CN105234599B - Welding temperature station control system and method - Google Patents
Welding temperature station control system and method Download PDFInfo
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- CN105234599B CN105234599B CN201510683866.1A CN201510683866A CN105234599B CN 105234599 B CN105234599 B CN 105234599B CN 201510683866 A CN201510683866 A CN 201510683866A CN 105234599 B CN105234599 B CN 105234599B
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- 238000003466 welding Methods 0.000 title claims abstract description 87
- 238000000034 method Methods 0.000 title claims abstract description 24
- 230000005855 radiation Effects 0.000 claims abstract description 8
- 238000009826 distribution Methods 0.000 claims abstract description 7
- 230000005540 biological transmission Effects 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 4
- 230000008018 melting Effects 0.000 claims description 4
- 238000005070 sampling Methods 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 3
- 238000003908 quality control method Methods 0.000 abstract description 8
- 238000001514 detection method Methods 0.000 abstract description 2
- 238000004519 manufacturing process Methods 0.000 abstract 1
- 230000004044 response Effects 0.000 description 10
- 238000004458 analytical method Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 230000035515 penetration Effects 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000011897 real-time detection Methods 0.000 description 3
- 230000001174 ascending effect Effects 0.000 description 2
- 230000003111 delayed effect Effects 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 230000003044 adaptive effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000004801 process automation Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000003079 width control Methods 0.000 description 1
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
- 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
- B23K31/02—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 soldering or welding
-
- 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01G—WEIGHING
- G01G5/00—Weighing apparatus wherein the balancing is effected by fluid action
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/27—Control of temperature characterised by the use of electric means with sensing element responsive to radiation
Abstract
The present invention relates to a kind of welding temperature station control system and method, the source of welding current of the output terminal connection welder system of dahlin control device, bath temperature measuring unit send the molten bath data detected to the acquisition signal input part of dahlin control device；Method is：Weld dimensions are divided into three high temperature, medium temperature, low temperature welding regions；Bath temperature measuring unit obtains the image of the thermal radiation field of two wave bands by CCD camera at the welding region back side；The image of collected thermal radiation field is filtered, obtains gray value and the correspondence of temperature；The distribution of entire field of welding temperature is obtained using above-mentioned correspondence；Isothermal line width is calculated, controlling value is exported to the source of welding current of welder system by dahlin control device.The present invention realizes the closed-loop control of weld dimensions back side isothermal line width, eliminates the remaining difference in automatic welding object, improves production efficiency, cost-effective, realizes quick, accurate, easily detection and quality control.
Description
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
Oneself is deep into from Macroscopic Process control in welding microscopic quality control for the research of welding process, with welding macroscopic quality
Control is the same, and the main difficulty of microscopic quality control is to obtain the sensing technology for characterizing these micro-qualities.Field of welding temperature
Distribution, determines the thermal cycle of welding, so as to also determine welding microstructure and its variation, determines weld seam and its heat affecting
The macro property in area, therefore the real-time detection and the extraction of thermal circulation parameters of field of welding temperature weld microscopic quality control to realizing
Have great importance.
Field of welding temperature is the basic characterization of welding thermal process, its distribution directly affects the fusion penetration and molten wide of weld seam,
It can be said that field of welding temperature is closely related with welding quality.By the real-time detection and control to field of welding temperature, and then
The molding of weld seam is controlled, improves the important research content that welding quality is current welding process automation.
The automation control of welding process is a key factor for ensureing welding quality.During actual welding, due to
The geomery of workpiece, fit-up gap, the geometry of weld seam, welding position Random Effect, only rely on the steady of welding conditions
It is qualitative to ensure that the consistency of joint penetration is extremely difficult, therefore, implement the self adaptive control of joint penetration, be to ensure weldering
The key of quality is connect, is the subject that welding technology field is paid special attention to.
Invention content
The stability of welding conditions is only relied on for welding process in the prior art to ensure that the consistency of joint penetration is non-
The deficiencies of often difficult, the technical problem to be solved in the present invention is to provide a kind of fast response times, can be to field of welding temperature and weldering
Connect welding temperature station control system and the method that quality is detected and controlled in real time.
