CN112388108A - Medium plate broken line weld joint tracking method based on three-wire cross swinging arc sensing - Google Patents
Medium plate broken line weld joint tracking method based on three-wire cross swinging arc sensing Download PDFInfo
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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
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- B23K9/28—Supporting devices for electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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Abstract
The invention relates to a medium plate broken line weld joint tracking method based on three-wire cross swinging arc sensing. The method applies a manipulator, a welding power supply, a wire feeder, a three-wire cross swing arc sensor, a three-wire cross swing arc welding gun, a three-wire cross swing arc welding seam tracking signal processor, a welding gun inclination angle arithmetic unit and a welding gun posture real-time regulator. The cross swing of the three-wire electric arc is that the guide electric arc swings in the same direction with the follow electric arc and swings in the opposite direction with the middle electric arc, and the three-wire electric arc has a sufficient stirring effect on a welding pool through the cross swing of the three-wire electric arc, so that the welding quality is improved. A left-right deviation signal and a high-low signal of a welding seam are extracted through a three-wire cross swinging arc sensor, so that the welding seam tracking is realized; the real-time automatic adjustment of the posture of the welding gun is realized by guiding the sudden change of high and low signals of the electric arc and the middle electric arc.
Description
Technical Field
The invention relates to the technical field of welding automation, in particular to a medium plate broken line weld joint tracking method based on three-wire crossed swinging arc sensing.
Background
With the rapid development of the manufacturing industry, the deposition rate and the welding speed of the traditional single-wire welding are close to the limit which can be reached by the process, the welding performance is difficult to further improve only by improving a welding power supply, a welding wire material, a protective gas and the like, and the requirements of the increasingly developing manufacturing industry are difficult to meet. In order to meet the requirements of high-efficiency and high-quality modern manufacturing, the multi-wire welding process technology which is one of high-efficiency welding process methods is increasingly emphasized. On the premise of ensuring the quality of welding products, the multi-arc co-molten pool welding is realized by optimizing the phase relation, frequency, welding process parameters and the like among arcs by using the number of welding wires as much as possible, the welding speed is increased to the maximum extent, and the production efficiency is greatly improved. As disclosed in the invention patent: one type of three-wire welding gun and multi-wire submerged arc welding process (application No. 201710915582X) uses a three-wire welding process, but it does not involve seam tracking.
The multi-wire welding technology is mostly used for submerged arc welding of medium and heavy plates, but submerged arc welding electric arcs and welding beads are difficult to observe, so that the visual sensor is difficult to be applied to seam tracking of the submerged arc welding, and the visual sensor has the great advantage over an electric arc sensor in realizing real-time adjustment of welding gun postures. Aiming at the contradiction, the invention designs a medium plate broken line weld joint tracking method based on three-wire cross swinging electric arc sensing, and can realize real-time adjustment of the welding gun posture by using an electric arc sensor. The method is not limited to use in submerged arc welding.
The welding seam tracking technology is one of key technologies for realizing welding automation and intellectualization. The extraction of the welding line deviation signal is the core of the welding line tracking technology, and the extraction quality of the deviation signal directly influences the welding line tracking effect. As disclosed in the invention patent: a complex fillet weld position detection method (application number 2014100428828) based on laser binocular vision adopts a binocular CCD camera shooting identification technology. CCD is easy to be interfered by arc light, and the general volume is large and is not easy to be installed, so that accessibility of a welding gun is limited. Compared with this, the arc sensor has an advantage of being difficult to replace. The arc sensor detects the height and the left-right deviation of the welding gun by using the welding current change caused by the distance change between the welding gun and the workpiece, has the advantages of strong anti-interference capability, good accessibility, strong real-time performance and the like, and has more researches and documents for detecting the welding seam deviation by using the arc sensor, but has less researches for identifying and adjusting the posture of the welding gun by using the arc sensor.
The three-wire welding and arc sensing weld seam tracking technology is fused, and a medium plate broken line weld seam tracking method based on three-wire cross swinging arc sensing is invented.
