CN108918309B - Welding spot detection method and welding spot detection equipment for galvanized steel sheet - Google Patents
Welding spot detection method and welding spot detection equipment for galvanized steel sheet Download PDFInfo
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- CN108918309B CN108918309B CN201810965307.3A CN201810965307A CN108918309B CN 108918309 B CN108918309 B CN 108918309B CN 201810965307 A CN201810965307 A CN 201810965307A CN 108918309 B CN108918309 B CN 108918309B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/40—Investigating hardness or rebound hardness
- G01N3/42—Investigating hardness or rebound hardness by performing impressions under a steady load by indentors, e.g. sphere, pyramid
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/0014—Type of force applied
- G01N2203/0016—Tensile or compressive
- G01N2203/0019—Compressive
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/0058—Kind of property studied
- G01N2203/0076—Hardness, compressibility or resistance to crushing
- G01N2203/0078—Hardness, compressibility or resistance to crushing using indentation
- G01N2203/008—Residual indentation measurement
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/026—Specifications of the specimen
- G01N2203/0296—Welds
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N2203/02—Details not specific for a particular testing method
- G01N2203/06—Indicating or recording means; Sensing means
- G01N2203/067—Parameter measured for estimating the property
- G01N2203/0682—Spatial dimension, e.g. length, area, angle
Abstract
The invention discloses a welding spot detection method and welding spot detection equipment for a galvanized steel sheet, and relates to the technical field of welding quality evaluation. The welding spot detection method of the galvanized steel sheet comprises the following steps: obtaining an indentation rate according to the detected total electrode displacement and the thickness of a material to be welded, judging the indentation rate and generating first welding spot quality qualified information, obtaining a weighting proportion according to a ring area weighting coefficient and a detected welding spot image, judging the weighting proportion and generating second welding spot quality qualified information, obtaining a splashing proportion according to a detected splashing trace and the welding spot image, judging the splashing proportion and generating third welding spot quality qualified information, and generating welding spot quality qualified information according to the first welding spot quality qualified information, the second welding spot quality qualified information and the third welding spot quality qualified information. The welding spot detection method and the welding spot detection equipment for the galvanized steel sheet can perform multi-aspect nondestructive detection on welding spots, and are high in detection efficiency, accuracy and reliability.
Description
Technical Field
The invention relates to the technical field of welding quality evaluation, in particular to a welding spot detection method and welding spot detection equipment for a galvanized steel sheet.
Background
Galvanized steel sheets are increasingly used in the manufacturing industry of automobiles and the like because of their good corrosion resistance.
In the use of galvanized steel sheets, a plurality of galvanized steel sheets need to be connected by spot welding to form a required structure, for example, in the manufacturing process of automobile bodies, resistance spot welding is an essential connection forming process, and it is counted that 3000 welding spots and 6000 welding spots exist on an automobile body, and the quality of the welding spots basically determines the quality of the automobile body, so the detection of the quality of the welding spots is very important. Most of traditional welding spot detection methods for galvanized steel sheets are destructive detection or semi-destructive detection, such as knocking and the like, are only suitable for sampling detection, have low efficiency and damage weldments, and are not suitable for being used as an online detection method for spot welding quality.
In view of the above, it is important to develop a method and an apparatus for detecting a welding spot of a galvanized steel sheet, which can solve the above technical problems.
Disclosure of Invention
The invention aims to provide a method for detecting welding spots of a galvanized steel sheet, which can carry out nondestructive detection on the welding spots in many aspects, has high detection efficiency and high detection accuracy and reliability.
Another object of the present invention is to provide a solder joint inspection apparatus, which can perform multi-aspect non-destructive inspection on solder joints, and has high inspection efficiency and high inspection accuracy and reliability.
The invention provides a technical scheme that:
in a first aspect, an embodiment of the present invention provides a method for detecting a welding spot of a galvanized steel sheet, including:
obtaining an indentation rate according to the detected total electrode displacement and the thickness of the material to be welded, wherein the total electrode displacement represents the depth of the spot welding electrode pressed into the material to be welded in the pre-pressing process and the spot welding process of the spot welding electrode on the material to be welded;
judging the indentation rate and generating first welding spot quality qualified information;
obtaining a weighting proportion according to the ring area weighting coefficient and the detected welding spot image, wherein the ring area weighting coefficient represents the correlation degree between the area of the corresponding welding spot image and the quality of the welding spot;
judging the weighting proportion and generating second welding spot quality qualified information;
obtaining a splashing proportion according to the detected splashing trace and the welding spot image;
judging the splashing proportion and generating qualified quality information of a third welding spot;
and generating qualified welding spot quality information according to the qualified first welding spot quality information, the qualified second welding spot quality information and the qualified third welding spot quality information.
With reference to the first aspect, in a first implementation manner of the first aspect, the determining the indentation rate and generating the first solder joint quality qualification information includes:
judging whether the indentation rate is smaller than a first preset upper threshold and larger than a first preset lower threshold, and generating first welding spot quality qualified information when the indentation rate is smaller than the first preset upper threshold and larger than the first preset lower threshold;
and when the first welding spot quality qualified information is generated, continuously executing the step of obtaining the weighting proportion according to the ring area weighting coefficient and the welding spot image.
With reference to the first aspect and the foregoing implementation manner of the first aspect, in a second implementation manner of the first aspect, the determining the weighting ratio and generating the second welding spot quality qualification information includes:
judging whether the weighting proportion is larger than a second threshold value or not, and generating qualified quality information of the second welding spot when the weighting proportion is larger than the second threshold value;
and when the second welding spot quality qualified information is generated, continuously executing the step of obtaining the spattering proportion according to the spattering trace and the welding spot image.
