CN117583698A - Automatic surfacing device and surfacing control method - Google Patents
Automatic surfacing device and surfacing control method Download PDFInfo
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- CN117583698A CN117583698A CN202410080758.4A CN202410080758A CN117583698A CN 117583698 A CN117583698 A CN 117583698A CN 202410080758 A CN202410080758 A CN 202410080758A CN 117583698 A CN117583698 A CN 117583698A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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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
- B23K9/095—Monitoring or automatic control of welding parameters
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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
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- 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
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses an automatic surfacing device and a surfacing control method, wherein the automatic surfacing device comprises a welding execution system, a visual identification system and a welding intelligent control system; the surfacing control method comprises the steps of establishing a corresponding rule table of welding process parameters and weld bead morphology relation parameters; establishing a coordinate system, planning a welding track and presetting welding parameters; starting welding and compensating the welding channel width and residual height in real time; scanning, detecting and reminding of repairing defect position and depth information. The invention is based on MIG welding technology, and carries out high-automation welding on a plurality of welding layers (a bottoming layer, a transition layer and a wear-resistant layer) of the surfacing roller sleeve, thereby improving the production efficiency. The quality of each welding link is controlled in a closed loop manner in the welding process, so that the quality consistency of a welding finished product is ensured.
Description
Technical Field
The invention relates to the technical field of surfacing, in particular to an automatic surfacing device and a surfacing control method.
Background
The roller press is one of core production equipment in the fields of cement, mining industry and the like, and the working performance of the roller press is closely related to the quality, the yield and the energy consumption of products. The roller sleeve is a part of the core of the roller press and has important influence on the working performance of the roller press. In the working process, the roller sleeve is directly contacted with the material to crush the material, so the roller sleeve is required to have the characteristics of high wear resistance and high compressive strength. Currently, two types of roller sleeves, a stud roller sleeve and a surfacing roller sleeve are mainly arranged on the market. The cast nail roller sleeve is forged by high wear-resistant alloy steel, and has long service life and high cost, and accounts for about 30% of market share. The overlaying roller sleeve is manufactured by layering overlaying welding wires made of different materials, the service life of the overlaying roller sleeve is relatively short, but the cost is low, and the overlaying roller sleeve accounts for about 70% of the market share. So-called overlay welding, i.e. multi-layer, multi-pass welding: and (3) densely welding a plurality of welding beads on a base material in sequence, tiling the welding beads to form a welding layer, and then continuing to weld on the welding beads of the welding layer to stack the welding beads until the size of a welded part is increased to a design value.
The surfacing roller sleeve takes medium carbon alloy steel such as 32CrMo and the like as a matrix, and the wear-resistant material is welded on the surface of the matrix through a surfacing process. The overlaying roller sleeve can be divided into a roller sleeve base material, a priming layer, a transition layer, a wear-resistant layer, a pattern layer and hard particles from inside to outside. The materials used in different levels are different, so that different mechanical properties are realized. The roll sleeve base material is formed by machining a cast billet, and all welding layers of the finished roll sleeve are stacked and welded layer by layer on the roll sleeve base material, so that the roll sleeve base material is in an initial form before the roll sleeve is welded. The primer layer has higher toughness, can improve the bonding strength of the workpiece and the hardening surface layer, release welding stress and effectively prevent the build-up welding crack from expanding to the matrix. The transition layer has higher welding hardness and good toughness, and has excellent wear resistance and extrusion resistance. Compared with the transition layer, the wear-resistant layer has more excellent wear resistance and extrusion abrasion resistance, the welding hardness of the used material is highest, and the surface hardness of the material needs to reach HRC58 and above. The pattern layer, the hard particles and the wear-resistant layer are made of the same material, and the effect of the roller sleeve on the material is mainly improved, so that the production efficiency is improved. In the process of producing the roller sleeve, the prime layer, the transition layer and the wear-resistant layer account for more than 90% of the surfacing operation amount. Once the bottom layer, the transition layer and the wear-resistant layer are welded, internal defects are difficult to detect, and the cost for repairing the defects is high and the period is long. Therefore, the manufacturing process of the surfacing roller sleeve is researched, the welding quality is improved, the working life is prolonged, and the surfacing roller sleeve has important application value and economic value.
The existing manufacture of the surfacing roller sleeve on the market usually adopts a manual welding or semi-automatic wear-resistant surfacing mode, and the traditional surfacing mode has the following defects:
1. the quality consistency is poor. The surfacing process of the roller sleeve is complex, the requirements on the welding experience and the welding technical level of a welder are high, and the size of a workpiece is large and the welding time is long, so that the welding quality is greatly influenced by the level of the welder and the working state of the welder during welding, the welding quality is difficult to control, and the service life consistency of the roller sleeve cannot be ensured when leaving the factory.
2. The quality of the build-up welding process cannot be checked and controlled. In the process of overlaying the roller sleeve, the welding widths of a plurality of welding beads need to be kept strictly consistent, otherwise, gaps are formed between the welding beads, and the gaps are buried when the next layer is welded subsequently, so that potential quality hazards are caused. Because a plurality of welding layers are stacked layer by layer, the residual height of each welding bead needs to be strictly consistent, otherwise, the size of the roller sleeve can deviate, and the cylindricity of the finished roller sleeve is not in accordance with the requirement and the quality is not up to standard. The existing surfacing process cannot monitor and control the parameters of the melting width and the residual height in the welding process in real time. The quality and the service life of the surfacing roller sleeve can only be verified in the use process, and once the welding quality is problematic, stress concentration of defective parts is caused, so that the problems of cracking, peeling, chipping and the like are caused at the initial stage of roller surface use, and great after-sales maintenance cost is brought.
