CN110434427B - Pulse GTA wire-filling additive manufacturing stack laminated sheet double-variable control method and system - Google Patents
Pulse GTA wire-filling additive manufacturing stack laminated sheet double-variable control method and system Download PDFInfo
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Abstract
The invention provides a double-variable control method and a system for pulse GTA wire-filling additive manufacturing stacked laminates, wherein the two side quantities of the stacked laminates are the width and the height of a stacked layer respectively, the width W of the stacked layer is acquired by a visual sensing system, the height H of the stacked layer is indirectly represented by an arc pressure U, the arc pressure U is acquired by a voltage sensing system, and the stable control of the width and the height of the stacked layer in the pulse GTA wire-filling additive manufacturing process is realized by adjusting a first control variable and a second control variable on line by taking the width deviation quantity delta W of the stacked layer and the arc pressure deviation quantity delta U of the arc pressure as input signals of a controller based on a double-variable decoupler, a visual sensor and a visual sensor, the stability of the control system is effectively increased, the fluctuation of the size of the accumulation layer is obviously reduced, and the engineering application of the pulse GTA wire filling additive manufacturing technology is facilitated.
Description
Technical Field
The invention belongs to the technical field of electric arc wire filling additive manufacturing, and particularly relates to a pulse GTA wire filling additive manufacturing stacked laminate double-variable control method and a pulse GTA wire filling additive manufacturing stacked laminate double-variable control system.
Background
The Gas Tungsten argon Arc (GTA) is a common heat source in the field of additive manufacturing technology of filler wires. The pulse GTA filler wire additive manufacturing technology based on the heat source adopts controllable pulse current to melt the filler wire, and has the remarkable advantages of small heat input, stable geometrical size of a stacking layer, low equipment cost, high wire material utilization rate and the like, so that the pulse GTA filler wire additive manufacturing technology has wide application prospect in the direct forming of metal and alloy components.
The pulse GTA wire filling additive manufacturing is based on a layered slicing principle, namely, components are stacked according to preset layer width and layer height, however, the stacked components show a geometric shape with a wide upper part and a narrow lower part under the interference of a plurality of factors such as technological parameter fluctuation, heat accumulation of stacked layers, stacking conditions of front layers and the like, the layer height is gradually reduced, the forming quality of the components is seriously reduced, and even the stacking process is blocked because electric arcs are elongated and extinguished. Karunakaran k.p. and the like adopt a mode of introducing circulating cooling water to the substrate to reduce heat accumulation in the accumulation process, but the method can only cool the substrate and cannot effectively improve the instability of the size of an accumulation layer; bintao Wu et al propose to install gas cooling nozzles on GTA guns and use gas to reduce the temperature of the front accumulation layer, although this strategy has some effect on the stable control of the size of the accumulation layer, the additional cooling device increases the complexity of the equipment. At present, the method cannot effectively ensure that the actual width and height of the accumulation layer are matched with the preset width and height. Therefore, it is necessary to adopt other means to enhance the real-time control of the size of the stacked layer.
Chinese patent application No.: 201711229471.X, entitled "GTA wire-filling additive manufacturing arc length feedforward detection and open-loop control method", provides a GTA wire-filling additive manufacturing arc length feedforward detection and open-loop control method, which adopts a vision system to collect GTA arc images to perform arc length feedforward detection, calculates arc length errors in advance to adjust univariate process parameters, and realizes stable control of the height of a deposited layer; chinese patent application No.: 201810524076.2 entitled "feedforward compensated GTA filler wire additive manufacturing forming height feedback control method" provides a feedforward compensated GTA filler wire additive manufacturing forming height feedback control method, which utilizes the advance prediction function of feedforward detection to introduce the height deviation of feedforward detection into the height deviation of feedback detection, controls the variation of single parameter and reduces the fluctuation of the height of the accumulation layer. The pulse GTA wire-filling additive manufacturing system is a multivariable, strong-coupling and time-lag-existing nonlinear system, namely, all parameters are mutually coupled and mutually influenced, the width and the height of a stacking layer can be changed simultaneously due to single parameter change, and the difficulty of real-time control of the system is obviously increased. In order to achieve the above dual-variable control of the stacked layer, it is necessary to select multiple sets of parameters as control variables, and how to remove the coupling relationship between the multiple sets of control variables, so as to reduce or even eliminate the mutual influence of the control variables on the dual variables of the stacked layer to the greatest extent, which becomes the difficulty of dual-variable control of the stacked layer in the pulse GTA wire-filling additive manufacturing. Therefore, it is urgently needed to provide a pulse GTA wire-filling additive manufacturing stack layer chip bivariate control method which selects multiple groups of parameters as control variables and realizes stable control of the width and height of a stack layer by adjusting process parameters on line.
