CN106808063B - A kind of method based on electric arc acoustic emission signal sensor monitoring electric arc arc length - Google Patents
A kind of method based on electric arc acoustic emission signal sensor monitoring electric arc arc length Download PDFInfo
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- CN106808063B CN106808063B CN201710095559.0A CN201710095559A CN106808063B CN 106808063 B CN106808063 B CN 106808063B CN 201710095559 A CN201710095559 A CN 201710095559A CN 106808063 B CN106808063 B CN 106808063B
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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
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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
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
Abstract
The present invention discloses a kind of method that electric arc arc length is monitored using electric arc acoustic emission signal.This method is by caused electric arc acoustic emission signal waveform during real-time detection electric arc welding or electric arc increasing material manufacturing, extraction obtains electric arc acoustic emission signal temporal signatures waveform higher than the time domain signal waveform of signal amplitude threshold value, de-noising is carried out to temporal signatures waveform using wavelet analysis, extract the low-frequency component in electric arc acoustic emission signal temporal signatures waveform, and draw out low-frequency component temporal signatures oscillogram, bring low-frequency component temporal signatures waveform into electric arc arc length that electric arc arc length mathematical modeling is calculated in process and change time domain waveform, drawn by electric arc arc length change time domain waveform and moment electric arc arc length value is arbitrarily processed in process.The offline inspection and on-line monitoring of the electric arc arc length to the electric arc welding processes such as TIG, MIG, MAG, PAW and metal material electric arc increasing material manufacturing process can be realized using the present invention.
Description
Technical field
The present invention relates to a kind of method based on electric arc acoustic emission signal sensor monitoring electric arc arc length, be not only suitable for TIG,
To the monitoring of electric arc arc length in the electric arc welding processes such as MIG, MAG, PAW, while it can be also suitably used for metal material arc surfacing, electricity
Monitoring during the electric arc increasing material manufacturing such as arc deposition and electric arc three-dimensional rapid forming to electric arc arc length.
Background technology
Using electric arc as thermal source, the electric arc welding manufacture and electric arc that can carry out various metal structures increase material system
Make.Under the fast-developing situation of intelligent Manufacturing Technology, the joint penetration control during electric arc welding and electric arc increasing material manufacturing
It is robot building automatic field significantly research topic with electric arc tracking technique.In order to obtain good be welded into
Form quality amount or increasing material manufacturing sedimentary quality, it is necessary to obtain the more information about electric arc thermal source, and electric arc is dynamically control on
Appropriate maintenance level.During electric arc welding manufacture and electric arc increasing material manufacturing, electric arc is not invariable, but as far as possible
Its own is set to be in dynamic thermal balance state, to obtain most stable energy output effect and optimal process state.Electric arc arc length
It is an important factor for electric arc dynamic change is influenceed in numerous arc heat source information.In process, the change of electric arc arc length is by shadow
The effective energy that electric arc thermal source acts on processing object is rung, starting arc heat-source energy acts on manufacturing district due to arc length change
And caused electric arc arcing and droplet transfer stability change and will greatly restrict welding or the raising of increasing material manufacturing quality.
Therefore, the offline inspection of electric arc arc length is realized during electric arc welding and electric arc increasing material manufacturing or is monitored on-line for manufacturing
The control of journey and the assessment of workmanship have very important realistic meaning.
In the manufacturing process using electric arc as processing thermal source, the interaction effect of electric arc thermal source, molten drop and molten bath formation
It can release energy in different forms, the sound emission discharged in the form of air load is one kind therein.Due to different arc electricity
The release of arc impact energy has notable difference, the change of electric arc arc length is formd certain mapping relations with electric arc sound emission.
The content of the invention
The present invention is for electric arc welding or electric arc increasing material manufacturing, there is provided one kind utilizes electric arc acoustic emission signal monitoring electric arc arc
Long method, the present invention detect sound emission caused by electric arc in real time by the use of the acoustic emission signal of arc excitation as information source
Signal, the indicatrix of electric arc acoustic emission signal is extracted using technologies such as wavelet analysises, realizes the monitoring to electric arc arc length.
