CN113523508A - Device and method for simulating welding process of circumferential weld narrow gap MAG and acquiring molten pool information - Google Patents
Device and method for simulating welding process of circumferential weld narrow gap MAG and acquiring molten pool information Download PDFInfo
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- CN113523508A CN113523508A CN202110878505.8A CN202110878505A CN113523508A CN 113523508 A CN113523508 A CN 113523508A CN 202110878505 A CN202110878505 A CN 202110878505A CN 113523508 A CN113523508 A CN 113523508A
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- 238000003466 welding Methods 0.000 title claims abstract description 211
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- 238000012360 testing method Methods 0.000 claims abstract description 41
- 239000002184 metal Substances 0.000 claims abstract description 37
- 238000012545 processing Methods 0.000 claims description 34
- 239000011521 glass Substances 0.000 claims description 11
- 230000003287 optical effect Effects 0.000 claims description 5
- 230000008859 change Effects 0.000 abstract description 3
- 230000006399 behavior Effects 0.000 description 13
- 230000007704 transition Effects 0.000 description 7
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- 238000004519 manufacturing process Methods 0.000 description 5
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- 238000009529 body temperature measurement Methods 0.000 description 3
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- 238000003892 spreading Methods 0.000 description 2
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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
- B23K9/16—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
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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
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Abstract
The invention discloses a device and a method for simulating a girth weld narrow gap MAG welding process and acquiring molten pool information in the technical field of welding. The device for simulating the MAG welding process of the girth weld narrow gap comprises: the device comprises a workbench, wherein a first clamp and a second clamp which can coaxially rotate are arranged on the workbench; a metal test piece fixed on the first clamp, wherein a specified welding groove is formed in one surface of the metal test piece; a light-transmitting plate fixed on the second fixture, wherein a designated welding groove is formed in one surface, which is attached to the metal test piece, of the light-transmitting plate, and a welding seam is formed between the designated welding groove and the welding groove on the metal test piece; and the MAG welding machine is used for carrying out simulated welding operation on the welding seam. The narrow-gap circumferential weld is simulated through the metal test piece with the welding groove and the light transmitting plate, the whole welding process can be simulated really, the internal change of a welding pool is convenient to observe, and conditions are created for researching the dynamic behavior of the welding pool and optimizing MAG welding parameters.
Description
Technical Field
The invention belongs to the technical field of welding, and particularly relates to a device and a method for simulating a girth weld narrow-gap MAG welding process and acquiring molten pool information.
Background
In recent years, large-thickness welded products are widely used in large-scale equipment such as ships and heavy machinery, but welding problems in the production and manufacturing processes are gradually remarkable. The traditional welding method usually adopts a large V-shaped groove, and the problems of large welding filling amount, low efficiency, difficult control of deformation and the like seriously affect the engineering production progress, so that how to realize the efficient and reliable connection of thick plates becomes one of the key technologies for realizing the manufacture of large-scale integral components.
The narrow-gap MAG welding method is a welding method which can greatly reduce the area of a groove and realize high-efficiency and high-quality welding under smaller welding line energy, and has become a welding method with great potential for solving the difficult problem of thick plate welding. The special welding gun is used for filling the narrow gap, so that the using amount of welding materials can be greatly saved, the welding efficiency is improved, and the production cost is reduced.
However, defects such as interlayer or side wall non-fusion and the like are often easy to occur in narrow gap welding due to a unique groove form, a process window is usually narrow, and process parameters need to be optimized through a large number of tests. In the MAG welding process, because of a plurality of adjustable parameters and strict requirements on parameters such as the position of a welding gun, the wire feeding speed and the like, once the parameters are poorly matched, the phenomenon of unstable welding process may occur. In addition, due to the existence of assembly errors, welding defects such as welding deviation, collapse, undercut, discontinuous welding seams and the like can occur, and the welding quality is greatly influenced. Therefore, how to quickly and efficiently obtain optimized process parameters and improve the parameter application range is particularly important.