Disclosure of Invention
The invention aims to solve the problem that the actual width and height of a stacked layer are difficult to completely coincide with the preset width and height in the pulse GTA wire filling additive manufacturing process, and provides a pulse GTA wire filling additive manufacturing stacked layer double-variable control method and a pulse GTA wire filling additive manufacturing stacked layer double-variable control system.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a pulse GTA filler wire additive manufacturing stack layer bivariate control method is disclosed, the stack layer bivariate is stack layer width and height respectively, wherein the stack layer width W is obtained by a visual sensing system, the stack layer height H is indirectly represented by arc pressure U, the arc pressure U is collected by a voltage sensing system, meanwhile, based on a bivariate decoupler, a stack layer width controller and an arc pressure controller, the stack layer width deviation delta W and the arc pressure deviation delta U are used as input signals of the controller, and the stable control of the stack layer width and height in the pulse GTA filler wire additive manufacturing process is realized by adjusting a first control variable and a second control variable on line, and the method comprises the following steps:
the method comprises the following steps: aiming at a pulse GTA wire filling additive manufacturing system, selecting a parameter which has the greatest influence on the width of a stacking layer as a first control variable and a parameter which has the greatest influence on arc pressure as a second control variable, designing a bivariate decoupler, removing the influence of the second control variable on the width of the stacking layer and the influence of the first control variable on the arc pressure, and forming a composite pulse GTA wire filling additive manufacturing system by the decoupler and the pulse GTA wire filling additive manufacturing system;
step two: aiming at a composite pulse GTA wire filling additive manufacturing system, respectively designing a stack layer width controller and an arc voltage controller;
step three: starting the GTA gun to be in arc striking, starting accumulation along a preset path, and starting a vision sensing system and a voltage sensing system after the GTA gun moves for 7-12 mm; at the moment, the electric arc is stably burnt, and the molten pool image and the arc voltage signal are most stable.
Step four: the visual sensing system collects the width image information of the accumulation layer, and the range of the image collecting time t is determined as follows: t is1/3+nT～2T1/3+ nT, where T1The duration of the base current in one pulse period, T is the pulse period, n is 0,1,2,3 …, and the continuously collected images are input into computer for image processing to extract characteristic width value W of accumulation layermWhile calculating WmAnd a preset width value WsetThe deviation amount Δ W of; the voltage sensing system collects arc voltage information, an arc voltage signal in a time range of (t-delta t, t + delta t) is processed by adopting an arc voltage filtering algorithm, and an arc voltage average value U of (t-delta t/10, t + delta t/10) is extractedmCalculate UmAnd set arc voltage UsetThe deviation amount Δ U, where Δ t is in the range: 0.05-0.1 s;
step five: calculating the adjustment quantity delta d of the first control variable based on the accumulated layer width deviation quantity delta W in the fourth step by adopting the accumulated layer width controller designed in the second step1Controlling the deviation amount Δ W of the width of the deposited layer<0.5mm, realizing the uniform control of the width of the accumulation layer; calculating the adjustment quantity delta d of the second control variable by adopting the arc voltage controller designed in the step two and based on the arc voltage deviation quantity delta U in the step four2Controlling the arc voltage deviation amount DeltaU<And 0.3V, realizing stable control of arc voltage, namely completing stable control of double variables of the width and the height of a stacking layer in the pulse GTA wire filling additive manufacturing process by a method of adjusting a first control variable and a second control variable on line.
Height H of the pile layerdThe reasons that can be characterized by the arc voltage U are: the arc voltage U and the arc length L have a certain mapping relationThe arc length L is the distance from the tip of the tungsten electrode to the upper surface of the accumulation layer, so that the arc voltage U indirectly represents the change of the height H of the accumulation layer.
The image-capturing time range is T1/3+nT～2T1The reasons for/3 + nT are: when the arc at the peak current is too strong, the deposit and the molten pool are substantially covered by the arc and blurred, and it is difficult to efficiently extract the relevant characteristic values of the image. T is13+ nT and 2T1The arc light between/3 + nT is darker, the definition of the acquired image is higher, meanwhile, the phenomenon that the arc light is too close to the rising edge and the falling edge of a current curve is avoided, and the stability of the image is ensured; the reason for selecting and processing the arc voltage information of the (t-delta t, t + delta t) time period is as follows: the method and the device have the advantages that the width image information and the arc voltage information of the accumulation layer at the same moment are acquired, double variables at the same position of the accumulation layer are controlled conveniently, and the hysteresis of a control system is reduced.
Preferably, the decoupling method based on the decoupler in the step one is a state feedback decoupling method, a fuzzy inference decoupling method or a neural network decoupling method.
Preferably, in the first step, the first controlled variable is a stacking speed, and the second controlled variable is a wire feeding speed.
Preferably, in the second step, the deposited layer width controller and the arc voltage controller are an internal model controller and a fuzzy inference controller, respectively.
Preferably, the predetermined path in step three is a multi-layer single-channel structure.
Preferably, the image processing procedure in step four includes median filtering, width edge detection, and edge straight line fitting.
Preferably, the arc voltage filtering algorithm in the fourth step is anti-pulse interference sliding mean filtering.