With reference to the first aspect and the foregoing implementation manner of the first aspect, in a third implementation manner of the first aspect, the determining the spattering ratio and generating the third welding spot quality qualification information includes:
judging whether the spattering proportion is smaller than a third threshold value or not, and generating qualified quality information of the third welding spot when the spattering proportion is smaller than the third threshold value;
and when third welding spot quality qualified information is generated, continuing to execute the step of generating the welding spot quality qualified information according to the first welding spot quality qualified information, the second welding spot quality qualified information and the third welding spot quality qualified information.
With reference to the first aspect and the foregoing implementation manner, in a fourth implementation manner of the first aspect, the step of deriving the indentation rate according to the total electrode displacement and the thickness of the material to be welded includes:
measuring and obtaining the displacement of a pre-pressing electrode of the spot welding electrode in the pre-pressing process of the material to be welded;
measuring and obtaining the spot welding electrode displacement of the spot welding electrode in the spot welding process of the material to be welded;
summing the spot welding electrode displacement and the pre-pressing electrode displacement to obtain the total electrode displacement;
and obtaining the indentation rate according to the total electrode displacement and the thickness of the material to be welded, wherein the calculation formula is as follows:
C＝(d1+d2)/(2*H)
wherein d1 represents the pre-pressing electrode displacement, d2 represents the spot welding electrode displacement, H represents the thickness of the material to be welded, and C represents the indentation rate.
With reference to the first aspect and the foregoing implementation manner of the first aspect, in a fifth implementation manner of the first aspect, the step of deriving a weighting ratio according to a ring area weighting coefficient and the weld spot image includes:
collecting and obtaining a welding spot image;
preprocessing the welding spot image to obtain a total characteristic ring area;
dividing the total characteristic ring area into three ring areas according to the pixel gray value, and sequentially forming a first characteristic ring area, a second characteristic ring area and a third characteristic ring area from the center of a welding spot to the outside;
respectively calculating the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area according to a pixel method;
calculating a ring area weighting area according to the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area, the third characteristic ring area and the ring area weighting coefficient, wherein the ring area weighting coefficient comprises a total characteristic ring area weighting coefficient, a first characteristic ring area weighting coefficient, a second characteristic ring area weighting coefficient and a third characteristic ring area weighting coefficient, and the calculation formula is as follows:
S＝k1*S1+k2*S2+k3*S3+k0*S0
wherein S1 represents the area of the first characteristic ring region, S2 represents the area of the second characteristic ring region, S3 represents the area of the third characteristic ring region, S0 represents the area of the total characteristic ring region, the area of the total characteristic ring region is the sum of the areas of the first characteristic ring region, the second characteristic ring region and the third characteristic ring region, k1 represents a first characteristic ring region weighting coefficient, k2 represents a second characteristic ring region weighting coefficient, k3 represents a third characteristic ring region weighting coefficient, k0 represents a total characteristic ring region weighting coefficient, and S represents the ring region weighting area;
and calculating the weighting proportion according to the weighted area of the ring area and the area of the total characteristic ring area, wherein the calculation formula is as follows:
K4＝S/S0
wherein K4 characterizes the weighted ratio.
With reference to the first aspect and the foregoing implementation manner, in a sixth implementation manner of the first aspect, before the step of calculating the weighted area of the ring area according to the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area, and the third characteristic ring area and the ring area weighting coefficient, the method further includes:
measuring respective ring area sequences x (n) of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area, and respective welding point parameter sequences y (n) corresponding to the respective ring area sequences x (n), wherein an autocorrelation coefficient ρ x of each ring area sequence x (n) is 1, and an autocorrelation coefficient ρ y of each welding point parameter sequence y (n) is 1;
calculating the total characteristic ring area weighting coefficient, the first characteristic ring area weighting coefficient, the second characteristic ring area weighting coefficient and the third characteristic ring area weighting coefficient according to the ring area sequence x (n) and the welding spot parameter sequence y (n) corresponding to the ring area sequence x (n);
wherein the calculation formula is as follows:
wherein k represents the total feature ring area weighting coefficient, the first feature ring area weighting coefficient, the second feature ring area weighting coefficient, or the third feature ring area weighting coefficient.
With reference to the first aspect and the foregoing implementation manner of the first aspect, in a seventh implementation manner of the first aspect, the step of deriving the spatter ratio according to the detected spatter trace and the welding spot image includes:
obtaining a splash trace according to the welding spot image;
calculating the area of the splash trace according to a pixel method;
calculating the splashing proportion according to the area of the splashing trace and the area of the total characteristic ring area; wherein the calculation formula is as follows:
K5＝Sf/S0
wherein K5 characterizes the spatter ratio and Sf characterizes the area of the spatter trace.
In a second aspect, an embodiment of the present invention provides a solder joint detection apparatus, including:
a memory for storing one or more programs;
a processor;
when the one or more programs are executed by the processor, the method for detecting the welding spots of the galvanized steel plate is realized.
With reference to the second aspect, in a first implementation manner of the second aspect, the solder joint detection device further includes an image sensor and a displacement sensor, and the processor is in communication connection with the image sensor and the displacement sensor respectively;
detecting the total displacement of the electrode by the displacement sensor;
the processor obtains the indentation rate according to the total electrode displacement and the thickness of the material to be welded;
collecting welding spot images through the image sensor;
the processor obtains a total characteristic ring area according to the welding spot image;
the processor obtains a weighting proportion according to the ring area weighting coefficient and the total characteristic ring area;
the processor obtains the splash trace according to the welding spot image;
the processor obtains the area of the splash trace according to the splash trace;
the processor obtains the splashing proportion according to the area of the splashing trace and the area of the total characteristic ring area;
and the processor judges the indentation rate, the weighting proportion and the splashing proportion and generates qualified welding spot quality information.