In order to solve the above technical problems, the technical solution adopted by the present invention is：
Welding temperature station control system of the present invention, including welder system, bath temperature measuring unit and dahlin control device,
The wherein source of welding current of the output terminal connection welder system of dahlin control device, the molten bath number that bath temperature measuring unit will detect
According to sending to the acquisition signal input part of dahlin control device.
The bath temperature measuring unit includes CCD camera, data collecting card and analysis shows that device, wherein CCD phases
Machine is mounted on shooting weld pool image immediately below the welding back side and is input to analysis shows that device, data collecting card will be collected
Data are sent to analysis shows that device.
Welding temperature field control method of the present invention includes the following steps：
Weld dimensions are divided into three high temperature, medium temperature, low temperature welding regions first, corresponding different sampling exposes
Between light time；
Bath temperature measuring unit obtains the figure of the thermal radiation field of two wave bands by CCD camera at the welding region back side
Picture；
The image of collected thermal radiation field is filtered, is carried out after the gray scale at same position is handled
Ratio proccessing obtains gray value and the correspondence of temperature；
Using the correspondence between gray value and temperature, the distribution of entire field of welding temperature is obtained；
Isothermal line width is calculated, adjustment amount is calculated, and export controlling value to welding machine by dahlin control device by dahlin algorithm
The source of welding current of system.
Gray scale at same position is carried out processing step is：
By 3 byte representations of the image collected, each byte corresponds to the brightness of R, G, B component, transformed black and white
The gray value of one pixel of image, one byte representation point, transformational relation are as follows：
Gray (i, j)=0.11R (i, j)+0.59G (i, j)+0.3B (i, j)
Wherein Gray (i, j) is gray value of the transformed black white image at (i, j) point.
Weld dimensions are divided into three high temperature, medium temperature, low temperature regions, respectively：
Assuming that melting point metal to be welded is A DEG C, then between detecting temperature range (A-200) DEG C~(A+200) DEG C, low temperature
Area：(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, medium temperature and low temperature trizonal time for exposure be respectively：1.5±0.3ms、300±60ms、50±
10ms。
Isothermal line width is calculated to include the following steps：
The corresponding gray value of set temperature value is T first0；
Thermoisopleth marginal point is searched for, since the upper left corner of image, is compared point by point by sequence from left to right, from top to down
Compared with, you can search top edge；
Since the lower right corner of image, by sequence point-by-point comparison from right-to-left, from bottom to top, you can under search thermoisopleth
Edge；
It is more than T for the first time when searching certain point gray value0When, which is isothermal marginal point.
Search thermoisopleth marginal point includes the following steps：
Entire image is divided into a certain size grid, interlacing carries out dot interlace comparison to grid every row, obtains initial side
Edge point；
Then on latter width temperature field image, from the thermoisopleth marginal point of previous sub-picture, if thermoisopleth side
Edge point moves inward, then inwardly search, and until first point met the requirements is found, which is exactly new marginal point.
If thermoisopleth marginal point does not move inward, search outward in turn, until first is unsatisfactory for requirement
The position of point, the point that the last one retrieved is met the requirements is exactly new marginal point.
The invention has the advantages that and advantage：
1. the present invention obtains Thermal Cycle parameter for the real-time detection of field of welding temperature in welding process, weld seam is realized
And the closed-loop control of heat affected area back side isothermal line width；It is the situation of delay system for welding process, based on dahlin algorithm
Selection fusing point or the isothermal line width close to melting temperature are controlled to achieve the purpose that control penetration.
2. the present invention controls the source of welding current using dahlin algorithm, the remaining difference in automatic welding object is eliminated, and to welding pair
As carrying out lag compensation, fast response time can detect and control field of welding temperature and welding quality in real time, be improved
Working efficiency and quality.
3. the method for the present invention obtains the thermal circulation parameters in welding region somewhere from the temperature field of molten pool detected in real time, for weldering
Quality control is connect to provide the foundation；It is the situation of delay system for welding process, is controlled it based on dahlin algorithm, is carried
It is high efficiency, cost-effective, realize quick, accurate, easily detection and quality control.