The method adopts a pulse GTA wire filling additive manufacturing stacking layer double-variable control system as a preferable mode, wherein the pulse GTA wire filling additive manufacturing stacking layer double-variable control system comprises a pulse GTA wire filling additive manufacturing system, a double-variable decoupler, a stacking layer width controller, an arc pressure controller, a voltage sensing system and a vision sensing system;
the pulse GTA wire filling additive manufacturing system is used for realizing a pulse GTA wire filling additive manufacturing process;
the double-variable decoupler is used for removing the influence of the first control variable on the arc voltage and the influence of the second control variable on the width of the accumulation layer;
the accumulated layer width controller adjusts the first control variable according to the deviation value of the accumulated layer width to complete the uniform control of the accumulated layer width;
the arc voltage controller adjusts a second control variable according to the arc voltage deviation value to complete stable control of the arc voltage in the stacking process; the voltage sensing system is used for detecting arc voltage information in the stacking process;
the visual sensing system is used for detecting accumulation layer width image information in the accumulation process;
the voltage sensing system collects arc voltage information in the stacking process, an arc voltage analog signal is transmitted to the data acquisition card, the data acquisition card converts the arc voltage analog signal into an arc voltage digital signal and inputs the arc voltage digital signal into the computer, and an arc voltage controller and a bivariate decoupler designed in the computer determine the adjustment quantity of a second control variable according to the input arc voltage digital signal; the visual sensing system collects width image information in the stacking process, the width image information is transmitted into the computer through the USB interface, the computer processes the width image information to obtain a stacking layer width value, and the designed stacking layer width controller and the bivariate decoupler determine the adjustment quantity of the first control variable according to the processed stacking layer width value.
Preferably, the pulse GTA wire-filling additive manufacturing system comprises: the device comprises a substrate 1, an accumulation layer 2, a visual sensing system 3, a GTA gun 4, a tungsten electrode 5, a filler wire 6, a pulse GTA additive manufacturing power supply 7, a voltage sensing system 8, a computer 9 and a wire feeder 10, wherein the negative electrode of the pulse GTA additive manufacturing power supply 7 is connected with the GTA gun 4, the positive electrode of the pulse GTA additive manufacturing power supply 7 is connected with the substrate 1, the GTA gun 4 is connected with the tungsten electrode 5, the wire feeder 10 and the GTA gun 4 are simultaneously connected with the computer 9 through a data acquisition card, the computer 9 is respectively connected with the visual sensing system 3 and the voltage sensing system 8 through a USB interface and the data acquisition card, and the voltage sensing system 8 is further connected with the pulse GTA additive manufacturing power supply 7; the voltage sensing system comprises a Hall voltage sensor and a data acquisition card, the voltage sensing system 8 acquires arc voltage information in the stacking process and transmits arc voltage analog signals to the data acquisition card, the data acquisition card converts the arc voltage analog signals into arc voltage digital signals and inputs the arc voltage digital signals into the computer 9, the vision sensing system 3 acquires width image information of the stacking layer 2 in the stacking process and transmits the width image information into the computer 9 through a USB interface, the computer 9 processes and analyzes the arc voltage digital signals and the width image information and sends out adjusting signals to change the stacking speed of the GTA gun 4 and the wire feeding speed of the wire feeder 10, and then stable control of double variables of the width and the height of the stacking layer 2 is realized; the motion actuating mechanism is a robot, the GTA gun is fixed on the sixth axis of the robot through a clamp, the robot controls the GTA gun to move, and the vision sensing system is installed behind the GTA gun.
In order to achieve the above object, the present invention further provides a pulse GTA wire filling additive manufacturing stack layer double-variable control system, which comprises a pulse GTA wire filling additive manufacturing system, a double-variable decoupler, a stack layer width controller, an arc voltage controller, a voltage sensing system and a vision sensing system;
wherein the pulsed GTA wire-filling additive manufacturing system is used to implement a pulsed GTA wire-filling additive manufacturing process.
The bivariate decoupler is used for removing the influence of the first control variable on the arc voltage, and the influence of the second control variable on the width of the accumulation layer.
The width controller of the accumulation layer adjusts the first control variable according to the deviation value of the width of the accumulation layer, and the uniform control of the width of the accumulation layer is completed.
And the arc voltage controller adjusts the second control variable according to the arc voltage deviation value to complete the stable control of the arc voltage in the stacking process.
The voltage sensing system is used for detecting arc voltage information in the stacking process.
The visual sensing system is used for detecting accumulation layer width image information in the accumulation process;
the voltage sensing system collects arc voltage information in the stacking process, an arc voltage analog signal is transmitted to the data acquisition card, the data acquisition card converts the arc voltage analog signal into an arc voltage digital signal and inputs the arc voltage digital signal into the computer, and an arc voltage controller and a bivariate decoupler designed in the computer determine the adjustment quantity of a second control variable according to the input arc voltage digital signal; the visual sensing system collects width image information in the stacking process, the width image information is transmitted into the computer through the USB interface, the computer processes the width image information to obtain a stacking layer width value, and the designed stacking layer width controller and the bivariate decoupler determine the adjustment quantity of the first control variable according to the processed stacking layer width value. The pulse GTA filler wire additive manufacturing system comprises: the device comprises a substrate 1, an accumulation layer 2, a visual sensing system 3, a GTA gun 4, a tungsten electrode 5, a filler wire 6, a pulse GTA additive manufacturing power supply 7, a voltage sensing system 8, a computer 9 and a wire feeder 10; the negative electrode of the pulse GTA additive manufacturing power supply 7 is connected with the GTA gun 4, the positive electrode of the pulse GTA additive manufacturing power supply is connected with the substrate 1, the GTA gun 4 is connected with the tungsten electrode 5, the wire feeder 10 and the GTA gun 4 are connected with the computer 9 through the data acquisition card at the same time, the computer 9 is connected with the visual sensing system 3 and the voltage sensing system 8 through the USB interface and the data acquisition card respectively, and the voltage sensing system 8 is connected with the pulse GTA additive manufacturing power supply 7; the voltage sensing system comprises a Hall voltage sensor and a data acquisition card, the voltage sensing system 8 acquires arc voltage information in the stacking process and transmits arc voltage analog signals to the data acquisition card, the data acquisition card converts the arc voltage analog signals into arc voltage digital signals and inputs the arc voltage digital signals into the computer 9, the vision sensing system 3 acquires width image information of the stacking layer 2 in the stacking process and transmits the width image information into the computer 9 through a USB interface, and the computer 9 processes and analyzes the arc voltage digital signals and the width image information and sends adjusting signals to change the stacking speed of the GTA gun 4 and the wire feeding speed of the wire feeder 10, so that the stable control of double variables of the width and the height of the stacking layer 2 is realized; the motion actuating mechanism is a robot, the GTA gun is fixed on the sixth axis of the robot through a clamp, the robot controls the GTA gun to move, and the vision sensing system is installed behind the GTA gun.
