CN115383258A - Symmetric magnetic pole compression control system of robot GMAW (gas metal arc welding) additive manufacturing arc form - Google Patents
Symmetric magnetic pole compression control system of robot GMAW (gas metal arc welding) additive manufacturing arc form Download PDFInfo
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- CN115383258A CN115383258A CN202210829709.7A CN202210829709A CN115383258A CN 115383258 A CN115383258 A CN 115383258A CN 202210829709 A CN202210829709 A CN 202210829709A CN 115383258 A CN115383258 A CN 115383258A
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- 230000000996 additive effect Effects 0.000 title claims abstract description 47
- 239000000654 additive Substances 0.000 title claims abstract description 46
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 26
- 230000006835 compression Effects 0.000 title claims abstract description 11
- 238000007906 compression Methods 0.000 title claims abstract description 11
- 229910052751 metal Inorganic materials 0.000 title description 3
- 239000002184 metal Substances 0.000 title description 3
- 238000003466 welding Methods 0.000 title description 3
- 230000005284 excitation Effects 0.000 claims abstract description 20
- 230000000007 visual effect Effects 0.000 claims abstract description 3
- 238000010891 electric arc Methods 0.000 claims description 28
- 239000000463 material Substances 0.000 claims description 17
- 230000009467 reduction Effects 0.000 claims description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 4
- 238000001914 filtration Methods 0.000 claims description 4
- 230000003287 optical effect Effects 0.000 claims description 3
- 238000004804 winding Methods 0.000 claims description 3
- 229910000838 Al alloy Inorganic materials 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 229910052742 iron Inorganic materials 0.000 claims description 2
- 238000007747 plating Methods 0.000 claims description 2
- 238000012545 processing Methods 0.000 claims description 2
- 230000005540 biological transmission Effects 0.000 claims 1
- 238000009825 accumulation Methods 0.000 abstract description 4
- 239000000758 substrate Substances 0.000 abstract description 3
- 238000013461 design Methods 0.000 abstract description 2
- 230000004069 differentiation Effects 0.000 abstract 1
- 230000010354 integration Effects 0.000 abstract 1
- 238000000034 method Methods 0.000 description 19
- 230000008569 process Effects 0.000 description 15
- 230000008859 change Effects 0.000 description 9
- 230000005672 electromagnetic field Effects 0.000 description 7
- 238000005253 cladding Methods 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
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- 230000003044 adaptive effect Effects 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
Images
Classifications
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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
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
-
- 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
- B23K9/08—Arrangements or circuits for magnetic control of the arc
-
- 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
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
-
- 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
- B23K9/32—Accessories
-
- 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
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Arc Welding Control (AREA)
Abstract
The invention provides a symmetric magnetic pole compression control system in a robot GMAW additive manufacturing arc form, which comprises a vision camera, a 5% dimmer, a 850nm high-pass filter, a computer, a symmetric magnetic pole, a PID (proportion integration differentiation) controller, an alternating-current excitation power supply, an electromagnetic coil and the like. The hardware structure of the invention is simple, the design is reasonable, the AC excitation power supply supplies power to the electromagnetic coil, the AC magnetic field which is symmetrically distributed is formed on two sides of the additive arc accumulation direction through the symmetric magnetic poles, the AC magnetic field compresses the arc to control the arc shape, the high-temperature arc acts on the substrate to form a molten pool, the visual camera detects the molten pool image in real time, the actual width of the molten pool is extracted through the image processing program of the computer, the deviation value of the theoretical width and the actual width data is input to the PID controller, the PID controller outputs the current amplitude increment and the frequency increment of the AC excitation power supply, the magnetic field size is changed, the arc shape is controlled, and the control of the additive molten pool width is realized.
Description
Technical Field
The invention relates to the field of industrial robot electric arc additive manufacturing, in particular to a symmetrical magnetic pole compression control system of a robot GMAW additive manufacturing electric arc form.
Background
In the robot electric arc additive process, the realization of high-precision control of the width of the additive cladding layer has important significance for improving the additive surface quality and is a hotspot and difficulty of additive manufacturing technology research. The traditional method is to detect the width of a molten pool in real time through a vision camera (CCD), and change the current, arc voltage, accumulation speed and other process parameters of an additive power supply in real time to change the linear energy of an electric arc according to the establishment of a control model of the width of the molten pool and the process parameters of the additive current, the arc voltage, the accumulation speed and the like, so as to control the width of the molten pool. However, the method directly changes the process parameters of the arc, which may bring about the change of the arc stability, cause the arc instability, and affect the forming quality; meanwhile, the change of the additive deposition efficiency caused by the change of the process parameters is not consistent with the existing theme that the path and deposition rate are planned by additive software and then additive manufacturing is carried out. Therefore, there is a need to explore new ways of molten pool control in additive manufacturing processes to provide new alternatives for precise control of additive manufacturing forming quality.
According to the physical theory of the electric arc, the tip of the wire material forms the electric arc through the current in the additive manufacturing process, the electric arc keeps a mechanical quasi-equilibrium state under the combined action of electromagnetic contraction force, plasma flow force, gravity and surface tension, the electric arc is in a bell-jar shape with normal Gaussian distribution and acts on the additive substrate to be melted to form a molten pool, and the width of the molten pool is closely related to the shape of the electric arc. It can be seen that changing the shape of the arc can also achieve changing the bath width. Modern electromagnetic theory states that interaction of a current conductor with an electromagnetic field can produce a force on the current conductor, which provides a concept for controlling additive manufacturing arc shape. Therefore, the control of the additive manufacturing arc form is realized through the reasonable designed electromagnetic field, certain practical significance is achieved for accurately controlling the width of an additive manufacturing molten pool, and a new optional method is provided for an additive manufacturing control theory.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the defects in the prior art are overcome, and the symmetrical magnetic pole compression control system in the form of the GMAW (gas metal arc welding) additive manufacturing arc is provided, and is suitable for assisting in controlling the size of the arc through an external magnetic field on the premise of not changing additive process parameters, and the width of a molten pool molten due to the change of the size of the arc is changed, so that the purpose of controlling the additive forming width is achieved.
The technical scheme adopted by the invention for solving the technical problems is as follows: a symmetric magnetic pole compression control system of a robot GMAW material increase manufacturing arc form comprises a vision camera, a computer, a PID controller and an electromagnetic control assembly which are sequentially connected in series, wherein the computer is used for running an image processing program, processing images collected by the vision camera and extracting the width of a molten pool, the electromagnetic control assembly comprises an electromagnetic coil, a symmetric magnetic pole and an alternating current excitation power supply, the alternating current excitation power supply is used for generating alternating current with certain amplitude and frequency and supplying power to the electromagnetic coil to generate an electromagnetic field, the electromagnetic field acts on a material increase arc area through the symmetric magnetic pole to control the shape of the arc, the input quantity of the PID controller is the difference value between the detection width of the molten pool and a target width, the output quantity is the increment of the current amplitude quantity and the frequency quantity of the alternating current excitation power supply, and parameter control is realized according to a relation model between the width of the molten pool and the current amplitude and frequency of the excitation power supply, which is established by a process experiment.
Furthermore, the vision camera is composed of a CMOS image core chip and an optical lens which are packaged by an aluminum alloy shell, and can realize the image acquisition of an electric arc and a molten pool area in the material increase process.
Furthermore, a light filtering dimmer is additionally arranged at the front part of the vision camera.
Further, the filtering dimmer comprises a 5% dimmer and an 850nm high-pass filter.
Further, the 5% light reduction plate is formed by plating a light reduction reflection film on a glass sheet, light rays with a wave band of 200nm-1200nm are attenuated by 95% after passing through the light reduction plate and are used for weakening electric arcs with over-high brightness and molten pool light rays, the 850nm high-pass filter is made of optical materials, only 850nm near-infrared wave band light components are allowed to pass through when the light rays irradiate on the high-pass filter, and the 850nm high-pass filter and the 5% light reduction plate are combined and arranged at the front part of the vision camera to realize the sensing acquisition of additive electric arcs and molten pool images in near-infrared wave bands above 850 nm.
Furthermore, the symmetrical magnetic poles are distributed on the left side and the right side of the electric arc in a direction parallel to the movement direction of the additive electric arc by taking the additive wire as an axis, and are used for converging an electromagnetic field in a tiny electric arc area to realize electric arc shape regulation and control, so that the width of a molten pool is controlled.
Furthermore, the symmetrical magnetic poles are made of industrial pure iron.
Furthermore, the electromagnetic coil is formed by winding a 0.6mm copper enameled wire for 400 turns, and can generate an electromagnetic field after being electrified.
The robot GMAW material increase manufacturing arc-shaped symmetrical magnetic pole compression control system has the beneficial effects that: by adding the symmetrically distributed alternating-current magnetic field, the problem of controlling the shape of the electric arc on the premise of not changing the additive process is solved, so that the aim of controlling the width of an additive molten pool and the forming width of a cladding layer is fulfilled, and a new thought is provided for online control of electric arc additive. The symmetrical magnetic poles related to the invention have simple structure and reasonable design, when the parameters of the AC excitation power supply are set, the excitation power supply outputs current, the current flows through the electromagnetic coils on the symmetrical magnetic field to generate a magnetic field, and the magnetic field is gathered at two sides of the electric arc in the material increase process through the symmetrical magnetic poles; in the material increase process, an electric arc and a molten pool area image are acquired by sensing through a vision camera, the image is processed through a computer to obtain the width of a molten pool, the difference value of the detected width data of the molten pool and the theoretical width is input into a PID controller, and the controller outputs the amplitude and the frequency quantity of the exciting current to an alternating current exciting power supply, so that the constant feedback control of the width of the material increase molten pool is realized, and a new method is provided for the material increase manufacturing forming control.
Drawings
The invention is further illustrated by the following examples in conjunction with the drawings.
FIG. 1 is an overall schematic view of the present invention;
FIG. 2 is a diagram of the relationship between the magnetic poles and the arc according to the present invention;
FIG. 3 is a diagram of an electromagnetic coil of the present invention;
FIG. 4 is a diagram of a symmetric magnetic pole of the present invention;
in the figure: 1. the vision camera, 2.850nm high-pass filter, 3.5% light reduction piece, 4. AC excitation power supply, 5. Electromagnetic coil, 6. Symmetrical magnetic pole, 7. Computer, 8.PID controller, 9. Air feeding mechanism, 10. Base plate, 11. Tooling platform, 12. Robot control cabinet, 13. Demonstrator, 14. Material adding power supply, 15. Robot, 16. Material adding gun, 17. Wire feeding mechanism.
Detailed Description
The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic views illustrating only the basic structure of the present invention in a schematic manner, and thus show only the constitution related to the present invention.
Referring to fig. 1-4, a symmetric magnetic pole compression control system for GMAW additive manufacturing arc shape of a robot is provided, in which 0.4A ac excitation power sources with frequencies of 50Hz and 100Hz are respectively set to act on an electromagnetic coil 5 to generate magnetic fields, the magnetic fields are applied to both sides of an arc through the symmetric magnetic poles to control the arc shape, and a vision camera 1 detects the width of a molten pool under the action of the arc in real time, so that the width of the molten pool is reduced compared with the arc shape under the state without the magnetic field. Then, the current and frequency parameters of the AC excitation power supply can be controlled in a feedback manner through the PID controller 8 by detecting the change of the width of the molten pool, so that the adaptive constant control of the width of the additive molten pool is realized.
As a preferred arrangement of the patent embodiment of the present invention, the ac excitation power source 4 can generate an ac current with a fixed amplitude and frequency, and an external communication RS232 interface is configured to implement external control of the current amplitude and frequency.
As a preferable arrangement of the patented embodiment of the invention, the electromagnetic coil 5 is formed by winding 5 layers of enameled wires with the diameter of 0.6mm for 400 turns, and an electromagnetic field is generated when current is passed through the enameled wires.
As a preferable arrangement of the patented embodiment of the invention, the electromagnetic coils 5 are wound on the symmetric magnetic poles 6 and distributed on two sides of the additive arc along the arc deposition direction.
As a preferred arrangement of the patent embodiment of the invention, the visual camera 1 collects the image of the molten pool, the computer 7 processes the image to obtain the width of the molten pool, and the AC excitation power supply 4 is controlled by the PID controller 8 according to the requirement of the change of the width of the molten pool, so as to change the size of the magnetic field applied to the two sides of the arc, realize the control of the shape of the arc and further control the width of the molten pool.
The working principle of the invention is as follows: the shape of the arc is compressed by the alternating magnetic field generated by the symmetrical magnetic poles 6, so that the problem that the width of a molten pool is controlled by changing the shape of the arc on the premise of not changing additive technological parameters is solved, and the high-precision control of an additive cladding layer is realized. Specifically, in the material increase process, alternating magnetic fields which are symmetrically distributed are formed on two sides of the material increase electric arc accumulation direction through symmetrical magnetic poles 6, the alternating magnetic fields compress the electric arc to control the shape of the electric arc, the high-temperature electric arc acts on a substrate to form a molten pool, the electric arc and a molten pool image in the material increase process are detected in real time through a vision camera 1, the image is processed by a computer 7 to obtain the width of the molten pool, the theoretical width and the image detection width difference value are input to a PID controller 8 according to the established PID control model of the width of the molten pool and the current amplitude/frequency of an alternating current excitation power supply, the current amplitude/frequency increment of the alternating current excitation power supply is output, and the size of the magnetic field is controlled, so that the purpose of controlling the width of the molten pool in a feedback mode is achieved.
The use process comprises the following steps: after the symmetrical magnetic pole 6 device is installed, an alternating current excitation power supply 4 is switched on, alternating current acts on an electromagnetic coil 5 on the magnetic pole to generate a magnetic field, the magnetic field is applied to an electric arc through the magnetic pole, the width of a molten pool is detected by a vision camera 1, and the current and the frequency of the excitation power supply are controlled by a PID controller 8 according to the requirement of the width of the molten pool, so that the width of the molten pool is controlled in a constant range, and the feedback control of the width of the molten pool is realized. When the magnetic field generator is not used, the power supply is turned off, the magnetic poles do not generate a magnetic field, and the magnetic field generator is convenient and quick to use.
In light of the foregoing description of the preferred embodiment of the present invention, many modifications and variations will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (8)
1. A robot GMAW additive manufacturing electric arc form symmetric magnetic pole compression control system is characterized in that: including visual camera (1), computer (7), PID controller (8) and the electromagnetic control assembly of series connection in proper order, the electromagnetic control assembly include symmetrical magnetic pole (6), coiling solenoid (5) on symmetrical magnetic pole (6), for alternating current excitation power supply (4) of solenoid (5) power supply, the input and the computer (7) of PID controller (8) be connected, the molten bath width difference of transmission computer processing, the output is connected with alternating current excitation power supply (4), control supply current and frequency increment.
2. The robotic GMAW additive manufacturing arc configuration symmetric pole compression control system of claim 1, wherein: the vision camera (1) is composed of a CMOS image core chip and an optical lens, wherein the CMOS image core chip is packaged by an aluminum alloy shell.
3. The system of claim 1, wherein the system is configured to control the GMAW additive manufacturing arc configuration by: the front part of the vision camera (1) is additionally provided with a light filtering dimmer.
4. The system of claim 3, wherein the system is configured to control the GMAW additive manufacturing arc configuration by: the filtering dimmer comprises a 5% dimmer (3) and a 850nm high-pass filter (2).
5. The system of claim 4, wherein the system is configured to control the GMAW additive manufacturing arc configuration by: the 5% light reduction sheet (3) is formed by plating a light reduction reflection film on a glass sheet.
6. The robotic GMAW additive manufacturing arc configuration symmetric pole compression control system of claim 1, wherein: the symmetrical magnetic poles (6) are made of industrial pure iron and are used for magnetic conduction.
7. The system of claim 6, wherein the system comprises: the symmetrical magnetic poles (6) are symmetrically distributed on the left side and the right side of the electric arc along the additive material stacking direction by taking the axis of the additive material electric arc as the center, and local symmetrically distributed magnetic fields are formed on the two sides of the electric arc.
8. The system of claim 1, wherein the system is configured to control the GMAW additive manufacturing arc configuration by: the electromagnetic coil (5) is formed by winding 400 turns of 0.6mm copper enameled wires.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210829709.7A CN115383258A (en) | 2022-07-15 | 2022-07-15 | Symmetric magnetic pole compression control system of robot GMAW (gas metal arc welding) additive manufacturing arc form |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210829709.7A CN115383258A (en) | 2022-07-15 | 2022-07-15 | Symmetric magnetic pole compression control system of robot GMAW (gas metal arc welding) additive manufacturing arc form |
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| CN115383258A true CN115383258A (en) | 2022-11-25 |
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2022
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