CN107999932A - GTA silk filling increasing material manufacturing arc length feed forward detections and open-loop control method - Google Patents
GTA silk filling increasing material manufacturing arc length feed forward detections and open-loop control method Download PDFInfo
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- CN107999932A CN107999932A CN201711229471.XA CN201711229471A CN107999932A CN 107999932 A CN107999932 A CN 107999932A CN 201711229471 A CN201711229471 A CN 201711229471A CN 107999932 A CN107999932 A CN 107999932A
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- arc length
- gta
- feed forward
- arc
- loop control
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
-
- 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
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/14—Measuring arrangements characterised by the use of optical techniques for measuring distance or clearance between spaced objects or spaced apertures
Abstract
The present invention provides a kind of GTA silk filling increasing material manufacturing arc length feed forward detections and open-loop control method, the described method comprises the following steps:Vision system gathers GTA arc images, and along accumulation path direction, detection window position is set in front of GTA electric arcs;Determine preceding layer solid metallic upper marginal position using smothing filtering, preceding layer solid metallic edge detection, edge pixel point Hough fitting scheduling algorithms, and calculate it and arrive the vertical range at tungsten electrode tip, electric arc arc length is characterized with this;Calculate the advanced step number of feed forward detection;After the delay of advanced step number, current time arc length error is determined, adjust single argument technological parameter and carry out arc length opened loop control.The method of the present invention proposes arc length feed forward detection, calculates arc length error in advance, treats that GTA welding guns move to inspection positions and start to control arc length, efficiently solves the detection of tradition feedback and control size fluctuation problem caused by detection process lags.
Description
Technical field
The invention belongs to electric arc silk filling increases material manufacturing technology field, and in particular to a kind of tungsten argon arc (Gas tungsten
Arc, GTA) fill silk increasing material manufacturing arc length feed forward detection and open-loop control method.
Background technology
GTA fills silk increasing material manufacturing using GTA electric arcs as heat source, and metal wire material is sent into arc-melting and forms continuous accumulation
Road, according to setting path stack shaping hardware layer by layer.Compared with other electric arcs fill silk increases material manufacturing technology, GTA fills silk
It is notable excellent that increasing material manufacturing has that equipment cost is low, heat input is small, forming accuracy is high, accumulation electric current and wire feed rate difference is adjustable etc.
Point, thus in precious metal, as titanium alloy, nickel base superalloy component direct forming on have good application prospect.
GTA silk filling increasing material manufacturings are multilayer banking processes, often accumulate one layer, and GTA welding guns raise a default floor height, due to
The influence of various disturbing factors, such as:Interlayer temperature, substrate situation, technological parameter fluctuation, the synusia height for causing actually to accumulate with
Setting floor height is not inconsistent, and after multilayer accumulation, causes tungsten electrode tip to change to accumulation horizon surface distance (electric arc arc length).If arc
Length is long, and arc energy disperses, and the droplet transfer has some setbacks, and banking process stability reduces;If arc length is too short, tungsten may be caused
Pole tip collides with accumulation horizon.Therefore, it is necessary to carry out the real-time Detection & Controling of GTA silk filling increasing material manufacturing arc length.
Vision-based detection is widely used in electric arc welding and increasing material manufacturing process due to informative, there is researcher
It is proposed that detect molten bath afterbody upper surface using visual sensing also can yet be regarded as a kind of Efficient Characterization to the distance at tungsten electrode tip, this method
The detection mode of arc length.But molten bath afterbody to tungsten electrode tip there are certain level distance, cause detection process to exist certain
Hysteresis, belongs to hysteresis detection, its welding arc control process belongs to be controlled later, although this method can improve GTA increasing material manufacturings
The stability of arc length, but there is very big fluctuation in control effect.Therefore, it is necessary to propose a kind of Detection & Controling side of no hysteresis
Method, so as to further improve the stability of GTA silk filling increasing material manufacturing arc length and banking process.
