CN111627013B - Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse - Google Patents
Method for detecting arc length in additive manufacturing of non-consumable electrode gas protection arc fuse Download PDFInfo
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Abstract
The invention discloses a method for detecting the arc length of additive manufacturing of a non-consumable electrode gas-shielded arc fuse. The method comprises the following steps: installing an industrial camera, adjusting an aperture until the pixel gray value of the whole arc area is 255, fixing the aperture, and collecting an image at the current moment; recording the coordinates of the tip of the tungsten electrode, dividing an image into two parts by taking the column of the tip of the tungsten electrode as a symmetry axis, selecting the part containing the tail of a molten pool for image processing, finally determining the coordinates of a point on the electric arc in the region farthest from the column of the tip of the tungsten electrode by sequentially adopting a domain average method, an edge detection method, a maximum variance threshold segmentation method, a difference coefficient method and a least square method, and calculating the difference between the row coordinates of the point and the row coordinates of the tip of the tungsten electrode so as to represent the arc length of the electric arc; the method effectively solves the problem of the additive manufacturing arc length detection of the non-consumable electrode gas-shielded arc fuse, and has the advantages of visual and accurate detection process, no interference of electric signals, small process detection hysteresis and easy realization of automation.
Description
Technical Field
The invention belongs to the technical field of electric arc filler wire additive manufacturing, and particularly relates to a method for detecting the arc length of additive manufacturing of a non-consumable electrode gas-shielded electric arc fuse wire.
Background
The additive manufacturing of the non-consumable electrode gas protection arc fuse wire is an advanced manufacturing technology which takes tungsten electrode argon arc or plasma arc as a heat source and metal wires as filling materials and is stacked layer by layer according to a set path to finally form a full-weld metal component. The technology has the advantages of small heat input, high forming precision, capability of realizing independent control of electric arcs and filling wires and the like, and is widely applied to the fields of aerospace, national defense and military industry, medical instruments, energy power and other top struts.
In the additive manufacturing process of the non-consumable electrode gas protection arc fuse, the actual forming height of the metal component is difficult to keep consistent with the preset layer height when one layer is stacked. If the actual forming height of the metal component is smaller than the preset layer height, the distance from the tip of the tungsten electrode to the surface of the metal component is increased, namely the arc length of the electric arc is too long, the electric arc is easy to drift, and molten drops cannot be smoothly transferred to a molten pool; if the actual forming height of the metal component is larger than the preset layer height, the distance from the tip of the tungsten electrode to the surface of the metal component is reduced, namely the arc length of the electric arc is too short, the tungsten is easy to collide with the accumulation layer, the tungsten electrode is damaged, and the tungsten is clamped by the molten pool. In order to improve the additive manufacturing forming quality of the non-consumable electrode gas-shielded arc fuse, the additive manufacturing arc length of the non-consumable electrode gas-shielded arc fuse is required to be detected. At present, relatively few researches on the method for detecting the additive manufacturing arc length of the non-consumable electrode gas protection arc fuse are conducted at home and abroad. Therefore, it is necessary to provide a method for detecting the additive manufacturing arc length of the non-consumable electrode gas-shielded arc fuse.
Chinese patent application No.: 201610940496.X entitled "arc voltage feedback-based GTAW additive manufacturing process stability detection method" proposes a method for detecting GTAW additive manufacturing process stability using arc voltage feedback, the method comprising the following specific steps: and obtaining a change signal of the arc voltage along a forming path in the GTAW additive manufacturing process by using a voltage sensor and a data acquisition card, indirectly feeding back the arc length by using the arc voltage, and judging that the forming process is stable if the arc length of the arc is within a certain range. However, the method described in chinese patent application No. 201610940496.X is susceptible to interference of electric signals of a welding power supply and equipment, and the arc voltage fluctuation is large, and a series of filtering operations are required to extract an effective signal, which is very complicated.
An expert scholars detects the distance from the upper surface of the tail part of a molten pool to the tip of a tungsten electrode by using a visual sensing device to represent the arc length, but the method has certain detection hysteresis, so that a novel method for detecting the arc length of the additive manufacturing of the non-consumable electrode gas protection arc fuse is needed.
