CN104972197B - Welding process quality evaluation method for shielded metal arc welding - Google Patents
Welding process quality evaluation method for shielded metal arc welding Download PDFInfo
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- CN104972197B CN104972197B CN201510425865.7A CN201510425865A CN104972197B CN 104972197 B CN104972197 B CN 104972197B CN 201510425865 A CN201510425865 A CN 201510425865A CN 104972197 B CN104972197 B CN 104972197B
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Classifications
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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
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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
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0953—Monitoring or automatic control of welding parameters using computing means
Abstract
The invention discloses a welding process quality evaluation method for shielded metal arc welding. Discrete welding voltage signals and discrete welding current signals are collected in a welding process, and low-frequency voltage signals and low-frequency current signals are obtained through wavelet transformation analysis. The welding process is divided into m equal time slots. The average value of the low-frequency voltage signals in each time slot is worked out and then the average value of m low-frequency current signal average values is worked out. A variation coefficient of the m low-frequency voltage signal average values is worked out and compared with a series of variation coefficients in a welding process judgment database, and a basic score of the welding process is worked out. Then, long short circuit time is adopted for correcting the basic score, and a final quantitative evaluation score of the welding process is obtained and serves as a basic criterion for reflecting operational capacity. The operating skills of welders can be judged objectively and standardly.
Description
Technical field
The present invention relates to a kind of technology for evaluating welding quality, more particularly to a kind of mistake connect to welding rod means of fusion arc welding
The method of Cheng Jinhang quantitative assessments.
Background technology
In SMAW, the operating technology of welder is the key factor for determining welding quality, important engineering project
It is middle to need reliable welding operation technology to ensure the welding quality of engineering.But up to the present, for welding engineering project is grasped
Make the screening operation of personnel is still carried out by artificial subjective judgement, and this mode on the one hand can be due to subjective factorss, to sieve
Result is selected to have undesirable effect；On the other hand, during welding operation process often changes at a high speed in one, change at a high speed
During welding operation flaw, it is difficult to simply by " naked eyes " judged judging.Therefore, effective method is also lacked at present
To carry out quantitatively evaluating to the operation level of welder.
Additionally, at present the training to welding operator relies on the experience of " master worker " to carry out " instructing in words and by deeds " substantially, impart knowledge to students
Process lacks the objective hints and tips suggestion of science, causes cycle length, the high cost for cultivating a qualified welder；Together
When, some non-standard operation methods and custom of " master worker " also influence whether the result of training of student.Therefore, if can be using visitor
See, reliable method for quantitatively evaluating is evaluated the operation level of welder, it is possible to greatly promote sending out for whole industry
Exhibition.
Voltage, current signal in SMAW welding process is the signal of interest source for monitoring electric arc welding process, is welded
Any minor variations in operating process are connect, the electrical signal wave disorder of internal organs of welding process can be all reflected in.Therefore, in welding process
The signal of telecommunication is used in the aspects such as the evaluation of welding material manufacturability, source of welding current performance detection.But up to the present, also do not grind
The person of studying carefully adopts this signal source, effectively realizes objectively evaluating welding process quality, this mainly with two key factors
It is relevant.
1) further investigation and the understanding to arc physics is lacked.Especially SMAW operation in, operator due to
Individuation feature, its arc manipulation method, welding position, the difference of welding maneuver, brings widely different arc shape, and its physics is special
Levy also far from it, be difficult to realize effective method for quantitatively evaluating.
2) in welding process, different welding position such as downhand welding, horizontal position welding, overhead welding, vertical position welding and different joint forms are such as
Tube sheet docking, T connector, groove type etc., to judge great difficulty is brought.
Simultaneously as lacking reliable standard, the horizontal rating scale of SMAW operation of maturation is not also set up so far,
Also certain difficulty is brought to the quantitatively evaluating of welding process quality.
The content of the invention
It is an object of the invention to provide a kind of welding process quality evaluating method of SMAW, with to SMAW
Welding quality carry out objective appraisal.
