CN112171022B - Swing welding optimization method based on synchronous electrical parameters and vision - Google Patents
Swing welding optimization method based on synchronous electrical parameters and vision Download PDFInfo
- Publication number
- CN112171022B CN112171022B CN202010944203.1A CN202010944203A CN112171022B CN 112171022 B CN112171022 B CN 112171022B CN 202010944203 A CN202010944203 A CN 202010944203A CN 112171022 B CN112171022 B CN 112171022B
- Authority
- CN
- China
- Prior art keywords
- welding
- swing
- condition
- gun
- current
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
Images
Classifications
-
- 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
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
-
- 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
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
-
- 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
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Abstract
The invention relates to a swing welding optimization method based on synchronous electrical parameters and vision, which comprises the following steps: the method comprises the following steps: collecting welding current, welding voltage and molten pool condition images in the swinging welding spattering process in the welding process; step two: if the following conditions are met, turning to the third step; otherwise, turning to the step one; condition 1: the frequency of the spatter generated in the welding process is positive integral multiple of the swing frequency of the welding gun; condition 2: the peak value and the base value of the welding current change by more than 50% of the average value, a plurality of maximum values exist, and the difference between the plurality of maximum values is more than 20%; condition 3: when the welding gun is at the maximum swing width position at two sides of the welding seam, the distance difference between the welding gun and the welding seam is more than 5%; step three: and adjusting the position of the welding gun. The invention can rapidly analyze and judge the cause of the splash through the electric signals and the image signals collected in the welding process, thereby being capable of pertinently implementing the process improvement measures.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a swing welding optimization method based on synchronous electrical parameters and vision.
Background
Swing welding is a welding operation in which a heat source regularly swings laterally on a weldment while welding. Welding spatter is one of the main problems which troubles the technicians and affects the stability of the welding process. When using gas metal active welding (MAG welding), spatter is inevitably present both in manual welding and in automatic welding. Sometimes the spatter is small and the particles are fine, sometimes the spatter is large and the particles are large, which is not distinguishable from the various factors affecting the welding process. When large and much splashing often occurs, not only is the stability of the welding process affected, but also the appearance of the welding seam is not good, the protection of a molten pool is not good, and even the internal quality of the welding seam is affected. In mass production application, due to various reasons such as poor consistency of materials and parts, deviation of positioning precision of a tool, poor calibration or repeated positioning of a robot, deviation of swing welding from a limit position, improper selection of welding process parameters, unstable output of a welding power supply, unstable wire output of a wire feeding mechanism and the like, a technician usually needs to analyze specific reasons caused by splashing through a large number of tests so as to improve the stability of a welding process, but the labor is consumed, the production period is prolonged, and the economic cost is high.
Disclosure of Invention
The invention provides a swing welding optimization method based on synchronous electrical parameters and vision, aiming at solving the technical problems in the prior art.
In order to solve the technical problems, the technical scheme of the invention is as follows:
a swing welding optimization method based on synchronous electrical parameters and vision is suitable for a welding device and comprises the following steps: the device comprises a welding gun, a welding power supply, a camera, a current sensor, a voltage sensor and a collection card; the welding gun is connected with the welding power supply; the camera can shoot a molten pool condition image; the current sensor is arranged at the output end of the welding power supply in series; the voltage sensor is arranged between the positive and negative output ends of the welding power supply in parallel;
the camera, the current sensor and the voltage sensor are respectively connected with the acquisition card; the acquisition card can acquire the welding current acquired by the current sensor, the welding voltage acquired by the voltage sensor and the molten pool condition image acquired by the camera;
the swing welding optimization method comprises the following steps:
the method comprises the following steps: collecting welding current, welding voltage and molten pool condition images in the swinging welding spattering process in the welding process;
step two: if the following conditions are met, turning to the third step; otherwise, turning to the step one;
condition 1: the frequency of the spatter generated in the welding process is positive integral multiple of the swing frequency of the welding gun;
condition 2: the peak value and the base value of the welding current change by more than 50% of the average value, a plurality of maximum values exist, and the difference between the plurality of maximum values is more than 20%;
condition 3: when the welding gun is at the maximum swing width position at two sides of the welding seam, the distance difference between the welding gun and the welding seam is more than 5%;
step three: adjusting the position of the welding gun to meet the following conditions:
if the welding seam is filling welding, then:
if the welding seam is a cover surface welding seam, then:
wherein A is the swing amplitude of the welding gun, Delta s is the centering deviation of the welding gun, and B is the width of the welding bead; and m is an empirical coefficient, and when the welding speed is less than or equal to 6mm/s, m is 2mm, and when the welding speed is higher than 6mm/s, m is 0.
