CN113927153A - Multi-stage pressure friction welding control and quality evaluation method based on flash vision - Google Patents

Multi-stage pressure friction welding control and quality evaluation method based on flash vision Download PDF

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CN113927153A
CN113927153A CN202111324933.2A CN202111324933A CN113927153A CN 113927153 A CN113927153 A CN 113927153A CN 202111324933 A CN202111324933 A CN 202111324933A CN 113927153 A CN113927153 A CN 113927153A
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camera
pipe fitting
flash
welding
built
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CN113927153B (en
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付扬帆
李忠盛
吴护林
陈大军
黄安畏
丛大龙
刘正涛
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No 59 Research Institute of China Ordnance Industry
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No 59 Research Institute of China Ordnance Industry
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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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/126—Workpiece support, i.e. backing or clamping
    • 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
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Quality & Reliability (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

The invention provides a multi-stage pressure friction welding control and quality evaluation method based on flash vision, which comprises the steps of workpiece installation and position adjustment, friction welding process starting, welding flash detection, welding process control and post-welding quality evaluation; the method adopts a multi-stage pressure friction welding device comprising a welding machine seat platform (10), a welding machine rotating end (20), a welding machine moving end (30), an oil pressure station (40), a camera support (50), a computer control system (60) and a welding machine control system (70) to carry out welding. The method does not need to damage the welding joint, can timely, efficiently and accurately evaluate the quality of the welding joint in the friction welding process and carry out process control, thereby reducing the welding detection time, improving the welding efficiency, ensuring the production qualification rate and reducing the production cost.

Description

Multi-stage pressure friction welding control and quality evaluation method based on flash vision
Technical Field
The invention relates to the technical field of friction welding, in particular to a method for controlling and evaluating quality of multi-stage pressure friction welding based on flash vision.
Background
Welding plays a crucial role in the manufacturing process, is a key basic technology of the manufacturing industry in China, and is widely applied in the fields of aerospace, automobile industry, powder metallurgy, biomedicine, microelectronic industry and the like. Friction welding is a solid-state welding method in which friction heat and plastic deformation heat are generated in a friction surface and its vicinity by relative motion between welding contact end surfaces under the action of pressure and under the action of constant or increasing pressure and torque, so that the temperature of the friction surface and its vicinity is raised to a temperature range close to (but generally lower than) a melting point, the deformation resistance of a material is reduced, the plasticity is improved, an oxide film at an interface is broken, and the material is plastically deformed and flowed by a top-forging pressure, and the welding is performed by molecular diffusion and recrystallization at the interface.
In the welding process, because the parameters related to the friction welding process are more, the mutual coupling among all factors easily causes the quality of the friction welding joint to be influenced. At present, when the friction welding quality is judged, a mode of combining nondestructive detection and destructive detection is usually needed, the detection period is long, the detection cost is high, and meanwhile, the detection has delay or time interruption, so that the method is not beneficial to timely tracing, cannot perform corresponding modification on the friction welding process, reduces the welding efficiency and increases the production cost.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a multistage pressure friction welding control and quality evaluation method based on flash vision, which can evaluate the quality of a welding joint in a friction welding process timely, efficiently and accurately without damaging the welding joint, thereby reducing the welding detection time, improving the welding efficiency, ensuring the production qualification rate and reducing the production cost.
The purpose of the invention is realized by the following technical scheme:
a multi-stage pressure friction welding control and quality evaluation method based on flash vision is characterized in that: welding by adopting a multistage pressurizing friction welding device, wherein the multistage pressurizing friction welding device comprises a welding machine seat platform, a welding machine rotating end, a welding machine moving end, an oil pressure station, a camera support, a computer control system and a welding machine control system; the welding machine rotating end and the welding machine moving end are oppositely arranged on the welding machine base platform, the welding machine rotating end is controlled through a rotating end spindle, and the welding machine moving end is controlled through a moving end spindle; the clamping part of the movable end of the welding machine comprises a telescopic loop bar, a clamping jaw and a fixed base, the telescopic loop bar comprises a fixed sleeve and an extension bar, the fixed sleeve is fixedly connected with the fixed base, the fixed sleeve is sleeved on the outer wall of the extension bar, the extension bar is in sliding connection with the fixed sleeve, one end of the extension bar penetrates through the fixed base, the clamping jaw is uniformly arranged on the outer ring of the fixed base around the central axis of the fixed base, and the central axes of the telescopic loop bar, the clamping jaw and the fixed base are collinear; the extension rod is far away from one end of the fixed base and is sequentially provided with a first built-in camera, a second built-in camera and a third built-in camera from far to near; the oil pressure station controls the movement of a main shaft at the moving end, and the clamping of a rotating end of the welding machine and a workpiece at the moving end of the welding machine; the camera support is a telescopic support, is arranged on the upper end surface of the welding machine base platform and is in sliding connection with the welding machine base platform, and is sequentially provided with a first external camera, a second external camera and a third external camera from the position close to the rotating end of the welding machine to the position far away from the rotating end of the welding machine; the computer control system is respectively electrically connected with the first built-in camera, the second built-in camera, the third built-in camera, the first external camera, the second external camera, the third external camera and the welding machine control system; the welding control system is respectively connected with the welding machine rotating end, the welding machine moving end and the oil pressure station;
