CN109570699B - Time-sharing control pipe plate welding regulation and control method - Google Patents

Time-sharing control pipe plate welding regulation and control method Download PDF

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CN109570699B
CN109570699B CN201910021361.7A CN201910021361A CN109570699B CN 109570699 B CN109570699 B CN 109570699B CN 201910021361 A CN201910021361 A CN 201910021361A CN 109570699 B CN109570699 B CN 109570699B
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洪波
张智勇
郭韬
刘锦
向垂悦
秦子濠
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Xiangtan University
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    • 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
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Abstract

The invention discloses a time-sharing control tube plate welding regulation and control method, which mainly solves the problems of accumulation of molten drops of a welding seam of a tube plate welding, a molten pool pit, incomplete fusion and incomplete penetration of the welding seam and the like, and is suitable for automatic welding of the welding seam of the tube plate. The system mainly comprises a time-sharing measuring device, a signal time-sharing processing module, an adjusting module and a driving device. The technical scheme of the invention is as follows: the time-sharing measuring device and the signal time-sharing processing module perform time-sharing control and processing on the acquired signals to obtain the optimal angular welding angular speed and the optimal welding current of a certain determined position, and the adjusting module combines the optimal angular welding angular speed and the optimal welding current to jointly adjust the welding gun to perform accurate welding work, so that high-quality and high-accuracy welding of the tube plate is realized.