Disclosure of Invention
Aiming at the problem that the welding seam tracking of the existing arc sensor cannot well realize real-time adjustment of the posture of a welding gun, and meanwhile, in order to improve the welding quality and efficiency of a medium plate with a broken line welding seam in particular, the invention provides a medium plate broken line welding seam tracking method based on three-wire cross swinging arc sensing. Referring to the attached figure 1, the method uses a manipulator, a welding power supply, a wire feeder, a three-wire cross swing arc sensor, a three-wire cross swing arc welding gun, a three-wire cross swing arc welding seam tracking signal processor, a welding gun inclination angle arithmetic unit and a welding gun posture real-time adjuster. The three-wire cross-swinging arc sensor has three current detection channels for respectively detecting three current components of the system. The three-wire cross swinging electric arc welding gun is a welding gun specially designed for the system, and as shown in the attached figure 2, the welding gun is also internally provided with a three-wire cross swinging mechanism 4 matched with the welding gun and a necessary damping and shock-absorbing pad 3 besides a gun head 2 and a cover plate 5. The three-wire cross swing mechanism 4 consists of three sets of cranks, sliding blocks and a hollow guide rod system; the welding wire is fed into the gun head from the hollow guide rod; the hollow guide rod is driven to do reciprocating swing through the whole-circle rotation of the crank and the connection of the slide block; the three cranks are connected to the same motor, and the swing frequency of the three wires is controlled by controlling the rotating speed of the motor; the crank can freely stretch out and draw back within a certain range, and the swinging amplitude of the three wires is controlled by controlling the length of the crank; the three-wire cross swing is realized by setting the initial position of the crank, the initial position of the crank connecting the guide wire guide rod and the follow wire guide rod is 90 degrees, and the initial position of the crank connecting the middle wire guide rod is 270 degrees. The three-wire cross-swinging electric arc welding seam tracking signal processor is designed on the basis of a welding seam tracking system with mature technology, and has the welding seam tracking function and the welding gun inclination angle self-adjusting function. And the welding gun inclination angle arithmetic unit calculates a welding gun inclination angle value C by guiding the sudden change of the high and low signal values of the electric arc and the middle electric arc and utilizing the difference value between the two high and low signal values and the horizontal distance between every two three welding wires. The real-time welding gun posture adjuster integrates two functions of welding seam tracking and welding gun inclination angle self-adjustment, and the two functions are coupled and are not independent.
A method for tracking a broken line weld joint of a medium plate based on three-wire cross swinging arc sensing comprises the following working procedures: referring to the attached drawing 3, the three-wire cross swing arc sensor collects welding seam deviation signals and sends the welding seam deviation signals to the three-wire cross swing arc welding seam tracking signal processor, three welding seam left and right deviation values A1, A2 and A3 and three welding seam height signal values B1, B2 and B3 are obtained after calculation, the three welding seam left and right deviation values and the three welding seam height signal values are respectively averaged to obtain A, B, and the welding gun is controlled A, B to realize welding gun centering and keep a certain height with the welding seam; the B value is simultaneously sent to a welding gun inclination angle arithmetic unit to calculate a welding gun inclination angle C which meets the welding process requirement; and finally, A, B, C is sent into a welding gun posture real-time regulator to control the manipulator to execute tracking action.
The working principle of the welding gun inclination angle arithmetic unit is as follows: referring to fig. 4, a broken line weld is shown, where the weld is centered and perpendicular to the weld at position a, where B1-B2-B3, and the angle of inclination of the weld is 90 °. When the welding gun moves to the position B, the distance from the guide welding wire to the workpiece is suddenly changed, so that the welding seam height signal value B1 is suddenly changed, the B1 and the B2 are not equal any more, and the B1 continuously changes along with the continuous movement of the welding gun. When the welding gun moves to the distance D from the position B, the distance from the middle welding wire to the workpiece changes suddenly, and therefore the welding seam height signal value B2 changes suddenly. At the moment, the welding gun inclination angle arithmetic unit starts operation to obtain the welding gun inclination angle theta to be adjusted through the operation,
d is the horizontal distance between every two three welding wires, the welding gun inclination angle C is alpha + theta, and the adjustment action of the welding gun inclination angle is finished once; after the adjustment operation is finished, checking whether B1 is equal to B2, if not, repeatedly executing the previous adjustment operation; if the two are equal, checking whether the B1, the B2 and the B3 are equal, and if not, stopping the machine and reporting errors; if the welding gun inclination angle is equal to the preset inclination angle, the welding gun inclination angle adjusting action is finished, and the welding gun continues to work forwards. When the welding gun moves to the position c, the arc height signal is induced to change suddenly again, and when the welding gun moves to the middle arc height signal, the welding gun inclination angle arithmetic unit starts operation again. Each time the operation is performed, alpha in the formula C ═ alpha + theta at the next operation is covered by the welding gun inclination angle value C obtained from the previous operation.
