CN106583961B - Continuous welding seam monitoring probe, welding seam monitoring system and method - Google Patents
Continuous welding seam monitoring probe, welding seam monitoring system and method Download PDFInfo
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- CN106583961B CN106583961B CN201710116946.8A CN201710116946A CN106583961B CN 106583961 B CN106583961 B CN 106583961B CN 201710116946 A CN201710116946 A CN 201710116946A CN 106583961 B CN106583961 B CN 106583961B
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- 238000003466 welding Methods 0.000 title claims abstract description 112
- 238000012544 monitoring process Methods 0.000 title claims abstract description 58
- 238000000034 method Methods 0.000 title claims abstract description 13
- 239000000523 sample Substances 0.000 title abstract description 23
- 238000001514 detection method Methods 0.000 claims abstract description 28
- 238000005286 illumination Methods 0.000 claims abstract description 17
- 238000004880 explosion Methods 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 abstract description 16
- 229910052710 silicon Inorganic materials 0.000 abstract description 16
- 239000010703 silicon Substances 0.000 abstract description 16
- 238000012806 monitoring device Methods 0.000 abstract description 2
- 229910000831 Steel Inorganic materials 0.000 description 10
- 239000010959 steel Substances 0.000 description 10
- 239000000428 dust Substances 0.000 description 5
- 239000000779 smoke Substances 0.000 description 5
- 239000011324 bead Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 238000010894 electron beam technology Methods 0.000 description 4
- 238000003672 processing method Methods 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000013072 incoming material Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000009191 jumping Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
Classifications
-
- 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
- B23K31/125—Weld quality monitoring
Landscapes
- Engineering & Computer Science (AREA)
- Quality & Reliability (AREA)
- Mechanical Engineering (AREA)
- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention discloses a continuous welding seam monitoring probe, a welding seam monitoring system and a continuous welding seam monitoring method, wherein the welding seam monitoring probe comprises a supporting seat, and a photoelectric detection unit which is fixedly arranged in the supporting seat and is used for monitoring a lower welding seam spark illumination signal generated by continuous welding. The photoelectric detection unit comprises a silicon photocell and a convex lens for collecting the collected spark illumination signals of the lower weld joint, and the convex lens is positioned between the silicon photocell and the spark of the lower weld joint. The output end of the photoelectric detection unit is electrically connected with the PC through the I/U isolator, the voltage signal monitor and the PC in sequence. The invention monitors the real-time welding quality by directly detecting the continuity of the lower weld spark illumination signal generated during continuous welding, is simple and easy to operate, and is suitable for monitoring various continuous welding modes; the welding monitoring device is suitable for welding monitoring in a closed vacuum chamber; meanwhile, the structure is simple, the cost is low, and the work is reliable.
Description
Technical Field
The invention belongs to the technical field of continuous welding quality detection, and particularly relates to a continuous welding seam monitoring probe, a welding seam monitoring system and a continuous welding seam monitoring method.
Background
Electron beam welding or laser composite steel strip welding is a method in which two materials are continuously welded on equipment without or with filler. In order to ensure the welding quality, the welding seam needs to be monitored, and the continuity of the welding seam is ensured.
The existing weld monitoring methods comprise an ultrasonic detection method, an eddy current detection method, a weld image detection method, an X-ray detection method and the like, and all the methods are used for directly detecting the weld, so that the size of a used weld monitoring probe is required to be adapted to the actual weld length, and the size of the weld monitoring probe is too large, so that the weld monitoring probe is inconvenient to install in a closed vacuum cavity for real-time monitoring; meanwhile, all the existing monitoring methods need to use complex processing methods such as an image processing method, so that the cost is high and the technology is complex.
Disclosure of Invention
The size of the existing continuous welding seam monitoring probes needs to be adapted to the actual welding seam length, and the probe is too large in size, so that the probe is inconvenient to install in a closed vacuum cavity for real-time monitoring; meanwhile, all the existing monitoring methods need to use complex processing methods such as an image processing method, so that the cost is high and the technology is complex. The invention aims to overcome the defects in the prior art and provide a continuous welding seam monitoring probe, a welding seam monitoring system and a continuous welding seam monitoring method, wherein the welding seam monitoring probe is small in size, suitable for welding monitoring in a closed vacuum chamber, simple in structure and low in cost.