the control and quality evaluation method specifically comprises the following steps:
a. workpiece installation and position adjustment: firstly, clamping a first pipe fitting by using a rotating end of a welding machine; then, the second pipe fitting is sleeved on the outer wall of the fixed sleeve, and the outer wall of the second pipe fitting is clamped through the clamping claws, so that the second pipe fitting is clamped by the movable end of the welding machine; then, controlling the main shaft at the movable end to drive the movable end of the welding machine to move towards the direction close to the rotating end of the welding machine, and when the second pipe fitting is contacted with the surface to be welded of the first pipe fitting, controlling the main shaft at the movable end to drive the movable end of the welding machine to retreat (namely, towards the direction far away from the rotating end of the welding machine) for a certain distance, and stopping the movement of the main shaft at the movable end; then the extension rod is controlled to move, so that the first built-in camera is positioned on the inner side of the first pipe fitting, the second built-in camera is positioned in the center of the inner side of the surface to be welded, and the third built-in camera is positioned on the inner side of the second pipe fitting; then adjusting the position of the camera support to enable the first external camera to be positioned outside the first pipe fitting, the second external camera to be positioned outside the surface to be welded and the third external camera to be positioned outside the second pipe fitting;
b. starting a friction welding process: starting the rotating end of the welding machine to drive the first pipe fitting to rotate at a high speed to a specified rotating speed, and then disconnecting the rotating end of the welding machine from the main shaft of the rotating end; simultaneously starting the oil pressure station to enable the moving end of the welding machine to drive the second pipe fitting to move towards the direction of the first pipe fitting, so that the first pipe fitting is in contact with the surface to be welded of the second pipe fitting, and heat is generated by means of high-speed autorotation friction of the first pipe fitting to realize welding;
c. detecting welding burrs: in the welding process, a first external camera is used for detecting the outline condition of the outer flash of the first pipe fitting in real time, a first internal camera is used for detecting the outline condition of the inner flash of the first pipe fitting in real time, a third external camera is used for detecting the outline condition of the outer flash of the second pipe fitting in real time, a third internal camera is used for detecting the outline condition of the inner flash of the second pipe fitting in real time, a second external camera is used for detecting the outline conditions of the outer flash of the first pipe fitting and the second pipe fitting in real time, and a second internal camera is used for detecting the outline conditions of the inner flash of the first pipe fitting and the second pipe fitting in real time; then processing and comprehensive calculation are carried out through a computer control system, and the size coefficients of the inner flash and the outer flash of the first pipe fitting and the second pipe fitting are respectively obtained;
d. controlling a welding process: the welding process is regarded as consisting of a plurality of delta t time periods, simultaneously, the computer control system presets a flash size coefficient threshold value (namely the inner and outer flash size coefficients of the first pipe fitting and the second pipe fitting) corresponding to the time periods, and the computer control system compares the flash size coefficient of each delta t time period with the flash size coefficient threshold value corresponding to the time period in real time, so that oil pressure adjustment or pressure maintaining is carried out through an oil pressure station until the welding is finished;
e. and (3) post-welding quality evaluation: after welding, the contour conditions of inner and outer flashes of the first pipe fitting and the second pipe fitting are shot in a delayed mode through the first built-in camera, the second built-in camera, the third built-in camera, the first external camera, the second external camera and the third external camera, the sizes of the inner and outer flashes of the first pipe fitting and the second pipe fitting are obtained through the computer control system respectively, and are compared with preset parameters of the welded flashes in the computer control system, so that the welding quality of the welded joint is judged.
Further preferably, the clamping jaw is a spring chuck type jaw.
For further optimization, the first built-in camera, the second built-in camera, the third built-in camera, the first external camera, the second external camera and the third external camera respectively comprise a camera body, a protective sleeve, an optical filter, a light-transmitting glass sheet and a protective sleeve cover; the protection sleeve is sleeved on the outer wall of the camera body, the inner wall of the protection sleeve cover is in threaded connection with the outer wall of the protection sleeve, the middle end of the protection sleeve cover corresponds to the camera body, a through hole is formed in the camera body, a light-transmitting glass sheet and a light filter are sequentially arranged between the protection sleeve cover and the camera body, and the light filter is attached to the camera body.
The first built-in camera and the third built-in camera are connected with the extension rod through a fixed support, the distance between the first built-in camera and the inner wall of the first pipe fitting is 3-5 mm, the distance between the third built-in camera and the inner wall of the second pipe fitting is 3-5 mm, the second built-in camera is arranged in the extension rod, and the normal line of the second built-in camera is over against the center of the surface to be welded on the inner side; the first external camera is 3-5 mm away from the outer wall of the first pipe fitting, the third external camera is 3-5 mm away from the outer wall of the second pipe fitting, and the normal line of the second external camera is right opposite to the center of the to-be-welded surface on the outer side.
