CN110640297B - Online control system and method for transient temperature of friction stir welding - Google Patents

Online control system and method for transient temperature of friction stir welding Download PDF

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Publication number
CN110640297B
CN110640297B CN201910915506.8A CN201910915506A CN110640297B CN 110640297 B CN110640297 B CN 110640297B CN 201910915506 A CN201910915506 A CN 201910915506A CN 110640297 B CN110640297 B CN 110640297B
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stirring head
temperature
color
friction stir
welding
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CN110640297A (en
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宋崎
姬书得
龚鹏
熊需海
任赵旭
胡为
王留芳
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Shenyang Aerospace University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/26—Auxiliary equipment

Abstract

The invention relates to an on-line control system and method for transient temperature of friction stir welding, wherein the control system comprises a high-precision camera, a white balance light source, a color sensor, a control computer and a liquid crystal display, the high-precision camera and the color sensor are arranged on two sides of a material to be welded on a main shaft bracket of a welding machine and are respectively connected with the control computer through signal wires, the white balance light source is arranged on the same side of the color sensor and comprises a white high-brightness LED lamp and a key control panel, the white high-brightness LED lamp is provided with a light-shading lampshade and is fixed on the main shaft bracket of the friction stir welding through a bolt and synchronously moves with a stirring head, the LED lamp emits white light to irradiate the stirring head, and the stirring head reflects light of the color of the stirring head to the color sensor. The control method can monitor the real-time temperature in the friction stir process on line, adjust the pressing amount of the shaft shoulder, improve the stability of the welding line and prolong the service life of the joint.

Description

Online control system and method for transient temperature of friction stir welding
Technical Field
The invention belongs to the technical field of welding process parameter online regulation and control, and particularly relates to a stirring friction welding transient temperature online control system and method.
Background
In recent years, with the development of the aerospace industry, high melting point materials represented by titanium alloys have been widely used. For welding of high melting point metal, there are conventional welding processes such as arc welding, electron beam welding, laser welding, etc., and friction stir welding, which is a novel solid phase welding technique for titanium alloy welding, has become a hot point of research. The friction stir welding technology mainly generates a large amount of friction heat through the friction between a stirring head with a stirring needle and a shaft shoulder and a workpiece to be welded, so that a welding seam material is softened to reach a thermoplastic state, the material in a welding seam area generates plastic flow and mixing under the rotating action of the stirring head and the forging action of the shaft shoulder, and finally solid-phase connection of the material is realized.
Friction stir welding is a solid phase welding technique, and the welding temperature change caused by friction is an important index in the friction stir welding process, which directly affects the quality of the welded joint. Too low temperature can lead to insufficient material softening, insufficient plastic fluidity and easy occurrence of defects such as holes in a welding seam area, but too high temperature can also generate the results of unfavorable welding seam performance such as growth of a structure, widening of a heat affected zone and the like. This requires efficient detection of temperature changes during the welding process. Common devices for detecting the temperature field of the stirring head adopt infrared radiation temperature measurement or thermocouple wired temperature measurement, but different types of thermocouples have different optimal measurement temperature ranges, and when the temperature field is not in the measurement range, the measurement error is obviously increased or the measurement cannot be carried out at all; and the infrared temperature measurement is easily influenced by external factors.
For friction stir welding of titanium alloy, which is a high-melting-point material, the material of the stirring head is usually high-temperature-resistant and wear-resistant materials such as expensive tungsten-rhenium (W-Re) alloy and Polycrystalline Cubic Boron Nitride (PCBN), and the stirring head turns red due to high temperature generated by friction in the welding process of the titanium alloy. In the actual welding process, a welder can judge the reddening degree of the stirring head according to experience to finely adjust parameters such as the pressing amount of the shaft shoulder and the like, so that the uniformity of the quality of a welding seam is ensured. However, this operation is too much affected by human factors, and the degree of improvement in the welding quality due to this operation cannot be determined. Therefore, according to the friction stir welding characteristics of the titanium alloy, which is a high-melting-point material, the real-time detection and control of the welding temperature are realized, and the method has important significance for ensuring the process stability of the welding line and prolonging the service life of the stirring head.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the on-line control system and the method for the transient temperature of the friction stir welding, and the measurement precision is high. The temperature change of the titanium alloy high-melting-point material in the friction stir welding process can be dynamically acquired and monitored in real time, and the pressing amount can be adjusted in real time according to the temperature change.