In the technical scheme, the collection of the welding current, the welding voltage and the weld pool image is started 2-10s before the step one.
In the above technical solution, the acquisition card is further connected to the computer, and the acquisition card can respectively transmit the welding current acquired by the current sensor, the welding voltage acquired by the voltage sensor, and the weld pool condition image acquired by the camera to the computer.
The invention has the following beneficial effects:
the swing welding optimization method based on the synchronous electrical parameters and vision can quickly analyze the reasons for generating the spatters, pertinently adjust the technological process, solve the spatter problem influencing the stability of the welding process, greatly improve the working efficiency and reduce the investment and waste.
The swing welding optimization method based on the synchronous electrical parameters and vision provided by the invention can rapidly analyze and judge the reasons of spatter generation through the electrical signals and image signals acquired in the welding process, thereby performing targeted process improvement measures. The process and time of a large amount of test analysis are avoided, manpower and material resources are saved, and the production period is shortened.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Fig. 1 is a schematic structural diagram of a welding device to which the swing welding optimization method based on synchronous electrical parameters and vision of the present invention is applied.
Fig. 2 is a schematic view of a connection structure of the welding apparatus shown in fig. 1.
The reference numerals in the figures denote:
1-a workpiece; 2-a welding gun; 3-welding seams; 4-a welding power supply; 5-a camera; 6-a current sensor; 7-a voltage sensor; 8-acquisition card; 9-computer.
Detailed Description
The present invention will be described in detail with reference to the accompanying drawings.
As shown in fig. 1 and 2, the welding device suitable for the swing welding optimization method based on the synchronous electrical parameter and vision of the invention comprises: the device comprises a welding gun 2, a welding power supply 4, a camera 5, a current sensor 6, a voltage sensor 7, a collection card 8 and a computer 9. The welding gun 2 is connected with a welding power supply 4; the camera 5 can shoot an image of the condition of the molten pool; the current sensor 6 is arranged at the output end of the welding power supply 4 in series; the voltage sensor 7 is arranged between the positive and negative output ends of the welding power supply 4 in parallel; the camera 5, the current sensor 6 and the voltage sensor 7 are respectively connected with the acquisition card 8; the acquisition card 8 can acquire the welding current acquired by the current sensor 6, the welding voltage acquired by the voltage sensor 7 and the molten pool condition image acquired by the camera 5; the acquisition card 8 is also connected with a computer 9, and the acquisition card 8 can respectively transmit the welding current acquired by the current sensor 6, the welding voltage acquired by the voltage sensor 7 and the molten pool condition image acquired by the camera 5 to the computer 9.
The swing welding optimization method based on the synchronous electrical parameters and the vision comprises the following steps:
before the welding process starts, the collection of welding current, welding voltage and molten pool condition images is started 2-10s in advance;
the method comprises the following steps: collecting welding current, welding voltage and molten pool condition images in the swinging welding spattering process in the welding process;
step two: if the following conditions are met, turning to the third step; otherwise, turning to the step one;
condition 1: the frequency of the spatter generated in the welding process is positive integral multiple of the swing frequency of the welding gun 2;
condition 2: the peak value and the base value of the welding current change by more than 50% of the average value, a plurality of maximum values exist, and the difference between the plurality of maximum values is more than 20%;
condition 3: when the welding gun 2 is at the maximum swing width position at two sides of the welding seam 3, the distance difference between the welding gun 2 and the welding seam 3 is more than 5 percent;
step three: the position of the welding torch 2 is adjusted so as to satisfy the following conditions:
if the weld 3 is a fill weld, then:
if the weld joint 3 is a cover surface weld, then:
wherein A is the swing amplitude of the welding gun 2, Delta s is the centering deviation of the welding gun 2, and B is the width of the welding bead; and m is an empirical coefficient, and when the welding speed is less than or equal to 6mm/s, m is 2mm, and when the welding speed is higher than 6mm/s, m is 0.