In order to solve the technical problems, the invention adopts the following technical scheme:
the continuous welding seam monitoring probe is structurally characterized by comprising a supporting seat and a photoelectric detection unit which is fixedly arranged in the supporting seat and is used for monitoring a lower welding seam spark illumination signal generated by continuous welding.
The inventors found that it is possible to judge whether or not the welding is normal by observing the state of the under-bead spark. For example, the discontinuous welding faults caused by various reasons such as incorrect position of an electron beam welding or laser welding focus, abnormal fixture guiding, inclusion of incoming materials, incomplete cleaning of the incoming materials and the like can be reflected by the change of the spark of the lower welding seam. The invention utilizes the photoelectric detection unit to monitor the spark illumination signal of the lower weld in real time, can monitor the change condition of the spark of the lower weld in real time, and can realize the continuous monitoring of the quality of the weld on line. The weld monitoring probe only needs to monitor the illumination signal change of the spark position of the lower weld, so the volume is smaller, and the weld monitoring probe is suitable for welding monitoring in a closed vacuum chamber.
As a preferred mode, the photodetection unit comprises a silicon photocell.
When the silicon photocell is irradiated by light, current can be generated, and when the illumination signal of the lower weld spark is changed, the current signal generated by the silicon photocell is also changed, so that the lower weld spark is monitored, and continuous welding quality monitoring is realized.
Further, the photoelectric detection unit also comprises a convex lens for collecting the collected spark illumination signals of the lower weld, and the convex lens is positioned between the silicon photocell and the lower weld spark.
Because the convex lens condenses, when the illumination signal of the spark with the lower welding seam with larger area irradiates the silicon photocell with smaller area, the silicon photocell is more sensitive to the light signal of the spark change with the lower welding seam due to condensation, thereby improving the detection precision and having high reliability of the detection result.
Based on the same inventive concept, the invention also provides a continuous welding seam monitoring system, which comprises the welding seam monitoring probe, the I/U isolator, the voltage signal monitor and the PC, wherein the output end of the photoelectric detection unit is electrically connected with the PC through the I/U isolator, the voltage signal monitor and the PC in sequence.
By means of the structure, the current signals monitored by the photoelectric detection unit are converted into voltage signals through the I/U isolator and output, and the voltage signals output by the I/U isolator are continuously collected by the voltage signal monitor and sent to the PC for real-time display and storage. The staff can timely find abnormal conditions of the welding seam and make relevant treatment by judging and observing the display result on the PC.
Further, a centrifugal fan for sucking smoke dust between the photoelectric detection unit and the under-weld spark is also included.
The centrifugal fan can pump away smoke dust between the photoelectric detection unit and the lower welding spark so as to protect the photoelectric detection unit (particularly the convex lens) from being polluted by the smoke dust and ensure the sensitivity of the probe.
Based on the same inventive concept, the invention also provides a continuous welding seam monitoring method, which comprises the following steps: monitoring illumination signals of lower weld sparks generated by continuous welding by utilizing a photoelectric detection unit; step two, converting a current signal output by the photoelectric detection unit into a voltage signal by using an I/U isolator; step three, a voltage signal monitor is used for collecting voltage signals output by the I/U isolator, and the voltage signal monitor sends the collected voltage signals to a PC; step four, monitoring the collected voltage signals on a PC: when the voltage signal is stable, the welding is stable; when the voltage signal rises sharply and forms an upper peak, the phenomenon of welding explosion or the increase of welding speed is shown; when the voltage signal drops sharply and forms a lower spike, it indicates that the welding speed is reduced; when the voltage signal drops sharply and does not form a downward spike, indicating that the focus of the device is shifted up; when the voltage signal rises sharply and does not spike up, this indicates that the focus of the device is moving down.
The invention monitors the real-time welding quality by directly detecting the continuity of the lower weld spark illumination signal generated during continuous welding, is simple and easy to operate, and is suitable for monitoring various continuous welding modes; the welding monitoring device is suitable for welding monitoring in a closed vacuum chamber; meanwhile, the structure is simple, the cost is low, and the work is reliable.
Drawings
Fig. 1 is a schematic diagram of welding of composite steel strips.
