CN112059388A - Method and device for monitoring welding quality of bimetal band saw blade - Google Patents
Method and device for monitoring welding quality of bimetal band saw blade Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 163
- 238000000034 method Methods 0.000 title claims abstract description 32
- 238000012544 monitoring process Methods 0.000 title claims abstract description 32
- 230000035515 penetration Effects 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims description 27
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 26
- 229910052802 copper Inorganic materials 0.000 claims description 26
- 239000010949 copper Substances 0.000 claims description 26
- 238000001514 detection method Methods 0.000 claims description 24
- 238000006073 displacement reaction Methods 0.000 claims description 11
- 230000004927 fusion Effects 0.000 claims description 9
- 238000012806 monitoring device Methods 0.000 claims description 4
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 9
- 229910052750 molybdenum Inorganic materials 0.000 description 9
- 239000011733 molybdenum Substances 0.000 description 9
- 238000005520 cutting process Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 229910000679 solder Inorganic materials 0.000 description 2
- 229910000997 High-speed steel Inorganic materials 0.000 description 1
- 229910000639 Spring steel Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 238000007405 data analysis Methods 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/002—Resistance welding; Severing by resistance heating specially adapted for particular articles or work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D65/00—Making tools for sawing machines or sawing devices for use in cutting any kind of material
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
- B23K11/256—Monitoring devices using digital means the measured parameter being the inter-electrode electrical resistance
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
- B23K11/257—Monitoring devices using digital means the measured parameter being an electrical current
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
- B23K11/252—Monitoring devices using digital means
- B23K11/258—Monitoring devices using digital means the measured parameter being a voltage
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
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Abstract
The invention discloses a method for monitoring the welding quality of a bimetal band saw blade, which comprises the following steps: s1, acquiring a top view image and a side view image of the welding joint; s2, acquiring L1 and L2 from an overhead view image of the welded joint, and calculating the difference delta L between L1 and L2; acquiring theta 1 and theta 2 from a side view image of the welding joint, and calculating a difference delta theta of the theta 1 and the theta 2; and S3, judging whether the quality of the welding joint is qualified according to the delta L and the delta theta. Due to the adoption of the technical scheme, compared with the prior art, the centering performance of the welding joint can be comprehensively detected from the vertical direction and the horizontal direction, so that the quality of the welding spot can be more accurately judged, and the reliability of the quality of the detected sawteeth is ensured; whether the welding quality meets the requirements or not is comprehensively judged through the dynamic resistance difference value of the welding electrode, the penetration data and the centering performance of the welding joint, and the accuracy of judging the quality of the welding spot and the reliability of the quality of the detected sawteeth are further improved.
Description
Technical Field
The invention relates to the field of welding quality detection, in particular to a method and a device for monitoring the welding quality of a bimetal band saw blade.
Background
The bimetallic band saw blade is a sawing industrial product with the characteristics of back toughness and tooth hardness, and is made by using high-performance materials such as high-hardness, high-wear-resistance and high-red-hardness high-speed steel or hard alloy as a tooth tip material and using low-alloy spring steel with excellent elasticity and toughness as a back material. The bimetal band saw blade as a blanking tool has the advantages of narrow cutting seam, high section precision, large cutting size, high sawing efficiency and the like, and is paid more and more attention recently, and the market share of the bimetal band saw blade is continuously expanded.
Because the manufacturing process of the tooth tip material is complex and the cost is high, the tooth tip block and the back material are generally welded to save the cost so as to achieve the effects of saving raw materials and reducing the production cost. The welding quality directly influences the performance of the bimetallic strip saw blade, if certain saw tooth is unqualified in welding quality, the problem of tooth broaching is caused, the whole saw band is scrapped in the actual cutting process, and the service life of the saw band is seriously influenced. At present, resistance spot welding is mainly used as a welding method of a bimetal band saw blade tooth tip material and a back material, so that quality detection of welding spots formed in the resistance spot welding process is very important. However, the duration of the entire process of resistance spot welding is very short, typically on the order of milliseconds, and the formation of the weld joint is not directly observable, which presents difficulties in determining the weld quality of the weld spot in real time.