The invention adopts the following technical scheme:
the utility model provides a friction stir welding transient state temperature on-line control system, includes high accuracy camera, white balance light source, color sensor, control computer and LCD, high accuracy camera and color sensor install the both sides of treating welding material on welding machine main shaft support to pass through the signal line and link to each other with the control computer respectively, white balance light source installs at the color sensor homonymy, including white highlight LED lamp and button control panel, white highlight LED lamp is equipped with the light-resistant lamp shade, fixes on friction stir welding main shaft support through the bolt, and along with stirring head synchronous motion, the LED lamp sends white light and shines on the stirring head, and the stirring head gives color sensor with the light reflection of self colour.
The forward voltage of the white high-brightness LED lamp is 3.0-7.2V, the luminous intensity is 1500-2000MCD, the forward current is 20mA, the color temperature is 2700-25000K, and the angle of the lamp cap can be controlled through the LED lamp self-rotating device.
The key control panel comprises an LCD display module and a power supply voltage setting key, a rechargeable lithium battery is matched with the 5V voltage stabilizing module to supply power to the LED lamp in the key control panel, and the LCD display module is used for displaying voltage values in real time.
The control method of the friction stir welding transient temperature online control system specifically comprises the following steps:
step 1: initializing a high-precision camera of a control system, a serial port, a timer and a register in a control computer;
step 2: white balance adjustment is carried out on the color sensor, and the color sensor carries out linearization processing on the collected color information of the stirring head after adjustment: sequentially gating the filters of the three colors of the sensor, counting output pulses, stopping counting when the number reaches 255, respectively calculating the time used by each channel, wherein the number of pulses measured in the period of time is the corresponding R, G, B value, and providing color parameters for the subsequent model establishment;
and step 3: obtaining temperature data around a plurality of groups of welding seams by a previous thermocouple measuring method, obtaining temperature values corresponding to the pressing quantities in the optimal state of a welding area, inputting the temperature values into a control computer, carrying out real-time color recognition on the control computer by adopting an OpenCV vision library function according to images acquired by a high-precision camera, establishing a linear relation model between the transient temperature of the stirring head and the pressing quantities of the shaft shoulder in the friction stir welding by combining R, G, B values after linear processing of a color sensor, and simultaneously calculating correction parameters of the pressing quantities of the shaft shoulder according to preset temperature values corresponding to the ideal pressing quantities to realize real-time adjustment of the pressing quantities in the friction stir welding process;
and 4, step 4: when the transient temperature of the stirring head is equal to a temperature value corresponding to a preset ideal pressing amount, maintaining the current shaft shoulder pressing amount parameter unchanged; when the temperature value exceeds the threshold value, reducing the pressing amount of the shaft shoulder according to the preset process specification; when the temperature data of the stirring head is lower than a threshold value, increasing the pressing amount of the shaft shoulder; the control computer feeds back the adjustment of the pressing amount to a numerical control system of the welding equipment to form cyclic control so as to achieve continuous stable welding.
The white balance adjustment method in step 2 is as follows:
through white balance light source control, place white highlight LED lamp in the colour sensor top, shine white light on the stirring head, and then colour sensor receives the light source, according to white balance adjustment's difference formula: difference RTo be measured-RStandard of merit|+|GTo be measured-GStandard of merit|+|BTo be measured-BStandard of meritAnd sequentially and respectively measuring RGB difference values of the red, the green and the blue, wherein the difference values provide correction parameters for the linearization processing of the color sensor.
The color recognition method in step 3 is as follows:
when the stirring head rotates to weld materials at a high speed, the high-precision camera acquires images and reduces the images to be 0.3 time of the original size, and the computer divides the images by adopting an improved watershed algorithm provided by OpenCV and acquires image parts of the stirring head; the R, G, B three color channels of the stir head image were separated according to the interface function prototype for computing the image histogram in OpenCV.
The method for the linear relation model of the transient temperature and the shoulder pressing amount of the stirring head in the step 3 comprises the following steps:
a supervised machine learning separator is provided according to a learning theory, a Support Vector Machine (SVM) algorithm is used, R, G, B values of color channel separation in a color recognition process are combined with R, G, B values obtained after linearization processing of a color sensor, color histogram calculation is carried out through a control computer, SVM parameters are initialized, an SVM training function is called for training, a linear relation model of the transient temperature of a stirring head of friction stir welding and the pressure under a shaft shoulder is generated, model data are transmitted to a liquid crystal display by the computer to display a stirring head temperature distribution image, and temperature change of the stirring head is monitored in real time.