However, due to the limitation of the narrow gap groove form, the existing monitoring technology is not ideal in effect. Typically to view an image of the weld pool within a narrow gap slope, the following two approaches are often used. The first is to directly observe the molten pool flowing condition in the bevel through a coaxial or paraxial mode, but the molten drop transition condition and the molten pool flowing behavior cannot be accurately observed due to the limitation of the bevel and the shielding of a welding torch on the molten drop and the molten pool. The other method is to adopt a flat plate overlaying mode to replace the real welding condition, and although the space limitation is eliminated, the welding condition is greatly different from the real welding condition, and the welding condition of a molten pool and a side wall in the groove cannot be truly reflected. The shortcomings of the methods greatly hinder the study of the narrow gap welding process and the dynamic behavior of a molten pool thereof, and also make the optimization of process parameters difficult. Therefore, a device for simulating molten pool and droplet characteristics in a narrow-gap groove to monitor the welding state in real time is needed.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a device and a method for simulating the welding process of the narrow-gap MAG of the girth weld and acquiring the welding pool information, which can truly simulate the welding process of the narrow-gap MAG of the girth weld and create conditions for researching the dynamic behavior of the welding pool and optimizing the MAG welding parameters.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
in a first aspect, a device for simulating a welding process of a girth weld narrow gap MAG is provided, which includes: the device comprises a workbench, wherein a first clamp and a second clamp which can coaxially rotate are arranged on the workbench; a metal test piece fixed on the first clamp, wherein a specified welding groove is formed in one surface of the metal test piece; a light-transmitting plate fixed on the second fixture, wherein a designated welding groove is formed in one surface, which is attached to the metal test piece, of the light-transmitting plate, and a welding seam is formed between the designated welding groove and the welding groove on the metal test piece; and the MAG welding machine is used for carrying out simulated welding operation on the welding seam.
Further, the first clamp is a three-jaw clamp.
Further, the second clamp is a vacuum chuck.
Further, the light-transmitting plate is GG17 high-temperature glass.
Further, the MAG welder includes a welding gun including a wire feeder for feeding welding wire and a gas feed tube for feeding shielding gas.
In a second aspect, a device for acquiring characteristic information of a molten pool in a girth weld narrow gap MAG welding process is provided, which comprises: the MAG welding process simulation device for the narrow gap of the circumferential weld of the first aspect; the industrial camera is arranged on the workbench and used for acquiring image information of a molten pool in the welding process of the MAG welding machine on the welding seam through the light-transmitting plate; and the data processing system is used for receiving and processing the image information of the molten pool acquired by the industrial camera to acquire the characteristic information of the molten pool.
Further, still include a plurality of temperature sensor, a plurality of temperature sensor evenly installs on the surface of metal test piece for gather the temperature of molten bath and upload to data processing system, the distance of the extension line of every temperature sensor and welding seam blunt edge is 3~5 mm.
Further, an optical filter is mounted on the industrial camera.
Further, the data processing system includes an industrial computer.
In a third aspect, a use method of a circumferential weld narrow gap MAG welding process molten pool characteristic information acquisition device is provided, which comprises the following steps: mounting the metal test piece with the well-processed welding groove on a first clamp; installing the light transmitting plate with the processed welding groove on a second fixture, and attaching the light transmitting plate to the metal test piece to enable the welding groove on the metal test piece and the welding groove on the light transmitting plate to form a welding seam; installing a welding gun of the debugged MAG welding machine at the position of a welding seam; starting the debugged industrial camera and the data processing system; and starting the MAG welding machine to weld the weld joint, and acquiring image information of the molten pool by the industrial camera and transmitting the image information to the data processing system for processing to obtain the characteristic information of the molten pool.
Compared with the prior art, the invention has the following beneficial effects:
(1) the narrow-gap girth weld is simulated through the metal test piece with the welding groove and the light-transmitting plate, the whole welding process can be simulated really, the internal change of a welding pool is convenient to observe, and conditions are created for researching the dynamic behavior of the welding pool and optimizing MAG welding parameters;
(2) according to the invention, the device for simulating the welding process of the narrow-gap MAG of the girth weld is combined with the industrial camera and the data processing system, so that the blockage of the narrow-gap groove on the dynamic information acquisition in the internal welding process is solved, the welding condition in the narrow-gap welding groove is directly observed through high-speed camera shooting, the visualization of the molten pool and the surface information in the welding process is realized, the device is simple and easy to realize, the work is stable and reliable, and the device can be widely applied to the narrow-gap MAG welding system;
(3) according to the method, the narrow-gap MAG filling welding process is known by shooting to obtain the flow behavior and the molten drop transition behavior of the molten pool in the narrow gap, and the characteristic information in the real-time image in the welding process is extracted through the data processing system, so that the welding quality is analyzed, the optimization of the test design is facilitated, and the stability of the welding process is improved;
(4) the method can obtain the spreading behavior of the welding wire in the narrow gap, is favorable for optimizing and designing the groove size, and avoids the generation of the fusion defect of the side wall of the wall surface. The device can be tested before a large number of welding, the characteristics and the stability of the welding process of the narrow-gap laser filler wire are known, the welding process is optimized, the welding cost is saved, the welding quality is ensured, the structure is simple, the cost is low, and the device is favorable for a large number of applications in laboratories and engineering practice.