At present, the method for detecting the welding quality of the bimetal band saw blade generally comprises the steps of cutting off the head and the tail of the band saw blade, carrying out destructive detection, and measuring the shearing strength of a welding spot, belongs to spot inspection, cannot reflect the welding condition of the whole band saw blade, has relatively complex influencing factors in the welding process, is easy to cause missed inspection, and forms economic loss. Moreover, the welding spot quality can not be accurately judged by manually observing the appearance of the welding spot by naked eyes, and a more scientific means is needed to ensure the welding quality. On the other hand, the method has low detection efficiency, cannot ensure the quality reliability of the saw teeth which are not detected, easily causes missing detection to cause unqualified quality of certain saw teeth, finally leads to scrapping of the whole saw belt and seriously influences the service life of the saw belt. Therefore, the online quality monitoring of the welding process of the resistance spot welding of the saw teeth of the bimetal band saw blade has important significance for ensuring the welding quality of the bimetal band saw blade.
Disclosure of Invention
In order to solve the problems that the welding point quality cannot be accurately judged by the existing detection method for the welding quality of the bimetal band saw blade in the background technology, and the quality reliability of undetected sawteeth cannot be ensured, the invention provides the method for monitoring the welding quality of the bimetal band saw blade, which comprehensively judges whether the welding quality meets the requirements or not by monitoring the dynamic resistance difference value of a welding electrode, and the penetration data and the centering performance of a welding joint.
A method for monitoring the welding quality of a bimetal band saw blade comprises the following steps:
s1, acquiring a top view image and a side view image of the welding joint;
s2, acquiring L1 and L2 from an overhead view image of the welded joint, and calculating the difference delta L between L1 and L2;
acquiring theta 1 and theta 2 from a side view image of the welding joint, and calculating a difference delta theta of the theta 1 and the theta 2; the L1 and the L2 are respectively the distance from the upper edge and the lower edge of the back material to the upper edge and the lower edge of the tooth top; the theta 1 and the theta 2 are respectively included angles between the central line of the backing material and the tooth tip side line;
and S3, judging whether the quality of the welding joint is qualified according to the delta L and the delta theta.
Methods for extracting L1, L2, theta 1 and theta 2 from the image are all existing methods, and reference can be made to 'high-precision industrial size measurement system research based on machine vision', Wangmiting, Qiyongfeng and the like, mechanical engineering and automation stage 6, and 12 months in 2013; workpiece image contour corner feature extraction algorithm, Liuchen, microwave, etc., school newspaper of Changchun industry university, volume 40, phase 5, month 10 in 2019.
The monitoring method can comprehensively detect the centering property of the welding joint from the vertical direction and the horizontal direction, thereby more accurately judging the quality of the welding spot and ensuring the reliability of the quality of the detected sawteeth. The vertical and horizontal centering performance is guaranteed, so that the welding joint is symmetrical relative to the back material tooth support, the tooth tip strength of the bimetal band saw blade after subsequent tooth milling is higher, and otherwise, the tooth breakage or tooth falling caused by uneven stress is easy to occur.
Preferably, in step S3, when both Δ L and Δ θ are smaller than the preset error range, the quality of the welded joint is determined to be qualified.
Preferably, in step S3, when Δ R, Δ X, Δ L, and Δ θ are all smaller than the preset error range, the quality of the welded joint is determined to be qualified; wherein, the delta R and the delta X are respectively a dynamic resistance difference value and a difference value of fusion depth data of a welding joint and standard fusion depth data.
The method comprehensively judges whether the welding quality meets the requirement or not by detecting the dynamic resistance difference value of the welding electrode and the penetration data and the centering performance of the welding joint, and only when the data are qualified, the welding quality of the welding joint is judged to be qualified, and factors influencing the welding quality are all in a feasible range.
