CN117047234A - Automatic tracking direct-current argon arc welding machine and welding method - Google Patents
Automatic tracking direct-current argon arc welding machine and welding method Download PDFInfo
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- CN117047234A CN117047234A CN202311080215.4A CN202311080215A CN117047234A CN 117047234 A CN117047234 A CN 117047234A CN 202311080215 A CN202311080215 A CN 202311080215A CN 117047234 A CN117047234 A CN 117047234A
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
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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
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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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
- B23K9/32—Accessories
Abstract
The invention discloses an automatic tracking direct current argon arc welding machine and a welding method, wherein the direct current argon arc welding machine comprises a power supply, a welding gun, an arc stabilizer, an air source system, a water cooling system, a wire feeding system, a welding gun running system, an ultrasonic detection system, a filtering camera system, a core control system and a remote operation control system; the welding method comprises the following steps: the ultrasonic wave tracking system detects the thickness and the material of a workpiece to be welded, the welding gun running system tracks a welding seam, the microprocessor unit receives a welding pool image and analyzes and processes the welding pool image, and the action of the welding gun running system and the welding wire speed of the wire feeding system are correspondingly adjusted until the welding is completed and data are stored; the direct current argon arc welding machine designed by the invention realizes automatic diagnosis, reduces the remanufacturing rate, improves the welding quality, improves the working efficiency, improves the intelligent degree and reduces the technical capability requirement of operators.
Description
Technical Field
The invention relates to the field of metal welding, in particular to an automatic tracking direct current argon arc welding machine and a welding method.
Background
An argon arc welding machine is welding equipment widely applied to the production and maintenance industries of metal products. With the continuous development and innovation of technology, the performance and the function of the argon arc welding machine are greatly improved, so that the welding requirements under different environments and requirements are met. At present, the main current situation of the argon arc welding machine is as follows:
1. the performance is continuously improved: with the continuous increase of welding requirements, the performances of the argon arc welding machine such as welding speed, welding quality, reliability and stability are continuously improved, and the argon arc welding machine can better adapt to different welding requirements.
2. The technology is continuously updated: the argon arc welder adopts an advanced welding technology and a control system, can realize automatic control and monitoring, ensures that the welding is more efficient, and reduces the operation difficulty and the operation time.
3. Type diversification: because the argon arc welding machine is applied to different welding requirements, different types of argon arc welding machines, such as a handheld type, a closed circular tube type, a desktop type, a streamline type, a digital type and the like, are appeared, and different working requirements are met.
4. The method is more environment-friendly: the use of argon is strictly controlled, so that air pollution is avoided, and the safety and the comfort of the operation process are improved.
The existing argon arc welding machine has the following defects:
1. The quality of the welding line is unstable: the argon arc welding machine is easily disturbed by the outside in the welding process, such as unstable factors of current, voltage, gas flow and the like, and the quality problems of air holes, slag inclusion, incomplete welding and the like are easily caused in the welding.
2. Complicated operation: the argon arc welder needs to use various equipment such as gas, power, electric arc, and the like, is complicated to operate, needs high technical level and professional knowledge, and is easy to cause safety accidents and quality problems.
3. The energy consumption is large: the argon arc welding machine needs to use a large amount of fuel gas and electric power, consumes large energy, causes pollution to the environment and increases the production cost.
4. The equipment cost is high: the equipment cost of the argon arc welding machine is high, so that a small enterprise is hard to bear, and the competitiveness of the argon arc welding machine is affected.
5. The gas price rises: the price fluctuation of the argon market is large, and the price rising can generate large economic pressure for enterprises, so that the normal production of the enterprises is influenced.
Disclosure of Invention
The purpose of the invention is that: the direct current argon arc welding machine and the welding method have the advantages that the efficiency and the accuracy of welding are improved, the waste of resources is reduced, and the quality of welding products is improved.
In order to achieve the functions, the invention designs the direct current argon arc welding machine with automatic tracking, which comprises a power supply for integrally supplying power, a welding gun, an arc stabilizer, an air source system, a water cooling system, a wire feeding system, a welding gun running system, an ultrasonic detection system, a filtering camera system, a core control system and a remote operation control system in communication connection with the direct current argon arc welding machine;
The core control system is connected with the welding gun, the arc stabilizer, the air source system, the water cooling system, the wire feeding system, the welding gun running system, the ultrasonic tracking system, the ultrasonic detection system, the filtering camera system and the remote operation control system, and is used for receiving and processing data sent by each system and sending corresponding instructions to each corresponding system;
the remote operation control system is used for controlling the start and stop of the direct current argon arc welding machine and setting welding parameters in the welding process, the ultrasonic tracking system and the ultrasonic detection system comprise an ultrasonic probe, and the ultrasonic probe of the ultrasonic tracking system is arranged at the front end of the welding gun and used for detecting the thickness, the material and the welding seam position of a workpiece to be welded so as to guide the movement direction of the direct current argon arc welding machine; the ultrasonic detection system is used for transmitting ultrasonic waves to the welding seam after welding is finished and transmitting ultrasonic wave echo data to the core control system so as to judge welding quality; the filtering camera system is used for collecting images in the welding process and sending the images to the core control system, and the welding gun running system is used for controlling the movement direction and the welding gun angle of the direct current argon arc welding machine according to the instruction of the core control system so as to finish tracking and welding of welding seams of workpieces to be welded.
As a preferred technical scheme of the invention: the core control system comprises a microprocessor unit, a data storage unit, a D/A converter, a USART interface, an interface unit and a wireless transceiver, wherein the data storage unit, the D/A converter, the USART interface, the interface unit and the wireless transceiver are connected with the microprocessor unit;
the D/A converter is connected with a power supply and used for generating analog voltage with preset size, the interface unit is connected with a welding gun, an arc stabilizer, an air source system, a water cooling system, a welding gun running system and a wire feeding system, corresponding welding gun motion control instructions, argon control valve switching instructions, cooling water control valve switching instructions and welding wire speed control instructions are respectively output to the systems, the wireless transceiver is used for being in communication connection with a remote operation control system, the USART interface is connected with an ultrasonic tracking system, an ultrasonic detection system and an filtering camera system and used for transmitting data acquired by the ultrasonic tracking system, the ultrasonic detection system and the filtering camera system in a welding process, and the data storage unit is used for storing a pre-established database, welding parameters in the welding process and the acquired data and instructions.
As a preferred technical scheme of the invention: the core control system of the direct current argon arc welding machine is provided with a preset unique ID, and the remote operation control system and the core control system are based on a communication protocol and respectively control one or more direct current argon arc welding machines according to the ID of the core control system.
The invention also designs a welding method of the direct current argon arc welding machine based on automatic tracking, and based on the direct current argon arc welding machine with automatic tracking, the following steps S1-S4 are executed to finish tracking and welding of welding seams of workpieces to be welded:
step S1: the remote operation control system sends a starting signal to the direct current argon arc welding machine, the core control system starts an ultrasonic detection flow, controls the ultrasonic tracking system to detect the thickness and the material of a workpiece to be welded by adopting ultrasonic waves, and transmits detection data to a microprocessor unit of the core control system;
step S2: the microprocessor unit respectively controls the air source system and the water cooling system to open the argon control valve and the cooling water control valve, and simultaneously controls the D/A converter to generate analog voltage with preset magnitude so as to control the power supply to output welding current; meanwhile, the microprocessor unit controls the welding gun running system to track a welding seam through the interface unit, controls the welding gun, the arc stabilizer and the wire feeding system to start welding after the direct current argon arc welding machine reaches the position of the welding seam, controls the filtering camera system to acquire images in the welding process, and sends the images to the microprocessor unit for analyzing and processing the welding pool images;
Step S3: the microprocessor unit receives detection data transmitted by the ultrasonic tracking system and images transmitted by the filtering camera system in real time, judges the shape and quality of a welding seam, identifies abnormal information, sends corresponding instructions to the welding gun running system and the wire feeding system according to preset rules, and adjusts the action of the welding gun running system and the wire speed of the wire feeding system until the welding is completed;
step S4: after welding is finished, an ultrasonic detection system is adopted to transmit ultrasonic waves to a welding seam, ultrasonic wave echo data are transmitted to a core control system to judge welding quality, and the judging result and welding parameters in the welding process are stored in a data storage unit.
As a preferred technical scheme of the invention: in step S1, an ultrasonic detection flow for detecting the material of the workpiece to be welded by the ultrasonic tracking system is as follows:
step S1.1: selecting an ultrasonic probe and ultrasonic frequency;
step S1.2: measuring and recording sound velocity of a workpiece to be welded by adopting a standard test block;
step S1.3: the ultrasonic probe is arranged at a preset distance above the workpiece to be welded, the thickness of the ultrasonic probe is measured by adopting ultrasonic waves and is transmitted to the microprocessor unit, and the microprocessor unit calculates the density of the workpiece to be welded according to the thickness and the sound velocity of the workpiece to be welded;
Step S1.4: and comparing the calculated density of the workpieces to be welded with standard data of various welding workpieces in a pre-established database to obtain the material of the workpieces to be welded, and automatically setting welding parameters with preset corresponding relations according to the material of the workpieces to be welded.
As a preferred technical scheme of the invention: the tracking process of the welding gun walking system in the step S2 is as follows:
s2.1, setting a trigger pulse width and a sampling interval of an ultrasonic tracking system;
s2.2, respectively measuring the distances between the welding gun and the two edges of the welding seam by the ultrasonic tracking system at set sampling intervals, and calculating the distance difference between the welding gun and the two edges of the welding seam;
s2.3, controlling a welding gun travelling system according to the distance difference between the welding gun and the two edges of the welding line, so that the direct current argon arc welding machine moves towards the central line of the welding line until the distance difference between the welding gun and the two edges of the welding line is 0, and considering that the direct current argon arc welding machine reaches a welding position;
s2.4, after the direct current argon arc welder reaches a welding position, starting to weld; in the welding process, an ultrasonic wave tracking system acquires an echo waveform and transmits the echo waveform to a microprocessor unit, the microprocessor unit compares the echo waveform with ultrasonic wave waveforms of various welding defects in a pre-established database, judges whether the welding defects exist in the welding process, and correspondingly adjusts welding parameters;
And S2.5, repeating the tracking process of the steps S2.1-S2.4 after the welding is finished.
As a preferred technical scheme of the invention: in the welding process, the microprocessor unit judges the shape and quality of the welding seam according to a preset method based on the image transmitted by the filtering camera system, and the process of identifying abnormal information is as follows:
s3.1, constructing a data set formed by images of various molten pool states in a welding process, wherein the various molten pool states comprise normal welding and various preset welding defects, and the various molten pool states are used as labels to correspond to the images in the data set one by one;
s3.2, constructing an argon arc welding image recognition model based on a neural network, wherein the argon arc welding image recognition model takes all images in a data set as input, takes labels corresponding to all the images as output, and trains the argon arc welding image recognition model to obtain a trained argon arc welding image recognition model;
s3.3, in the welding process, the filtering camera system collects images of the molten pool in real time and transmits the images to the microprocessor unit;
s3.4, the microprocessor unit preprocesses the images, inputs the preprocessed images into a pre-trained argon arc welding image recognition model, outputs labels corresponding to the images, and completes recognition of the molten pool state in the welding process;
And S3.5, according to the recognition result of the molten pool state in the welding process, adjusting welding parameters according to the corresponding preset instruction.
As a preferred technical scheme of the invention: in the step S4, an ultrasonic detection system is adopted to transmit ultrasonic waves to a welding seam, and the method for judging the welding quality according to the ultrasonic echo data comprises the following steps: and comparing the ultrasonic echo data with ultrasonic echo data of various welding quality in a pre-established database to obtain the welding quality of the welding seam.
The beneficial effects are that: the advantages of the present invention over the prior art include:
1. for industrial welding, the reduction of welding cost and the improvement of output quality can be realized through data analysis and improvement.
2. The direct current argon arc welding machine designed by the invention can realize automatic diagnosis, reduce the remanufacturing rate, improve the welding quality and improve the working efficiency, and is suitable for the fields of automobile parts, special metal pipeline welding, machine manufacturing and the like.
3. The intelligent degree is greatly improved, and related parameters are selected once, automatically set and automatically controlled in the welding process of one-key input operation. Meanwhile, the direct current argon arc welding machine can realize full-automatic welding with one-key operation, and in the mode, the direct current argon arc welding machine automatically completes one-key operation from the measurement of the material of a welding workpiece, the measurement of the thickness of the welding workpiece and the tracking of a welding seam. Thereby reducing operator skill requirements.
4. The direct current argon arc welding machine designed by the invention can be used for a multi-machine work control system of a large production line due to the realization of wireless remote control and multi-machine control, and has practical application prospect and economic benefit.
Drawings
FIG. 1 is a schematic diagram of a system for a DC argon arc welder provided in accordance with an embodiment of the present invention;
FIG. 2 is a circuit diagram of an MCU of a core control system provided according to an embodiment of the present invention;
FIG. 3 is a circuit diagram of a data storage unit of a core control system provided according to an embodiment of the present invention;
FIG. 4 is a circuit diagram of a D/A converter of a core control system provided in accordance with an embodiment of the present invention;
fig. 5 is a switch control circuit diagram of a core control system provided according to an embodiment of the present invention;
fig. 6 is a wireless communication circuit diagram of a core control system according to an embodiment of the present invention;
fig. 7 is a circuit diagram of an RS485 interface provided according to an embodiment of the present invention;
fig. 8 is a relay driving circuit diagram provided according to an embodiment of the present invention;
FIG. 9 is an ultrasonic circuit diagram provided in accordance with an embodiment of the present invention;
FIG. 10 is a flow chart of operation of a DC argon arc welder provided in accordance with an embodiment of the present invention;
fig. 11 is an ultrasonic echo waveform diagram corresponding to a welding defect according to an embodiment of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for more clearly illustrating the technical aspects of the present invention, and are not intended to limit the scope of the present invention.
Referring to fig. 1, the direct current argon arc welding machine comprises a power supply for integrally supplying power, a welding gun, an arc stabilizer, an air source system, a water cooling system, a wire feeding system, a welding gun running system, an ultrasonic detection system, a filtering camera system, a core control system and a remote operation control system in communication connection with the direct current argon arc welding machine;
the core control system is connected with the welding gun, the arc stabilizer, the air source system, the water cooling system, the wire feeding system, the welding gun running system, the ultrasonic tracking system, the ultrasonic detection system, the filtering camera system and the remote operation control system, and is used for receiving and processing data sent by each system and sending corresponding instructions to each corresponding system;
the remote operation control system is used for controlling the start and stop of the direct current argon arc welding machine and setting welding parameters in the welding process, the ultrasonic tracking system and the ultrasonic detection system comprise an ultrasonic probe, and the ultrasonic probe of the ultrasonic tracking system is arranged at the front end of the welding gun and used for detecting the thickness, the material and the welding seam position of a workpiece to be welded so as to guide the movement direction of the direct current argon arc welding machine; the ultrasonic detection system is used for transmitting ultrasonic waves to the welding seam after welding is finished and transmitting ultrasonic wave echo data to the core control system so as to judge welding quality; the filtering camera system is used for collecting images in the welding process and sending the images to the core control system, the welding gun running system is used for controlling the movement direction and the welding gun angle of the direct current argon arc welding machine according to the instruction of the core control system, tracking and welding of welding seams of workpieces to be welded are completed, the welding gun running system adopts a wheel type trolley structure, and a motor in the wheel type trolley structure is driven to drive the direct current argon arc welding machine to move towards a welding area according to the instruction of the core control system.
The core control system comprises a microprocessor unit, a data storage unit, a D/A converter, a USART interface, an interface unit and a wireless transceiver, wherein the data storage unit, the D/A converter, the USART interface, the interface unit and the wireless transceiver are connected with the microprocessor unit;
the D/A converter is connected with a power supply and used for generating analog voltage with preset size, the interface unit is connected with a welding gun, an arc stabilizer, an air source system, a water cooling system, a welding gun running system and a wire feeding system, corresponding welding gun motion control instructions, argon control valve switching instructions, cooling water control valve switching instructions and welding wire speed control instructions are respectively output to the systems, the wireless transceiver is used for being in communication connection with a remote operation control system, the USART interface is connected with an ultrasonic tracking system, an ultrasonic detection system and an filtering camera system and used for transmitting data acquired by the ultrasonic tracking system, the ultrasonic detection system and the filtering camera system in a welding process, and the data storage unit is used for storing a pre-established database, welding parameters in the welding process and the acquired data and instructions.
In one embodiment, the core control system adopts a low-power wireless transceiver and a low-power switch control circuit which are composed of an ST microprocessor, a 16-bit D/A converter, an RS485 interface circuit and an Si4463, the relay driving circuit is used for a remote operation control system adopts a 10.1-inch color touch screen hand-held operation terminal, and the hand-held operation terminal and the core control system adopt an SI4463 wireless communication module for data exchange.
The MCU circuit diagram of the core control system is referred to fig. 2, the data storage unit circuit diagram is referred to fig. 3, the d/a converter circuit diagram is referred to fig. 4, the switch control circuit diagram is referred to fig. 5, the wireless communication circuit diagram is referred to fig. 6, the rs485 interface circuit diagram is referred to fig. 7, the relay driving circuit diagram is referred to fig. 8, and the ultrasonic circuit diagrams of the ultrasonic tracking system and the ultrasonic detection system are referred to fig. 9.
The core control system of the direct current argon arc welding machine is provided with a preset unique ID, and the remote operation control system and the core control system are based on a communication protocol and respectively control one or more direct current argon arc welding machines according to the ID of the core control system.
Because the communication connection between the remote operation control system and the core control system is realized through the low-power wireless SI4463 wireless transceiver system, the effect that the operation control end controls a plurality of extensions to work simultaneously can be realized. Each core control board has unique ID, and the operation terminal is according to communication protocol. The operation terminal can control any one or a plurality of welding machines to work simultaneously by arbitrary networking. Single machine control and multi-machine control can be realized. Meanwhile, each direct current argon arc welding machine has ultrasonic detection, so that each unit can realize automatic tracking and automatic welding. And welding of a plurality of different tasks is completed. This remote control mode of operation. Can be suitable for high-risk environment and high-temperature environment operation.
The power supply is a core component of the argon arc welding machine and is mainly used for providing electric energy required by welding. The power supply is divided into a direct current power supply and an alternating current power supply, wherein the direct current power supply is generally used for welding stainless steel, nickel alloy and other materials, and the alternating current power supply is suitable for welding aluminum alloy materials. The power supply part is mainly composed of a PWM controller, a high-frequency transformer and an IGBT power circuit, and the output current can be regulated by a potentiometer. The DC argon arc welder adopts a 16-bit D/A conversion circuit to output 0-15V analog voltage to realize the control and adjustment of the output current of the power supply. Thereby realizing a digital automatic control current output arc stabilizing circuit. The circuit of the power supply and the current-voltage output protection circuit are all common circuits of the mature argon arc welding machine, and are not repeated here. The MCU of the core control system controls the output of the D/A converter to realize the control of the current output of the power supply part, and the part conveniently and flexibly realizes the digital braking control of argon arc welding machines with various models through embedded software. The user can select parameter setting corresponding to the operation in the parameter library of the 10.1 inch touch screen, and then click to start welding, so that one-key operation automatic welding is realized. The core control board is communicated with the welding gun running control circuit and the welding wire feeding control circuit through the RS485 interface circuit, so that the purposes of controlling the welding gun running speed and the welding wire feeding speed are achieved. The USART interface of the MCU of the core control system is used for data exchange with the ultrasonic tracking system, the ultrasonic detection system and the filtering camera.
The arc stabilizer of the power supply is an important component for controlling the arc stabilization, and the main function of the arc stabilizer is to maintain stable arc and constant current. The gas source system mainly comprises an argon bottle, a gas pressure reducer, a gas pipe and the like and is used for providing argon protection and adjusting the gas pressure.
The DC argon arc welding machine realizes the control of the current output of the power supply part by controlling the analog voltage output by the D/A converter. And the welding speed control and the welding gun angle control are realized by adjusting the speed of the welding gun running system. The size of the molten pool and the smoothness of the welding line are regulated by regulating the wire feeding speed.
The wire feeding system mainly comprises a welding wire wheel, a welding wire transmission shaft, a wire drawing wheel and other parts and is used for feeding welding wires into welding seams.
Referring to fig. 10, a working flow chart of the direct current argon arc welding machine designed by the invention is as follows:
the operator manually sets related parameters according to the material of the welded workpiece at the control terminal of the handheld 10.1 inch color liquid crystal touch screen, and can also select an automatic welding mode by one key, and under the automatic welding mode, the direct current argon arc welding machine starts an ultrasonic detection flow to detect the material of the workpiece and the thickness of the workpiece. And then automatically selecting standard welding parameters in a corresponding parameter library according to the detection result, and automatically generating a series of welding parameters. The MCU of the core control system firstly opens an argon control valve and a cooling water control valve according to the parameters, and simultaneously controls the D/A conversion unit to generate corresponding analog voltage so as to control the power supply to output welding current and voltage. Simultaneously, the MCU sends out an instruction through the RS-485 interface circuit to control the welding gun running system and the wire feeding system, and the welding gun angle adjusting mechanism performs corresponding operation to start welding. The system has a memory function and automatically stores the last welding parameters and the common parameters. The control terminal transmits related parameters to the main control board in a wireless communication mode, and the main control board controls D/A digital-to-analog conversion to generate welding current according to the parameters transmitted by the control center, and starts the welding gun running system and the wire feeding system to automatically weld.
The embodiment of the invention provides a welding method of a direct current argon arc welding machine based on automatic tracking, which is based on the automatic tracking direct current argon arc welding machine, and comprises the following steps S1-S4, wherein the tracking and welding of welding seams of workpieces to be welded are completed, and the method is realized based on embedded software:
step S1: the remote operation control system sends a starting signal to the direct current argon arc welding machine, the core control system starts an ultrasonic detection flow, controls the ultrasonic tracking system to detect the thickness and the material of a workpiece to be welded by adopting ultrasonic waves, and transmits detection data to a microprocessor unit of the core control system;
in step S1, an ultrasonic detection flow for detecting the material of the workpiece to be welded by the ultrasonic tracking system is as follows:
step S1.1: selecting an ultrasonic probe and ultrasonic frequency;
step S1.2: measuring and recording sound velocity of a workpiece to be welded by adopting a standard test block;
step S1.3: the ultrasonic probe is arranged at a preset distance above the workpiece to be welded, the thickness of the ultrasonic probe is measured by adopting ultrasonic waves and is transmitted to the microprocessor unit, and the microprocessor unit calculates the density of the workpiece to be welded according to the thickness and the sound velocity of the workpiece to be welded;
step S1.4: according to the calculated density of the workpieces to be welded, comparing the calculated density with standard data of various welding workpieces in a pre-established database to obtain the material of the workpieces to be welded, and automatically setting welding parameters with preset corresponding relations according to the material of the workpieces to be welded; the welding parameters comprise arc power, current magnitude, welding speed, welding gun angle and argon flow;
The principle of distinguishing metal types by ultrasonic waves is to distinguish different metal types by utilizing the difference in the speed and attenuation characteristics of ultrasonic waves propagating in different substances. When ultrasonic waves propagate through a metal, they are affected by physical properties such as the density, hardness, and sound velocity of the metal. The characteristics of different metals are different, so that the propagation speed, attenuation degree, reflection condition and the like of ultrasonic waves in the different metals are different, and the type of the metal to be detected can be judged by monitoring the ultrasonic waves by utilizing the characteristics, so that the purpose of distinguishing the metal type is achieved.
Similarly, the metal thickness is measured by ultrasonic waves. Since the propagation speed of ultrasonic waves varies among different materials, and the thickness of metal can be measured by the propagation time and propagation distance of ultrasonic waves.
The microprocessor unit of the core control system receives and analyzes the ultrasonic probe signals transmitted by the ultrasonic tracking system, establishes a corresponding database, stores a successful welding sample plate database, distinguishes the metal type of the weldment, measures the thickness of the weldment and automatically gives welding parameter settings.
Step S2: the microprocessor unit respectively controls the air source system and the water cooling system to open the argon control valve and the cooling water control valve, and simultaneously controls the D/A converter to generate analog voltage with preset magnitude so as to control the power supply to output welding current; meanwhile, the microprocessor unit controls the welding gun running system to track a welding seam through the interface unit, controls the welding gun, the arc stabilizer and the wire feeding system to start welding after the direct current argon arc welding machine reaches the position of the welding seam, controls the filtering camera system to acquire images in the welding process, and sends the images to the microprocessor unit for analyzing and processing the welding pool images;
The tracking process of the welding gun walking system in the step S2 is as follows:
s2.1, setting a trigger pulse width and a sampling interval of an ultrasonic tracking system;
s2.2, respectively measuring the distances between the welding gun and the two edges of the welding seam by the ultrasonic tracking system at set sampling intervals, and calculating the distance difference between the welding gun and the two edges of the welding seam;
s2.3, controlling a welding gun travelling system according to the distance difference between the welding gun and the two edges of the welding line, so that the direct current argon arc welding machine moves towards the central line of the welding line until the distance difference between the welding gun and the two edges of the welding line is 0, and considering that the direct current argon arc welding machine reaches a welding position;
s2.4, after the direct current argon arc welder reaches a welding position, starting to weld;
in the welding process, an ultrasonic wave tracking system detects possible defects, slag inclusion, cracks and other problems in a welding line according to echo waveforms. The detection method can realize nondestructive detection and can greatly improve the quality and reliability of the welding joint. In the welding process, based on ultrasonic detection, the quality of the welded joint is monitored in real time through a core control system, and when defects or cracks, bubbles, slag inclusion, gaps and other problems are found, welding parameters are adjusted through the core control system so as to achieve a better welding effect, and the method comprises the following steps:
When the direct current argon arc welding machine passes through the welding area, the ultrasonic wave seeking system can emit ultrasonic waves for multiple times, and the welding workpiece is reflected for multiple times. The ultrasonic wave receiving probe feeds back the received echo data to an A/D conversion port of an MCU of the core control system, the MCU compares the A/D conversion data with a system database, and if no abnormal waveform data exists, the welding quality is good, and the welding is continued. When the comparison data is abnormal, the welding quality problem is shown. The core control system automatically identifies the type of welding defects according to the echo data characteristics, then sends out corresponding instructions, and adjusts welding parameters until the welding quality problem is eliminated. The principle process is that the first reflection point is usually due to corrosion or oxidation, etc. causing reflection at the interface. The next reflection point may be reflection caused by defects in the welded joint such as voids, inclusions, cracks, transition layers, etc. These defects cause changes in the propagation speed, amplitude, energy, and other characteristics of the ultrasonic wave, and thus cause changes in the reflected echo. The ultrasonic echo waveforms corresponding to the various types of pores, inclusions and crack welding defects are shown in fig. 11.
By detecting the characteristics of the reflected echoes, such as intensity, time, waveform, etc., it is possible to determine whether there are defects or deformations in the weld area. The core control system further analyzes the type, the size and the position of the defect while receiving the ultrasonic echo data, and sends out instructions to guide the subsequent repair work or the operations such as re-welding.
And S2.5, repeating the tracking process of the steps S2.1-S2.4 after the welding is finished.
Step S3: the microprocessor unit receives detection data transmitted by the ultrasonic tracking system and images transmitted by the filtering camera system in real time, judges the shape and quality of a welding seam, identifies abnormal information, sends corresponding instructions to the welding gun running system and the wire feeding system according to preset rules, and adjusts the action of the welding gun running system and the wire speed of the wire feeding system until the welding is completed;
in the welding process, the microprocessor unit judges the shape and quality of the welding seam according to a preset method based on the image transmitted by the filtering camera system, and the process of identifying abnormal information is as follows:
s3.1, constructing a data set formed by images of various molten pool states in a welding process, wherein the various molten pool states comprise normal welding and various preset types of welding defects, and the preset types of welding defects comprise insufficient penetration, air holes, cracks, inclusions and warpage; taking various molten pool states as labels to correspond to the images in the data set one by one; the acquired image can be preprocessed by image processing techniques such as graying, filtering, binarization, edge detection, etc., to improve image quality and reduce noise.
And S3.2, constructing an argon arc welding image recognition model based on the neural network, and extracting the characteristics of the welding line. The feature description may be built from geometric shapes, gray values, pixel information, etc. Scanning a welding area, extracting welding characteristics including welding depth, width, shape, extremely high point, instantaneous gradient and the like, taking each image in a data set as input, taking a label corresponding to each image as output, and training the argon arc welding image recognition model to obtain a trained argon arc welding image recognition model; the neural network can adopt a convolutional neural network or a cyclic neural network;
s3.3, in the welding process, the filtering camera system collects images of the molten pool in real time and transmits the images to the microprocessor unit;
s3.4, the microprocessor unit preprocesses the images, inputs the preprocessed images into a pre-trained argon arc welding image recognition model, outputs labels corresponding to the images, and completes recognition of the molten pool state in the welding process;
and S3.5, according to the recognition result of the molten pool state in the welding process, according to the corresponding preset instruction, adjusting welding parameters such as electric arc power, current magnitude, welding speed, welding gun angle, argon flow and the like, and adjusting the corresponding current magnitude by the welding power supply part according to the issuing parameters so as to optimize welding quality and efficiency, eliminate welding flaws and improve welding quality, thereby ensuring welding quality and stability.
The recognition of the molten pool and the maintenance of the optimal state of the molten pool in the welding process of the argon arc welding machine are complex processes, and involve various physical and chemical phenomena. In this problem, the principle of the AI algorithm for the bath recognition and maintaining the optimum state is adopted.
1. The principle of molten pool identification:
the goal of puddle identification is to monitor puddle shape and size in real-time during welding. To achieve this goal, computer vision and deep learning techniques are used. The method comprises the following specific steps:
and (3) data collection: first, a large number of puddle images under different welding conditions need to be collected. These images can be captured in real time during argon arc welding by a high-speed camera or a camera;
data preprocessing: and preprocessing the collected image, including denoising, graying, histogram equalization and the like, so as to improve the image quality and the feature extraction effect.
Feature extraction: features of the puddle, such as shape, area, perimeter, etc., are extracted from the preprocessed image. These features help to distinguish between puddles under different welding conditions.
Model training: the extracted features are trained using a deep learning algorithm (e.g., convolutional neural network CNN) to identify puddles under different welding conditions. In the training process, the model learns the shape, the size and other characteristics of the molten pool, so that the molten pool can be accurately identified.
2. Principle of maintaining optimal state of molten pool:
in order to maintain the optimum state of the weld pool, parameters such as current, voltage, wire feed speed, etc. during the welding process need to be monitored in real time. These parameters can affect the shape and size of the weld pool, which in turn can affect weld quality. These parameters are adjusted in real time using the AI algorithm to maintain the optimum state of the puddle. The method comprises the following specific steps:
and (3) data collection: molten pool parameter data, such as current, voltage, wire feed speed, etc., under different welding conditions are collected. These data may be acquired in real time by sensors on the welding equipment.
Data preprocessing: and preprocessing the collected parameter data, including outlier removal, normalization and other operations, so as to improve the data quality and the feature extraction effect.
Feature extraction: and extracting the optimal state characteristics of the molten pool, such as the optimal combination of current, voltage and wire feeding speed, from the preprocessed parameter data. These features help to distinguish between the optimum conditions of the weld pool for different welding conditions.
Model training: the extracted best state features are trained using machine learning algorithms (e.g., support vector machines SVM, random forest RF, etc.) to predict the molten pool best state under different welding conditions. During the training process, the model combines the parameters that learn the optimal state of the puddle, so that the optimal state of the puddle can be predicted and maintained.
Through the steps, the molten pool identification and the optimal state maintenance in the welding process of the argon arc welding machine are realized. In practical applications, various interference factors, such as ambient temperature, humidity, etc., are also considered to improve the robustness and accuracy of the algorithm.
The AI algorithm principle of the argon arc welder is mainly to realize intelligent control and optimization of the welding process by monitoring and analyzing various parameters in the welding process, such as current, voltage, arc length and the like. These parameters can be acquired in real time by sensors and then the data is input into the AI algorithm for processing.
In the AI algorithm of the argon arc welder, the theoretical derivation formula adopted by the method comprises the following steps:
(1) Current-voltage relationship:
in argon arc welding, there is a certain relationship between current and voltage. In general, this relationship can be described by ohm's law:
I＝V/R
wherein I is current, V is voltage, R is resistance;
(2) Arc length-current relationship:
there is also a certain relationship between arc length and current. Typically, as the current increases, the arc length increases accordingly. This relationship can be described by an empirical formula:
L＝k*I^n
wherein L is arc length, I is current, and k and n are empirical coefficients;
(3) Welding speed-current relationship:
There is also a relationship between the welding speed and the current. Typically, as the current increases, the welding speed increases accordingly. This relationship can be described by an empirical formula:
V＝k*I^n
wherein V is welding speed, I is current, and k and n are empirical coefficients;
(4) Penetration-current relationship:
there is also a relationship between penetration and current. Typically, as the current increases, the penetration increases accordingly. This relationship can be described by an empirical formula:
D＝k*I^n
wherein D is penetration, I is current, and k and n are empirical coefficients.
The AI algorithm of the argon arc welder monitors and analyzes various parameters in the welding process in real time according to the formulas, and automatically adjusts the welding parameters according to the analysis result so as to realize intelligent control and optimization of the welding process. Meanwhile, the AI algorithm can further improve welding quality and efficiency through learning and optimizing algorithms.
Step S4: after welding is finished, an ultrasonic detection system is adopted to transmit ultrasonic waves to a welding seam, ultrasonic wave echo data are transmitted to a core control system to judge welding quality, and the judging result and welding parameters in the welding process are stored in a data storage unit.
In the step S4, an ultrasonic detection system is adopted to transmit ultrasonic waves to a welding seam, and the method for judging the welding quality according to the ultrasonic echo data comprises the following steps: and comparing the ultrasonic echo data with ultrasonic echo data of various welding quality in a pre-established database to obtain the welding quality of the welding seam.
In summary, the automatic tracking-based direct current argon arc welding machine and the welding method realize the following functions:
(1) Realizing multi-level gas flow control, and respectively controlling gas acceleration flow, shielding gas flow, buffer gas flow and the like.
(2) And the sensor is used for collecting data information such as temperature, voltage, current and the like of the welding interface in real time, analyzing and processing the data information, and continuously optimizing welding parameters.
(3) And the welding data is analyzed and processed by utilizing a deep learning technology, parameters are changed in the welding process, the running speed of the welding gun is adjusted, the angle of the welding gun is adjusted, the distance between the welding gun and a workpiece is adjusted, and the welding quality and the welding precision are improved, so that the production cost is reduced.
(4) And the automatic diagnosis system detects abnormal signals in the welding process, alarms and adjusts in time, and unnecessary losses are avoided.
(5) And the data traceability function is used for analyzing the historical welding data, finding out the cause of the problem and improving the welding process and parameters.
(6) Ultrasonic wave automatic identification metal attribute kind measures thickness function. The welding parameters are automatically given. Thereby realizing one-key automatic welding.
The embodiments of the present invention have been described in detail with reference to the drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the spirit of the present invention.
Claims (8)
1. The automatic tracking direct current argon arc welding machine comprises a power supply for integrally supplying power, a welding gun, an electric arc stabilizer, an air source system, a water cooling system and a wire feeding system, and is characterized by further comprising a welding gun running system, an ultrasonic detection system, a filtering camera system and a core control system, and further comprising a remote operation control system in communication connection with the direct current argon arc welding machine;
the core control system is connected with the welding gun, the arc stabilizer, the air source system, the water cooling system, the wire feeding system, the welding gun running system, the ultrasonic tracking system, the ultrasonic detection system, the filtering camera system and the remote operation control system, and is used for receiving and processing data sent by each system and sending corresponding instructions to each corresponding system;
The remote operation control system is used for controlling the start and stop of the direct current argon arc welding machine and setting welding parameters in the welding process, the ultrasonic tracking system and the ultrasonic detection system comprise an ultrasonic probe, and the ultrasonic probe of the ultrasonic tracking system is arranged at the front end of the welding gun and used for detecting the thickness, the material and the welding seam position of a workpiece to be welded so as to guide the movement direction of the direct current argon arc welding machine; the ultrasonic detection system is used for transmitting ultrasonic waves to the welding seam after welding is finished and transmitting ultrasonic wave echo data to the core control system so as to judge welding quality; the filtering camera system is used for collecting images in the welding process and sending the images to the core control system, and the welding gun running system is used for controlling the movement direction and the welding gun angle of the direct current argon arc welding machine according to the instruction of the core control system so as to finish tracking and welding of welding seams of workpieces to be welded.
2. The automatic tracking direct current argon arc welding machine according to claim 1, wherein the core control system comprises a microprocessor unit, and a data storage unit, a D/A converter, a USART interface, an interface unit and a wireless transceiver which are connected with the microprocessor unit;
The D/A converter is connected with a power supply and used for generating analog voltage with preset size, the interface unit is connected with a welding gun, an arc stabilizer, an air source system, a water cooling system, a welding gun running system and a wire feeding system, corresponding welding gun motion control instructions, argon control valve switching instructions, cooling water control valve switching instructions and welding wire speed control instructions are respectively output to the systems, the wireless transceiver is used for being in communication connection with a remote operation control system, the USART interface is connected with an ultrasonic tracking system, an ultrasonic detection system and an filtering camera system and used for transmitting data acquired by the ultrasonic tracking system, the ultrasonic detection system and the filtering camera system in a welding process, and the data storage unit is used for storing a pre-established database, welding parameters in the welding process and the acquired data and instructions.
3. The automatic tracking direct current argon arc welding machine according to claim 1, wherein a core control system of the direct current argon arc welding machine is provided with a preset unique ID, and the remote operation control system and the core control system are respectively used for controlling one or more direct current argon arc welding machines according to the ID of the core control system based on a communication protocol.
4. The welding method of the direct current argon arc welding machine based on automatic tracking is characterized in that the following steps S1-S4 are executed on the basis of the direct current argon arc welding machine with automatic tracking as claimed in claim 2 or 3, and the tracking and welding of the welding seam of a workpiece to be welded are completed:
step S1: the remote operation control system sends a starting signal to the direct current argon arc welding machine, the core control system starts an ultrasonic detection flow, controls the ultrasonic tracking system to detect the thickness and the material of a workpiece to be welded by adopting ultrasonic waves, and transmits detection data to a microprocessor unit of the core control system;
step S2: the microprocessor unit respectively controls the air source system and the water cooling system to open the argon control valve and the cooling water control valve, and simultaneously controls the D/A converter to generate analog voltage with preset magnitude so as to control the power supply to output welding current; meanwhile, the microprocessor unit controls the welding gun running system to track a welding seam through the interface unit, controls the welding gun, the arc stabilizer and the wire feeding system to start welding after the direct current argon arc welding machine reaches the position of the welding seam, controls the filtering camera system to acquire images in the welding process, and sends the images to the microprocessor unit for analyzing and processing the welding pool images;
Step S3: the microprocessor unit receives detection data transmitted by the ultrasonic tracking system and images transmitted by the filtering camera system in real time, judges the shape and quality of a welding seam, identifies abnormal information, sends corresponding instructions to the welding gun running system and the wire feeding system according to preset rules, and adjusts the action of the welding gun running system and the wire speed of the wire feeding system until the welding is completed;
step S4: after welding is finished, an ultrasonic detection system is adopted to transmit ultrasonic waves to a welding seam, ultrasonic wave echo data are transmitted to a core control system to judge welding quality, and the judging result and welding parameters in the welding process are stored in a data storage unit.
5. The welding method of the automatic tracking-based direct current argon arc welding machine according to claim 4, wherein the ultrasonic detection flow of detecting the material of the workpiece to be welded by the ultrasonic tracking system in the step S1 is as follows:
step S1.1: selecting an ultrasonic probe and ultrasonic frequency;
step S1.2: measuring and recording sound velocity of a workpiece to be welded by adopting a standard test block;
step S1.3: the ultrasonic probe is arranged at a preset distance above the workpiece to be welded, the thickness of the ultrasonic probe is measured by adopting ultrasonic waves and is transmitted to the microprocessor unit, and the microprocessor unit calculates the density of the workpiece to be welded according to the thickness and the sound velocity of the workpiece to be welded;
Step S1.4: and comparing the calculated density of the workpieces to be welded with standard data of various welding workpieces in a pre-established database to obtain the material of the workpieces to be welded, and automatically setting welding parameters with preset corresponding relations according to the material of the workpieces to be welded.
6. The welding method of the automatic tracking-based direct current argon arc welding machine according to claim 4, wherein the tracking process of the welding gun running system in the step S2 is as follows:
s2.1, setting a trigger pulse width and a sampling interval of an ultrasonic tracking system;
s2.2, respectively measuring the distances between the welding gun and the two edges of the welding seam by the ultrasonic tracking system at set sampling intervals, and calculating the distance difference between the welding gun and the two edges of the welding seam;
s2.3, controlling a welding gun travelling system according to the distance difference between the welding gun and the two edges of the welding line, so that the direct current argon arc welding machine moves towards the central line of the welding line until the distance difference between the welding gun and the two edges of the welding line is 0, and considering that the direct current argon arc welding machine reaches a welding position;
s2.4, after the direct current argon arc welder reaches a welding position, starting to weld; in the welding process, an ultrasonic wave tracking system acquires an echo waveform and transmits the echo waveform to a microprocessor unit, the microprocessor unit compares the echo waveform with ultrasonic wave waveforms of various welding defects in a pre-established database, judges whether the welding defects exist in the welding process, and correspondingly adjusts welding parameters;
And S2.5, repeating the tracking process of the steps S2.1-S2.4 after the welding is finished.
7. The welding method of the automatic tracking-based direct current argon arc welding machine according to claim 4, wherein in the welding process in the step S3, the microprocessor unit judges the shape of the welding seam and the quality of the welding seam according to a preset method based on the image transmitted by the filtering camera system, and the process of identifying abnormal information is as follows:
s3.1, constructing a data set formed by images of various molten pool states in a welding process, wherein the various molten pool states comprise normal welding and various preset welding defects, and the various molten pool states are used as labels to correspond to the images in the data set one by one;
s3.2, constructing an argon arc welding image recognition model based on a neural network, wherein the argon arc welding image recognition model takes all images in a data set as input, takes labels corresponding to all the images as output, and trains the argon arc welding image recognition model to obtain a trained argon arc welding image recognition model;
s3.3, in the welding process, the filtering camera system collects images of the molten pool in real time and transmits the images to the microprocessor unit;
s3.4, the microprocessor unit preprocesses the images, inputs the preprocessed images into a pre-trained argon arc welding image recognition model, outputs labels corresponding to the images, and completes recognition of the molten pool state in the welding process;
And S3.5, according to the recognition result of the molten pool state in the welding process, adjusting welding parameters according to the corresponding preset instruction.
8. The welding method of the automatic tracking-based direct current argon arc welding machine according to claim 4, wherein in the step S4, an ultrasonic detection system is adopted to transmit ultrasonic waves to a welding line, and the method for judging the welding quality according to ultrasonic echo data is as follows: and comparing the ultrasonic echo data with ultrasonic echo data of various welding quality in a pre-established database to obtain the welding quality of the welding seam.
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