A CN201510229590 A CN 201510229590A CN 104858559 A CN104858559 A CN 104858559A
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
Abstract
The invention discloses a device and a method for analyzing the dripping speed of molten drop in consumable electrode pulsed argon arc welding. The transition process of each molten drop is shot by a high-speed camera to obtain a group of continuous pictures, the outline of the molten drop is extracted by digital image processing software (MATLAB), and the centroid of the molten drop is obtained by fitting. The molten drop speed can be obtained through the centroid distance of two adjacent pictures of the molten drop and the shooting frequency. And connecting all the obtained speed coordinate points to obtain an accurate speed curve chart of the molten drop in the arc transition. Based on the curve, the kinetic energy change condition, the acceleration change condition and the stress change condition of the molten drop can be analyzed, and the state change of the molten drop in the dropping process can be accurately mastered. The invention is also suitable for the drop transition analysis of common gas metal arc welding (such as direct current and alternating current MIG \ MAG).
Description
Technical field
The invention relates to pulsed metal argon-arc-welding (P-MIG), particularly a kind of utilize digital image processing techniques to analyze the dropleting speed of P-MIG molten drop device and analytical method.
Background technology
Pulsed metal argon-arc-welding (P-MIG) uses welding wire as consumable electrode, and inert gas Ar or Ar+He, as protective gas, utilizes pulse current to control the arc welding method of droplet transfer.Because it has controlled thermal input, quality of weld seam molding is good, and Technological adaptability is wide and be specially adapted to the advantage such as welding of non-ferrous metal, becomes a kind of welding procedure of industrial extensive use.
In welding process, welding wire is formed the droplet transfer in molten bath by high-temperature electric arc heat fused, to molten bath transmission heat, and momentum and quality, to final molten bath solidify and quality of weld seam molding can have a huge impact, therefore analyze the transient process of molten drop in electric arc most important.
All the time, a lot of to the transition research of gas metal-arc welding molten drop.Waszink.H. and Graat, L.H.J etc. nineteen eighty-three means analysis by experiment act on power on molten drop, and propose two kinds of metal transfer theories: the theoretical and constriction instability theory of standing balance, for theoretical foundation has been established in follow-up research and simulation.Lancaster proposed molten drop transient process in 1984 is divided into 3 stages: be separated, drippage shifts and crashes into molten bath.Kou proposed 3 kinds of different transition modes of gas metal-arc welding molten drop in 1987: short circuiting transfer, drop-wise transition and spray transfer.Y-S.KIM and T.W.EAGAR analyzed the transition mode of gas metal-arc welding molten drop in 1993 by means of high speed photography, predicted the size of molten drop, and restrictive condition theoretical before proposing.The proposition of metal transfer theory and transition mode is the basic research of droplet transfer behavior, does not relate to the drippage process of molten drop in electric arc.In the existing document analyzed about molten drop drippage process state, major part all concentrates on the separation phase of molten drop and crashes into the state behind molten bath, to the drippage motion state of molten drop in whole electric arc atmosphere analyze less.Patent of invention " a kind of method for quantitatively evaluating of arc welding droplet transfer process stability " publication number 102430835A, disclose the method and first the voltage and current signal in arc welding process is carried out autocorrelation analysis, solve the positional information of all peak values and formation sequence peakPosition, the spacing calculating adjacent peak again obtains pitch sequence space, finally ask the coefficient of variation varCoef of pitch sequence, using the parameter of this quantized value as quantitative assessment arc welding droplet transfer process stability degree.In addition; patent of invention " spectral control method of pulsed gas metal arc welding droplet transfer " publication number 1291534A; disclosing the method is utilize spectral detection system; select the characteristic spectral line on electric arc and molten drop testing section; spectral signal is converted to the signal of telecommunication of sufficient intensity; after analog-to-digital conversion, input MICROCOMPUTER PROCESSING, the control signal of output exports drive pulse signal through PWM again and drives IGBT to implement the action of shear electric current, reaches the control object of one pulse-one droplet.These two patents individually disclose the assessment method of droplet transfer process stability and control the method for droplet transfer process, and do not relate to the analysis of P-MIG molten drop drippage process.The research major part of dripping process about molten drop in electric arc is afterwards all based on numerical simulation with by high speed photography.J.Haidar and .J.Lowke adopts method for numerical simulation to predict the forming process of molten drop.F.L.Zhu etc. simulate the whole drippage transient process of gas metal-arc welding molten drop.S.SUBRAMANIAM and D.R.WHITE etc. have studied protective gas composition to the capillary impact of molten drop, by means of high speed photography, observed the reforming phenomena of molten drop in transient process, and be dependent on this concussion frequency meter calculated the surface tension of molten drop.But all there is following deficiency in these methods:
1, numerical simulation technology is adopted to analyze the correlation properties of droplet transfer process, too simplify many relevancy factors such as molten drop is stressed, arc atmosphere, although there is certain good effect, must have very large error with actual conditions, its accuracy and actual directive significance have much room for improvement.
