CN114273754A - Automatic welding control method - Google Patents
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- CN114273754A CN114273754A CN202210067367.XA CN202210067367A CN114273754A CN 114273754 A CN114273754 A CN 114273754A CN 202210067367 A CN202210067367 A CN 202210067367A CN 114273754 A CN114273754 A CN 114273754A
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Abstract
The invention discloses an automatic welding control method. Through removing the welding unit, discernment pipeline butt joint position makes the welding unit be located directly over the pipeline butt joint position, through this automatic control mode, has reduced the cost of labor. Initializing a welding unit, obtaining an initial position of the welding unit, scanning the butt joint position of the pipeline to obtain scanning data, obtaining the position of a welding gun through the scanning data, planning welding parameters and a welding path, and controlling the welding unit to carry out welding operation. The position of the welding gun is obtained through sensor calculation, and the welding parameters and the welding path are automatically planned through a deep learning network, so that the automation of the whole welding process is realized, the labor cost is greatly reduced, the precision error caused by manual operation is eliminated, and the welding precision is improved.
Description
Technical Field
The invention relates to the field of welding, in particular to an automatic welding control method.
Background
With the rapid increase of the demand of human beings on various resources along with the progress of social technology, the long-distance pipeline is developed towards the direction of large caliber, long distance, high pressure and high steel grade, the traditional manual welding and semi-automatic welding are difficult to meet the requirement of pipeline welding, the welding technology is also developed towards the direction of automatic welding, multilayer and multi-pass welding is adopted, an inner welding machine is adopted for bottoming welding, and then an outer welding machine is used for hot welding, filling welding and cover surface welding.
At present, the outer welding adopts a manual control remote controller to control a welding machine to weld the groove in a single layer, the initial positions of all units are obtained before welding, welding parameters are preset manually, the number of welding layers and welding paths are planned, errors of manual operation may influence the planning of the welding parameters and the welding paths, and the precision of subsequent welding operation is influenced. The welding gun is required to be manually aligned to the center of the groove, after welding is finished, the equipment is required to be manually moved to the arc starting point of the next welding layer from the end point, the training time of an operator is long, the requirement on the skill is high, and the welding efficiency and the welding precision cannot be guaranteed.
Disclosure of Invention
In view of the above, the invention provides an automatic welding control method, which solves the problems of high labor cost, low welding efficiency, low welding precision and low welding qualification rate by automatically controlling a welding workstation.
The invention provides a control method of an automatic welding machine, which comprises the following steps:
the welding unit is moved, the pipeline butt joint position is identified, whether the welding unit is located right above the pipeline butt joint position is judged, if not, the welding unit is continuously moved until the welding unit is located right above the pipeline butt joint position, and if yes, the welding unit is continuously moved until the welding unit is located right above the pipeline butt joint position;
initializing a welding unit, determining the initial position of the welding unit, and scanning the outline of the butt joint position of the pipeline to obtain pre-scanning data;
determining the position of a welding gun according to the pre-scanning data, and planning welding parameters and a welding path;
and controlling the welding unit to perform welding operation according to the position of the welding gun, the welding parameters and the welding path until the welding operation is finished.
Preferably, the identifying the pipe butting position and judging whether the welding unit is located right above the pipe butting position includes:
the method comprises the steps that the position of a pipeline groove is detected based on a groove detection unit, the welding unit is driven to move to the position above a pipeline butt joint position, and when the groove detection unit detects that the distance between the welding unit and the pipeline butt joint position in the pipeline extending direction is smaller than a first precision threshold value, the welding unit is finely adjusted to enable the horizontal distance between the welding unit and the pipeline butt joint position to be smaller than a second precision threshold value.
Preferably, the groove recognition unit comprises a visible light camera module, an infrared camera module or a structured light camera module.
Preferably, the initializing the welding unit and determining the initial position of the welding unit comprises:
controlling the clamping unit to clamp the pipeline, and judging whether the clamping is stable or not, if so, judging whether the clamping is stable or not;
and electrifying the welding unit to obtain the initial position of the welding unit on the clamping unit.