Compared with the prior art, the welding spot detection method and the welding spot detection equipment for the galvanized steel sheet provided by the embodiment of the invention have the beneficial effects that:
and obtaining the indentation rate according to the detected total electrode displacement and the thickness of the material to be welded, judging the indentation rate, and generating first welding spot quality qualified information. Obtaining a weighting proportion according to the ring area weighting coefficient and the detected welding spot image, further judging the weighting proportion, and generating second welding spot quality qualified information; obtaining a splashing proportion according to the detected splashing trace and the welding spot image; further judging the splashing proportion and generating qualified quality information of a third welding spot; the quality qualified information of the welding spot is generated according to the quality qualified information of the first welding spot, the quality qualified information of the second welding spot and the quality qualified information of the third welding spot, after the three quality qualified information are obtained, the quality qualified information of the first welding spot, the quality qualified information of the second welding spot and the quality qualified information of the third welding spot are obtained, the quality qualified information of the welding spot can be generated, and the quality of the welding spot is judged to be qualified.
In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required to be used in the embodiments will be briefly described below. It is appreciated that the following drawings depict only certain embodiments of the invention and are therefore not to be considered limiting of its scope. For a person skilled in the art, it is possible to derive other relevant figures from these figures without inventive effort.
Fig. 1 is a schematic structural diagram of a solder joint inspection apparatus according to an embodiment of the present invention.
Fig. 2 is a schematic flowchart of a solder joint inspection apparatus according to an embodiment of the present invention.
Fig. 3 is a schematic flow chart of the substeps of step S100 in fig. 2.
Fig. 4 is a schematic flow chart of the sub-steps of step S200 in fig. 2.
Fig. 5 is a schematic flow chart of the sub-steps of step S300 in fig. 2.
Fig. 6 is a schematic flow chart of the sub-steps of step S400 in fig. 2.
Fig. 7 is a schematic flow chart of the sub-steps of step S500 in fig. 2.
Fig. 8 is a schematic flow chart of the sub-steps of step S600 in fig. 2.
Icon: 70-solder joint detection equipment; 710-a memory; 720-a processor; 730-a storage controller; 740 — a peripheral interface; 750-a radio frequency unit; 760-communication bus/signal lines; 770-a displacement sensor; 780-image sensor.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures. The terms "upper", "lower", "inner", "outer", "left", "right", and the like, refer to an orientation or positional relationship as shown in the drawings, or as would be conventionally found in use of the inventive product, or as would be conventionally understood by one skilled in the art, and are used merely to facilitate the description and simplify the description, but do not indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are therefore not to be construed as limiting the present invention. The terms "first," "second," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.
It is also to be understood that, unless expressly stated or limited otherwise, the terms "disposed," "connected," and the like are intended to be open-ended, and mean "connected," i.e., fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; the connection may be direct or indirect via an intermediate medium, and may be a communication between the two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
At present, in the use of galvanized steel sheets, a plurality of galvanized steel sheets need to be connected by spot welding to form a required structure, for example, in the manufacturing process of an automobile body, resistance spot welding is an indispensable connection forming process, and it is counted that 3000-6000 welding spots exist on one automobile body, and the quality of the welding spots basically determines the quality of the automobile body, so the detection of the quality of the welding spots is very important. Most of traditional welding spot detection methods for galvanized steel sheets are destructive detection or semi-destructive detection, such as knocking and the like, are only suitable for sampling detection, have low efficiency and damage weldments, and are not suitable for being used as an online detection method for spot welding quality.
The embodiment of the invention provides a welding spot detection method and welding spot detection equipment for a galvanized steel sheet.
The following detailed description of embodiments of the invention refers to the accompanying drawings.
Example (b):
referring to fig. 1, fig. 1 is a schematic structural diagram of a solder joint inspection apparatus 70 according to an embodiment of the present invention.
The solder joint detection apparatus 70 may be, but is not limited to, a smart phone, a Personal Computer (PC), a tablet PC, a Personal Digital Assistant (PDA), a wearable mobile terminal, and the like, and the solder joint detection apparatus 70 includes a memory 710, a memory controller 730, one or more processors 720 (only one is shown), a radio frequency unit 750, a peripheral interface 740, and the like. These components communicate with each other via one or more communication buses/signal lines 760.
The memory 710 can be used for storing software programs and modules, such as program instructions/modules corresponding to the point cloud registration apparatus provided by the embodiment of the present invention, and the processor 720 executes various functional applications and data processing, such as the point cloud registration method provided by the embodiment of the present invention, by operating the software programs and modules stored in the memory 710.
The Memory 710 may be, but is not limited to, a Random Access Memory 710 (RAM), a Read Only Memory 710 (ROM), a Programmable Read Only Memory 710 (PROM), an Erasable Read Only Memory 710 (EPROM), an electrically Erasable Read Only Memory 710 (EEPROM), and the like.
The rf unit 750 is used for receiving and transmitting electromagnetic waves, and implementing interconversion between the electromagnetic waves and electrical signals, so as to communicate with a communication network or other devices.
It will be appreciated that the configuration shown in FIG. 1 is merely illustrative and that the solder joint inspection apparatus 70 may include more or fewer components than shown in FIG. 1, or may have a different configuration than shown in FIG. 1. The components shown in fig. 1 may be implemented in hardware, software, or a combination thereof.