Disclosure of Invention
The invention aims to solve the problem of poor forming quality caused by arc length fluctuation in the additive manufacturing process of a non-consumable electrode gas-shielded arc fuse, and provides a method for detecting the arc length of the additive manufacturing process of the non-consumable electrode gas-shielded arc fuse.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a method for detecting the arc length of additive manufacturing of a non-consumable electrode gas protection arc fuse wire comprises the following steps:
the method comprises the following steps: installing an industrial camera on a non-consumable electrode gas shielded welding gun by using a clamp, so that the industrial camera is opposite to a tungsten electrode, and the plane of a lens of the industrial camera is parallel to the plane formed by the axis of the non-consumable electrode gas shielded welding gun and a stacking path;
step two: starting an industrial camera, collecting and storing an image of the tungsten electrode tip, determining a position point P (M, N) of the tungsten electrode tip in the image, wherein M is a row coordinate, N is a column coordinate, calibrating the image, and marking a calibration scale factor as l;
step three: installing a filtering system at the front end of the industrial camera, adjusting a non-consumable electrode gas protection welding gun to be above a substrate, starting a non-consumable electrode gas protection power supply, igniting an electric arc, continuously acquiring an electric arc image, adjusting an aperture of the industrial camera to adjust the pixel gray value of the whole electric arc area to 255, fixing the aperture, and processing a sampling image at the current moment;
step four: taking the Nth column where the tungsten electrode tip point P is located as a symmetry axis, dividing an image into two parts, defining a part containing the tail of a molten pool as an area A, developing an image processing algorithm, and extracting a row coordinate K of a point Q which is farthest from the Nth column on an electric arc in the area A, wherein the specific steps are as follows:
(1) smoothing and denoising the image in the area A by adopting a domain averaging method;
(2) processing the image of the area A by adopting an edge detection operator;
(3) processing the image in the area A by adopting a maximum variance threshold segmentation method;
(4) traversing horizontally in the area A by taking the point P (M, N) as a starting point, stopping traversing and storing a pixel G when traversing to a pixel with the gray value of 2551(x1,y1) Wherein x is1Is the line coordinate, y1Is a column coordinate; traversing horizontally in the area A by taking (M +1, N) as a starting point, stopping traversing and storing a pixel G when a pixel with a gray value of 255 is traversed2(x2,y2) (ii) a Repeating the steps until the pixel point G at the junction of the electric arc and the molten poole(xe,ye) Storing until the storage is finished;
(5) for pixel point G1(x1,y1)，G2(x2,y2)，……，Ge(xe,ye) Processing is carried out, s pixel points are taken at intervals of q pixel points every time, the value range of q is 2-4, and the value range of s is 18-25; calculating the difference coefficient CV of the row coordinates of the 1 st to s th pixel points1Calculating the difference coefficient CV of the row coordinates of the (1+ q) th to (s + q) th pixel points2Calculating the difference coefficient CV of the row coordinates of the (1+2q) th to (s +2q) th pixel points3… … calculating the difference coefficient CV of the column coordinates of the (1+ wq) th to (s + wq) th pixel points(w+1)To therein, wherein
Wherein the content of the first and second substances,
represents a rounded up symbol;
the coefficient of difference is expressed as
Wherein s is the number of pixel points, yiIs the arc edge pixel point column coordinate, and y is the average value of the arc edge pixel point column coordinate;
the reason why the value range of q is set to 2-4 is as follows: if q is too small, the difference coefficient CV which needs to be calculated is too much, the program running time is too long, and the real-time detection effect of the arc length of the electric arc is poor; if Q is too large, a part far away from the Nth row on the arc is likely to be missed, and the result of a point Q on the arc far away from the Nth row is inaccurate, so that the value range of Q in the text is 2-4;
the reason why the value range of s is set to 18 to 25 is as follows: if s is too small, when a part far away from the Nth column on the arc is detected, the part cannot be completely included, and finally the result is inaccurate; if s is too large, the pixel point covers the arc edge inflection point part, so that the subsequent fitting effect is poor, and the value range of s in the text is 18-25.
(6) Comparing the w +1 difference coefficients, determining S pixel points with the minimum difference coefficient, fitting the row coordinates and the column coordinates of the S pixel points by adopting a least square method, marking as a curve S, and determining the row coordinate K of a point Q which is farthest from the Nth column on the curve S;
(7) arc length H ═ l (K-M);
step five: after the first layer is stacked, the non-consumable electrode gas shielded welding gun is lifted by a preset layer height;
step six: and repeating the fourth step and the fifth step until the stacking is finished.
Preferably, the axis of the industrial camera in the first step is 5-7 mm lower than the tip of the tungsten electrode.
