CN111299894A - Welding defect detection system and method - Google Patents
Welding defect detection system and method Download PDFInfo
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- CN111299894A CN111299894A CN201911246581.6A CN201911246581A CN111299894A CN 111299894 A CN111299894 A CN 111299894A CN 201911246581 A CN201911246581 A CN 201911246581A CN 111299894 A CN111299894 A CN 111299894A
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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Abstract
The invention relates to the technical field of welding detection, and discloses a welding defect detection system and a method, wherein the welding defect detection system comprises: the device comprises a high-frequency power generator, an induction coil, an infrared image sensor and a processor; the high-frequency power supply generator is used for generating high-frequency current and transmitting the high-frequency current to the induction coil; the induction coil is used for heating the to-be-detected hemming welding joint and the welding spot according to the high-frequency current, and generating a dynamic temperature field on the welding spot; the infrared image sensor is used for detecting the dynamic temperature field, acquiring a temperature field image and transmitting the temperature field image to the processor; and the processor is used for detecting whether the welding spot has welding defects according to the temperature field image. The high-frequency power generator and the induction coil are used for heating by adopting an electromagnetic induction heating method to generate a dynamic temperature field, and welding defects are detected according to the infrared image sensor, so that heating is more uniform, and the detection accuracy of the welding defects is improved.
Description
Technical Field
The invention relates to the technical field of welding detection, in particular to a welding defect detection system and method.
Background
The small-sized crimp welding joint is a connecting joint widely used for motor windings, two wires are welded together by using the small-sized crimp welding joint, and dozens or even hundreds of the small-sized crimp welding joints are often arranged in a motor, but welding defects such as air holes, inclusions or incomplete welding and the like are inevitably generated in the welding process. It is a technical difficulty in the manufacture of windings of such motors to detect welding defects, because such welding defects may be superficial or may exist inside the weld, and particularly, for such small-sized hemmed joints, the existing methods of detection such as X-ray, ultrasonic, etc. are not suitable.
In the infrared nondestructive inspection method developed in recent years, an active heat source is adopted to heat a workpiece to be detected in order to improve detection sensitivity and precision, a main infrared radiation lamp of the active heat source is adopted in infrared nondestructive inspection at present, a laser is also adopted, and the problems of low heating efficiency and uneven heating exist in the small-size hemming welding joint no matter which method is adopted, so that the detection result is not accurate.
Therefore, there is a technical problem of how to improve the accuracy of detection of welding defects.
The above is only for the purpose of assisting understanding of the technical aspects of the present invention, and does not represent an admission that the above is prior art.
Disclosure of Invention
The invention mainly aims to provide a welding defect detection system and a welding defect detection method, and aims to solve the technical problem of improving the welding defect detection accuracy.
To achieve the above object, the present invention provides a welding defect detection system, including: the device comprises a high-frequency power generator, an induction coil, an infrared image sensor and a processor, wherein the induction coil is sleeved outside a to-be-detected crimping welding joint;
the high-frequency power supply generator is used for generating high-frequency current and transmitting the high-frequency current to the induction coil;
the induction coil is used for heating the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and generating a dynamic temperature field on the welding spots;
the infrared image sensor is used for detecting the dynamic temperature field, acquiring a temperature field image and transmitting the temperature field image to the processor;
and the processor is used for detecting whether the welding spot has welding defects according to the temperature field image.
Preferably, the induction coil is further configured to generate an eddy current in the welding spot of the to-be-detected hemming welding joint and the welding spot of the to-be-detected hemming welding joint according to the high-frequency current;
the induction coil is further used for heating the to-be-detected hemming welding joint and the welding spot according to the eddy current, and a dynamic temperature field is generated on the welding spot.
Preferably, the processor is further configured to select a plurality of sample points from the temperature field image, and obtain a sample temperature of each sample point;
the processor is further used for calculating the sample temperature difference of each sample point according to the sample temperature;
the processor is further used for judging whether the temperature difference of the sample is larger than a preset temperature difference threshold value;
and the processor is also used for detecting whether the welding spot has welding defects according to the judgment result.
Preferably, the processor is further configured to determine that the welding spot has no welding defect when the sample temperature difference is not greater than the preset temperature difference threshold;
the processor is further used for judging that the welding spot has welding defects when the sample temperature difference is larger than the preset temperature difference threshold value.