Specifically, the method for obtaining the dynamic resistance difference value includes:
s31, acquiring a voltage value between the first copper electrode and the second copper electrode;
s32, acquiring the current value of the welding work loop;
s33, calculating according to the voltage value and the current value to obtain a dynamic resistance curve;
and S34, comparing the dynamic resistance curve with the standard dynamic resistance curve to obtain a dynamic resistance difference value.
Whether the penetration data is qualified or not is related to the voltage value between electrodes, the current value of a welding working loop and the neutrality. According to the monitoring result, if the neutrality is not a problem, but the penetration data is larger or smaller, the welding quality is not good due to the fact that the surface of the welded particle or the back material is dirty, the electrode is adhered or abraded after long-time working, the mechanical structure of the machine head is unstable and the like. At the moment, the measured voltage value and the measured current value can be processed to obtain a dynamic resistance curve, and whether the spatter occurs in the welding process is judged according to the dynamic resistance curve, so that the cause of the occurrence of the fault is eliminated. If the spatter appears, it indicates that the electrode is in trouble or the surface of the material is not clean; if no spatter is present, this is an indication that the mechanical structure of the head is unstable and the weld quality is unreliable.
Preferably, the method further comprises detecting whether the size of the weld heat affected zone is within an acceptable range.
Based on the same inventive concept, the invention also provides a device for monitoring the welding quality of the bimetal band saw blade, which is characterized in that: the device comprises a first shooting device, a second shooting device and a controller, wherein the first shooting device and the second shooting device are respectively connected with the controller; the first shooting device is positioned above the welding joint and used for acquiring an overlook image of the welding joint; the second shooting device is positioned on the side face of the welding joint and used for acquiring a side view image of the welding joint; the controller is used for acquiring L1 and L2 from a top view image of the welding joint, calculating a difference value delta L of L1 and L2, acquiring theta 1 and theta 2 from a side view image of the welding joint, calculating a difference value delta theta of the theta 1 and the theta 2, and judging whether the quality of the welding joint is qualified or not according to the delta L and the delta theta; the L1 and the L2 are respectively the distance from the upper edge and the lower edge of the back material to the upper edge and the lower edge of the tooth top; and the theta 1 and the theta 2 are respectively included angles between the central line of the back material and the tooth tip side line.
From this, obtain welding joint's overlook image and side view image through first camera and second camera to come the centering nature of comprehensive detection welding joint from two aspects of vertical direction and horizontal direction through the controller, thereby can judge the solder joint quality more accurately, guarantee to be detected the reliability of sawtooth quality.
Preferably, when both the Δ L and the Δ θ are smaller than the preset error range, the controller judges that the quality of the welding joint is qualified.
Preferably, the monitoring device further comprises:
one end of the first copper electrode is connected with one end of the power supply, and the other end of the first copper electrode is connected with the welding electrode;
one end of the second copper electrode is connected with the band saw blade, and the other end of the second copper electrode is connected with the other end of the power supply;
the detection end of the voltage sensor is respectively connected with the first copper electrode and the second copper electrode, and the voltage sensor is used for detecting the working voltage value between the two electrodes and sending the detection result to the controller;
the current sensor is arranged in a working loop of the welding electrode and used for detecting the working current value of the welding electrode and sending the detection result to the controller;
the displacement sensor is arranged on the welding electrode and used for detecting the penetration data of the welding joint and sending the detection result to the controller;
the controller is used for judging that the quality of the welding joint is qualified when the delta R, the delta X, the delta L and the delta theta are all smaller than a preset error range; wherein, the delta R and the delta X are respectively a dynamic resistance difference value and a difference value of fusion depth data of a welding joint and standard fusion depth data.