3. Low production efficiency and bad operation environment. The current manual overlaying and semiautomatic overlaying are largely dependent on manual operation, and the production efficiency is low. In the process of overlaying the wear-resistant roller sleeve, smoke dust is extremely large, overlaying working hours are long, physical injury and chemical injury can be caused to a worker body by a severe working environment, and the risk of occupational diseases of welders is increased.
Disclosure of Invention
The invention aims to provide an automatic surfacing device and a surfacing control method, which are used for solving the problems in the background art, and the invention is based on an MIG welding process to carry out high-automation welding on a plurality of welding layers (a priming layer, a transition layer and a wear-resistant layer) of a surfacing roller sleeve, so that the production efficiency is improved. The quality of each welding link is controlled in a closed loop manner in the welding process, so that the quality consistency of a welding finished product is ensured.
In order to achieve the above purpose, the present invention provides the following technical solutions:
the invention discloses a control method for automatic surfacing, which comprises the following steps:
s1, establishing a corresponding rule table of welding process parameters and weld bead morphology relation parameters, wherein the welding process parameters comprise: swing of a welding gun, wire feeding speed, welding current and welding voltage; the welding bead morphology parameters comprise welding bead melting width and welding bead residual height;
s2, planning a welding track: the roller sleeve rotates at a constant speed, and the welding gun performs reciprocating swing welding motion at the starting point; when the roller sleeve rotates at a constant speed for one circle, completing one circle of welding bead welding, the welding gun immediately axially translates a standard welding bead width distance to the roller sleeve, and starting the next welding path welding until the welding of all welding beads of the current welding layer is completed; after the welding of the current welding layer is completed, the welding gun moves to the initial welding position of the next welding layer, and the welding task of the next welding layer is executed;
the preset working parameters comprise: welding layer number and welding rodStandard value of brand, welding speed and welding bead widthA welding bead fusion width deviation allowable value and a welding bead residual height standard value +.>A weld bead residual height deviation allowable value and a roller sleeve surface 'true defect' area threshold value;
s3, starting a welding task of a current layer: the roller sleeve and the welding gun are controlled to act according to the welding track set in the step S2, and the standard value of the welding width of the preset welding bead is adoptedStandard value of weld bead residual height->Searching a rule table, and searching and setting current welding process parameters;
step S3 also comprises real-time compensation of weld bead fusion width and weld bead residual height, and specifically comprises the following steps:
monitoring a current welding bead molten pool in real time through a molten pool camera, and calculating the current welding bead molten width in real time according to a molten pool image detection algorithmThe residual height of the current welding bead +.>Obtaining the deviation of the morphological parameters->,/>Represents the current welding bead width value +.>And welding bead fusion width standard value->Difference of->Representing the residual value of the current weld bead +.>Standard value of the residual height of the welding bead->Is a difference in (2);
if it isNot more than the allowable value of weld bead width deviation, and +.>If the deviation is not larger than the allowable value of the residual height deviation of the welding bead, continuing to execute the welding process with the established welding process parameters, otherwise, starting a deviation correcting program, readjusting the welding process parameters and continuing to weld until the current layer of welding is completed;
s4, shooting a current welding layer through a line laser scanning camera, and executing defect detection, wherein the method specifically comprises the following steps of:
if the defect does not exist, the next welding layer welding task is directly executed;
if the defects exist, a defect early warning is sent out, and after the repair is completed, a next welding layer welding task is carried out;
s5, repeatedly executing the steps S3-S4 until all welding layers are welded.
As a further aspect of the invention: the rule table establishing process comprises the following steps:
the welding wire mark and the welding speed are consistent with those of actual welding; from small to largeSwing of each welding gun>The interval between adjacent welding gun swing ranges is +.>The method comprises the steps of carrying out a first treatment on the surface of the Setting from small to large->Individual wire feed speed->The interval between adjacent wire feeding speeds is +.>The method comprises the steps of carrying out a first treatment on the surface of the Let welding current->Welding voltage->According to the empirical formula->Follow wire feed speed->A change; wherein->In amperes, ">In cm/min,/d->In volts; every time a set of welding process parameters is changedObtaining a group of corresponding bead shapes +.>And obtaining a plurality of groups of data through multiple experiments, and obtaining the rule table.
As a further aspect of the invention: the deviation rectifying program specifically comprises the following steps:
establishing the adjustment direction of welding process parametersAnd->Is a relationship rule; according to the current->And->Determining the adjustment direction of welding process parameters; in the rule table, the current welding process parameters are +.>、/>For the starting point, with the determined welding process parameters +.>、/>Is adjusted to>And->For the search interval, find the off-bead topography parameter +.>The nearest point is recorded the welding process parameter set +.>The method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>Represents->And (3) withDifference of->Represents->And->Is a difference in (2);
adjusting the swing of the welding gun to beWire feed speed is +.>Welding current is +.>Welding voltage is +.>And continuing welding according to the preset welding track.
As a further aspect of the invention: the welding process parameter adjusting direction and the welding process parameter adjusting directionAnd->The relationship rules of (a) are:
if it is＞0、/>=0, then the gun swing and wire feed speed are reduced simultaneously;
if it is＜0、/>=0, then increase the gun swing and wire feed speed simultaneously;
if it is=0、/>Increasing the swing of the welding gun and reducing the wire feeding speed if the swing is more than 0;
if it is=0、/>Reducing the swing of the welding gun and increasing the wire feeding speed if the swing is less than 0;
if it is＜0、/>If the speed is less than 0, the swing of the original welding gun is kept, and the wire feeding speed is increased;
if it is＞0、/>If more than 0, the swing of the original welding gun is kept, and the wire feeding speed is reduced;
if it is＞0、/>Reducing the swing of the welding gun and keeping the original wire feeding speed;
if it is＜0、/>And if the welding gun swing is larger than 0, the original wire feeding speed is kept.