Preferably, the process of obtaining the initial position of the welding unit comprises:
and calculating the absolute value position of the driving motor according to a multi-turn absolute value decoder of the driving motor of the welding unit to be used as the initial position of the welding unit.
Preferably, the method further comprises the following steps:
collecting the temperature of the pipeline in the area of the pipeline butt joint position, judging whether the temperature is lower than the preset temperature, if so, heating the area through a heating coil on the clamping unit until the temperature of the pipeline in the area is not lower than the preset temperature, and entering the next step.
Preferably, the step of scanning the contour of the butt joint position of the pipeline to obtain the pre-scanning data includes:
and circumferentially scanning the pipeline butt joint position based on the initial position of the welding unit to obtain pre-scanning data of the pipeline butt joint position along the circumferential direction, wherein the pre-scanning data comprises one or more of the type of a welding seam, the angle of a groove, the width, the height, the area of a tangent plane and the amount of misalignment.
Preferably, the step of determining the position of the welding gun according to the profile scanning data and planning the welding parameters and the welding path includes:
adjusting the angle and the dry extension of a welding gun based on the initial position of the welding unit and the pre-scanning data, and determining the position of the welding gun;
extracting key point coordinates of the pipeline butt joint position and the appearance of the pipeline butt joint position based on pre-scanning data;
planning the number of welding layers and welding beads according to the shape of the butt joint position of the pipeline, and evaluating the shape of the welding seam of each welding layer and each welding bead;
generating welding parameters required for welding the corresponding welding seam appearance according to the appearance of each welding seam;
and generating a welding path according to the welding parameters and the key point coordinates.
Preferably, the step of generating welding parameters and generating welding paths required by the welding corresponding to the weld morphology includes:
inputting the welding line appearance of each welding layer and each welding path into a first neural network, and predicting welding parameters required to be used;
sending the welding parameters into a second neural network, and reversely predicting the appearance of the welding seam;
comparing the predicted weld appearance with the weld appearance of each weld layer and each weld pass, judging whether a third precision threshold is met, if so, outputting welding parameters, otherwise, adjusting the welding parameters, and re-comparing;
and inputting the welding parameters and the key point coordinates into a third neural network to generate a welding path.
Preferably, the process of extracting the key point coordinates of the pipeline docking position includes:
according to the pre-scanning data, the inflection point and the lowest point are taken as the coordinates of the key point in a two-dimensional coordinate system.
Preferably, the welding operation process comprises:
the gas sensor monitors the flow rate of the shielding gas, the concentration of the shielding gas and the pressure in real time, and judges whether any one of the flow rate of the shielding gas, the concentration of the shielding gas and the pressure is lower than a threshold value or not respectively, if so, the gas sensor gives an alarm and stops welding, and if not, the welding operation is continued.
Preferably, the method further comprises the following steps:
and the temperature sensor monitors the welding temperature in real time, judges whether the welding temperature is within a preset welding temperature interval or not, alarms and stops welding if not, and continues welding operation if yes.
Preferably, the method further comprises the following steps:
and after each welding is finished, polishing the arc closing point position.
The automatic control method has the primary improvement that the welding unit is moved to identify the butt joint position of the pipeline, so that the welding unit is positioned right above the butt joint position of the pipeline, and the labor cost is reduced through the automatic control method. Initializing a welding unit, obtaining an initial position of the welding unit, scanning the butt joint position of the pipeline to obtain scanning data, obtaining the position of a welding gun through the scanning data, planning welding parameters and a welding path, and controlling the welding unit to carry out welding operation. The position of the welding gun is obtained through sensor calculation, welding parameters and a welding path are automatically planned, automation of the whole welding process is achieved, labor cost is greatly reduced, precision errors caused by manual operation are eliminated, and welding precision is improved.
Drawings
FIG. 1 is a schematic flow diagram of an automatic welding control method;
fig. 2 is a schematic view of an outer welding station.
Detailed Description
In order that those skilled in the art will better understand the technical solutions of the present invention, the present invention will be further described in detail with reference to the following embodiments.