2, based on high speed photography obtain current the researching and analysing of image, major part is carried out qualitatively according to picture, or rough quantitative (as molten drop concussion etc.), the accuracy of analysis is not high, and does not analyze the speed of the whole drippage process of molten drop yet.
Summary of the invention
Object of the present invention, is for the above deficiency about P-MIG droplet transfer process analysis procedure analysis research and prior art Problems existing, provides a kind of P-MIG droplet transfer process real-time monitoring device and monitoring method.This device is made up of welding portion and high-speed camera collecting part two parts.Wherein, welding portion is by the V350 type welding machine of LINCOLN company, and wire-feed motor and the welded sheet material of Q235 steel form; High-speed camera collecting part is made up of FASTCAM-Super 10KC type high-speed camera, camera lens, back light xenon lamp and computer system.
One disclosed by the invention analyzes P-MIG droplet transfer process digital image processing method, by the accurate extraction of MATLAB software programming realization to transition molten drop edge contour, and the barycenter of molten drop is marked, then accurately calculate the velocity magnitude of molten drop when arc space transition.
The present invention obtains the transient process of pulsed metal argon-arc-welding (P-MIG) molten drop in electric arc by digital image processing techniques, i.e. the speed curve diagram of molten drop in arc space during transition.Taken the transient process of each molten drop by high-speed camera, obtain one group of continuous print picture, then use digital imaging processing software (MATLAB) to extract the profile of molten drop, and matching obtains the barycenter of molten drop.Like this, on each pictures, the barycenter pixel coordinate of molten drop just determines, and the frequency frame of high-speed camera is known, then the time interval of two photos just can be determined, supposes that the molten drop barycenter pixel coordinate on adjacent two photos is respectively (x
1, y
1) and (x
2, y
2).Then molten drop can be similar in speed v during this period of time and think:
Wherein, l is number of pixels corresponding to gage of wire thus actual size corresponding to the single pixel pushed away, and dt is the time interval of adjacent picture.All speed coordinate points of trying to achieve are coupled together and just obtains the speed curve diagram of molten drop at arc space.
For this reason, object of the present invention, is to provide a kind of device and method analyzing P-MIG droplet transfer process based on digital image processing techniques, to obtain the precise speed curve map of molten drop in electric arc during transition.
The object of the invention is to be achieved through the following technical solutions:
Analyze a device for pulsed metal argon-arc-welding molten drop dropleting speed, comprise welding portion and high-speed camera collecting part; It is characterized in that, described welding portion is welding machine, wire-feed motor and sheet material, and described high-speed camera collecting part is high-speed camera, camera lens, xenon lamp and computer system.
Described welding machine is the V350 type welding machine that LINCOLN company produces, and described high-speed camera is FASTCAM-Super10KC type high-speed camera, and sample frequency is 2000Hz, and resolution ratio is 256*120.