Voltage, electricity that the welding process quality evaluating method of the SMAW that the present invention is provided passes through extraction welding process
Stream signal effective information, it is theoretical with reference to droplet transfer and arc physics, spectrum analyses and wavelet filteration method have been used, and consider
To the physical significance that signal of telecommunication high frequency signal and low frequency signal are included, further by mathematical statistics method, extract point
The section low-frequency voltage coefficient of variation and it is long when two important evaluation indexes of short circuit duration, the quality for establishing welding process quantitatively comments
Valency index and parameter, are reliably evaluated with the operation level to welder.
Welding process quality evaluating method of the present invention is comprised the following steps：
1）Discrete weldingvoltage signal in collection SMAW welding processV(n) and welding current signalI(n)；
2）The weldingvoltage signal collected using the wfilters function pairs in MATLABV(n) and welding current signalI
N () carries out wavelet transformation analysis, obtain db6 scaling functions, obtains low-frequency voltage signalL V (n) and low-frequency current signalL I (n)；
3）Exist low-frequency voltage signal be unsatisfactory for 18V≤L V (n)≤35V or low-frequency current signal be unsatisfactory for 90A≤L I (n)
The welding process of≤135A, is evaluated as welding process unqualified；
4）For low-frequency voltage signalL V (n) excursion all the time between 18V～35V, while low-frequency current signalL I
N () excursion welding process all the time between 90A～135A, the m sections of time period such as is divided into by the welding process, calculate
Low-frequency voltage signal in each time periodL V The meansigma methodss of (n)L av (i)（I=1,2 ... ..., m)；
5）Obtain m low-frequency voltage signal meansigma methodssL av (i)（I=1,2 ... ..., meansigma methodss m), according to formula
（1）Calculate the m low-frequency voltage signal meansigma methodssL av (i)（I=1,2 ... ..., coefficient of variation m)CV, as the weldering
The coefficient of variation of termination process：
In formula：L av I () represents the meansigma methodss of low-frequency voltage signal in certain time period,Represent m low-frequency voltage
Signal averagingL av (i)（I=1,2 ... ..., meansigma methodss m)；
6）Obtain the coefficient of variation no less than 200 welding processes, it is established that welding process passes judgment on data baseCV cj, j >=
200, and find out the maximum coefficient of variation in data baseCV c maxWith the minimum coefficient of variationCV c min；
7）According to step 1）～5）Weldingvoltage signal to intending evaluating welding process is processed, and obtains described welding
The coefficient of variation of journeyCV, according to formula（2）It is calculated the basic score value of the welding processEi：
In formula：CV c maxThe maximum coefficient of variation in for data base,CV c minThe minimum coefficient of variation in for data base,CV cj
For the coefficient of variation of each welding process in data base,CVTo be evaluated the coefficient of variation of welding process.
Further, described to be divided into welding process etc. in the m sections of time period, per of time is preferably 0.5～1s.
Further, the present invention can also be using following methods to basic score value obtained aboveEiFurther corrected：
1）The critical voltage value for occurring short-circuit voltage in welding process is set as 10V, weldingvoltage signalVN () is from being less than
Critical voltage starts, and is short circuit duration to the time interval for being higher than again critical voltageT, set >=short circuit duration of 30ms is as length
When short circuit durationTi；
2）From discrete weldingvoltage signalVShort circuit duration when finding out whole long in (n)Ti, with formula（3）To describedTi
It is modified, short circuit duration when obtaining total longTc：
In formula：η i For correction factor, when 30≤TiWhen≤100,η i =1；As 100 ＜TiWhen≤300,η i =10；WhenTi＞
When 300,η i =50；
3）With it is total long when short circuit durationTcAs correction value, according to formula（4）To basic score valueEiIt is modified, obtains institute
State the last quantitatively evaluating score value of welding process：
In formula：R 1=100ms,R 2=500ms,R 3=1000ms。
The welding process of SMAW includes downhand welding, horizontal position welding, overhead welding, four kinds of modes of vertical position welding, above-mentioned evaluation of the invention
Method is equally applicable to four kinds of modes of the above, but needs to set up every kind of welding manner respective welding process judge data base.