The dynamic resistance difference value can be calculated according to the working voltage value between the two electrodes and the working current value of the welding electrode. The dynamic resistance difference value and the penetration data of the welding joint are obtained by arranging the voltage sensor, the current sensor and the displacement sensor, whether the welding quality meets the requirement or not is comprehensively judged by integrating the data and the centering performance of the welding joint, the welding quality of the welding joint is judged to be qualified only when the data are qualified, and factors influencing the welding quality are all in a feasible range.
Whether the penetration data is qualified or not is related to the voltage value between electrodes, the current value of a welding working loop and the neutrality. According to the monitoring result, if the neutrality is not a problem, but the penetration data is larger or smaller, the welding quality is not good due to the fact that the surface of the welded particle or the back material is dirty, the electrode is adhered or abraded after long-time working, the mechanical structure of the machine head is unstable and the like. At the moment, the measured voltage value and the measured current value can be processed to obtain a dynamic resistance curve, and whether the spatter occurs in the welding process is judged according to the dynamic resistance curve, so that the cause of the occurrence of the fault is eliminated. If the spatter appears, it indicates that the electrode is in trouble or the surface of the material is not clean; if no spatter is present, this is an indication that the mechanical structure of the head is unstable and the weld quality is unreliable.
Preferably, the device further comprises a memory for storing a standard dynamic resistance curve and standard penetration data; the memory is connected with the controller, and the controller is used for calculating to obtain a dynamic resistance curve according to the working voltage value between the two electrodes and the working current value of the welding electrode, and comparing the dynamic resistance curve with a standard dynamic resistance curve to obtain delta R; and comparing the penetration data with the standard penetration data to obtain the delta X.
Due to the adoption of the technical scheme, compared with the prior art, the centering performance of the welding joint can be comprehensively detected from the vertical direction and the horizontal direction, so that the quality of the welding spot can be more accurately judged, and the reliability of the quality of the detected sawteeth is ensured; whether the welding quality meets the requirements or not is comprehensively judged through the dynamic resistance difference value of the welding electrode, the penetration data and the centering performance of the welding joint, and the accuracy of judging the quality of the welding spot and the reliability of the quality of the detected sawteeth are further improved.
Drawings
FIG. 1 is a schematic structural view of a device for monitoring the welding quality of a bimetal band saw blade according to the present invention;
FIG. 2 is a perspective view of the device for monitoring the welding quality of a bimetal band saw blade according to the present invention;
FIG. 3 is a schematic circuit diagram of the device for monitoring the welding quality of the bimetal band saw blade according to the present invention;
FIG. 4 is a schematic illustration of the effect of the vertical centering of the weld joint of the present invention;
FIG. 5 is a schematic illustration of the effect of the centering of the weld joint of the present invention in the horizontal direction;
fig. 6 is a flow chart of the method for monitoring the welding quality of the bimetal band saw blade.
Detailed Description
The present invention is described in further detail below with reference to the attached drawing figures.
Example 1
Referring to fig. 1-3, a device for monitoring the welding quality of a bi-metal band saw blade is mounted on a resistance welding machine. The band saw blade 1 to be welded is positioned on a workbench 2 of a resistance welding machine, and a support 3 is arranged on the workbench 2.
The monitoring device includes a first camera 31, a second camera 32, a voltage sensor 4, a current sensor 5, a displacement sensor 6, a memory 7, and a controller 8. The first shooting device 31 and the second shooting device 32 are both mounted on the support 3, the first shooting device 31 is located above the welding joint (formed by welding the tooth tip block at the welding position on the band saw blade 1) and is used for acquiring an overhead image of the welding joint, as shown in fig. 2, that is, the first shooting device 31 shoots the image formed by the welding joint from top to bottom; the second camera 32 is located at the side of the weld joint for obtaining a side view image of the weld joint, as shown in fig. 2, i.e. the second camera 32 takes an image of the weld joint from the side. A light source 33 facilitating image acquisition is further arranged between the welding joint and the first shooting device 31.
The first camera 31, the second camera 32, the voltage sensor 4, the current sensor 5, the displacement sensor 6, and the memory 7 are connected to the controller 8. The first and second cameras 31 and 32 transmit the acquired images to the controller.