With reference to fig. 1, the solder joint detection apparatus 70 may further include an image sensor 780 and a displacement sensor 770, wherein the processor 720 is in communication connection with the image sensor 780 and the displacement sensor 770, respectively, and it can be understood that the processor 720 may be in communication connection with the image sensor 780 and the displacement sensor 770 through an external interface and a communication bus/signal line 760, respectively;
the obtained total displacement of the electrodes is detected by a displacement sensor 770; the processor 720 receives the total electrode displacement and obtains the indentation rate according to the total electrode displacement and the thickness of the material to be welded;
the image sensor 780 acquires an image of the welding spot, and it can be understood that the image of the welding spot may also be an image of the welding spot including the welding spot ring area to be preprocessed, or may also be an image of a larger range including the welding spot ring area and spatter traces near the welding spot ring area; processor 720 receives the solder joint image and obtains a total feature ring area according to the solder joint image; the processor 720 obtains a weighting ratio according to the ring area weighting coefficient and the total characteristic ring area;
the processor 720 obtains a splash trace according to the welding spot image; the processor 720 obtains the area of the splash trace according to the splash trace; the processor 720 obtains the splashing proportion according to the area of the splashing trace and the area of the total characteristic ring area;
finally, the processor 720 judges the indentation rate, the weighting ratio and the spattering ratio and generates welding spot quality qualified information. The detection of the quality of the welding spots is completed, and because the nondestructive detection of three parameters, namely the indentation rate, the weighting proportion and the splashing proportion, is used in the detection process, the welding spot detection equipment 70 can perform multi-aspect nondestructive detection on the welding spots, has higher detection efficiency, and has high detection accuracy and reliability.
The working principle and the beneficial effects of the method for detecting welding spots of the galvanized steel sheet provided by the embodiment of the invention are specifically described below.
Referring to fig. 2, fig. 2 is a schematic flow chart of a solder joint inspection apparatus 70 according to an embodiment of the present invention. The welding spot detection method of the galvanized steel sheet comprises the following steps:
step S100: obtaining the indentation rate according to the detected total displacement of the electrode and the thickness of the material to be welded; the total electrode displacement represents the depth of the spot welding electrode pressed into the material to be welded in the pre-pressing process and the spot welding process of the spot welding electrode on the material to be welded.
Step S200: and judging the indentation rate and generating first welding spot quality qualified information.
When spot welding operation is carried out, the spot welding electrode is to prepressing to the opposite both sides of waiting to weld the material, and the spot welding electrode is to waiting to weld the material feed again to form the reaction nugget on waiting to weld the material, the solder joint promptly, because in prepressing and spot welding in-process, the spot welding electrode will treat to weld the material and exert certain pressure, and wait to weld the material when forming the reaction nugget and soften because of high temperature, so the spot welding electrode will leave the indentation on waiting to weld the material, and the degree of depth and solder joint quality of indentation have close relation, for example:
when the depth of the indentation is too small, the welding heat generated in the welding process is too small, the metal at the contact part of the spot welding electrode and the material to be welded is not fully melted, only less molten metal is pushed around under the action of the spot welding electrode, the reaction nugget is not formed or is not formed enough, the connection strength of the welding spot is not high, and the fracture mode is that the joint surface is fractured;
when the depth of the indentation is too large, the attractive appearance and smoothness of the surface of the welding spot are affected, the size of the section is reduced, stress concentration is caused, and the connection strength of the welding spot is reduced.
Therefore, the indentation rate obtained by the total electrode displacement and the thickness of the material to be welded is judged to generate first welding spot quality qualified information, the quality condition of the welding spot is directly reflected, the step is a nondestructive detection method, the electrode displacement sensor 770 can be directly installed on the spot welding electrode, and the quality of the welding spot is not influenced in the detection process.
Step S300: obtaining a weighting proportion according to the ring area weighting coefficient and the detected welding spot image; the ring area weighting coefficient represents the correlation degree between the area of the corresponding welding spot image and the quality of the welding spot.
Step S400: judging the weighting proportion and generating qualified quality information of the second welding spot;
in the process of forming the welding spot, the temperature change, the pressure change and the like of the reaction nugget directly react to the surface color of the welding spot, so the difference between the color of the welding spot and the area corresponding to the color area can be used for representing the difference of the welding spot in different spot welding processes and process condition changes, the quality of the welding spot can be directly reflected, the quality of the welding spot cannot be influenced by the actions of collecting images of the welding spot, the time required for collecting the images of the welding spot is short, and the step can carry out rapid and nondestructive detection on the welding spot.
Step S500: obtaining a splashing proportion according to the detected splashing trace and the welding spot image;
step S600: judging the splashing proportion and generating qualified quality information of a third welding spot;
in the spot welding process, after the minimum reaction nugget is formed, power feeding is continued, so that the reaction nugget and the plastic ring are continuously expanded outwards, when the expansion speed of the reaction nugget is greater than that of the plastic ring, molten liquid metal can fly out of a material to be welded to form splashing, in the splashing process, the splashed molten liquid metal leaves a little splashed liquid drop around a welding point, the molten liquid drop is gradually solidified and forms a gray black splashing trace around the welding point, and the larger the splashing degree is, the larger the splashing trace can be left around the welding point. The splashing proportion obtained by the splashing traces and the welding spot images can roughly judge the splashing condition, and further reflect the quality of the welding spot. And in the judgment process of the splashing proportion, the collection action of the welding spot image is fast, and the quality of the welding spot cannot be influenced, so that the welding spot can be quickly and nondestructively detected in the step.
Step S700: and generating qualified welding spot quality information according to the qualified first welding spot quality information, the qualified second welding spot quality information and the qualified third welding spot quality information.