FIG. 2 is a schematic diagram of a lower weld spark produced by continuous welding.
FIG. 3 is a schematic diagram of a weld monitoring probe of the present invention receiving a downweld spark illumination signal.
FIG. 4 is a schematic diagram of a weld monitoring system according to the present invention.
Wherein, 1 is the front guide wheel, 2 is the first steel band, 3 is welding jig, 4 is the second steel band, 5 is the rear guide wheel, 6 is the molten pool, 7 is the welding seam, 8 is the line energy, 9 is the lower welding seam spark, 10 is the silicon photocell, 11 is the PC, 12 is the focus of convex lens, 13 is convex lens, 14 is the supporting seat, 15 is centrifugal fan, 16 is I/U isolator, 17 is voltage signal monitor, 171 is switch type alarm unit.
Detailed Description
As shown in fig. 1 and 2, the direction of the arrow is the welding running direction, and when laser welding and electron beam welding are performed, under the action of the line energy 8, the molten pool 6 melt generates very strong visible light due to downward flow to form a lower weld spark 9. After the first steel strip 2 and the second steel strip 4 are clamped by the front guide wheel 1 and the rear guide wheel 5 and by the upper and lower welding jigs 3, the molten pool 6 is generally at the same position, but the size difference, external vibration and the molten pool 6 position of the first steel strip 2 and the second steel strip 4 slightly change due to the runout of the welding jigs 3, and the effect on the size of the lower weld sparks 9 is not great. When these factors are fully ensured, it is the stability of the welding energy output by the welding head itself that needs to be monitored, the focal position change and the effect of foreign matter such as water on the welding quality during welding. Whereas in the case of electron beam welding and laser welding the position of the focal spot is extremely sensitive, so that variations in the position of the melt pool 6 up and down have a significant effect on the size of the downweld spark 9. Moreover, if impurities or moisture are contained on the steel strips 2,4 during welding of materials difficult to weld, the size of the spark 9 of the lower weld can be obviously influenced. Problems with the weld head itself, such as defocusing, failure of the welding energy to be transmitted in time, can also have a significant impact on the size of the downweld spark 9. The continuity of the welding line 7 can be indirectly monitored by reasonably monitoring the spark 9 of the lower welding line, and the continuous welding quality can be monitored.
As shown in fig. 3, the continuous welding seam monitoring probe of the invention comprises a supporting seat 14, and a photoelectric detection unit which is fixedly arranged in the supporting seat 14 and is used for monitoring illumination signals of the under-welding seam spark 9 generated by continuous welding. The photodetection unit comprises a silicon photocell 10. The photoelectric detection unit further comprises a convex lens 13 for collecting illumination signals of the gathered lower weld sparks 9, and the convex lens 13 is positioned between the silicon photocell 10 and the lower weld sparks 9.
As shown in FIG. 4, the continuous welding seam monitoring system comprises the welding seam monitoring probe, an I/U isolator 16, a voltage signal monitor 17 and a PC 11, wherein the output end of the photoelectric detection unit is electrically connected with the PC 11 through the I/U isolator 16, the voltage signal monitor 17. The continuous weld monitoring system further comprises a centrifugal fan 15 for sucking in smoke dust between the photo detection unit and the under-weld spark 9. The voltage signal monitor 17 is provided with a switch type alarm unit 171, a link relay or a buzzer, and alarms when welding is unstable.
In the welding of the steel strip with the thickness of 0.6 mm-2 mm, the relatively concentrated lower welding seam sparks 9 approximately show a radial shape with the radius of about 50mm, so that a convex lens 13 with the diameter of about 50mm is adopted, then illumination signals of the lower welding seam sparks 9 are gathered through the convex lens 13, (when the convex lens 13 is selected, the total focal length is controlled to be about 25mm so as to reduce the volume of a welding seam monitoring probe and facilitate installation). The silicon photocell 10 is 2DU10, which is located slightly behind the focal point 12 of the convex lens, to avoid burning out components due to too concentrated energy). The convex lens 13 and the silicon photocell 10 are mounted in a support base 14 and fixed to the soldering base. The convex lens 13 is located on one side of the under-bead spark 9 and is kept at a distance of at least 300mm or more from the under-bead spark 9. A centrifugal fan 15 (in non-vacuum welding) or a suction port is arranged between the convex lens 13 and the lower welding spark 9, so that welding smoke dust can be kept from polluting the convex lens 13, and the measurement of a probe is failed.