As shown in fig. 1 and 3, a first copper electrode 91 is mounted on the handpiece, one end of which is electrically connected to a power source and the other end of which is electrically connected to a welding electrode (i.e., molybdenum electrode 11); the second copper electrode 92 is mounted on the band saw blade 1 and electrically connected to the band saw blade 1, and the other end is electrically connected to a power supply. Two detection ends of the voltage sensor 4 are respectively connected with the first copper electrode 91 and the second copper electrode 92, and are used for detecting a voltage value between the two electrodes and sending a detection result to the controller 8; the current sensor 5 is arranged in a working loop of the welding electrode and used for detecting the working current value of the electrode and sending the detection result to the controller 8; the displacement sensor 6 is arranged at the rear end of the welding electrode and used for detecting the penetration data of the welding joint and sending the detection result to the controller 8; the memory 7 is used for storing a standard dynamic resistance curve and standard penetration data.
As shown in fig. 1, when the resistance welder works, under the driving action of a welding head, the first copper electrode 91 and the molybdenum electrode 11 fixed on the first copper electrode 91 are driven to move towards the tooth tip block 12, after the tip of the molybdenum electrode 11 contacts the tooth tip block 12, the tooth tip block 12 is driven to move towards the band saw blade 1 together, and pre-pressing is started for a plurality of milliseconds after the tip of the molybdenum electrode 11 contacts a sawtooth support of the band saw blade 1. Then, the power supply is excited to discharge, and a closed loop is formed by the first copper electrode, the molybdenum electrode 11, the tooth tip block 12, the band saw blade 1 and the second copper electrode through the transformer, so that welding is started. During the welding process, joule heat is generated between the tooth tip block 12 and the saw blade holder of the band saw blade 1, and partial metal is melted and extruded under the continuous pressing of the machine head, and finally a welded joint is formed.
In the welding process, the voltage sensor 4 and the current sensor 5 respectively detect a voltage value and a current value, after the voltage value and the current value are filtered by the signal conditioning circuit board 13, relevant data are transmitted to the oscilloscope 14 for data acquisition and waveform display, output digital signals are transmitted to the controller 8 for data analysis, and a dynamic resistance curve is obtained through calculation. The displacement sensor 6 is arranged on the molybdenum electrode 11 and is used for detecting a displacement signal of the molybdenum electrode 11, and the molybdenum electrode 11 is closely connected with the tooth tip block and the sawtooth support of the band saw blade 1, so that the displacement signal of the molybdenum electrode 11 reflects the displacement of the welding joint, namely the penetration data of the welding joint.
After the welding is completed, the first camera 31 and the second camera 32 respectively acquire a top view image and a side view image of the welded joint, and transmit the images to the controller 8. The controller 8 acquires L1 and L2 from the overhead view image of the welding joint and calculates the difference DeltaL between L1 and L2; acquiring theta 1 and theta 2 from a side view image of the welding joint, and calculating a difference delta theta of the theta 1 and the theta 2; the L1 and the L2 are respectively the distance from the upper edge and the lower edge of the back material to the upper edge and the lower edge of the tooth top; and the theta 1 and the theta 2 are respectively included angles between the central line of the back material and the tooth tip side line. The controller 8 also compares the dynamic resistance curve and the penetration data with a standard dynamic resistance curve and standard penetration data stored in the memory 7 respectively to obtain a dynamic resistance difference value delta R and a difference delta X between the penetration data and the standard penetration data.
Finally, the controller judges whether the delta R, the delta X, the delta L and the delta theta are all smaller than a preset error range. If the error ranges are smaller than the error ranges, the quality of the welding joint can be judged to be qualified, and otherwise, the quality of the welding joint is judged to be unqualified. The preset error range can be set according to specific welding quality requirements, for example, the preset error range of Δ R can be set to 0-20 μ Ω, the preset error range of Δ X can be set to 0-0.02 mm, the preset error range of Δ L can be set to 0' 0.05mm, and the preset error range of Δ θ can be set to 0-3 °.