The method is further optimized, the first built-in camera, the second built-in camera, the third built-in camera, the first external camera, the second external camera and the third external camera are wide-scene cameras, the joints of the first built-in camera, the second built-in camera and the third built-in camera and the extension rod are provided with rubber shock pads of 3-5 mm; shock absorbers are arranged at the joints of the extension rod, the camera support and the welding machine.
Preferably, the extension rod and the camera support are made of high-rigidity materials.
For further optimization, the method for obtaining the flash size coefficient through the flash contour condition in the step c specifically comprises the following steps: the method comprises the steps of firstly obtaining the length L of a flash through the absolute value of the difference value of the maximum value of the rotating contour diameter of the surface (namely the inner surface or the outer surface) of a pipe fitting (namely a first pipe fitting or a second pipe fitting) to be welded (namely the first pipe fitting or the second pipe fitting), then obtaining the maximum value D of the width of the flash through the shooting contour of a camera (namely a second external camera or a second internal camera), and finally obtaining the size coefficient A of the flash through the width of the flash and the length of the flash, wherein the method specifically comprises the following steps:
Figure BDA0003346611610000041
wherein k is a constant and is obtained according to the material, the outer diameter and the inner diameter of the pipe fitting to be welded (i.e. the first pipe fitting or the second pipe fitting).
Preferably, the Δ t time period is 2 s.
Further optimization, the specific steps of adjusting oil pressure or maintaining pressure in the step d are as follows: firstly, presetting an oil pressure value corresponding to a flange size coefficient threshold value in each delta t time period in a computer control system (namely a function curve of the flange size coefficient and the oil pressure value is obtained by fitting according to a large amount of experimental data), then comparing the average value of the actual flange size coefficient in the delta t time period with the flange size coefficient threshold value in the corresponding time period, if the average value is smaller than the threshold value, the friction is insufficient, and increasing the oil pressure value in the next time period to the oil pressure value corresponding to the flange size coefficient threshold value in the next time period; otherwise, the oil pressure value is kept unchanged in the next time period.
And d, further optimizing, wherein a flash ending size coefficient (comprising an inner flash ending size coefficient and an outer flash ending size coefficient) is also set in the step d, if the inner and outer flash size coefficients of the first pipe fitting and the second pipe fitting are both larger than the flash ending size coefficient, the welding machine control system directly produces an upsetting control signal, and the oil pressure station directly raises the oil pressure to the upsetting oil pressure and maintains the pressure until the first pipe fitting stops rotating, and the welding is finished.
Preferably, the time for the delayed shooting in the step e is 2-3 s.
And (e) further optimizing, wherein the preset parameters of the flash after welding in the step (e) are as follows: "X1The length of the outer flash of the first pipe fitting is more than or equal to X2And X3The length of the inner flash of the first pipe fitting is more than or equal to X4And X5The length of the outer flash of the second pipe fitting is more than or equal to X6And X7The length of the inner flash of the second pipe fitting is more than or equal to X8And X9The width of the outer flash of the first pipe fitting is more than or equal to X10And X11The width of the inner flash of the first pipe fitting is more than or equal to X12And X13The width of the outer flash of the second pipe fitting is more than or equal to X14And X15The width of the inner flash of the second pipe fitting is more than or equal to X16", i.e., qualified; wherein, X1～X16The material, structure, size and the like of the pipe fitting to be welded are preset according to actual conditions.
The invention has the following technical effects:
according to the method, the flash detection is carried out through six dimensions, and the multistage controllable pressurized friction welding is realized through the interrelation of the size of the flash, the size coefficient of the flash and the oil pressure value, so that the adjustability and controllability of the friction welding process are ensured, and the welding quality is improved; meanwhile, the camera body, the protective sleeve, the optical filter, the light-transmitting glass sheet and the protective sleeve cover are matched, so that the damage of the camera caused by splashes in the welding process is effectively prevented (only the light-transmitting glass sheet needs to be replaced after the light-transmitting glass sheet is adhered to the splashes), the strong light interference in the welding process is avoided, and the problems that the image shooting is interfered by 'false images' and the splashes, and the test result is inaccurate or the shooting cannot be carried out are effectively prevented; the effect of preventing shaking and keeping stability is achieved by arranging a 3-5 mm rubber shock pad at the contact end of the camera and arranging a shock absorber at the contact end of the welding machine.
According to the method, the welding process control in the welding process is realized through the detection of the flash, the evaluation of the welding quality after welding is realized, and the welding process is associated with the evaluation of the welding quality after welding, so that the whole friction welding is evaluated timely, efficiently and accurately, the welding detection and evaluation time is shortened, the welding efficiency is improved, and the production qualification rate and the production cost are ensured.
Drawings
Fig. 1 is a schematic structural diagram of a multistage pressure friction welding device in an embodiment of the present invention.
FIG. 2 is a schematic structural diagram of a clamping portion of a moving end of a welding machine of the multistage pressure friction welding device in the embodiment of the invention.
Fig. 3 is a schematic structural diagram of the position of the camera during the welding process in the embodiment of the invention.
Fig. 4 is a schematic structural diagram of a camera of the multistage pressure friction welding device in the embodiment of the present invention.