When building test platform, the camera lens of described high-speed camera is parallel with welded mother metal plane with the straight line at the xenon lamp place as back light, to reduce measure error.
The analytical method of the device of this analysis pulsed metal argon-arc-welding molten drop dropleting speed, the accurate extraction to transition molten drop edge contour is realized by Digital Image Processing MATLAB software programming, and the barycenter of molten drop is marked, then accurately calculate the transition speed of molten drop at arc space; There are following steps:
(1) image of one group of continuous print droplet transfer process is obtained by high-speed camera shooting;
(2) Digital Image Processing MATLAB software is utilized to carry out greyscale transformation to the image that step (1) gathers;
(3) median filter is used to remove the noise of image to the image of step (2) again, and with median filter to the smoothing denoising of image;
(4) method of histogram specification is adopted to strengthen the contrast of picture;
(5) adopt Log function to carry out edge extracting to image, then delete small size object, i.e. the noise of non-elimination in picture;
(6) extract the profile of molten drop again with Digital Image Processing MATLAB software, adopt least square method to carry out matching to the edge of molten drop, and obtain the barycenter of molten drop;
(7) the molten drop barycenter pixel coordinate on adjacent two photos is established to be respectively (x
1, y
1) and (x
2, y
2), then molten drop can be similar in speed v during this period of time and think:
Wherein, l is number of pixels corresponding to gage of wire thus actual size corresponding to the single pixel pushed away, and dt is the time interval of adjacent picture; All speed coordinate points of trying to achieve are coupled together and just obtains the speed curve diagram of molten drop at arc space.
Described molten drop in the transition speed characteristic distributions of arc space is: molten drop does accelerated motion in arc column district, does retarded motion in nearly cathodic region and nearly anode region, and nearly cathodic region deceleration amplitude is larger.
The velocity variations situation of molten drop in free transition can be understood in depth by the present invention, and then grasp molten drop and enter the kinetic energy change behind molten bath, thus the inner link of weld penetration, molten wide and droplet transfer process can be grasped in itself.Do not consider that molten drop behavior in drippage process, just simple analysis technological parameter rule (such as welding current is larger, fusion penetration is darker) will be goed deep into many relatively at present.Therefore, grasp droplet transfer change in process characteristic rule by method of the present invention, and then meticulous selection can be carried out to welding condition, promote the Physical Mechanism understanding of molten drop drippage process.In addition, based on the method, also can control to the droplet transfer analysis that new tool gos deep into internal, such as study in molten drop drippage process and add magnetic control etc.
Accompanying drawing explanation
Fig. 1 is the schematic diagram analyzing pulsed metal argon-arc-welding molten drop dropleting speed device;
Fig. 2 is the picture after carrying out greyscale transformation;
Fig. 3 is the picture after carrying out medium filtering;
Fig. 4 is the picture after carrying out image enhaucament;
Fig. 5 is the picture after carrying out edge extracting;
Fig. 6 is the picture after carrying out noise filtration;
Fig. 7 is the picture after carrying out edge fitting;
Fig. 8 is the complete transient process picture of undressed molten drop;
Fig. 9 is the complete transient process picture of molten drop after digital imaging processing software (MATLAB) process;
Figure 10 is the speed curve diagram of molten drop transition in electric arc.
Detailed description of the invention
Below in conjunction with drawings and Examples, the method based on digital image processing techniques analysis P-MIG droplet transfer process of the present invention is further described.
The digital image processing techniques of the present embodiment analyze P-MIG droplet transfer process, and the welding real-time monitoring device of employing comprises welding portion and high-speed camera collecting part.Described welding portion comprises LINCOLN V350 type welding machine, wire-feed motor and the welded sheet material of Q235 steel.Described high-speed camera collecting part comprises FASTCAM-Super 10KC type high-speed camera, camera lens, back light xenon lamp and computer system.Sample frequency is 2KHz, resolution ratio 256*120.Soldering test device schematic diagram as shown in Figure 1.