The control method provided by the invention is specifically shown in figure 1, and comprises the following steps:
the welding unit is moved, the pipeline butt joint position is identified, whether the welding unit is located right above the pipeline butt joint position is judged, if not, the welding unit is continuously moved until the welding unit is located right above the pipeline butt joint position, and if yes, the welding unit is continuously moved until the welding unit is located right above the pipeline butt joint position;
initializing a welding unit, determining the initial position of the welding unit, and scanning the outline of the butt joint position of the pipeline to obtain pre-scanning data;
determining the position of a welding gun according to the pre-scanning data, and planning welding parameters and a welding path;
and controlling the welding unit to perform welding operation according to the position of the welding gun, the welding parameters and the welding path until the welding operation is finished.
The technical scheme disclosed by the invention can control the welding system to finish automatic welding in one key mode through a wired or wireless remote controller and a remote instruction.
In a preferred embodiment of the application of the method, a welding station is included which is integrated with the pipe external welding device, which may be a relatively closed van welding station, which houses the external welding device, the power supply, the control system, and even a computer with data edge processing capabilities. The welding station allows the pipe to be welded to pass therethrough and allows the pipe to be welded safely and reliably in a relatively enclosed space within the welding station. In other embodiments of the present application, the welding station may also be an external welding machine and its associated equipment mounted on a moving cart, and it should be noted that the method claimed in the present application may also be applied to a single external welding equipment for pipelines without a welding station housing, and therefore, the system or apparatus applying the method of the present application should not be considered as limiting the application environment of the method of the present application.
In the above preferred embodiment, as shown in fig. 2, the outer welding station includes:
the casing for the suit is peripheral at the pipeline of waiting to weld, and accessible lifting device or the moving platform monolithic moving who carries on are provided with in it:
the external welding equipment comprises a groove identification unit, a welding unit, a clamping track and other necessary auxiliary devices of the external welding equipment.
The units are connected with the main control unit through cables, the main control unit receives starting signals, and the welding station is automatically controlled to complete the method disclosed by the application, so that automatic welding of pipelines is realized. The method specifically comprises the following steps:
after receiving a starting signal;
the driving welding station moves along the extending direction of the pipeline, the groove identification unit detects the surface of the pipeline below the driving welding station in real time, judges whether the groove exists and the distance between the groove and the groove, and judges whether the welding unit moves to the position above the butt joint position of the grooves of the two pipelines to be welded.
In the preferred embodiment, the groove identification unit is an infrared camera module, detects an image of the surface of the pipeline in real time, detects whether the horizontal distance between the current position of the groove identification unit and the butt joint position of the pipeline is smaller than a first precision threshold value through an infrared distance measurement algorithm, such as 2cm, and if not, the walking unit continues to control the welding workstation to move along the extension direction of the pipeline;
when the current position is smaller than the first precision threshold value, the main control unit controls the walking unit to stop moving, the welding station moves in place, then the outer welding equipment is enabled to accurately adjust the position of the welding unit relative to the groove to be welded along the sliding rail through the sliding block carried on the welding unit until the horizontal distance between the current position of the groove identification unit and the butt joint position of the pipeline is smaller than a second precision threshold value, such as 1.5mm, and the welding unit is located right above the butt joint position of the pipeline.
In other embodiments of the present application, the slide carried on the welding unit may also be directly driven without the need to move the welding station as a whole. In addition, the groove identification unit can also be a visible light camera module or a structured light camera module, and the horizontal distance between the current position of the groove identification unit and the pipeline butt joint position is detected by means of a distance calculation algorithm, image identification and the like.
Because the pipeline outer welding equipment has larger volume and weight, the traditional outer welding equipment is often dependent on the hoisting and manual alignment of constructors, and the working strength is higher. According to the welding device, the groove identification unit is used for identifying the position to be welded when the welding unit moves along the pipeline, errors possibly generated in the overall movement of the pipeline external welding equipment are eliminated in a mode of matching coarse and fine adjustment combination, the welding unit can move to the position above the pipeline butt joint position more accurately, and the defect that the automation degree of the pipeline external welding system is low due to the fact that the groove butt joint position cannot be effectively aligned in the prior art is overcome.