The present invention takes following technical scheme：
A kind of method based on electric arc acoustic emission signal sensor monitoring electric arc arc length, methods described detect process in real time
In electric arc acoustic emission signal, using the quantitative relationship of electric arc sound emission and electric arc arc length, realize and electric arc welding or electric arc increased
The monitoring of material manufacturing process electric arc arc length, it is as follows the step of methods described：
（1）Acoustic emission sensor is installed on substrate, and the center in face processing and manufacturing region；
（2）Arc power is opened, starts the processing and manufacturing to destination object；
（3）Collection exports the molten bath of arc energy bump substrate or fabrication region and excites caused sound emission in real time
Signal, and draw out the dynamic waveform figure of signal；
（4）Processing and manufacturing terminates, and closes down arc energy output, and stop acoustic emission signal on-line checking
（5）Set electric arc acoustic emission signal amplitude threshold value, electric arc acoustic emission signal time domain ripple of the extraction higher than threshold value
Shape, obtain electric arc acoustic emission signal temporal signatures waveform；
（6）De-noising is carried out to electric arc acoustic emission signal temporal signatures waveform using wavelet analysis method；
（7）The low-frequency component in electric arc acoustic emission signal temporal signatures waveform is extracted using analysis method of wavelet packet, and is painted
Make electric arc acoustic emission signal low-frequency component signature waveform figure；
（8）By electric arc acoustic emission signal low-frequency component signature waveform bring into electric arc arc length mathematical modeling be calculated it is processed
Electric arc arc length change time domain waveform in journey；
（9）Drawn by electric arc arc length change time domain waveform and moment electric arc arc length value is arbitrarily processed in process.
The preparation method of the electric arc arc length mathematical modeling is as follows：
（1）Installation base plate, and confidence level is fixed, and arc welding gun is held on to the vehicle with walking machine of three-dimension numerical controlled workbench
Structure, adjustment arc welding gun direction, makes it vertical with base plan；
（2）Any speed and stroke are set in the x-direction, electric arc is at the uniform velocity walked in combustion, and make electric arc simultaneously
Arc length continuously changes in the z-direction；
（3）Electric arc acoustic emission signal in collection electric arc arc length change procedure in real time, when drawing out electric arc acoustic emission signal
Domain waveform；
（4）X directional runs terminate, and stop electric arc work and the collection of electric arc acoustic emission signal；
（5）Set electric arc acoustic emission signal amplitude threshold value, electric arc acoustic emission signal time domain ripple of the extraction higher than threshold value
Shape, obtain electric arc acoustic emission signal temporal signatures waveform；
（6）De-noising is carried out to electric arc acoustic emission signal temporal signatures waveform using wavelet analysis method；
（7）Electric arc acoustic emission signal temporal signatures waveform in electric arc arc length change procedure is extracted using analysis method of wavelet packet
In low-frequency component, so as to draw out electric arc acoustic emission signal low-frequency component temporal signatures oscillogram；
（8）Change the trigonometric function relation to be formed in the stroke in x directions and the arc length in z directions using electric arc walking to be changed
Calculate, draw electric arc arc length-electric arc sound emission amplitude relation curve map；
（9）Electric arc arc length-electric arc sound emission amplitude relation curve is carried out curve fitting, obtains electric arc arc length and welding arc sound
Relational model between transmission signal, i.e. electric arc arc length mathematical modeling.
The electric arc acoustic emission signal amplitude threshold value need to be not less than the 1/3 of electric arc acoustic emission signal mean amplitude of tide.