During welding, the H08Mn2SiA welding wire of to be diameter the be 1.2mm that welding wire adopts, mother metal is Q235 steel, is of a size of 200 × 100 × 10mm.Electric arc polarity is DC reverse connection, and welding manner is disk diffusion method, and the transient mode of molten drop is one pulse-one droplet.Concrete soldering test parameter is as shown in the table.
The implementation step analyzing P-MIG droplet transfer process based on digital image processing techniques is specific as follows:
1, build test platform and debug picture signal acquisition system, to collect high-speed photograph clearly.When building test platform, the present embodiment will make high-speed camera camera lens parallel with welded mother metal plane with the straight line at back light (xenon lamp) place, to reduce measure error.Experimental rig schematic diagram as shown in Figure 1.
2, as Fig. 1, computer system provides triggering signal to carry out the collection of picture signal for high-speed camera, takes the transient process of each molten drop, obtains each molten drop one group of continuous print picture, as shown in Figure 8.
3, by the further enhancing process of digital imaging processing software (MATLAB) do and edge contour extraction, molten drop outline is clearly obtained to a series of pictures that step 2 photographs, as shown in Figure 9, so that the follow-up rate curve drawing molten drop is to analyze the transient process of molten drop in electric arc.
4, the picture photographed high-speed camera strengthens and edge contour extraction process, and concrete steps are as follows:
4.1) utilize original image captured by high-speed camera as Fig. 2;
4.2) the rgb2gray function that provides in MATLAB image processing toolbox and medifilt2 function is utilized to carry out greyscale transformation and medium filtering process to original image respectively, to remove the noise of image, and the edge feature information infringement of this function to image is less, and the image after process is as Fig. 3;
4.3) by 4.2) integral image that obtains is too dark, and the contrast of molten drop and background is strong, utilizes the histep function in MATLAB to carry out histogram specification process to image, the contrast of enhancing picture.Image after process is as Fig. 4;
4.4) utilize the Log function in MATLAB to 4.3) in the image that obtains carry out edge extracting, the image after process is as Fig. 5.Delete small size object again, i.e. the noise of non-elimination in figure, the image after process is as Fig. 6;
4.5) owing to there is breakpoint sometimes when extracting molten drop edge, use least square method to carry out matching to the edge of molten drop, and obtain the barycenter of molten drop, such as the dot in Fig. 7, figure of the image after process is the barycenter of molten drop.
5, in actual welding, welding gun is motionless, and workpiece low carbon steel plate to be welded carries out relative motion.Therefore pixel coordinate system can be set up as the origin of coordinates in the image upper left corner in high-speed camera, thus the position of the system of guarantee is relatively constant.X-axis is set as welding the direction of motion, and Y-axis is set as that, perpendicular to the welding direction of motion, on such each photographed pictures, the barycenter pixel coordinate of molten drop just determines (coordinate value is demarcated with pixel).The frequency frame of high-speed camera is 2000Hz, and namely the time interval of adjacent two photos is 0.5ms, supposes that the molten drop center-of-mass coordinate on adjacent two photos is respectively (x
1, y
1) and (x
2, y
2).Then molten drop can by following formulae discovery in speed v during this period of time:
Wherein, l is number of pixels corresponding to gage of wire thus actual size corresponding to the single pixel pushed away, and dt is the time interval (0.5ms) of adjacent picture.Coupled together by all speed coordinate points of trying to achieve in MATLAB and just obtain the speed curve diagram (Figure 10) of molten drop at arc space, known speed, can also calculate acceleration and the stressing conditions of molten drop simultaneously.