The invention has the beneficial effects that:
(1) the novel friction stir welding temperature monitoring system automatically adjusts welding process parameters according to the temperature change of the stirring head for welding the high-melting-point material, namely titanium alloy, ensures the consistency of the temperature peak value of the welding line in the welding process, improves the stability of the quality of the welding line, can avoid the damage of the stirring head to a certain extent, and prolongs the service life of the stirring head.
(2) A linear relation model of transient temperature of the stirring head and the pressing amount of the shaft shoulder is established based on a machine learning theory, and camera image color recognition and color sensor recognition algorithms are fused and corrected, so that temperature detection is more real-time and area authenticity, and the measurement precision of the temperature peak value in the friction stir welding process can be improved.
(3) According to the invention, a large amount of temperature change information of the stirring head in the welding process of the high-melting-point material can be recorded through the cooperative work of the high-precision camera and the color sensor, so that the temperature change of the welding seam area can be calculated, and the temperature research of the friction stir welding seam area is facilitated.
Drawings
FIG. 1 is a control system connection diagram of the present invention;
FIG. 2 is a schematic diagram of the operation of the control system of the present invention;
FIG. 3 is a schematic view of a high-precision camera employed in the embodiment;
FIG. 4 is a schematic diagram of a white balance light source according to the present invention;
wherein the content of the first and second substances,
01-white balance light source, 02-color sensor, 03-high precision camera, 04-liquid crystal display, 05-control computer, 06-shaft shoulder, 07-stirring head, 08-welding material, 21-power supply voltage setting key, 22-LCD display module, 23-main shaft bracket, 24-light-shading lampshade, 25-white high-brightness LED lamp, 26-rotating device, 27-bolt, 31-embedded computer hardware system, 32-signal output interface, 33-power supply module, 34-digital signal processing module, 35-high resolution CCD imaging module, 36-digital image storage, 37-camera body, and 38-commercial optical lens.
Detailed Description
For better understanding of the present invention, the technical solutions and effects of the present invention will be described in detail by the following embodiments with reference to the accompanying drawings.
As shown in fig. 1-2, an on-line control system for transient temperature of friction stir welding comprises a high-precision camera 03, a white balance light source 01, a color sensor 02, a control computer 05 and a liquid crystal display 04, wherein the high-precision camera 03 and the color sensor 02 are installed on two sides of a material 08 to be welded on a main shaft bracket 23 of a welding machine and are respectively connected with the control computer 05 through signal lines. In this implementation, a TCS230 sensor is employed.
The white balance light source 01 is installed on the same side of the color sensor 02, and comprises a white high-brightness LED lamp 25 and a key control panel, as shown in fig. 4, the white high-brightness LED lamp 25 is provided with a light-shading lampshade 24, is fixed on the friction stir welding spindle support 23 through a bolt 27, and synchronously moves with the stirring head 07, the white high-brightness LED lamp 25 emits white light to illuminate the stirring head 07, and the stirring head 07 reflects light of the color of the stirring head 07 to the color sensor 02. White highlight LED lamp 25 forward voltage is 3.0 ~ 7.2V, sets for button 21 through mains voltage in this embodiment with voltage control at 5V to guarantee that luminous intensity is stable at 1600MCD, forward current is 20mA, according to stirring head 07 length and the volume of pushing down, through LED lamp self rotary device 26 control lamp holder angle, make light aim at stirring head 07.
The key control panel comprises an LCD display module 22 and a power supply voltage setting key 21, a rechargeable lithium battery is matched with a 5V voltage stabilizing module to supply power to a white high-brightness LED lamp 25 in the key control panel, and the LCD display module 22 is used for displaying voltage values in real time.
