CN115890055A - Welding experiment frame and method for exploring association rule of molten pool and welding quality - Google Patents
Welding experiment frame and method for exploring association rule of molten pool and welding quality Download PDFInfo
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Abstract
The invention discloses a welding experiment frame and a method for exploring a correlation rule of a molten pool and welding quality, and relates to the technical field of welding quality. The vision module comprises a fixed plate, wherein a driving mechanism, a positioning mechanism and a vision module are mounted at the top of the fixed plate, the positioning mechanism is positioned at the top end of the driving mechanism, and the vision module is positioned at one end of the driving mechanism; actuating mechanism includes locating rack, step motor and drive screw, and the top of fixed plate is fixed with the locating rack, and then can fix actuating mechanism's position, and the one end of locating rack is fixed with step motor, and step motor's output is connected with drive screw to can drive screw fast and rotate. According to the invention, through the matching of the driving mechanism, the positioning mechanism and the vision module, the welding position, the welding angle and the welding speed of the welding gun can be stably adjusted during use, and the welding quality is shot through the vision module, so that the welding quality can be conveniently evaluated.
Description
Technical Field
The invention belongs to the technical field of welding quality, and particularly relates to a welding experiment frame and a method for researching a correlation rule of a molten pool and the welding quality.
Background
During manual welding operation, the accuracy and stability of a welding gun are difficult to control during manual regulation of the working angle, the welding distance and the welding speed of the welding gun in the welding process, so that the welding quality is unstable. And strong arc light, high temperature, smoke, splash and toxic gas generated in the welding process cause great harm to the bodies of welding workers. Therefore, a welding robot having advantages of high efficiency, replaceability, and no fatigue is being gradually developed. The problem that the function is single exists in the regulation and control of the intelligent welding robot on the market to welding quality at present, and the welding seam shaping quality after welding can only be detected, and repair welding is carried out on the defect part of the welding seam. The process greatly reduces the efficiency of welding construction, and the repair welding process of the welding seam defect part is time-consuming and labor-consuming and can influence the strength of the repair welding joint or be scrapped due to ineffective correction. If the welding quality can be controlled in real time in the welding process, the working efficiency can be greatly improved, and the potential safety hazard caused by secondary reworking of workers can be reduced.
With the development of machine vision technology, welding robots begin to use vision detection technology to judge welding quality. The size and temperature distribution of the molten pool can judge the quality of the molten pool, and the quality control of the molten pool determines the welding quality. The size of a molten pool and the temperature distribution of the molten pool are key problems influencing the welding quality in the welding process, so that the exploration of the association rule of the molten pool and the welding quality is particularly important. The welding robot is provided with a welding vision module with the characteristics of large information amount, visual observation, high real-time performance and the like, and a correlation platform between a molten pool and welding quality can be established. In the welding process, a vision module at the tail end of the welding gun acquires image information of a front molten pool, and the current molten pool size and the molten pool temperature distribution can be obtained by using an image processing method. The size of the molten pool can be used for visually judging the current welding quality, but whether bubbles and slag are generated inside the molten pool or not cannot be clearly analyzed. The temperature distribution of the molten pool can be used for exploring key information in the molten pool, and the combination of the two greatly ensures the accuracy of judging the quality of the molten pool.
Therefore, a monitoring welding experiment table with double feedback of the size of the molten pool and the temperature distribution of the molten pool is needed to be designed, so that the quality of formed welding seams can be controlled in real time.
Disclosure of Invention
The invention aims to provide a welding experiment frame and a method thereof for researching the association rule of a molten pool and welding quality, so as to solve the problems in the background technology.
In order to solve the technical problems, the invention is realized by the following technical scheme:
the invention relates to a welding experiment frame for researching association rules of a molten pool and welding quality, which comprises a fixed plate, wherein the top of the fixed plate is provided with a driving mechanism and a positioning mechanism, and the positioning mechanism is positioned at the top end of the driving mechanism;
the driving mechanism comprises a positioning frame, a stepping motor and a transmission lead screw, the positioning frame is fixed at the top of the fixing plate, the stepping motor is fixed at one end of the positioning frame, and the output end of the stepping motor is connected with the transmission lead screw.