As a preferred mode, the image calibration in the step two specifically comprises the following steps: a steel ruler is vertically placed on the side of a tungsten electrode and is superposed with a plane formed by the axis of a non-consumable electrode gas shielded welding gun and a stacking path, the pixel occupied by the tungsten electrode in an image and the actual length of the tungsten electrode are recorded, the calculation formula is that L is L/c, L is a scaling scale factor and has the unit of millimeter/pixel, L is the actual length of the tungsten electrode and has the unit of millimeter, and c is the number of pixels occupied by the tungsten electrode in the image.
Preferably, the filtering system in the third step comprises a narrow-band filter with the center wavelength of 650nm, a dimmer and a glass sheet.
Preferably, the non-consumable electrode gas-shielded arc power supply in the third step comprises a plasma arc power supply and a tungsten electrode argon arc power supply.
Preferably, the edge detection operator in step four comprises a Robert operator or a Prewitt operator.
The invention has the beneficial effects that: the invention adopts a visual sensing method, the pixel gray value of the whole arc area is adjusted to 255, the point which is the farthest from the tungsten electrode tip on the tungsten electrode tip and the arc edge is extracted, and the difference of two-point row coordinates is used for representing the arc length of the arc. The invention effectively solves the problem of poor forming quality caused by arc length fluctuation in the additive manufacturing process of the non-consumable electrode gas-shielded arc fuse wire, and provides the method for detecting the arc length of the additive manufacturing process of the non-consumable electrode gas-shielded arc fuse wire. Compared with the prior art, the method is not interfered by the electric signal of the equipment, the arc length detection process is visual and accurate, the hysteresis is small, and a solid foundation is laid for the real-time control of the arc length in the subsequent additive manufacturing of the non-consumable electrode gas-shielded arc fuse.
Drawings
FIG. 1 is a flow chart of non-consumable electrode gas shielded arc fuse additive manufacturing arc length detection image processing;
FIG. 2 is a schematic diagram of a non-consumable gas shielded arc fuse additive manufacturing arc length detection system;
FIG. 3 is an arc image acquired by an industrial camera with pixel gray scale values adjusted to 255 throughout the arc region;
FIG. 4 is an image after domain averaging processing;
FIG. 5 is an image after processing by an edge detection operator;
FIG. 6 is an image after maximum variance thresholding;
fig. 7 is an image after the difference coefficient method and the least square method are processed.
Fig. 8 is a partially enlarged image after the difference coefficient method and the least square method processing.
In the figure, 1-non-consumable electrode gas shielded welding gun, 2-wire feeding system, 3-tungsten electrode, 4-electric arc, 5-accumulation layer, 6-molten pool, 7-substrate, 8-optical filtering system, 9-clamp and 10-industrial camera.
Detailed Description
The specific test platform of this embodiment: the GTA wire filling additive manufacturing power supply is Magicwave3000JobG/F, the robot is a MOTOMAN-MA2010 robot produced by YASKAWA company of Japan, a GTA welding gun is fixed at the end part and is provided with a teaching programmer, a DX200 robot control cabinet and an industrial camera; 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 150mm multiplied by 80mm multiplied by 4 mm. The technological parameters for the test are as follows: the current is 140A, the walking speed is 3.3mm/s, the wire feeding speed is 2m/min, pure argon is used as protective gas, and the gas flow is 15L/min.
FIG. 1 shows a flow chart of image processing for additive manufacturing arc length detection of a non-consumable electrode gas-shielded arc fuse, and the method for detecting the additive manufacturing arc length of the non-consumable electrode gas-shielded arc fuse comprises the following steps
The method comprises the following steps: the schematic diagram of a non-consumable electrode gas-shielded arc fuse additive manufacturing arc length detection system is shown in fig. 2, an industrial camera is mounted on a non-consumable electrode gas-shielded welding gun by using a clamp, the industrial camera moves along with the non-consumable electrode gas-shielded welding gun, the industrial camera is opposite to a tungsten electrode, and the plane where the lens of the industrial camera is located is parallel to the plane formed by the axis of the non-consumable electrode gas-shielded welding gun and a stacking path; the axis of the industrial camera is 5-7 mm lower than the tip of the tungsten electrode.