FIG. 5 is a schematic structural view of the size of the flash in an embodiment of the present invention; wherein, FIG. 5(a) is a schematic representation of the length of the flash; fig. 5(b) is a schematic view showing the width of the burr.
10, a welding machine seat platform; 100. welding a flash; 101. a first built-in camera; 102. a second built-in camera; 103. a third built-in camera; 104. a first external camera; 105. a second external camera; 106. a third external camera; 1011. a camera body; 1012. a protective sleeve; 1013. an optical filter; 1014. a light-transmitting glass sheet; 1015. a protective cylinder cover; 20. a rotating end of the welding machine; 30. a welding machine moving end; 31. a telescopic loop bar; 311. fixing a sleeve; 312. an extension rod; 32. clamping jaws; 33. a fixed base; 40. an oil pressure station; 50. a camera head bracket; 60. a computer control system; 70. a welder control system; 80. a first pipe member; 90. a second pipe.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
Example (b):
as shown in fig. 1 to 5, a method for controlling and evaluating quality of multistage pressure friction welding based on flash vision is characterized in that: welding by adopting a multi-stage pressurizing friction welding device, wherein the multi-stage pressurizing friction welding device comprises a welding machine seat platform 10, a welding machine rotating end 20, a welding machine moving end 30, an oil pressure station 40, a camera support 50, a computer control system 60 and a welding machine control system 70; the welding machine rotating end 20 and the welding machine moving end 30 are oppositely arranged on the welding machine seat platform 10, the welding machine rotating end 20 is controlled through a rotating end spindle, and the welding machine moving end 30 is controlled through a moving end spindle; the clamping part of the welding machine moving end 30 comprises a telescopic loop bar 31, clamping jaws 32 and a fixed base 33, the telescopic loop bar 31 comprises a fixed sleeve 311 and an extension bar 312, the fixed sleeve 311 is fixedly connected with the fixed base 33, the fixed sleeve 311 is sleeved on the outer wall of the extension bar 312, the extension bar 312 is in sliding connection with the fixed sleeve 311, one end of the extension bar 312 penetrates through the fixed base 33, the clamping jaws 32 are uniformly arranged on the outer ring of the fixed base 33 around the central axis of the fixed base 33, and the central axes of the telescopic loop bar 31, the clamping jaws 32 and the fixed base 33 are collinear; the extension rod 312 is far away from one end of the fixed base 33 and is provided with a first built-in camera 101, a second built-in camera 102 and a third built-in camera 103 in sequence from far to near; the oil pressure station 40 controls the movement of the main shaft at the moving end and the workpiece clamping at the rotating end 20 and the moving end 30 of the welding machine; the camera support 50 is a telescopic support, is arranged on the upper end surface of the welding machine seat platform 10 and is in sliding connection with the welding machine seat platform 10, and the first external camera 104, the second external camera 105 and the third external camera 106 are sequentially arranged from the position close to the welding machine rotating end 20 to the position far away from the welding machine rotating end 50; the computer control system 60 is electrically connected with the first internal camera 101, the second internal camera 102, the third internal camera 103, the first external camera 104, the second external camera 105, the third external camera 106 and the welder control system 70 respectively; the welding control system 70 is respectively connected with the welding machine rotating end 20, the welding machine moving end 30 and the oil pressure station 40;
the clamping jaw 32 adopts a spring chuck type jaw; the first internal camera 101, the second internal camera 102, the third internal camera 103, the first external camera 104, the second external camera 105 and the third external camera 106 all comprise a camera body 1011, a protective sleeve 1012, a light filter 1013, a light-transmitting glass sheet 1014 and a protective sleeve cover 1015; the protective sleeve 1012 is sleeved on the outer wall of the camera body 1011, the inner wall of the protective sleeve cover 1015 is in threaded connection with the outer wall of the protective sleeve 1012, a through hole is formed in the middle end of the protective sleeve cover 1015 corresponding to the camera body 1011, a light-transmitting glass sheet 1014 and a light filter 1013 are sequentially arranged between the protective sleeve cover 1015 and the camera body 1011, and the light filter 1013 is attached to the camera body 1011; the extension bar 312 and the camera support 50 are made of a highly rigid material.