The invention has the beneficial effects that: compared with the traditional control method for controlling the size stability of the GTA filler wire additive manufacturing accumulation layer, the double-variable decoupler is designed, and the coupling relation between two sets of parameter variables is eliminated. Based on the designed width controller of the accumulation layer and the designed arc pressure controller, the deviation value of the width of the accumulation layer and the deviation value of the arc pressure are controlled within a certain precision range through a strategy of adjusting two groups of process parameters on line, so that the simultaneous control of the width and the height of the accumulation layer in the pulse GTA filler wire additive manufacturing process is realized, the stability of a control system is effectively improved, the fluctuation of the size of the accumulation layer is obviously reduced, and the practical application of the pulse GTA filler wire additive manufacturing technology is facilitated. Furthermore, the voltage sensing system greatly reduces the complexity of the system setup. The difficult problem that the actual width and height of the accumulation layer are difficult to completely coincide with the preset width and height in the pulse GTA wire filling additive manufacturing process is effectively solved.
Drawings
Fig. 1 is a diagram of a pulsed GTA wire-fill additive manufacturing stack-up laminate dual-variable control system.
Figure 2 is a diagram of a pulse GTA wire-fill additive manufacturing stack-up laminate dual variable control hardware architecture.
The device comprises a base plate 1, a deposition layer 2, a vision sensing system 3, a GTA gun 4, a tungsten electrode 5, a filler wire 6, a pulse GTA additive manufacturing power supply 7, a voltage sensing system 8, a computer 9 and a wire feeder 10.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention.
Example 1
A pulse GTA filler wire additive manufacturing stack layer bivariate control method is disclosed, the stack layer bivariate is stack layer width and height respectively, wherein the stack layer width W is obtained by a visual sensing system, the stack layer height H is indirectly represented by arc pressure U, the arc pressure U is collected by a voltage sensing system, meanwhile, based on a bivariate decoupler, a stack layer width controller and an arc pressure controller, the stack layer width deviation delta W and the arc pressure deviation delta U are used as input signals of the controller, and the stable control of the stack layer width and height in the pulse GTA filler wire additive manufacturing process is realized by adjusting a first control variable and a second control variable on line, and the method comprises the following steps:
the method comprises the following steps: aiming at a pulse GTA wire filling additive manufacturing system, selecting a parameter which has the greatest influence on the width of a stacking layer as a first control variable and a parameter which has the greatest influence on arc pressure as a second control variable, designing a bivariate decoupler, removing the influence of the second control variable on the width of the stacking layer and the influence of the first control variable on the arc pressure, and forming a composite pulse GTA wire filling additive manufacturing system by the decoupler and the pulse GTA wire filling additive manufacturing system;
step two: aiming at a composite pulse GTA wire filling additive manufacturing system, respectively designing a stack layer width controller and an arc voltage controller;
step three: starting the GTA gun to be in arc striking, starting accumulation along a preset path, and starting a vision sensing system and a voltage sensing system after the GTA gun moves for 7-12 mm; at the moment, the electric arc is stably burnt, and the molten pool image and the arc voltage signal are most stable.
Step four: the visual sensing system collects the width image information of the accumulation layer, and the range of the image collecting time t is determined as follows: t is1/3+nT～2T1/3+ nT, where T1The duration of the base current in one pulse period, T is the pulse period, n is 0,1,2,3 …, and the continuously collected images are input into computer for image processing to extract characteristic width value W of accumulation layermWhile calculating WmAnd a preset width value WsetThe deviation amount Δ W of; the voltage sensing system collects arc voltage information, an arc voltage signal in a time range of (t-delta t, t + delta t) is processed by adopting an arc voltage filtering algorithm, and an arc voltage average value U of (t-delta t/10, t + delta t/10) is extractedmCalculate UmAnd settingArc voltage UsetThe deviation amount Δ U, where Δ t is in the range: 0.05-0.1 s;
step five: calculating the adjustment quantity delta d of the first control variable based on the accumulated layer width deviation quantity delta W in the fourth step by adopting the accumulated layer width controller designed in the second step1Controlling the deviation amount Δ W of the width of the deposited layer<0.5mm, realizing the uniform control of the width of the accumulation layer; calculating the adjustment quantity delta d of the second control variable by adopting the arc voltage controller designed in the step two and based on the arc voltage deviation quantity delta U in the step four2Controlling the arc voltage deviation amount DeltaU<And 0.3V, realizing stable control of arc voltage, namely completing stable control of double variables of the width and the height of a stacking layer in the pulse GTA wire filling additive manufacturing process by a method of adjusting a first control variable and a second control variable on line.