When the welding unit is located directly over the pipeline butt joint position, initializing the welding unit and determining the initial position of the welding unit, specifically comprising:
controlling the clamping unit to clamp the pipeline to be welded so as to fix the pipeline to be welded;
and electrifying the welding unit to obtain the initial position of the welding unit on the clamping unit.
The clamping unit described herein includes a clamping rail, a heating coil disposed on the clamping rail, and a temperature sensor.
The clamping track comprises at least two hinged track parts, the track parts are connected with clamping cylinders, and the clamping cylinders are used for driving the track parts to enable the track parts to surround to form an annular track for clamping and fixing two pipelines to be welded.
In other embodiments of the application, the clamping can be completed by using a clamping cylinder, and the clamping can also be completed by using a hydraulic push rod, a motor drive and other modes. And the clamping rail is determined to be clamped and fixed through the stroke or stress feedback of a driving device such as a hydraulic push rod or an air cylinder.
Because there may be low temperature weather in some areas, the pipeline temperature is too low to be favorable to the formation of pipeline welding seam, consequently can also be provided with the heating coil that is used for heating for pipeline butt joint position on the centre gripping track, after the centre gripping is accomplished, temperature sensor gathers the temperature in pipeline slope district's region to give the main control unit with temperature data signal transmission, when pipeline butt joint position temperature is less than preset temperature, if 15 ℃, the heating coil on the main control unit control centre gripping track heats the pipeline butt joint position, at this in-process, temperature sensor continues to gather pipeline butt joint position temperature, when the temperature reaches preset temperature, heating coil stops heating. This application is through with heating coil integration on the centre gripping track, need not artifical repeated installation, has satisfied under the different work condition to automatic weld's demand, further improve equipment automation welding's flow.
The welding unit is provided with a driving motor used for driving the welding unit to move along the track, the driving motor is provided with an absolute encoder, after the welding unit is powered on, the initial position of the welding unit on the clamping track is determined through the absolute encoder, and in other embodiments, the welding unit is further provided with an angle sensor used for assisting in determining the initial position of the welding unit. The position of the welding unit is determined through the absolute value encoder, so that the welding unit can start to execute follow-up actions from the initial position after each welding is finished, and meanwhile, path interference among a plurality of welding units and between the welding unit and other equipment can be avoided.
After initialization is completed, the welding unit scans the contour of the butt joint position of the pipeline along the rail operation, specifically performs circumferential scanning on the contour of the butt joint position of the pipeline through the laser scanner, sends a scanning signal to the main control unit, records the scanning as pre-scanning, and calculates to obtain the contour data of the butt joint position of the pipeline, such as the type of a welding seam, the angle of a groove, the width, the height, the area of a tangent plane, the misalignment amount and the like.
And calculating to generate a central value of the welding line and the required dry extension based on the profile data of the butt joint position of the pipeline, controlling the welding unit to drive the welding gun to align to the center of the welding line by the main control unit according to the central value of the welding line and the required dry extension, and adjusting the dry extension of the welding wire to ensure the success rate of arcing without manual verification.
Extracting weld line morphology and extracting inflection points and lowest points in a two-dimensional coordinate system as key point coordinates according to contour data of pipeline butt joint positions, planning the number of welding layers and welding passes based on the weld line morphology, determining the weld line morphology of each layer, inputting the planned weld line morphology into a first neural network to predict welding parameters, inputting the predicted welding parameters into a second neural network to reversely predict the weld line morphology because output parameters of the first neural network are greater than input parameters and the prediction accuracy is poor, comparing the planned weld line morphology with the predicted weld line morphology, judging whether errors are smaller than a third precision threshold value or not, and if so, outputting the welding parameters predicted by the first neural network; if not, adjusting the welding parameters, inputting the welding parameters into the second neural network again for comparison, and outputting the welding parameters until the error is smaller than the third precision threshold.