In the above-mentioned welding process quality evaluating method of the present invention, the data in the welding process judge data base of institute's foundation are simultaneously
It is not unalterable, it is also possible to which the data in data base are modified, its concrete grammar is：When being evaluated welding process
The coefficient of variationCVMore than data base's maximum coefficient of variationCV c maxOr less than data base's minimum coefficient of variationCV c minWhen, will be described
The coefficient of variationCVIn being added to data base, replace the maximum coefficient of variation of data baseCV c maxOr the minimum coefficient of variationCV c min, it is right
Data base is modified.
SMAW has strict requirements for the arc manipulation process of operator, in operation, must protect
The reliable and stable arc manipulation of card, could form good weld seam.The SMAW welding process quality evaluation side that the present invention sets up
Method carries out wavelet transformation by obtaining weldingvoltage, the welding current information of the change of welding process high speed to it, obtains
The time and frequency domain characteristics of the signal of telecommunication such that it is able to get operational stability characteristic signal（Using the segmentation low-frequency voltage coefficient of variation
Realize）And droplet transfer controlling feature signal（Short circuit duration signal when long）, the stability of arc manipulation process is evaluated well.
Result of the present invention based on wavelet analysises, to raw electrical signal scaling down processing is carried out, and has respectively obtained high-frequency signal
Information and low frequency signal information.
During different operating position, its low frequency signal signature is simultaneously differed, and voltage range and distribution all have differences, and this can be with
As statistical analysiss（The segmentation low-frequency voltage coefficient of variation）Basis, welding operation is judged according to the periodicity of low frequency signal
Stability, as the basis for estimation of rod-moving operation.
The present invention is processed low-frequency information, according to the periodicity and letter of low frequency signal after low frequency signal is obtained
Number fluctuating characteristic, initial data is distributed according to the dominant frequency that wavelet transformation determines, because manipulation of electrode is made in identification operating process
Into signal fluctuation periodic characteristic, further using the segmentation low-frequency voltage coefficient of variation sentencing knowledge process stability.Variation Lines
Number is bigger, and the basic operational capability of operator is poorer, and the segmentation low-frequency voltage coefficient of variation has reflected basic to welding operation
The evaluation of ability.
Simultaneously it can also be seen that high-frequency signal during different operating position is also different, reflect under different welding positions,
Droplet transfer feature is different, and short-circuit instantaneous time is different from the arc reignition time, this foundation that can be calculated as short circuit duration,
The control ability to the droplet transfer is judged according to the feature of high-frequency signal.
The present invention is processed high-frequency signal, is judged according to high-frequency signal feature in droplet transfer link operator
Control ability.The short circuit duration and splashing size of droplet transfer are the keys that high-frequency signal sentences knowledge, using high current it is long when
Short circuit duration determines different coefficients as judging quota, different short circuit durations, short circuit duration when thus obtaining longTcValue,
For correcting the score value of operation evaluation, control ability of the operator to the welding process droplet transfer is reflected.
After the numerical value of characteristic information is obtained using the inventive method, the coefficient of variation of low frequency signal is pressed as base using Segmented electrical
This scoring criterion, by point library searching correspondence parameter value in the different welding method rating databases set up, using comparison database
In standard and related algorithm be calculated basic score value.On basic score value, control of the operator to the droplet transfer is considered further that
Ability processed, short circuit duration judges the improper transient condition in welding process as Con trolling index when will be long, corrects quantitative assessment
Relevance score, thus obtains last quantitatively evaluating score value, used as the Basic Criteria of reflection operational capacity.