The present invention is described in further detail below.
The swing welding optimization method based on the synchronous electrical parameters and the vision utilizes the coupling relation of electrical signals and image signals in the welding process, obtains the signal relation when the spatters are generated through collection, analyzes the reason of the spatters, and accordingly obtains improvement measures. The swing welding optimization method based on the synchronous electrical parameters and the vision comprises the following steps:
firstly, a swing welding spattering process is acquired by adopting synchronous electrical parameters and vision.
The current sensor 6 is connected in series with the output end of the positive (or negative) welding power supply 4; the voltage sensor 7 is arranged between the positive and negative output ends of the welding power supply 4 in parallel; the camera 5 is arranged in a region capable of directly shooting the condition of the molten pool and is divided into a fixed installation mode and a follow-up installation mode, the fixed installation mode means that the relative position of the camera 5 and the molten pool region can be changed along with the progress of the welding process, and the follow-up installation mode means that the camera 5 is fixed on the welding gun 2, so that the relative position of the molten pool region and the camera 5 is guaranteed to be fixed in the whole welding process.
When the camera is fixedly installed, the lens of the camera 5 is required to have large depth of field, good focusing and imaging in a welding area are guaranteed, and the camera can be applied to automatic welding and manual welding methods. When the follow-up type is installed, the load of a moving mechanism of the welding gun 2 is required to have the allowance according with the weight of the camera 5, and the support has better rigidity, so that the phenomenon that the imaging is influenced by shaking generated during swing welding is avoided, and the follow-up type automatic welding method can be applied to an automatic welding method as far as possible.
And secondly, collecting data of the welding process.
And debugging the synchronous acquisition system before the welding process to be tested begins. And after the confirmation of no error, opening an acquisition switch before arc striking of welding, and starting the acquisition of welding current, welding voltage and a molten pool image 2-10s ahead of time.
The main purpose of welding process data acquisition is to capture the spatter generating process to be diagnosed in an acquisition system so as to facilitate the subsequent diagnosis work. And closing the acquisition system in time after the welding process is finished.
Thirdly, analyzing and optimizing the welding spatter cause.
By analyzing the electrical parameters and images in synchronization when the splash is generated, the following phenomena are observed at the same time:
(1) the frequency of spatter generation during welding is the same as or an integer multiple of the wobble frequency.
(2) When analyzed according to the swing frequency, the peak value and the base value of the welding current change by more than 50% of the average value, a plurality of maximum values exist, and the value difference is more than 20%.
(3) When the welding gun 2 is at the maximum swing width position of the two sides of the groove, the distance between the welding gun 2 and the surface of the groove at the same side is asymmetric (the difference is more than 5%).
The cause of the spatter generation is determined as follows: the swing range of the welding gun 2 deviates to a groove on one side, and the arc length change exceeds the control range of stable melting of the welding wire.
The method for reducing the spatter in the optimized welding process comprises the following steps: the centering and swinging amplitude of the welding gun 2 is adjusted to meet the following conditions:
if the weld 3 of the workpiece 1 is a fill weld:
if the weld 3 of the workpiece 1 is a cover weld:
as shown in fig. 1, where a is the swing amplitude of the welding gun 2, Δ s is the centering deviation of the welding gun 2, and B is the bead width of the welded bead; m is an empirical coefficient, which is related to the welding speed, and when the welding speed is less than or equal to 6mm/s, m is 2 mm; the welding speed is higher than 6mm/s, and m is 0.