The cross swing of the three-wire electric arc is realized by a three-wire cross swing mechanism which is arranged in a three-wire cross swing electric arc welding gun, wherein the guide electric arc swings in the same direction with the electric arc and swings in the opposite direction with the middle electric arc. The three wires are in cross swing instead of in the same direction so as to better stir the molten pool, thereby improving the welding quality. Under the action of the cross oscillation of the three-wire arc, the molten metal of the welding pool makes complex cyclic motion and eddy motion, which results in stirring action of the metal in the welding pool. During the stirring process, the temperature in the welding molten pool becomes more balanced, so that the temperature gradient before the crystallization front is improved, and the crystallization front of the molten pool is continuously washed. This stirring action on the one hand refines the grains and on the other hand disturbs the direction of dendrite growth, changing the crystalline state. In the welding process, the cross swing of the three wires can improve the crystalline structure of the welding seam, reduce the residual stress of the welding joint and improve the performance of the welding joint, and particularly has great superiority in the welding of a bearing component with high rigidity.
The invention has the beneficial effects that:
the invention relates to a medium plate broken line weld joint tracking method based on three-wire cross swing arc sensor, which extracts left and right deviation signals and high and low signals of a weld joint through the three-wire cross swing arc sensor to realize weld joint tracking; the real-time automatic adjustment of the posture of the welding gun is realized by guiding the sudden change of high and low signals of the electric arc and the middle electric arc. The three wires can better stir the molten pool by swinging in a crossed way instead of swinging in the same direction, thereby improving the welding quality. The invention effectively solves the problem of real-time automatic adjustment of the posture of the welding gun in the tracking of the arc sensing welding seam, and simultaneously improves the welding efficiency and quality of the medium plate with the broken line welding seam.
Drawings
FIG. 1 is a system hardware overview
FIG. 2 is a structural diagram of a three-wire cross swing arc welding gun and a built-in three-wire cross swing mechanism
FIG. 3 is a system schematic
FIG. 4 is a diagram illustrating the real-time automatic adjustment of the inclination angle of the welding torch
FIG. 5 is a real-time automatic adjustment algorithm for the inclination angle of the welding gun
Detailed Description
In order to better express the technical scheme and the beneficial effects of the whole invention, the invention is further described in detail with reference to the accompanying drawings and the implementation examples. But the embodiments of the present invention are not limited thereto.
Fig. 1 is a system hardware connection diagram according to an embodiment of the present invention, which includes a manipulator 1, wire feeders 2 to 4, a welding gun attitude real-time adjuster 5, a three-wire cross swing arc welding seam tracking signal processor 6, a welding gun inclination calculator 7, a three-wire cross swing arc welding gun 8, a three-wire cross swing arc sensor 9, and welding power supplies 10 to 12.
The three-wire cross swing electric arc welding gun 8 is a welding gun specially designed for the system, and referring to the attached figure 2, the welding gun is also internally provided with a three-wire cross swing mechanism 4 matched with the welding gun and a necessary damping and shock-absorbing pad 3 besides a gun head 2 and a cover plate 5. The three-wire cross swing mechanism 4 consists of three sets of cranks, sliding blocks and a hollow guide rod system; the welding wire is fed into the gun head from the hollow guide rod; the hollow guide rod is driven to do reciprocating swing through the whole-circle rotation of the crank and the connection of the slide block; the three cranks are connected to the same motor, and the swing frequency of the three wires is controlled by controlling the rotating speed of the motor; the crank can freely stretch out and draw back within a certain range, and the swinging amplitude of the three wires is controlled by controlling the length of the crank; the three-wire cross swing is realized by setting the initial position of the crank, the initial position of the crank connecting the guide wire guide rod and the follow wire guide rod is 90 degrees, and the initial position of the crank connecting the middle wire guide rod is 270 degrees.