The control and quality evaluation method comprises the following steps:
a. workpiece installation and position adjustment: first, clamping a first pipe fitting 80 with the rotating end 20 of the welder; then, the second pipe fitting 90 is sleeved on the outer wall of the fixed sleeve 311, and the outer wall of the second pipe fitting 90 is clamped through the clamping claws 32, so that the second pipe fitting 90 is clamped by the movable end 30 of the welding machine; then, controlling the main shaft of the movable end to drive the movable end 30 of the welding machine to move towards the direction close to the rotating end 20 of the welding machine, and when the second pipe fitting 90 is in contact with the surface to be welded of the first pipe fitting 80, controlling the main shaft of the movable end to drive the movable end 30 of the welding machine to retreat (i.e. towards the direction far away from the rotating end 20 of the welding machine) for a certain distance, and stopping the main shaft of the movable end to move; then the extension rod 312 is controlled to move, so that the first built-in camera 101 is positioned on the inner side of the first pipe fitting 80, the second built-in camera 102 is positioned in the center of the inner side of the surface to be welded, and the third built-in camera 103 is positioned on the inner side of the second pipe fitting 90; then adjusting the position of the camera bracket 50, so that the first external camera 104 is positioned outside the first pipe fitting 80, the second external camera 105 is positioned outside the surface to be welded, and the third external camera 106 is positioned outside the second pipe fitting 90;
the method specifically comprises the following steps: the first built-in camera 101 and the third built-in camera 103 are connected with the extension rod 312 through a fixed support, the distance between the first built-in camera 101 and the inner wall of the first pipe fitting 80 is 3-5 mm, the distance between the third built-in camera 103 and the inner wall of the second pipe fitting 90 is 3-5 mm, the second built-in camera 102 is arranged in the extension rod 312, and the normal line of the second built-in camera is opposite to the center of the inner side surface to be welded (as shown in FIG. 3); the first external camera 104 is 3-5 mm away from the outer wall of the first pipe fitting 80, the third external camera 106 is 3-5 mm away from the outer wall of the second pipe fitting 90, and the normal of the second external camera 105 is over against the center of the to-be-welded surface on the outer side (as shown in fig. 3).
Meanwhile, the first built-in camera 101, the second built-in camera 102, the third built-in camera 103, the first external camera 104, the second external camera 105 and the third external camera 106 are wide-scene cameras, 3-5 mm rubber shock-absorbing pads are arranged at the joints of the first built-in camera 101, the second built-in camera 102 and the third built-in camera 103 and the extension rod 312, and the joints of the first external camera 104, the second external camera 105 and the third external camera 106 and the camera bracket 50, so that buffering shock absorption is provided, and the situation that the camera is damaged by splashes is avoided; and shock absorbers are provided at the end of the extension rod 312 and the lower end of the camera bracket 50.
b. Starting a friction welding process: starting the welding machine rotating end 20 to drive the first pipe fitting 80 to rotate at a high speed to a specified rotating speed, and then disconnecting the welding machine rotating end 20 from a rotating end main shaft; meanwhile, the oil pressure station 40 is started, so that the welding machine moving end 30 drives the second pipe fitting 90 to move towards the first pipe fitting 80, the first pipe fitting 80 is in contact with the surface to be welded of the second pipe fitting 90, and heat is generated by means of high-speed rotation friction of the first pipe fitting 80 to realize welding;
c. detecting welding burrs: in the welding process, the outline condition of the outer flash of the first pipe fitting 80 is detected in real time through the first external camera 104, the outline condition of the inner flash of the first pipe fitting 80 is detected in real time through the first internal camera 101, the outline condition of the outer flash of the second pipe fitting 90 is detected in real time through the third external camera 106, the outline condition of the inner flash of the second pipe fitting 90 is detected in real time through the third internal camera 103, the outline conditions of the outer flash of the first pipe fitting 80 and the second pipe fitting 90 are detected in real time through the second external camera 105, and the outline conditions of the inner flash of the first pipe fitting 80 and the second pipe fitting 90 are detected in real time through the second internal camera 102; then, the computer control system 60 is used for processing and comprehensive calculation to respectively obtain the size coefficients of the inner and outer flashes of the first pipe fitting 80 and the second pipe fitting 90;
the method specifically comprises the following steps:
firstly, the length L of the flash is obtained by the maximum difference between the diameter of the rotary profile of the flash and the diameter of the rotary profile of the surface (i.e., the inner surface or the outer surface) of the pipe to be welded (i.e., the first pipe 80 or the second pipe 90), then the maximum value D of the width of the flash is obtained by the shooting profile of the camera (i.e., the second external camera 105 or the second internal camera 102), and finally the size coefficient a of the flash is obtained by the width of the flash and the length of the flash, which is specifically as follows:
Figure BDA0003346611610000091
where k is a constant and is obtained according to the material, the outer diameter, and the inner diameter of the pipe to be welded (i.e., the first pipe 80 or the second pipe 90).