Above-mentioned monitoring devices obtains welded joint's overlook image and side view image through first camera device and second camera device, and come the centering nature of comprehensive detection welded joint from vertical direction and horizontal direction two aspects through the controller, and whether come dynamic resistance difference and welded joint's penetration data of detection electrode through voltage sensor, current sensor and displacement sensor in error range, have when all data are all qualified, just judge welded joint's welding quality qualified, thereby can judge the solder joint quality more accurately, guarantee to be detected the reliability of sawtooth quality.
FIGS. 4 and 5 are schematic diagrams showing the effect of the neutrality of the weld joint in the vertical direction (top view) and horizontal direction (side view), respectively; in the figure, 19 is a back material heat affected zone, 20 is a tooth tip material, and 21 is a back material base material.
Example 2
As shown in fig. 6, a method for monitoring the welding quality of a bimetal band saw blade includes the following steps:
s1, acquiring a top view image and a side view image of the welding joint, and acquiring an electrode working voltage value, an electrode working current value and fusion depth data of the welding joint;
s2, acquiring L1 and L2 from an overhead view image of the welded joint, and calculating the difference delta L between L1 and L2;
acquiring theta 1 and theta 2 from a side view image of the welding joint, and calculating a difference delta theta of the theta 1 and the theta 2;
calculating delta R and delta X;
the L1 and the L2 are respectively the distance from the upper edge and the lower edge of the back material to the upper edge and the lower edge of the tooth top; the theta 1 and the theta 2 are respectively included angles between the central line of the backing material and the tooth tip side line; the delta R and the delta X are respectively the difference value of the dynamic resistance of the electrode and the difference value of the penetration data of the welding joint and the standard penetration data;
and S3, judging that the quality of the welding joint is qualified when the delta R, the delta X, the delta L and the delta theta are all smaller than a preset error range, otherwise judging that the quality of the welding joint is unqualified, and sending an alarm to stop the machine.
Specifically, the method for obtaining the dynamic resistance difference value includes:
s31, acquiring a voltage value between the first copper electrode and the second copper electrode;
s32, acquiring the current value of the welding work loop;
s33, calculating according to the voltage value and the current value to obtain a dynamic resistance curve;
and S34, comparing the dynamic resistance curve with the standard dynamic resistance curve to obtain a dynamic resistance difference value.
The invention provides an easy-to-implement, full-automatic and convenient-to-evaluate on-line monitoring method for welding spot quality, which can realize comprehensive monitoring of the welding of the saw teeth of the bimetal band saw blade without missing detection; the whole monitoring process is controlled by a program, and the sawtooth welding and the quality monitoring are simultaneously completed, so that the method is time-saving, labor-saving, safe and reliable, the yield is improved, and the production cost is reduced. The detection method can realize full-automatic online monitoring, has no missing detection condition, saves time and labor and reduces labor cost; three kinds of monitoring systems are arranged, the welding quality of the sawtooth welding joint is judged from different angles, the quality monitoring is stricter, and the bad tooth rate can be greatly reduced.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (8)
1. A method for monitoring the welding quality of a bimetal band saw blade comprises the following steps:
s1, acquiring a top view image and a side view image of the welding joint;
s2, acquiring L1 and L2 from an overhead view image of the welded joint, and calculating the difference delta L between L1 and L2;
acquiring theta 1 and theta 2 from a side view image of the welding joint, and calculating a difference delta theta of the theta 1 and the theta 2; the L1 and the L2 are respectively the distance from the upper edge and the lower edge of the back material to the upper edge and the lower edge of the tooth top; the theta 1 and the theta 2 are respectively included angles between the central line of the backing material and the tooth tip side line;
and S3, judging whether the quality of the welding joint is qualified according to the delta L and the delta theta.
