CN105234599A - Welding temperature field control system and method - Google Patents

Welding temperature field control system and method Download PDF

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Publication number
CN105234599A
CN105234599A CN201510683866.1A CN201510683866A CN105234599A CN 105234599 A CN105234599 A CN 105234599A CN 201510683866 A CN201510683866 A CN 201510683866A CN 105234599 A CN105234599 A CN 105234599A
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Prior art keywords
welding
temperature
point
image
thermoisopleth
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CN105234599B (en
Inventor
刘雷
乔红超
李茂程
刘冬菊
唐伟东
谯永鹏
李文明
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Shenyang Fortune Precision Equipment Co Ltd
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Shenyang Fortune Precision Equipment Co Ltd
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Priority to KR1020187003278A priority patent/KR102133657B1/en
Priority to PCT/CN2016/089586 priority patent/WO2017067241A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01GWEIGHING
    • G01G5/00Weighing apparatus wherein the balancing is effected by fluid action
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05DSYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D23/00Control of temperature
    • G05D23/19Control of temperature characterised by the use of electric means
    • G05D23/27Control of temperature characterised by the use of electric means with sensing element responsive to radiation

Abstract

The invention relates to a welding temperature field control system and method. The output end of a Dahlin controller is connected with a welding power supply of a welding machine system, and a welding pool temperature measuring unit transmits detected welding pool data to the collected signal input end of the Dahlin controller. The method includes the steps that a welding line and heat effect zone is divided into a high-temperature welding zone, a medium-temperature welding zone and a low-temperature welding zone; the welding pool temperature measuring unit acquires an image of a heat radiation field of two wave bands on the back sides of the welding zones through a CCD camera; filtering processing is performed on the collected image of the heat radiation field to obtain the corresponding relation between the grey level and temperature; distribution of the whole welding field temperature is obtained according to the corresponding relation; and the width of an isotherm is calculated, and the Dahlin controller outputs a control value to the welding power supply of the welding machine system. By means of the method, closed-loop control over the width of the isotherm of the back side of the welding line and heat effect zone is achieved, residual errors in automatic welding objects are eliminated, production efficiency is improved, cost is lowered, and rapid, accurate and convenient detection and quality control are achieved.

Description

Welding temperature station control system and method
Technical field
The present invention relates to a kind of welding quality control technology field, specifically a kind of welding temperature station control system and method.
Background technology
The research of welding process is own to be controlled to be deep into welding microscopic quality control from Macroscopic Process, and with the control of welding macroscopic quality, the main difficulty of microscopic quality control obtains the sensing technology characterizing these micro-qualities.The distribution of field of welding temperature, determine the thermal cycle of welding, thus also determine welding microstructure and change thereof, determine the macro property of weld seam and heat affected area thereof, therefore the real-time detection of field of welding temperature and the extraction of thermal circulation parameters have great importance to realization welding microscopic quality control.
Field of welding temperature is the basic sign of welding thermal process, and its distribution directly affects the fusion penetration of weld seam and molten wide, therefore can say field of welding temperature and welding quality closely related.By to the real-time detection of field of welding temperature and control, and then control the shaping of weld seam, improve the important research content that welding quality is current welding process automation.
The Automated condtrol of welding process is the key factor ensureing welding quality.In actual welding process, due to the geomery of workpiece, fit-up gap, the geometry of weld seam, the Random Effect of welding position, only rely on the stability of welding conditions to ensure that the uniformity of joint penetration is very difficult, therefore, implement the Self Adaptive Control of joint penetration, being the key ensureing welding quality, is the problem that welding technology field is paid special attention to.
Summary of the invention
Only rely on the stability of welding conditions to ensure the deficiencies such as the uniformity of joint penetration is very difficult for welding process in prior art, the technical problem to be solved in the present invention is to provide a kind of fast response time, can carry out welding temperature station control system and the method for real-time detection and control to field of welding temperature and welding quality.
For solving the problems of the technologies described above, the technical solution used in the present invention is:
Welding temperature station control system of the present invention, comprise welder system, bath temperature measuring unit and dahlin control device, wherein the output of dahlin control device connects the source of welding current of welder system, and the molten bath data detected are delivered to the collection signal input of dahlin control device by bath temperature measuring unit.