Description of the drawings
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 delay single loop inertia system block diagram；
Fig. 4 is the response curve of present system control object；
Fig. 5 compares figure for undisturbed step response simulation curve of the present invention；
Fig. 6 has disturbance step response simulation curve to compare figure for the present invention；
Fig. 7 device operation program block diagrams in order to control.
Specific embodiment
The present invention is further elaborated with reference to the accompanying drawings of the specification.
As shown in Figure 1, a kind of welding temperature station control system of the present invention, including welder system, bath temperature measuring unit
And the source of welding current of dahlin control device, wherein the output terminal connection welder system of dahlin control device, bath temperature measuring unit
The molten bath data detected are sent to the acquisition signal input part of dahlin control device.
As shown in Fig. 2, bath temperature measuring unit includes CCD camera, data collecting card and analysis shows that device, wherein
CCD camera is mounted on shooting weld pool image immediately below the welding back side and is input to analysis shows that device, data collecting card will be adopted
The data collected are sent to analysis shows that device.
In the present invention, welder system includes welding gun, the source of welding current and wire-feed motor；Bath temperature measuring system includes CCD phases
Machine, data collecting card and analysis shows that system；Dahlin control device output terminal connecting welding power supply, adjusts its welding current.This
Invention controls the source of welding current using dahlin algorithm, eliminates the remaining difference in automatic welding object, and carry out lag benefit to welding object
It repays.
A kind of welding temperature field control method of the present invention includes the following steps：
Weld dimensions are divided into three high temperature, medium temperature, low temperature welding regions, corresponding different sampling exposure first
Time；
Bath temperature measuring unit obtains the figure of the thermal radiation field of two wave bands by CCD camera at the welding region back side
Picture；
The image of collected thermal radiation field is filtered, is carried out after the gray scale at same position is handled
Ratio proccessing obtains gray value and the correspondence of temperature；
Using the correspondence between gray value and temperature, the distribution of entire field of welding temperature is obtained；
Isothermal line width is calculated, adjustment amount is calculated, and export controlling value to welding machine by dahlin control device by dahlin algorithm
The source of welding current of system.
In the present embodiment, weld dimensions are divided into three high temperature, medium temperature, low temperature regions, respectively：It is assuming that be welded
Melting point metal for A DEG C, then between detecting temperature range (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, medium temperature and low temperature
The trizonal time for exposure is respectively：1.5±0.3ms、300±60ms、50±10ms.
The image collected is filtered, because different gray values has correspondence with temperature, by identical bits
The gray scale put carries out ratio proccessing, utilizes the correspondence between gray value and temperature, it is possible to obtain entire field of welding temperature
Distribution.
Welding temperature field control method of the present invention, the gray scale at same position is carried out processing step is：
By 3 byte representations of the image collected, each byte corresponds to the brightness of R, G, B component, transformed black and white
The gray value of one pixel of image, one byte representation point, transformational relation are as follows：
Gray (i, j)=0.11R (i, j)+0.59G (i, j)+0.3B (i, j)
Wherein Gray (i, j) is gray value of the transformed black white image at (i, j) point.
Isothermal line width is calculated to include the following steps：
The corresponding gray value of set temperature value is T first0；
Thermoisopleth marginal point is searched for, since the upper left corner of image, is compared point by point by sequence from left to right, from top to down
Compared with, you can search top edge；
Since the lower right corner of image, by sequence point-by-point comparison from right-to-left, from bottom to top, you can under search thermoisopleth
Edge；
It is more than T for the first time when searching certain point gray value0When, which is isothermal marginal point.
Search thermoisopleth marginal point includes the following steps：
Entire image is divided into a certain size grid, interlacing carries out dot interlace comparison to grid every row, obtains initial side
Edge point；
Then on latter width temperature field image, from the thermoisopleth marginal point of previous sub-picture, first judge thermoisopleth
Whether marginal point moves inward；If thermoisopleth marginal point moves inward, inwardly search for, met the requirements until finding first
Point until, which is exactly new marginal point.