As a further aspect of the invention: in step S4, the defect detection process is performed specifically including:
s41, continuously rotating the roller sleeve at a constant speed, and moving the line laser scanning camera at intervals along the axial direction of the roller sleeve, wherein each time a picture is shot, so that all shot pictures cover the complete roller surface;
s42, cutting and splicing all pictures to form a roll surface large picture;
s43, detecting and extracting position and depth information of a defect in the roll surface large map, and converting the position of the defect into a welding robot coordinate system;
s44, displaying and reminding of repairing the defect.
As a further aspect of the invention: in step S43, the depth information is a roller sleeve radius corresponding to each pixel gray value in the roller surface large map, and the roller sleeve radiusDistance between line laser scanning camera and axis of roller sleeve during shooting>Gray values of corresponding pixel points on the large graph of the roller sleeve.
As a further aspect of the invention: in step S43, the process of detecting and extracting the defect specifically includes:
setting the attribute characteristic values of all pixel points in the roll surface large graph to be 0, and according to the theoretical radius of each point on the roll sleeveOriginal radius ∈of welding>Single-layer weld bead residual height standard value ∈>Number of welded layers->Detecting whether the gray value of each pixel point in the roll surface large graph is equal to the theoretical radius one by one according to the allowable value of the residual height deviation of the welding bead, and if not, setting the attribute characteristic value of the pixel to be 1; a detection attribute value of 1Whether the pixel points are communicated or not, if so, adding the pixel points into the same data set; repeating the above process until all pixel points are detected, obtaining a plurality of data sets which are not communicated with each other, and calculating the defect area corresponding to the number of pixels in each data set; if the defect area of the data set is larger than the preset area threshold value of the true defect of the surface of the roller sleeve, the data set is marked as the true defect, otherwise, the data set is marked as the false defect; let the pixel coordinate of a pixel point of the 'true defect' A in the roll surface large diagram beThe gray value is +.>According to->Transforming it into a cylindrical coordinate system of the roll sleeveIn (1)>And translation matrix->Transforming the pixel coordinates of the "true defect" to the welding robot coordinate system +.>Lower, i.e.)>The method comprises the steps of carrying out a first treatment on the surface of the Wherein: />Expressed in a cylindrical coordinate system->Under the heading, < "> the distance of a certain pixel point of" true defect "A from the origin, <" > the pixel point of "true defect" A>Some kind of indication "true defect" AThe pixel points are relative to a cylindrical coordinate system>Is->Rotation angle of shaft>A pixel point representing a "true defect" A is in the cylindrical coordinate system +.>Is->Projection length of axis>Representing the total number of pixel rows of the roll surface map.
The invention further discloses an automatic welding device adopted by the control method according to any one of the above, which comprises a welding executing mechanism, a visual recognition mechanism and a welding intelligent control mechanism, wherein:
the welding executing mechanism comprises a welding robot and a welding gun fixedly arranged at the tail end of the welding robot; the welding machine comprises a welding gun nozzle, a welding machine, a wire feeder and a speed sensor, wherein the welding machine is used for providing stable current;
the visual recognition mechanism comprises a molten pool camera and a line laser scanning camera which are fixedly arranged at the tail end of the welding robot;
the intelligent welding control mechanism comprises an image processing unit electrically connected with the molten pool camera and the line laser scanning camera, a welding control unit electrically connected with the welding robot, the wire feeder, the welding machine and the position changing machine, and a man-machine interaction unit.
Compared with the prior art, the invention has the beneficial effects that:
the invention improves the automation level and the production efficiency of the welding process of the roller sleeve and improves the working environment of operators. The welding robot is matched with the position changing machine to realize automatic welding of the large-scale rotary welding piece, replaces the original manual welding and semiautomatic welding, greatly improves the automation level of production and improves the production efficiency. The working environment of operators is improved, so that the operators are separated from the working environment with high smoke, arc light and noise during field welding, and the labor intensity and the workload of the operators are reduced.
The invention adopts the machine to automatically weld, reduces the quality problem caused by human factors, adopts a molten pool camera to monitor the weld bead width and residual height change in the welding process, establishes a weld bead morphology parameter control model, and adopts a negative feedback control strategy of multi-process parameter coordination control, so that the weld bead morphology can be always kept within a set value range. In the adjustment process, technological parameters such as welding machine current, welding voltage, wire feeding speed and the like can be continuously and rapidly adjusted according to a control model, so that fine control which cannot be operated during manual and semi-automatic welding is realized, and high controllability and high consistency of the appearance of a welding bead are ensured. After each welding pass is finished, a line laser scanning camera is used for detecting the three-dimensional shape of the welding layer, so that operators are timely reminded of repairing possible defects on the roller surface, the defects are prevented from being buried when the next welding layer is directly welded, hidden danger of causing welding quality defects is eliminated, and the quality of the welding process is controllable. The scanning result can accurately display the area, depth and coordinates of the defects in a coordinate system, provides visual reference for operators, and even provides possibility for automatically repairing the defects on the welding layer of the welding robot in the future.
Is convenient for quality tracing and improving process. And in the welding process, the welding process parameters and the shape parameters of the welding bead are fully automatically recorded, so that the tracking of the welding process and the traceability of the welding quality are facilitated. In the welding process, the welding process parameter data is out of limit and can be warned, so that the reliability is high. After accumulating a large amount of production data, mass data mining can be performed, a high-quality welding process is reproduced, the process level is continuously improved, and the welding quality is improved.