Height H of the pile layerdThe reasons that can be characterized by the arc voltage U are: the arc voltage U and the arc length L have a certain mapping relation, and the arc length L is the distance from the tip of the tungsten electrode to the upper surface of the accumulation layer, so that the arc voltage U indirectly represents the change of the height H of the accumulation layer.
The image-capturing time range is T1/3+nT～2T1The reasons for/3 + nT are: when the arc at the peak current is too strong, the deposit and the molten pool are substantially covered by the arc and blurred, and it is difficult to efficiently extract the relevant characteristic values of the image. T is13+ nT and 2T1The arc light between/3 + nT is darker, the definition of the acquired image is higher, meanwhile, the phenomenon that the arc light is too close to the rising edge and the falling edge of a current curve is avoided, and the stability of the image is ensured; the reason for selecting and processing the arc voltage information of the (t-delta t, t + delta t) time period is as follows: the method and the device have the advantages that the width image information and the arc voltage information of the accumulation layer at the same moment are acquired, double variables at the same position of the accumulation layer are controlled conveniently, and the hysteresis of a control system is reduced.
Specifically, the decoupling method based on the decoupler in the step one is a state feedback decoupling method, a fuzzy inference decoupling method or a neural network decoupling method.
Specifically, in the first step, the first control variable is the stacking speed, and the second control variable is the wire feeding speed.
Specifically, in the second step, the accumulation layer width controller and the arc voltage controller are respectively an internal model controller and a fuzzy inference controller.
Specifically, the predetermined path in step three is a multilayer single-channel structure.
Specifically, the image processing procedures in the fourth step are median filtering, width edge detection and edge straight line fitting.
Specifically, the arc voltage filtering algorithm in the fourth step is anti-pulse interference sliding mean filtering.
Example 2
The embodiment provides a pulse GTA wire-filling additive manufacturing stacked laminate double-variable control system, which is used for the pulse GTA wire-filling additive manufacturing stacked laminate double-variable control method in embodiment 1, and comprises a pulse GTA wire-filling additive manufacturing system, a double-variable decoupler, a stacked layer width controller, an arc voltage controller, a voltage sensing system and a visual sensing system;
wherein the pulsed GTA wire-filling additive manufacturing system is used to implement a pulsed GTA wire-filling additive manufacturing process.
The bivariate decoupler is used for removing the influence of the first control variable on the arc voltage, and the influence of the second control variable on the width of the accumulation layer.
The width controller of the accumulation layer adjusts the first control variable according to the deviation value of the width of the accumulation layer, and the uniform control of the width of the accumulation layer is completed.
And the arc voltage controller adjusts the second control variable according to the arc voltage deviation value to complete the stable control of the arc voltage in the stacking process.
The voltage sensing system is used for detecting arc voltage information in the stacking process.
The visual sensing system is used for detecting accumulation layer width image information in the accumulation process;
the voltage sensing system collects arc voltage information in the stacking process, an arc voltage analog signal is transmitted to the data acquisition card, the data acquisition card converts the arc voltage analog signal into an arc voltage digital signal and inputs the arc voltage digital signal into the computer, and an arc voltage controller and a bivariate decoupler designed in the computer determine the adjustment quantity of a second control variable according to the input arc voltage digital signal; the visual sensing system collects width image information in the stacking process, the width image information is transmitted into the computer through the USB interface, the computer processes the width image information to obtain a stacking layer width value, and the designed stacking layer width controller and the bivariate decoupler determine the adjustment quantity of the first control variable according to the processed stacking layer width value. The pulse GTA filler wire additive manufacturing system comprises: the device comprises a substrate 1, an accumulation layer 2, a visual sensing system 3, a GTA gun 4, a tungsten electrode 5, a filler wire 6, a pulse GTA additive manufacturing power supply 7, a voltage sensing system 8, a computer 9 and a wire feeder 10; the negative electrode of the pulse GTA additive manufacturing power supply 7 is connected with the GTA gun 4, the positive electrode of the pulse GTA additive manufacturing power supply is connected with the substrate 1, the GTA gun 4 is connected with the tungsten electrode 5, the wire feeder 10 and the GTA gun 4 are connected with the computer 9 through the data acquisition card at the same time, the computer 9 is connected with the visual sensing system 3 and the voltage sensing system 8 through the USB interface and the data acquisition card respectively, and the voltage sensing system 8 is connected with the pulse GTA additive manufacturing power supply 7;
the voltage sensing system comprises a Hall voltage sensor and a data acquisition card, the voltage sensing system 8 acquires the arc voltage information in the stacking process, meanwhile, the arc voltage analog signal is transmitted to the data acquisition card, the data acquisition card converts the arc voltage analog signal into an arc voltage digital signal and inputs the arc voltage digital signal into the computer 9, the visual sensing system 3 collects the width image information of the accumulation layer 2 in the accumulation process, the visual sensing system 3 consists of an optical filter, a dimmer, an image acquisition card and a CCD camera, in the accumulation process, the CCD camera sequentially shoots the width images of the accumulation layer according to the preset image acquisition time, width image information is transmitted into the computer 9 through a USB interface, the computer 9 obtains arc voltage digital signals and the width image information, processes and analyzes the arc voltage digital signals and the width image information, sends out adjusting signals to change the stacking speed of the GTA gun 4 and the wire feeding speed of the wire feeder 10, and further realizes stable control of double variables of the width and the height of the stacking layer 2; the motion actuating mechanism is a robot, the GTA gun is fixed on the sixth axis of the robot through a clamp, the robot controls the GTA gun to move, and the vision sensing system is installed behind the GTA gun.