If thermoisopleth marginal point does not move inward, search outward in turn, until first is unsatisfactory for requirement
The position of point, the point that the last one retrieved is met the requirements is exactly new marginal point.
For the present invention by the input quantity selected as welding current of control object, output quantity is field of welding temperature.By object approximation
For single order be delayed single loop inertia system, as shown in Figure 3：
GC(s)=Ke-τs/(TDs+1) (1)
S is Laplace operator in formula；τ is pure delay time constant, and K is proportionality coefficient；TDFor controlled device inertial time
Between constant, GC(S) it is controlled device transmission function；
Closed-loop system transmission function Φ (Z) can use formula (2) to represent：
GP(Z) it is the transform of controlled device transmission function, GC(Z) it is digitial controller, Y (Z) is output signal, and R (Z) is
Input signal.
Digitial controller can be solved from (2)
By taking 75mm × 200mm × 1mm mild steel as an example, using plasma welding method, the response curve of system object is such as
Shown in Fig. 4, the welding current in Fig. 4 is at 10s by analysis shows that system controls welding current by 60A Spline smoothings to 70A, weldering
Electric current is connect at 20s and changes back to 60A, is changed in Fig. 4 for 1200 DEG C of temperature field isothermal line width with the response of current time.
Export transmission function：The step response of one order inertia delayed time system is the index ascending curve of delay, can use following formula
It represents：
Y (t)=A (1-exp (- α (t-t0)))·U(t-t0) (4)
Wherein A is amplitude, and α is index coefficient, t0For time delay constant, t times, U is input signal；Laplace change is carried out to it
It changes：
Y (t)=A α exp (- t0·S)/(S·(S+α)) (5)
Its transmission function is then：
H (S)=Y (S) S=Aexp (- t0·S)/(tr·S+1) (6)
Wherein, tr=1/ α is rise-time constant, and α is index coefficient, and S is the operator of Laplace transform.
With reference to Fig. 4 and formula (4), (5), (6), can be derived according to the method that transmission function is derived in Theory of Automatic Control
Controlled device transmission function (formula (1)), is not repeating, herein in the present embodiment：
GC(s)=0.2e-0.22s/(0.8s+1) (7)
According to dahlin algorithm, desired closed-loop control system transmission function is：
T in formulaCFor desired closed-loop control system inertia time constant.Empirically, T is approximately equal to 0.9 under normal circumstances
τ, TCIt is approximately equal to 0.3 τ~0.5TDBetween, T=0.2s, T in the present embodimentC=0.233.
By Φ (s), GC(s) corresponding Z functions are converted into：Φ(Z)、GC(Z), digitial controller G then can be obtainedP
(Z)。
When Fig. 5 and Fig. 6 is undisturbed respectively system step respond and when having disturbance the traditional pid algorithm of system step response and
Figure is compared in the emulation of dahlin algorithm, and as can be seen from the figure dahlin algorithm dynamic response and traditional pid algorithm ratio are slightly fast, and system is steady
Dahlin algorithm non-overshoot before fixed, dahlin algorithm overshoot is smaller than traditional pid algorithm when adding in disturbance.
Controller programming：
U (Z)=GC(Z) E (Z)=(num (Z)/den (Z)) E (Z) (12)
Wherein num (Z) is GC(Z) numerator coefficients, den (Z) is GC(Z) denominator coefficients, i.e.,：
U(Z)·∑arZ-r=E (Z) ∑s brZ-r(r=0,1,2 ..., 7) (13)
Wherein ar、brIt is G respectivelyC(Z) each term coefficient that molecule, denominator items are arranged according to power ascending power, transformation of inverting
：
∑arU (k-r)=∑ br·e(k-r) (14)
It solves, wherein k is sampling number.
After solving u (k), sequential operation is carried out as shown in Fig. 7 controller operational flowcharts, first initialize storage unit and
Coefficient, then starts to acquire and image information and handles, and dahlin algorithm calculates output and exported by controller to the source of welding current, finally
Repeat this process.