The method of the invention proposes and establishes dependent quantization evaluation criterion and the data base of welding process, to Welder
The operation level of people carries out quantitatively evaluating, because its evaluation criterion is built upon on the basis of the physical property of welding arc, by not
Obtain in the welding process electrical signal information of same Type of Welding, method and position, the operant skill of welder can be carried out
Objective, standard judgement, is suitable for screening, welding operation staff training, examination of important welding engineering project operation personnel etc.
Aspect application.
Specific embodiment
The content of welding process quality evaluating method of the present invention is expanded on further with reference to specific embodiment.The reality
Apply example technology design only to illustrate the invention and feature, it is impossible to limit the scope of the invention with this.It is all in base of the present invention
Equivalence changes or modification on plinth, all should be included within the scope of the present invention.
The specifically used J422 welding rods of the present embodiment carry out the downhand welding operation of arc welding, to weld to the welding process
The quantitative assessment of quality.
Welding process information is obtained initially with weldingvoltage and welding current sensor.Weldingvoltage and welding current point
Not through Hall element, Jing after signal conditioning circuit process, it is transformed into the voltage signal of 0～5V, obtains one in welding process
The discrete weldingvoltage signal of groupV(n) and welding current signalI(n), then the data of collection are demarcated by data collecting card,
Under acquisition software control, computer is transferred signals to.
Using the wfilters functions in MATLAB, according to following formula（5）Mathematic(al) representation, be transferred to calculating to above-mentioned
The welding process signal of telecommunication of machine, that is, the weldingvoltage signal for collectingV(n) and welding current signalIN () carries out wavelet transformation,
Obtain the time and frequency domain characteristics of the signal of telecommunication.
Then according to the result of wavelet transformation, frequency dividing analysis is carried out to raw electrical signal, obtains each frequency range of operator
The amplitude-frequency characteristic of the signal of telecommunication, and then db6 scaling functions are therefrom obtained, obtain low-frequency voltage signalL V (n) and low-frequency current signalL I
(n), and high-frequency voltage signalH V (n) and high-frequency current signalH I (n)。
To the low-frequency voltage signal in above-mentioned welding processL V (n) and low-frequency current signalL I N () is analyzed, judge weldering
Whether there is low-frequency voltage signal in termination process less than 18V or higher than 35V, or low-frequency current signal is less than 90A or is higher than
The phenomenon of 135A, both can be directly unqualified by the welding process evaluation as long as one of which situation occurred once.
For low-frequency voltage signalL V (n) all the time between 18V～35V change, while low-frequency current signalL I N () all the time
The welding process changed between 90A～135A, into following quantitatively evaluating link.
First the welding process is divided into into m sections, every section of time 0.5s.Calculate low-frequency voltage signal in each time periodL V
The meansigma methodss of (n)L av (i)（I=1,2 ... ..., m)；M low-frequency voltage signal meansigma methodss are obtained againL av (i)（I=1,2 ... ...,
M) meansigma methodss, according to formula（1）Calculate the m low-frequency voltage signal meansigma methodssL av (i)（I=1,2 ... ..., m)
The coefficient of variationCV, as the segmentation low-frequency voltage coefficient of variation of this welding process.
In formula：L av I () represents the meansigma methodss of low-frequency voltage signal in certain time period,Represent m low-frequency voltage
Signal averagingL av (i)（I=1,2 ... ..., meansigma methodss m).
Gathered based on previously passed mass data, the signal of telecommunication and automatic welding of different operating levels operation personnel are taken over
Journey is analyzed, and the coefficient of variation no less than 200 welding processes is acquired, using it as evaluation criterion, it is established that welding
Process passes judgment on data baseCV cj, the maximum coefficient of variation stored in j >=200, and data baseCV c maxWith the minimum coefficient of variationCV c minData, according to formula（2）It is calculated the basic score value of the welding processEi。
In formula：CV c maxThe maximum coefficient of variation in for data base,CV c minThe minimum coefficient of variation in for data base,CV cj
For the coefficient of variation of each welding process in data base,CVFor the coefficient of variation that the present embodiment is evaluated welding process.