Drawings
FIG. 1 is a system diagram of a circumferential weld narrow gap MAG welding process molten pool characteristic information acquisition device provided by an embodiment of the invention;
FIG. 2 is a schematic three-dimensional structure diagram of a circumferential weld narrow gap MAG welding process simulation apparatus provided in an embodiment of the present invention;
FIG. 3 is a schematic diagram of a groove on a metal test piece in the embodiment of the invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present invention is not limited thereby.
The first embodiment is as follows:
as shown in fig. 1 and 2, a MAG welding process simulator for narrow gap girth weld includes: the device comprises a workbench 1, wherein a first clamp 2 and a second clamp 6 which can coaxially rotate are arranged on the workbench 1; a metal test piece 3 fixed on the first clamp 2, wherein a specified welding groove is arranged on one surface of the metal test piece 3; a light-transmitting plate 5 fixed on the second fixture 6, wherein a designated welding groove is formed on one surface, which is attached to the metal test piece 3, of the light-transmitting plate 5, and a welding seam is formed between the designated welding groove and the welding groove on the metal test piece 3; and the MAG welding machine 9 is used for carrying out simulated welding operation on the welding seam.
In the present embodiment, the first clamp 2 is a three-jaw clamp; the second clamp 6 is a vacuum chuck; the driving mechanism on the workbench 1 drives the three-jaw clamp to rotate, and the metal test piece 3 is clamped on the three-jaw clamp to coaxially rotate with the three-jaw clamp and drive the light transmission plate 5 to rotate. The light-transmitting plate 5 is GG17 high-temperature glass, and the whole dynamic process of a molten pool and a molten drop in a welding area can be dynamically observed through the GG17 high-temperature glass. The MAG welder includes a welding gun 4, the welding gun 4 including a wire feeder for feeding welding wire and a gas feed tube for feeding shielding gas.
In the embodiment, the narrow-gap girth weld is simulated through the metal test piece with the welding groove and the light-transmitting plate, the whole welding process can be simulated really, the internal change of the welding pool is convenient to observe, and conditions are created for researching the dynamic behavior of the welding pool and optimizing MAG welding parameters.
Example two:
as shown in fig. 1 and fig. 2, based on the first embodiment of the apparatus for simulating the girth weld narrow gap MAG welding process, the present embodiment provides an apparatus for acquiring characteristics of a weld pool in the girth weld narrow gap MAG welding process, including: the MAG welding process simulation device of the narrow gap of the circumferential weld of the embodiment I; the industrial camera 7 is arranged on the workbench 1 and used for acquiring image information of a molten pool in the welding process of the MAG welding machine on the welding seam through the light transmitting plate 5; and the data processing system 8 is used for receiving and processing the image information of the molten pool acquired by the industrial camera 7 and acquiring the characteristic information of the molten pool.
In the embodiment, the contact part of the metal test piece 3 and GG17 high-temperature glass is processed into a narrow gap groove simulating the actual welding state; the image acquisition system comprises a high-dynamic industrial camera 7 which is arranged on one side of GG17 high-temperature glass and is right opposite to a welding area in the groove, images are acquired through high-speed shooting and are connected with an industrial computer, in the embodiment, the industrial camera is an industrial CCD camera and has a high dynamic range which is larger than or equal to 100Hz, a narrow-band optical filter is adopted as the optical filter, and the filtering wavelength is 635 +/-20 nm; the data processing system 8 comprises an industrial computer. In this embodiment, the data processing system is integrated into an industrial computer. The industrial camera 7 is provided with an optical filter for filtering the interference of the arc plasma.