Drawings
FIG. 1 is a schematic diagram of the structure of the present invention;
FIG. 2 is a flow chart of a weld overlay control method in an embodiment of the invention;
FIG. 3 is a graph showing the relationship between the adjustment direction of the welding process parameter and the change direction of the shape parameter of the welding bead in the invention;
in the figure: 1-welding robot, 2-welder, 3-molten pool camera, 4-line laser scanning camera, 5-positioner, 6-wire feeder, 7-welder, 8-image processing unit, 9-welding control unit, 10-man-machine interaction unit, 11-roller sleeve.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the present invention, it should be noted that, directions or positional relationships indicated by terms such as "upper", "lower", "left", "right", "inner", "outer", etc., are directions or positional relationships based on those shown in the drawings, or those that are conventionally put in use of the inventive product, are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the apparatus or elements referred to must have a specific direction, be configured and operated in a specific direction, and thus should not be construed as limiting the present invention.
In the description of the present invention, it should also be noted that, unless explicitly specified and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; the device can be mechanically connected or in communication; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
Referring to fig. 1-3, in an embodiment of the present invention, an automatic overlay welding apparatus is provided. Including welding actuating mechanism, visual identification mechanism and welding intelligent control mechanism, wherein, welding actuating mechanism includes:
the welding robot 1, preferably a six-axis industrial mechanical arm, supports off-line programming and on-line programming, and can receive external control instructions in a communication manner to act in the welding process;
and a welding gun 2 fixed at the tail end of the sixth shaft of the welding robot 1, wherein when the MIG welding process is adopted, the welding wire passes through the middle of the welding gun, and the welding gun plays a role of clamping and fixing the welding wire.
The wire feeder 6 is fixedly arranged on the body of the welding robot 1, and the welding wire passes through the wire feeder, so that the welding wire can continuously and stably move forwards until reaching the mouth of the welding gun 2 during welding, and continuous arc breaking and arc extinguishing are ensured. An external signal can be received to control the wire feeding speed;
and a welder 7 for controlling the arc striking and extinguishing of the welding wire, maintaining the current during welding. The external signal can be received to control the current and voltage in the welding process;
and the positioner 5 is used for positioning, clamping and supporting the roller sleeve 11 to be welded and driving the roller sleeve 11 to rotate at a set angular speed. The encoder is arranged on the rotary shaft, so that the angular speed and the angular displacement of the rotary shaft can be detected. External rotational speed and position control signals may be received.
The visual recognition mechanism is used for detecting and feeding back the roller surface state in the welding process, and specifically comprises the following steps:
a line laser scanning camera 4 is mounted on the end of the welding robot 1 via a camera mount. The line laser scanning camera adopts the principle of triangular ranging, and the pixel gray information of the shot picture stores the morphology of the shot object. The starting of the line laser scanning camera can be triggered by an external signal, and the shooting result supports the transmission of an electric signal to the outside;
the molten pool camera 3 is also installed at the end of the welding robot 1 through a camera bracket, and is used for shooting the shape of a molten pool at a welding position in real time during welding. The molten pool camera matched software is provided with a molten pool appearance detection model, can predict and output molten pool appearance parameters such as the molten width, the residual height, the welding wire dry extension and the like of a welding bead after molten pool condensation at a shooting position according to the molten pool appearance of the current real-time shooting position, has the detection precision of 0.1mm, and supports communication output of detection results.
The welding execution mechanism is used for controlling the welding execution system to act according to the set track and dynamically adjusting the action of the welding execution system according to the detection result of the visual recognition system, and specifically comprises the following steps:
and the image processing unit 8 is electrically connected with the line laser scanning camera 4 and the bath camera 3, and is used for receiving and processing the image and video information and sending a starting instruction to the line laser scanning camera 4 and the bath camera 3. The device is electrically connected with the welding control unit 9, can send the processing results of images and videos to the welding control unit 9 and receive the control instruction of the welding control unit 9;
a welding control unit 9 electrically connected to the welding robot 1, the wire feeder 6, the welder 7, and the positioner 5, and configured to control these devices to perform various operations and receive feedback signals thereof; the device is electrically connected with the image processing unit 8, receives the image and video processing results and sends a starting instruction to the image processing unit 8; the system is electrically connected with the man-machine interaction unit 10, receives control instructions and parameters input by external workers, and feeds back the state parameters of the current system to the man-machine interaction unit;
the man-machine interaction unit 10, the medium for the interaction between the operator and the system can be a touch screen or a computer, and the man-machine interaction unit can be arranged at a local or remote end and electrically connected with the welding control unit 9 to exchange information with each other.
An automatic build-up welding control method comprises the following steps:
s1, establishing a corresponding rule table of welding process parameters and weld bead morphology relation parameters, and determining a quantitative relation between the welding process parameters and the weld bead morphology relation parameters, wherein the welding process parameters comprise welding gun swing amplitudeWire feed speed->Welding current->Welding voltage->The method comprises the steps of carrying out a first treatment on the surface of the The bead morphology parameters include bead width +.>Weld bead excess->. The quantitative relation between the welding process parameters and the appearance of the welding bead can be determined through experiments, and the brand of the welding wire is controlled to be consistent with the actual welding. Setting the swing of the welding gun 2 from small to large during welding>And sequentially compriseThe adjustment interval is +.>. Controlling the wire feed speed setting from small to large +.>And sequentially comprises->The adjustment interval is +.>. Welding current->Welding voltage->According to the empirical formula->Follow wire feed speed->And (3) a change. Wherein the method comprises the steps ofIIn units of amperes of (a),Vin units of centimeters per minute,Uin volts. Then in experiments, a group of +.>A group of corresponding bead shapes can be obtained>According to the adjustment interval->And->Multiple sets of experiments were performed to obtain multiple sets of data, and a rule table as shown in table 1 was obtained.
As shown in fig. 3, the adjustment direction of the welding process parameter corresponds to the change direction of the bead morphology parameter. Assume that the current welding process parameters areIf the current welding bead width is +>Lower and weld bead remaining height +>Normally, the welding width should be increased (direction +.>∈) is adjusted according to fig. 3, the gun swing is increased +.>Increase wire feed speed +.>Welding current->And welding voltage->And synchronously adjusting along with an empirical formula. The quantitative influence of the amplitude of the adjustment process parameters on the change amplitude of the weld bead morphology is known by combining the table 1, namely, a weld bead morphology parameter control model is established.
The "rule table corresponding to the relation between the technological parameters and the appearance of the weld bead" and the "relation between the adjustment direction of the technological parameters and the change direction of the appearance parameters of the weld bead" are converted into rules and stored in the welding control unit 9, so that the appearance of the weld bead is changed, and the coordinated control of a plurality of technological parameters of the weld bead is realized.
TABLE 1
S2, establishing a coordinate system, planning a welding track, and presetting welding parameters, wherein the method specifically comprises the following steps:
establishing a coordinate system: the coordinate system of the roller sleeve is required to be established before weldingRobot coordinate System->The conversion relation between the two is defined. As shown in FIG. 1, coordinate system +.>And->Are right-hand rectangular coordinate systems, +.>The axis is the axial direction of the roll mantle 11, +.>The axis is in the horizontal plane and->The direction perpendicular to the axis, ">The axis is vertical to the vertical horizontal plane, wherein the coordinate system +.>The center of the end face of the roller sleeve 11 is used as an origin, and is called a workpiece coordinate system. Coordinate system->The origin is placed in the center of rotation of the 1 st axis of the welding robot 1, called the robot coordinate system +.>. The point on the sleeve 11 can be represented by a rotation matrix +.>And translation matrix->Conversion to the robot coordinate system, i.e. +.>. Rotation matrix->And translation matrix->The acquisition method of (1): in the object coordinate system->4 points with known coordinates are marked down, the welding wire vertexes at the sixth shaft end of the mobile welding robot touch the 4 points just respectively, and the 4 points are recorded to be>The coordinates below, namely the same 4 points are respectively in the object coordinate system +.>And robot coordinate systemThe two sets of coordinates below. According to the two sets of coordinates, a SVD singular value decomposition algorithm is utilized to obtain a rotation matrix when two coordinate systems are converted>And translation matrix->。
Planning a welding track: the positioner 5 rotates at a set constant rotation speed, and the welding robot 1 moves to a welding position of a first welding bead above the roller sleeve 11 to drive the welding gun 2 to do reciprocating swing welding motion at the point. When the positioner 5 rotates to the 0 position of the encoder, the welding control unit 9 controls the wire feeder 6 to start wire feeding, and the welding machine 7 starts arc starting to start welding. After one revolution of the positioner 5, the melted welding wire forms a bead on the sleeve 11. At this time, the welding robot 1 immediately moves toCoordinate system +.>Axis negative direction translation distance +.>And then the welding is carried out for the next welding bead after the welding is kept fixed. Assume that the axial length of the roll mantle 11 is +.>The welding robot 1 moves +.>And after the second time, the welding of all the welding beads of the single layer is completed. Before starting the welding task of the next welding layer, the rotation speed of the position changer 5 needs to be adjusted. Assume that the diameter of the roll mantle 11 before welding is +.>The diameter of the sleeve 11 after welding is +.>The rotation speed of the pre-welding positioner 5 is +.>The rotation speed of the position changer is adjusted to be +>Therefore, when the roller sleeve 11 is used for welding different welding layers, the relative speed between the roller sleeve 11 and the welding gun 2 is constant, namely the welding speed is controlled to be unchanged. Assume that the thickness of a certain solder layer is +.>The residual height of a single welding bead is +.>The build-up layer is then welded>And (5) welding layers. After the welding task of the surfacing layer is completed, the welding wire with the brand corresponding to the next surfacing layer is replaced, and the welding of the next surfacing layer is started until the welding of all surfacing layers is completed. The operation control programs of the welding robot 1 and the positioner 5 are stored in the welding control unit 9.
The operator inputs welding parameters through the man-machine interaction unit 10 and stores the welding parameters in the welding control unit 9. The welding preset parameters are specifically preset welding technological parameters and welding morphology parameter standard values, and allowable deviation ranges, and comprise: the welding layer number, the welding rod brand, the welding speed, the welding bead melting width, the welding bead residual height, the welding bead melting width deviation allowable value, the welding bead residual height deviation allowable value and the roller sleeve surface 'true defect' area threshold value.
S3, starting welding through the man-machine interaction unit 10, and sending a control instruction to the welding robot 1 and the positioner 5 by the welding control unit 9 so that the welding robot 1 and the positioner 5 start moving along a welding track preset in the step S2.