Meanwhile, judge the coefficient of variation with data base's maximum coefficient of variationCV c maxWith the minimum coefficient of variationCV c min's
Relation, if the coefficient of variationCVIt is more thanCV c maxOr be less thanCV c min, then by this coefficient of variationCVIn being added to data base, generation
For original maximum coefficient of variationCV c maxOr the minimum coefficient of variationCV c min, data base is modified.If located inCV c max
WithCV c minBetween, then keep legacy data storehouse constant.
Then, further to basic score valueEiIt is modified, finds out the time for occurring short-circuit voltage in welding process, that is, welds
Weldingvoltage signal in termination processVN () starts to the time for being higher than again 10V, as short circuit duration less than 10VT, and therefrom sieve
Select the short circuit duration of whole >=30ms as it is long when short circuit durationTi.With formula（3）To describedTiIt is modified, obtains total length
When short circuit durationTc。
In formula：η i For correction factor, when 30≤TiWhen≤100,η i =1；As 100 ＜TiWhen≤300,η i =10；WhenTi＞
When 300,η i =50。
With it is total long when short circuit durationTcAs correction value, according to formula（4）To basic score valueEiIt is modified, obtains this
The last quantitatively evaluating score value of welding process：
In formula：R 1=100ms,R 2=500ms,R 3=1000ms。
Meanwhile, according to identifying result and parameter, this evaluation methodology can be combined with arc physics theory, analyze its reflection
Operating process information, provides suggestion for operation and deficiency analysis.
Claims (5)
1. a kind of welding process quality evaluating method of SMAW, comprises the following steps：
1）Discrete weldingvoltage signal in collection SMAW welding processV(n) and welding current signalI(n)；
2）The weldingvoltage signal collected using the wfilters function pairs in MATLABV(n) and welding current signalI(n)
Wavelet transformation analysis are carried out, db6 scaling functions are obtained, low-frequency voltage signal is obtainedL V (n) and low-frequency current signalL I (n)；
3）Exist low-frequency voltage signal be unsatisfactory for 18V≤L V (n)≤35V or low-frequency current signal be unsatisfactory for 90A≤L I (n)≤
The welding process of 135A, is evaluated as welding process unqualified；
4）For low-frequency voltage signalL V (n) excursion all the time between 18V～35V, while low-frequency current signalL I N () becomes
Change scope welding process all the time between 90A～135A, the welding process such as is divided into at the m sections of time period, calculate each
Low-frequency voltage signal in time periodL V The meansigma methodss of (n)L av (i), i=1,2 ... ..., m；
5）Obtain m low-frequency voltage signal meansigma methodssL av (i), the meansigma methodss of i=1,2 ... ..., m, according to formula（1）Calculate
Go out the m low-frequency voltage signal meansigma methodssL av (i), the coefficient of variation of i=1,2 ... ..., mCV, as the welding process
The coefficient of variation：
In formula：L av I () represents the meansigma methodss of low-frequency voltage signal in certain time period,Represent that m low-frequency voltage signal is put down
AverageL av (i), the meansigma methodss of i=1,2 ... ..., m；
6）Obtain the coefficient of variation no less than 200 welding processes, it is established that welding process passes judgment on data baseCV cj, j >=200, and
Find out the maximum coefficient of variation in data baseCV c maxWith the minimum coefficient of variationCV c min；
7）According to step 1）～5）Weldingvoltage signal to intending evaluating welding process is processed, and obtains the welding process
The coefficient of variationCV, according to formula（2）It is calculated the basic score value of the welding processEi：
In formula：CV c maxThe maximum coefficient of variation in for data base,CV c minThe minimum coefficient of variation in for data base,CV cjFor number
According to the coefficient of variation of each welding process in storehouse,CVTo be evaluated the coefficient of variation of welding process.
2. welding process quality evaluating method according to claim 1, is characterized in that also including to basic score valueEiCarry out
Correct, the modification method is：
1）The critical voltage value for occurring short-circuit voltage in welding process is set as 10V, weldingvoltage signalVN () is from less than critical
Voltage starts, and is short circuit duration to the time interval for being higher than again critical voltageT, set >=short circuit duration of 30ms as long when it is short
The road timeTi；
2）From discrete weldingvoltage signalVShort circuit duration when finding out whole long in (n)Ti, with formula（3）To describedTiCarry out
Amendment, short circuit duration when obtaining total longTc：
In formula：η i For correction factor, when 30≤TiWhen≤100,η i =1；As 100 ＜TiWhen≤300,η i =10；WhenTiDuring ＞ 300,η i =50；
3）With it is total long when short circuit durationTcAs correction value, according to formula（4）To basic score valueEiIt is modified, obtains the weldering
The last quantitatively evaluating score value of termination process：
In formula：R 1=100ms,R 2=500ms,R 3=1000ms。
3. welding process quality evaluating method according to claim 1 and 2, is characterized in that when the change for being evaluated welding process
Different coefficientCVMore than data base's maximum coefficient of variationCV c maxOr less than data base's minimum coefficient of variationCV c minWhen, by the change
Different coefficientCVIn being added to data base, replace data base's maximum coefficient of variationCV c maxOr the minimum coefficient of variationCV c min, to data
Storehouse is modified.
4. welding process quality evaluating method according to claim 1 and 2, is characterized in that described welding process includes flat
Weldering, horizontal position welding, overhead welding, four kinds of modes of vertical position welding, every kind of welding manner sets up respective judge data base.
5. welding process quality evaluating method according to claim 1 and 2, the time that it is characterized in that the m sections is 0.5～
1s。
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| CN111037056B (en) * | 2019-12-19 | 2021-11-19 | 深圳市佳士科技股份有限公司 | Welding process performance evaluation method and system |
| CN111531251B (en) * | 2020-05-23 | 2022-09-27 | 上海沪工焊接集团股份有限公司 | Arc welding power supply short circuit transition control method, system and device and storage medium thereof |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3965329A (en) * | 1971-04-22 | 1976-06-22 | Petrides Petros T | Electrical system for automatic arc welding |
| JPH0890230A (en) * | 1994-09-12 | 1996-04-09 | Miyachi Technos Corp | Arc welding monitoring device |
| CN101977720A (en) * | 2009-05-22 | 2011-02-16 | C.R.F.阿西安尼顾问公司 | System for monitoring arc welding processes and corresponding monitoring method |
| CN102430835A (en) * | 2011-10-31 | 2012-05-02 | 华南理工大学 | Quantitative evaluation method for arc welding drop transfer process stability |
| CN104625332A (en) * | 2015-01-27 | 2015-05-20 | 天津大学 | Stability evaluation system and method based on carbon dioxide welding input end electric signal |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7109439B2 (en) * | 2004-02-23 | 2006-09-19 | Lincoln Global, Inc. | Short circuit arc welder and method of controlling same |
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2015
- 2015-07-20 CN CN201510425865.7A patent/CN104972197B/en not_active Expired - Fee Related
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3965329A (en) * | 1971-04-22 | 1976-06-22 | Petrides Petros T | Electrical system for automatic arc welding |
| JPH0890230A (en) * | 1994-09-12 | 1996-04-09 | Miyachi Technos Corp | Arc welding monitoring device |
| CN101977720A (en) * | 2009-05-22 | 2011-02-16 | C.R.F.阿西安尼顾问公司 | System for monitoring arc welding processes and corresponding monitoring method |
| CN102430835A (en) * | 2011-10-31 | 2012-05-02 | 华南理工大学 | Quantitative evaluation method for arc welding drop transfer process stability |
| CN104625332A (en) * | 2015-01-27 | 2015-05-20 | 天津大学 | Stability evaluation system and method based on carbon dioxide welding input end electric signal |
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