CN115156662A - Space weld track step-by-step adjusting welding method for fan impeller - Google Patents
Space weld track step-by-step adjusting welding method for fan impeller Download PDFInfo
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- CN115156662A CN115156662A CN202210926389.7A CN202210926389A CN115156662A CN 115156662 A CN115156662 A CN 115156662A CN 202210926389 A CN202210926389 A CN 202210926389A CN 115156662 A CN115156662 A CN 115156662A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
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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
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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- 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
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
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Abstract
A space weld track step-by-step adjusting welding method for a fan impeller mainly solves the technical problems that the welding precision of the fan impeller is low, the welding difficulty of an underwater fan impeller is high and the like at present. The technical scheme includes that a weld joint detector carries out prescanning on the position to be welded of a fan impeller to obtain a weld joint track, the weld joint track is subjected to self-adaptive segmentation, a welding posture regulating and controlling system carries out comparison calculation on welding speed information and welding current information acquired in real time and each piece of weld joint information scanned in advance to obtain the optimal welding angle and the optimal space posture of a welding gun in each piece of weld joint track, then the value is compared with the real-time welding angle and the real-time welding posture to obtain a difference value, and the difference value is used as a basis for carrying out real-time regulation on the angle and the posture of the welding gun, so that the welding gun always keeps the optimal welding angle and the optimal welding posture in the welding process, the welding precision is greatly improved, and high-quality automatic welding is achieved.
Description
Technical Field
The invention relates to a welding seam tracking technology, in particular to a welding method for regulating a space welding seam track step by step for a fan impeller.
Background
The fan impeller is a key component of the fan, and drives gas to flow in a rotating mode in the working process, so that the gas is discharged and conveyed. The quality of the fan impeller not only affects the quality, efficiency and service life of the fan, but also affects the motion balance stability, noise level and the like of the fan. However, the impeller of the fan is eroded by solid or liquid substances such as gravel, rainwater and the like, so that the abrasion and erosion phenomena of the blades are caused, and the normal operation of the whole fan is influenced. At present, people are limited to manual welding or semi-manual welding for the welding technology of the fan impeller, and the impeller is required to be taken off from the fan before welding the fan impeller, so that the welding work can be carried out on the fan impeller, the welding speed is low, the welding positioning is not accurate, the welding precision is low, the underwater welding work difficulty is high, and the technical requirement on welding workers is high.
In order to solve the problems related to the welding process of the fan impeller, many researchers have made corresponding researches. For example, chinese invention patent (CN 106181087B): the on-line welding method for the impeller of the circulating fan has the advantages that the penetration is more sufficient by increasing the depth of the throat, the stress bearing capacity of a welding seam is improved, the time for the welding seam to crack is delayed, and the service time after the crack is repaired is prolonged. Chinese invention patent (CN 109249120B): a multi-station full-automatic welding method for machining a fan impeller is characterized in that a chassis positioning process, a chassis alternating process, a blade and chassis assembling, positioning and welding process, a top cover feeding process, a welding process, a turning and welding process and a discharging process are arranged, and full-automatic welding of the fan impeller is achieved according to production requirements. Although the two patents can realize automatic welding, the process is complex, the welding precision is not enough, and the prior art does not provide a full-automatic welding method for the impeller of the underwater fan.
Disclosure of Invention
The invention aims to provide a space weld track step-by-step adjusting welding method for a fan impeller, which solves the problems of low welding precision of the fan impeller, high welding difficulty of an underwater fan impeller and the like by adjusting the relative space pose between a welding gun and a weld step by step.
A space welding seam track step-by-step adjusting welding method for a fan impeller is characterized by comprising a welding seam detector, a welding position adjusting and controlling system, a Hall sensor, an MEMS sensor, a driving device and a rotator. The inside of the welding seam detector consists of a fan impeller scanning camera, a welding seam track segmentation processor, an impeller welding seam information memory and an impeller image information converter, and the outside of the welding seam detector is wrapped by a water-drop-shaped titanium alloy material shell. The welding posture regulating system consists of an impeller information memory, a balancing instrument, a current information processing regulator, an angle information processing regulator, a posture information processing regulator and a digital-to-analog converter. The driving device consists of a telescopic rod, a rotator and a driver. The rotator is connected with a welding gun, and the welding seam detector, the Hall sensor and the MEMS sensor are attached to the welding gun together. The welding seam detector scans the fan impeller along with the welding gun to obtain a complete welding seam track, and performs self-adaptive segmentation on the welding seam track. The Hall sensor and the MEMS sensor respectively collect current information and welding speed information of the welding gun in real time and transmit the current information and the welding speed information to the welding posture regulating and controlling system. The welding posture regulating and controlling system respectively receives current information and welding speed information of the welding guns, compares the current information and the welding speed information with segmented welding seam information from the welding seam detector, calculates and processes the segmented welding seam information to obtain the optimal space posture and the optimal welding angle of the welding guns relative to the welding seam in each segment, and immediately controls the driving device to regulate the space posture and the welding angle of the welding guns. After the adjustment is completed, the welding gun starts to work. The method realizes the accurate full-automatic welding of the impeller of the underwater fan by firstly segmenting the welding line and then adjusting the welding gun step by step.
A space weld track step-by-step adjusting welding method for a fan impeller comprises the following working procedures: the rotator drives the welding gun to rotate around the blade wind wheel, the welding gun does not work, a welding seam detector on the welding gun scans the fan impeller to obtain a complete welding seam track, the welding seam is subjected to self-adaptive segmentation, and then segmented welding seam information is transmitted to a welding posture regulating and controlling system. The welding posture adjusting and controlling system receives welding speed information of the welding gun acquired by the MEMS sensor in real time, compares the welding speed information with the sectional welding seam information, calculates and processes the welding speed information and the sectional welding seam information to obtain the optimal welding angle of the welding gun relative to each section of welding seam under the posture, and immediately starts the driving device to adjust the angle of the welding gun. Meanwhile, the welding posture regulating and controlling system receives current information of the welding gun collected by the Hall sensor in real time, compares the current information with the received segmented welding seam information, calculates and processes the current information and the received segmented welding seam information to obtain the optimal space posture relation between the welding gun and the welding seam in each segment of welding seam, and then controls the driving device to regulate the space posture of the welding gun. And after the welding gun is adjusted to be in place, the welding gun starts to perform welding work.
The weld joint detector in the method is characterized in that: the welding seam detector is internally composed of a fan impeller scanning camera, a welding seam track segmentation processor, an impeller welding seam information memory and an impeller image information converter, and the outside of the welding seam detector is wrapped by a water-drop-shaped titanium alloy material shell. The external structure of the welding seam detector enables the welding seam detector to be well suitable for the working environment in deep water, and has good compression resistance and corrosion resistance. The welding seam detector scans the fan impeller along with the welding gun, acquires the whole welding seam track, arranges the acquired image information, and performs self-adaptive segmentation on the whole welding seam according to the image information. And then, the welding seam detector transmits the sorted segmented welding seam information to a welding attitude regulating and controlling system.
The welding posture regulating system in the method is characterized in that: the welding posture regulating system consists of an impeller information memory, a balancing instrument, a current information processing regulator, an angle information processing regulator, a posture information processing regulator and a digital-to-analog converter. The welding posture regulating and controlling system receives welding current information and welding speed information transmitted by the Hall sensor and the MEMS sensor while receiving welding seam information transmitted by the welding seam detector, and compares, calculates and processes the welding current information and the welding speed information in sequence to obtain the optimal space posture and the optimal welding angle of the welding gun relative to the welding seam in each section of the welding seam. And then controlling a driving device to adjust the space pose and the welding angle of the welding gun, so that the welding gun is always kept at the optimal welding pose and the optimal welding angle in the welding process.
The method for adaptively segmenting the welding seam is characterized by comprising the following steps: after scanning the fan impeller, the welding seam detector acquires the whole welding seam track, and divides the welding seam into n sections (S1, S2, S3, sn) according to the distance and the deflection angle according to the characteristics of the welding seam of the impeller. Wherein, the distance of each section of welding line is more than 2 times of the diameter of the welding gun and less than 4 times of the diameter of the welding gun, and the deflection angle of the welding line is less than 15 degrees.