For example: as shown in fig. 5(a), the maximum value of the outer flash rotation profile diameter of the first pipe 80 is first obtained by the first external camera 104 (assumed as S)1) Maximum value (assumed as S) of the diameter of the rotational profile of the outer surface of the first pipe 802) Then, the absolute value of the difference is calculated (i.e. Δ S ═ S)1-S2L) to obtain the outer flash length (i.e., L) of first tube 801Δ S); in this way, the flash length L in the first pipe 80 is obtained by the first built-in camera 101, respectively2The outer flash length L of the second pipe fitting 90 is obtained through the third external camera 1063And obtaining the inner flash length L of the second pipe fitting 90 through the third built-in camera 1034(ii) a Then, as shown in fig. 5(b), the maximum width D of the burrs inside the first pipe 80 and the second pipe 90 is obtained by the second built-in camera 1021' and D2' the maximum width D of the outer fins of the first tube 80 and the second tube 90 is obtained by the second external camera 1051And D2Finally, the size coefficient A of the outer flash of the first pipe fitting 80 is obtained1(ii) a Namely, it is
Figure BDA0003346611610000101
Sequentially obtaining the size coefficient A of the inner flash of the first pipe fitting 802The outside flash size coefficient A of the second pipe fitting 903And the coefficient of size of the inner flash A of the second pipe 904。
d. Controlling a welding process: regarding the welding process as a plurality of time periods of delta t, wherein the delta t is 2s, presetting a flash size coefficient threshold value (namely the inner and outer flash size coefficients of the first pipe fitting 80 and the second pipe fitting 90) corresponding to the time periods in the computer control system 60, and comparing the flash size coefficient of each time period of 2s with the flash size coefficient threshold value corresponding to the time period in real time by the computer control system 60, so as to adjust or maintain the oil pressure through an oil pressure station until the welding is finished;
the method specifically comprises the following steps: firstly, presetting an oil pressure value (namely a function curve of a flash size coefficient and the oil pressure value) corresponding to a flash size coefficient threshold value in each delta t time period (namely in each 2 s), and then comparing the actual flash size coefficient mean value of the nth delta t time period with the flash size coefficient threshold value in the corresponding time period, if the actual flash size coefficient mean value is smaller than the flash size coefficient threshold value, the friction is insufficient, and the oil pressure value of the next time period is increased to the oil pressure value corresponding to the flash size coefficient threshold value of the next time period; otherwise, the oil pressure value is kept unchanged in the next time period.
For example: calculating to obtain the average value of the coefficient of the size of the flash in the second 2s time period (namely
Figure BDA0003346611610000102
) If the oil pressure value is smaller than the preset flash size coefficient threshold value at the 4 th s, the friction is considered to be insufficient, and the oil pressure value in the next (namely, the third) 2s time period is increased to the oil pressure value corresponding to the flash size coefficient threshold value at the 6 th s; otherwise (namely the average value of the actual flange size coefficients of the time period delta t is greater than or equal to the threshold value of the flange size coefficients corresponding to the time period delta t), the oil pressure value is kept unchanged in the next time period (namely the oil pressure value is not adjusted)Integer). The hydraulic pressure value corresponding to the burr size coefficient threshold value at the time of the above-described 6s is calculated as follows: the expert library of the welding machine control system corresponds to the O-shaped oil pressure value of the 6 th s according to the size coefficient of the inner flange of the first pipe fitting1n(ii) a The expert library of the welding machine control system corresponds to the O-shaped oil pressure value of the 6 th s according to the size coefficient of the outer flange of the first pipe fitting1w(ii) a The expert library of the welding machine control system corresponds to the O-shaped oil pressure value of the 6 th s according to the size coefficient of the inner flange of the second pipe fitting2n(ii) a The expert library of the welding machine control system corresponds to the O-shaped oil pressure value of the 6 th s according to the size coefficient of the outer flange of the first pipe fitting2w. The oil pressure value O at the 6 th timeeqThe method comprises the following steps: o iseq＝(Ο1w+Ο1n+Ο2w+Ο2n)/4。
Meanwhile, the end size coefficient of the flash (including the end size coefficient of the inner flash and the end size coefficient of the outer flash) is also set in the welding process, if the inner and outer flash size coefficients of the first pipe fitting 80 and the second pipe fitting 90 are both larger than the end size coefficient of the flash, the welder control system 70 directly generates an upsetting control signal, and the oil pressure station 40 directly raises the oil pressure to the upsetting oil pressure and maintains the pressure until the first pipe fitting 80 stops rotating, and the welding is finished.
e. And (3) post-welding quality evaluation: after welding, shooting the inner and outer flash contour conditions of the first pipe fitting and the second pipe fitting by delaying for 2-3 s through the first built-in camera, the second built-in camera, the third built-in camera, the first external camera, the second external camera and the third external camera, respectively obtaining the inner and outer flash sizes of the first pipe fitting and the second pipe fitting through the computer control system, and comparing with preset parameters of the welded flash in the computer control system, thereby judging the welding quality of the welding joint.
The preset parameters of the flash after welding are as follows: "X1The length of the outer flash of the first pipe fitting is more than or equal to X2And X3The length of the inner flash of the first pipe fitting is more than or equal to X4And X5The length of the outer flash of the second pipe fitting is more than or equal to X6And X7The length of the inner flash of the second pipe fitting is more than or equal to X8And X9The width of the outer flash of the first pipe fitting is more than or equal to X10And X11Not less than the first pipe fitting inner flyThe width of the edge is more than or equal to X12And X13The width of the outer flash of the second pipe fitting is more than or equal to X14And X15The width of the inner flash of the second pipe fitting is more than or equal to X16", i.e., qualified; wherein, X1～X16The method is related to the material, structure, size and the like of the pipe fitting to be welded (obtained by fitting a large amount of experimental data into an expert database), and is preset according to actual conditions.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned. Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.