Further, positioning mechanism includes supporting seat, vertical axle, horizontal axle, vertical clamp and horizontal clamp, supporting seat threaded connection is in drive screw's the outside, the top of supporting seat is fixed with vertical axle, the outside of vertical axle is provided with vertical clamp, the one end that vertical pressed from both sides is fixed with horizontal clamp, the inboard that horizontal pressed from both sides is provided with horizontal axle.
Furthermore, one side of the transverse shaft is provided with a fixing clamp, a welding gun is arranged on the inner side of the fixing clamp, and a welding pipe is arranged at one end of the welding gun.
Furthermore, the top of the fixing plate is also provided with a welding base metal.
Further, the vision module that is used for detecting is installed in the outside of welding the pipe, the vision module includes two mesh cameras and link, the top of two mesh cameras is fixed with the link, the top and the welding pipe sliding connection of link, the top of link has the cardboard still that screw connection has.
A method for researching a welding experiment rack for a correlation rule between a molten pool and welding quality is used for any one of the above steps:
s1: starting the stepping motor 3 to move the supporting seat 5;
s2: adjusting the positions of the vertical clamp 12 and the transverse clamp 13;
s3: adjusting the angle of the retaining clip 14;
s4: welding the welding torch 6 to weld the welding parent metal 8 by electrifying;
s5: and the vision module detects the welding position in the fourth step.
Further, the detection of the vision module is according to the following steps:
the method comprises the following steps that I, under the action of a light reducing mirror and a light filter, the outline of a molten pool is clear, and the molten pool is divided into a molten pool and a cooling molten pool during welding;
II, extracting the contour edge of the molten pool in real time;
and IV, independently taking out the part of the molten pool during welding to compare with an edge standard in real time, and judging whether current and voltage are required to be adjusted or the angle and the welding speed of a welding gun are required to be adjusted.
The invention has the following beneficial effects:
1. according to the invention, through the matching of the driving mechanism, the positioning mechanism and the vision module, the welding position, the welding angle and the welding speed of the welding gun can be stably adjusted during use, and the welding quality is shot through the vision module, so that the welding quality can be conveniently evaluated.
2. According to the invention, through the matching of the positioning frame, the stepping motor, the transmission lead screw and the supporting seat, the rotation speed of the transmission lead screw can be controlled by driving the transmission lead screw to rotate through the stepping motor, and the movement of the welding gun can be controlled through the supporting seat, so that the accurate and uniform movement of the welding gun is realized.
3. According to the invention, the angle of the welding gun is controlled by adjusting the transverse clamp through the matching of the vertical shaft, the transverse shaft, the vertical clamp, the transverse clamp and the fixing clamp, the extending distance of the welding gun is adjusted through the matching of the transverse shaft and the transverse clamp, and the vertical distance of the welding gun is adjusted through the vertical shaft and the vertical clamp.
4. The welding quality is detected through the binocular camera, and the quality of a molten pool of the welding gun after working on the welding parent metal can be monitored so as to feed back the molten pool to the computer for adjustment.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic view of the overall structure of the present invention;
FIG. 2 is a rear elevational view of the invention as a whole;
FIG. 3 is a schematic view of the binocular camera of the present invention;
FIG. 4 is a schematic diagram of the operation of the vision system of the present invention;
FIG. 5 is a weld puddle image output to a computer via a vision system in accordance with the present invention;
FIG. 6 is a schematic diagram of the image processing and feedback process according to the present invention;
FIG. 7 is a schematic diagram of the edge criteria of the present invention.
In the drawings, the components represented by the respective reference numerals are listed below:
1. a fixing plate; 2. a positioning frame; 3. a stepping motor; 4. a drive screw; 5. a supporting base; 6. a welding gun; 7. a binocular camera; 8. welding a base material; 9. a molten pool; 10. a vertical shaft; 11. a transverse axis; 12. vertically clamping; 13. transversely clamping; 14. a fixing clip; 15. and a connecting frame.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious 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.