After the three quality qualified information is obtained, the first welding spot quality qualified information, the second welding spot quality qualified information and the third welding spot quality qualified information are obtained, the welding spot quality qualified information can be generated, and the quality of the welding spot is judged to be qualified.
Referring to fig. 3, fig. 3 is a schematic flow chart of the sub-steps of step S100 in fig. 2. In this embodiment of the present invention, step S100 may further include the following sub-steps:
substep S101: measuring and obtaining the displacement of the pre-pressed electrode of the spot welding electrode in the pre-pressing process of the material to be welded;
substep S102: measuring and obtaining the spot welding electrode displacement of the spot welding electrode in the spot welding process of the material to be welded;
substep S103: summing the spot welding electrode displacement and the prepressing electrode displacement to obtain the total electrode displacement; the total displacement of the electrode is based on the moving distance of the spot welding electrode in the prepressing process and the reaction nugget forming process in the spot welding process, and the depth condition of the reaction indentation can be more comprehensively reflected.
Substep S104: and obtaining the indentation rate according to the total displacement of the electrode and the thickness of the material to be welded, wherein the calculation formula is as follows:
C＝(d1+d2)/(2*H)
wherein d1 represents the prepressing electrode displacement, d2 represents the spot welding electrode displacement, H represents the thickness of the material to be welded, and C represents the indentation rate.
Taking the example of spot welding a DP600+ Z galvanized steel sheet with a thickness of 1.4mm, when the displacement amount d1 of the electrode in the pre-pressing process and the displacement amount d2 in the reaction nugget forming process were detected by the displacement sensor 770 in the spot welding process as 0.02mm, the indentation ratio C was 4.5% (d1+ d2)/(2 × H).
Referring to fig. 4, fig. 4 is a schematic flow chart of the sub-steps of step S200 in fig. 2. In this embodiment of the present invention, step S200 may further include the following sub-steps:
substep S201: and judging whether the indentation rate is smaller than a first preset upper threshold and larger than a first preset lower threshold.
Substep S202: and when the indentation rate is smaller than a first preset upper threshold and larger than a first preset lower threshold, generating first welding spot quality qualified information.
Since the fact that the depth of the indentation is too small or the depth of the indentation is too large means that problems of too small welding heat, insufficient metal melting at the welding spot, no or insufficient forming of a reaction nugget, low connection strength of the welding spot, stress concentration and the like occur in the welding spot forming process, whether the actually detected indentation rate is qualified needs to be judged by using the range of the preset indentation rate, and in the embodiment of the invention, the first preset upper threshold value is 15%, and the first preset lower threshold value is 5%.
Also taking the above-mentioned spot welding process of the DP600+ Z galvanized steel sheet with a thickness of 1.4mm as an example, if the indentation rate C ═ (d1+ d2)/(2 × H) ═ 4.5% is less than the first preset lower threshold, then the first quality of the welding spot is not qualified, and the welding spot is not qualified.
And after performing the sub-step S202, performing the step S300, that is, when the first welding spot quality qualified information is generated, continuing to perform the step S300.
The step S300 is only performed after the first welding spot quality qualified information is generated, namely, the subsequent steps are not performed under the condition that the welding spot quality is unqualified, so that the detection time is saved.
Referring to fig. 5, fig. 5 is a schematic flow chart of the sub-steps of step S300 in fig. 2. In this embodiment of the present invention, step S300 may further include the following sub-steps:
substep S307: collecting and obtaining a welding spot image;
substep S308: preprocessing a welding spot image and obtaining a total characteristic ring area; and facilitating subsequent segmentation, wherein the preprocessing comprises sequentially performing format conversion, gray level processing, equalization processing, linear filtering and edge detection on the welding spot image to obtain a total characteristic ring area.
Substep S309: dividing the total characteristic ring area into three ring areas according to the pixel gray value; and a first characteristic ring area, a second characteristic ring area and a third characteristic ring area are arranged from the center of the welding spot to the outside in sequence; for example, the threshold T1 and the threshold T2 are set to 50 and 150, respectively. And dividing the image of the total characteristic ring area into three parts by two thresholds, wherein the area with the pixel gray value smaller than T1 is a first characteristic ring area, the area with the pixel gray value larger than T1 and smaller than T2 is a third characteristic ring area, and the area with the pixel gray value larger than T2 is a second characteristic ring area.
Substep S310: respectively calculating the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area according to a pixel method;
the substeps of S308-S310 are processes of the processor obtaining the total feature ring region according to the weld image. Wherein, the surface of the welding spot of the galvanized steel sheet can be divided into a plurality of ring areas, which is convenient for the fine evaluation of the corresponding parameters of the ring areas and improves the accuracy of the welding spot detection method of the galvanized steel sheet, which is positioned in the central area of the surface of the welding spot and is formed by directly contacting the material to be welded during the welding process, the shape is approximately circular, the temperature of the first characteristic ring area is highest in the spot welding process, the heat generated in the welding process can melt the coating of the material to be welded and be squeezed away by the electrode, so that the base material is exposed, and for the DP600+ Z galvanized steel sheet, because the melting point of zinc is lower, the heat generated during welding is easier to melt the zinc layer and extrude away by the electrode, so that the base material is exposed, therefore, for the first characteristic ring region, the area directly reflects the temperature condition of the welding process, whether the time is proper or not during welding and the like.
For the second characteristic ring area, which is arranged outside the first characteristic ring area, the section contour line of the second characteristic ring area has a great relation with the depth of the indentation at the welding point and the shape of the end surface of the spot welding electrode, the spot welding electrode is spherical, and when the size of the spot welding electrode cap is fixed, the larger the depth of the indentation is, the larger the curvature of the arc contour line of the second characteristic ring area is. Therefore, the area of the second ring region further reflects the quality of the spot welding process relative to the depth of the indentation, and the welding reflected by the first ring region.