The content of the invention
The purpose of the present invention is fill silk accumulation defect caused by increasing material manufacturing arc length stability difference and existing to solve GTA
The problem such as control stability difference caused by hysteresis detection, there is provided a kind of GTA silk filling increasing material manufacturing arc length feed forward detections and open loop control
Method processed.
For achieving the above object, the present invention provides a kind of GTA silk filling increasing material manufacturing arc length feed forward detections and open loop control
Method processed, arc length is characterized by the vertical range at tungsten electrode tip in GTA welding guns to preceding layer solid metallic surface, before arc length
Feedback detection refers to that, along accumulation path direction, the solid metallic surface in detection window be located at tungsten electrode front, and arc length opened loop control is
According to the arc length error of feed forward detection, technological parameter and opened loop control arc length are adjusted, is comprised the following steps:
Step 1:Passive vision sensor-based system face GTA welding guns, gather GTA arc images, along accumulation path direction, inspection
Survey the window's position and be located at GTA electric arcs front, the horizontal distance D of window center to tungsten electrode tip is 7-12mm, GTA arc radiation light
GTA immediate vicinity preceding layer solid metallic surfaces are illuminated, the preceding layer solid metallic surface in window is detected;
It is because if the horizontal distance at window center to tungsten electrode tip is too small that D, which is set in 7-12mm, then detection window holds
It is vulnerable to the interference of GTA electric arcs fluctuation, causes the half-tone information of pixel in window to be fallen into oblivion by electric arc, it is difficult to detect preceding layer and consolidate
State metal surface;If the horizontal distance at window center to tungsten electrode tip is excessive, preceding layer solid metallic surface in window by
GTA arc lightings are weaker, cause top edge to be difficult to detect, and it is rational that therefore, in text D, which is set in the range of this,.
Step 2:Smothing filtering, preceding layer solid metallic surface top edge are carried out to all pixels point in window ranges
Detection, the Hough fittings of edge pixel point, arc length are vertical range H of the preceding layer solid metallic top edge to tungsten electrode tip;
Step 3:Calculate the advanced step number n=[D/ (VS)+0.5] of arc length feed forward detection
Wherein, V is the speed of travel, and unit mm/s, S are the sampling period of detecting system, and unit s, [] represents rounding
Symbol;
Step 4:The arc length of feed forward detection calculates current k moment arc length error es (k)=H (k-n)-h- after n step delays
H0, wherein, H (k-n) represents that the preceding layer solid metallic top edge of (k-n) moment detection is to the vertical range at tungsten electrode tip, h
The floor height of hierarchy slicing, H0For initial setting arc length;
Step 5:Calculate single argument process parameter value W (k)=e (k)/P+W of k moment opened loop controls0,
Wherein, P is gain coefficient, W0For initial single argument process parameter value;
Step 6:Repeat step two and step 4, in each sampling instant, the arc length error judgment determined according to step 4
Whether opened loop control is carried out, if arc length error is zero, single argument process parameter value is W0, otherwise, calculated according to step 5
New single argument process parameter value, and realize the opened loop control of GTA silk filling increasing material manufacturing arc length.
It is preferred that the single argument technological parameter described in step 5 is accumulation electric current or wire feed rate.