Description

Time-sharing control pipe plate welding regulation and control method
Technical Field
The invention relates to the technical field of automatic welding, in particular to a time-sharing control pipe plate adjusting and controlling system and a time-sharing control pipe plate adjusting and controlling method.
Background
Along with the maximization of a chemical container, the diameter of a tube plate is also increased continuously, the thickness is also gradually thickened, an automation technology is introduced for processing and welding the tube plate, the problems of complexity and cost of manual tube plate welding are effectively solved, the quality of the automatic tube plate welding is not high at present, the welding quality is directly related to the safety coefficient of a product, and the requirements on the compactness and fusion of a welding seam are extremely strict. In addition, large vehicles such as airplanes and submarines also have a plurality of tube plate structures. The tube plate structure on the surface of the airplane is subjected to very large atmospheric pressure in high altitude, and the submarine is also subjected to strong pressure in deep sea, so that the requirements on the welding quality are very strict, and particularly the problems of incomplete welding and incomplete fusion are solved. According to statistics, most of tube head leakage is caused by the welding quality of the tube plate, and the main reasons of the welding quality of the tube plate are welding defects such as weld pits, weld beading, incomplete penetration and incomplete fusion caused by uneven stress of a molten pool, improper selection of welding control parameters and the like during welding.
The design controls the distribution of welding wire molten drops by adjusting the rotation angular velocity of the welding gun and the self-adaptive current during welding, solves the problems of weld pits, welding beading, incomplete penetration, incomplete fusion and the like, and improves the welding quality. The visualized efficient tube plate welding system in the patent 'visualized efficient tube plate welding system' with the application number of 201310703835.9 has the characteristics of digitalization, visualization, automation, portability, compactness, stable and reliable performance and the like, and is connected with a tube plate welding head through a visualized human-computer interaction system to realize the convenience of operation and improve the stability and the welding efficiency of the system; the visual multi-degree-of-freedom robot controls the welding gun to weld the tube plate in patent 201810367183.9, and realizes efficient welding mainly by adjusting the relative angle of the welding gun to the welding seam, thereby greatly improving the welding efficiency. Both of the two methods effectively improve the welding efficiency, but neglect the welding quality of the tube plate, and particularly solve the problems of welding beading or pits, incomplete penetration, incomplete fusion and the like caused by uneven distribution of welding seam molten drops. The method is characterized in that the position and pose of the welding gun are measured, parameters are adjusted in a self-adaptive mode, and an adjusting module controls the rotating angular velocity and the welding current of the welding gun, so that welding seam molten drops are distributed uniformly, and the welding quality and precision are improved.
Disclosure of Invention
The invention aims to solve the problem of welding quality caused by uneven distribution of molten drops of a welding seam of a tube plate. The system comprises a time-sharing measuring device, a signal processor, a time-sharing operation processor, 2 time-sharing controllers, an angular speed regulator, a differentiator, an arc sensor, a rotator, a memory, an adaptive current regulator, an arc sensor, a welding frame, a welding gun and the like. The measuring device consists of a micro-mechanical system (MEMS) gyroscope and a time-sharing controller; the signal time-sharing processing module consists of a signal processor, a time-sharing operation processor, a time-sharing controller and a differentiator; the adjusting module is composed of an angular speed regulator, an adaptive current regulator and a memory. A micro-mechanical (MEMS) gyroscope is attached to a welding gun, and a rotator is connected with the welding gun to control the rotator to rotate (as shown in figure 1). The time-sharing measuring device is used for measuring an attitude signal and an angular speed signal of the welding gun; the signal time-sharing processing module calculates the optimal welding angular speed and the optimal welding current at a certain position based on the measured signals, properly processes the signals and sends the signals to the adjusting module; the adjusting module is responsible for feeding back the received signals to the time-sharing measuring device and adjusting the welding gun to work. The method realizes uniform molten drop distribution and complete penetration welding by time-sharing control of the system.
A time-sharing control tube plate welding regulation and control system and a method thereof have the following working procedures: when the system is electrified to start the switch, the rotator drives the welding gun to rotate at a constant speed, and the welding gun does not work at the moment and only rotates at a constant speed along with the rotator. The measuring device obtains an attitude signal of the welding gun and sends the attitude signal to the signal time-sharing processing module, the time-sharing arithmetic unit carries out arithmetic processing on the basis of the attitude signal to obtain the optimal welding angular velocity, the differentiator carries out differentiation processing on the attitude signal to obtain an angular velocity signal and then sends the angular velocity signal to the adjusting module, the memory stores the signal in a memory mode, the velocity signal is fed back to the time-sharing measuring device, the time-sharing measuring device measures the fed-back angular velocity signal, and the time-sharing arithmetic processor of the signal time-sharing processing module carries out arithmetic processing on the basis of the signal to obtain the optimal welding current. After the optimal angular speed and the optimal welding current are obtained, the driving device is started to control the welding gun to start welding, the adjusting module is combined with the optimal welding speed and the optimal welding current at the position to jointly adjust the welding gun to work, and real-time automatic high-quality and high-precision welding of the system is achieved.
The time-sharing control method in the system is characterized in that: the time-sharing control signal is one cycle through 1-5 processes around the main module of the system (fig. 2). The system records cycles through memory while operating. Within a period, when a signal passes through the memory for the first time, the speed adjusting module feeds back the received signal to the time-sharing measuring device through a path 3; when the signal passes through the memory for the second time, the signal passes through 6 to start the arc sensor to control the welding gun to work, and the adjusting module adjusts the rotation angular velocity and the welding current of the rotator, so that the welding angular velocity and the welding current are the optimal values of the position, and the welding precision is ensured.
The time-sharing control method in the system is characterized in that: when the system works, the time-sharing measuring device respectively measures and processes the signals; during the first half period, the time-sharing controller controls the time-sharing measuring device to only measure the attitude signal of the welding gun, namely only measure the attitude signal of the welding gun; and in the second half period, the time-sharing controller controls the time-sharing measuring device to measure the fed back angular velocity signal again, namely only the angular velocity signal is measured. The signal time-sharing processing module calculates the optimal welding angular velocity, differentiates the signals, calculates the optimal welding current and optimizes the signals, namely calculates the optimal welding angular velocity and the differentiation in the first half period and calculates the optimal welding current and optimizes the welding current in the second half period.