The pulse GTA wire filling additive manufacturing power supply is Fronius MW300, the model of the wire feeder is KD4010, the motion execution mechanism is a MOTOMAN robot, the GTA gun is fixed on the sixth axis of the MOTOMAN robot through a clamp, the robot controls the GTA gun to move, the vision system is installed behind the GTA gun, and the voltage sensor consists of a Hall voltage sensor and a data acquisition card. The filling wire is an ER506 mild steel welding wire, the diameter of the wire is 1.2mm, the material of the substrate is Q235B mild steel, and the size of the substrate is 300mm multiplied by 200mm multiplied by 6 mm. The technological parameters for the test are as follows: the peak current 230A, the base current 30A, the pulse frequency 2Hz, the accumulation speed 3.3mm/s, the wire feeding speed 1.7m/min, pure argon as the protective gas, and the gas flow 15L/min.
The hardware structure diagram of the pulse GTA wire-filling additive manufacturing stacked layer bivariate control system is shown in fig. 2, wherein the vision sensing system 3 and the voltage sensing system 8 are connected with the computer 9, the computer 9 processes and analyzes the acquired relevant signals, and sends out an adjusting signal to change the stacking speed of the GTA gun 4 and the wire feeding speed of the wire feeder 10, thereby realizing the stable control of the width and height bivariate of the stacked layer 2.
The method comprises the following steps: aiming at a pulse GTA wire filling additive manufacturing system, selecting an accumulation speed as a control variable 1 and a wire feeding speed as a control variable 2, designing a bivariate decoupler based on a neural network decoupling method, removing the influence of the wire feeding speed on the width of an accumulation layer and the influence of the accumulation speed on arc pressure, forming a composite pulse GTA wire filling additive manufacturing system by the decoupler and the pulse GTA wire filling additive manufacturing system, wherein in the composite pulse GTA wire filling additive manufacturing system, the accumulation speed only influences the width of the accumulation layer, and the wire feeding speed only influences the arc pressure;
step two: aiming at a composite pulse GTA wire filling additive manufacturing system, designing a neural network width controller and a fuzzy inference arc voltage controller;
step three: starting a GTA gun to perform arc striking, starting accumulation, starting a vision sensing system and a voltage sensing system after the GTA gun moves d to be 8mm, wherein the accumulation path is of a multi-layer single-channel structure, and the accumulation layers are 50;
step four: the visual sensing system collects the width image information of the accumulation layer and determines the image collecting time T as T1/2+ nT, where T1Is the duration of the base current in a pulse period, T is the pulseThe pulse period n is 0,1,2,3 …, and the continuously collected images are input into computer and the characteristic width W of accumulation layer is extracted by image processing programmWhile calculating WmAnd a preset width value WsetThe deviation amount Δ W of; collecting arc voltage information by a voltage sensing system, processing an arc voltage signal in a time range of (t-0.075s, t +0.075s) by adopting a pulse interference prevention sliding mean filtering algorithm, and extracting an arc voltage mean value U of (t-0.0075s, t +0.0075s)mCalculate UmAnd set arc voltage UsetThe deviation amount Δ U;
step five: calculating the adjustment quantity delta V of the stacking speed by adopting the stacking layer width controller designed in the step two and based on the stacking layer width deviation quantity delta W in the step fourdRealizing the stable control of the width of the accumulation layer; calculating the wire feeding speed adjustment quantity delta V by adopting the arc voltage controller designed in the step two and based on the arc voltage deviation quantity delta U in the step fourfAnd realizing stable control of arc voltage, namely finishing the stable control of double variables of the width and the height of a stacking layer in the pulse GTA wire filling additive manufacturing process by a strategy of adjusting the stacking speed and the wire feeding speed on line.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (10)
1. A pulse GTA wire-filling additive manufacturing stack layer bivariate control method is provided, the stack layer bivariate is stack layer width and height respectively, wherein the stack layer width isWThe height of the accumulated layer is obtained by a vision sensing systemHBy arc pressureUIndirect characterisation, but arc voltageUCollected by a voltage sensing system, and simultaneously based on a bivariate decoupler, a stacked layer width controller and an arc voltage controller, the voltage sensing system is used for measuring the width deviation of the stacked layerΔWDeviation from arc voltageMeasurement ofΔUThe method is characterized by comprising the following steps of (1) realizing stable control of the width and height of a stacking layer in the pulse GTA wire filling additive manufacturing process by adjusting a first control variable and a second control variable on line for an input signal of a controller, wherein the stable control comprises the following steps:
the method comprises the following steps: aiming at a pulse GTA wire filling additive manufacturing system, selecting a parameter which has the greatest influence on the width of a stacking layer as a first control variable and a parameter which has the greatest influence on arc pressure as a second control variable, designing a bivariate decoupler, removing the influence of the second control variable on the width of the stacking layer and the influence of the first control variable on the arc pressure, and forming a composite pulse GTA wire filling additive manufacturing system by the decoupler and the pulse GTA wire filling additive manufacturing system;