Step two: starting an industrial camera, collecting and storing an image of the tungsten electrode tip, determining a position point P (M, N) of the tungsten electrode tip in the image, wherein M is a row coordinate, N is a column coordinate, calibrating the image, and marking a calibration scale factor as l;
the specific process of image calibration is as follows: a steel ruler is vertically placed on the side of a tungsten electrode and is superposed with a plane formed by the axis of a non-consumable electrode gas shielded welding gun and a stacking path, the pixel occupied by the tungsten electrode in an image and the actual length of the tungsten electrode are recorded, the calculation formula is that L is L/c, L is a scaling scale factor and has the unit of millimeter/pixel, L is the actual length of the tungsten electrode and has the unit of millimeter, and c is the number of pixels occupied by the tungsten electrode in the image.
Step three: a light filtering system is arranged at the front end of the industrial camera, and comprises a narrow-band filter with the center wavelength of 650nm, a dimmer and a glass sheet. Adjusting the non-consumable electrode gas protection welding gun above the substrate, and starting a non-consumable electrode gas protection electric arc power supply, wherein the non-consumable electrode gas protection electric arc power supply comprises a plasma arc power supply and a tungsten electrode argon arc power supply. Igniting the arc, continuously acquiring arc images, adjusting the aperture of the industrial camera to adjust the pixel gray value of the whole arc area to 255, fixing the aperture as shown in fig. 3, and processing the current sampling image;
step four: taking the Nth column where the tungsten electrode tip point P is located as a symmetry axis, dividing an image into two parts, defining a part containing the tail of a molten pool as an area A, developing an image processing algorithm, and extracting a row coordinate K of a point Q which is farthest from the Nth column on an electric arc in the area A, wherein the specific steps are as follows:
(1) smoothing and denoising the image in the area A by adopting a domain average method, wherein the processed image is shown in FIG. 4;
(2) processing the image in the area A by adopting an edge detection operator, wherein the edge detection operator comprises a Robert operator or a Prewitt operator, and the processed image is shown in FIG. 5;
(3) processing the image in the area A by adopting a maximum variance threshold segmentation method, wherein the processed image is shown in FIG. 6;
(4) traversing horizontally in the area A by taking the point P (M, N) as a starting point, stopping traversing and storing a pixel G when traversing to a pixel with the gray value of 2551(x1,y1) Wherein x is1Is the line coordinate, y1Is a column coordinate; traversing horizontally in the area A by taking (M +1, N) as a starting point, stopping traversing and storing a pixel G when a pixel with a gray value of 255 is traversed2(x2,y2) (ii) a Repeating the steps until the pixel point G at the junction of the electric arc and the molten poole(xe,ye) Storing until the storage is finished;
(5) for pixel point G1(x1,y1)，G2(x2,y2)，……，Ge(xe,ye) Processing is carried out, s pixel points are taken at intervals of q pixel points every time, the value range of q is 2-4, and the value range of s is 18-25; calculating the difference coefficient CV of the row coordinates of the 1 st to s th pixel points1Calculating the difference coefficient CV of the row coordinates of the (1+ q) th to (s + q) th pixel points2Calculating the difference coefficient CV of the row coordinates of the (1+2q) th to (s +2q) th pixel points3… … calculating the difference coefficient of the column coordinates of the (1+ wq) - (s + wq) th pixel pointsCV(w+1)To therein, wherein
Wherein the content of the first and second substances,
represents a rounded up symbol;
the coefficient of difference is expressed as
Wherein s is the number of pixel points, yiIs the arc edge pixel point column coordinate, and y is the average value of the arc edge pixel point column coordinate;
(6) comparing the w +1 difference coefficients, determining S pixel points with the minimum difference coefficient, fitting the row coordinates and the column coordinates of the S pixel points by adopting a least square method, marking as a curve S, determining the row coordinate K of a point Q which is farthest from the Nth column on the curve S, and obtaining a processed image as shown in FIG. 7;
(7) arc length H ═ l (K-M);
step five: after the first layer is stacked, the non-consumable electrode gas shielded welding gun is lifted by a preset layer height;
step six: and repeating the fourth step and the fifth step until the stacking is finished.