For the third characteristic ring area, which is a heat affected area at the outer edge of the welding point, the part of the plating metal is partially oxidized after being heated to generate corresponding oxide, and for the DP600+ Z galvanized steel sheet, the part of the plating metal is partially oxidized after being heated to generate zinc oxide. Therefore, the area of the third ring region further reflects the spot welding time and temperature during spot welding.
Further, the substep of step S300 further comprises:
substep S311: calculating the weighted area of the ring area according to the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area and the ring area weighting coefficient;
the ring area weighting coefficient comprises a total characteristic ring area weighting coefficient, a first characteristic ring area weighting coefficient, a second characteristic ring area weighting coefficient and a third characteristic ring area weighting coefficient, wherein the calculation formula is as follows:
S＝k1*S1+k2*S2+k3*S3+k0*S0
wherein S1 represents the area of the first characteristic ring region, S2 represents the area of the second characteristic ring region, S3 represents the area of the third characteristic ring region, S0 represents the area of the total characteristic ring region, the area of the total characteristic ring region is the sum of the areas of the first characteristic ring region, the second characteristic ring region and the third characteristic ring region, k1 represents the weighting coefficient of the first characteristic ring region, k2 represents the weighting coefficient of the second characteristic ring region, k3 represents the weighting coefficient of the third characteristic ring region, k0 represents the weighting coefficient of the total characteristic ring region, and S represents the weighted area of the ring regions.
Substep S312: and calculating to obtain a weighting proportion according to the weighting area of the ring area and the area of the total characteristic ring area.
Wherein, the calculation formula is as follows:
K4＝S/S0
where K4 characterizes the weighted ratio.
Since the first characteristic ring area, the second characteristic ring area, the third characteristic ring area and the sum of the three characteristic ring areas correspond to different conditions in the welding process or different parameter correlation numbers in the welding process, the corresponding weighting coefficients are adopted to more accurately reflect the quality of the welding spot.
For example, when k1 is 0.935, k2 is 0.863, k3 is 0.942, and k0 is 0.966, the areas of the first, second, and third eigen-ring regions of the solder joint are calculated to be S1 is 21.24mm2，S2＝26.54mm2，S3＝30.76mm2When the total characteristic ring area is S0-78.54 mm2Thus, the weighted area of the ring region is s.k 1S1+ k2S2+ k3S3+ k0S 0. 147.61mm2Then, the weighting ratio K4 is S/S0 is 1.88.
It is understood that step S302 may be preceded by:
substep S301: respectively measuring the respective ring area sequences x (n) of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area, and the welding spot parameter sequences y (n) corresponding to the respective ring area sequences x (n). It should be noted that the welding point parameter sequence may be a sequence of tensile and shear loads at the welding point, and the like.
The autocorrelation coefficient of each ring area sequence x (n) is ρ x ═ 1, and the autocorrelation coefficient of each welding spot parameter sequence y (n) is ρ y ═ 1;
substep S302: and respectively calculating a total characteristic ring area weighting coefficient, a first characteristic ring area weighting coefficient, a second characteristic ring area weighting coefficient and a third characteristic ring area weighting coefficient according to the ring area sequence x (n) and the welding spot parameter sequence y (n) corresponding to the ring area sequence x (n).
Wherein the calculation formula is as follows:
wherein k represents a total characteristic ring area weighting coefficient, a first characteristic ring area weighting coefficient, a second characteristic ring area weighting coefficient or a third characteristic ring area weighting coefficient.
The substep S302 can improve the accuracy of the method for detecting the welding spot of the galvanized steel sheet, and particularly for purchasing the materials to be welded in batches, respectively collecting a plurality of groups of welding samples, and measuring the respective area sequences x (n) of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area of the welding samples and the welding spot parameter sequences y (n) corresponding to the respective area sequences x (n) of the ring areas to reflect the weighting coefficients of the responses of the materials to be welded in batches, so as to more accurately reflect the welding quality through the method for detecting the welding spot of the galvanized steel sheet.
Referring to fig. 6, fig. 6 is a schematic flow chart of the sub-steps of step S400 in fig. 2. In the embodiment of the present invention, step S400 may further include the following sub-steps:
substep S401: judging whether the weighting proportion is larger than a second threshold value;
substep S402: when the weighting proportion is larger than a second threshold value, second welding spot quality qualified information is generated; wherein the second threshold is 1.85.
For example, in the previous experiment, 30 groups of ring area sequences x (n) of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area of the welding spot of the DP600+ Z galvanized steel plate with the thickness of 1.4mm and a welding spot parameter sequence y (n) corresponding to the respective ring area sequence x (n) are detected, wherein the welding spot parameter sequence y (n) represents a tensile shear load data sequence of the welding spot, and a corresponding weighting coefficient is derived through the formula. The obtained product has k 1-0.935, k 2-0.863, k 3-0.942, and k 0-0.966.
When the areas of the first characteristic ring area, the second characteristic ring area and the third characteristic ring area of the welding spot are calculated to be S1-21.24 mm2, S2-26.54 mm2 and S3-30.76 mm2, the total characteristic ring area is S0-78.54 mm2, so that the weighted area of the ring areas is S-k 1S1+ k2S2+ k3S3+ k0S 0-147.61 mm 35522And when the weight ratio is more than 1.85 × S0-145.299 mm2, and the weight ratio is K4-S/S0-1.88, the weight ratio of the welding spot is qualified.
Further, the sub-step of step S400 may further include:
and after the sub-step S402 is performed, the step S500 is performed, that is, when the second welding spot quality qualified information is generated, the step of deriving the spatter ratio according to the spatter trace and the welding spot image is continuously performed.