step two: aiming at a composite pulse GTA wire filling additive manufacturing system, respectively designing a stack layer width controller and an arc voltage controller;
step three: GTA gun arcing, start stacking along a predetermined path, GTA gun motiondAfter the width is not less than 7-12 mm, starting a visual sensing system and a voltage sensing system;
step four: the visual sensing system collects the width image information of the accumulation layer and determines the image collecting timetThe range of (A) is as follows:T 1/3+nT~2T 1/3+nTwhereinT 1The duration of the base current within a pulse period,Tn =0,1,2,3 … for pulse period, inputting continuously collected images into computer, and extracting stacking layer characteristic width value by image processing programW m Simultaneously calculateW m And a preset width valueW set Amount of deviation ofΔW(ii) a The voltage sensing system collects arc voltage information and adopts an arc voltage filtering algorithm pair: (t-∆ t，t+∆t) Processing the arc voltage signal in the time range, extractingt-∆t /10，t+∆t/10) mean value of arc voltageU m CalculatingU m And set arc voltageU set Amount of deviation ofΔUWherein∆tThe value range is as follows: 0.05-0.1 s;
step five: using the controller for the width of the stacked layer designed in the second step and based on the deviation of the width of the stacked layer in the fourth stepΔWCalculating the adjustment amount of the first control variableΔd 1Controlling the deviation of the width of the deposited layerΔW<0.5mm, realizing the uniform control of the width of the accumulation layer; adopting the arc voltage controller designed in the second step and based on the arc voltage deviation amount in the fourth stepΔUCalculating the adjustment amount of the second control variableΔd 2Controlling the amount of arc voltage deviationΔU<And 0.3V, realizing stable control of arc voltage, namely completing stable control of double variables of the width and the height of a stacking layer in the pulse GTA wire filling additive manufacturing process by a method of adjusting a first control variable and a second control variable on line.
2. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: the decoupling method based on the decoupler is a state feedback decoupling method, a fuzzy inference decoupling method or a neural network decoupling method.
3. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: step one, the first control variable is the stacking speed, and the second control variable is the wire feeding speed.
4. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: and step two, the accumulation layer width controller and the arc voltage controller are respectively an internal model controller and a fuzzy inference controller.
5. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: and step three, the preset path is of a multilayer single-channel structure.
6. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: and step four, the image processing procedures comprise median filtering, width edge detection and edge straight line fitting.
7. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: and fourthly, the arc voltage filtering algorithm is anti-pulse interference sliding mean filtering.
8. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacking layer plate according to claim 1, wherein: the method adopts a pulse GTA wire filling additive manufacturing stack laminated sheet bivariate control system, and the pulse GTA wire filling additive manufacturing stack laminated sheet bivariate control system comprises a pulse GTA wire filling additive manufacturing system, a bivariate decoupler, a stack layer width controller, an arc pressure controller, a voltage sensing system and a vision sensing system;
the pulse GTA wire filling additive manufacturing system is used for realizing a pulse GTA wire filling additive manufacturing process;
the double-variable decoupler is used for removing the influence of the first control variable on the arc voltage and the influence of the second control variable on the width of the accumulation layer;
the accumulated layer width controller adjusts the first control variable according to the deviation value of the accumulated layer width to complete the uniform control of the accumulated layer width;
the arc voltage controller adjusts a second control variable according to the arc voltage deviation value to complete stable control of the arc voltage in the stacking process; the voltage sensing system is used for detecting arc voltage information in the stacking process;
the visual sensing system is used for detecting accumulation layer width image information in the accumulation process;
the voltage sensing system collects arc voltage information in the stacking process, an arc voltage analog signal is transmitted to the data acquisition card, the data acquisition card converts the arc voltage analog signal into an arc voltage digital signal and inputs the arc voltage digital signal into the computer, and an arc voltage controller and a bivariate decoupler designed in the computer determine the adjustment quantity of a second control variable according to the input arc voltage digital signal; the visual sensing system collects width image information in the stacking process, the width image information is transmitted into the computer through the USB interface, the computer processes the width image information to obtain a stacking layer width value, and the designed stacking layer width controller and the bivariate decoupler determine the adjustment quantity of the first control variable according to the processed stacking layer width value.