The optimal value of the method is characterized in that an optimal welding pose and an optimal welding angle exist between the welding gun and the welding seam in each section of the welding seam. The welding seam detector segments the welding seam and transmits segmented welding seam information to the welding posture regulating and controlling system, and the welding posture regulating and controlling system compares the segmented welding seam information with welding current information and welding speed information of welding guns to calculate the optimal posture relation (A1, A2, A3,, an) and the optimal welding angle (B1, B2, B3,, bn) of the welding guns and the welding seam in each segment.
The invention is mainly characterized in that: the method includes the steps of welding a workpiece according to a part-to-whole idea, segmenting a weld track obtained through pre-scanning, calculating the space attitude and the welding angle of a welding gun in each segment of weld track, comparing the space attitude and the welding angle of the welding gun measured in real time with pre-calculated data in actual welding, adjusting the space attitude and the welding angle of the welding gun in real time, and performing independent welding on any segment. The structure and the characteristics of the welding seam detector and the welding posture regulating and controlling system enable the method to be suitable for underwater and overwater welding work at the same time, enable the welding gun to carry out self-adaptive regulation on the angle and the posture according to the structure of a workpiece to be welded, greatly improve the welding precision and achieve full-automatic welding of the fan impeller.
The invention has the beneficial effects that the invention provides the welding method for adjusting the space welding seam track step by step for the fan impeller, the welding method is suitable for the dual environment on water and under water and the welding work of various complex curved surfaces, and the welding precision is greatly improved by the way of acquiring and segmenting the welding seam track and then correspondingly adjusting the space pose and the welding angle of the welding gun relative to each welding seam.
Drawings
FIG. 1 is a flow chart of a spatial weld track step-by-step adjustment welding method for a fan wheel
FIG. 2 is a schematic view of a weld operation on a partial weld path
FIG. 3 is a schematic view of the pose and angle of a welding gun on a segmented weld path
FIG. 4, FIG. 5, FIG. 6, FIG. 7 and FIG. 8 are schematic diagrams of the working principle
Detailed Description
The embodiments of the invention are described in detail below with reference to the drawings: the present embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation manner and a process are given, but the scope of the present invention is not limited to the following embodiments.
The method is completed on equipment consisting of a welding seam detector, a welding posture regulating system, a Hall sensor, an MEMS sensor, a driving device, a rotator and the like. The welding position adjusting system receives welding speed information acquired by an MEMS sensor and welding current information acquired by a Hall sensor, compares the welding speed information with segmented welding line information transmitted by the welding position detector, calculates and processes the welding current information and the segmented welding line information to obtain the welding position relation and the optimal welding angle of a welding gun relative to the welding line in each segment of the welding line, starts to adjust the angle and the space position of the welding gun, enables the welding gun to be aligned with the center of the welding line, and then carries out welding work on the fan impeller.
Example 1, welding when the work piece surfaces on both sides of the weld are parallel. The welding seam detector scans the fan impeller, performs self-adaptive segmentation on the welding seam track, and transmits the segmented welding seam information to the welding attitude regulating and controlling system. The welding posture control system obtains that the workpiece surfaces on the two sides of the welding seam are parallel from the sectional information, and as shown in fig. 4 and 5, the welding posture control system receives welding speed information from the MEMS sensor as a monitoring signal at the moment, and does not adjust the welding angle of the welding gun. Meanwhile, the welding posture regulating system receives welding current information transmitted from the Hall sensor, compares the welding current information with the sectional welding seam information to calculate, obtains the optimal space posture of the welding gun in each section of welding seam, and controls the driving device to adjust the space posture of the welding gun according to the real-time welding seam track, so that the welding gun is aligned to the center of the welding seam, and the automatic welding of the fan impeller is realized.
Example 2, welding when the workpiece surfaces on both sides of the weld form a certain included angle. As shown in fig. 6 and 7, when an included angle exists between the two workpiece surfaces on the two sides of the weld joint, the welding posture control system combines the sectional weld joint information of the weld joint detector and the welding speed information of the MEMS sensor, performs comparison calculation to obtain the optimal welding angle in the section of weld joint, and then controls the driving device to perform swing adjustment on the welding gun so that the welding gun rotates to the optimal welding angle. Then, the welding posture regulating system combines the segmented welding seam information and the welding current information acquired by the Hall sensor, obtains the optimal welding posture of the welding gun in the segment of welding seam after comparison and calculation, and regulates the space posture of the welding gun in real time according to different welding seam tracks, so that the welding gun is always aligned with the center of the welding seam, and the welding precision and the welding quality are greatly improved. The welding method used in the embodiment is a FCAW and plasma arc hybrid welding method, and the problem of high welding difficulty of the impeller of the underwater fan is successfully solved.
Example 3, the welding between the two workpiece surfaces on the two sides of the welding seam is gradually changed from parallel to a certain angle. As shown in fig. 8, when the workpiece surfaces on both sides of the weld form an angle of 0 degree, the welding pose adjusting system compares the segmented weld information with the welding current signal collected by the hall sensor to obtain the optimal welding pose of the welding gun on each segment of weld, and then adjusts the pose of the welding gun according to the actual measurement pose. When the workpiece surfaces on the two sides of the welding line gradually form a certain angle, the welding posture regulating and controlling system compares and calculates the sectional welding line information with the welding speed information to obtain the optimal welding angle in each section of welding line, and regulates the angle of the welding gun in real time according to the actually measured welding angle. After the angle adjustment is completed, the welding pose regulating and controlling system regulates the space pose of the welding gun according to the optimal welding pose and the actually measured welding pose. No matter how the angles of the workpiece surfaces on the two sides of the welding line change, the welding gun is always aligned with the center of the welding line in each section of welding line, and high-quality welding is guaranteed to be completed. Meanwhile, the structural characteristics of the welding line detector enable the welding line detector to be well suitable for a deep water environment, and the welding method at the moment is the FCAW and plasma arc hybrid welding, so that the problem of welding the impeller of the underwater fan is solved.
The above description is only an individual embodiment of the present invention, and is not intended to limit the present invention, and all technical solutions obtained by equivalent substitution or equivalent transformation under the technical guidance of the present invention fall within the protection scope of the present invention.
Claims (3)
1. A space welding seam track step-by-step adjusting and welding method for a fan impeller is completed on equipment consisting of a welding seam detector, a welding posture adjusting and controlling system, a Hall sensor, an MEMS sensor, a driving device and a rotator. The welding posture regulating system consists of an impeller information memory, a balancing instrument, a current information processing regulator, an angle information processing regulator, a posture information processing regulator and a digital-to-analog converter.
2. A space weld track step-by-step adjusting welding method for a fan impeller is characterized by comprising the following steps of:
the method comprises the following steps: the welding seam detector scans the fan impeller, acquires the whole irregular welding seam track and performs self-adaptive segmentation on the irregular welding seam track;
step two: the welding posture regulating and controlling system receives welding speed information acquired by the MEMS sensor in real time, obtains the optimal welding angle between a welding gun and a welding seam in each section of path after comparing and calculating with the sectional welding seam information, and immediately controls the driving device to adjust the angle of the welding gun in real time;
step three: the welding posture regulating system receives welding current information acquired by the Hall sensor in real time and welding seam information of each section detected by the welding seam detector, obtains the optimal welding posture relation between a welding gun and a welding seam in each section of path after calculation processing, immediately controls the driving device to regulate the space posture of the welding gun in real time, and enables the welding gun to be aligned to the center of the welding seam, so that accurate automatic welding is realized.
3. The spatial weld trajectory step-adjustment welding method for wind turbine blades, as recited in claim 2, wherein the welding torch corresponds to a set of optimal welding torch poses and optimal welding angles in each segment of the weld. After a welding seam detector acquires a welding seam track, the welding seam track is divided into n sections (S1, S2, S3, sn), and the welding attitude regulation and control system respectively compares and calculates the welding seam information with welding current information and welding speed information to obtain the optimal welding attitude (A1, A2, A3, an) and the optimal welding angle (B1, B2, B3, bn) of a welding gun and the welding seam in each section.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116160174A (en) * | 2023-04-21 | 2023-05-26 | 山东芯合机器人科技有限公司 | Binocular vision-based weld joint identification and tracking control method |
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