It is preferred that gain coefficient P is through the following steps that definite in step 5:
(a) GTA welding guns move to surface, and GTA welding guns direction is vertical with substrate surface, initially sets arc length as H0,
That is tungsten electrode tip accumulates N layers of single track straight wall part using same technological parameter to the distance of substrate surface on substrate, N=4-8,
Single argument technological parameter initial value is W0, the accumulation path direction of adjacent interlayer is on the contrary, often accumulated one layer, GTA arc extinctions,
Interlayer waits 30-120s;
(b) accumulation (N+1) layer is continued, single argument technological parameter is W0, treat arc motion to accumulation path length half
When, the single argument technological parameter of adjusting is by W0Instantaneous step is to new value W1, after (N+1) layer accumulation to be done, measure single argument work
The average height Q of (N+1) layer before skill parameter step1With the average height Q of (N+1) layer after step2;
(c) gain coefficient P=(Q2-Q1)/(W1-W0)。
The outstanding advantages that the method for the present invention has are:The method of the present invention is using passive vision monitoring edge accumulation path direction position
Preceding layer solid metallic surface in front of GTA electric arcs, algorithm for design extract preceding layer solid metallic surface to tungsten electrode tip
Vertical range, calculates advanced step number and feed forward detection the arc length error of feed forward detection, it is determined that single argument process parameter control value.
Compared with conventional method, the method for the present invention proposes feed forward detection, calculates arc length error in advance, treats that GTA welding guns move to check bit
Place is put, real-time opened loop control is started according to arc length error, efficiently solves the detection of tradition feedback since detection process hysteresis causes
Control fluctuation problem.
Brief description of the drawings
Fig. 1 is GTA silk filling increasing material manufacturing arc length visual sensing test position schematic diagrames;
Fig. 2 is feedforward vision-based detection and open-loop control system schematic diagram;
Fig. 3 is the original arc image and feed forward detection the window's position of collection;
Fig. 4 is the detection of preceding layer solid metallic surface top edge;
Fig. 5 is the typical straight wall part of feedforward control accumulation.
Embodiment
Illustrate embodiments of the present invention below by way of specific instantiation, those skilled in the art can be by this specification
Disclosed content understands other advantages and effect of the present invention easily.The present invention can also pass through in addition different specific realities
The mode of applying is embodied or practiced, the various details in this specification can also be based on different viewpoints with application, without departing from
Various modifications or alterations are carried out under the spirit of the present invention.
The specific test platform of the present embodiment:The GTA increasing material manufacturing power supplys that fill silk are Fronius MW300, wire-feed motor model
For KD4010, movement executing mechanism is MOTOMAN robots, and GTA welding guns are fixed on the 6th shaft end of MOTOMAN robots,
Robot controls the movement of GTA welding guns, and filling silk material is ER506 mild steel weldinmg rods, silk material diameter 1.2mm, and substrate material is
Q235B mild steel, substrate size are 150mm × 80mm × 4mm.Experiment is with technological parameter:Electric current 150A, stackeding speed
3.3mm/s, wire feed rate 1.7m/min, straight argon is as protection gas, gas flow 15L/min.
The visual sensing system that the present embodiment uses for:As shown in Figure 1, GTA welding guns are perpendicular to base plan, edge accumulation road
Footpath direction, the silk material in wire leading pipe are sent into along in front of electric arc, and visual sensing system is made of video camera and light damping plate, visual sensing
System is located in X-axis and its axis is perpendicular to YOZ planes, i.e. installation site face GTA welding guns.