The steady current collected when it stabilizes the weld is different for different welding parameters and welding materials. Aiming at the welding of the bimetallic strip saw blade with the specification of 27mm and the thickness of 0.9mm, when the silicon photocell 10 collects the welded optical signals, the current amplitude of the silicon photocell varies at the amplitude of 0-6 mA, and the following situations can occur:
when the welding is stable, the current is about 4 mA.
When the welding explodes (due to the presence of contaminants such as water and oil), the lower weld spark 9 increases sharply, and the current rises sharply, forming a current spike.
When the focus of the device moves up (due to the strip runout or the device itself shaking) the under-weld spark 9 suddenly becomes smaller and the current drops dramatically.
When the focus of the device moves down (due to the strip jumping or the shaking of the device itself), the under-weld spark 9 suddenly becomes large and the current rises sharply.
When the welding speed suddenly increases or decreases (the speed decreases due to traction equipment or the like), the melt increases, the lower bead spark 9 becomes large or small, and the current suddenly increases or decreases, forming an upper and lower spike.
The current value monitored by the silicon photocell 10 is sent to the PC 11 for monitoring and displaying after passing through the I/U isolator 16 and the voltage signal monitor 17, and a worker can know the change condition of the lower welding seam spark 9 according to the data change condition, so that whether the welding seam 7 is continuous or not is further known, and the welding quality is ensured.
The continuous welding seam monitoring method comprises the following steps:
step one, monitoring an illumination signal of the under-weld spark 9 generated by continuous welding by utilizing a photoelectric detection unit.
And step two, the current signal output by the photoelectric detection unit is converted into a voltage signal by using the I/U isolator 16.
And thirdly, acquiring the voltage signal output by the I/U isolator 16 by using the voltage signal monitor 17, and simultaneously sending the acquired voltage signal to the PC 11 by the voltage signal monitor 17 for real-time display and storage.
Step four, monitoring the collected voltage signals on the PC 11: when the voltage signal is stable, the welding is stable; when the voltage signal rises sharply and forms an upper peak, the phenomenon of welding explosion or the increase of welding speed is shown; when the voltage signal drops sharply and forms a lower spike, it indicates that the welding speed is reduced; when the voltage signal drops sharply and does not form a downward spike, indicating that the focus of the device is shifted up; when the voltage signal rises sharply and does not spike up, this indicates that the focus of the device is moving down.
The embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to the above-described embodiments, which are merely illustrative and not restrictive, and many forms may be made by those having ordinary skill in the art without departing from the spirit of the present invention and the scope of the claims, which are all within the scope of the present invention.
Claims (1)
1. A method of monitoring a continuous weld, comprising the steps of:
monitoring illumination signals of lower weld sparks (9) generated by continuous welding by utilizing a photoelectric detection unit;
step two, converting a current signal output by the photoelectric detection unit into a voltage signal by using an I/U isolator (16);
step three, a voltage signal monitor (17) is used for collecting voltage signals output by an I/U isolator (16), and the voltage signal monitor (17) sends the collected voltage signals to a PC (11);
step four, monitoring the collected voltage signals on a PC (11): when the voltage signal is stable, the welding is stable; when the voltage signal rises sharply and forms an upper peak, the phenomenon of welding explosion or the increase of welding speed is shown; when the voltage signal drops sharply and forms a lower spike, it indicates that the welding speed is reduced; when the voltage signal drops sharply and does not form a downward spike, indicating that the focus of the device is shifted up; when the voltage signal rises sharply and does not spike up, this indicates that the focus of the device is moving down.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201710116946.8A CN106583961B (en) | 2017-03-01 | 2017-03-01 | Continuous welding seam monitoring probe, welding seam monitoring system and method |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201710116946.8A CN106583961B (en) | 2017-03-01 | 2017-03-01 | Continuous welding seam monitoring probe, welding seam monitoring system and method |
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| CN106583961A CN106583961A (en) | 2017-04-26 |
| CN106583961B true CN106583961B (en) | 2023-10-24 |
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