CN114700606B - System and method for monitoring weld quality - Google Patents

System and method for monitoring weld quality Download PDF

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CN114700606B
CN114700606B CN202210415229.6A CN202210415229A CN114700606B CN 114700606 B CN114700606 B CN 114700606B CN 202210415229 A CN202210415229 A CN 202210415229A CN 114700606 B CN114700606 B CN 114700606B
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welding
ultrasonic
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CN114700606A (en
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杨肖如
王敌兵
黄成�
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Wuxi Lien Machinery Manufacturing Co ltd
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Wuxi Lien Machinery Manufacturing Co ltd
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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
    • 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
    • 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
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B23K20/106—Features related to sonotrodes
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/11—Analysing solids by measuring attenuation of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/08—Investigating strength properties of solid materials by application of mechanical stress by applying steady tensile or compressive forces
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/30—Investigating strength properties of solid materials by application of mechanical stress by applying a single impulsive force, e.g. by falling weight
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30—Computing systems specially adapted for manufacturing

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  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

The invention discloses a system and a method for monitoring welding quality, which belong to the technical field of welding monitoring and are used for solving the problems that the existing detection means belong to national standards or European standards, the detection means need to be subjected to sampling processes such as cutting and polishing, the detection speed is low, the detection cost is high, and the feedback cannot be quickly checked in the production process; the welding processing module comprises an ultrasonic processing unit, a supplementary processing unit and a supplementary detection unit, wherein the ultrasonic processing unit is used for processing the detection result of the detection module.

Description

System and method for monitoring weld quality
Technical Field
The invention belongs to the technical field of welding monitoring, relates to a welding quality monitoring processing technology, and particularly relates to a system and a method for monitoring welding quality.
Background
The welding quality detection refers to the detection of welding results, and aims to ensure the integrity, reliability, safety and usability of a welding structure. In addition to the requirements for welding technology and welding process, weld quality detection is also an important part of the quality management of welded structures.
In the prior art, a plurality of methods are available for detecting welding results, but the existing methods belong to national standards or European standards, the detection methods need to be subjected to sampling processes such as cutting and polishing, the detection speed is low, the detection cost is high, rapid spot check feedback cannot be performed in the production process, and a non-standard rapid detection method is lacked.
Disclosure of Invention
In response to the deficiencies of the prior art, it is an object of the present invention to provide a system and method for monitoring weld quality.
The technical problem to be solved by the invention is as follows: the existing detection means belong to national standards or European standards, the detection means need to be subjected to sampling processes such as cutting and polishing, the detection speed is low, the detection cost is high, and rapid spot check feedback cannot be realized in the production process.
The purpose of the invention can be realized by the following technical scheme: the system comprises a detection module, a welding processing module and a sampling supplement module, wherein the detection module is used for detecting the welding position of a welding product by ultrasonic waves;
the welding processing module comprises an ultrasonic processing unit, a supplementary processing unit and a supplementary detection unit, and the ultrasonic processing unit is used for processing the detection result of the detection module; the supplementary processing unit is used for controlling the sampling supplementary module to carry out supplementary detection operation; the supplementary detection unit is used for comprehensively processing the processing results of the ultrasonic processing unit and the supplementary processing unit to obtain an adjusted ultrasonic detection result;
the sampling supplement module comprises a tensile supplement test unit, a compressive supplement test unit and an anti-collision supplement test unit, and is configured with a sampling supplement strategy, wherein the sampling supplement strategy comprises the following steps: the method comprises the steps of firstly selecting a section of welding product body, then selecting a section of welded product, enabling the welding position of the welded product to be located in the middle position, enabling the welding product body to be the same as the welded product in selected length, and then conducting tensile test, compressive test and anti-collision test on the welding position of the welding product body and the welded product through a tensile supplementary test unit, a compressive supplementary test unit and an anti-collision supplementary test unit.
Further, the detection module is configured with an ultrasonic detection strategy comprising: detecting by adopting an angle perpendicular to a welding position of a welding product, acquiring a first group of ultrasonic reflected waves within a first time length, setting the detection position as a first detection position, and setting the detection angle as a first detection angle;
continuing to detect the starting point by using the first detection position, and then rotating towards the first direction by using the first detection position as a circle center to obtain a second group of ultrasonic reflected waves within a first time length;
and continuing to detect the starting point at the first detection position, keeping the same distance with the welded product, and performing surrounding detection on the welded product along the first direction to obtain a third group of ultrasonic reflected waves within the first time length.
Further, the sonication unit is configured with a sonication strategy comprising: taking the time length of the first time length as an abscissa and taking the signal amplitude of the ultrasonic reflected wave as an ordinate to manufacture a reflected wave amplitude diagram;
a reflected wave amplitude diagram is made on the basis of the first ultrasonic reflected wave and is set as a first ultrasonic reflected wave amplitude diagram; a reflected wave amplitude diagram is made on the basis of the second ultrasonic reflected wave and is set as a second ultrasonic reflected wave amplitude diagram; a reflected wave amplitude diagram is made on the basis of the third ultrasonic reflected wave and is set as a third ultrasonic reflected wave amplitude diagram;
setting a line shape in which the fluctuation amplitude in the first abscissa length in the first ultrasonic reflected wave amplitude diagram, the second ultrasonic reflected wave amplitude diagram and the third ultrasonic reflected wave amplitude diagram is greater than a first floating threshold value as a first fluctuation peak value graph;
setting the line shape with more than or equal to three first fluctuation peak value graphs appearing in the second abscissa length as a second fluctuation peak value graph;
setting the line shape with more than or equal to three second fluctuation peak value graphs appearing in the third abscissa length as a third fluctuation peak value graph;
respectively acquiring the number of first fluctuation peak value graphs, second fluctuation peak value graphs and third fluctuation peak value graphs in the first ultrasonic reflection wave amplitude graph, the second ultrasonic reflection wave amplitude graph and the third ultrasonic reflection wave amplitude graph;
respectively setting the number of a first fluctuation peak value graph, a second fluctuation peak value graph and a third fluctuation peak value graph in the first ultrasonic reflected wave amplitude graph as a first fluctuation number, a second fluctuation number and a third fluctuation number;
respectively setting the number of the first fluctuation peak value graph, the second fluctuation peak value graph and the third fluctuation peak value graph in the second ultrasonic reflected wave amplitude graph as a fourth fluctuation number, a fifth fluctuation number and a sixth fluctuation number;
respectively setting the number of the first fluctuation peak value pattern, the second fluctuation peak value pattern and the third fluctuation peak value pattern in the third ultrasonic reflected wave amplitude diagram as a seventh fluctuation number, an eighth fluctuation number and a ninth fluctuation number;
substituting the first fluctuation quantity, the second fluctuation quantity and the third fluctuation quantity into a first ultrasonic detection formula to obtain a first ultrasonic detection value; substituting the fourth fluctuation quantity, the fifth fluctuation quantity and the sixth fluctuation quantity into a second ultrasonic detection formula to obtain a second ultrasonic detection value; and substituting the seventh fluctuation quantity, the eighth fluctuation quantity and the ninth fluctuation quantity into a third ultrasonic detection formula to obtain a third ultrasonic detection value.
Further, the first ultrasonic detection formula is configured to: pcs1= (Ssc 1 × a1+ Ssc2 × a 2) Ssc3 (ii) a The second ultrasonic detection formula is configured to: pcs2= (Ssc 4 × b1+ Ssc5 × b 2) Ssc6 (ii) a The third ultrasonic detection formula is configured to: pcs3= (Ssc 7 × c1+ Ssc8 × c 2) Ssc9 (ii) a Wherein Pcs1 is a first ultrasonic detection value, pcs2 is a second ultrasonic detection value, pcs3 is a third ultrasonic detection value, ssc1, ssc2, ssc3, ssc4, ssc5, ssc6, ssc7, ssc8 and Ssc9 are a first fluctuation number, a second fluctuation number, a third fluctuation number, a fourth fluctuation number, a fifth fluctuation number, a sixth fluctuation number, a seventh fluctuation number, an eighth fluctuation number and a ninth fluctuation number, respectively, a1 is a first fluctuation number conversion coefficient, a2 is a second fluctuation number conversion coefficient, the values of a1 and a2 are between 1 and 2, the specific values of a1 and a2 are set according to the specific weight of the first fluctuation peak value pattern and the second fluctuation peak value pattern in the first ultrasonic detection, b1 is a fourth fluctuation quantity conversion coefficient, b2 is a fifth fluctuation quantity conversion coefficient, wherein the values of b1 and b2 are between 1 and 2, the specific values of b1 and b2 are set according to the specific weight of the first fluctuation peak value pattern and the second fluctuation peak value pattern in the second ultrasonic detection, c1 is a seventh fluctuation quantity conversion coefficient, and c2 is an eighth fluctuation quantity conversion coefficientAnd the values of c1 and c2 are between 1 and 2, and the specific values of c1 and c2 are set according to the specific weight of the first fluctuation peak value graph and the second fluctuation peak value graph in the third ultrasonic detection.
Further, the tensile supplementary test unit is configured with a tensile test strategy, the tensile test strategy comprising: respectively stretching the welding product body and the welding position of the welding product by adopting a first stretching strength, and setting a body stretching resistance index and a welding position stretching resistance index according to stretching resistance results, wherein the set values of the body stretching resistance index and the welding position stretching resistance index are different when the welding position of the welding product body and the welding product is fractured and is not fractured;
the compression-resistant supplementary test unit is provided with a compression-resistant test strategy, and the compression-resistant test strategy comprises the following steps: respectively fixing two ends of a welding product body and the two ends of the welded product, then carrying out compression testing on the two ends of the welding product body and the welded product at a first compression resistance degree, keeping the first compression resistance degree for a first compression resistance time, then measuring the distance between the two ends of the welding product body and the two ends of the welded product, and respectively setting the distance as a first compression resistance distance and a second compression resistance distance;
the anti-collision supplementary test unit is configured with an anti-collision test strategy, and the anti-collision test strategy comprises the following steps: the method comprises the steps of fixing two ends of a welding product body and two ends of a welded product respectively, then carrying out collision resistance on the welding product body and the middle position of the welded product respectively with first collision resistance, measuring distances between the two ends of the welding product body and the two ends of the welded product after the welding product is welded for a first time with the first collision resistance, and setting the distances as a first collision resistance distance and a second collision resistance distance respectively.
Further, the supplemental processing unit is configured with a supplemental processing policy, the supplemental processing policy comprising: substituting the tensile index of the body, the tensile index of the welding position, the first compression distance, the second compression distance, the first collision distance and the second collision distance into a complementary processing formula to obtain a complementary processing value.
Further, the supplemental processing formula is configured to: pbc = (Zhj-Zbt) × k1+ (Swq 1-Swq 2) × k2+ (Scj 1-Scj 2) × k3. Wherein Pbc is a complementary processing value, zhj is a body tensile index, zbt is a welding part tensile index, k1 is a tensile complementary coefficient, swq1 is a first compression-resistant distance, swq2 is a second compression-resistant distance, k2 is a compression-resistant complementary coefficient, scj1 is a first collision-resistant distance, scj2 is the second collision resistance distance, k3 is the collision resistance supplement coefficient, wherein the values of k1, k2 and k3 are all larger than zero, and the specific values of k1, k2 and k3 are set according to the proportion of tensile, compressive and collision resistance tests in supplement detection.
Further, the supplementary detection unit is configured with a supplementary detection policy, the supplementary detection policy comprising: substituting the supplementary processing value, the first ultrasonic detection value, the second ultrasonic detection value and the third ultrasonic detection value into a supplementary detection formula to obtain a supplementary ultrasonic detection value; when the supplementary ultrasonic detection value is less than or equal to a first ultrasonic detection threshold value, dividing the welding quality of the welding product into a first welding grade; when the supplementary ultrasonic detection value is larger than the first ultrasonic detection threshold value and smaller than or equal to a second ultrasonic detection threshold value, dividing the welding quality of the welding product into a second welding grade; and when the supplementary ultrasonic detection value is greater than a second ultrasonic detection threshold value, dividing the welding quality of the welding product into a third welding grade, wherein the first ultrasonic detection threshold value is smaller than the second ultrasonic detection threshold value, the welding quality of the first welding grade is superior to that of the second welding grade, and the welding quality of the second welding grade is superior to that of the third welding grade.
Further, the supplemental detection formula is configured to: pbj = (Pcs 1+ Pcs2+ Pcs 3) Pbc (ii) a Wherein Pbj is the supplemental ultrasound detection value.
A method for a system for monitoring weld quality, the method comprising the steps of: s1, detecting a welding position of a welding product through ultrasonic waves;
s2, selecting a section of welding product body, selecting a section of welded product, wherein the welding position of the welded product is located in the middle position, the selected lengths of the welding product body and the welded product are the same, and then respectively performing tensile test, compressive test and anti-collision test on the welding position of the welding product body and the welded product;
and S3, comprehensively processing the detection results obtained in the processing procedures of the S1 and the S2 to obtain the adjusted ultrasonic detection result.
Compared with the prior art, the invention has the beneficial effects that: firstly, detecting a welding position of a welded product by ultrasonic waves; then, respectively carrying out a tensile test, a compressive test and an anti-collision test on the welding position of the welding product body and the welded welding product through a tensile supplementary test unit, a compressive supplementary test unit and an anti-collision supplementary test unit; and the supplementary detection unit can comprehensively process the processing results of the ultrasonic processing unit and the supplementary processing unit to obtain an adjusted ultrasonic detection result, so that nondestructive ultrasonic detection and destructive sampling detection are combined, the damage cost and the detection difficulty of the detection are reduced, and the efficiency of the whole nondestructive detection and the accuracy of the nondestructive detection are improved.
Drawings
To facilitate understanding for those skilled in the art, the present invention will be further described with reference to the accompanying drawings.
FIG. 1 is a schematic block diagram of the system of the present invention;
FIG. 2 is a flow chart of the method of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the invention provides a system for monitoring welding quality, which is used for solving the problems that the existing detection means belong to national standards or european standards, the detection means need to be subjected to sampling processes such as cutting and polishing, the detection speed is slow, the detection cost is high, and the feedback cannot be quickly checked in the production process.
The system comprises a detection module, a welding processing module and a sampling supplement module.
The detection module is used for detecting the welding position of the welding product through ultrasonic waves; when the problem that gas pocket, contained sediment, incomplete penetration of welding, not fuse and crackle appear in the welding department is, the fluctuation condition of the ultrasonic reflection wave that its feedback was come out also can aggravate, consequently through the detection of ultrasonic wave, can reflect welding quality, detection module disposes ultrasonic testing tactics, ultrasonic testing tactics includes: detecting by adopting an angle perpendicular to a welding position of a welding product, acquiring a first group of ultrasonic reflected waves within a first time length, setting the detection position as a first detection position, and setting the detection angle as a first detection angle;
continuing to detect the starting point by taking the first detection position as a circle center, and then rotating towards the first direction by taking the first detection position as a circle center to obtain a second group of ultrasonic reflection waves within a first time length; and continuously detecting the starting point at the first detection position, keeping the same distance with the welded product, performing surrounding detection on the welded product along the first direction, and acquiring a third group of ultrasonic reflected waves within the first time length.
The sampling supplement module comprises a tensile supplement testing unit, a compression supplement testing unit and an anti-collision supplement testing unit, the sampling supplement module adopts a destructive testing mode, the sampling detection is also carried out, the extracted samples are set by the material of an actual product, the minimum samples are one, the sampling supplement module can be used as ultrasonic testing for supplement through destructive testing, the follow-up large-scale ultrasonic nondestructive testing mode is convenient, and meanwhile the accuracy of the corresponding detection can be improved. The sample supplement module is configured with a sample supplement strategy that includes: the method comprises the steps of firstly selecting a section of welding product body, then selecting a section of welded product, enabling the welding position of the welded product to be located in the middle position, enabling the welding product body to be the same as the welded product in selected length, and then conducting tensile test, compressive test and anti-collision test on the welding position of the welding product body and the welded product through a tensile supplementary test unit, a compressive supplementary test unit and an anti-collision supplementary test unit.
The tensile supplementary test unit is configured with a tensile test strategy, which comprises: respectively stretching the welding product body and the welding position of the welding product by adopting a first stretching strength, and setting a body stretching resistance index and a welding position stretching resistance index according to stretching resistance results, wherein the set values of the body stretching resistance index and the welding position stretching resistance index are different when the welding position of the welding product body and the welding product is fractured and is not fractured; the welding product body randomly selects one end from the welding products to be detected as a sample for sampling test, the selected length of the welded products is consistent with that of the sampled welding products, and the welding position of the welded products needs to be located in the middle of the welding position.
The compression-resistant supplementary test unit is provided with a compression-resistant test strategy, and the compression-resistant test strategy comprises the following steps: fixing two ends of a welding product body and a welded product respectively, then carrying out compression testing on the two ends of the welding product body and the welded product by using a first compression resistance degree, keeping the first compression resistance degree for a first compression resistance time, then measuring the distance between the two ends of the welding product body and the two ends of the welded product, and setting the distance as a first compression resistance distance and a second compression resistance distance respectively;
the anti-collision supplementary test unit is configured with an anti-collision test strategy, and the anti-collision test strategy comprises the following steps: the method comprises the steps of fixing two ends of a welding product body and two ends of a welded product respectively, then carrying out collision resistance on the welding product body and the middle position of the welded product respectively with first collision resistance, measuring distances between the two ends of the welding product body and the two ends of the welded product after the welding product is welded for a first time with the first collision resistance, and setting the distances as a first collision resistance distance and a second collision resistance distance respectively.
The welding processing module comprises an ultrasonic processing unit, a supplementary processing unit and a supplementary detection unit.
The ultrasonic processing unit is used for processing the detection result of the detection module; the sonication unit is configured with a sonication strategy comprising: taking the time length of the first time length as an abscissa and taking the signal amplitude of the ultrasonic reflected wave as an ordinate to manufacture a reflected wave amplitude diagram; a reflected wave amplitude diagram is made on the basis of the first ultrasonic reflected wave and is set as a first ultrasonic reflected wave amplitude diagram; a reflected wave amplitude diagram is made on the basis of the second ultrasonic reflected wave and is set as a second ultrasonic reflected wave amplitude diagram; a reflected wave amplitude diagram is made on the basis of the third ultrasonic reflected wave and is set as a third ultrasonic reflected wave amplitude diagram; setting a line shape in which the fluctuation amplitude in the first abscissa length in the first ultrasonic reflected wave amplitude diagram, the second ultrasonic reflected wave amplitude diagram and the third ultrasonic reflected wave amplitude diagram is greater than a first floating threshold value as a first fluctuation peak value graph; setting the line shape with more than or equal to three first fluctuation peak value graphs appearing in the second abscissa length as a second fluctuation peak value graph; setting the line shape with more than or equal to three second fluctuation peak value graphs appearing in the third abscissa length as a third fluctuation peak value graph; respectively acquiring the number of first fluctuation peak value graphs, second fluctuation peak value graphs and third fluctuation peak value graphs in the first ultrasonic reflection wave amplitude graph, the second ultrasonic reflection wave amplitude graph and the third ultrasonic reflection wave amplitude graph; respectively setting the number of a first fluctuation peak value pattern, a second fluctuation peak value pattern and a third fluctuation peak value pattern in the first ultrasonic reflection wave amplitude diagram as a first fluctuation number, a second fluctuation number and a third fluctuation number; respectively setting the number of the first fluctuation peak value graph, the second fluctuation peak value graph and the third fluctuation peak value graph in the second ultrasonic reflected wave amplitude graph as a fourth fluctuation number, a fifth fluctuation number and a sixth fluctuation number; respectively setting the number of the first fluctuation peak value pattern, the second fluctuation peak value pattern and the third fluctuation peak value pattern in the third ultrasonic reflected wave amplitude diagram as a seventh fluctuation number, an eighth fluctuation number and a ninth fluctuation number; substituting the first fluctuation quantity, the second fluctuation quantity and the third fluctuation quantity into a first ultrasonic detection formula to obtain a first ultrasonic detection value; substituting the fourth fluctuation quantity, the fifth fluctuation quantity and the sixth fluctuation quantity into a second ultrasonic detection formula to obtain a second ultrasonic detection value; substituting the seventh fluctuation quantity, the eighth fluctuation quantity and the ninth fluctuation quantity into a third ultrasonic detection formula to obtain a third ultrasonic detection value;
the first ultrasonic detection formula is configured to: pcs1= (Ssc 1 × a1+ Ssc2 × a 2) Ssc3 (ii) a The second ultrasonic detection formula is configured to: pcs2= (Ssc 4 × b1+ Ssc5 × b 2) Ssc6 (ii) a The third ultrasonic detection formula is configured to: pcs3= (Ssc 7 × c1+ Ssc8 × c 2) Ssc9 (ii) a Wherein Pcs1 is a first ultrasonic detection value, pcs2 is a second ultrasonic detection value, pcs3 is a third ultrasonic detection value, ssc1, ssc2, ssc3, ssc4, ssc5, ssc6, ssc7, ssc8 and Ssc9 are a first fluctuation number, a second fluctuation number, a third fluctuation number, a fourth fluctuation number, a fifth fluctuation number, a sixth fluctuation number, a seventh fluctuation number, an eighth fluctuation number and a ninth fluctuation number, respectively, a1 is a first fluctuation number conversion coefficient, a2 is a second fluctuation number conversion coefficient, wherein values of a1 and a2 are 1 to 2, specific values of a1 and a2 are set according to a ratio of the first fluctuation peak pattern and the second fluctuation peak pattern in the first ultrasonic detection, b1 is a fourth fluctuation number conversion coefficient, and b2 is a fifth fluctuation number conversion coefficient, the values of b1 and b2 are between 1 and 2, the specific values of b1 and b2 are set according to the specific weight of the first fluctuation peak value pattern and the second fluctuation peak value pattern in the second ultrasonic detection, c1 is a seventh fluctuation number conversion coefficient, and c2 is an eighth fluctuation number conversion coefficient, wherein the values of c1 and c2 are between 1 and 2, and the specific values of c1 and c2 are set according to the specific weight of the first fluctuation peak value pattern and the second fluctuation peak value pattern in the third ultrasonic detection.
The supplementary processing unit is used for controlling the sampling supplementary module to carry out supplementary detection operation; the supplemental processing unit is configured with a supplemental processing policy, the supplemental processing policy comprising: substituting the tensile index of the body, the tensile index of the welding position, the first compression distance, the second compression distance, the first collision distance and the second collision distance into a complementary processing formula to obtain a complementary processing value; the supplemental processing formula is configured to: pbc = (Zhj-Zbt) × k1+ (Swq 1-Swq 2) × k2+ (Scj 1-Scj 2) × k3. Wherein Pbc is a supplement processing value, zhj is a body tensile index, zbt is a welding part tensile index, k1 is a tensile supplement coefficient, swq1 is a first compression distance, swq2 is a second compression distance, k2 is a compression supplement coefficient, scj1 is a first collision distance, scj2 is a second collision distance, and k3 is a collision supplement coefficient, wherein the values of k1, k2, and k3 are all greater than zero, the specific setting needs to be respectively set by referring to the proportion occupied by the tensile, compression, and collision tests in supplement detection, and in a supplement processing formula, the detection parameters of the welded product after welding are subtracted from the detection parameters of the welded product body, and each detection parameter: the larger the numerical values of the tensile index, the compression distance and the crashworthiness are, the better the quality strength is, and therefore, the larger the supplementary processing value is, the poorer the welding quality of the welded product after welding is.
The supplementary detection unit is used for comprehensively processing the processing results of the ultrasonic processing unit and the supplementary processing unit to obtain an adjusted ultrasonic detection result; the supplementary detection unit is configured with a supplementary detection strategy, which includes: substituting the supplementary processing value and the first ultrasonic detection value, the second ultrasonic detection value and the third ultrasonic detection value into a supplementary detection formula to obtain a supplementary ultrasonic detection value; the supplemental detection formula is configured to: pbj = (Pcs 1+ Pcs2+ Pcs 3) Pbc (ii) a Wherein Pbj is a supplementary ultrasound detection value.
When the supplementary ultrasonic detection value is less than or equal to a first ultrasonic detection threshold value, dividing the welding quality of the welding product into a first welding grade; when the supplementary ultrasonic detection value is larger than the first ultrasonic detection threshold value and smaller than or equal to the second ultrasonic detection threshold value, dividing the welding quality of the welding product into a second welding grade; when the supplementary ultrasonic detection value is greater than a second ultrasonic detection threshold value, the welding quality of the welding product is classified into a third welding grade, and the detection formula and the explanation can obtain the relation that the supplementary processing value, the first ultrasonic detection value, the second ultrasonic detection value and the third ultrasonic detection value are all in negative correlation with the welding quality, so that the welding quality is poorer as the supplementary ultrasonic detection value represented by Pbj is larger according to the supplementary detection formula, wherein the second ultrasonic detection threshold value is greater than the first ultrasonic detection threshold value, the classification of the first ultrasonic detection threshold value and the second ultrasonic detection threshold value is defined by referring to a quality detection experiment of a specific welding product, the first ultrasonic detection threshold value and the second ultrasonic detection threshold value are used for classifying the welding quality grade, and the specific setting is carried out by referring to materials of different welding products, so that the welding quality of the first welding grade is better than the welding quality of the second welding grade, and the welding quality of the second welding grade is better than the welding quality of the third welding grade.
Referring to fig. 2, the present invention also provides a method for monitoring the welding quality, the method comprising the steps of: s1, detecting a welding position of a welding product through ultrasonic waves; detecting by adopting an angle perpendicular to a welding position of a welding product, acquiring a first group of ultrasonic reflected waves within a first time length, setting the detection position as a first detection position, and setting the detection angle as a first detection angle; continuing to detect the starting point by using the first detection position, and then rotating towards the first direction by using the first detection position as a circle center to obtain a second group of ultrasonic reflected waves within a first time length; and continuing to detect the starting point at the first detection position, keeping the same distance with the welded product, and performing surrounding detection on the welded product along the first direction to obtain a third group of ultrasonic reflected waves within the first time length.
S2, selecting a section of welding product body, selecting a section of welded product, wherein the welding position of the welded product is located in the middle position, the selected lengths of the welding product body and the welded product are the same, and then respectively performing tensile test, compressive test and anti-collision test on the welding position of the welding product body and the welded product;
respectively stretching the welding product body and the welding position of the welding product by adopting a first stretching strength, and setting a body stretching resistance index and a welding position stretching resistance index according to stretching resistance results, wherein the set values of the body stretching resistance index and the welding position stretching resistance index are different when the welding position of the welding product body and the welding product is fractured and is not fractured;
fixing two ends of a welding product body and a welded product respectively, then carrying out compression testing on the two ends of the welding product body and the welded product by using a first compression resistance degree, keeping the first compression resistance degree for a first compression resistance time, then measuring the distance between the two ends of the welding product body and the two ends of the welded product, and setting the distance as a first compression resistance distance and a second compression resistance distance respectively;
the method comprises the steps of fixing two ends of a welded product body and two ends of a welded product respectively, then carrying out anti-collision on the middle positions of the welded product body and the welded product respectively with first anti-collision force, after the first anti-collision force is used for anti-collision for a first time, measuring distances between the two ends of the welded product body and the two ends of the welded product, and setting the distances as a first anti-collision distance and a second anti-collision distance respectively.
S3, comprehensively processing the detection results obtained in the processing procedures of the S1 and the S2 to obtain an adjusted ultrasonic detection result; taking the time length of the first time length as an abscissa and taking the signal amplitude of the ultrasonic reflected wave as an ordinate to manufacture a reflected wave amplitude diagram; a reflected wave amplitude map is made on the basis of the first ultrasonic reflected wave and set as a first ultrasonic reflected wave amplitude map; a reflected wave amplitude map is made on the basis of the second ultrasonic reflected wave and set as a second ultrasonic reflected wave amplitude map; a reflected wave amplitude diagram is made on the basis of the third ultrasonic reflected wave and is set as a third ultrasonic reflected wave amplitude diagram; setting a line shape in which the fluctuation amplitude in the first abscissa length in the first ultrasonic reflected wave amplitude diagram, the second ultrasonic reflected wave amplitude diagram and the third ultrasonic reflected wave amplitude diagram is greater than a first floating threshold value as a first fluctuation peak value graph; setting the line shape with more than or equal to three first fluctuation peak value graphs appearing in the second abscissa length as a second fluctuation peak value graph; setting the line shape with more than or equal to three second fluctuation peak value graphs appearing in the third abscissa length as a third fluctuation peak value graph; respectively acquiring the number of first fluctuation peak value graphs, second fluctuation peak value graphs and third fluctuation peak value graphs in the first ultrasonic reflection wave amplitude graph, the second ultrasonic reflection wave amplitude graph and the third ultrasonic reflection wave amplitude graph; respectively setting the number of a first fluctuation peak value graph, a second fluctuation peak value graph and a third fluctuation peak value graph in the first ultrasonic reflected wave amplitude graph as a first fluctuation number, a second fluctuation number and a third fluctuation number; respectively setting the number of the first fluctuation peak value graph, the second fluctuation peak value graph and the third fluctuation peak value graph in the second ultrasonic reflected wave amplitude graph as a fourth fluctuation number, a fifth fluctuation number and a sixth fluctuation number; respectively setting the number of the first fluctuation peak value pattern, the second fluctuation peak value pattern and the third fluctuation peak value pattern in the third ultrasonic reflected wave amplitude diagram as a seventh fluctuation number, an eighth fluctuation number and a ninth fluctuation number; substituting the first fluctuation quantity, the second fluctuation quantity and the third fluctuation quantity into a first ultrasonic detection formula to obtain a first ultrasonic detection value; substituting the fourth fluctuation quantity, the fifth fluctuation quantity and the sixth fluctuation quantity into a second ultrasonic detection formula to obtain a second ultrasonic detection value; substituting the seventh fluctuation quantity, the eighth fluctuation quantity and the ninth fluctuation quantity into a third ultrasonic detection formula to obtain a third ultrasonic detection value;
substituting the tensile index of the body, the tensile index of the welding position, the first compression distance, the second compression distance, the first collision distance and the second collision distance into a complementary processing formula to obtain a complementary processing value;
substituting the supplementary processing value and the first ultrasonic detection value, the second ultrasonic detection value and the third ultrasonic detection value into a supplementary detection formula to obtain a supplementary ultrasonic detection value; when the supplementary ultrasonic detection value is less than or equal to a first ultrasonic detection threshold value, dividing the welding quality of the welding product into a first welding grade; when the supplementary ultrasonic detection value is larger than the first ultrasonic detection threshold value and smaller than or equal to a second ultrasonic detection threshold value, dividing the welding quality of the welding product into a second welding grade; and when the supplementary ultrasonic detection value is larger than the second ultrasonic detection threshold value, the welding quality of the welding product is classified into a third welding grade.
The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims (2)

1. The system is used for monitoring the welding quality and is characterized by comprising a detection module, a welding processing module and a sampling supplement module, wherein the detection module is used for detecting the welding position of a welding product through ultrasonic waves;
the welding processing module comprises an ultrasonic processing unit, a supplementary processing unit and a supplementary detection unit, and the ultrasonic processing unit is used for processing the detection result of the detection module; the supplementary processing unit is used for controlling the sampling supplementary module to carry out supplementary detection operation; the supplementary detection unit is used for comprehensively processing the processing results of the ultrasonic processing unit and the supplementary processing unit to obtain an adjusted ultrasonic detection result;
the sampling supplement module comprises a tensile supplement testing unit, a compressive supplement testing unit and an anti-collision supplement testing unit, and is configured with a sampling supplement strategy, wherein the sampling supplement strategy comprises the following steps: firstly, selecting a section of welding product body, then selecting a section of welded product, wherein the welding position of the welded product is located in the middle position, the selected length of the welding product body is the same as that of the welded product, then respectively carrying out tensile test, compressive test and anti-collision test on the welding position of the welding product body and the welded product through a tensile supplementary test unit, a compressive supplementary test unit and an anti-collision supplementary test unit, wherein the detection module is configured with an ultrasonic detection strategy, and the ultrasonic detection strategy comprises the following steps: detecting by adopting an angle perpendicular to a welding position of a welding product, acquiring a first group of ultrasonic reflected waves within a first time length, setting the detection position as a first detection position, and setting the detection angle as a first detection angle;
continuing to detect the starting point by taking the first detection position as a circle center, and then rotating towards the first direction by taking the first detection position as a circle center to obtain a second group of ultrasonic reflection waves within a first time length;
continuing to perform a detection starting point at the first detection position, keeping the same distance with the welded product, performing surrounding detection on the welded product along the first direction, and acquiring a third group of ultrasonic reflected waves within a first time length, wherein the ultrasonic processing unit is configured with an ultrasonic processing strategy, and the ultrasonic processing strategy comprises: taking the time length of the first time length as a horizontal coordinate, and taking the signal amplitude of the ultrasonic reflected wave as a vertical coordinate to manufacture a reflected wave amplitude diagram;
a reflected wave amplitude diagram is made on the basis of the first group of ultrasonic reflected waves and is set as a first ultrasonic reflected wave amplitude diagram; a reflected wave amplitude diagram is made on the basis of the second group of ultrasonic reflected waves and is set as a second ultrasonic reflected wave amplitude diagram; a reflected wave amplitude diagram is manufactured on the basis of the third group of ultrasonic reflected waves and is set as a third ultrasonic reflected wave amplitude diagram;
setting a line shape in which the fluctuation amplitude in the first abscissa length in the first ultrasonic reflected wave amplitude diagram, the second ultrasonic reflected wave amplitude diagram and the third ultrasonic reflected wave amplitude diagram is greater than a first floating threshold value as a first fluctuation peak value graph;
setting the line shape with more than or equal to three first fluctuation peak value graphs appearing in the second abscissa length as a second fluctuation peak value graph;
setting the line shape with more than or equal to three second fluctuation peak value graphs appearing in the third abscissa length as a third fluctuation peak value graph;
respectively acquiring the number of first fluctuation peak value graphs, second fluctuation peak value graphs and third fluctuation peak value graphs in the first ultrasonic reflection wave amplitude graph, the second ultrasonic reflection wave amplitude graph and the third ultrasonic reflection wave amplitude graph;
respectively setting the number of a first fluctuation peak value graph, a second fluctuation peak value graph and a third fluctuation peak value graph in the first ultrasonic reflected wave amplitude graph as a first fluctuation number, a second fluctuation number and a third fluctuation number;
respectively setting the number of the first fluctuation peak value graph, the second fluctuation peak value graph and the third fluctuation peak value graph in the second ultrasonic reflected wave amplitude graph as a fourth fluctuation number, a fifth fluctuation number and a sixth fluctuation number;
respectively setting the number of the first fluctuation peak value pattern, the second fluctuation peak value pattern and the third fluctuation peak value pattern in the third ultrasonic reflected wave amplitude diagram as a seventh fluctuation number, an eighth fluctuation number and a ninth fluctuation number;
substituting the first fluctuation quantity, the second fluctuation quantity and the third fluctuation quantity into a first ultrasonic detection formula to obtain a first ultrasonic detection value; substituting the fourth fluctuation quantity, the fifth fluctuation quantity and the sixth fluctuation quantity into a second ultrasonic detection formula to obtain a second ultrasonic detection value; substituting the seventh fluctuation number, the eighth fluctuation number, and the ninth fluctuation number into a third ultrasonic detection formula to obtain a third ultrasonic detection value, wherein the first ultrasonic detection formula is configured to: pcs1= (Ssc 1 × a1+ Ssc2 × a 2) Ssc3; the second ultrasonic detection formula is configured to: pcs2= (Ssc 4 × b1+ Ssc5 × b 2) Ssc6; the third ultrasonic detection formula is configured to: pcs3= (Ssc 7 × c1+ Ssc8 × c 2) Ssc9; wherein Pcs1 is a first ultrasonic detection value, pcs2 is a second ultrasonic detection value, pcs3 is a third ultrasonic detection value, ssc1, ssc2, ssc3, ssc4, ssc5, ssc6, ssc7, ssc8 and Ssc9 are respectively a first fluctuation quantity, a second fluctuation quantity, a third fluctuation quantity, a fourth fluctuation quantity, a fifth fluctuation quantity, a sixth fluctuation quantity, a seventh fluctuation quantity, an eighth fluctuation quantity and a ninth fluctuation quantity, a1 is a first fluctuation quantity conversion coefficient, a2 is a second fluctuation quantity conversion coefficient, b1 is a fourth fluctuation quantity conversion coefficient, b2 is a fifth fluctuation quantity conversion coefficient, c1 is a seventh fluctuation quantity conversion coefficient, and c2 is an eighth fluctuation quantity conversion coefficient, the tensile supplementary test unit is configured with a tensile test strategy, and the tensile test strategy comprises: respectively stretching the welding product body and the welding position of the welding product by adopting a first stretching strength, and setting a body stretching resistance index and a welding position stretching resistance index according to stretching resistance results, wherein the set values of the body stretching resistance index and the welding position stretching resistance index are different when the welding position of the welding product body and the welding product is fractured and is not fractured;
the compression-resistant supplementary test unit is provided with a compression-resistant test strategy, and the compression-resistant test strategy comprises the following steps: respectively fixing two ends of a welding product body and the two ends of the welded product, then carrying out compression testing on the two ends of the welding product body and the welded product at a first compression resistance degree, keeping the first compression resistance degree for testing a first compression resistance time, then measuring distances between the two ends of the welding product body and the two ends of the welded product, and respectively setting the distances as a first compression resistance distance and a second compression resistance distance;
the anti-collision supplementary test unit is configured with an anti-collision test strategy, and the anti-collision test strategy comprises the following steps: fixing two ends of a welding product body and a welded welding product respectively, then carrying out anti-collision on the middle positions of the welding product body and the welded welding product respectively with first anti-collision force, after the first anti-collision force is used for anti-collision for a first time, measuring the distances between the two ends of the welding product body and the two ends of the welded welding product, and setting the distances as a first anti-collision distance and a second anti-collision distance respectively, wherein a supplementary processing strategy is configured for a supplementary processing unit, and comprises the following steps: substituting the body tensile index, the welding part tensile index, the first compression distance, the second compression distance, the first collision distance and the second collision distance into a supplementary processing formula to obtain a supplementary processing value, wherein the supplementary processing formula is configured as follows: pbc = (Zhj-Zbt) × k1+ (Swq 1-Swq 2) × k2+ (Scj 1-Scj 2) × k3; wherein Pbc is a supplement processing value, zhj is a body tensile index, zbt is a welding part tensile index, k1 is a tensile supplement coefficient, swq1 is a first compression distance, swq2 is a second compression distance, k2 is a compression supplement coefficient, scj1 is a first collision distance, scj2 is a second collision distance, k3 is a collision supplement coefficient, the supplement detection unit is configured with a supplement detection strategy, and the supplement detection strategy comprises: substituting the supplementary processing value and the first ultrasonic detection value, the second ultrasonic detection value and the third ultrasonic detection value into a supplementary detection formula to obtain a supplementary ultrasonic detection value; when the supplementary ultrasonic detection value is less than or equal to a first ultrasonic detection threshold value, dividing the welding quality of the welding product into a first welding grade; when the supplementary ultrasonic detection value is larger than the first ultrasonic detection threshold value and smaller than or equal to a second ultrasonic detection threshold value, dividing the welding quality of the welding product into a second welding grade; when the supplementary ultrasonic detection value is larger than a second ultrasonic detection threshold value, dividing the welding quality of the welding product into a third welding grade, wherein the first ultrasonic detection threshold value is smaller than the second ultrasonic detection threshold value, the welding quality of the first welding grade is better than that of the second welding grade, the welding quality of the second welding grade is better than that of the third welding grade, and the supplementary detection formula is configured as follows: pbj = (Pcs 1+ Pcs2+ Pcs 3) Pbc; wherein Pbj is the supplemental ultrasound detection value.
2. The method of a system for monitoring weld quality according to claim 1, comprising the steps of: s1, detecting a welding position of a welding product through ultrasonic waves;
s2, selecting a section of welding product body, selecting a section of welded product, wherein the welding position of the welded product is located in the middle position, the selected lengths of the welding product body and the welded product are the same, and then respectively carrying out tensile test, compression test and collision test on the welding position of the welding product body and the welded product;
and S3, comprehensively processing the detection results obtained in the processing procedures of the S1 and the S2 to obtain the adjusted ultrasonic detection result.
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