The innovation of the present invention is that establish electric arc arc length using wavelet analysis and signal characteristic abstraction believes with electric arc sound emission
Relational model between number, by the real-time detection to electric arc acoustic emission signal, the monitoring to electric arc arc length is realized, with existing skill
Art, which is compared, has advantages below：
（1）It is workable, the offline inspection and on-line monitoring of electric arc arc length can be achieved；
（2）System design is cheap with manufacturing cost；
（3）Monitoring result is directly perceived, and meets the actual condition of electric arc welding or electric arc increasing material manufacturing；
（4）Data amount of calculation is small, and fast slowdown monitoring can be achieved.
Brief description of the drawings
Fig. 1 is electric arc arc length monitoring system composition schematic diagram.
Fig. 2 is the electric arc arc length change procedure electric arc acoustic emission signal time domain waveform that embodiment 1 detects.
Fig. 3 is the electric arc arc length change procedure electric arc acoustic emission signal low-frequency component temporal signatures waveform that embodiment 1 is extracted.
Fig. 4 is the electric arc arc length-acoustic emission signal amplitude relation curve map and its matched curve that embodiment 1 is extracted.
Fig. 5 is that the electric arc sound emission of 1 electric arc to be detected of embodiment changes over time signal waveform.
Fig. 6 is the electric arc acoustic emission signal low-frequency component signature waveform figure of 1 electric arc to be detected of embodiment.
Fig. 7 is the electric arc arc length change time domain waveform of 1 electric arc to be detected of embodiment.
Fig. 8 is the electric arc arc length change procedure electric arc acoustic emission signal time domain waveform that embodiment 2 detects.
Fig. 9 is the electric arc arc length change procedure electric arc acoustic emission signal low-frequency component temporal signatures waveform that embodiment 2 is extracted.
Figure 10 is the electric arc arc length-acoustic emission signal amplitude relation curve map and its matched curve that embodiment 2 is extracted.
Figure 11 is that the electric arc sound emission of 2 electric arc to be detected of embodiment changes over time signal waveform.
Figure 12 is the electric arc acoustic emission signal low-frequency component signature waveform figure of 2 electric arc to be detected of embodiment.
Figure 13 is the electric arc arc length change time domain waveform of 2 electric arc to be detected of embodiment.
In figure, 1 three-dimension numerical controlled workbench walking mechanism bare terminal end, 2 arc welding guns, 3 electric arcs, 4 weldments or substrate, 5 sound
Emission sensor, 6 preamplifiers, 7 signal conditioners, 8 data collecting cards, 9 computers.
Embodiment
With reference to specific embodiment, the present invention is expanded on further.
Referring to Fig. 1, electric arc arc length monitoring system mainly includes walking mechanism bare terminal end 1, arc welding gun 2, voice sending sensor
Device 5, preamplifier 6, signal conditioner 7, data collecting card 8 and computer 9 etc..Electric arc 3 acts on caused by arc welding gun 2
On weldment or substrate 4, the sensing of the acoustic emission signal excited to electric arc 4 is realized using acoustic emission sensor 5.Detect obtained electricity
Arc acoustic emission signal passes to preamplifier 6 and signal conditioner 7 is handled, then by being sent to computer after data collecting card 8
9, signal is carried out by the software that computer 9 loads the processing such as to calculate, obtains testing result.
Embodiment 1：
MIG welding is carried out, a diameter of 1.2mm is selected as substrate, metal welding wire using thickness 6mm 6061 aluminium alloy plates
4043 aluminium alloy welding wires, protective gas is the high-purity argon gas of purity 99.999%, and shield gas flow rate is 18L/min.Build first
The mathematical modeling of vertical electric arc arc length：Setting arc current output be 120A, and it is 18.2V that arc voltage, which exports, electric arc pulse frequency
100Hz, walking mechanism translational speed are 30mm/s.Aluminium alloy welding wire used connects positive source, and substrate connects power cathode.Installation
Substrate, and confidence level is fixed, and MIG arc welding guns are held on to the walking mechanism of three-dimension numerical controlled workbench.Adjust MIG welding guns
Direction, make it vertical with base plan.Acoustic emission sensor is installed on substrate, and the centre bit in face processing and manufacturing region
Put.The speed of travel is set in the x-direction as 30mm/s, and walk duration 2.3s, stroke 69.0mm.Make electric arc even in combustion
Speed walking, and electric arc arc length is continuously shortened 2mm in the z-direction simultaneously.Caused electricity in collection electric arc arc length change procedure in real time
Arc acoustic emission signal, electric arc acoustic emission signal time domain waveform is drawn out, as shown in Figure 2.After x directional runs terminate, stop electric arc
Work and the collection of electric arc acoustic emission signal.Electric arc acoustic emission signal amplitude threshold value is set as 0.6, electricity of the extraction higher than threshold value
Arc acoustic emission signal time domain waveform, obtain electric arc acoustic emission signal temporal signatures waveform.Using wavelet analysis to electric arc sound emission
Signal temporal signatures waveform carries out de-noising, when extracting electric arc acoustic emission signal in electric arc arc length change procedure using wavelet packet analysis
Low-frequency component in domain waveform, electric arc acoustic emission signal low-frequency component temporal signatures oscillogram is drawn out, as shown in Figure 3.Utilize
Electric arc walking changes the trigonometric function relation to be formed in the stroke in x directions and the arc length in z directions and converted, and draws electric arc arc
Length-electric arc sound emission amplitude relation curve map is as shown in Figure 4.Electric arc arc length-electric arc sound emission amplitude relation curve is carried out straight
Line is fitted, and obtains electric arc arc length（L）With electric arc acoustic emission amplitude（M）Between relational model, i.e. electric arc arc length mathematical modeling：
M=-0.028+0.049×L
In the formal monitoring process of electric arc arc length, caused electric arc acoustic emission signal during complete machining is gathered in real time,
It is as shown in Figure 5 that drafting obtains the signal waveform that electric arc sound emission changes over time.Set electric arc acoustic emission signal amplitude threshold value
For 0.6, extraction obtains electric arc sound emission temporal signatures ripple higher than the time domain signal waveform of electric arc acoustic emission signal amplitude threshold value
Shape.De-noising is carried out to electric arc sound emission temporal signatures waveform using wavelet analysis, electric arc sound emission is extracted using wavelet packet analysis
Low-frequency component in temporal signatures waveform, and electric arc acoustic emission signal low-frequency component temporal signatures oscillogram is drawn out, such as Fig. 6 institutes
Show.Electric arc acoustic emission signal low-frequency component temporal signatures waveform is brought into electric arc arc length mathematical modeling to be calculated in process
Electric arc arc length change time domain waveform, as shown in Figure 7, you can draw in process arbitrarily processing moment electric arc arc length value.
Embodiment 2：
MIG welding is carried out, a diameter of 1.2mm is selected as substrate, metal welding wire using thickness 6mm 6061 aluminium alloy plates
4043 aluminium alloy welding wires, protective gas is the high-purity argon gas of purity 99.999%, and shield gas flow rate is 18L/min.Build first
The mathematical modeling of vertical electric arc arc length：Setting arc current output be 115A, and it is 17.6V that arc voltage, which exports, electric arc pulse frequency
100Hz, walking mechanism translational speed are 30mm/s.Aluminium alloy welding wire used connects positive source, and substrate connects power cathode.Installation
Substrate, and confidence level is fixed, and MIG arc welding guns are held on to the walking mechanism of three-dimension numerical controlled workbench.Adjust MIG welding guns
Direction, make it vertical with base plan.Acoustic emission sensor is installed on substrate, and the centre bit in face processing and manufacturing region
Put.The speed of travel is set in the x-direction as 30mm/s, and walk duration 2.2s, stroke 66mm.Make electric arc in combustion at the uniform velocity
Walking, and electric arc arc length is increased continuously 3.5mm in the z-direction simultaneously.Caused electricity in collection electric arc arc length change procedure in real time
Arc acoustic emission signal, electric arc acoustic emission signal time domain waveform is drawn out, as shown in Figure 8.After x directional runs terminate, stop electric arc
Work and the collection of electric arc acoustic emission signal.Electric arc acoustic emission signal amplitude threshold value is set as 0.5, electricity of the extraction higher than threshold value
Arc acoustic emission signal time domain waveform, obtain electric arc acoustic emission signal temporal signatures waveform.Using wavelet analysis to electric arc sound emission
Signal temporal signatures waveform carries out de-noising, when extracting electric arc acoustic emission signal in electric arc arc length change procedure using wavelet packet analysis
Low-frequency component in domain waveform, electric arc acoustic emission signal low-frequency component temporal signatures oscillogram is drawn out, as shown in Figure 9.Utilize
Electric arc walking changes the trigonometric function relation to be formed in the stroke in x directions and the arc length in z directions and converted, and draws electric arc arc
Length-electric arc sound emission amplitude relation curve map is as shown in Figure 10.Electric arc arc length-electric arc sound emission amplitude relation curve is carried out straight
Line is fitted, and obtains electric arc arc length（L）With electric arc acoustic emission amplitude（M）Between relational model, i.e. electric arc arc length mathematical modeling：
M=-0.138+0.066×L
In the formal monitoring process of electric arc arc length, caused electric arc acoustic emission signal during complete machining is gathered in real time,
It is as shown in figure 11 that drafting obtains the signal waveform that electric arc sound emission changes over time.Set electric arc acoustic emission signal amplitude threshold value
For 0.7, extraction obtains electric arc sound emission temporal signatures ripple higher than the time domain signal waveform of electric arc acoustic emission signal amplitude threshold value
Shape.De-noising is carried out to electric arc sound emission temporal signatures waveform using wavelet analysis, electric arc sound emission is extracted using wavelet packet analysis
Low-frequency component in temporal signatures waveform, and draw out electric arc acoustic emission signal low-frequency component temporal signatures oscillogram, such as Figure 12
It is shown.Bring electric arc acoustic emission signal low-frequency component temporal signatures waveform into electric arc arc length mathematical modeling and process is calculated
In electric arc arc length change time domain waveform, as shown in figure 13, you can draw in process arbitrarily processing moment electric arc arc length value.
It can be seen from the result of above-described embodiment electricity more can be accurately and quickly realized using the method for the invention
To the monitoring of electric arc arc length change during arc welding or electric arc increasing material manufacturing.
Claims (2)
1. a kind of method based on electric arc acoustic emission signal sensor monitoring electric arc arc length, methods described are detected in process in real time
Electric arc acoustic emission signal, using the quantitative relationship of electric arc sound emission and electric arc arc length, realize and material increased to electric arc welding or electric arc
The monitoring of manufacturing process electric arc arc length, it is characterised in that as follows the step of methods described：
（1）Acoustic emission sensor is installed on substrate, and the center in face processing and manufacturing region；
（2）Arc power is opened, starts the processing and manufacturing to destination object；
（3）Collection in real time exports the molten bath of arc energy bump substrate or fabrication region and excites caused sound emission letter
Number, and draw out the dynamic waveform figure of signal；
（4）Processing and manufacturing terminates, and closes down arc energy output, and stop acoustic emission signal on-line checking；
（5）Electric arc acoustic emission signal amplitude threshold value is set, extraction obtains higher than the electric arc acoustic emission signal time domain waveform of threshold value
To electric arc acoustic emission signal temporal signatures waveform；
（6）De-noising is carried out to electric arc acoustic emission signal temporal signatures waveform using wavelet analysis method；
（7）The low-frequency component in electric arc acoustic emission signal temporal signatures waveform is extracted using analysis method of wavelet packet, and is drawn out
Electric arc acoustic emission signal low-frequency component signature waveform figure；
（8）Electric arc acoustic emission signal low-frequency component signature waveform is brought into electric arc arc length mathematical modeling to be calculated in process
Electric arc arc length change time domain waveform；
（9）Drawn by electric arc arc length change time domain waveform and moment electric arc arc length value is arbitrarily processed in process；
The preparation method of the electric arc arc length mathematical modeling is as follows：
（8.1）Installation base plate, and confidence level is fixed, and arc welding gun is held on to the walking mechanism of three-dimension numerical controlled workbench,
Arc welding gun direction is adjusted, makes it vertical with base plan；
（8.2）Any speed and stroke are set in the x-direction, electric arc is at the uniform velocity walked in combustion, and make electric arc arc simultaneously
Long change continuous in the z-direction；
（8.3）Electric arc acoustic emission signal in collection electric arc arc length change procedure in real time, draws out electric arc acoustic emission signal time domain
Waveform；
（8.4）X directional runs terminate, and stop electric arc work and the collection of electric arc acoustic emission signal；
（8.5）Electric arc acoustic emission signal amplitude threshold value is set, extraction is higher than the electric arc acoustic emission signal time domain waveform of threshold value,
Obtain electric arc acoustic emission signal temporal signatures waveform；
（8.6）De-noising is carried out to electric arc acoustic emission signal temporal signatures waveform using wavelet analysis method；
（8.7）Extracted using analysis method of wavelet packet in electric arc arc length change procedure in electric arc acoustic emission signal temporal signatures waveform
Low-frequency component, so as to draw out electric arc acoustic emission signal low-frequency component temporal signatures oscillogram；
（8.8）Change the trigonometric function relation to be formed in the stroke in x directions and the arc length in z directions using electric arc walking to be changed
Calculate, draw electric arc arc length-electric arc sound emission amplitude relation curve map；
（8.9）Electric arc arc length-electric arc sound emission amplitude relation curve is carried out curve fitting, electric arc arc length is obtained and is sent out with welding arc sound
The relational model penetrated between signal, i.e. electric arc arc length mathematical modeling.
2. the method according to claim 1 based on electric arc acoustic emission signal sensor monitoring electric arc arc length, it is characterised in that：
The electric arc acoustic emission signal amplitude threshold value need to be not less than the 1/3 of electric arc acoustic emission signal mean amplitude of tide.
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| JP3160514B2 (en) * | 1995-11-27 | 2001-04-25 | 三菱重工業株式会社 | Method for improving ultrasonic flaw detection of weld metal |
| JP2001198677A (en) * | 2000-01-14 | 2001-07-24 | Ishikawajima Harima Heavy Ind Co Ltd | Agitation welding method and device |
| US6441342B1 (en) * | 2000-11-20 | 2002-08-27 | Lincoln Global, Inc. | Monitor for electric arc welder |
| US20050127052A1 (en) * | 2003-12-12 | 2005-06-16 | Spencer Mark S. | Near real time arc welding monitor |
| CN102744493B (en) * | 2012-07-03 | 2014-10-22 | 广东技术师范学院 | Quantitative evaluation method of arc welding process stability based on electric arc sound |
| CN103487136B (en) * | 2013-10-15 | 2016-01-20 | 重庆理工大学 | A kind of method utilizing resistance spot welding process Acoustic Emission Signal Energy equivalent quantitatively to detect welding splash |
| JP6354941B2 (en) * | 2014-04-28 | 2018-07-11 | 株式会社石井鐵工所 | Method for suppressing groove shrinkage in automatic TIG back wave welding |
| CN104772550B (en) * | 2015-04-28 | 2017-04-05 | 北京石油化工学院 | A kind of welding process multi signal collection and jig kinetic control system |
| CN105643054B (en) * | 2016-01-19 | 2018-04-13 | 中国电子科技集团公司第三十八研究所 | A kind of robot arc welding process method for real-time monitoring and real-time monitoring system |
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