Described bath temperature measuring unit comprises CCD camera, data collecting card and analyzes display unit, wherein CCD camera is arranged on immediately below the welding back side and takes weld pool image and input to analysis display unit, and the data collected are delivered to analysis display unit by data collecting card.
Welding temperature field control method of the present invention comprises the following steps:
First weld dimensions is divided into high temperature, middle temperature, low temperature three welding regions, the corresponding different sampling time for exposure;
Bath temperature measuring unit obtains the image of the thermal radiation field of two wave bands at the welding region back side by CCD camera;
Filtering process is carried out to the image of the thermal radiation field collected, carries out ratio proccessing after the gray scale at same position place being processed, obtain the corresponding relation of gray value and temperature;
Utilize the corresponding relation between gray value and temperature, obtain the distribution of whole field of welding temperature;
Calculate thermoisopleth width, calculate adjustment amount by dahlin algorithm, and export the source of welding current of controlling value to welder system by dahlin control device.
The gray scale at same position place is carried out treatment step is:
By image 3 byte representations collected, the brightness of corresponding R, G, B component of each byte, a pixel of the black white image after the conversion gray value of this point of byte representation, transformational relation is as follows:
Gray(i,j)=0.11R(i,j)+0.59G(i,j)+0.3B(i,j)
Wherein Gray (i, j) is the gray value of black white image at (i, j) some place after conversion.
Weld dimensions is divided into high temperature, middle temperature, low temperature three regions, is respectively:
Suppose that melting point metal to be welded is A DEG C, between then detected temperatures scope (A-200) DEG C ~ (A+200) DEG C, low-temperature space: (A-200) DEG C ~ (A-50) DEG C, middle warm area: (A-50) DEG C ~ (A+50) DEG C, high-temperature region: (A+50) DEG C ~ (A+200) DEG C.
High temperature, middle temperature and low temperature trizonal time for exposure are respectively: 1.5 ± 0.3ms, 300 ± 60ms, 50 ± 10ms.
Calculate thermoisopleth width to comprise the following steps:
First the gray value that set temperature value is corresponding is T 0;
Search thermoisopleth marginal point, from the upper left corner of image, by order point-by-point comparison from left to right, from top to down, can search top edge;
From the lower right corner of image, by from right-to-left, order point-by-point comparison from bottom to top, thermoisopleth lower limb can be searched for;
T is greater than when searching certain some gray value first time 0time, this point is isothermal marginal point.
Search thermoisopleth marginal point comprises the following steps:
Entire image is divided into a certain size grid, interlacing is carried out dot interlace every row to grid and is compared, and obtains initial marginal point;
Then on a rear width temperature field image, from the thermoisopleth marginal point of last sub-picture, if thermoisopleth marginal point moves inward, then inwardly search for, till the point met the demands until finding first, this point is exactly new marginal point.
If thermoisopleth marginal point does not move inward, then outwards search for conversely, until the position of first point do not met the demands, last point met the demands retrieved is exactly new marginal point.
The present invention has following beneficial effect and advantage:
1. the present invention is directed to the real-time detection of field of welding temperature in welding process and obtain Thermal Cycle parameter, realize the closed-loop control of weld dimensions back side thermoisopleth width; For the situation that welding process is delay system, select fusing point based on dahlin algorithm or carry out controlling to reach the object controlled penetration close to the thermoisopleth width of melting temperature.
2. the present invention adopts dahlin algorithm to control the source of welding current, eliminate the remaining difference in automatic welding object, and lag compensation is carried out to welding object, fast response time, real-time detection and control can be carried out to field of welding temperature and welding quality, improve operating efficiency and quality.
3. the inventive method obtains the thermal circulation parameters in welding region somewhere from the temperature field of molten pool detected in real time, for welding quality controls to provide the foundation; For the situation that welding process is delay system, based on dahlin algorithm, it controlled, enhance productivity, cost-saving, achieve fast, detect accurately, easily and quality control.