Claims (7)

1. A multi-stage pressure friction welding control and quality evaluation method based on flash vision is characterized in that: welding by adopting a multi-stage pressurizing friction welding device, wherein the multi-stage pressurizing friction welding device comprises a welding machine seat platform (10), a welding machine rotating end (20), a welding machine moving end (30), an oil pressure station (40), a camera support (50), a computer control system (60) and a welding machine control system (70); the welding machine rotating end (20) and the welding machine moving end (30) are oppositely arranged on the welding machine seat platform (10), the welding machine rotating end (20) is controlled through a rotating end spindle, and the welding machine moving end (30) is controlled through a moving end spindle; the clamping part of the welding machine moving end (30) comprises a telescopic loop bar (31), clamping jaws (32) and a fixed base (33), the telescopic loop bar (31) comprises a fixed sleeve (311) and an extension rod (312), the fixed sleeve (311) is fixedly connected with the fixed base (33), the fixed sleeve (311) is sleeved on the outer wall of the extension rod (312), the extension rod (312) is slidably connected with the fixed sleeve (311), one end of the extension rod penetrates through the fixed base (33), the clamping jaws (32) are uniformly arranged on the outer ring of the fixed base (33) around the central axis of the fixed base, and the central axes of the telescopic loop bar (31), the clamping jaws (32) and the fixed base (33) are collinear; the extension rod (312) is far away from one end of the fixed base (33) and is sequentially provided with a first built-in camera (101), a second built-in camera (102) and a third built-in camera (103) from far to near; the oil pressure station (40) controls the movement of a main shaft at the moving end, and the clamping of workpieces at the rotating end (20) and the moving end (30) of the welding machine; the camera support (50) is a telescopic support and is arranged on the upper end face of the welding machine seat platform (10) and is in sliding connection with the welding machine seat platform (10), and the camera support (50) is sequentially provided with a first external camera (104), a second external camera (105) and a third external camera (106) from the position close to the welding machine rotating end (20) to the position far away from the welding machine rotating end; the computer control system (60) is respectively electrically connected with the first built-in camera (101), the second built-in camera (102), the third built-in camera (103), the first external camera (104), the second external camera (105), the third external camera (106) and the welding machine control system (70); the welding control system (70) is respectively connected with the welding machine rotating end (20), the welding machine moving end (30) and the oil pressure station (40);
the control and quality evaluation method specifically comprises the following steps:
a. workpiece installation and position adjustment: firstly, clamping a first pipe fitting (80) by using a rotating end (20) of a welding machine; then, the second pipe fitting (90) is sleeved on the outer wall of the fixed sleeve (311), and the outer wall of the second pipe fitting (90) is clamped through the clamping claws (32), so that the second pipe fitting (90) is clamped by the movable end (30) of the welding machine; then controlling the main shaft of the movable end to drive the movable end (30) of the welding machine to move towards the direction close to the rotating end (20) of the welding machine, and controlling the main shaft of the movable end to drive the movable end (30) of the welding machine to retreat for a certain distance when the second pipe fitting (90) is contacted with the surface to be welded of the first pipe fitting (80), and stopping the main shaft of the movable end to move; then the extension rod (312) is controlled to move, so that the first built-in camera (101) is located on the inner side of the first pipe fitting (80), the second built-in camera (102) is located in the center of the inner side of the surface to be welded, and the third built-in camera (103) is located on the inner side of the second pipe fitting (90); then adjusting the position of the camera support (50) to enable a first external camera (104) to be positioned outside the first pipe fitting (80), a second external camera (105) to be positioned outside a surface to be welded and a third external camera (106) to be positioned outside the second pipe fitting (90);
b. starting a friction welding process: starting the welding machine rotating end (20) to drive the first pipe fitting (80) to rotate at a high speed to a specified rotating speed, and then disconnecting the welding machine rotating end (20) from a rotating end main shaft; simultaneously starting the oil pressure station (40) to enable the welding machine moving end (30) to drive the second pipe fitting (90) to move towards the first pipe fitting (80), so that the first pipe fitting (80) is in contact with the to-be-welded surface of the second pipe fitting (90) and generates heat by means of high-speed autorotation friction of the first pipe fitting (80) to realize welding;
c. detecting welding burrs: in the welding process, the outer flash contour condition of the first pipe fitting (80) is detected in real time through a first external camera (104), the inner flash contour condition of the first pipe fitting (80) is detected in real time through a first internal camera (101), the outer flash contour condition of the second pipe fitting (90) is detected in real time through a third external camera (106), the inner flash contour condition of the second pipe fitting (90) is detected in real time through a third internal camera (103), the outer flash contour conditions of the first pipe fitting (80) and the second pipe fitting (90) are detected in real time through a second external camera (105), and the inner flash contour conditions of the first pipe fitting (80) and the second pipe fitting (90) are detected in real time through a second internal camera (102); then, processing and comprehensive calculation are carried out through a computer control system (60), and the size coefficients of the inner flash and the outer flash of the first pipe fitting (80) and the second pipe fitting (90) are respectively obtained;
d. controlling a welding process: the welding process is regarded as consisting of a plurality of delta t time periods, simultaneously, a flash size coefficient threshold value corresponding to the time period is preset in a computer control system (60), and the computer control system (60) compares the flash size coefficient of each delta t time period with the flash size coefficient threshold value corresponding to the time period in real time, so that oil pressure adjustment or pressure maintaining is carried out through an oil pressure station (40) until welding is finished;
e. and (3) post-welding quality evaluation: after welding, the inner and outer flash contour conditions of the first pipe fitting (80) and the second pipe fitting (90) are shot in a delayed mode through the first built-in camera (101), the second built-in camera (102), the third built-in camera (103), the first external camera (104), the second external camera (105) and the third external camera (106), the inner and outer flash sizes of the first pipe fitting (80) and the second pipe fitting (90) are obtained through the computer control system (60) respectively, and are compared with the preset parameters of the welded flash in the computer control system (60), so that the welding quality of the welding joint is judged.