And inputting the planned welding morphology and the welding parameters into a third neural network to generate a welding path. In the automatic welding operation process of the application, errors can be accumulated in processes such as preorder welding station movement, welding unit movement, pipeline clamping and the like, errors such as position deviation, track angle deviation and the like accumulated in the process of welding station movement, clamping and the like in preorder automatic execution actions are eliminated by utilizing contour scanning of pipeline butt joint positions and neural network-based welding path planning, and the welding unit can plan a welding path based on scanning data to form a welding seam meeting welding quality requirements.
It should be noted that, in this embodiment, all the neural networks are CNN deep learning neural networks.
Controlling a welding unit to weld the butt joint position of the pipeline according to the planned welding parameters and welding path, monitoring the flow, the concentration and the pressure of the protective gas in real time by a gas sensor in the welding process, and alarming and stopping welding when the flow, the concentration and the pressure of the protective gas are lower than any one of a flow threshold, a concentration threshold and a pressure threshold of the protective gas;
in the welding process, the temperature sensor monitors the welding temperature in real time, and when the welding temperature is not in the welding temperature range, such as 800-1600 ℃, the alarm is given and the welding is stopped.
Preferably, after each welding is completed, the welding unit is controlled to return to the initial position, the butt joint positions of the pipelines are scanned, the appearance of the welding seam welded at the time is obtained, if the welding seam appearance accords with the planned welding seam appearance, the next welding is carried out, and if the welding seam appearance does not accord with the planned welding seam appearance, an alarm is given and the welding is stopped, so that the welding quality of each butt joint position of the pipelines is ensured.
It should be noted that after the current welding is completed, whether the current welding is the last welding needs to be judged based on the path planning, so as to feed back that the current external welding of the pipeline is completed.
In a more preferred embodiment, after each welding, the main control unit controls the grinding unit to grind the arc-closing point and sends a grinding completion signal to the main control unit, so that the welding unit starts from the initial position and performs the next welding.
In another embodiment of the present invention, the profile scanning and welding of the pipe butt joint position may be performed simultaneously or staggered. For example, a plurality of welding units, such as two welding units, may be disposed on the clamping track, the main control unit sends a control signal to start a welding operation, a laser sensor mounted on a first welding unit in the front operates to scan a pipeline butt joint position, and sends the scanning signal to the main control unit, the main control unit plans a welding path and welding parameters in real time, and sends the welding parameters and the welding path to a second welding unit to perform the welding operation, and the second welding unit starts the welding operation until the welding operation is completed in a process that the first welding unit scans the pipeline butt joint position. The initial positions of the first welding unit and the second welding unit are obtained through the multi-circle absolute value encoder, the first welding unit and the second welding unit can be prevented from colliding when moving according to a welding path, scanning and welding operation are carried out simultaneously, welding efficiency is improved, and engineering time is shortened.
The above is only a preferred embodiment of the present invention, and it should be noted that the above preferred embodiment should not be considered as limiting the present invention, and the protection scope of the present invention should be subject to the scope defined by the claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and these modifications and adaptations should be considered within the scope of the invention.
Claims (13)
1. An automatic welding control method, characterized in that the method comprises:
the welding unit is moved, the pipeline butt joint position is identified, whether the welding unit is located right above the pipeline butt joint position is judged, if not, the welding unit is continuously moved until the welding unit is located right above the pipeline butt joint position, and if yes, the welding unit is continuously moved until the welding unit is located right above the pipeline butt joint position;
initializing a welding unit, determining the initial position of the welding unit, and scanning the outline of the butt joint position of the pipeline to obtain pre-scanning data;
determining the position of a welding gun according to the pre-scanning data, and planning welding parameters and a welding path;
and controlling the welding unit to perform welding operation according to the position of the welding gun, the welding parameters and the welding path until the welding operation is finished.
2. The automatic weld control method of claim 1, wherein the identifying the pipe docking location and determining whether the welding unit is positioned directly above the pipe docking location comprises:
the method comprises the steps that the position of a pipeline groove is detected based on a groove detection unit, the welding unit is driven to move to the position above a pipeline butt joint position, and when the groove detection unit detects that the distance between the welding unit and the pipeline butt joint position in the pipeline extending direction is smaller than a first precision threshold value, the welding unit is finely adjusted to enable the horizontal distance between the welding unit and the pipeline butt joint position to be smaller than a second precision threshold value.