Preferably, the processor is further configured to calculate a target difference value according to the sample temperature difference and a preset temperature difference threshold value when the welding spot has a welding defect;
and the processor is also used for determining the welding defect degree of the welding spot according to the target difference value.
In addition, in order to achieve the above object, the present invention further provides a welding defect detecting method, wherein the welding defect detecting method is based on a welding defect detecting system, and the welding defect detecting system comprises: the welding defect detection method comprises the following steps of (1) a high-frequency power generator, an induction coil and an infrared image sensor, wherein the induction coil is sleeved on the outer side of a to-be-detected hemming welding joint, and the welding defect detection method comprises the following steps:
the high-frequency power supply generator generates high-frequency current and transmits the high-frequency current to the induction coil;
the induction coil heats the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and a dynamic temperature field is generated on the welding spots;
the infrared image sensor detects the dynamic temperature field to obtain a temperature field image, and transmits the temperature field image to the processor;
and the processor detects whether the welding spot has welding defects according to the temperature field image.
Preferably, the induction coil heats the welding spot of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and generates a dynamic temperature field on the welding spot, which specifically includes:
the induction coil generates eddy currents in the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current;
and the induction coil heats the to-be-detected hemming welding joint and the welding spot according to the eddy current, and a dynamic temperature field is generated on the welding spot.
Preferably, the processor detects whether the welding spot has a welding defect according to the temperature field image, and specifically includes:
the processor selects a plurality of sample points from the temperature field image and obtains the sample temperature of each sample point;
the processor calculates the sample temperature difference of each sample point according to the sample temperature;
the processor judges whether the temperature difference of the sample is larger than a preset temperature difference threshold value or not;
and the processor detects whether the welding spot has welding defects according to the judgment result.
Preferably, the processor detects whether the welding spot has a welding defect according to the judgment result, and specifically includes:
when the sample temperature difference is not larger than the preset temperature difference threshold value, the processor judges that the welding spot has no welding defect;
and when the temperature difference of the sample is greater than the preset temperature difference threshold value, the processor judges that the welding spot has welding defects.
Preferably, after the processor detects whether the welding spot has the welding defect according to the judgment result, the method further includes:
when the welding spot has a welding defect, the processor calculates a target difference value according to the sample temperature difference and a preset temperature difference threshold value;
and the processor determines the welding defect degree of the welding spot according to the target difference value.
The welding defect detection system provided by the invention comprises: the device comprises a high-frequency power generator, an induction coil, an infrared image sensor and a processor, wherein the induction coil is sleeved outside a to-be-detected crimping welding joint; the high-frequency power supply generator is used for generating high-frequency current and transmitting the high-frequency current to the induction coil; the induction coil is used for heating the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and generating a dynamic temperature field on the welding spots; the infrared image sensor is used for detecting the dynamic temperature field, acquiring a temperature field image and transmitting the temperature field image to the processor; and the processor is used for detecting whether the welding spot has welding defects according to the temperature field image. The high-frequency power generator and the induction coil are used for heating by adopting an electromagnetic induction heating method to generate a dynamic temperature field, and welding defects are detected according to the infrared image sensor, so that heating is more uniform, and the detection accuracy of the welding defects is improved.
Drawings
FIG. 1 is a functional block diagram of a welding defect detection system according to a first embodiment of the present invention;
FIG. 2 is a front view of a workpiece to be welded of a first embodiment of the weld defect detection system of the present invention;
FIG. 3 is a top view of a workpiece to be welded of a first embodiment of the weld defect detection system of the present invention;
FIG. 4 is a front view of a hem weld joint to be inspected in accordance with a first embodiment of the weld defect detection system of the present invention;
FIG. 5 is a top view of a hem weld joint to be inspected in accordance with a first embodiment of the weld defect detection system of the present invention;
FIG. 6 is an elevational view of the configuration of a welding defect detection system in accordance with a first embodiment of the welding defect detection system of the present invention;
FIG. 7 is a side view of the configuration of a welding defect detection system of the first embodiment of the welding defect detection system of the present invention;
FIG. 8 is a top view of the configuration of a welding defect detection system in accordance with a first embodiment of the welding defect detection system of the present invention;
FIG. 9 is a functional block diagram of a welding defect detection system according to a second embodiment of the present invention;
FIG. 10 is a functional block diagram of a welding defect detection system according to a third embodiment of the present invention;
FIG. 11 is a schematic flow chart illustrating a welding defect detecting method according to a first embodiment of the present invention;
FIG. 12 is a flowchart illustrating a welding defect detecting method according to a second embodiment of the present invention;
fig. 13 is a flowchart illustrating a welding defect detecting method according to a third embodiment of the present invention.