As shown in fig. 3, the high-precision camera 03 includes a commercial optical lens 38, a camera body 37, a high-resolution CCD imaging module 35, an embedded computer hardware system 31, a digital signal processing module 34, a digital image storage 36, a power supply module 33, and a signal output interface 32, and completes imaging of the mixing head 07, and converts the imaging into an electronic signal, and transmits the signal to the control computer 05. The main parameters of the commercial optical lens 38 are the focal length f, the relationship between the focal length f and the field angle θ and the image plane width L is as follows: tg (θ/2) — L/2)/f, and the field angle of the high-precision camera 03 in this embodiment is set to 45 ° according to the position of the stirring head 07 and the requirements of the welding equipment.
The control computer 05 is used for communicating with the high-precision camera 03 and the color sensor TCS 23002, and realizes on-line regulation and control of process parameters.
An on-line control method for the transient temperature of friction stir welding specifically comprises the following steps:
step 1: initializing a high-precision camera 03 of a control system, and a serial port, a timer and a register inside a control computer 05;
step 2: the white balance adjustment is performed on the color sensor 02 by the following specific method: by the control of the white balance light source 01, the white high-brightness LED lamp 25 is placed above the color sensor 02, the white light is irradiated onto the stirring head 07, and then the color sensor 02 receives the light source, according to the difference formula of the white balance adjustment: difference RTo be measured-RStandard of merit|+|GTo be measured-GStandard of merit|+|BTo be measured-BStandard of meritSequentially and respectively measuring RGB difference values of red, green and blue colors, wherein the difference values provide correction parameters for the color sensor 02 linearization processing;
the color sensor 02 after white balance adjustment carries out linearization processing on the collected color information of the stirring head 07: sequentially gating the filters of the three colors of the sensor, counting output pulses, stopping counting when the number reaches 255, respectively calculating the time used by each channel, wherein the number of pulses measured in the period of time is the corresponding R, G, B value, and providing color parameters for the subsequent model establishment;
and step 3: obtaining temperature data around a plurality of groups of welding seams by a previous thermocouple measuring method, obtaining temperature values corresponding to the pressing quantities in the optimal state of a welding area, inputting the temperature values into a control computer 05, carrying out real-time color recognition by the control computer 05 based on an OpenCV vision library function according to images collected by a high-precision camera 03, establishing a linear relation model between the transient temperature of a friction stir welding stirring head 07 and the pressing quantities of a shaft shoulder 06 according to corrected colors, and calculating correction parameters of the pressing quantities of the shaft shoulder according to preset temperature values corresponding to the ideal pressing quantities to realize real-time adjustment of the pressing quantities in the friction stir welding process;
the color identification method specifically comprises the following steps:
when the stirring head 07 rotates to weld the material 08 at a high speed, the high-precision camera 03 collects images at 20FPS frames, the control computer 05 reduces the size of the collected stirring head 07 image to 0.3 time of the original size (1555px X1037 px), and the computer segments the image by using an improved watershed algorithm provided by OpenCV and collects the image part of the stirring head 07; the R, G, B three color channels of the whisk head 07 image are separated according to the interface function prototype of the computed image histogram in OpenCV.
The method for the linear relation model of the transient temperature and the shoulder pressing amount of the stirring head 07 for friction stir welding is as follows:
according to a supervised machine learning separator provided by a learning theory, a Support Vector Machine (SVM) algorithm is used, R, G, B values of color channel separation in a color recognition process are combined with R, G, B values obtained after linearization processing of a color sensor 02, color histogram calculation is carried out through a control computer 05, SVM parameters are initialized, an SVM training function is called for training, a linear relation model of the transient temperature of a friction stir welding stirring head 07 and the pressure under a shaft shoulder is generated, model data are transmitted to a liquid crystal display 04 by the computer to display a stirring head temperature distribution image, and temperature change of the stirring head 07 is monitored in real time.
And 4, step 4: when the transient temperature of the stirring head 07 is equal to a temperature value corresponding to a preset ideal pressing amount, maintaining the current shaft shoulder pressing amount parameter unchanged; when the temperature value exceeds the threshold value, reducing the pressing amount of the shaft shoulder according to the preset process specification; when the temperature data of the stirring head 07 is lower than a threshold value, increasing the pressing amount of the shaft shoulder; the control computer 05 feeds back the adjustment of the pressing amount to the numerical control system of the welding equipment to form cyclic control so as to achieve continuous steady-state welding.