While the present invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (6)
1. A method for detecting the arc length of additive manufacturing of a non-consumable electrode gas protection arc fuse is characterized by comprising the following steps:
the method comprises the following steps: installing an industrial camera on a non-consumable electrode gas shielded welding gun by using a clamp, so that the industrial camera is opposite to a tungsten electrode, and the plane of a lens of the industrial camera is parallel to the plane formed by the axis of the non-consumable electrode gas shielded welding gun and a stacking path;
step two: starting an industrial camera, collecting and storing an image of the tungsten electrode tip, determining a position point P (M, N) of the tungsten electrode tip in the image, wherein M is a row coordinate, N is a column coordinate, calibrating the image, and marking a calibration scale factor as l;
step three: installing a filtering system at the front end of the industrial camera, adjusting a non-consumable electrode gas protection welding gun to be above a substrate, starting a non-consumable electrode gas protection power supply, igniting an electric arc, continuously acquiring an electric arc image, adjusting an aperture of the industrial camera to adjust the pixel gray value of the whole electric arc area to 255, fixing the aperture, and processing a sampling image at the current moment;
step four: taking the Nth column where the tungsten electrode tip point P is located as a symmetry axis, dividing an image into two parts, defining a part containing the tail of a molten pool as an area A, developing an image processing algorithm, and extracting a row coordinate K of a point Q which is farthest from the Nth column on an electric arc in the area A, wherein the specific steps are as follows:
(1) smoothing and denoising the image in the area A by adopting a domain averaging method;
(2) processing the image of the area A by adopting an edge detection operator;
(3) processing the image in the area A by adopting a maximum variance threshold segmentation method;
(4) traversing horizontally in the area A by taking the point P (M, N) as a starting point, stopping traversing and storing a pixel G when traversing to a pixel with the gray value of 2551(x1,y1) Wherein x is1Is the line coordinate, y1Is a column coordinate; traversing horizontally in the area A by taking (M +1, N) as a starting point, stopping traversing and storing a pixel G when a pixel with a gray value of 255 is traversed2(x2,y2) (ii) a Repeating the steps until the pixel point G at the junction of the electric arc and the molten poole(xe,ye) Storing until the storage is finished;
(5) for pixel point G1(x1,y1)，G2(x2,y2)，……，Ge(xe,ye) Processing is carried out, s pixel points are taken at intervals of q pixel points every time, the value range of q is 2-4, and the value range of s is 18-25; calculating the difference coefficient CV of the row coordinates of the 1 st to s th pixel points1Calculating the difference coefficient CV of the row coordinates of the (1+ q) th to (s + q) th pixel points2Calculating the difference coefficient CV of the row coordinates of the (1+2q) th to (s +2q) th pixel points3… … calculating the difference coefficient CV of the column coordinates of the (1+ wq) th to (s + wq) th pixel points(w+1)To therein, wherein
Wherein the content of the first and second substances,
represents a rounded up symbol;
the coefficient of difference is expressed as
Wherein s is the number of pixel points, yiIs the arc edge pixel point column coordinate, and y is the average value of the arc edge pixel point column coordinate;
(6) comparing the w +1 difference coefficients, determining S pixel points with the minimum difference coefficient, fitting the row coordinates and the column coordinates of the S pixel points by adopting a least square method, marking as a curve S, and determining the row coordinate K of a point Q which is farthest from the Nth column on the curve S;
(7) arc length H ═ l (K-M);
step five: after the first layer is stacked, the non-consumable electrode gas shielded welding gun is lifted by a preset layer height;
step six: and repeating the fourth step and the fifth step until the stacking is finished.
2. The method of claim 1, wherein in step one, the axis of the industrial camera is 5-7 mm below the tip of the tungsten electrode.
3. The method for detecting the arc length of the additive manufacturing of the non-consumable electrode gas-shielded arc fuse according to claim 1, wherein the image calibration in the second step comprises the following specific steps: a steel ruler is vertically placed on the side of a tungsten electrode and is superposed with a plane formed by the axis of a non-consumable electrode gas shielded welding gun and a stacking path, the pixel occupied by the tungsten electrode in an image and the actual length of the tungsten electrode are recorded, the calculation formula is that L is L/c, L is a scaling scale factor and has the unit of millimeter/pixel, L is the actual length of the tungsten electrode and has the unit of millimeter, and c is the number of pixels occupied by the tungsten electrode in the image.
4. The method of claim 1, wherein the filter system comprises a narrowband filter with a center wavelength of 650nm, a dimmer, and a glass plate.
5. The method of claim 1, wherein the third step comprises a non-consumable electrode gas-shielded arc power supply including a plasma arc power supply and a tungsten argon arc power supply.
6. The method of claim 1, wherein the step four edge detection operator comprises a Robert operator or a Prewitt operator.
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| CN106735738A (en) * | 2016-12-30 | 2017-05-31 | 华南理工大学 | A kind of deeply molten TIG welderings arc length detecting and controlling system of lockhole |
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