The first embodiment is as follows:
referring to fig. 1-7, the invention relates to a welding experiment frame for researching association rules of a molten pool and welding quality, which comprises a fixing plate 1, wherein a driving mechanism, a positioning mechanism and a vision module are arranged at the top of the fixing plate 1, the positioning mechanism is positioned at the top end of the driving mechanism, and the vision module is positioned at one end of the driving mechanism;
the driving mechanism comprises a positioning frame 2, a stepping motor 3 and a transmission lead screw 4, the positioning frame 2 is fixed at the top of the fixing plate 1, and further the position of the driving mechanism can be fixed, the stepping motor 3 is fixed at one end of the positioning frame 2, and the transmission lead screw 4 is connected with the output end of the stepping motor 3, so that the transmission lead screw 4 can be rapidly driven to rotate;
preferably, the driving mechanism further comprises a control panel, so that the electrical components can be controlled through the control panel, and the moving speed of the driving mechanism can be seen.
The positioning mechanism comprises a supporting seat 5, a vertical shaft 10, a transverse shaft 11, a vertical clamp 12 and a transverse clamp 13, the supporting seat 5 is in threaded connection with the outer side of the transmission screw rod 4, the supporting seat 5 is in sliding connection with the positioning frame 2, so that the transmission screw rod 4 can be driven to move by rotation of the supporting seat 5, the vertical shaft 10 is fixed at the top of the supporting seat 5, the vertical clamp 12 is arranged on the outer side of the vertical shaft 10, the transverse clamp 13 is fixed at one end of the vertical clamp 12, and the transverse shaft 11 is arranged on the inner side of the transverse clamp 13; the axial moving direction of the supporting seat 5 and the moving speed (4 mm-8 mm/s) can be controlled by the rotation of the transmission screw rod 4;
preferably, the vertical clamp 12 and the horizontal clamp 13 are both tightened by bolts.
Preferably, the inner side of the vertical clamp 12 is provided with a first gear, and the first gear is meshed with the vertical shaft 10, so that the vertical clamp 12 can be driven to lift on the outer side of the vertical shaft 10 through the rotation of the first gear.
Preferably, a second gear is arranged on the inner side of the transverse clamp 13, and the second gear is meshed with the transverse shaft 11, so that the transverse clamp 13 can be driven to move on the outer side of the transverse shaft 11 by the rotation of the first gear.
A fixing clamp 14 is arranged on one side of the transverse shaft 11, the fixing clamp 14 is tightly pressed through a bolt, so that the fixing clamp 14 can rotate with the transverse shaft 11 and can be clamped and fixed after rotation, the angle can be adjusted through rotation of the fixing clamp 14, a welding gun 6 is arranged on the inner side of the fixing clamp 14, the position of the welding gun 6 can be fixed, and a welding pipe is arranged at one end of the welding gun 6;
preferably, the inside of one side of the transverse shaft 11 is fixed with a positioning column, the inside of the fixing clamp 14 is provided with a positioning groove slightly smaller than the diameter of the positioning column, and the fixing clamp 14 is rotatably connected with the transverse shaft 11 through the positioning column and is positioned after being rotatably connected.
A welding base metal 8 is further arranged at the top of the fixing plate 1, and a molten pool 9 is formed at the position, in contact with the welding gun 6, of the inner side of the welding base metal 8;
in this embodiment, the welding gun 6 is a mature structure, and is not described in detail.
When the welding device is used, the welding speed is greatly related to the melting and covering of the molten pool 9, and the welding quality is further influenced, so that the accurate control of the uniform-speed movement of the transmission lead screw 4 at (4 mm-8 mm/s) is also important. The stepper motor 3 controller can program its speed.
The vision module that is used for detecting is installed in the outside of welding pipe, the vision module includes two mesh cameras 7 and link 15, two mesh cameras 7's top is fixed with link 15, the top and the welding pipe sliding connection of link 15, make two mesh cameras 7 can remove in the outside of welding pipe, there is the cardboard at link 15's top still screwed connection, and then can fix two mesh cameras 7 in the outside of welding pipe through cardboard and link 15's connection, thereby can detect the form of state molten bath 9 of welding experiment in-process molten bath 9 and the temperature of molten bath 9 through the vision module, and shoot and gather image information.
In this embodiment, the binocular camera 7 is a mature structure, and is not described in detail.
The binocular camera 7 consists of a camera and a composite filtering system, successfully overcomes the interference of over-strong arc light, and acquires a clear molten pool image. The image obtained by directly using the camera for information acquisition without any processing is filled by strong arc light, and the required geometric information of the molten pool cannot be obtained. Therefore, the core problem of the molten pool visualizer is that the industrial camera adopts proper dimming and filtering operations to remove the interference of excessive arc light on the imaging area of the molten pool, thereby obtaining high-quality image information. The infrared camera shoots text file information of the obtained temperature matrix, transmits the text file information to the computer, and processes the text file information into a temperature map through a program. A dual feedback vision system is formed.
The welding experiment table mainly comprises a driving mechanism for driving a welding gun to move, a positioning mechanism for adjusting the direction and the angle of the welding gun and a vision module. The visual module is used as an important component of the welding pool, the sensing system respectively detects the welding process state information into a molten pool shape and molten pool temperature distribution in real time through an industrial camera and an infrared camera, and feeds back the acquired information to the computer in real time, so that the control of the molten pool quality is realized. The driving mechanism and the positioning mechanism not only play a role of moving the welding gun, but also can be used for adjusting the welding parameters, such as welding speed, welding angle and welding distance, so as to explore the association rule of the molten pool and the welding quality;
size and the temperature of molten pool are the key problem that influences the welding seam shaping quality among the welding process, can regulate and control welding parameters such as the working angle of welder among the welding process through the control module of welding test bench, walking angle and welding speed, the molten pool parameter of molten pool size and molten pool temperature of welding process is monitored through the terminal vision module of welder, and then realize the intelligent welding technical scheme of monitoring molten pool parameter feedback regulation and control welding parameter, with the welding efficiency of welding robot under the extreme environment of promotion long-span arch bridge owner arch welding, ensure welding quality.
The driving mechanism and the positioning mechanism are used for adjusting welding parameters such as welding speed, welding distance, welding angle and the like of the welding machine, researching the influence rule of the welding parameters on a molten pool in the welding process and evaluating the welding quality, so that the association rule of the molten pool and the welding quality in the welding process is determined, and the purpose of controlling the welding parameters, adjusting the characteristics of the molten pool and controlling the welding quality is achieved. Firstly, a stepping motor in the driving mechanism drives a transmission screw rod to rotate so as to control the rotating speed of the transmission screw rod, so that a positioning mechanism above a supporting seat is driven to move, and the accurate movement of a welding gun on the positioning mechanism is realized. And then, the extension distance of the welding gun is adjusted by matching a gear and a rack between the transverse shaft and the transverse clamp, and the up-down distance of the welding gun is adjusted by the vertical shaft and the vertical clamp. Secondly, the transverse clamp and the fixing clamp are used for completing the welding angle of the welding gun. And in the moving working process of the welding gun, the visual module component collects image information of a molten pool in the welding process and extracts the overall dimension and the temperature distribution of the molten pool in the molten pool image in real time. And finally, evaluating the weld quality through nondestructive detection of internal defects of the weld. The process control of the welding quality is realized by exploring the association rule between the welding parameters, the welding pool and the welding quality.
Example two:
on the basis of the above example 1, the method of use thereof is disclosed
The first step is as follows: starting the stepping motor 3 to move the supporting seat 5;
the second step is that: adjusting the positions of the vertical clamp 12 and the transverse clamp 13;
the third step: adjusting the angle of the retaining clip 14;
the fourth step: welding the welding torch 6 to weld the welding parent metal 8 by electrifying;
the fifth step: the vision module detects the welding position in the fourth step;
preferably, the detection of the vision module is according to the following steps:
i, in an original image: the outline of the molten pool is clearer through the action of the light reduction mirror and the light filter, and the molten pool is divided into a molten pool during welding (refer to a figure 6) and a cooling molten pool (refer to a figure 5);
II, during edge detection: extracting the contour edge of the molten pool in real time by using a program;
III, molten pool distinguishing: because we are mainly concerned about the contour edge of the weld puddle as the wire melts, a distinction needs to be made between "cooling the puddle" and "weld puddle" as it melts;
IV, in molten pool differentiation: separately taking out the part of the molten pool during welding, comparing the part with the edge standard in real time, and feeding back to a computer, wherein the computer judges whether current and voltage need to be adjusted or parameters such as the angle of a welding gun, the welding speed and the like need to be adjusted;
in the feedback process: before the computer feeds back the molten pool, the computer needs a large amount of molten pool images for machine learning.
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
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 embodiments 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 (7)
1. A welding experiment frame for exploring association rules of a molten pool and welding quality comprises a fixing plate (1), and is characterized in that: the top of the fixed plate (1) is provided with a driving mechanism, a positioning mechanism and a vision module, the positioning mechanism is positioned at the top end of the driving mechanism, and the vision module is positioned at one end of the driving mechanism;
actuating mechanism includes locating rack (2), step motor (3) and drive screw (4), the top of fixed plate (1) is fixed with locating rack (2), the one end of locating rack (2) is fixed with step motor (3), the output of step motor (3) is connected with drive screw (4).
2. The welding experiment frame for researching the association rule of the molten pool and the welding quality as claimed in claim 1, wherein the positioning mechanism comprises a supporting seat (5), a vertical shaft (10), a transverse shaft (11), a vertical clamp (12) and a transverse clamp (13), the supporting seat (5) is in threaded connection with the outer side of the transmission screw (4), the vertical shaft (10) is fixed to the top of the supporting seat (5), the vertical clamp (12) is arranged on the outer side of the vertical shaft (10), the transverse clamp (13) is fixed to one end of the vertical clamp (12), and the transverse shaft (11) is arranged on the inner side of the transverse clamp (13).
3. A welding experiment frame for researching the relation rule between the molten pool and the welding quality according to the claim 2 is characterized in that one side of the transverse shaft (11) is provided with a fixing clamp (14), the inner side of the fixing clamp (14) is provided with a welding gun (6), and one end of the welding gun (6) is provided with a welding pipe.
4. A welding experiment frame for researching the relation rule between the molten pool and the welding quality according to the claim 1 is characterized in that the top of the fixed plate (1) is also provided with a welding parent metal (8).
5. The welding experiment frame for researching association law of the molten pool and the welding quality as claimed in claim 3, wherein a vision module for detection is installed on the outer side of the welding pipe, the vision module comprises a binocular camera (7) and a connecting frame (15), the connecting frame (15) is fixed to the top of the binocular camera (7), the top of the connecting frame (15) is in sliding connection with the welding pipe, and a clamping plate is further connected to the top of the connecting frame (15) through screws.
6. A method of a welding bench for exploring the correlation law of a molten pool and welding quality, which is used for the building demolition apparatus according to any one of claims 1 to 5, characterized by the steps of:
s1: starting the stepping motor 3 to move the supporting seat 5;
s2: adjusting the positions of the vertical clamp 12 and the transverse clamp 13;
s3: adjusting the angle of the retaining clip 14;
s4: welding the welding torch 6 to weld the welding parent metal 8 by electrifying;
s5: and the vision module detects the welding position in the fourth step.
7. The method of claim 6, wherein the visual module detects the weld according to the following steps:
the method comprises the following steps that I, under the action of a light reduction mirror and a light filter, the outline of a molten pool is clear, and the molten pool is divided into a molten pool and a cooling molten pool during welding;
II, extracting the contour edge of the molten pool in real time;
and IV, independently taking out the part of the molten pool during welding, comparing the part with an edge standard in real time, and judging whether current and voltage need to be adjusted or the angle and the welding speed of a welding gun need to be adjusted.
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