Fourthly, welding by adopting the adjusted parameters.
The swing welding optimization method based on the synchronous electrical parameters and vision can quickly analyze the reasons for generating the spatters, pertinently adjust the technological process, solve the spatter problem influencing the stability of the welding process, greatly improve the working efficiency and reduce the investment and waste.
The swing welding optimization method based on the synchronous electrical parameters and vision provided by the invention can rapidly analyze and judge the reasons of spatter generation through the electrical signals and image signals acquired in the welding process, thereby performing targeted process improvement measures. The process and time of a large amount of test analysis are avoided, manpower and material resources are saved, and the production period is shortened.
Claims (3)
1. A swing welding optimization method based on synchronous electrical parameters and vision is characterized in that a welding device applicable to the swing welding optimization method comprises the following steps: the device comprises a welding gun (2), a welding power supply (4), a camera (5), a current sensor (6), a voltage sensor (7) and a collection card (8); the welding gun (2) is connected with the welding power supply (4); the camera (5) can shoot a molten pool condition image; the current sensor (6) is arranged at the output end of the welding power supply (4) in series; the voltage sensor (7) is arranged between the positive and negative output ends of the welding power supply (4) in parallel;
the camera (5), the current sensor (6) and the voltage sensor (7) are respectively connected with the acquisition card (8); the acquisition card (8) can acquire the welding current acquired by the current sensor (6), the welding voltage acquired by the voltage sensor (7) and the molten pool condition image acquired by the camera (5);
the swing welding optimization method comprises the following steps:
the method comprises the following steps: collecting welding current, welding voltage and molten pool condition images in the swinging welding spattering process in the welding process;
step two: if the following conditions are met, turning to the third step; otherwise, turning to the step one;
condition 1: the frequency of the spatter generated in the welding process is positive integral multiple of the swing frequency of the welding gun (2);
condition 2: the peak value and the base value of the welding current change by more than 50% of the average value, a plurality of maximum values exist, and the difference between the plurality of maximum values is more than 20%;
condition 3: when the welding gun (2) is at the maximum swing width position at two sides of the welding seam (3), the distance difference between the welding gun (2) and the welding seam (3) is more than 5 percent;
step three: the position of the welding gun (2) is adjusted to meet the following conditions:
if the welding seam (3) is filling welding, then:
if the welding seam (3) is a cover surface welding seam, then:
wherein A is the swing amplitude of the welding gun (2), Delta s is the centering deviation of the welding gun (2), and B is the width of the welding bead; and m is an empirical coefficient, and when the welding speed is less than or equal to 6mm/s, m is 2mm, and when the welding speed is higher than 6mm/s, m is 0.
2. The method of claim 1, wherein the acquisition of welding current, welding voltage and puddle image is started 2-10s before step one.
