CN117428302B - Intelligent dynamic control method and system for air supply flow rate of welded pipeline - Google Patents
Intelligent dynamic control method and system for air supply flow rate of welded pipeline Download PDFInfo
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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
- B23K9/32—Accessories
- B23K9/325—Devices for supplying or evacuating 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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Abstract
The invention discloses an intelligent dynamic control method and system for the air supply flow rate of a welding pipeline. Adjusting the fluctuation of the gas flow rate between the upper limit and the lower limit after the driving current is obtained; in addition, the invention also provides an adjusting method for different fluctuation periods by adopting an interpolation method according to the actual welding working condition; aiming at the problem of inaccurate driving current caused by flow speed change, the invention also provides a calibration method, which ensures that the air flow fluctuates within a set flow speed range, saves pipeline air supply and prevents air flow speed errors caused by proportional valve control errors.
Description
Technical Field
The invention belongs to the technical field of intelligent welding, and particularly relates to an intelligent dynamic control method and system for the air supply flow rate of a welded pipeline.
Background
In the conventional welding operation, the welding shielding gas is generally in the form of bottled gas or pipeline gas, and the flow rate of the output gas is controlled to be maintained in a reasonable range by presetting a gas flow value. The flow rate control of traditional bottled air supply or pipeline air supply adopts the manual regulation to install the mechanical relief pressure valve on the gas circuit, and during actual welding, the gas flow is adjusted according to experience by the welder, generally adjusts the gas flow to the gas flow rate that is fit for work piece welding according to welding process regulation WPS. In actual operation, workers do not frequently adjust the gas flow rate, but maintain the gas flow rate at a relatively high level, so that welding quality is ensured not to be affected, and welding defects are caused. However, in actual welding, due to factors such as current change or unstable gas supply, the effect of feeding gas according to needs cannot be achieved all the time in a traditional manual adjustment mode, and a large amount of gas is wasted in order to ensure welding quality. In addition, because the accuracy of the float gauge on the mechanical pressure reducing valve is not high, the welding air flow is not in the process range, the actual air flow rate is larger, and the air waste is further caused.
In the prior art, an electromagnetic proportional valve is generally adopted for air flow control, the proportional valve is installed in a protective air pipeline when in use, the opening and closing degree of the proportional valve is directly controlled through externally input driving current, and the air flow speed in the pipeline is controlled. However, as the air flow speed changes, the pressure in the pipeline also changes, and at this time, the same driving current corresponds to the adjustable air flow speed, and the control accuracy of the proportional valve is not constant any more.
Disclosure of Invention
The invention aims to: aiming at the problems in the background technology, the invention provides an intelligent dynamic control method for the gas supply flow rate of a welding pipeline, which is characterized in that a proportional valve for accurately controlling the gas flow rate is added in a traditional pipeline gas supply circuit, corresponding driving current is given based on the upper limit and the lower limit of the gas flow rate given by an actual process, and a fluctuation control method for the gas flow rate is designed, so that the problem of gas waste in constant-flow gas supply is solved. In addition, aiming at the problem that the driving current of the proportional valve is inaccurate to the gas flow rate caused by the change of the air pressure in the pipeline, and further the deviation of the control effect occurs, a real-time calibration method is provided, and when the gas flow rate has larger deviation, calibration and back control are performed.
The technical scheme is as follows: an intelligent dynamic control method for the air supply flow rate of a welded pipeline comprises the following steps:
step S1, setting an upper flow speed limit Vmax and a lower flow speed limit Vmin in fluctuation control, and calibrating a proportional valve based on the set upper flow speed limit and the set lower flow speed limit to respectively obtain proportional valve driving currents IH and IL corresponding to the Vmax;
step S2, setting a waveform period of fluctuation control according to an actual welding condition, realizing control of the waveform period in an interpolation control mode, and acquiring a calibrated airflow waveform;
and S3, after the calibrated airflow waveform is obtained, sequentially performing repetition period control according to the driving current obtained by interpolation in the step S2.
Further, in the calibration process of the proportional valve, the fluctuation error is set to be +/-0.5L/min, when the protective gas pipeline starts to be ventilated, the gas flow rate of the pipeline is detected in real time through the gas flow sensor, and the host computer receives the flow rate data in real time and compares the flow rate data with the set upper flow rate limit Vmax and the set lower flow rate limit Vmin respectively; when the gas flow rate is lower than Vmin, the PID method is adopted to raise the gas flow rate to Vmin, and the proportional valve driving current IL corresponding to the current state is obtained; when the gas flow rate is higher than Vmax, the PID control method is adopted to adjust the gas flow rate to Vmax, and the proportional valve driving current IH corresponding to the current state is obtained.
Further, the specific method for interpolation control in step S2 includes:
according to the set waveform control period T, driving current interpolation is carried out between IH-IL, and the number X of interpolation points meets the following conditions:
;
drive current corresponding to the x-th interpolation pointI x The method meets the following conditions:
;
wherein x=0, 1,2, …, X;
obtaining interpolation point driving currentI x And sequentially sending a driving current instruction from the IL to the IH by the host, controlling the proportional valve to adjust for x times, then symmetrically reducing the driving current from the IH to the IL, and controlling the opening and closing degree of the proportional valve to finally obtain a complete airflow waveform, wherein the airflow waveform is the calibrated airflow waveform.
Further, calculating a waveform difference between the actual waveform and the calibrated airflow waveform in each subsequent period when the period control is repeated in the step S3, and carrying out recalibration when the difference is greater than a preset range; the method for calculating the waveform difference comprises any one of Euclidean distance, manhattan distance and DTW algorithm.
Further, a waveform difference calculation method based on the euclidean distance is adopted, and specifically,
the calibrated airflow waveform obtained in the step S2 contains the total airflow point number P, and the flow velocity of each airflow point after calibration is set asThe velocity of each airflow point in the current actual waveform is +.>Wherein p=0, 1,2,;
under the control of the proportional valve, each new waveform period is generated, the current waveform is calculatedAnd the flow rate of each air flow point after calibration +.>The Euclidean distance d between them is as follows:
;
setting an error threshold th1 and a calibration threshold th2, and when d-th1 is more than or equal to th2, representing that the waveform difference is too large, immediately recalibrating the host in the next waveform period; when d-th1 is more than 0 and less than th2, representing that the waveforms have differences, not immediately carrying out recalibration at the moment, and when n new waveforms all meet 0 and less than d-th1 and less than th2, carrying out recalibration again; when d.ltoreq.th1, there is no obvious effect on the representative difference and no recalibration is performed.
Further, when recalibrating, repeating the related steps in the steps S1-S2, adopting a PID linear control method to redetermine IL and IH, and carrying out interpolation again to realize the set waveform period; and after the recalibration is finished, continuing to carry out fluctuation control within the preset upper and lower flow rate limits.
A control system adopting the intelligent dynamic control method for the gas supply flow rate of the welding pipeline comprises a shielding gas source, a gas flow sensor, a proportional valve, a host machine and a gas end for a welding machine; the welding protection gas source is used to the gas end of the welding machine through conveying the welding protection gas to the gas end of the welding machine through the gas inlet gas path, the gas inlet gas path is provided with a high-precision gas flow sensor, the gas flow sensor detects the flow rate of the protection gas in the current pipeline in real time and transmits the protection gas to the host, the gas inlet gas path is simultaneously provided with the proportional valve, and the host controls the opening and closing degree of the proportional valve to further control the flow rate of the protection gas in the gas inlet gas path, so that the protection gas finally flows into the gas end of the welding machine.
Compared with the prior art, the technical scheme adopted by the invention has the following beneficial effects:
(1) The intelligent dynamic control method for the welding pipeline air supply flow rate is different from the existing constant-value flow rate control method, can accurately realize fluctuation control in the set upper and lower limiting flow rate ranges, and can effectively save the consumption of shielding gas.
(2) The invention adopts the interpolation control method to control the waveform period, selects different waveform periods according to different welding working conditions, and ensures that the welding quality problem caused by the reduction of the gas flow rate is avoided while saving gas.
(3) Aiming at the problem that the corresponding relation between the driving current of the proportional valve and the pipeline flow velocity under different external conditions is possibly changed, the invention provides a waveform self-adaptive calibration method, and the accurate control of the waveform is realized by calculating the waveform difference and providing the calibration method.
Drawings
FIG. 1 is a block diagram of a welded pipe air supply system provided by the present invention;
FIG. 2 is a schematic diagram of an intelligent dynamic control method for the air supply flow rate of a welding pipeline;
FIG. 3 is a schematic diagram showing the effect of saving gas under high frequency fluctuation in the embodiment of the invention.
Description of the embodiments
Compared with fixed-value air supply in the prior art, the invention provides an intelligent dynamic control method and system for the air supply flow rate of a welding pipeline. The gas flow rate is adjusted to fluctuate between upper and lower limits after the drive current is acquired. In addition, the invention also provides a method for adjusting different fluctuation frequencies by adopting a difference value method according to the actual welding process requirement. Aiming at the problem of inaccurate driving current caused by flow speed change, the invention also provides a calibration method, which ensures that the air flow fluctuates within a set flow speed range, saves pipeline air supply and prevents air flow speed errors caused by proportional valve control errors. A specific example is given below to describe in detail the conditioning method of the present invention.
As shown in FIG. 1, the intelligent fluctuation control system for the pipeline gas supply flow rate provided by the invention has the advantages that a protective gas source conveys welding protective gas to a gas end of a welding machine from an air inlet path, a high-precision air flow sensor is arranged on the air inlet path, the air flow sensor detects the current protective gas flow rate in a pipeline in real time and transmits the current protective gas flow rate to a host, a proportional valve is simultaneously arranged on the air inlet path, the host outputs driving current after receiving gas flow rate data, the opening and closing degree of the proportional valve is controlled, the flow rate of the protective gas in the air inlet path is controlled, and finally the protective gas flows into the gas end of the welding machine.
The intelligent dynamic control method for the pipeline air supply flow rate provided by the invention is shown in fig. 2, and comprises the following steps:
s1, setting an upper flow speed limit Vmax and a lower flow speed limit Vmin in fluctuation control, and setting a fluctuation error to be +/-0.5L/min; and calibrating the proportional valve based on the set upper and lower flow speed limits.
When the protective gas pipeline starts to be ventilated, detecting the gas flow rate of the pipeline in real time through the gas flow sensor, and enabling the host to receive the flow rate data in real time and compare the flow rate data with a set flow rate upper limit Vmax and a set flow rate lower limit Vmin respectively; when the gas flow rate is lower than Vmin, the PID method is adopted to raise the gas flow rate to Vmin, and the proportional valve driving current IL corresponding to the current state is obtained; when the gas flow rate is higher than Vmax, the PID control method is adopted to adjust the gas flow rate to Vmax, and the proportional valve driving current IH corresponding to the current state is obtained.
And S2, setting a waveform period of fluctuation control according to the actual welding working condition, and realizing the control of the waveform period in an interpolation control mode.
In this embodiment, an interpolation control method is adopted to increase or shorten the period of the fluctuation control, so that the switching of the low frequency, the intermediate frequency and the high frequency of the airflow waveform frequency can be realized. Specifically, after the calibration is completed in step S1, driving current interpolation is performed between IH-IL according to a set waveform control period T, and the number X of interpolation points satisfies:
;
drive current corresponding to the x-th interpolation pointI x The method meets the following conditions:
;
where x=0, 1,2, …, X.
Obtaining interpolation point driving currentI x And sequentially sending a driving current instruction from the IL to the IH by the host, controlling the proportional valve to adjust for x times, then symmetrically reducing the driving current from the IH to the IL, and controlling the opening and closing degree of the proportional valve to finally obtain a complete airflow waveform, wherein the airflow waveform is the calibrated airflow waveform.
And step S3, after the interpolation process of the step S2 is completed, the proportional valve does not perform PID control any more, and the driving current repetition period control is performed according to the driving current obtained in the step S2 in sequence.
In the actual pipeline gas supply state, the gas flow rate in the pipeline is continuously changed, and the pressure is also continuously changed, so that the same driving current is used for driving the proportional valve, and the obtained pipeline gas flow rates are different, and therefore calibration and back control are needed. In this embodiment, a reverse control calibration method based on waveform difference calculation is provided, by calculating waveform differences between each subsequent period and the calibrated airflow waveform, when the differences are too large, a new round of driving current calibration is immediately performed, when the differences are not large, accumulated driving current calibration is performed, and when the differences do not exceed a preset range, a calibration mode is not adopted. In actual calculation of the waveform difference, indexes such as Euclidean distance and Manhattan distance can be used as indexes for measuring the waveform difference, and the time sequence similarity can be calculated by adopting a DTW algorithm and the like. In this embodiment, a difference value calculated based on the euclidean distance and a calibration method are provided, which are specifically as follows:
s3.1, the calibrated airflow waveform obtained in the step S2 comprises the total airflow point number P, and the flow velocity of each airflow point after calibration is set asThe velocity of each airflow point in the current actual waveform is +.>Where p=0, 1,2,..p-1.
Under the control of the proportional valve, each new waveform period is generated, the current waveform is calculatedAnd the flow rate of each air flow point after calibration +.>The Euclidean distance d between them is as follows:
;
s3.2, setting an error threshold th1 and a calibration threshold th2, wherein when d-th1 is more than or equal to th2, the difference of the waveforms is overlarge, and the host is immediately recalibrated in the next waveform period; when d-th1 is more than 0 and less than th2, representing that the waveforms have differences, not immediately carrying out recalibration at the moment, and when n new waveforms all meet 0 and less than d-th1 and less than th2, carrying out recalibration again; when d.ltoreq.th1, there is no obvious effect on the representative difference and no recalibration is performed.
Specifically, when recalibration is performed, the relevant steps in the steps S1-S2 are repeated, IL and IH are redetermined by adopting a PID linear control method, interpolation is performed again, and a set waveform period is realized. And after the recalibration is finished, continuing to carry out fluctuation control within the preset upper and lower flow rate limits.
In the above-described gas flow rate fluctuation control method, compared with the conventional control method, the control method of eliminating a fixed gas flow value is omitted, and as shown in fig. 3, taking a high-frequency waveform as an example, each waveform may be approximately a triangle, and the area enclosed under the waveform is the amount of the gas to be used. Compared with the traditional airflow control method with the flow rate fixed value at the peak value, more air can be obviously saved. According to the invention, different waveform frequencies are controlled by an interpolation method according to actual welding conditions, and different welding seam conditions are corresponding, so that the problem of welding quality caused by the reduction of the gas flow rate can be avoided while gas is saved. Finally, the invention considers the problem that the gas flow rate and the driving current can not be corresponding any more when the driving current calibrated by the proportional valve changes along with the external conditions such as the gas flow rate, the pressure and the like, and provides a recalibration concept, so that the follow-up waveform has the self-adaptive correction capability, and more accurate fluctuation control is realized.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (2)
1. An intelligent dynamic control method for the air supply flow rate of a welded pipeline is characterized by comprising the following steps:
step S1, setting an upper flow speed limit Vmax and a lower flow speed limit Vmin in fluctuation control, and calibrating a proportional valve based on the set upper flow speed limit and the set lower flow speed limit to respectively obtain proportional valve driving currents IH and IL corresponding to the Vmax; in particular, the method comprises the steps of,
in the calibration process of the proportional valve, setting the fluctuation error to be +/-0.5L/min, detecting the gas flow rate of the pipeline in real time through an airflow sensor when the protective gas pipeline starts to be ventilated, and comparing the flow rate data with the set upper flow rate limit Vmax and the set lower flow rate limit Vmin respectively by a host computer in real time; when the gas flow rate is lower than Vmin, the PID method is adopted to raise the gas flow rate to Vmin, and the proportional valve driving current IL corresponding to the current state is obtained; when the gas flow rate is higher than Vmax, adjusting the gas flow rate to Vmax by adopting a PID control method, and obtaining a proportional valve driving current IH corresponding to the current state;
step S2, setting a waveform period of fluctuation control according to an actual welding condition, realizing control of the waveform period in an interpolation control mode, and acquiring a calibrated airflow waveform; the interpolation control specific method comprises the following steps: according to the set waveform control period T, driving current interpolation is carried out between IH-IL, and the number X of interpolation points meets the following conditions:;
drive current corresponding to the x-th interpolation pointI x The method meets the following conditions:;
wherein x=1, 2, …, X;
obtaining interpolation point driving currentI x Then, sequentially sending a driving current instruction from IL to IH by the host, controlling the proportional valve to adjust for x times, then symmetrically reducing the driving current from IH to IL, controlling the opening and closing degree of the proportional valve, and finally obtaining a complete airflow waveform, wherein the airflow waveform is the calibrated airflow waveform;
step S3, after the calibrated airflow waveform is obtained, carrying out repeated period control according to the driving current obtained by interpolation in the step S2; calculating the difference between the actual waveform and the calibrated airflow waveform in each subsequent period when the period control is repeated in the step S3, and carrying out recalibration when the difference is larger than a preset range; the method for calculating the waveform difference comprises any one of Euclidean distance, manhattan distance and DTW algorithm; specifically, a waveform difference calculation method based on Euclidean distance is adopted,
the calibrated airflow waveform obtained in the step S2 contains the total airflow point number P, and the flow velocity of each airflow point after calibration is set asThe velocity of each airflow point in the current actual waveform is +.>Wherein p=0, 1,2,;
under the control of the proportional valve, each new waveform period is generated, the current waveform is calculatedAnd the flow rate of each air flow point after calibration +.>The Euclidean distance d between them is as follows: />;
Setting an error threshold th1 and a calibration threshold th2, and when d-th1 is more than or equal to th2, representing that the waveform difference is too large, immediately recalibrating the host in the next waveform period; when d-th1 is more than 0 and less than th2, representing that the waveforms have differences, not immediately carrying out recalibration at the moment, and when n new waveforms all meet 0 and less than d-th1 and less than th2, carrying out recalibration again; when d is less than or equal to th1, the representative difference has no obvious influence, and recalibration is not performed;
when recalibration is carried out, the relevant steps in the steps S1-S2 are repeated, IL and IH are redetermined by adopting a PID linear control method, interpolation is carried out again, and a set waveform period is realized; and after the recalibration is finished, continuing to carry out fluctuation control within the preset upper and lower flow rate limits.
2. A control system adopting the intelligent dynamic control method for the gas supply flow rate of the welding pipeline according to claim 1, which is characterized by comprising a shielding gas source, a gas flow sensor, a proportional valve, a host and a gas end for a welding machine; the welding protection gas source is used to the gas end of the welding machine through conveying the welding protection gas to the gas end of the welding machine through the gas inlet gas path, the gas inlet gas path is provided with a high-precision gas flow sensor, the gas flow sensor detects the flow rate of the protection gas in the current pipeline in real time and transmits the protection gas to the host, the gas inlet gas path is simultaneously provided with the proportional valve, and the host controls the opening and closing degree of the proportional valve to further control the flow rate of the protection gas in the gas inlet gas path, so that the protection gas finally flows into the gas end of the welding machine.
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