In fig. 1, the three-wire cross-swing arc sensor 9 has three current sensing channels for sensing three current components of the system, respectively. The three-wire cross-swinging arc welding seam tracking signal processor 6 is designed and improved on the basis of a welding seam tracking system with mature technology, and has the welding seam tracking function and the welding gun inclination angle self-adjusting function. The welding gun inclination angle arithmetic unit 7 calculates the angle of the welding gun by using the welding seam height information acquired by the three-wire cross swinging electric arc sensor 9 through the sudden change of the high and low signals of the guide electric arc and the middle electric arc. The welding gun posture real-time adjuster 5 integrates two functions of welding seam tracking and welding gun inclination angle self-adjustment, and the two functions are coupled and are not independent.
A method for tracking a broken line weld joint of a medium plate based on three-wire cross swinging arc sensing comprises the following working procedures: referring to the attached drawing 3, the three-wire cross swing arc sensor collects welding seam deviation signals and sends the welding seam deviation signals to the three-wire cross swing arc welding seam tracking signal processor, three welding seam left and right deviation values A1, A2 and A3 and three welding seam height signal values B1, B2 and B3 are obtained after calculation, the three welding seam left and right deviation values and the three welding seam height signal values are respectively averaged to obtain A, B, and the welding gun is controlled A, B to realize welding gun centering and keep a certain height with the welding seam; the B value is simultaneously sent to a welding gun inclination angle arithmetic unit to calculate a welding gun inclination angle C which meets the welding process requirement; and finally, A, B, C is sent into a welding gun posture real-time regulator to control the manipulator to execute tracking action.
The working principle of the welding gun inclination angle arithmetic unit is as follows: referring to fig. 4, a broken line weld is shown, where the weld is centered and perpendicular to the weld at position a, where B1-B2-B3, and the angle of inclination of the weld is 90 °. When the welding gun moves to the position B, the distance from the guide welding wire to the workpiece is suddenly changed, so that the welding seam height signal value B1 is suddenly changedInstead, B1 and B2 are no longer equal, and B1 continues to change as the torch continues to move. When the welding gun moves to the distance D from the position B, the distance from the middle welding wire to the workpiece changes suddenly, and therefore the welding seam height signal value B2 changes suddenly. At the moment, the welding gun inclination angle arithmetic unit starts operation to obtain the welding gun inclination angle theta to be adjusted through the operation,
d is the horizontal distance between every two three welding wires, the welding gun inclination angle C is alpha + theta, and the adjustment action of the welding gun inclination angle is finished once; after the adjustment operation is finished, checking whether B1 is equal to B2, if not, repeatedly executing the previous adjustment operation; if the two are equal, checking whether the B1, the B2 and the B3 are equal, and if not, stopping the machine and reporting errors; if the welding gun inclination angle is equal to the preset inclination angle, the welding gun inclination angle adjusting action is ended, and the welding gun continues to work forwards; when the welding gun moves to the position c, the arc height signal is induced to change suddenly again, and when the welding gun moves to the middle arc height signal, the welding gun inclination angle arithmetic unit starts operation again. Each time the operation is performed, alpha in the formula C ═ alpha + theta at the next operation is covered by the welding gun inclination angle value C obtained from the previous operation.
The cross swing of the three-wire electric arc is realized by a three-wire cross swing mechanism which is arranged in a three-wire cross swing electric arc welding gun, wherein the guide electric arc swings in the same direction with the electric arc and swings in the opposite direction with the middle electric arc. The three wires are in cross swing instead of in the same direction so as to better stir the molten pool, thereby improving the welding quality. Under the action of the cross oscillation of the three-wire arc, the molten metal of the welding pool makes complex cyclic motion and eddy motion, which results in stirring action of the metal in the welding pool. During the stirring process, the temperature in the welding molten pool becomes more balanced, so that the temperature gradient before the crystallization front is improved, and the crystallization front of the molten pool is continuously washed. This stirring action on the one hand refines the grains and on the other hand disturbs the direction of dendrite growth, changing the crystalline state. In the welding process, the cross swing of the three wires can improve the crystalline structure of the welding seam, reduce the residual stress of the welding joint and improve the performance of the welding joint, and particularly has great superiority in the welding of a bearing component with high rigidity.