6, according to the speed curve diagram (Figure 10) of obtained molten drop at arc space, the transient process of P-MIG molten drop in electric arc can be analyzed.For understanding this variation tendency of speed, curve is divided into arc column district, nearly cathodic region and three, nearly anode region part carry out piecewise analysis.It should be noted that, nearly cathodic region here and nearly anode region are different from negative and positive polar region, because real negative and positive polar region is very short by (10
-3-10
-6cm).Namely molten drop does accelerated motion in arc column district, and what do in nearly cathodic region and nearly anode region is retarded motion.
In addition, the present invention except being used for the pulsed argon arc welding of drop-wise transition, general gas metal-arc welding (as direct current, interchange MIG MAG etc.) drop-wise transition the method also can use.
Claims (5)
1. analyze a device for pulsed metal argon-arc-welding molten drop dropleting speed, comprise welding portion and high-speed camera collecting part; It is characterized in that, described welding portion is welding machine, wire-feed motor and sheet material, and described high-speed camera collecting part is high-speed camera, camera lens, xenon lamp and computer system.
2. a kind of device analyzing pulsed metal argon-arc-welding molten drop dropleting speed according to claim 1, it is characterized in that, described welding machine is the V350 type welding machine that LINCOLN company produces, described high-speed camera is FASTCAM-Super10KC type high-speed camera, sample frequency is 2000Hz, and resolution ratio is 256*120.
3. a kind of device analyzing pulsed metal argon-arc-welding molten drop dropleting speed according to claim 1, it is characterized in that, when building test platform, the camera lens of described high-speed camera is parallel with welded mother metal plane with the straight line at the xenon lamp place as back light, to reduce measure error.
4. the analytical method of the device of the analysis pulsed metal argon-arc-welding molten drop dropleting speed of claim 1, the accurate extraction to transition molten drop edge contour is realized by Digital Image Processing MATLAB software programming, and the barycenter of molten drop is marked, then accurately calculate the transition speed of molten drop at arc space; There are following steps:
(1) image of one group of continuous print droplet transfer process is obtained by high-speed camera shooting;
(2) Digital Image Processing MATLAB software is utilized to carry out greyscale transformation to the image that step (1) gathers;
(3) median filter is used to remove the noise of image to the image of step (2) again, and with median filter to the smoothing denoising of image;
(4) method of histogram specification is adopted to strengthen the contrast of picture;
(5) adopt Log function to carry out edge extracting to image, then delete small size object, i.e. the noise of non-elimination in picture;
(6) extract the profile of molten drop again with Digital Image Processing MATLAB software, adopt least square method to carry out matching to the edge of molten drop, and obtain the barycenter of molten drop;
(7) the molten drop barycenter pixel coordinate on adjacent two photos is established to be respectively (x
1, y
1) and (x
2, y
2), then molten drop can be similar in speed v during this period of time and think:
Wherein, l is number of pixels corresponding to gage of wire thus actual size corresponding to the single pixel pushed away, and dt is the time interval of adjacent picture; All speed coordinate points of trying to achieve are coupled together and just obtains the speed curve diagram of molten drop at arc space.
5. the analytical method of the device of analysis pulsed metal argon-arc-welding molten drop dropleting speed according to claim 4, it is characterized in that, described molten drop in the transition speed characteristic distributions of arc space is: molten drop does accelerated motion in arc column district, do retarded motion in nearly cathodic region and nearly anode region, and nearly cathodic region deceleration amplitude is larger.
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Cited By (3)
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| CN111044434A (en) * | 2019-12-31 | 2020-04-21 | 太原科技大学 | Simulation device and method for gas metal arc welding molten drop transition process |
| CN113295581A (en) * | 2021-05-24 | 2021-08-24 | 兰州理工大学 | Method and device for dynamically measuring surface tension of welding molten drop and data processing terminal |
| CN114932290A (en) * | 2022-06-10 | 2022-08-23 | 浙江海洋大学 | Electric arc additive manufacturing system and method based on molten drop control characteristics |
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| CN114932290A (en) * | 2022-06-10 | 2022-08-23 | 浙江海洋大学 | Electric arc additive manufacturing system and method based on molten drop control characteristics |
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