3. The swing welding optimization method based on synchronous electrical parameters and vision according to claim 1, characterized in that the acquisition card (8) is further connected to a computer (9), and the acquisition card (8) can transmit the welding current acquired by the current sensor (6), the welding voltage acquired by the voltage sensor (7) and the weld pool condition image acquired by the camera (5) to the computer (9), respectively.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010944203.1A CN112171022B (en) | 2020-09-10 | 2020-09-10 | Swing welding optimization method based on synchronous electrical parameters and vision |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010944203.1A CN112171022B (en) | 2020-09-10 | 2020-09-10 | Swing welding optimization method based on synchronous electrical parameters and vision |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN112171022A CN112171022A (en) | 2021-01-05 |
| CN112171022B true CN112171022B (en) | 2022-03-08 |
Family
ID=73920437
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202010944203.1A Active CN112171022B (en) | 2020-09-10 | 2020-09-10 | Swing welding optimization method based on synchronous electrical parameters and vision |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN112171022B (en) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107008999A (en) * | 2017-04-26 | 2017-08-04 | 湘潭大学 | A kind of electricity, the weld seam tracking sensor of magnetic field dual control electric arc |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102005037360A1 (en) * | 2005-08-08 | 2007-02-15 | Siemens Ag | Submerged-narrow gap welding process with oscillating electrode |
| CN103182589B (en) * | 2011-12-30 | 2015-10-21 | 中国科学院沈阳自动化研究所 | Based on the gas shielded arc welding electric arc tracking that electric arc swings |
| US9174294B2 (en) * | 2012-03-30 | 2015-11-03 | Illinois Tool Works Inc. | Devices and methods for analyzing spatter generating events |
| CN103862142B (en) * | 2014-03-20 | 2016-01-20 | 中铁山桥集团有限公司 | Orthotropic plate U-shaped angle of rib weld seam robot prosposition single track balanced welding method |
| DE102014223203A1 (en) * | 2014-11-13 | 2016-05-19 | Kuka Roboter Gmbh | Method for pendulum welding |
| CN104551347B (en) * | 2014-12-30 | 2016-05-25 | 江苏科技大学 | Infrared visual sensing detection method and the device of narrow gap weld seam deviation |
| CN111570975B (en) * | 2020-05-12 | 2022-04-05 | 湖北文理学院 | Welding deviation measuring method and device based on synchronous drawing and automatic welding system |
-
2020
- 2020-09-10 CN CN202010944203.1A patent/CN112171022B/en active Active
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107008999A (en) * | 2017-04-26 | 2017-08-04 | 湘潭大学 | A kind of electricity, the weld seam tracking sensor of magnetic field dual control electric arc |
Also Published As
| Publication number | Publication date |
|---|---|
| CN112171022A (en) | 2021-01-05 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US9221118B2 (en) | Adaptive control hybrid welding system and methods of controlling | |
| US6744012B2 (en) | Control method of arc welding and arc welder | |
| CN107552932A (en) | It is a kind of based on the variable-polarity plasma welding method of quality control controlled keyhole profile and device | |
| CN106001926A (en) | Vision sensing-based laser-electric arc hybrid welding real-time automatic control device and welding method thereof | |
| US20090289040A1 (en) | Method and Device for Measuring Resistance Spot Welding Electrode Tips While Connected to a Robotic Welder | |
| Guo et al. | Study of metal transfer control in underwater wet FCAW using pulsed wire feed method | |
| CN109262109B (en) | Feedback control device and method for TIG (tungsten inert gas) arc additive forming morphology | |
| CN112692418A (en) | Spot welding quality monitoring device and method based on dynamic machine vision | |
| CN105414821A (en) | Automatic tracking system for welding robot welding seam | |
| CN114260547B (en) | Narrow-gap rotating arc GTAW tungsten electrode position correction method based on deep learning algorithm | |
| CN112171022B (en) | Swing welding optimization method based on synchronous electrical parameters and vision | |
| CN206105156U (en) | Three -dimensional rectangular robot line laser welding seam automatic tracking system | |
| CN108544068B (en) | Welding quality control system and method for arc temperature difference before and after plasma arc perforation | |
| CN104772554A (en) | Stepping arc welding type pulse tungsten argon arc welding arc voltage sensing fusion penetration control method | |
| CN102179604B (en) | Automation welding system method of hollow stationary blades of steam turbine | |
| CN204018930U (en) | A kind of welder | |
| CN210648953U (en) | Welding system | |
| CN217433311U (en) | Welding equipment | |
| JP3675304B2 (en) | Arc welding condition setting method and arc welding condition setting device | |
| CN114967006A (en) | Welding control method based on image processing in optical module laser welding coupling | |
| CN113523508A (en) | Device and method for simulating welding process of circumferential weld narrow gap MAG and acquiring molten pool information | |
| CA3134743A1 (en) | Systems and methods to control welding processes using weld pool attributes | |
| CN209681389U (en) | One kind controlling Control System of Welding Robot based on PLC | |
| CN204524507U (en) | Arc welding robot intelligence coupled system | |
| CN112676726A (en) | Automatic welding device for lower side door and welding method and application thereof |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |