CN114309852A - Self-adaptive wire filling device and method for precise laser welding - Google Patents
Self-adaptive wire filling device and method for precise laser welding Download PDFInfo
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Abstract
The invention relates to the technical field of laser wire filling welding, and discloses a self-adaptive wire filling device and method for precise laser welding. The invention aims to provide a self-adaptive wire filling device and a method for eliminating the defect, so that the welding involution precision is effectively improved. Based on the weld data acquired by the weld detection system in real time, the three-dimensional modeling module can perform real-time accurate modeling on the weld, and the identification module identifies and extracts weld characteristics such as weld gaps, step differences and the like. Based on the welding seam characteristics, the process knowledge base can judge whether the wire is filled under the current working condition, and the wire feeding mechanism is controlled to start and stop in real time through the wire feeding control system, so that the self-adaptive wire filling of the laser welding is realized.
Description
The technical field is as follows:
the invention relates to the technical field of laser wire filling welding, in particular to a self-adaptive wire filling device and method for precise laser welding.
Background art:
the assembly clearance requirement of the laser welding butt welding parts is high, a laser filler wire welding process needs to be adopted for certain welding parts with large clearances, otherwise, welding leakage defects are easily caused, and the assembly precision is influenced. However, due to the limitation of the processing precision of the previous process, the weld gap of the weldment is inevitably uneven in the actual production, and the precise welding of the weldment is often difficult to realize by single laser self-fluxing welding or laser wire filling welding.
In view of the above problems, there are two common solutions: the other method is a segmentation method, wherein the welding seam is processed in a segmentation way, the welding seam is welded by adopting laser filler wires at the position with larger clearance, and the welding seam is welded by adopting laser self-melting at the position with smaller clearance. The segmentation method can be completed only by welding a welding seam for many times, thereby not only wasting time and labor, but also being easy to introduce more welding defects; the other method is a preset method, and the start and stop of the wire feeding mechanism are preset, so that the efficient one-step forming of the uneven-gap welding line can be realized. The problems are solved to a certain extent in advance, but the weld gap may also change dynamically in the welding process under the influence of high energy density of laser welding, and the preset method cannot adjust the change, so that the strict precision requirements in the fields of aerospace and the like are still difficult to meet.
Therefore, the prior art schemes have certain limitations, high-efficiency precise laser welding of uneven gap welding seams cannot be realized, and a device and a method which are self-adaptive to dynamic change of the welding seams and can control a wire filling mechanism to start and stop at any time in real time are urgently needed.
The invention content is as follows:
aiming at the defects of the prior art, the invention provides a self-adaptive wire filling device and a self-adaptive wire filling method for precise laser welding, aiming at controlling the start and stop of a wire feeding mechanism in the laser welding process in real time so as to solve the problems that the uneven gap welding seam of the laser welding has low precision and is easy to cause defects in the prior technical scheme.
In order to achieve the above object, the present invention provides a self-adaptive wire filling device for precision laser welding, which is used for controlling the start and stop of a wire feeding mechanism in the laser welding process in real time, and comprises: the device comprises a welding seam detection system, a three-dimensional modeling module, an identification module, a laser wire filling welding process knowledge base and a wire feeding control system. The welding seam detection system can acquire welding seam data in the laser welding process in real time; the three-dimensional modeling module can perform real-time accurate three-dimensional modeling on the welding seam based on the welding seam data; the identification module can identify and extract the welding seam characteristics; the laser wire filling welding process knowledge base can judge whether the current working condition needs wire filling according to the welding seam characteristics and output a control signal; the wire feeding control system can control the start and stop of the wire feeding mechanism in real time, so that the self-adaptive wire filling of laser welding is realized;
a self-adaptive wire filling method for precision laser welding specifically comprises the following steps:
step 1, scanning a weldment before welding, performing three-dimensional pre-modeling on the weldment, identifying and extracting weld joint characteristics of a welding spot, and setting an initial state of a wire filling mechanism;
step 2, starting laser welding, and acquiring welding seam information in real time by a welding seam detection system and transmitting the welding seam information to a data processing end;
step 3, based on the welding seam information, the three-dimensional modeling module corrects the pre-built three-dimensional model in real time, the welding seam characteristics are identified and extracted through the identification module, and the welding seam characteristics are sent to the computer terminal through the CAN bus;
step 4, based on the weld joint characteristics, matching process data by a laser wire filling welding process knowledge base, making a decision on the current working condition, and outputting a wire feeding mechanism control instruction signal through a CAN bus;
step 5, the wire feeding control system receives the instruction and controls the start and stop of the wire feeding mechanism in real time;
and 6, repeating the steps 3-5, extracting the weld joint characteristics based on the weld joint information feedback value, and carrying out closed-loop control on the wire feeding mechanism by the process knowledge base module and the wire feeding control system until the self-adaptive wire filling laser welding is finished.
Further, the weld detection system in the step 2 includes, but is not limited to, an industrial CCD camera and a structured light three-dimensional scanning measuring instrument, is loaded on a laser head, and can acquire data of a weld to be welded at the front end of a molten pool in the laser welding process in real time; the weld data includes, but is not limited to, high definition images, three dimensional deformation, etc. of the weld to be welded.
Further, the three-dimensional modeling module and the identification module in the step 3 are embedded software, and can perform filtering noise reduction and pattern identification on the welding seam data to extract welding seam characteristics; the weld features include, but are not limited to, weld gap and step; before laser welding starts, the three-dimensional modeling module and the identification module perform three-dimensional pre-modeling on the welding piece, and weld joint features of the welding point are extracted.
Further, the process knowledge base for the laser filler wire welding in the step 4 at least comprises a process parameter knowledge base and an auxiliary decision knowledge base; the decision criteria include, but are not limited to, a gap threshold, and when the actual gap value is smaller than the preset gap threshold, the wire feeding mechanism is controlled to stop feeding the wire, otherwise, the wire feeding is started.
Further, in step 5, the wire feeding control system is an MRAC system, and the adaptive control process thereof is as follows:
firstly, a process knowledge base module gives an initial decision according to the characteristics of a starting welding spot welding line extracted by a pre-established model, a wire feeding control system receives a decision instruction signal of the process knowledge base module, and the start-stop state of a wire feeding mechanism is adjusted according to the decision instruction;
secondly, the weld joint detection system collects the weld joint deformation feedback value at the next moment, corrects the pre-established model and extracts the weld joint characteristics to be welded at the next moment;
and finally, the process knowledge base module and the wire feeding control system carry out closed-loop control on the wire feeding mechanism according to the characteristics of the to-be-welded weld joint, and update the start-stop state of the wire feeding mechanism.
Compared with the prior art, the self-adaptive wire filling device and method for precise laser welding at least have the following beneficial effects:
1. the invention solves the problem that the prior technical scheme can not adapt to the dynamic change of the welding seam. The invention adopts the weld joint detection system to collect the dynamic change of the weld joint in the laser welding process in real time, and based on the weld joint characteristics to be welded which are obtained in real time, the self-adaptive control module feeds back the measured value of the weld joint characteristics to the process knowledge base to carry out closed-loop control on the wire feeding mechanism, thereby realizing the self-adaptive start and stop of the wire feeding mechanism along with welding. 2. According to the invention, the wire feeding mechanism is controlled to be started and stopped adaptively, and meanwhile, the accurate weld joint characteristics are obtained by adopting a three-dimensional real-time modeling technology, so that the wire feeding mechanism can be ensured to accurately discharge wires according to the working condition requirements, and the involution precision of welding parts is ensured. 3. The invention adopts the technical scheme of performing three-dimensional pre-modeling by scanning before welding, feeds back and corrects the model in real time based on the acquired welding seam information, effectively optimizes the recognition speed of the welding seam characteristics, and performs closed-loop control on the wire feeding mechanism, thereby ensuring the response speed of an adaptive control system and greatly improving the welding efficiency. Based on the beneficial effects, the invention can be widely applied to laser welding for manufacturing precise components.
Drawings
FIG. 1 is a schematic diagram of a laser welding adaptive wire-filling control system according to the present invention;
FIG. 2 is a schematic view of a weld gap and step;
FIG. 3 is a schematic diagram of a wire feeder closed loop control method.
The specific implementation mode is as follows:
in order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and that not all embodiments are intended to be exhaustive. All other embodiments, which can be derived by a person skilled in the art from the described embodiments of the invention without any inventive step, are within the scope of protection of the invention.
Please refer to fig. 1 to fig. 3, which respectively show: the laser welding self-adaptive wire filling control system adopted by the invention has a schematic structure diagram, a schematic diagram of a weld gap and a step difference, and a schematic diagram of a wire feeding mechanism closed-loop control method.
The invention provides a self-adaptive wire filling device for precise laser welding, which is characterized in that the structure of a control system is shown in figure 1, the control system is used for laser welding of a plate shown in figure 2, the start and stop of a wire feeding mechanism can be controlled in real time in the welding process, and the self-adaptive wire filling device comprises: the device comprises a welding seam detection system 1, a three-dimensional modeling module 2, an identification module 3, a laser wire filling welding process knowledge base 4 and a wire feeding control system 5. The welding seam detection system 1 can collect welding seam data in the laser welding process in real time; the three-dimensional modeling module 2 can perform real-time accurate three-dimensional modeling on the welding seam based on the welding seam data; the identification module 3 can identify and extract the welding seam characteristics; the laser wire filling welding process knowledge base 4 can judge whether the current working condition needs wire filling according to the welding seam characteristics and output a control signal; the wire feeding control system 5 can control the start and stop of the wire feeding mechanism in real time, and realizes the self-adaptive wire filling of laser welding. The method adopts a self-adaptive wire filling method for laser welding, and comprises the following specific implementation steps:
1) the method comprises the steps of scanning a weldment before welding, conducting three-dimensional pre-modeling on the weldment through a three-dimensional modeling module and an identification module, extracting a weld gap and a step of a starting welding point, giving an initial decision by a process knowledge base module according to the weld gap and the step extracted by the pre-built model, receiving a decision instruction signal of the process knowledge base module by a wire feeding control system, and adjusting the starting and stopping state of a wire feeding mechanism according to the decision instruction.
2) And when laser welding is started, the welding seam detection system collects high-definition images and three-dimensional deformation of the welding seam in real time and transmits the high-definition images and the three-dimensional deformation to the data processing end. The welding seam detection system consists of an industrial CCD camera and a structured light three-dimensional scanning measuring instrument, is loaded on a laser head, and collects data such as high-definition images, three-dimensional deformation and the like of a welding seam to be welded at the front end of a molten pool in the laser welding process in real time.
3) And based on data such as high-definition images and three-dimensional deformation of the welding seams to be welded, the three-dimensional modeling module carries out real-time feedback correction on the pre-built three-dimensional model. The identification module carries out filtering noise reduction and mode identification on the welding seam data, extracts gaps and step differences of welding seams to be welded, and sends the gaps and the step differences to the computer terminal through the CAN bus.
4) Based on the gap and the step of the welding seam to be welded, the process parameter knowledge base of the laser wire filling welding is matched with process data, a decision is made on the current working condition through the auxiliary decision knowledge base, when the actual measured value of the gap is smaller than a preset gap threshold value, the wire feeding mechanism is controlled to stop feeding the wire, otherwise, the wire feeding mechanism is started, and a control instruction signal of the wire feeding mechanism is output through a CAN bus.
5) The wire feeding control system receives the instruction and controls the start and stop of the wire feeding mechanism in real time, the principle of the closed-loop control method is shown in figure 3, and the self-adaptive control process is as follows:
firstly, a process knowledge base module gives an initial decision according to a starting welding spot welding seam gap and a step difference extracted by a pre-established model, a wire feeding control system receives a decision instruction signal of the process knowledge base module, and the start-stop state of a wire feeding mechanism is adjusted according to the decision instruction;
secondly, the welding seam detection system collects the welding seam deformation feedback value at the next moment, corrects the pre-established model and extracts the gap and the step difference of the welding seam to be welded at the next moment;
and finally, the process knowledge base module and the wire feeding control system carry out closed-loop control on the wire feeding mechanism according to the gap and the step difference of the to-be-welded weld joint, and update the start-stop state of the wire feeding mechanism.
And repeating the steps 3) -5), extracting the gap and the step difference of the welding seam to be welded based on the welding seam deformation feedback value, and performing closed-loop control on the wire feeding mechanism by the process knowledge base module and the wire feeding control system until the self-adaptive wire filling laser welding is finished.
Claims (5)
1. The utility model provides a wire device is filled out to accurate laser welding's self-adaptation for wire feeder opens and stops among real time control laser welding process, its characterized in that includes: the device comprises a welding seam detection system, a three-dimensional modeling module, an identification module, a laser wire filling welding process knowledge base and a wire feeding control system. The welding seam detection system can acquire welding seam data in the laser welding process in real time; the three-dimensional modeling module can perform real-time accurate three-dimensional modeling on the welding seam based on the welding seam data; the identification module can identify and extract the welding seam characteristics; the laser wire filling welding process knowledge base can judge whether the current working condition needs wire filling according to the welding seam characteristics and output a control signal; the wire feeding control system can control the start and stop of the wire feeding mechanism in real time, so that the self-adaptive wire filling of laser welding is realized;
a self-adaptive wire filling method for precision laser welding is characterized by comprising the following steps:
step 1, scanning a weldment before welding, performing three-dimensional pre-modeling on the weldment, identifying and extracting weld joint characteristics of a welding spot, and setting an initial state of a wire filling mechanism;
step 2, starting laser welding, and acquiring welding seam information in real time by a welding seam detection system and transmitting the welding seam information to a data processing end;
step 3, based on the welding seam information, the three-dimensional modeling module corrects the pre-built three-dimensional model in real time, the welding seam characteristics are identified and extracted through the identification module, and the welding seam characteristics are sent to the computer terminal through the CAN bus;
step 4, based on the weld joint characteristics, matching process data by a laser wire filling welding process knowledge base, making a decision on the current working condition, and outputting a wire feeding mechanism control instruction signal through a CAN bus;
step 5, the wire feeding control system receives the instruction and controls the start and stop of the wire feeding mechanism in real time;
and 6, repeating the steps 3-5, extracting the weld joint characteristics based on the weld joint information feedback value, and carrying out closed-loop control on the wire feeding mechanism by the process knowledge base module and the wire feeding control system until the self-adaptive wire filling laser welding is finished.
2. The adaptive wire filling device and method for precision laser welding according to claim 1, wherein the weld detection system in step 2 includes, but is not limited to, an industrial CCD camera, a structured light three-dimensional scanning measuring instrument, which is mounted on a laser head and can collect data of the weld to be welded at the front end of a molten pool in the laser welding process in real time; the weld data includes, but is not limited to, high definition images, three dimensional deformation, etc. of the weld to be welded.
3. The adaptive wire filling device and method for precision laser welding according to claim 1, wherein the three-dimensional modeling module and the identification module in step 3 are embedded software, and can perform filtering noise reduction and pattern identification on welding seam data to extract welding seam features; the weld features include, but are not limited to, weld gap and step; before laser welding starts, the three-dimensional modeling module and the identification module perform three-dimensional pre-modeling on the welding piece, and weld joint features of the welding point are extracted.
4. The adaptive wire filling device and method for precision laser welding according to claim 1, wherein the knowledge base of the laser wire filling welding process in step 4 at least comprises a knowledge base of process parameters and a knowledge base of aid decision; the decision criteria include, but are not limited to, a gap threshold, and when the actual gap value is smaller than the preset gap threshold, the wire feeding mechanism is controlled to stop feeding the wire, otherwise, the wire feeding is started.
5. The adaptive wire filling device and method for precision laser welding according to claim 1, wherein the wire feeding control system in step 5 is an MRAC system, and the adaptive control process comprises:
firstly, a process knowledge base module gives an initial decision according to the characteristics of a starting welding spot welding line extracted by a pre-established model, a wire feeding control system receives a decision instruction signal of the process knowledge base module, and the start-stop state of a wire feeding mechanism is adjusted according to the decision instruction;
secondly, the weld joint detection system collects the weld joint deformation feedback value at the next moment, corrects the pre-established model and extracts the weld joint characteristics to be welded at the next moment;
and finally, the process knowledge base module and the wire feeding control system carry out closed-loop control on the wire feeding mechanism according to the characteristics of the to-be-welded weld joint, and update the start-stop state of the wire feeding mechanism.
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Application publication date: 20220412 |