Claims (5)

1. A control method of a friction stir welding transient temperature on-line control system comprises a high-precision camera, a white balance light source, a color sensor, a control computer and a liquid crystal display, wherein the high-precision camera and the color sensor are arranged on two sides of a material to be welded on a welding machine spindle support and are respectively connected with the control computer through signal lines;
the forward voltage of the white high-brightness LED lamp is 3.0-7.2V, the luminous intensity is 1500-2000MCD, the forward current is 20mA, the color temperature is 2700-25000K, and the angle of the lamp cap can be controlled by the LED lamp self-rotating device;
the method is characterized in that: the method specifically comprises the following steps:
step 1: initializing a high-precision camera of a control system, a serial port, a timer and a register in a control computer;
step 2: white balance adjustment is carried out on the color sensor, and the color sensor carries out linearization processing on the collected color information of the stirring head after adjustment: sequentially gating the filters of the three colors of the sensor, counting output pulses, stopping counting when the number reaches 255, respectively calculating the time used by each channel, wherein the number of pulses measured in the period of time is the corresponding R, G, B value, and providing color parameters for the subsequent model establishment;
and step 3: obtaining temperature data around a plurality of groups of welding seams by a previous thermocouple measuring method, obtaining temperature values corresponding to the pressing quantities in the optimal state of a welding area, inputting the temperature values into a control computer, carrying out real-time color recognition on the control computer by adopting an OpenCV vision library function according to images acquired by a high-precision camera, establishing a linear relation model between the transient temperature of the stirring head and the pressing quantities of the shaft shoulder in the friction stir welding by combining R, G, B values after linear processing of a color sensor, and simultaneously calculating correction parameters of the pressing quantities of the shaft shoulder according to preset temperature values corresponding to the ideal pressing quantities to realize real-time adjustment of the pressing quantities in the friction stir welding process;
and 4, step 4: when the transient temperature of the stirring head is equal to a temperature value corresponding to a preset ideal pressing amount, maintaining the current shaft shoulder pressing amount parameter unchanged; when the temperature value exceeds the threshold value, reducing the pressing amount of the shaft shoulder according to the preset process specification; when the temperature data of the stirring head is lower than a threshold value, increasing the pressing amount of the shaft shoulder; the control computer feeds back the adjustment of the pressing amount to a numerical control system of the welding equipment to form cyclic control so as to achieve continuous stable welding.
2. The control method of the friction stir welding transient temperature online control system according to claim 1, characterized in that: the key control panel comprises an LCD display module and a power supply voltage setting key, a rechargeable lithium battery is matched with the 5V voltage stabilizing module to supply power to the LED lamp in the key control panel, and the LCD display module is used for displaying voltage values in real time.
3. The control method of the friction stir welding transient temperature online control system according to claim 1, characterized in that: the white balance adjustment method in step 2 is as follows:
through white balance light source control, place white highlight LED lamp in the colour sensor top, shine white light on the stirring head, and then colour sensor receives the light source, according to white balance adjustment's difference formula: difference RTo be measured-RStandard of merit|+|GTo be measured-GStandard of merit|+|BTo be measured-BStandard of meritAnd sequentially and respectively measuring RGB difference values of the red, the green and the blue, wherein the difference values provide correction parameters for the linearization processing of the color sensor.
4. The control method of the friction stir welding transient temperature online control system according to claim 1, characterized in that: the color recognition method in step 3 is as follows:
when the stirring head rotates to weld materials at a high speed, the high-precision camera acquires images and reduces the images to be 0.3 time of the original size, and the computer divides the images by adopting an improved watershed algorithm provided by OpenCV and acquires image parts of the stirring head; the R, G, B three color channels of the stir head image were separated according to the interface function prototype for computing the image histogram in OpenCV.
5. The control method of the friction stir welding transient temperature online control system according to claim 1, characterized in that: the method for the linear relation model of the transient temperature and the shoulder pressing amount of the stirring head in the step 3 comprises the following steps:
a supervised machine learning separator is provided according to a learning theory, a Support Vector Machine (SVM) algorithm is used, R, G, B values of color channel separation in a color recognition process are combined with R, G, B values obtained after linearization processing of a color sensor, color histogram calculation is carried out through a control computer, SVM parameters are initialized, an SVM training function is called for training, a linear relation model of the transient temperature of a stirring head of friction stir welding and the pressure under a shaft shoulder is generated, model data are transmitted to a liquid crystal display by the computer to display a stirring head temperature distribution image, and temperature change of the stirring head is monitored in real time.
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