The welding control unit 9 controls the welding process according to the welding bead width preset in the step S2Welding and solderingExcess of (I)>Automatically searching an internally stored 'technological parameter and weld bead morphology relation corresponding rule table' (namely table 1), and searching a corresponding welding technological parameter setAnd controls the welding robot 1 so that the welding gun swing is +.>The wire feeding speed of the wire feeder 6 is controlled to be +.>The welding current of the welder 7 is +.>The welding voltage of the welder 7 is +.>。
Further, step S3 further includes real-time compensation of the welding bead width and the welding bead residual height, which may cause the welding bead width, residual height and the like to deviate from the set values when various working conditions such as welding wire quality non-uniformity, welding speed deviation, actuator movement error and the like occur. The invention can detect the deviation degree of the appearance parameters of the welding bead in real time, compensates the welding channel width and the residual height in real time, realizes the negative feedback control of the appearance of the welding bead, and comprises the following specific steps:
(1) The puddle camera 3 monitors the puddle of the current weld bead in real time and transmits the puddle to the image processing unit 8. The image processing unit 8 calculates the width of the current weld bead in real time according to the molten pool image detection algorithmResidual height->Output to the welding control unit 9;
(2) The welding control unit 9 calculates the appearance of the current weld bead output by the molten pool cameraDeviation of parameters from set standard valuesIf the deviation exceeds the welding bead fusion width deviation allowable value or the welding bead residual height deviation allowable value set in the step S2, starting a deviation correcting program;
(3) The welding control unit 9 is dependent on the current、/>The deviation direction, according to the stored rule (as figure 3) of the relation between the welding process parameter adjustment direction and the welding bead morphology parameter change direction, determining the current welding process parameter +.>Is used for adjusting the direction;
(4) The welding control unit 9 uses the current welding process parameters according to the corresponding rule table of the process parameters and the morphology relation of the welding bead、/>For the adjusted starting point, the welding process parameters determined in accordance with the previous step are +.>、/>Is adjusted to>And->For the search interval, find the off-bead topography parameter +.>The nearest point, recordThe welding process parameters set at the following time>；
(5) The welding control unit 9 controls the welding robot 1 so that the welding gun swing becomesThe wire feeding speed of the wire feeder 6 is controlled to be +.>The welding current of the welder 7 is controlled to be +.>The welding voltage of the welder 7 is controlled to be +.>And continuing to weld the current welding layer according to the preset welding track until the welding is completed.
And S4, scanning and establishing a three-dimensional model of the current welding layer, detecting welding defects and carrying out repair early warning.
After the welding bead of the current layer is finished, in order to avoid 'masking' the welding bead defect of the current welding layer when the next layer is welded, the quality hidden trouble is caused, and the defect and repair of the current finished welding layer are required to be detected and repaired immediately. The detection and repair process is as follows:
(1) The number of pictures to be taken by the line laser scanning camera 4 and the taking position are calculated. The line laser scanning camera 4 is made to shoot against the axle center of the roller sleeve 11, and the distance from the axle center isThe first and last time line laser edges are shot just at the axial edge of the roll sleeve 11. Assume that the axial length of the roll mantle 11 is +.>The axial length of the single picture covering roller sleeve 11 taken by the line laser scanning camera 4 is +.>Then a total of +.>And (5) a picture. The welding robot 1 drives the line laser scanning camera 4 to move axially along the roller sleeve 11 from the first shooting position>Once, the distance interval remains equal each time a position is moved, taking a picture. The photographed +.>The pictures can cover the complete roller surface, and two adjacent photographed pictures are partially overlapped along the axial direction of the roller sleeve 11;
(2) And shooting single pictures one by one according to the set positions. After the welding control unit 9 controls the welding robot 1 to drive the line laser scanning camera 4 to reach a certain set shooting position, when the welding control unit 9 monitors that the rotating shaft of the positioner 5 rotates to the point of the encoder 0, a shooting instruction is sent to the image processing unit 8. The image processing unit 8 triggers the line laser scanning camera 4 to start photographing. Let the shooting frame rate of the line laser scanning camera 4 beThe rotation period of the roll mantle 11 is +.>The number of frames per picture taken by the line laser scanning camera 4 is +.>I.e. the pixel height of each picture is +.>. Let the circumference of the photographed roll cover 11 end face circle be +.>The pixel height resolution of each picture is +.>. The pixel width of each picture is fixed, assuming +.>Because the axial length of the covered sleeve 11 is +.>Therefore, the resolution in the pixel width direction of each picture is +.>。
(3) Cutting and splicing pictures to form a roll surface large picture. The image processing unit 8 is used for processing the axial length of the roller sleeve 11 covered by each pictureNumber of pictures photographed->Axial length of the sleeve 11>The overlapping length of two adjacent shooting pictures along the axial direction can be calculated to be +.>Dividing the resolution of the pixel width of each picture by the pixel width of the overlapping portion is +.>. Each picture cuts out the overlapping part +.>After the pixel widths, the pixels are aligned and spliced together in the height direction to form a complete roll surface large graph, and the complete roll sleeve 11 is covered by the roll surface large graph. The gray value of each pixel point of the large roller surface graph corresponds to the depth information of the corresponding point of the roller sleeve 11, namely: distance between roller sleeve axes during camera shootingdGray value of a pixel point on the large graph of the roll surface = roll sleeve radius of the corresponding position of the a pixel point on the roll sleeve 11.