The implementation, functional features and advantages of the objects of the present invention will be further explained with reference to the accompanying drawings.
Detailed Description
It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Referring to fig. 1, fig. 1 is a block diagram illustrating a welding defect detecting system according to a first embodiment of the present invention. The welding defect detection system includes: the device comprises a high-frequency power supply generator 10, an induction coil 20, an infrared image sensor 30 and a processor 40, wherein the induction coil 20 is sleeved outside a to-be-detected crimping welding joint;
the high frequency power generator 10 is configured to generate a high frequency current and transmit the high frequency current to the induction coil 20.
It should be noted that the to-be-detected crimping welding joint is a small-sized crimping welding joint, the induction ring is sleeved outside the to-be-detected crimping welding joint, and the to-be-detected crimping welding joint can be heated by the high-frequency power generator 10 and the induction coil 20 by using an electromagnetic induction heating method.
It is understood that the high frequency power generator 10 can generate a high frequency current, which is a high frequency alternating current.
In a specific implementation, as shown in fig. 2, 3, fig. 2 is a front view of a workpiece to be welded, and fig. 3 is a top view of the workpiece to be welded, wherein the first workpiece 101 and the second workpiece 102 are a pair of workpieces to be welded in the form of hems.
In a specific implementation, as shown in fig. 4 and 5, fig. 4 is a front view of a to-be-detected hemming welded joint after welding a to-be-welded workpiece, and fig. 5 is a top view of the to-be-detected hemming welded joint after welding the to-be-welded workpiece, where a welding spot 201 is a fusion spot and a welding spot formed after welding, and a certain welding defect may exist in the welding spot 201, and therefore, it is required to detect the welding defect, and a main object of the present invention is to detect whether the welding spot 201 has the welding defect.
The induction coil 20 is configured to heat the welding spot of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and generate a dynamic temperature field on the welding spot.
It can be understood that the induction coil inductively heats the welding spots of the to-be-detected hemming welding joint and the to-be-detected welding joint according to the high-frequency current, so that the temperature on the welding spots is increased, and a dynamic temperature field is generated.
In a specific implementation, as shown in fig. 6, 7, and 8, fig. 6 is a front view of a welding defect detecting system structure, fig. 7 is a side view of the welding defect detecting system structure, fig. 8 is a top view of the welding defect detecting system structure, wherein a first workpiece 101 and a second workpiece 102 are welded together by a welding spot 201, and in order to detect a temperature field of the welding spot 201, an induction coil 301 is used to perform induction heating, a high-frequency power generator 401 outputs a high-frequency current I1 with a frequency of 100KHz or more, a high-frequency current I1 flows through the induction coil 301, and generates an induction current I2 in the first workpiece 101, the second workpiece 102, and the welding spot 201, the induction current I2 is also called an eddy current, the eddy current is a distribution parameter, and the eddy current heats the first workpiece 101, the second workpiece 102, and the welding spot 201 to raise a surface temperature of the welding spot 201 to generate a dynamic temperature field, the infrared image sensor 501 detects the dynamic temperature field, a temperature field image can be obtained.
It will be appreciated that the crimp weld to be tested comprises a first workpiece and a second workpiece.
The infrared image sensor 30 is configured to detect the dynamic temperature field, obtain a temperature field image, and transmit the temperature field image to the processor 40.
It can be understood that the infrared image sensor 30 detects the dynamic temperature field at the welding spot to obtain a temperature field image, and transmits the temperature field image to the processor 40, so that the processor can determine whether the welding spot has a welding defect according to the temperature field image.
And the processor 40 is used for detecting whether the welding spot has welding defects according to the temperature field image.
It should be understood that the processor 40 can determine whether the temperature field on the welding spot is uniform according to the temperature field image, and when the temperature field is not uniform, it can determine that the welding spot has a welding defect, and further process the temperature field image to detect the degree of the welding defect.
In this embodiment, by adopting the above scheme, the welding defect detection system includes: the device comprises a high-frequency power supply generator 10, an induction coil 20, an infrared image sensor 30 and a processor 40, wherein the induction coil 20 is sleeved outside a to-be-detected crimping welding joint; the high-frequency power generator 10 is used for generating high-frequency current and transmitting the high-frequency current to the induction coil 20; the induction coil 20 is configured to heat the welding spot of the to-be-detected hemming welding joint and the welding spot of the to-be-detected hemming welding joint according to the high-frequency current, and generate a dynamic temperature field on the welding spot; the infrared image sensor 30 is configured to detect the dynamic temperature field, obtain a temperature field image, and transmit the temperature field image to the processor 40; and the processor 40 is used for detecting whether the welding spot has welding defects according to the temperature field image. The high frequency power generator 10 and the induction coil 20 are heated by an electromagnetic induction heating method to generate a dynamic temperature field, and welding defects are detected according to the infrared image sensor 30, so that heating is more uniform, and the welding defect detection accuracy is improved.
Further, referring to fig. 9, fig. 9 is a block diagram illustrating a second embodiment of the welding defect detecting system according to the present invention, and the second embodiment of the welding defect detecting system according to the present invention is proposed based on the embodiment illustrated in fig. 1.
The induction coil 20' is further configured to generate an eddy current in the welding spot of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high frequency current.
It will be understood that the induction coil 20' generates an induction current, also called eddy current, in the crimp weld to be detected and in the weld spot of the crimp weld to be detected, depending on the high-frequency current.
The induction coil 20' is further configured to heat the to-be-detected hemming welding joint and the welding spot according to the eddy current, and generate a dynamic temperature field on the welding spot.
It should be appreciated that the induction coil 20' inductively heats the hem weld joint and the weld spot to be inspected based on eddy currents, causing the temperature of the weld spot to rise, creating a dynamic temperature field.
It can be understood that the high-frequency induction heating mode is used for heating the to-be-detected hemming welding joint and the welding spot, so that the heating problem of the small-size hemming welding seam is solved, the distribution uniformity of eddy currents in the welding spot is influenced due to the existence of the welding defect, the non-uniformity of the eddy current distribution can cause the non-uniformity of the heating effect, the non-uniformity of the surface temperature field of the welding spot is increased, the sensibility of the welding defect is further increased, and the sensitivity of the welding defect detection is improved.
According to the scheme provided by the embodiment, firstly, eddy currents are generated in the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, then the to-be-detected hemming welding joint and the welding spots are heated according to the eddy currents, and a dynamic temperature field is generated on the welding spots, so that the to-be-detected hemming welding joint and the welding spots are heated in a high-frequency induction heating mode, and the sensitivity of welding defect detection is improved.
Further, referring to fig. 10, fig. 10 is a block diagram illustrating a third embodiment of the welding defect detecting system according to the present invention, and the third embodiment of the welding defect detecting system according to the present invention is proposed based on the above-mentioned embodiment shown in fig. 1 or fig. 9, and is explained based on fig. 1:
the processor 40' is further configured to select a plurality of sample points from the temperature field image and obtain a sample temperature of each sample point.
It can be understood that, in order to determine whether the dynamic temperature field on the surface of the welding spot is uniform, a plurality of sample points may be selected from the temperature field image, and the manner of selecting the sample points may be random sampling or average sampling.
It should be understood that after selecting a plurality of sample points, the sample temperature for each sample point may be obtained from the temperature field image.
The processor 40' is further configured to calculate a sample temperature difference for each sample point according to the sample temperature.
It can be understood that after the plurality of sample points and the sample temperature of each sample point are obtained, the sample temperature difference between the samples can be obtained by performing a plurality of calculations according to the sample temperatures, and whether the temperature field on the surface of the welding spot is uniform can be determined according to the sample temperature difference.
The processor 40' is further configured to determine whether the sample temperature difference is greater than a preset temperature difference threshold.
It should be understood that the preset temperature difference threshold may be a threshold preset according to an actual situation, and by determining whether the sample temperature difference is greater than the preset temperature difference threshold, it may be determined whether the non-uniformity of the dynamic temperature field on the welding spot is within a qualified range, and then it may be determined whether the welding spot has a welding defect.
It should be understood that, whether the welding spot has the welding defect or not can be judged according to the uniformity of the dynamic temperature field on the welding spot because, when the welding spot has no welding defect, the heat conduction performance of the welding spot can be relatively uniform, so after the welding spot is heated, the temperature field on the welding spot can be relatively uniform, and when the welding spot is uneven or has a welding seam and a hole, the temperature field on the heated welding spot can be uneven, so whether the welding spot has the welding defect or not can be judged by detecting whether the temperature field on the welding spot is even or not.
The processor 40' is further configured to detect whether the welding spot has a welding defect according to the determination result.
It can be understood that when the sample temperature difference is not greater than the preset temperature difference threshold, the non-uniformity degree of the dynamic temperature field on the welding spot is in the qualified range, the temperature field is relatively uniform, and it is determined that the welding spot has no welding defect.
It can be understood that when the sample temperature difference is greater than the preset temperature difference threshold value, the non-uniformity degree of the dynamic temperature field on the welding spot is not within the qualified range, and is a non-uniform temperature field, and the non-uniformity is caused by the welding defect of the welding spot, so that the welding spot is judged to have the welding defect.
Further, the processor 40' is further configured to calculate a target difference value according to the sample temperature difference and a preset temperature difference threshold; the processor 40' is further configured to determine a welding defect degree of the welding spot according to the target difference.
It can be understood that when the welding spot has welding defects, the target difference value is calculated according to the sample temperature difference and the preset temperature difference threshold value, the welding defect grade corresponding to the target difference value is searched, and the welding defect degree of the welding spot can be determined according to the welding defect grade.
It should be understood that the principle of determining the welding defect degree according to the welding defect grade corresponding to the target difference value is that, when the welding defect degree is larger, the dynamic temperature field on the welding spot is more uneven, that is, the uneven degree of the sample temperature field is larger, and further the target difference value is larger.
According to the scheme provided by the embodiment, a plurality of sample points are selected from the temperature field image, the sample temperature of each sample point is obtained, the sample temperature difference of each sample point is calculated according to the sample temperature, whether the sample temperature difference is larger than a preset temperature difference threshold value or not is judged, whether the welding spot has the welding defect or not is detected according to the judgment result, the non-uniformity degree of the dynamic temperature field on the welding spot is reflected according to the sample temperature difference, and the non-uniformity degree is compared with the preset temperature difference threshold value to judge whether the welding spot has the welding defect or not.
Referring to fig. 11, the present invention provides a welding defect detection method, wherein the welding defect detection method is based on a welding defect detection system, and the welding defect detection system comprises: the method comprises the following steps of (1) a high-frequency power generator, an induction coil, an infrared image sensor and a processor, wherein the induction coil is sleeved outside a to-be-detected hemming welding joint, and the welding defect detection method comprises the following steps:
step S10, the high frequency power generator generates a high frequency current and transmits the high frequency current to the induction coil.
It should be noted that the to-be-detected crimping welding joint is a small-sized crimping welding joint, the induction ring is sleeved outside the to-be-detected crimping welding joint, and the to-be-detected crimping welding joint can be heated by the high-frequency power generator and the induction coil by using an electromagnetic induction heating method.
It is understood that the high frequency power generator can generate a high frequency current, which is a high frequency alternating current.
In a specific implementation, as shown in fig. 2, 3, fig. 2 is a front view of a workpiece to be welded, and fig. 3 is a top view of the workpiece to be welded, wherein the first workpiece 101 and the second workpiece 102 are a pair of workpieces to be welded in the form of hems.
In a specific implementation, as shown in fig. 4 and 5, fig. 4 is a front view of a to-be-detected hemming welded joint after welding a to-be-welded workpiece, and fig. 5 is a top view of the to-be-detected hemming welded joint after welding the to-be-welded workpiece, where a welding spot 201 is a fusion spot and a welding spot formed after welding, and a certain welding defect may exist in the welding spot 201, and therefore, it is required to detect the welding defect, and a main object of the present invention is to detect whether the welding spot 201 has the welding defect.
And step S20, the induction coil heats the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and a dynamic temperature field is generated on the welding spots.
It can be understood that the induction coil inductively heats the welding spots of the to-be-detected hemming welding joint and the to-be-detected welding joint according to the high-frequency current, so that the temperature on the welding spots is increased, and a dynamic temperature field is generated.
In a specific implementation, as shown in fig. 6, 7, and 8, fig. 6 is a front view of a welding defect detecting system structure, fig. 7 is a side view of the welding defect detecting system structure, fig. 8 is a top view of the welding defect detecting system structure, wherein a first workpiece 101 and a second workpiece 102 are welded together by a welding spot 201, and in order to detect a temperature field of the welding spot 201, an induction coil 301 is used to perform induction heating, a high-frequency power generator 401 outputs a high-frequency current I1 with a frequency of 100KHz or more, a high-frequency current I1 flows through the induction coil 301, and generates an induction current I2 in the first workpiece 101, the second workpiece 102, and the welding spot 201, the induction current I2 is also called an eddy current, the eddy current is a distribution parameter, and the eddy current heats the first workpiece 101, the second workpiece 102, and the welding spot 201 to raise a surface temperature of the welding spot 201 to generate a dynamic temperature field, the infrared image sensor 501 detects the dynamic temperature field, a temperature field image can be obtained.
It will be appreciated that the crimp weld to be tested comprises a first workpiece and a second workpiece.
And step S30, the infrared image sensor detects the dynamic temperature field, obtains a temperature field image, and transmits the temperature field image to the processor.
It can be understood that the infrared image sensor detects a dynamic temperature field on the welding spot to obtain a temperature field image, and the temperature field image is the temperature field image on the welding spot and is transmitted to the processor, so that the processor judges whether the welding spot has a welding defect according to the temperature field image.
And step S40, the processor detects whether the welding spot has welding defects according to the temperature field image.
It should be understood that the processor can judge whether the temperature field on the welding spot is uniform or not according to the temperature field image, and when the temperature field is not uniform, the welding spot can be judged to have welding defects, and the temperature field image is further processed to detect the degree of the welding defects.
In the embodiment, by adopting the scheme, the high-frequency power generator generates high-frequency current and transmits the high-frequency current to the induction coil; the induction coil heats the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and a dynamic temperature field is generated on the welding spots; the infrared image sensor detects the dynamic temperature field to obtain a temperature field image, and transmits the temperature field image to the processor; and the processor detects whether the welding spot has welding defects according to the temperature field image. The high-frequency power generator and the induction coil are used for heating by adopting an electromagnetic induction heating method to generate a dynamic temperature field, and welding defects are detected according to the infrared image sensor, so that heating is more uniform, and the detection accuracy of the welding defects is improved.
Further, as shown in fig. 12, a second embodiment of the welding defect detecting method of the present invention is proposed based on the first embodiment, and in this embodiment, the step S20 includes:
step S201, the induction coil generates eddy currents in the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current.
It is understood that the induction coil generates an induction current, also called eddy current, in the crimp weld to be detected and in the weld spot of the crimp weld to be detected depending on the high-frequency current.
Step S202, the induction coil heats the to-be-detected hemming welding joint and the welding spot according to the eddy current, and a dynamic temperature field is generated on the welding spot.
It should be understood that the induction coil inductively heats the to-be-inspected hemmed weld joint and the weld spot according to the eddy current, so that the temperature of the weld spot is raised, and a dynamic temperature field is generated.
It can be understood that the high-frequency induction heating mode is used for heating the to-be-detected hemming welding joint and the welding spot, so that the heating problem of the small-size hemming welding seam is solved, the distribution uniformity of eddy currents in the welding spot is influenced due to the existence of the welding defect, the non-uniformity of the eddy current distribution can cause the non-uniformity of the heating effect, the non-uniformity of the surface temperature field of the welding spot is increased, the sensibility of the welding defect is further increased, and the sensitivity of the welding defect detection is improved.
According to the scheme provided by the embodiment, firstly, eddy currents are generated in the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, then the to-be-detected hemming welding joint and the welding spots are heated according to the eddy currents, and a dynamic temperature field is generated on the welding spots, so that the to-be-detected hemming welding joint and the welding spots are heated in a high-frequency induction heating mode, and the sensitivity of welding defect detection is improved.
Further, as shown in fig. 13, a third embodiment of the welding defect detecting method according to the present invention is proposed based on the first embodiment or the second embodiment, and in this embodiment, the description is made based on the first embodiment, and the step S40 includes:
step S401, the processor selects a plurality of sample points from the temperature field image, and obtains a sample temperature of each sample point.
It can be understood that, in order to determine whether the dynamic temperature field on the surface of the welding spot is uniform, a plurality of sample points may be selected from the temperature field image, and the manner of selecting the sample points may be random sampling or average sampling.
It should be understood that after selecting a plurality of sample points, the sample temperature for each sample point may be obtained from the temperature field image.
Step S402, the processor calculates the sample temperature difference of each sample point according to the sample temperature.
It can be understood that after the plurality of sample points and the sample temperature of each sample point are obtained, the sample temperature difference between the samples can be obtained by performing a plurality of calculations according to the sample temperatures, and whether the temperature field on the surface of the welding spot is uniform can be determined according to the sample temperature difference.
In step S403, the processor determines whether the sample temperature difference is greater than a preset temperature difference threshold.
It should be understood that the preset temperature difference threshold may be a threshold preset according to an actual situation, and by determining whether the sample temperature difference is greater than the preset temperature difference threshold, it may be determined whether the non-uniformity of the dynamic temperature field on the welding spot is within a qualified range, and then it may be determined whether the welding spot has a welding defect.
It should be understood that, whether the welding spot has the welding defect or not can be judged according to the uniformity of the dynamic temperature field on the welding spot because, when the welding spot has no welding defect, the heat conduction performance of the welding spot can be relatively uniform, so after the welding spot is heated, the temperature field on the welding spot can be relatively uniform, and when the welding spot is uneven or has a welding seam and a hole, the temperature field on the heated welding spot can be uneven, so whether the welding spot has the welding defect or not can be judged by detecting whether the temperature field on the welding spot is even or not.
And S404, detecting whether the welding spot has welding defects or not by the processor according to the judgment result.
It can be understood that when the sample temperature difference is not greater than the preset temperature difference threshold, the non-uniformity degree of the dynamic temperature field on the welding spot is in the qualified range, the temperature field is relatively uniform, and it is determined that the welding spot has no welding defect.
It can be understood that when the sample temperature difference is greater than the preset temperature difference threshold value, the non-uniformity degree of the dynamic temperature field on the welding spot is not within the qualified range, and is a non-uniform temperature field, and the non-uniformity is caused by the welding defect of the welding spot, so that the welding spot is judged to have the welding defect.
Further, after the step S404, the method further includes:
when the welding spot has a welding defect, the processor calculates a target difference value according to the sample temperature difference and a preset temperature difference threshold value; and the processor determines the welding defect degree of the welding spot according to the target difference value.
It can be understood that when the welding spot has welding defects, the target difference value is calculated according to the sample temperature difference and the preset temperature difference threshold value, the welding defect grade corresponding to the target difference value is searched, and the welding defect degree of the welding spot can be determined according to the welding defect grade.
It should be understood that the principle of determining the welding defect degree according to the welding defect grade corresponding to the target difference value is that, when the welding defect degree is larger, the dynamic temperature field on the welding spot is more uneven, that is, the uneven degree of the sample temperature field is larger, and further the target difference value is larger.
According to the scheme provided by the embodiment, a plurality of sample points are selected from the temperature field image, the sample temperature of each sample point is obtained, the sample temperature difference of each sample point is calculated according to the sample temperature, whether the sample temperature difference is larger than a preset temperature difference threshold value or not is judged, whether the welding spot has the welding defect or not is detected according to the judgment result, the non-uniformity degree of the dynamic temperature field on the welding spot is reflected according to the sample temperature difference, and the non-uniformity degree is compared with the preset temperature difference threshold value to judge whether the welding spot has the welding defect or not.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.
The above-mentioned serial numbers of the embodiments of the present invention are merely for description and do not represent the merits of the embodiments.
Through the above description of the embodiments, those skilled in the art will clearly understand that the method of the above embodiments can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware, but in many cases, the former is a better implementation manner. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a computer-readable storage medium (such as ROM/RAM, magnetic disk, optical disk) as described above, and includes several instructions for enabling an intelligent terminal (which may be a mobile phone, a computer, a terminal, an air conditioner, or a network terminal) to execute the method according to the embodiments of the present invention.
The above description is only a preferred embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes, which are made by using the contents of the present specification and the accompanying drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. A welding defect detection system, comprising: the device comprises a high-frequency power generator, an induction coil, an infrared image sensor and a processor, wherein the induction coil is sleeved outside a to-be-detected crimping welding joint;
the high-frequency power supply generator is used for generating high-frequency current and transmitting the high-frequency current to the induction coil;
the induction coil is used for heating the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and generating a dynamic temperature field on the welding spots;
the infrared image sensor is used for detecting the dynamic temperature field, acquiring a temperature field image and transmitting the temperature field image to the processor;
and the processor is used for detecting whether the welding spot has welding defects according to the temperature field image.