The step S500 is only performed after the second welding spot quality qualified information is generated, that is, the subsequent steps are not performed under the condition that the welding spot quality is unqualified, so that the detection time is saved.
Referring to fig. 7, fig. 7 is a schematic flowchart illustrating sub-steps of step S500 in fig. 2. In this embodiment of the present invention, step S500 may further include the following sub-steps:
substep S501: obtaining a splash trace according to the welding spot image;
substep S502: calculating the area of the splash trace according to a pixel method;
substep S503: calculating the splashing proportion according to the area of the splashing trace and the area of the total characteristic ring area; wherein the calculation formula is as follows:
K5＝Sf/S0
where K5 represents the spatter ratio and Sf represents the area of the spatter trace.
For example, the image around a certain captured DP600+ Z welding point is preprocessed, and the area Sf of the spatter trace is obtained to be 2.13mm2, and the area S0 of the total characteristic ring region is obtained to be 78.54mm2, so that the spatter trace area ratio D is obtained to be Sf/S0 to be 2.71%.
Through the splashing proportion, in the spot welding process, molten liquid metal flies out from the material to be welded to form splashing, and the splashing degree further reflects the quality of the welding spot. And in the judgment process of the splashing proportion, the collection action of the welding spot image is fast, and the quality of the welding spot cannot be influenced, so that the welding spot can be quickly and nondestructively detected in the step.
Referring to fig. 8, fig. 8 is a schematic flowchart of the sub-steps of step S600 in fig. 2. In this embodiment of the present invention, step S600 may further include the following sub-steps:
substep S601: judging whether the splash proportion is smaller than a third threshold value or not;
substep S602: when the sputtering proportion is smaller than a third threshold value, generating third welding spot quality qualified information; in an embodiment of the invention, the third threshold is 10%.
For example, the spatter trace area ratio D is Sf/S0 of 2.71% which is less than 10%, so the spatter ratio at the welding point is qualified.
After the sub-step S602, step S700 is executed, that is, when the third welding spot quality qualified information is generated, the welding spot quality qualified information is generated according to the first welding spot quality qualified information, the second welding spot quality qualified information and the third welding spot quality qualified information. Namely, after the three quality qualified information are obtained, the first welding spot quality qualified information, the second welding spot quality qualified information and the third welding spot quality qualified information are obtained, the welding spot quality qualified information can be generated, and the quality of the welding spot is judged to be qualified.
The working principle of the welding spot detection method of the galvanized steel sheet provided by the embodiment of the invention is as follows:
and obtaining the indentation rate according to the detected total electrode displacement and the thickness of the material to be welded, judging the indentation rate, and generating first welding spot quality qualified information. Obtaining a weighting proportion according to the ring area weighting coefficient and the detected welding spot image, further judging the weighting proportion, and generating second welding spot quality qualified information; obtaining a splashing proportion according to the detected splashing trace and the welding spot image; further judging the splashing proportion and generating qualified quality information of a third welding spot; the quality qualified information of the welding spot is generated according to the quality qualified information of the first welding spot, the quality qualified information of the second welding spot and the quality qualified information of the third welding spot, after the three quality qualified information are obtained, the quality qualified information of the first welding spot, the quality qualified information of the second welding spot and the quality qualified information of the third welding spot are obtained, the quality qualified information of the welding spot can be generated, and the quality of the welding spot is judged to be qualified.
In summary, the following steps:
according to the method for detecting the welding spots of the galvanized steel sheet provided by the embodiment of the invention, the welding spots can be subjected to multi-aspect nondestructive detection, the detection efficiency is high, and the detection accuracy and reliability are high.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and it is obvious to those skilled in the art that the features in the above embodiments may be combined with each other and the present invention may be variously modified and changed without conflict. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention. The present embodiments are to be considered as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Claims (7)
1. A welding spot detection method of a galvanized steel sheet is characterized by comprising the following steps:
obtaining an indentation rate according to the detected total electrode displacement and the thickness of the material to be welded, wherein the total electrode displacement represents the depth of the spot welding electrode pressed into the material to be welded in the pre-pressing process and the spot welding process of the spot welding electrode on the material to be welded;
judging the indentation rate and generating first welding spot quality qualified information;
obtaining a weighting proportion according to the ring area weighting coefficient and the detected welding spot image, wherein the ring area weighting coefficient represents the correlation degree between the area of the corresponding welding spot image and the quality of the welding spot;
judging the weighting proportion and generating second welding spot quality qualified information;
obtaining a splashing proportion according to the detected splashing trace and the welding spot image;
judging the splashing proportion and generating qualified quality information of a third welding spot;
generating qualified welding spot quality information according to the qualified first welding spot quality information, the qualified second welding spot quality information and the qualified third welding spot quality information;
the step of obtaining the weighting proportion according to the ring area weighting coefficient and the welding spot image comprises the following steps:
collecting and obtaining a welding spot image;
preprocessing the welding spot image to obtain a total characteristic ring area;
dividing the total characteristic ring area into three ring areas according to the pixel gray value, and sequentially forming a first characteristic ring area, a second characteristic ring area and a third characteristic ring area from the center of a welding spot to the outside;
respectively calculating the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area according to a pixel method;
calculating a ring area weighting area according to the areas of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area, the third characteristic ring area and the ring area weighting coefficient, wherein the ring area weighting coefficient comprises a total characteristic ring area weighting coefficient, a first characteristic ring area weighting coefficient, a second characteristic ring area weighting coefficient and a third characteristic ring area weighting coefficient, and the calculation formula is as follows:
S＝k1*S1+k2*S2+k3*S3+k0*S0
wherein S1 represents the area of the first characteristic ring region, S2 represents the area of the second characteristic ring region, S3 represents the area of the third characteristic ring region, S0 represents the area of the total characteristic ring region, the area of the total characteristic ring region is the sum of the areas of the first characteristic ring region, the second characteristic ring region and the third characteristic ring region, k1 represents a first characteristic ring region weighting coefficient, k2 represents a second characteristic ring region weighting coefficient, k3 represents a third characteristic ring region weighting coefficient, k0 represents a total characteristic ring region weighting coefficient, and S represents the ring region weighting area;
and calculating the weighting proportion according to the weighted area of the ring area and the area of the total characteristic ring area, wherein the calculation formula is as follows:
K4＝S/S0
wherein K4 characterizes the weighted ratio;
the step of calculating the weighted area of the ring region according to the areas of the total characteristic ring region, the first characteristic ring region, the second characteristic ring region, the third characteristic ring region and the ring region weighting coefficient further comprises:
measuring respective ring area sequences x (n) of the total characteristic ring area, the first characteristic ring area, the second characteristic ring area and the third characteristic ring area, and respective welding point parameter sequences y (n) corresponding to the respective ring area sequences x (n), wherein an autocorrelation coefficient ρ x of each ring area sequence x (n) is 1, and an autocorrelation coefficient ρ y of each welding point parameter sequence y (n) is 1;
calculating the total characteristic ring area weighting coefficient, the first characteristic ring area weighting coefficient, the second characteristic ring area weighting coefficient and the third characteristic ring area weighting coefficient according to the ring area sequence x (n) and the welding spot parameter sequence y (n) corresponding to the ring area sequence x (n);
wherein the calculation formula is as follows:
wherein k represents the total feature ring area weighting coefficient, the first feature ring area weighting coefficient, the second feature ring area weighting coefficient, or the third feature ring area weighting coefficient;
and the step of obtaining the spattering ratio according to the spattering trace obtained by detection and the welding spot image comprises the following steps of:
obtaining a splash trace according to the welding spot image;
calculating the area of the splash trace according to a pixel method;
calculating the splashing proportion according to the area of the splashing trace and the area of the total characteristic ring area; wherein the calculation formula is as follows:
K5＝Sf/S0
wherein K5 characterizes the spatter ratio and Sf characterizes the area of the spatter trace.
2. The method of claim 1, wherein the step of determining the indentation rate and generating the first spot quality qualification information comprises:
judging whether the indentation rate is smaller than a first preset upper threshold and larger than a first preset lower threshold, and generating first welding spot quality qualified information when the indentation rate is smaller than the first preset upper threshold and larger than the first preset lower threshold;
and when the first welding spot quality qualified information is generated, continuously executing the step of obtaining the weighting proportion according to the ring area weighting coefficient and the welding spot image.
3. The method of claim 2, wherein the determining the weighted ratio and generating the second weld quality qualification information comprises:
judging whether the weighting proportion is larger than a second threshold value or not, and generating qualified quality information of the second welding spot when the weighting proportion is larger than the second threshold value;
and when the second welding spot quality qualified information is generated, continuously executing the step of obtaining the spattering proportion according to the spattering trace and the welding spot image.
4. The method according to claim 3, wherein the step of determining the spatter ratio and generating the third welding spot quality qualification information comprises:
judging whether the spattering proportion is smaller than a third threshold value or not, and generating qualified quality information of the third welding spot when the spattering proportion is smaller than the third threshold value;
and when third welding spot quality qualified information is generated, continuing to execute the step of generating the welding spot quality qualified information according to the first welding spot quality qualified information, the second welding spot quality qualified information and the third welding spot quality qualified information.
5. The method for detecting welding spots of a galvanized steel sheet according to claim 1, wherein the step of deriving the indentation rate according to the total displacement of the electrodes and the thickness of the material to be welded comprises:
measuring and obtaining the displacement of a pre-pressing electrode of the spot welding electrode in the pre-pressing process of the material to be welded;
measuring and obtaining the spot welding electrode displacement of the spot welding electrode in the spot welding process of the material to be welded;
summing the spot welding electrode displacement and the pre-pressing electrode displacement to obtain the total electrode displacement;
and obtaining the indentation rate according to the total electrode displacement and the thickness of the material to be welded, wherein the calculation formula is as follows:
C＝(d1+d2)/(2*H)
wherein d1 represents the pre-pressing electrode displacement, d2 represents the spot welding electrode displacement, H represents the thickness of the material to be welded, and C represents the indentation rate.
6. A solder joint inspection apparatus, comprising:
a memory for storing one or more programs;
a processor;
the one or more programs, when executed by the processor, implement the method for solder joint inspection of a galvanized steel sheet according to any one of claims 1 to 5.
7. The welding spot detection device according to claim 6, further comprising an image sensor and a displacement sensor, wherein the processor is in communication connection with the image sensor and the displacement sensor, respectively;
detecting by the displacement sensor to obtain the total displacement of the electrode;
the processor obtains the indentation rate according to the total electrode displacement and the thickness of the material to be welded;
collecting welding spot images through the image sensor;
the processor obtains a total characteristic ring area according to the welding spot image;
the processor obtains a weighting proportion according to the ring area weighting coefficient and the total characteristic ring area;
the processor obtains the splash trace according to the welding spot image;
the processor obtains the area of the splash trace according to the splash trace;
the processor obtains the splashing proportion according to the area of the splashing trace and the area of the total characteristic ring area;
and the processor judges the indentation rate, the weighting proportion and the splashing proportion and generates qualified welding spot quality information.
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