（4) The image processing unit 8 extracts a defect in the roll surface map and converts the defect position coordinates to a robot coordinate system. The defect detection and extraction process is as follows: theoretical radius of each point on the current roll sleeve 11Original radius of welding parent metalSingle-layer weld bead residual height standard value ∈>Number of welded layers->Allowable value of weld bead residual height deviation; and setting the attribute characteristic values of all pixel points in the roll surface large graph to 0. Detecting the roller surface large map one by one>If the radius of the roller sleeve corresponding to each pixel point is equal to the theoretical radius, setting the attribute characteristic value of the pixel to be 1; detecting whether the pixel points with the attribute value of 1 are communicated, namely if the pixel points with the attribute value of 1 exist in the 8 adjacent areas of one pixel point, adding the pixel points into the same data set if the two pixel points are considered to be communicated>Is a kind of medium. Repeating the above process until all the pixel points are detected, and obtaining a plurality of data sets which are not communicated with each other and correspond to independent defects on the roller sleeve 11; each data set +.>The number of pixels in the pixel is counted, the number of pixels is +.>Pixel high resolution->Pixel width resolution->Defective area. Judging by using the threshold value of the area of the true defect of the roller sleeve surface set in the step S2, if the data set is +.>If the area of the defect is larger than the preset defect area threshold value, the defect is marked as a true defect, otherwise, the defect is regarded as a false defect; setting' true defect>The pixel coordinate of a certain pixel point in the roll surface large graph isThe gray value is +.>It is transformed into the cylindrical coordinate system of the roll mantle 11 +.>The transformation relation of (2) isThe method comprises the steps of carrying out a first treatment on the surface of the Wherein: />Expressed in a cylindrical coordinate system->Under the heading, < "> the distance of a certain pixel point of" true defect "A from the origin, <" > the pixel point of "true defect" A>A pixel point representing a "true defect" A is +.>Is->Rotation angle of shaft>A pixel point representing a "true defect" A is in the cylindrical coordinate system +.>Is->Projection length of axis>Representing the total number of pixel rows of the roll surface map. Similarly, the rotation matrix described in step S2 can be used>And translation matrix->Transforming the pixel coordinates of the "true defect" to the robot coordinate system +.>Lower, i.e.)>. After the above operation is completed, the "true defect" coordinates and depth information are transmitted to the welding control unit 9 for saving.
(5) Displaying and repairing the true defect. The welding control unit transmits the coordinates and depth information of the "true defect" calculated in step (4) to the man-machine interaction unit 10. The man-machine interaction unit 10 renders the image and displays the image in a roller sleeve coordinate systemOr robot coordinate system->Is a kind of medium. The man-machine interaction unit 10 gives an early warning to the operator, and reminds the operator to repair the found defects in time. After the repair of the operator is completed, clicking the repair completion confirming button in the man-machine interaction unit 10 to mark that the welding pass of the layer is repaired, and welding the next welding layer can be performedA task;
s5, repeatedly executing the steps S3-S4, and continuing to weld the weld beads layer by layer until all the surfacing layers (the bottoming layer, the transition layer and the wear-resistant layer) are welded. In the welding process, a welding control unit automatically and periodically records welding technological parameters and welding morphology parameters such as welding voltage, current, welding speed, positioner rotation angle, wire feeding speed and the like according to set time intervals, displays the welding technological parameters and the welding morphology parameters to a man-machine interaction unit in real time, and gives an alarm for overrun values.
Although the present disclosure describes embodiments, not every embodiment is described in terms of a single embodiment, and such description is for clarity only, and one skilled in the art will recognize that the embodiments described in the disclosure as a whole may be combined appropriately to form other embodiments that will be apparent to those skilled in the art.
Therefore, the above description is only of the preferred embodiments of the present application and is not intended to limit the scope of the present application; all changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims (8)
1. The control method of the automatic build-up welding is characterized by comprising the following steps:
s1, establishing a corresponding rule table of welding process parameters and weld bead morphology relation parameters, wherein the welding process parameters comprise: swing of a welding gun, wire feeding speed, welding current and welding voltage; the welding bead morphology parameters comprise welding bead melting width and welding bead residual height;
s2, planning a welding track: the roller sleeve rotates at a constant speed, and the welding gun performs reciprocating swing welding motion at the starting point; when the roller sleeve rotates at a constant speed for one circle, completing one circle of welding bead welding, the welding gun immediately axially translates a standard welding bead width distance to the roller sleeve, and starting the next welding path welding until the welding of all welding beads of the current welding layer is completed; after the welding of the current welding layer is completed, the welding gun moves to the initial welding position of the next welding layer, and the welding task of the next welding layer is executed;
the preset working parameters comprise: welding layer number and welding rodStandard value of brand, welding speed and welding bead widthA welding bead fusion width deviation allowable value and a welding bead residual height standard value +.>A weld bead residual height deviation allowable value and a roller sleeve surface 'true defect' area threshold value;
s3, starting a welding task of a current layer: the roller sleeve and the welding gun are controlled to act according to the welding track set in the step S2, and the standard value of the welding width of the preset welding bead is adoptedStandard value of weld bead residual height->Searching a rule table, and searching and setting current welding process parameters;
step S3 also comprises real-time compensation of weld bead fusion width and weld bead residual height, and specifically comprises the following steps:
monitoring a current welding bead molten pool in real time through a molten pool camera, and calculating the current welding bead molten width in real time according to a molten pool image detection algorithmThe residual height of the current welding bead +.>Obtaining the deviation of the morphological parameters->,/>Represents the current welding bead width value +.>And welding bead fusion width standard value->Difference of->Representing the residual value of the current weld bead +.>Standard value for residual height of welding beadIs a difference in (2);
if it isNot more than the allowable value of weld bead width deviation, and +.>If the deviation is not larger than the allowable value of the residual height deviation of the welding bead, continuing to execute the welding process with the established welding process parameters, otherwise, starting a deviation correcting program, readjusting the welding process parameters and continuing to weld until the current layer of welding is completed;
s4, shooting a current welding layer through a line laser scanning camera, and executing defect detection, wherein the method specifically comprises the following steps of:
if the defect does not exist, the next welding layer welding task is directly executed;
if the defects exist, a defect early warning is sent out, and after the repair is completed, a next welding layer welding task is carried out;
s5, repeatedly executing the steps S3-S4 until all welding layers are welded.