The increasing material manufacturing arc length feedforward as shown in Fig. 2, a kind of GTA fills silk of the vision-based detection that feedovers and open-loop control system schematic diagram
Detection and open-loop control method, arc length are by tungsten electrode tip in GTA welding guns to the vertical range of preceding layer solid metallic surface
Characterization, arc length feed forward detection refers to that, along accumulation path direction, the solid metallic surface in detection window be located at tungsten electrode front, arc
Long opened loop control is the arc length error according to feed forward detection, adjusts technological parameter and opened loop control arc length, comprises the following steps:
Step 1:Passive vision sensor-based system face GTA welding guns, gather GTA arc images, along accumulation path direction, inspection
Survey the window's position and be located at GTA electric arcs front, the horizontal distance D of window center to tungsten electrode tip is 7-12mm, GTA arc radiation light
GTA immediate vicinity preceding layer solid metallic surfaces are illuminated, the preceding layer solid metallic surface in window is detected, collection
Arc image and feed forward detection window setting position are as shown in Figure 3;
Step 2:Smothing filtering, preceding layer solid metallic surface top edge are carried out to all pixels point in window ranges
Detection, the Hough fittings of edge pixel point, the testing result of preceding layer solid metallic surface top edge is as shown in figure 4, arc length is
Vertical range H of the preceding layer solid metallic top edge to tungsten electrode tip;
Step 3:The advanced step number n=[D/ (VS)+0.5] of arc length feed forward detection is calculated,
Wherein, V is the speed of travel, and unit mm/s, S are the sampling period of detecting system, and unit s, [] represents rounding
Symbol;
Step 4:The arc length of feed forward detection calculates current k moment arc length error es (k)=H (k-n)-h- after n step delays
H0Wherein, H (k-n) represents that the preceding layer solid metallic top edge of (k-n) moment detection is to the vertical range at tungsten electrode tip, h
The floor height of hierarchy slicing, H0For initial setting arc length;
Step 5:Calculate single argument process parameter value W (k)=e (k)/P+W of k moment opened loop controls0
Wherein, P is gain coefficient, W0For initial single argument process parameter value;
Step 6:Repeat step two and step 4, in each sampling instant, the arc length error judgment determined according to step 4
Whether opened loop control is carried out, if arc length error is zero, single argument process parameter value is W0, otherwise, calculated according to step 5
New single argument process parameter value, and realize the opened loop control of GTA silk filling increasing material manufacturing arc length, Fig. 5 is feedforward control accumulation
Typical straight wall part.
Single argument technological parameter described in step 5 is accumulation electric current or wire feed rate.
Gain coefficient P is through the following steps that definite in step 5:
(a) GTA welding guns move to surface, and GTA welding guns direction is vertical with substrate surface, initially sets arc length as H0,
That is tungsten electrode tip accumulates N layers of single track straight wall part using same technological parameter to the distance of substrate surface on substrate, N=4-8,
Single argument technological parameter initial value is W0, the accumulation path direction of adjacent interlayer is on the contrary, often accumulated one layer, GTA arc extinctions,
Interlayer waits 30-120s;
(b) accumulation (N+1) layer is continued, single argument technological parameter is W0, treat arc motion to accumulation path length half
When, the single argument technological parameter of adjusting is by W0Instantaneous step is to new value W1, after (N+1) layer accumulation to be done, measure single argument work
The average height Q of (N+1) layer before skill parameter step1With the average height Q of (N+1) layer after step2;
(c) gain coefficient P=(Q2-Q1)/(W1-W0)。
The above-described embodiments merely illustrate the principles and effects of the present invention, not for the limitation present invention.It is any ripe
Know the personage of this technology all can carry out modifications and changes under the spirit and scope without prejudice to the present invention to above-described embodiment.Cause
This, all those of ordinary skill in the art without departing from disclosed spirit with being completed under technological thought
All equivalent modifications or change, should by the present invention claim be covered.