Accompanying drawing explanation
Fig. 1 is thermoisopleth width control system flow chart of the present invention;
Fig. 2 is field of welding temperature measuring unit block diagram of the present invention;
Fig. 3 is single order time delay single loop inertia system block diagram;
Fig. 4 is the response curve of present system control object;
Fig. 5 is undisturbed step response simulation curve comparison diagram of the present invention;
Fig. 6 is that the present invention has disturbance step response simulation curve comparison diagram;
Fig. 7 is controller operation program block diagram.
Detailed description of the invention
Below in conjunction with Figure of description, the present invention is further elaborated.
As shown in Figure 1, a kind of welding temperature station control system of the present invention, comprise welder system, bath temperature measuring unit and dahlin control device, wherein the output of dahlin control device connects the source of welding current of welder system, and the molten bath data detected are delivered to the collection signal input of dahlin control device by bath temperature measuring unit.(this section of content is not very corresponding with the word in Fig. 1, should do unified process)
As shown in Figure 2, bath temperature measuring unit comprises CCD camera, data collecting card and analyzes display unit, wherein CCD camera is arranged on immediately below the welding back side and takes weld pool image and input to analysis display unit, and the data collected are delivered to analysis display unit by data collecting card.
In the present invention, welder system comprises welding gun, the source of welding current and wire-feed motor; Bath temperature measuring system comprises CCD camera, data collecting card and analysis display system; Dahlin control device output connecting welding power supply, regulates its welding current.The present invention adopts dahlin algorithm to control the source of welding current, eliminates the remaining difference in automatic welding object, and carries out lag compensation to welding object.
A kind of welding temperature field control method of the present invention comprises the following steps:
First weld dimensions is divided into high temperature, middle temperature, low temperature three welding regions, the corresponding different sampling time for exposure;
Bath temperature measuring unit obtains the image of the thermal radiation field of two wave bands at the welding region back side by CCD camera;
Filtering process is carried out to the image of the thermal radiation field collected, carries out ratio proccessing after the gray scale at same position place being processed, obtain the corresponding relation of gray value and temperature;
Utilize the corresponding relation between gray value and temperature, obtain the distribution of whole field of welding temperature;
Calculate thermoisopleth width, calculate adjustment amount by dahlin algorithm, and export the source of welding current of controlling value to welder system by dahlin control device.
In the present embodiment, weld dimensions is divided into high temperature, middle temperature, low temperature three regions, be respectively: suppose that melting point metal to be welded is A DEG C, between then detected temperatures scope (A-200) DEG C ~ (A+200) DEG C, low-temperature space: (A-200) DEG C ~ (A-50) DEG C, middle warm area: (A-50) DEG C ~ (A+50) DEG C, high-temperature region: (A+50) DEG C ~ (A+200) DEG C; High temperature, middle temperature and low temperature trizonal time for exposure are respectively: 1.5 ± 0.3ms, 300 ± 60ms, 50 ± 10ms.
The image collected is carried out filtering process, because different gray values and temperature have corresponding relation, the gray scale of same position is carried out ratio proccessing, utilize the corresponding relation between gray value and temperature, just can obtain the distribution of whole field of welding temperature.
Welding temperature field control method of the present invention, the gray scale at same position place is carried out treatment step is:
By image 3 byte representations collected, the brightness of corresponding R, G, B component of each byte, a pixel of the black white image after the conversion gray value of this point of byte representation, transformational relation is as follows:
Gray(i,j)=0.11R(i,j)+0.59G(i,j)+0.3B(i,j)
Wherein Gray (i, j) is the gray value of black white image at (i, j) some place after conversion.
Calculate thermoisopleth width to comprise the following steps:
First the gray value that set temperature value is corresponding is T 0;
Search thermoisopleth marginal point, from the upper left corner of image, by order point-by-point comparison from left to right, from top to down, can search top edge;
From the lower right corner of image, by from right-to-left, order point-by-point comparison from bottom to top, thermoisopleth lower limb can be searched for;
T is greater than when searching certain some gray value first time 0time, this point is isothermal marginal point.