9. The dual-variable control method for the pulse GTA wire-filling additive manufacturing stacked laminates as claimed in claim 8, wherein: the pulse GTA filler wire additive manufacturing system comprises: the device comprises a substrate (1), a deposition layer (2), a vision sensing system (3), a GTA gun (4), a tungsten electrode (5), a filler wire (6), a pulse GTA additive manufacturing power supply (7), a voltage sensing system (8), a computer (9) and a wire feeder (10); the cathode of the pulse GTA additive manufacturing power supply (7) is connected with the GTA gun (4), the anode of the pulse GTA additive manufacturing power supply is connected with the substrate (1), the GTA gun (4) is connected with the tungsten electrode (5), the wire feeder (10) and the GTA gun (4) are connected with the computer (9) through the data acquisition card, the computer (9) is connected with the vision sensing system (3) and the voltage sensing system (8) through the USB interface and the data acquisition card respectively, and the voltage sensing system (8) is connected to the pulse GTA additive manufacturing power supply (7); the voltage sensing system comprises a Hall voltage sensor and a data acquisition card, the voltage sensing system (8) acquires arc voltage information in the accumulation process, and simultaneously transmits arc voltage analog signals to the data acquisition card, the data acquisition card converts the arc voltage analog signals into arc voltage digital signals and inputs the arc voltage digital signals into a computer (9), the vision sensing system (3) acquires width image information of an accumulation layer (2) in the accumulation process and transmits the width image information into the computer (9) through a USB interface, the computer (9) processes and analyzes the arc voltage digital signals and the width image information after acquiring the arc voltage digital signals and the width image information, an adjusting signal is sent out to change the accumulation speed of a GTA gun (4) and the wire feeding speed of a wire feeder (10), and then the stable control of double variables of the width and the height of the accumulation layer (2) is realized; the motion actuating mechanism is a robot, the GTA gun is fixed on the sixth axis of the robot through a clamp, the robot controls the GTA gun to move, and the vision sensing system is installed behind the GTA gun.
10. A pulse GTA wire filling additive manufacturing stacking layer double-variable control system comprises a pulse GTA wire filling additive manufacturing system, a double-variable decoupler, a stacking layer width controller and an arc pressure controller;
the pulse GTA wire filling additive manufacturing system is used for realizing a pulse GTA wire filling additive manufacturing process;
the double-variable decoupler is used for removing the influence of the first control variable on the arc voltage and the influence of the second control variable on the width of the accumulation layer;
the accumulated layer width controller adjusts the first control variable according to the deviation value of the accumulated layer width to complete the uniform control of the accumulated layer width; the arc voltage controller adjusts a second control variable according to the arc voltage deviation value to complete stable control of the arc voltage in the stacking process;
the voltage sensing system collects arc voltage information in the stacking process, an arc voltage analog signal is transmitted to the data acquisition card, the data acquisition card converts the arc voltage analog signal into an arc voltage digital signal and inputs the arc voltage digital signal into the computer, and an arc voltage controller and a bivariate decoupler designed in the computer determine the adjustment quantity of a second control variable according to the input arc voltage digital signal; the visual sensing system collects width image information in the stacking process and transmits the width image information into the computer through the USB interface, the computer processes the width image information to obtain a stacking layer width value, and the designed stacking layer width controller and the bivariate decoupler determine the adjustment quantity of the first control variable according to the processed stacking layer width value;
the pulse GTA filler wire additive manufacturing system comprises: the device comprises a substrate (1), a deposition layer (2), a vision sensing system (3), a GTA gun (4), a tungsten electrode (5), a filler wire (6), a pulse GTA additive manufacturing power supply (7), a voltage sensing system (8), a computer (9) and a wire feeder (10), wherein the voltage sensing system is used for detecting arc voltage information in the deposition process; the visual sensing system is used for detecting accumulation layer width image information in the accumulation process; the cathode of the pulse GTA additive manufacturing power supply (7) is connected with the GTA gun (4), the anode of the pulse GTA additive manufacturing power supply is connected with the substrate (1), the GTA gun (4) is connected with the tungsten electrode (5), the wire feeder (10) and the GTA gun (4) are connected with the computer (9) through the data acquisition card, the computer (9) is connected with the vision sensing system (3) and the voltage sensing system (8) through the USB interface and the data acquisition card respectively, and the voltage sensing system (8) is connected to the pulse GTA additive manufacturing power supply (7); the voltage sensing system comprises a Hall voltage sensor and a data acquisition card, the voltage sensing system (8) acquires arc voltage information in the accumulation process, and simultaneously transmits arc voltage analog signals to the data acquisition card, the data acquisition card converts the arc voltage analog signals into arc voltage digital signals and inputs the arc voltage digital signals into a computer (9), the vision sensing system (3) acquires width image information of an accumulation layer (2) in the accumulation process and transmits the width image information into the computer (9) through a USB interface, the computer (9) processes and analyzes the arc voltage digital signals and the width image information after acquiring the arc voltage digital signals and the width image information, an adjusting signal is sent out to change the accumulation speed of a GTA gun (4) and the wire feeding speed of a wire feeder (10), and then the stable control of double variables of the width and the height of the accumulation layer (2) is realized; the motion actuating mechanism is a robot, the GTA gun is fixed on the sixth axis of the robot through a clamp, the robot controls the GTA gun to move, and the vision sensing system is installed behind the GTA gun.
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