As shown in fig. 3, the present embodiment may further integrate a real-time temperature measurement unit, where the temperature measurement unit includes a plurality of temperature sensors 31, the temperature sensors 31 may be disposed on the surface of the metal test piece 3, a distance a between each temperature sensor 31 and the extension line of the weld fillet 32 is 3-5 mm, the temperature sensors 31 acquire temperature changes during the welding process, and an output end of each temperature sensor 31 may also be connected to the data processing system 8. The temperature measurement unit is used for collecting and analyzing temperature signals at different positions, and can be combined with a welded structure performance test result to analyze the thermal cycle of the welding process, so that the process parameters can be further optimized.
The embodiment can also monitor the molten drop transition behavior through the image acquisition system. The specific method comprises the following steps: aligning an industrial camera to the annular welding seam welding pool; a filter is added in front of the camera to filter arc plasma; the camera collects welding pool image information and transmits the welding pool image information to the data processing system; and acquiring an MAG welding wire molten drop transition molten pool image in the narrow gap slope through corresponding image processing of the data processing system. By monitoring the droplet transition, on the one hand the way in which the wire melts into the puddle and its stability can be known, and on the other hand the interaction between the arc and the droplet can also be observed.
According to the embodiment, the device for simulating the welding process of the narrow-gap MAG of the girth weld is combined with the industrial camera and the data processing system, the problem that the narrow-gap groove blocks dynamic information acquisition in the internal welding process is solved, the welding condition in the narrow-gap welding groove is directly observed through high-speed camera shooting, so that the molten pool and surface information are visualized in the welding process, the device is simple and easy to realize, the work is stable and reliable, and the device can be widely applied to the narrow-gap MAG welding system.
In the embodiment, the flowing behavior and the molten drop transition behavior of the molten pool in the narrow gap are obtained through shooting, the narrow gap MAG filling welding process is known, and the characteristic information in the real-time image in the welding process is extracted through the data processing system, so that the welding quality is analyzed, the optimization of the test design is facilitated, and the stability of the welding process is improved.
The embodiment can obtain the spreading behavior of the welding wire in the narrow gap, is beneficial to optimally designing the groove size, and avoids the generation of the fusion defect of the side wall of the wall surface. The device can be tested before a large number of welding, the characteristics and the stability of the welding process of the narrow-gap laser filler wire are known, the welding process is optimized, the welding cost is saved, the welding quality is ensured, the structure is simple, the cost is low, and the device is favorable for a large number of applications in laboratories and engineering practice.
Example three:
based on the girth weld narrow gap MAG welding process simulation device of the first embodiment and the girth weld narrow gap MAG welding process molten pool characteristic information acquisition device of the second embodiment, the present embodiment provides a use method of the girth weld narrow gap MAG welding process molten pool characteristic information acquisition device, including: mounting the metal test piece with the well-processed welding groove on a first clamp; installing the light transmitting plate with the processed welding groove on a second fixture, and attaching the light transmitting plate to the metal test piece to enable the welding groove on the metal test piece and the welding groove on the light transmitting plate to form a welding seam; installing a welding gun of the debugged MAG welding machine at the position of a welding seam; starting the debugged industrial camera and the data processing system; and starting the MAG welding machine to weld the weld joint, and acquiring image information of the molten pool by the industrial camera and transmitting the image information to the data processing system for processing to obtain the characteristic information of the molten pool.