Search thermoisopleth marginal point comprises the following steps:
Entire image is divided into a certain size grid, interlacing is carried out dot interlace every row to grid and is compared, and obtains initial marginal point;
Then on a rear width temperature field image, from the thermoisopleth marginal point of last sub-picture, first judge whether thermoisopleth marginal point moves inward; If thermoisopleth marginal point moves inward, then inwardly search for, till the point met the demands until finding first, this point is exactly new marginal point.
If thermoisopleth marginal point does not move inward, then outwards search for conversely, until the position of first point do not met the demands, last point met the demands retrieved is exactly new marginal point.
The input quantity of control object is chosen as welding current by the present invention, and output quantity is field of welding temperature.Object is approximately single order time delay single loop inertia system, as shown in Figure 3: (following content is included in which step above?)
G C(s)=Ke -τs/(T Ds+1)(1)
In formula, s is Laplace operator; τ is pure delay time constant, and K is proportionality coefficient; T dfor controlled device inertia time constant, G cs () is controlled device transfer function;
Closed-loop system transfer function Φ (Z) available formula (2) represents:
Φ ( Z ) = Y ( Z ) R ( Z ) = G C ( Z ) G P ( Z ) 1 + G C ( Z ) G P ( Z ) - - - ( 2 )
G p(Z) be the transform of controlled device transfer function, G c(Z) be digitial controller, Y (Z) is output signal, and R (Z) is input signal.
Digitial controller can be solved from (2)
G P ( Z ) = U ( Z ) E ( Z ) = Φ ( Z ) G C ( Z ) ( I + Φ ( Z ) ) - - - ( 3 )
For 75mm × 200mm × 1mm mild steel, adopt plasma welding method, the response curve of system object as shown in Figure 4, welding current in Fig. 4 controls welding current by 60A Spline smoothing to 70A at 10s place by analyzing display system, welding current changes back to 60A again at 20s place, is the response change of 1200 DEG C, temperature field thermoisopleth width along with current time in Fig. 4.
Derive transfer function: the step response of one order inertia delayed time system is the index ascending curve of time delay, can be represented by the formula:
Y(t)=A·(1-exp(α(t-t 0)))·U(t-t 0)(4)
Wherein A is amplitude, and α is index coefficient, t 0for time delay constant, the t time, U is input signal; Laplace transformation is carried out to it:
Y(t)=A·α·exp(-t 0·S)/(S·(S+α))(5)
Its transfer function is then:
H(S)=Y(S)·S=A·exp(-t 0·S)/(t γ·S+1)(6)
Wherein, t γ=1/ α is rise-time constant, and α is index coefficient, and S is the operator of Laplace transform.
Composition graphs 4 and formula (4), (5), (6), controlled device transfer function (formula (1)) can be derived according to the method for transfer function of deriving in Theory of Automatic Control, do not repeating, in the present embodiment at this:
G C(s)=0.2e -0.22s/(0.8s+1)(7)
According to dahlin algorithm, the closed-loop control system transfer function expected is:
Φ ( s ) = e - τ s 1 + T C s - - - ( 11 )
T in formula cfor the closed-loop control system inertia time constant expected.Empirically, generally T approximates 0.9 τ, T capproximate 0.3 τ ~ 0.5T dbetween, T=0.2s, T in the present embodiment c=0.233.
By Φ (s), G cs () converts corresponding Z function to: Φ (Z), G c(Z), then just digitial controller G can be obtained p(Z).
System step response and the emulation comparison diagram of system step response traditional PI D-algorithm and dahlin algorithm when having a disturbance when Fig. 5 and Fig. 6 is undisturbed respectively, as can be seen from the figure dahlin algorithm dynamic response and traditional PI D-algorithm are than slightly fast, dahlin algorithm non-overshoot before system stability, when adding disturbance, dahlin algorithm overshoot is less than traditional PI D-algorithm.
Controller is programmed:
U(Z)=G C(Z)·E(Z)=(num(Z)/den(Z))·E(Z)(12)
Wherein num (Z) is G c(Z) numerator coefficients, den (Z) is G c(Z) denominator coefficients, that is:
U(Z)·∑a rZ =E(Z)·∑b rZ (r=0,1,2,…,7)(13)
Wherein a r, b rg respectively c(Z) molecule, the every each term coefficient according to the arrangement of power ascending power of denominator, invert and convert:
∑a r·u(k-r)=∑b r·e(k-r)(14)
Solve, wherein k is sampling number.
