CN116202409A - Welding spot penetration rate online detection method and system considering welding working conditions - Google Patents

Welding spot penetration rate online detection method and system considering welding working conditions Download PDF

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Publication number
CN116202409A
CN116202409A CN202211455377.7A CN202211455377A CN116202409A CN 116202409 A CN116202409 A CN 116202409A CN 202211455377 A CN202211455377 A CN 202211455377A CN 116202409 A CN116202409 A CN 116202409A
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welding
signal
workpiece
penetration rate
current
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夏裕俊
李卓然
马春辉
王松林
李永兵
张雷雷
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Shanghai Jiaotong University
China National Heavy Duty Truck Group Jinan Power Co Ltd
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Shanghai Jiaotong University
China National Heavy Duty Truck Group Jinan Power 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
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/36—Auxiliary equipment
    • 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
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/10—Spot welding; Stitch welding
    • B23K11/11—Spot welding
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
    • G01B7/06—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness
    • 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
    • Y02E30/00—Energy generation of nuclear origin
    • Y02E30/30—Nuclear fission reactors

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  • General Physics & Mathematics (AREA)
  • Resistance Welding (AREA)

Abstract

The invention discloses a welding spot penetration rate online detection method and a welding spot penetration rate online detection system considering welding working conditions, and mainly relates to the technical field of welding. The method comprises the following steps: the method comprises the steps that sensors are arranged on two electrodes to collect current signals and intrinsic process signals in real time; establishing a relation diagram of the signal change along with time; segmenting the relation graph according to the current signal and the intrinsic process signal, and extracting signal characteristic quantities in the relation graph; according to welding working conditions, different analytical models are selected to calculate the thickness of the nugget and the final thickness of the workpiece; and obtaining a predicted value of the penetration rate. The invention has the beneficial effects that: the method has the characteristics of low cost, strong timeliness and higher measurement accuracy, and can be applied to a welding production line.

Description

Welding spot penetration rate online detection method and system considering welding working conditions
Technical Field
The invention relates to the technical field of welding, in particular to a welding spot penetration rate online detection method and system considering welding working conditions.
Background
More than 90% of the welding work of the all-steel vehicle body is completed by a resistance spot welding process. Resistance spot welding is based on the principle that a large current of several hundred to several tens of thousands of amperes is applied between two electrodes and a workpiece to be welded, and the interface of the workpiece is melted and a welding spot is generated by the combined action of pressure and joule heat. In general, the penetration rate cannot be too small or too large, which can cause insufficient quality of welding spots to support stable connection of the welding pieces, and the penetration rate is too large, which can cause softening of the materials of the workpieces to be welded and even splashing in the welding process, so that the welding quality is affected. The traditional penetration rate detection method is mainly manual spot inspection and metallographic experiments, and the method is strong in destructiveness and can only realize detection of partial welding spots, so that the detection structure is not comprehensive and reliable enough. In addition, the method needs to undergo steps of cutting, grinding, polishing, corrosion and the like, and is long in time consumption and cannot achieve real-time detection.
Disclosure of Invention
The invention aims to provide a welding spot penetration rate online detection method and a welding spot penetration rate online detection system considering welding conditions, which have the characteristics of low cost, strong timeliness and higher accuracy and can be applied to a welding production line.
The invention aims to achieve the aim, and the aim is achieved by the following technical scheme:
a welding spot penetration rate online detection method considering welding working conditions comprises the following steps: the method comprises the steps that sensors are arranged on two electrodes to collect current signals and intrinsic process signals in real time; establishing a relation diagram of the current signal and the intrinsic process signal changing along with time; segmenting the relation graph according to the current signal and the intrinsic process signal, and extracting signal characteristic quantities in the relation graph; according to welding working conditions, different analytical models are selected to calculate the thickness of the nugget and the final thickness of the workpiece; and calculating the penetration rate.
Preferably, the analytical model is a parameterized model constructed based on basic functions, including: a workpiece weld zone diameter analytical model, a nugget volume analytical model, and an indentation depth analytical model.
Preferably, the workpiece welding area diameter analysis model is as follows:
Figure BDA0003953346140000021
wherein: d (D) S R is the predicted value of the diameter of a welding area of a workpiece B D is the dynamic resistance signal value at the end of the welding current E The distance from the center of the welding spot nugget to the edge of the workpiece is H, the total thickness of the workpiece to be welded is rho, and the resistivity of the workpiece to be welded is the resistivity.
The nugget volume analytical model is:
Figure BDA0003953346140000022
wherein: v (V) N As a predicted value of nugget volume, Δs BC For the change value of the dynamic electrode displacement signal from the welding current end time to the time when the inflection point of the dynamic electrode displacement signal occurs, l M The initial gap between two plates of the workpiece under the gap working condition is H is the total thickness of the workpiece to be welded, alpha is the thermal expansion coefficient of the workpiece to be welded, and T m Is the melting point of the workpiece to be welded.
The indentation depth analysis model is as follows:
D I ＝ΔS AD /cosθ
wherein: d (D) I As a predicted value of the indentation depth, Δs AD And the change value of the dynamic electrode displacement signal from the welding current conduction time to the electrode opening time is that theta is the included angle between the normal line of the workpiece to be welded and the electrode and the axis.
Preferably, the calculation formula of the nugget thickness is:
P N ＝V N /D S
wherein: p (P) N To melt core thickness, V N For the volume of nugget, D S A predicted value of the diameter of a welding area of the workpiece;
the calculation formula of the final thickness of the workpiece is as follows:
h S ＝H-D I
wherein: h is a S The final thickness of the workpiece is H, the total thickness of the workpiece to be welded is D I Is the indentation depth;
the calculation formula of the welding spot penetration rate is as follows:
λ＝P N /h S
wherein: lambda is the penetration rate of the solder joint.
Preferably, the intrinsic process signal is a dynamic resistance signal and a dynamic electrode displacement signal, and the welding conditions include: standard working condition, margin working condition, clearance working condition and electrode tilt working condition, signal characteristic quantity includes: the dynamic resistance signal value at the welding current end time, the dynamic electrode displacement signal change value from the welding current end time to the dynamic electrode displacement signal inflection point occurrence time, and the dynamic electrode displacement signal change value from the welding current conduction time to the electrode opening time.
Preferably, the inflection point of the dynamic electrode displacement signal is obtained by comparing the differential of the dynamic electrode displacement signal with a preset threshold.
Preferably, the segmentation process is to obtain the relationship graph into a plurality of phases according to different moments of current signals and dynamic electrode displacement signals.
Preferably, the different moments include: welding current conduction time, welding current end time, dynamic electrode displacement inflection point occurrence time and electrode opening time, wherein the plurality of stages comprise: pre-pressing stage before welding, electrifying welding stage, pressure maintaining early stage and pressure maintaining later stage.
Preferably, the pre-welding pre-pressing stage refers to a stage of closing and clamping the workpiece to be welded by the electrode until a welding current signal is conducted, the electrified welding stage refers to a stage from the conduction to the disconnection of the welding current signal, the pressure maintaining early stage refers to a stage from the disconnection of the welding current signal to the occurrence of an inflection point of a dynamic electrode displacement signal, and the pressure maintaining later stage refers to a stage from the occurrence of the inflection point of the dynamic electrode displacement signal to the opening of the electrode.
An on-line detection system for weld penetration rate considering welding conditions, comprising: the device comprises a calculation and analysis module, a current signal acquisition module and an intrinsic process signal acquisition module, wherein the current signal acquisition module is connected with current sensors arranged at two electrodes and acquires current signals, two input ends of the intrinsic process signal acquisition module are respectively connected with displacement signal sensors arranged at the two electrodes and acquire an upper electrode displacement signal and a lower electrode displacement signal in the welding process, and the calculation and analysis module calculates two intrinsic process signals according to the acquired signals: and calculating the welding spot penetration rate value according to the intrinsic process signal and the current signal.
Compared with the prior art, the invention has the beneficial effects that:
the method is based on a penetration rate calculation formula of the signal characteristic quantity of the intrinsic process of the resistance spot welding, predicts the penetration rate of the welding spot in real time, realizes the online quantitative evaluation and automatic detection of the appearance of the nugget of the spot welding, overcomes the defect that the traditional technology relies on manual detection, has high detection precision and high calculation speed, has low requirements on a hardware system, and is suitable for various resistance spot welding application scenes; the influence of different welding working conditions is considered by introducing various analytical models, the applicability is strong, and when the welding working conditions deviate from the standard working conditions, the analytical models can be corrected by measuring the geometric states of the working conditions, so that the prediction accuracy of the penetration rate is ensured.
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Fig. 1 is a process flow of the present invention.
Fig. 2 is a schematic diagram of the system of the present invention.
FIG. 3 is a schematic diagram of the standard operating mode of the present invention.
FIG. 4 is a schematic diagram of the margin operating mode of the present invention.
FIG. 5 is a schematic diagram of the gap operating mode of the present invention.
FIG. 6 is a schematic view of the tilt mode of the present invention.
Fig. 7 is a schematic view of a partial cross section of a weld.
Fig. 8 is a graph of the evolution of the spot welding process signal over time.
Fig. 9 is a schematic diagram of dynamic electrode displacement signal inflection points.
FIG. 10 is a scatter plot of predicted and measured penetration values for different welding conditions.
The reference numbers shown in the drawings:
1. a calculation and analysis module; 2. an intrinsic process signal acquisition module; 3. a current signal acquisition module; 4. a current sensor; 5. a displacement signal sensor; 6. a voltage signal sensor; 7. a workpiece; 8. an electrode; 9. welding spot nuggets; 10. a gasket.
Detailed Description
The invention will be further illustrated with reference to specific examples. It is to be understood that these examples are illustrative of the present invention and are not intended to limit the scope of the present invention. Further, it will be understood that various changes or modifications may be made by those skilled in the art after reading the teachings of the invention, and such equivalents are intended to fall within the scope of the invention as defined herein.
Example 1: welding spot penetration rate online detection method and system considering welding working conditions
The example relates to an online measurement method of welding spot penetration rate considering welding working conditions, as shown in fig. 1, firstly, installing sensors on two electrodes to collect current signals and intrinsic process signals in real time; establishing a relation diagram of the current signal and the intrinsic process signal along with the time change according to the acquired current signal and the intrinsic process signal; segmenting the relation graph according to the current signal and the intrinsic process signal, and extracting signal characteristic quantities in the relation graph; then, according to different welding working conditions, different analytical models are selected to calculate the thickness of the nugget and the final thickness of the workpiece; and finally, calculating according to the thickness of the nugget and the final thickness of the working condition to obtain the penetration rate.
As shown in FIG. 2, the weld penetration rate for the present embodiment is calculated based on the welding conditionsThe line prediction system mainly comprises: the device comprises a calculation and analysis module, an intrinsic process signal acquisition module and a current signal acquisition module which are respectively connected with the calculation and analysis module, wherein the current signal acquisition module is connected with a current sensor arranged on a lower electrode and acquires a current signal I, and two input ends of the intrinsic process signal acquisition module are connected with displacement signal sensors arranged on two electrodes so as to respectively acquire an upper electrode displacement signal S in the welding process 1 And a lower electrode displacement signal S 2 The other two input ends of the intrinsic process signal acquisition module are connected with voltage signal sensors arranged on the two electrodes to acquire a voltage signal U between the two electrodes, and the calculation and analysis module calculates two intrinsic process signals according to the acquired current signals, voltage signals and electrode displacement signals: and calculating a predicted value of the welding spot penetration rate according to the intrinsic process signal and the current signal.
The upper electrode, the upper electrode displacement signal sensor and the upper electrode voltage signal sensor are sequentially arranged on the upper surface of the workpiece, and the lower electrode, the lower electrode displacement signal sensor and the lower electrode voltage signal sensor are sequentially arranged on the lower surface of the workpiece.
The current sensor is a rogowski coil; the upper electrode voltage signal sensor and the lower electrode voltage signal sensor are isolation probes; the upper electrode displacement signal sensor and the lower electrode displacement signal sensor are grating ruler displacement sensors.
The workpiece is two metal plates stacked in a laminated way, and the workpiece can be made of steel, aluminum alloy, copper alloy, magnesium alloy, titanium alloy and combinations thereof.
The calculation and analysis module comprises: microprocessor, industrial computer, PLC, monitor, welding controller, desktop, notebook computer, server or workstation, this embodiment adopts the monitor.
As shown in fig. 3, the welding condition of this example is a standard condition, the welding spot nugget is located at the center of the workpiece to be welded, and the upper electrode and the lower electrode are perpendicular to the workpiece to be welded.
As shown in fig. 7, a schematic cross-sectional view of the welded joint is shown,wherein: the welding spot nugget is positioned between two metal plates, and the welding spot penetration rate refers to the thickness P of the welding spot nugget N And the final thickness h of the workpiece S The ratio of (2) reflects the penetration state of the welding spot and is an important index for evaluating the quality of the welding spot.
As shown in fig. 8, the calculation of the intrinsic process signal means that the current signal I is divided by the voltage signal U between the two electrodes, so as to obtain a dynamic resistance signal R of the spot welding process; by means of upper electrode displacement signal S 1 And a lower electrode displacement signal S 2 And subtracting to obtain a dynamic electrode displacement signal S of the spot welding process.
The relation diagram segmentation processing refers to dividing the relation diagram into four stages by using a current signal I and a dynamic electrode displacement signal S, and specifically comprises the following steps: a pre-welding pre-pressing stage T1, an electrified welding stage T2, a pressure maintaining early stage T3 and a pressure maintaining later stage T4, wherein: the pre-welding pre-pressing stage T1 refers to a stage that an electrode is closed and clamps a workpiece to be welded until a welding current signal I is conducted; the electrified welding stage T2 refers to a stage from the on state to the off state of a welding current signal I; the welding current signal I is turned off and then the electrode is opened to form a pressure maintaining stage, which can be further divided into a pressure maintaining early stage T3 and a pressure maintaining later stage T4, wherein: the pressure maintaining early stage T3 refers to the period from the switching-off of the welding current signal I to the occurrence of the inflection point S of the dynamic electrode displacement signal S C Stage (a); the pressure maintaining later stage T4 refers to the inflection point S appearing in the dynamic electrode displacement signal S C To the stage of electrode opening.
As shown in FIG. 9, the inflection point S of the dynamic electrode displacement signal S C Is obtained by comparing the differential of the dynamic electrode displacement signal S with a preset threshold, and specifically comprises the following steps: in the voltage-maintaining phase, when the differential of the dynamic electrode displacement signal S with respect to time is equal to the preset threshold A, i.e. intersects the threshold horizontal line at point J s If it is determined that the inflection point is started, the point J s The corresponding time is recorded as the starting time t j The method comprises the steps of carrying out a first treatment on the surface of the After the inflection point is judged to be started, when the differential of the dynamic electrode displacement signal S is equal to the threshold A again, namely the dynamic electrode displacement signal S intersects with the threshold horizontal line at a point K S If it is determined that the inflection point is ended, K is determined as S The corresponding time is recorded as the end time t k The method comprises the steps of carrying out a first treatment on the surface of the Let t j And t k Is taken as the inflection point occurrence time t C I.e. t C ＝(t j +t k ) 2, t C The dynamic electrode displacement signal S corresponding to the moment is recorded as inflection point displacement S C . The present embodiment sets the threshold a to 2 μm.
The signal feature extraction refers to recording the conduction time of a welding current signal I as t according to the segmentation result of the relation diagram A Will t A The dynamic electrode displacement signal S corresponding to the moment is recorded as the conduction displacement S A The method comprises the steps of carrying out a first treatment on the surface of the The turn-off time of the welding current signal I is recorded as t B Will t B The dynamic electrode displacement signal S corresponding to the moment is recorded as the turn-off displacement S B Will t B The dynamic resistance signal R corresponding to the moment is recorded as an off resistance R B The method comprises the steps of carrying out a first treatment on the surface of the The electrode opening time is denoted as t D Will t D Dynamic electrode displacement signal t corresponding to time D Is recorded as an opening displacement S D The method comprises the steps of carrying out a first treatment on the surface of the Will turn off the shift S B And inflection point displacement S C The difference in (2) is recorded as nugget characteristic ΔS BC I.e. DeltaS BC ＝S B -S C The method comprises the steps of carrying out a first treatment on the surface of the Will conduct the displacement S A And opening displacement S D The difference in thickness characteristic DeltaS is recorded AD I.e. DeltaS AD ＝S A -S D 。
The key morphological features of the welding spots comprise: workpiece weld area diameter D S Volume of nugget V N And indentation depth D I And (2) and
Figure BDA0003953346140000081
D I ＝ΔS AD wherein: h is the total thickness of the workpiece to be welded, ρ is the resistivity of the workpiece to be welded, α is the thermal expansion coefficient of the workpiece to be welded, T m The melting point of the workpiece to be welded; in this example, H=1.6 mm, ρ=1.2X10-7Ω m, α=1.1X10-5, T is taken m =1520 ℃. Under standard working condition, the nugget thickness P of the welding spot N Is P N ＝V N /D S Final thickness h of workpiece S Is h S ＝H-D I The welding spot penetration rate λ is λ=p N /h S 。
As shown in fig. 10 (a), a scatter diagram of predicted values of the penetration rate and measured values of the penetration rate in this example is shown, in which: the welding current is 4-9 kA, the welding time is 150ms, and the pressure maintaining time is 550ms. As can be seen from the graph, under the standard working condition, the predicted value of the welding spot penetration and the actually measured value of the penetration have good linear relation, the determination coefficient is 0.988, the root mean square error is 0.172mm, and the prediction precision is high; meanwhile, the average calculation time of the predicted penetration rate is 0.05s, and the calculation speed is high.
Example 2: welding spot penetration rate online detection method and system considering welding working conditions
Compared with embodiment 1, the welding condition of this embodiment is a margin condition, as shown in fig. 4, that is, the welding spot is deviated from the center of the workpiece to be welded during the welding process. Under the margin working condition, the analysis and prediction model of the workpiece welding area diameter is as follows:
Figure BDA0003953346140000082
wherein: d (D) S R is the predicted value of the diameter of a welding area of a workpiece B D is the dynamic resistance signal value at the end of the welding current E In this embodiment, d is taken as the distance from the center of the nugget to the edge of the workpiece E =3mm, h is the total thickness of the workpiece to be welded, ρ is the resistivity of the workpiece to be welded.
As shown in fig. 10 (b), a scatter diagram of the predicted value of the penetration rate and the measured value of the penetration rate in this example is shown. It can be seen from the graph that under the margin working condition, the predicted value of the welding spot penetration rate and the actually measured value of the penetration rate have a very strong linear relation, the determination coefficient is 0.985, the root mean square error is 0.174mm, and the prediction precision is high.
Example 3: welding spot penetration rate online detection method and system considering welding working conditions
Compared with embodiment 1, the welding condition of this embodiment is a gap condition, as shown in fig. 5, that is, there is an initial gap between the two metal plates of the workpiece to be welded in the welding process. Under the gap working condition, the analysis and prediction model of the nugget volume is as follows:
Figure BDA0003953346140000091
wherein: v (V) N As a predicted value of nugget volume, Δs BC For the change value of the dynamic electrode displacement signal from the welding current end time to the time when the inflection point of the dynamic electrode displacement signal occurs, l M The initial gap between the two plates of the workpiece under the gap working condition can be obtained by measuring the thickness of the insulating cushion block, and l is taken in the embodiment M 1mm, H is the total thickness of the workpiece to be welded, α is the thermal expansion coefficient of the workpiece to be welded, T m Is the melting point of the workpiece to be welded.
As shown in fig. 10 (c), a scatter diagram of the predicted value of the penetration rate and the measured value of the penetration rate in this example is shown. It can be seen that under the gap working condition, the predicted value of the penetration rate and the actually measured value of the penetration rate have strong linear correlation, the determination coefficient is 0.988, the root mean square error is 0.167, and the prediction precision is high.
Example 4: welding spot penetration rate online detection method and system considering welding working conditions
Compared with embodiment 1, the welding condition of this example is an inclined condition, as shown in fig. 6, i.e., the workpiece to be welded is not perpendicular to the electrode and the electrode. Under the inclined working condition, the analysis and prediction model of the indentation depth is as follows:
D I ＝ΔS AD /cosθ
wherein: d (D) I As a predicted value of the indentation depth, Δs AD In order to change the dynamic electrode displacement signal from the welding current conduction time to the electrode opening time, θ is the included angle between the normal line of the workpiece to be welded and the electrode and the axis, and θ=3° is taken in this embodiment.
As shown in fig. 10 (d), a scatter diagram of the predicted value of the penetration rate and the measured value of the penetration rate in this example is shown. It can be seen that under the inclined welding working condition, the predicted value of the penetration rate of the welding spot and the actually measured value of the penetration rate have strong linear correlation, the determination coefficient is 0.983, the root mean square error is 0.145, and the prediction precision is high.

Claims (10)

1. The welding spot penetration rate online detection method considering welding working conditions is characterized by comprising the following steps of:
the method comprises the steps that sensors are arranged on two electrodes to collect current signals and intrinsic process signals in real time;
establishing a relation diagram of the current signal and the intrinsic process signal changing along with time;
segmenting the relation graph according to the current signal and the intrinsic process signal, and extracting signal characteristic quantities in the relation graph;
according to welding working conditions, different analytical models are selected to calculate the thickness of the nugget and the final thickness of the workpiece;
and calculating the penetration rate.
2. The method for online detection of penetration of a weld joint in consideration of welding conditions according to claim 1, wherein the analytical model is a parameterized model constructed based on a basis function, comprising: a workpiece weld zone diameter analytical model, a nugget volume analytical model, and an indentation depth analytical model.
3. The method for online detection of welding spot penetration rate considering welding conditions according to claim 2, wherein the workpiece welding area diameter analysis model is as follows:
Figure FDA0003953346130000011
wherein: d (D) S R is the predicted value of the diameter of a welding area of a workpiece B D is the dynamic resistance signal value at the end of the welding current E The distance from the center of the welding spot nugget to the edge of the workpiece is H, the total thickness of the workpiece to be welded is rho, and the resistivity of the workpiece to be welded is the resistivity.
The nugget volume analytical model is:
Figure FDA0003953346130000012
wherein: v (V) N As a predicted value of nugget volume, Δs BC For the change value of the dynamic electrode displacement signal from the welding current end time to the time when the inflection point of the dynamic electrode displacement signal occurs, l M The initial gap between two plates of the workpiece under the gap working condition is H is the total thickness of the workpiece to be welded, alpha is the thermal expansion coefficient of the workpiece to be welded, and T m Is the melting point of the workpiece to be welded.
The indentation depth analysis model is as follows:
D I ＝ΔS AD /cosθ
wherein: d (D) I As a predicted value of the indentation depth, Δs AD And the change value of the dynamic electrode displacement signal from the welding current conduction time to the electrode opening time is that theta is the included angle between the normal line of the workpiece to be welded and the electrode and the axis.
4. The welding spot penetration rate online detection method considering welding conditions according to any one of claims 1 to 3, wherein the calculation formula of the nugget thickness is:
P N ＝V N /D S
wherein: p (P) N To melt core thickness, V N For the volume of nugget, D S A predicted value of the diameter of a welding area of the workpiece;
the calculation formula of the final thickness of the workpiece is as follows:
h S ＝H-D I
wherein: h is a S The final thickness of the workpiece is H, the total thickness of the workpiece to be welded is D I Is the indentation depth;
the calculation formula of the welding spot penetration rate is as follows:
λ＝P N /h S
wherein: lambda is the penetration rate of the solder joint.
5. A method for online detection of weld penetration taking into account weld conditions according to any one of claims 1-3, wherein the intrinsic process signals are dynamic resistance signals and dynamic electrode displacement signals, the weld conditions comprising: standard working condition, margin working condition, clearance working condition and electrode tilt working condition, signal characteristic quantity includes: the dynamic resistance signal value at the welding current end time, the dynamic electrode displacement signal change value from the welding current end time to the dynamic electrode displacement signal inflection point occurrence time, and the dynamic electrode displacement signal change value from the welding current conduction time to the electrode opening time.
6. The method for online detection of welding spot penetration taking welding conditions into consideration according to claim 5, wherein the inflection point of the dynamic electrode displacement signal is obtained by comparing the differential of the dynamic electrode displacement signal with a preset threshold.
7. The method for online detection of welding spot penetration rate considering welding conditions according to claim 5, wherein the segmentation process is to obtain the relationship graph into a plurality of stages at different moments according to the current signal and the dynamic electrode displacement signal.
8. The method for online detection of penetration of a weld joint according to claim 7, wherein the different moments comprise: welding current conduction time, welding current end time, dynamic electrode displacement inflection point occurrence time and electrode opening time, wherein the plurality of stages comprise: pre-pressing stage before welding, electrifying welding stage, pressure maintaining early stage and pressure maintaining later stage.
9. The welding spot penetration rate online detection method considering welding working conditions according to claim 8, wherein the pre-welding pre-pressing stage T1 refers to a stage of closing and clamping a workpiece to be welded by an electrode until a welding current signal is conducted, the electrifying welding stage T2 refers to a stage from the conduction of the welding current signal to the disconnection, the pressure maintaining early stage T3 refers to a stage from the disconnection of the welding current signal to the occurrence of an inflection point of a dynamic electrode displacement signal, and the pressure maintaining later stage T4 refers to a stage from the occurrence of the inflection point of the dynamic electrode displacement signal to the opening of the electrode.
10. The utility model provides a take into account welding condition's solder joint penetration rate on-line measuring system which characterized in that includes: the device comprises a calculation and analysis module, a current signal acquisition module and an intrinsic process signal acquisition module, wherein the current signal acquisition module is connected with current sensors arranged at two electrodes and acquires current signals, two input ends of the intrinsic process signal acquisition module are respectively connected with displacement signal sensors arranged at the two electrodes and acquire an upper electrode displacement signal and a lower electrode displacement signal in the welding process, and the calculation and analysis module calculates two intrinsic process signals according to the acquired signals: and calculating the welding spot penetration rate value according to the intrinsic process signal and the current signal.
CN202211455377.7A 2022-11-21 2022-11-21 Welding spot penetration rate online detection method and system considering welding working conditions Pending CN116202409A (en)

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