2. The method of monitoring the welding quality of a bimetal band saw blade as set forth in claim 1, wherein: in step S3, when both Δ L and Δ θ are smaller than the preset error range, the quality of the welded joint is determined to be acceptable.
3. The method for monitoring the welding quality of a bimetal band saw blade as claimed in claim 1, wherein in step S3, when Δ R, Δ X, Δ L and Δ θ are all smaller than a preset error range, the quality of the welding joint is judged to be qualified; wherein, the delta R and the delta X are respectively a dynamic resistance difference value and a difference value of fusion depth data of a welding joint and standard fusion depth data.
4. The method for monitoring the welding quality of a bimetal band saw blade as claimed in claim 3, wherein said dynamic resistance difference value is obtained by:
s31, acquiring a voltage value between the first copper electrode and the second copper electrode;
s32, acquiring the current value of the welding work loop;
s33, calculating according to the voltage value and the current value to obtain a dynamic resistance curve;
and S34, comparing the dynamic resistance curve with the standard dynamic resistance curve to obtain a dynamic resistance difference value.
5. The utility model provides a bimetal band saw blade welding quality's monitoring devices which characterized in that: the device comprises a first shooting device, a second shooting device and a controller, wherein the first shooting device and the second shooting device are respectively connected with the controller; the first shooting device is positioned above the welding joint and used for acquiring an overlook image of the welding joint; the second shooting device is positioned on the side face of the welding joint and used for acquiring a side view image of the welding joint; the controller is used for acquiring L1 and L2 from a top view image of the welding joint, calculating a difference value delta L of L1 and L2, acquiring theta 1 and theta 2 from a side view image of the welding joint, calculating a difference value delta theta of the theta 1 and the theta 2, and judging whether the quality of the welding joint is qualified or not according to the delta L and the delta theta; the L1 and the L2 are respectively the distance from the upper edge and the lower edge of the back material to the upper edge and the lower edge of the tooth top; and the theta 1 and the theta 2 are respectively included angles between the central line of the back material and the tooth tip side line.
6. The device for monitoring the welding quality of a bimetal band saw blade as set forth in claim 5, wherein: and when both the delta L and the delta theta are smaller than the preset error range, the controller judges that the quality of the welding joint is qualified.
7. The apparatus for monitoring the welding quality of a bimetal band saw blade as set forth in claim 5, further comprising:
one end of the first copper electrode is connected with one end of the power supply, and the other end of the first copper electrode is connected with the welding electrode;
one end of the second copper electrode is connected with the band saw blade, and the other end of the second copper electrode is connected with the other end of the power supply;
the detection end of the voltage sensor is respectively connected with the first copper electrode and the second copper electrode, and the voltage sensor is used for detecting the working voltage value between the two electrodes and sending the detection result to the controller;
the current sensor is arranged in a working loop of the welding electrode and used for detecting the working current value of the welding electrode and sending the detection result to the controller;
the displacement sensor is arranged on the welding electrode and used for detecting the penetration data of the welding joint and sending the detection result to the controller;
the controller is used for judging that the quality of the welding joint is qualified when the delta R, the delta X, the delta L and the delta theta are all smaller than a preset error range; wherein, the delta R and the delta X are respectively a dynamic resistance difference value and a difference value of fusion depth data of a welding joint and standard fusion depth data.
8. The device for monitoring the welding quality of a bimetal band saw blade as set forth in claim 7, wherein: the device also comprises a memory for storing a standard dynamic resistance curve and standard penetration data; the memory is connected with the controller, and the controller is used for calculating to obtain a dynamic resistance curve according to the working voltage value between the two electrodes and the working current value of the welding electrode, and comparing the dynamic resistance curve with a standard dynamic resistance curve to obtain delta R; and comparing the penetration data with the standard penetration data to obtain the delta X.
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| CN114769828A (en) * | 2022-04-13 | 2022-07-22 | 江苏诺森特电子科技有限公司 | Welding method, welding device, and storage medium |
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