The specific use method is as follows:
a. preparing a simulation piece which comprises a metal test piece and GG17 high-temperature glass, arranging a narrow-gap groove simulating an actual welding joint on the metal test piece and a GG17 high-temperature glass test plate, fixing one side of the GG17 high-temperature glass by using a vacuum chuck, and attaching the side of the GG17 high-temperature glass to the side of the metal test piece to ensure that the grooves are aligned;
b. arranging a high-speed camera and a temperature sensor on one side of GG17 high-temperature glass, aligning monitoring equipment of the high-speed camera and the temperature sensor to a welding area, and ensuring that the monitoring equipment does not block the rotation of a rotary table during arrangement; the output ends of the monitoring devices are connected with a data processing system;
c. a narrow-gap special wire feeding gun for feeding welding wires and a narrow-gap gas feeding pipe for feeding welding shielding gas are arranged in the narrow-gap groove, and the wire filling welding process in the narrow gap is simulated;
d. in the welding process, a narrow-band filter is placed in front of the industrial camera, a dimmer is properly added according to the actual situation, the interference of arc plasma is filtered, and the narrow-band filter is aligned to the welding pool area. After welding is started, the position of a camera is kept still, a workbench rotates at a constant speed to perform girth welding, an industrial camera starts to acquire dynamic images of a molten pool and molten drop transition behaviors, and image information is transmitted to a data processing system; the acquired image is subjected to binarization processing through an image processing function of a data processing system, a proper threshold value is set according to the actual working condition, the contour edge of a welding pool of the welding pool is obtained, the geometric shape of the welding pool and corresponding characteristic information data are extracted, and then a real-time image of a welding area in a narrow-gap MAG welding slope and geometric characteristic information of the welding pool image can be obtained.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, it is possible to make several modifications and variations without departing from the technical principle of the present invention, and the present invention is also applicable to girth joint narrow gap laser welding, girth joint narrow gap TIG welding, etc., and these modifications and variations should be considered as the protection scope of the present invention.
Claims (10)
1. A kind of girth weld narrow gap MAG welding process analogue means, characterized by that, including:
the device comprises a workbench, wherein a first clamp and a second clamp which can coaxially rotate are arranged on the workbench;
a metal test piece fixed on the first clamp, wherein a specified welding groove is formed in one surface of the metal test piece;
a light-transmitting plate fixed on the second fixture, wherein a designated welding groove is formed in one surface, which is attached to the metal test piece, of the light-transmitting plate, and a welding seam is formed between the designated welding groove and the welding groove on the metal test piece;
and the MAG welding machine is used for carrying out simulated welding operation on the welding seam.
2. The apparatus of claim 1 wherein the first clamp is a three-jaw clamp.
3. The apparatus of claim 1, wherein the second fixture is a vacuum chuck.
4. The apparatus of claim 1, wherein the light-transmitting plate is GG17 high temperature glass.
5. The apparatus for simulating a narrow-gap MAG welding process according to claim 1 wherein the MAG welder includes a welding gun including a wire feeder for feeding a welding wire and a gas feed tube for feeding a shielding gas.
6. The utility model provides a girth weld narrow gap MAG welding process molten bath characteristic information acquisition device, characterized by includes:
the device for simulating the narrow-gap MAG welding process of the circumferential weld of any one of claims 1 to 5;
the industrial camera is arranged on the workbench and used for acquiring image information of a molten pool in the welding process of the MAG welding machine on the welding seam through the light-transmitting plate;
and the data processing system is used for receiving and processing the image information of the molten pool acquired by the industrial camera to acquire the characteristic information of the molten pool.
7. The device for acquiring the characteristic information of the molten pool in the narrow-gap MAG welding process of the circumferential weld according to claim 6, further comprising a plurality of temperature sensors, wherein the plurality of temperature sensors are uniformly arranged on the surface of the metal test piece and used for acquiring the temperature of the molten pool and uploading the temperature to a data processing system, and the distance between each temperature sensor and the extension line of the truncated edge of the welding line is 3-5 mm.
8. The device for acquiring the characteristic information of the welding pool in the narrow-gap girth MAG welding process of the circumferential weld according to claim 6, wherein the industrial camera is provided with an optical filter.
9. The apparatus of claim 6, wherein the data processing system comprises an industrial computer.
10. The use method of the device for acquiring the characteristic information of the molten pool in the circumferential weld narrow gap MAG welding process is characterized by comprising the following steps of:
mounting the metal test piece with the well-processed welding groove on a first clamp;
installing the light transmitting plate with the processed welding groove on a second fixture, and attaching the light transmitting plate to the metal test piece to enable the welding groove on the metal test piece and the welding groove on the light transmitting plate to form a welding seam;
installing a welding gun of the debugged MAG welding machine at the position of a welding seam;
starting the debugged industrial camera and the data processing system;
and starting the MAG welding machine to weld the weld joint, and acquiring image information of the molten pool by the industrial camera and transmitting the image information to the data processing system for processing to obtain the characteristic information of the molten pool.
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| CN114749849A (en) * | 2022-06-01 | 2022-07-15 | 江苏徐工工程机械研究院有限公司 | Welding control method, device and system |
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Application publication date: 20211022 |
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