The optimal values are different at different positions of the welding gun, and each position of the welding gun corresponds to an optimal welding angular velocity and an optimal welding current which are respectively in a specific function of one-to-one correspondence. Assume an optimum welding angular velocity at the initial position of w1The welding angular velocity of the corresponding other positions is w1,w2,w3…wnI.e. f (x)n)＝wn(ii) a Assume that the optimal welding current at the initial position is i1The optimal welding current corresponding to other positions is i1,i2,i3…inI.e. f (x)n)＝in. The adjusting module is combined with two variables of the optimal welding angular speed and the optimal welding current at a certain position to realize accurate automatic welding.
The benefits of the invention are:
firstly, welding angular velocity and welding current are controlled in a self-adaptive mode, the uniform distribution of welding seam molten drops and the welding seam fusion degree are adjusted, and the welding seam quality and the welding seam precision are improved;
and secondly, the time-sharing measurement device and the signal time-sharing processing module of the system are controlled by using a time-sharing control method, the real-time control of the system work is maintained, the problems of instability, poor controllability and the like in the welding production process are solved, the welding is promoted to develop towards the automation direction, the welding efficiency is improved, and the welding quality is ensured.
Description of the drawings:
fig. 1 is a schematic view of the overall macroscopic structure of the present invention.
Fig. 2 is a block diagram of the system of the present invention.
Fig. 3 is a frequency domain analysis diagram of signal sampling and conversion processing in an embodiment of the present invention.
In fig. 1: 1-time sharing controller, 2-micro mechanical (MEMS) gyroscope, 3-arc sensor, 4-memory, 5-angular velocity regulator, 6-signal processor, 7-differentiator, 8-rotator, 9-adaptive current regulator, 10-time sharing operation processor, 11-welding gun, 12-welding frame
The specific implementation mode is as follows:
in order to better express the technical scheme and the beneficial effects of the whole invention, the invention is further described in detail with reference to the accompanying drawings and the embodiments.
Embodiment 1 the invention relates to a time-sharing control pipe plate welding regulation and control method. The system comprises a time-sharing measuring device, a signal time-sharing processor, a time-sharing operation processor, 2 time-sharing controllers, an angular speed regulator, a differentiator, an arc sensor, a self-adaptive current regulator, a rotator, a memory, an arc sensor, a welding frame, a welding gun and the like. The measuring device consists of a micro-mechanical system (MEMS) gyroscope and a time-sharing controller; the signal time-sharing processing module consists of a signal processor, a time-sharing operation processor, a time-sharing controller and a differentiator; the adjusting module is composed of an angular speed regulator, an adaptive current regulator and a memory. A micro-mechanical system (MEMS) gyroscope is attached to a welding gun, and a rotator is connected with the welding gun to control the rotator to rotate. The time-sharing measurement device obtains an attitude signal of a welding gun and sends the attitude signal to the signal time-sharing processing module, the time-sharing operation processor calculates the optimal welding angular velocity at a certain determined position based on the attitude signal, the differentiator differentiates the signal to obtain an angular velocity signal and sends the angular velocity signal to the adjusting module, the adjusting module feeds the received signal back to the time-sharing measurement device for measurement again and sends the signal to the signal time-sharing processing module, the time-sharing operation processor calculates the optimal welding current at the certain determined position based on the angular velocity signal, the signal processor optimizes the signal, and the system combines two groups of optimal values and time-sharing control to realize high-quality and high-standard automatic welding.
One of the methods of the present invention to improve the accuracy of the weld is to combine the best values of the two variables at a certain location for adjustment. The welding guns have different optimal values at different positions, and each position of the welding guns corresponds to an optimal welding angular velocity sumAn optimum welding current is respectively a specific function of a one-to-one correspondence relationship. Assume an optimum welding angular velocity at the initial position of w1The welding angular velocity of the corresponding other positions is w1,w2,w3…wnI.e. f (x)n)＝wn(ii) a Assume that the optimal welding current at the initial position is i1The optimal welding current corresponding to other positions is i1,i2,i3…inI.e. f (x)n)＝in. The adjusting module is combined with two variables of the optimal welding angular speed and the optimal welding current at a certain position to realize accurate automatic welding.
Embodiment 2 the invention is used for combining the photoelectric periscope at the upper part of the submarine with the surrounding shell of the command console, and the parameter range of the welding current needs to be adjusted to be between 600 and 810A in addition to the welding wire of high-strength steel because the object is high-strength steel, so that the welding wire is completely fused and completely welded; the diameter of the photoelectric periscope is about 50mm, and the number of the position points is set as 100 in order to ensure the compactness and the fusion of the welding seam, and the corresponding optimal welding current is i1,i2,i3…i100The optimum welding speed is w1,w2,w3…wnThe fusion of the photoelectric periscope and the command console enclosure is thorough, and the purposes of high quality, high requirement and high standard of submarine tube plate welding are achieved.
The essence of the method is to discretize the continuous signals, to perform discrete conversion on the continuous attitude signals and angular velocity signals to obtain the attitude angular velocity of each specific position, and to obtain the optimal welding angular velocity and the optimal welding current through a time-sharing calculation processor. Sampling and changing continuous attitude and angular velocity signals into discretization, namely: x (t) ═ x (n); the impulse sequence sampling process (fig. 3) is shown, where x (t) is continuous signal, p (t) is unit impulse sequence, xp(T) is the sampling signal, T is the sampling period, and the sampling frequency is
Figure GDA0003165668950000031
After sampling the signal xp(t) ═ x (t) p (t), where
Figure GDA0003165668950000032
Sampling frequency domain process formula:
Figure GDA0003165668950000041
wherein the content of the first and second substances,
Figure GDA0003165668950000042
Figure GDA0003165668950000043
the other method for improving the precision of the invention is to carry out time-sharing control on the system, and a time-sharing measuring device respectively carries out measurement and processing on signals; during the first half period, the time-sharing controller controls the time-sharing measuring device to only measure the attitude signal of the welding gun, namely only measure the attitude signal of the welding gun; in the second half period, the time-sharing controller controls the time-sharing measuring device to measure the fed back angular velocity signal again, namely only the angular velocity signal is measured; the signal time-sharing processing module respectively carries out the processing of calculating the optimal welding angular velocity, differentiating operation, calculating the optimal current, optimizing and the like on the signals, namely calculating the optimal welding angular velocity and carrying out the differentiating operation processing in the first half period, and calculating the optimal welding current and carrying out the optimizing operation processing in the second half period. The two modules of the system adopt a time-sharing processing method to measure and process signals twice, and the purpose of improving the precision can be achieved.
The above examples do not limit the invention in any way, and all technical solutions obtained by means of equivalent substitution or equivalent transformation fall within the scope of protection of the invention.

Claims (2)

1. A time-sharing control tube plate welding regulation and control method is characterized by comprising the following steps: the system comprises a time-sharing control tube plate welding system, a time-sharing control device, a signal time-sharing processing module, an adjusting module and a driving device; the time-sharing measuring device consists of a micro-mechanical system (MEMS) gyroscope and a time-sharing controller; the signal time-sharing processing module consists of a time-sharing operation processor, a time-sharing controller, a signal processor and a differentiator; the adjusting module consists of an angular speed regulator, a self-adaptive current regulator and a memory; the driving device consists of an arc sensor and a driver; the time-sharing measurement device acquires an attitude signal of a welding gun and then sends the attitude signal to the signal time-sharing processing module, the signal time-sharing processing module calculates the optimal welding angular velocity of the position of the welding gun and performs differential processing on the attitude signal and then sends the attitude signal to the adjustment module, the adjustment module feeds the signal back to the time-sharing measurement device, the time-sharing measurement device measures the fed-back angular velocity signal and then sends the signal to the signal time-sharing processing module, the signal time-sharing processing module performs operation processing on the signal to obtain the optimal welding current, and after the optimal angular velocity and the optimal welding current are obtained, the driving device is started to control the welding gun to start welding work; the adjusting module combines the welding angular velocity and the welding current to jointly adjust the work of the welding gun, the time-sharing measuring device and the signal time-sharing processing module adopt time-sharing control, and the time-sharing measuring device respectively measures and processes the attitude signal and the angular velocity signal; during the first half period, the time-sharing controller controls the time-sharing measuring device to measure only the attitude signal of the welding gun; and in the second half period, the time-sharing controller controls the time-sharing measuring device to measure the fed-back angular velocity signal again, the signal time-sharing processing module calculates the optimal welding angular velocity, differentiates the signal and calculates the optimal welding current and optimizes the signal, the first half period calculates the optimal welding angular velocity and the differentiation, and the second half period calculates the optimal welding current and optimizes the signal.
2. The time-sharing control tube plate welding regulation and control method as claimed in claim 1, characterized in that: each position of the welding gun corresponds to a group of optimal welding angular speed and optimal welding current, and the adjusting module is combined with the optimal welding angular speed and the optimal welding current to realize automatic control on the system; the position of the welding gun is in a specific function relationship with the optimal welding angular velocity and the optimal welding current in a one-to-one corresponding relationship respectively, and the optimal welding angular velocity at the initial position is assumed to be w0Corresponding to the optimum angular velocity of the weld at the other positionsIs w1,w2,w3…wnI.e. f (x)n)＝wn(ii) a Assume that the optimal welding current at the initial position is i0The optimal welding current corresponding to other positions is i1,i2,i3…inI.e. F (x)n)＝in。
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