2. The control method according to claim 1, wherein the rule table creation process includes:
the welding wire mark and the welding speed are consistent with those of actual welding; from small to largeSwing of each welding gun>The interval between adjacent welding gun swing ranges is +.>The method comprises the steps of carrying out a first treatment on the surface of the Setting from small to large->Individual wire feed speed->The interval between adjacent wire feeding speeds is +.>The method comprises the steps of carrying out a first treatment on the surface of the Let welding current->Welding voltage->According to the empirical formula->Follow wire feed speed->A change; wherein->In amperes, ">In cm/min,/d->In volts; every time a set of welding process parameters is changedObtaining a group of corresponding bead shapes +.>And obtaining a plurality of groups of data through multiple experiments, and obtaining the rule table.
3. The control method according to claim 2, wherein the deviation correcting program specifically includes:
establishing the adjustment direction of welding process parametersAnd->Is a relationship rule; according to the current->And->Determining the adjustment direction of welding process parameters; in the rule table, the current welding process parameters are +.>、/>For the starting point, with the determined welding process parameters +.>、/>Is adjusted to>And->For the search interval, find the off-bead topography parameter +.>The nearest point is recorded the welding process parameter set +.>The method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>Represents->And->Difference of->Represents->And->Is a difference in (2);
adjusting the swing of the welding gun to beWire feed speed is +.>Welding current is +.>Welding voltage is +.>And continuing welding according to the preset welding track.
4. A control method according to claim 3, wherein the welding process parameter adjusting methodDirection and directionAnd->The relationship rules of (a) are:
if it is＞0、/>=0, then the gun swing and wire feed speed are reduced simultaneously;
if it is＜0、/>=0, then increase the gun swing and wire feed speed simultaneously;
if it is=0、/>Increasing the swing of the welding gun and reducing the wire feeding speed if the swing is more than 0;
if it is=0、/>Reducing the swing of the welding gun and increasing the wire feeding speed if the swing is less than 0;
if it is＜0、/>< 0, thenMaintaining the swing of an original welding gun and increasing the wire feeding speed;
if it is＞0、/>If more than 0, the swing of the original welding gun is kept, and the wire feeding speed is reduced;
if it is＞0、/>Reducing the swing of the welding gun and keeping the original wire feeding speed;
if it is＜0、/>And if the welding gun swing is larger than 0, the original wire feeding speed is kept.
5. The control method according to claim 1, wherein in step S4, performing the defect detection process specifically includes:
s41, continuously rotating the roller sleeve at a constant speed, and moving the line laser scanning camera at intervals along the axial direction of the roller sleeve, wherein each time a picture is shot, so that all shot pictures cover the complete roller surface;
s42, cutting and splicing all pictures to form a roll surface large picture;
s43, detecting and extracting position and depth information of a defect in the roll surface large map, and converting the position of the defect into a welding robot coordinate system;
s44, displaying and reminding of repairing the defect.
6. The control method according to claim 5, wherein in step S43, the depth signalThe information is the roller sleeve radius corresponding to the gray value of each pixel point in the large roller surface graph, and the roller sleeve radiusDistance between line laser scanning camera and axis of roller sleeve during shooting>Gray values of corresponding pixel points on the large graph of the roller sleeve.
7. The control method according to claim 5, wherein in step S43, the process of detecting and extracting the defect specifically includes:
setting the attribute characteristic values of all pixel points in the roll surface large graph to be 0, and according to the theoretical radius of each point on the roll sleeveOriginal radius ∈of welding>Single-layer weld bead residual height standard value ∈>Number of welded layers->Detecting whether the gray value of each pixel point in the roll surface large graph is equal to the theoretical radius one by one according to the allowable value of the residual height deviation of the welding bead, and if not, setting the attribute characteristic value of the pixel to be 1; detecting whether pixel points with the attribute value of 1 are communicated, and if so, adding the pixel points into the same data set; repeating the above process until all pixel points are detected, obtaining a plurality of data sets which are not communicated with each other, and calculating the defect area corresponding to the number of pixels in each data set; if the defect area of the data set is larger than the preset area threshold value of the true defect of the surface of the roller sleeve, the data set is marked as the true defect, otherwise, the data set is marked as the false defect; let the pixel coordinate of a pixel point of the 'true defect' A in the roll surface large diagram be +.>The gray value is +.>According to->Transforming it into the cylindrical coordinate system of the roll mantle>In (1) according to the rotation matrix->And translation matrix->Transforming the pixel coordinates of the "true defect" to the welding robot coordinate system +.>Down, i.eThe method comprises the steps of carrying out a first treatment on the surface of the Wherein: />Expressed in a cylindrical coordinate system->Under the heading, < "> the distance of a certain pixel point of" true defect "A from the origin, <" > the pixel point of "true defect" A>A pixel point representing a "true defect" A is +.>Is->Rotation angle of shaft>A pixel point representing a "true defect" A is in the cylindrical coordinate system +.>Is->Projection length of axis>Representing the total number of pixel rows of the roll surface map.
8. The automatic welding apparatus used in the control method according to any one of claims 1 to 7, comprising a welding actuator, a visual recognition mechanism, and a welding intelligent control mechanism, wherein:
the welding executing mechanism comprises a welding robot and a welding gun fixedly arranged at the tail end of the welding robot; the welding machine comprises a welding gun nozzle, a welding machine, a wire feeder and a speed sensor, wherein the welding machine is used for providing stable current;
the visual recognition mechanism comprises a molten pool camera and a line laser scanning camera which are fixedly arranged at the tail end of the welding robot;
the intelligent welding control mechanism comprises an image processing unit electrically connected with the molten pool camera and the line laser scanning camera, a welding control unit electrically connected with the welding robot, the wire feeder, the welding machine and the position changing machine, and a man-machine interaction unit.
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