The invention effectively solves the problem of real-time automatic adjustment of the posture of the welding gun in the tracking of the arc sensing welding seam, and simultaneously improves the welding efficiency and quality of the medium plate with the broken line welding seam.
Claims (3)
1. A method for tracking a broken line weld joint of a medium plate based on three-wire crossed swinging arc sensing uses a manipulator, a welding power supply, a wire feeder, a three-wire crossed swinging arc sensor, a three-wire crossed swinging arc welding gun, a three-wire crossed swinging arc weld joint tracking signal processor, a welding gun inclination angle arithmetic unit and a welding gun posture real-time adjuster; the method is characterized by comprising the following steps: when the system works, the three-wire cross swing arc sensor collects welding line deviation signals and sends the welding line deviation signals to the three-wire cross swing arc welding line tracking signal processor, three welding line left and right deviation values A1, A2 and A3 and three welding line height signal values B1, B2 and B3 are obtained after calculation, the three welding line left and right deviation values and the three welding line height signal values are respectively averaged to obtain A, B, and the A, B is controlled to realize welding gun centering and keep a certain height with the welding line; the B value is simultaneously sent to a welding gun inclination angle arithmetic unit to calculate a welding gun inclination angle C which meets the welding process requirement; and finally, A, B, C is sent into a welding gun posture real-time regulator to control the manipulator to execute tracking action.
2. The medium plate broken line weld joint tracking method based on the three-wire cross swinging arc sensing is characterized in that: and the welding gun inclination angle arithmetic unit calculates a welding gun inclination angle value C by guiding the sudden change of the high and low signal values of the electric arc and the middle electric arc and utilizing the difference value between the two high and low signal values and the horizontal distance between every two three welding wires.
3. The medium plate broken line weld joint tracking method based on the three-wire cross swinging arc sensing is characterized in that: the cross swing of the three-wire electric arc is realized by a three-wire cross swing mechanism which is arranged in a three-wire cross swing electric arc welding gun, wherein the three-wire electric arc guide swing swings in the same direction as the electric arc and swings in the opposite direction with the middle electric arc; the three-wire cross swing mechanism consists of three sets of cranks, a slide block and a hollow guide rod system; the welding wire is fed into the gun head from the hollow guide rod; the hollow guide rod is driven to do reciprocating swing through the whole-circle rotation of the crank and the connection of the slide block; the three cranks are connected to the same motor, and the swing frequency of the three wires is controlled by controlling the rotating speed of the motor; the crank can freely stretch out and draw back within a certain range, and the swinging amplitude of the three wires is controlled by controlling the length of the crank; the three-wire cross swing is realized by setting the initial position of the crank, the initial position of the crank connecting the guide wire guide rod and the follow wire guide rod is 90 degrees, and the initial position of the crank connecting the middle wire guide rod is 270 degrees.
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| CN114101869A (en) * | 2021-10-21 | 2022-03-01 | 湘潭大学 | Welding seam forming regulation and control method based on arc swing coupling welding parameter follow-up of space circular arc track |
| CN114619123A (en) * | 2022-04-15 | 2022-06-14 | 广东省科学院中乌焊接研究所 | Narrow gap welding method, device and system |
| CN115055788A (en) * | 2022-07-11 | 2022-09-16 | 湘潭大学 | Arc oscillation amplitude control method based on magnetic control GTAW arc sensing |
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| CN114101869A (en) * | 2021-10-21 | 2022-03-01 | 湘潭大学 | Welding seam forming regulation and control method based on arc swing coupling welding parameter follow-up of space circular arc track |
| CN114619123A (en) * | 2022-04-15 | 2022-06-14 | 广东省科学院中乌焊接研究所 | Narrow gap welding method, device and system |
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| CN115055788B (en) * | 2022-07-11 | 2023-08-25 | 湘潭大学 | Arc swing amplitude control method based on magnetic control GTAW arc sensing |
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