Claims (4)
1. a kind of welding temperature field control method, it is characterised in that include the following steps：
Weld dimensions are divided into three high temperature, medium temperature, low temperature welding regions first, when corresponding different sampling exposes
Between；
Bath temperature measuring unit obtains the image of the thermal radiation field of two wave bands by CCD camera at the welding region back side；
The image of collected thermal radiation field is filtered, ratio is carried out after the gray scale at same position is handled
Processing, obtains gray value and the correspondence of temperature；
Using the correspondence between gray value and temperature, the distribution of entire field of welding temperature is obtained；
Isothermal line width is calculated, adjustment amount is calculated, and export controlling value to welder system by dahlin control device by dahlin algorithm
The source of welding current；
Isothermal line width is calculated to include the following steps：
The corresponding gray value of set temperature value is T first0；
Thermoisopleth marginal point is searched for, since the upper left corner of image, by sequence point-by-point comparison from left to right, from top to down, i.e.,
It can search for top edge；
Since the lower right corner of image, by sequence point-by-point comparison from right-to-left, from bottom to top, you can search thermoisopleth is following
Edge；
It is more than T for the first time when searching certain point gray value0When, which is isothermal marginal point；
According to dahlin algorithm, desired closed-loop control system transmission function is：
T in formulaCFor desired closed-loop control system inertia time constant, T=0.2s, TC=0.233；
By Φ (s), GC(s) corresponding Z functions are converted into：Φ(Z)、GC(Z), digitial controller G is then obtainedP(Z)；
Gray scale at same position is carried out processing step is：
By 1 byte representation of the image collected, each byte corresponds to the brightness of R, G, B component, transformed black white image
One byte representation point of a pixel gray value, 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 gray value of the transformed black white image at (i, j) point；
High temperature, medium temperature and low temperature trizonal time for exposure be respectively：1.5±0.3ms、300±60ms、50±10ms.
2. welding temperature field control method as described in claim 1, it is characterised in that：
Weld dimensions are divided into three high temperature, medium temperature, low temperature regions, respectively：
Assuming that melting point metal to be welded is A DEG C, then between detecting temperature range (A-200) DEG C~(A+200) DEG C, low-temperature space：(A-
DEG C 200)~(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.
3. welding temperature field control method as described in claim 1, it is characterised in that：Thermoisopleth marginal point is searched for including following
Step：
Entire image is divided into a certain size grid, interlacing carries out dot interlace comparison to grid every row, obtains initial marginal point；
Then on latter width temperature field image, from the thermoisopleth marginal point of previous sub-picture, if thermoisopleth marginal point
It moves inward, then inwardly search, until first point met the requirements is found, which is exactly new marginal point.
4. welding temperature field control method as described in claim 3, it is characterised in that：
If thermoisopleth marginal point does not move inward, search outward in turn, until first is unsatisfactory for desired point
Position, the point that the last one retrieved is met the requirements are exactly new marginal point.
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| CN201510683866.1A CN105234599B (en) | 2015-10-20 | 2015-10-20 | Welding temperature station control system and method |
| KR1020187003278A KR102133657B1 (en) | 2015-10-20 | 2016-07-11 | Welding temperature field control system and method |
| PCT/CN2016/089586 WO2017067241A1 (en) | 2015-10-20 | 2016-07-11 | Welding temperature field control system and method |
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| CN105234599B (en) * | 2015-10-20 | 2018-06-12 | 沈阳富创精密设备有限公司 | Welding temperature station control system and method |
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| CN111443748A (en) * | 2020-03-10 | 2020-07-24 | 江苏理工学院 | Stability control system of molten pool state in material increase repair process |
| CN112621005B (en) * | 2020-12-29 | 2022-04-19 | 北京工业大学 | Control method and device for effectively improving polarity-variable plasma arc asymmetric weld joint |
| CN114571037B (en) * | 2022-03-28 | 2024-03-19 | 深圳市爱达思技术有限公司 | Welding process control method and device |
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| Publication number | Publication date |
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| KR102133657B1 (en) | 2020-07-22 |
| WO2017067241A1 (en) | 2017-04-27 |
| CN105234599A (en) | 2016-01-13 |
| KR20180018822A (en) | 2018-02-21 |
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