3. The automatic welding control method of claim 2, wherein the groove identification unit comprises a visible light camera module, an infrared camera module, or a structured light camera module.
4. The automatic weld control method of claim 1, wherein the initializing a welding unit and determining an initial position of the welding unit comprises:
controlling the clamping unit to clamp the pipeline, and judging whether the clamping is stable or not, if so, judging whether the clamping is stable or not;
and electrifying the welding unit to obtain the initial position of the welding unit on the clamping unit.
5. The automatic welding control method according to claim 4, characterized in that said process of obtaining the initial position of the welding unit is:
and calculating the absolute value position of the driving motor according to a multi-turn absolute value decoder of the driving motor of the welding unit to be used as the initial position of the welding unit.
6. The automatic weld control method of claim 4, further comprising:
collecting the temperature of the pipeline in the area of the pipeline butt joint position, judging whether the temperature is lower than the preset temperature, if so, heating the area through a heating coil on the clamping unit until the temperature of the pipeline in the area is not lower than the preset temperature, and entering the next step.
7. The automatic weld control method of claim 1, wherein the step of scanning the pipe butt joint location profile to obtain pre-scan data comprises:
and circumferentially scanning the pipeline butt joint position based on the initial position of the welding unit to obtain pre-scanning data of the pipeline butt joint position along the circumferential direction, wherein the pre-scanning data comprises one or more of the type of a welding seam, the angle of a groove, the width, the height, the area of a tangent plane and the amount of misalignment.
8. The automatic weld control method of claim 1, wherein the step of determining a torch position and planning welding parameters and a welding path based on the profile scan data comprises:
adjusting the angle and the dry extension of a welding gun based on the initial position of the welding unit and the pre-scanning data, and determining the position of the welding gun;
extracting key point coordinates of the pipeline butt joint position and the appearance of the pipeline butt joint position based on pre-scanning data;
planning the number of welding layers and welding beads according to the shape of the butt joint position of the pipeline, and evaluating the shape of the welding seam of each welding layer and each welding bead;
generating welding parameters required for welding the corresponding welding seam appearance according to the appearance of each welding seam;
and generating a welding path according to the welding parameters and the key point coordinates.
9. The automatic weld control method of claim 8, wherein the generating weld parameters and generating weld paths required for welding the corresponding weld profile comprises:
inputting the welding line appearance of each welding layer and each welding path into a first neural network, and predicting welding parameters required to be used;
sending the welding parameters into a second neural network, and reversely predicting the appearance of the welding seam;
comparing the predicted weld appearance with the weld appearance of each weld layer and each weld pass, judging whether a third precision threshold is met, if so, outputting welding parameters, otherwise, adjusting the welding parameters, and re-comparing;
and inputting the welding parameters and the key point coordinates into a third neural network to generate a welding path.
10. The automatic welding control method according to claim 8, wherein the process of extracting the coordinates of the key points of the pipe butt joint position is:
according to the pre-scanning data, the inflection point and the lowest point are taken as the coordinates of the key point in a two-dimensional coordinate system.
11. The automatic weld control method of claim 1, wherein the welding operation includes:
the gas sensor monitors the flow rate of the shielding gas, the concentration of the shielding gas and the pressure in real time, and judges whether any one of the flow rate of the shielding gas, the concentration of the shielding gas and the pressure is lower than a threshold value or not respectively, if so, the gas sensor gives an alarm and stops welding, and if not, the welding operation is continued.
12. The automatic weld control method of claim 1, further comprising:
and the temperature sensor monitors the welding temperature in real time, judges whether the welding temperature is within a preset welding temperature interval or not, alarms and stops welding if not, and continues welding operation if yes.
13. The automatic weld control method of claim 1, wherein the welding operation further comprises:
and after each welding is finished, polishing the arc closing point position.
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