Claims (3)
- Increasing material manufacturing arc length feed forward detection and open-loop control method 1. a kind of GTA fills silk, arc length are by tungsten electrode point in GTA welding guns Hold what the vertical range of preceding layer solid metallic surface characterized, arc length feed forward detection refers to, along accumulation path direction, detect window Solid metallic surface in mouthful is located in front of tungsten electrode, and arc length opened loop control is the arc length error according to feed forward detection, adjusts technique Parameter and opened loop control arc length, it is characterised in that comprise the following steps:Step 1:Passive vision sensor-based system face GTA welding guns, gather GTA arc images, along accumulation path direction, detect window Mouthful position be located at GTA electric arcs front, and the horizontal distance D of window center to tungsten electrode tip is 7-12mm, GTA arc radiation optical illumination GTA immediate vicinity preceding layer solid metallic surfaces, are detected the preceding layer solid metallic surface in window;Step 2:To in window ranges all pixels point carry out smothing filtering, preceding layer solid metallic surface edge detection, The Hough fittings of edge pixel point, arc length are vertical range H of the preceding layer solid metallic top edge to tungsten electrode tip;Step 3:The advanced step number n=[D/ (VS)+0.5] of arc length feed forward detection is calculated,Wherein, V is the speed of travel, and unit mm/s, S are the sampling period of detecting system, and unit s, [] represents rounding symbol;Step 4:The arc length of feed forward detection calculates current k moment arc length error es (k)=H (k-n)-h-H after n step delays0, its In, for the preceding layer solid metallic top edge of H (k-n) expression (k-n) moment detections to the vertical range at tungsten electrode tip, h is layering The floor height of section, H0For initial setting arc length;Step 5:Calculate single argument process parameter value W (k)=e (k)/P+W of k moment opened loop controls0,Wherein, P is gain coefficient, W0For initial single argument process parameter value;Step 6:Repeat step two and step 4, in each sampling instant, whether the arc length error judgment determined according to step 4 Opened loop control is carried out, if arc length error is zero, single argument process parameter value is W0;Otherwise, calculated newly according to step 5 Single argument process parameter value, and realize the opened loop control of GTA silk filling increasing material manufacturing arc length.
- Increasing material manufacturing arc length feed forward detection and open-loop control method 2. GTA according to claim 1 fills silk, it is characterised in that Single argument technological parameter described in step 5 is accumulation electric current or wire feed rate.
- Increasing material manufacturing arc length feed forward detection and open-loop control method 3. GTA according to claim 1 fills silk, it is characterised in that Gain coefficient P is through the following steps that definite in step 5:(a) GTA welding guns move to surface, and GTA welding guns direction is vertical with substrate surface, initially sets arc length as H0, i.e. tungsten electrode N layers of single track straight wall part, N=4-8, single argument are accumulated on substrate using same technological parameter to the distance of substrate surface in tip Technological parameter initial value is W0, the accumulation path direction of adjacent interlayer is on the contrary, often accumulated one layer, GTA arc extinctions, interlayer etc. Treat 30-120s;(b) accumulation (N+1) layer is continued, single argument technological parameter is W0, when arc motion to when accumulating path length half, adjust The single argument technological parameter of section is by W0Instantaneous step is to new value W1, after (N+1) layer accumulation to be done, measurement single argument technique ginseng The average height Q of (N+1) layer before number step1With the average height Q of (N+1) layer after step2;(c) gain coefficient P=(Q2-Q1)/(W1-W0)。
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CN108723550A (en) * | 2018-05-28 | 2018-11-02 | 西南交通大学 | The GTA silk filling increasing material manufacturing forming height feedbacks of feedforward compensation |
CN108875149A (en) * | 2018-05-28 | 2018-11-23 | 西南交通大学 | A kind of GMA increasing material manufacturing accumulation road morphology control method |
CN109128177A (en) * | 2018-09-14 | 2019-01-04 | 河海大学常州校区 | A method of control increasing material manufacturing electric arc arc length and drip molding end face flatness |
CN109352139A (en) * | 2018-08-07 | 2019-02-19 | 燕山大学 | A kind of oxygen controlled framework metalloid part GTAW electric arc increasing material manufacturing system and method |
CN111627013A (en) * | 2020-05-28 | 2020-09-04 | 西南交通大学 | Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse |
CN112620652A (en) * | 2020-11-27 | 2021-04-09 | 哈尔滨工业大学 | Self-adaptive control system and method for electric arc additive manufacturing process |
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CN111627013A (en) * | 2020-05-28 | 2020-09-04 | 西南交通大学 | Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse |
CN111627013B (en) * | 2020-05-28 | 2022-04-22 | 西南交通大学 | Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse |
CN112620652A (en) * | 2020-11-27 | 2021-04-09 | 哈尔滨工业大学 | Self-adaptive control system and method for electric arc additive manufacturing process |
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