2. The welding defect detection system of claim 1, wherein the induction coil is further configured to generate eddy currents in the weld points of the to-be-detected crimp weld joint and the to-be-detected crimp weld joint according to the high frequency current;
the induction coil is further used for heating the to-be-detected hemming welding joint and the welding spot according to the eddy current, and a dynamic temperature field is generated on the welding spot.
3. The weld defect detection system of claim 1, wherein the processor is further configured to select a plurality of sample points from the temperature field image and obtain a sample temperature for each sample point;
the processor is further used for calculating the sample temperature difference of each sample point according to the sample temperature;
the processor is further used for judging whether the temperature difference of the sample is larger than a preset temperature difference threshold value;
and the processor is also used for detecting whether the welding spot has welding defects according to the judgment result.
4. The welding defect detection system of claim 3, wherein the processor is further configured to determine that the weld spot is free of a welding defect when the sample temperature difference is not greater than the preset temperature difference threshold;
the processor is further used for judging that the welding spot has welding defects when the sample temperature difference is larger than the preset temperature difference threshold value.
5. The welding defect detection system of claim 3, wherein the processor is further configured to calculate a target difference value based on the sample temperature difference and a preset temperature difference threshold when the weld spot has a welding defect;
and the processor is also used for determining the welding defect degree of the welding spot according to the target difference value.
6. A welding defect detection method, wherein the welding defect detection method is based on a welding defect detection system, the welding defect detection system comprising: the method comprises the following steps of (1) a high-frequency power generator, an induction coil, an infrared image sensor and a processor, wherein the induction coil is sleeved outside a to-be-detected hemming welding joint, and the welding defect detection method comprises the following steps:
the high-frequency power supply generator generates high-frequency current and transmits the high-frequency current to the induction coil;
the induction coil heats the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current, and a dynamic temperature field is generated on the welding spots;
the infrared image sensor detects the dynamic temperature field to obtain a temperature field image, and transmits the temperature field image to the processor;
and the processor detects whether the welding spot has welding defects according to the temperature field image.
7. The welding defect detection method according to claim 6, wherein the induction coil heats the welding spot of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high frequency current, and generates a dynamic temperature field on the welding spot, and specifically comprises:
the induction coil generates eddy currents in the welding spots of the to-be-detected hemming welding joint and the to-be-detected hemming welding joint according to the high-frequency current;
and the induction coil heats the to-be-detected hemming welding joint and the welding spot according to the eddy current, and a dynamic temperature field is generated on the welding spot.
8. The welding defect detection method of claim 6, wherein the processor detects whether the welding spot has a welding defect according to the temperature field image, and specifically comprises:
the processor selects a plurality of sample points from the temperature field image and obtains the sample temperature of each sample point;
the processor calculates the sample temperature difference of each sample point according to the sample temperature;
the processor judges whether the temperature difference of the sample is larger than a preset temperature difference threshold value or not;
and the processor detects whether the welding spot has welding defects according to the judgment result.
9. The welding defect detection method of claim 8, wherein the processor detects whether the welding spot has the welding defect according to the judgment result, and specifically comprises:
when the sample temperature difference is not larger than the preset temperature difference threshold value, the processor judges that the welding spot has no welding defect;
and when the temperature difference of the sample is greater than the preset temperature difference threshold value, the processor judges that the welding spot has welding defects.
10. The welding defect detecting method of claim 8, wherein after the processor detects whether the welding spot has the welding defect according to the determination result, the method further comprises:
when the welding spot has a welding defect, the processor calculates a target difference value according to the sample temperature difference and a preset temperature difference threshold value;
and the processor determines the welding defect degree of the welding spot according to the target difference value.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111796174A (en) * | 2020-09-09 | 2020-10-20 | 国网山东省电力公司高密市供电公司 | Detection device for high-voltage cable head |
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Inventor after: Qiu Guang Inventor after: Jiang Ming Inventor after: Geng Zheng Inventor after: Wang Wei Inventor after: Li Yangchao Inventor before: Qiu Guang Inventor before: Geng Zheng Inventor before: Wang Wei Inventor before: Jiang Ming Inventor before: Li Yangchao |
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