After solving u (k), as shown in Fig. 7 controller operational flowchart, carry out sequential operation, first initialize memory cell and coefficient, then start gather image information and process, dahlin algorithm calculates and exports and export to the source of welding current by controller, finally repeats this process.

Claims (9)

1. a welding temperature station control system, it is characterized in that: comprise welder system, bath temperature measuring unit and dahlin control device, wherein the output of dahlin control device connects the source of welding current of welder system, and the molten bath data detected are delivered to the collection signal input of dahlin control device by bath temperature measuring unit.
2. by welding temperature station control system according to claim 1, it is characterized in that: described bath temperature measuring unit comprises CCD camera, data collecting card and analyzes display unit, wherein CCD camera is arranged on immediately below the welding back side and takes weld pool image and input to analysis display unit, and the data collected are delivered to analysis display unit by data collecting card.
3. a welding temperature field control method, is characterized in that comprising the following steps:
First weld dimensions is divided into high temperature, middle temperature, low temperature three welding regions, the corresponding different sampling time for exposure;
Bath temperature measuring unit obtains the image of the thermal radiation field of two wave bands at the welding region back side by CCD camera;
Filtering process is carried out to the image of the thermal radiation field collected, carries out ratio proccessing after the gray scale at same position place being processed, obtain the corresponding relation of gray value and temperature;
Utilize the corresponding relation between gray value and temperature, obtain the distribution of whole field of welding temperature;
Calculate thermoisopleth width, calculate adjustment amount by dahlin algorithm, and export the source of welding current of controlling value to welder system by dahlin control device.
4., by welding temperature field control method according to claim 3, it is characterized in that: the gray scale at same position place is carried out treatment step is:
By image 3 byte representations collected, the brightness of corresponding R, G, B component of each byte, a pixel of the black white image after the conversion gray value of this point of byte representation, transformational relation is as follows:
Gray(i,j)=0.11R(i,j)+0.59G(i,j)+0.3B(i,j)
Wherein Gray (i, j) is the gray value of black white image at (i, j) some place after conversion.
5., by welding temperature field control method according to claim 3, it is characterized in that:
Weld dimensions is divided into high temperature, middle temperature, low temperature three regions, is respectively:
Suppose that melting point metal to be welded is A DEG C, between then detected temperatures scope (A-200) DEG C ~ (A+200) DEG C, low-temperature space: (A-200) DEG C ~ (A-50) DEG C, middle warm area: (A-50) DEG C ~ (A+50) DEG C, high-temperature region: (A+50) DEG C ~ (A+200) DEG C.
6., by welding temperature field control method according to claim 3, it is characterized in that:
High temperature, middle temperature and low temperature trizonal time for exposure are respectively: 1.5 ± 0.3ms, 300 ± 60ms, 50 ± 10ms.
7. by the welding temperature field control method that claim 3 is stated, it is characterized in that: calculate thermoisopleth width and comprise the following steps:
First the gray value that set temperature value is corresponding is T 0;
Search thermoisopleth marginal point, from the upper left corner of image, by order point-by-point comparison from left to right, from top to down, can search top edge;
From the lower right corner of image, by from right-to-left, order point-by-point comparison from bottom to top, thermoisopleth lower limb can be searched for;
T is greater than when searching certain some gray value first time 0time, this point is isothermal marginal point.
8. by welding temperature field control method according to claim 7, it is characterized in that: search thermoisopleth marginal point comprises the following steps:
Entire image is divided into a certain size grid, interlacing is carried out dot interlace every row to grid and is compared, and obtains initial marginal point;
Then on a rear width temperature field image, from the thermoisopleth marginal point of last sub-picture, if thermoisopleth marginal point moves inward, then inwardly search for, till the point met the demands until finding first, this point is exactly new marginal point.
9., by welding temperature field control method according to claim 8, it is characterized in that:
If thermoisopleth marginal point does not move inward, then outwards search for conversely, until the position of first point do not met the demands, last point met the demands retrieved is exactly new marginal point.
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