2. The flash vision-based multistage pressure friction welding control and quality evaluation method according to claim 1, characterized in that: the camera comprises a first built-in camera (101), a second built-in camera (102), a third built-in camera (103), a first external camera (104), a second external camera (105) and a third external camera (106), wherein the first built-in camera, the second built-in camera and the third external camera respectively comprise a camera body (1011), a protective sleeve (1012), an optical filter (1013), a light-transmitting glass sheet (1014) and a protective sleeve cover (1015); the protection sleeve (1012) is sleeved on the outer wall of the camera body (1011) and the inner wall of the protection sleeve cover (1015) is in threaded connection with the outer wall of the protection sleeve (1012), the middle end of the protection sleeve cover (1015) corresponds to the camera body (1011) and is provided with a through hole, a light-transmitting glass sheet (1014) and an optical filter (1013) are sequentially arranged between the protection sleeve cover (1015) and the camera body (1011), and the optical filter (1013) is attached to the camera body (1011).
3. The flash vision-based multistage pressure friction welding control and quality evaluation method according to claim 1 or 2, characterized in that: the first built-in camera (101) and the third built-in camera (103) are connected with the extension rod (312) through a fixed support, the distance between the first built-in camera (101) and the inner wall of the first pipe fitting (80) is 3-5 mm, the distance between the third built-in camera (103) and the inner wall of the second pipe fitting (90) is 3-5 mm, the second built-in camera (102) is arranged in the extension rod (312), and the normal line of the second built-in camera is opposite to the center of the surface to be welded on the inner side; the first external camera (104) is 3-5 mm away from the outer wall of the first pipe fitting (80), the third external camera (106) is 3-5 mm away from the outer wall of the second pipe fitting (90), and the normal line of the second external camera (105) is right opposite to the center of the outer side surface to be welded.
4. The method for controlling and evaluating the quality of the multistage pressure friction welding based on the flash vision according to any one of claims 1 to 3, which is characterized in that: the first built-in camera (101), the second built-in camera (102), the third built-in camera (103), the first external camera (104), the second external camera (105) and the third external camera (106) are wide-scene cameras, the joints of the first built-in camera (101), the second built-in camera (102) and the third built-in camera (103) and the extension rod (312) are provided with rubber shock pads of 3-5 mm; shock absorbers are arranged at the joints of the extension rod (312), the camera support (50) and the welding machine.
5. The flash vision-based multistage pressure friction welding control and quality evaluation method according to claim 1, characterized in that: the method for obtaining the flash size coefficient through the flash contour condition in the step c specifically comprises the following steps: the method comprises the steps of firstly obtaining the length L of a flash through the absolute value of the difference value of the diameter of the rotary profile of the flash and the maximum value of the diameter of the rotary profile of the surface of a pipe to be welded, then obtaining the maximum value D of the width of the flash through the shooting profile of a camera, and finally obtaining the size coefficient A of the flash through the width of the flash and the length of the flash, wherein the method specifically comprises the following steps:
Figure FDA0003346611600000041
in the formula, k is a constant and is obtained according to the material, the outer diameter and the inner diameter of the pipe fitting to be welded.
6. The flash vision-based multistage pressure friction welding control and quality evaluation method according to claim 1, characterized in that: the step d of oil pressure adjustment or pressure maintaining comprises the following specific steps: firstly, presetting an oil pressure value corresponding to a flash size coefficient threshold value in each delta t time period in a computer control system (60), then comparing the average value of the actual flash size coefficients of the nth delta t time period with the flash size coefficient threshold value in the corresponding time period, if the average value is smaller than the flash size coefficient threshold value, ensuring that the friction is insufficient, and increasing the oil pressure value of the next time period to the oil pressure value corresponding to the flash size coefficient threshold value of the next time period; otherwise, the oil pressure value is kept unchanged in the next time period.
7. The flash vision-based multistage pressure friction welding control and quality evaluation method according to claim 1 or 6, characterized in that: and d, setting a flash ending size coefficient, if the inner and outer flash size coefficients of the first pipe fitting (80) and the second pipe fitting (90) are both larger than the flash ending size coefficient, directly generating an upsetting control signal by a welding machine control system (70), directly increasing the oil pressure to the upsetting oil pressure by an oil pressure station (40) and maintaining the pressure until the first pipe fitting (80) stops rotating, and finishing welding.
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