CN117644267A - Method and system for detecting quality of resistance welding spot based on acoustic emission sensor - Google Patents
Method and system for detecting quality of resistance welding spot based on acoustic emission sensor Download PDFInfo
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- CN117644267A CN117644267A CN202311546135.3A CN202311546135A CN117644267A CN 117644267 A CN117644267 A CN 117644267A CN 202311546135 A CN202311546135 A CN 202311546135A CN 117644267 A CN117644267 A CN 117644267A
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- 238000001514 detection method Methods 0.000 claims description 25
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- 238000004458 analytical method Methods 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 4
- 230000007547 defect Effects 0.000 claims description 4
- 239000000284 extract Substances 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000007711 solidification Methods 0.000 claims description 2
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- 238000012545 processing Methods 0.000 description 10
- 238000010586 diagram Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 230000001066 destructive effect Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 238000011897 real-time detection Methods 0.000 description 3
- 239000000956 alloy Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000010801 machine learning Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000003062 neural network model Methods 0.000 description 1
- 238000009659 non-destructive testing Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001902 propagating effect Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000026676 system process Effects 0.000 description 1
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/14—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object using acoustic emission techniques
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/46—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by spectral analysis, e.g. Fourier analysis or wavelet analysis
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/267—Welds
- G01N2291/2672—Spot welding
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- Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)
Abstract
A method for detecting quality of welding spots of resistance welding based on acoustic emission sensors includes arranging acoustic emission sensors around top of end face of electrode cap on static arm side of resistance welding equidistantly, collecting acoustic signals in real time during welding, collecting sensor signals and marking after welding, comparing data of obtained signals in same time domain, extracting common frequency spectrum information, and establishing association relation of frequency spectrum information on quality of welding spots based on frequency spectrum analysis. The invention can accurately and effectively reflect the welding quality.
Description
Technical Field
The invention relates to the field of nondestructive detection of resistance welding quality, in particular to a method and a system for detecting welding quality by arranging a plurality of acoustic sensors on a resistance welding device at equal intervals by taking the center top of the end face of a static arm side electrode cap of the resistance welding as the center.
Background
Resistance welding is a method of welding by locally heating a weldment and pressurizing the weldment while using resistance heat generated by passing an electric current through the weldment and a contact portion as a heat source. The method has the advantages of no need of filling metal, high productivity, small deformation of weldment, simple operation and the like, can greatly improve the production efficiency of the manufacturing process and reduce the cost especially in the field of intelligent automobile manufacturing.
In the automobile manufacturing process, the number of welding spots of a single automobile body is thousands, so that the improvement of nondestructive testing accuracy on the quality of the welding spots is very important. At present, the existing quality detection method of the welding spots of the resistance welding mainly comprises destructive detection and nondestructive detection, wherein the destructive detection is used for measuring the diameter of a nugget after the resistance welding in a tearing mode to detect the welding quality, and the method is used for sampling detection, so that all the welding spots cannot be detected, potential safety hazards exist in a welding part, and real-time detection cannot be performed. The nondestructive detection method is mostly indirect detection, and the welding quality is predicted by collecting signals such as pressure, resistance, displacement, temperature and the like and establishing a model, but the accuracy is low and the welding quality is easy to interfere. The detection modes such as ultrasonic wave are high in cost, and real-time detection cannot be realized, so that the generation efficiency is reduced.
In order to solve the problems, the method is a feasible method for acquiring acoustic emission signals in the welding process through the sensors, the method does not need to extract weldments to carry out destructive tests, only a plurality of acoustic sensors are required to be installed to acquire acoustic data, noise is removed through filtering, and experimental data is subjected to machine learning to establish a neural network model so as to judge the welding quality. The existing acoustic emission detection schemes are mostly fixed acoustic sensors, namely acoustic signals are received at fixed positions, the acoustic signals are easy to be interfered by external noise, and the welding process is difficult to accurately detect due to distance limitation. The existing acoustic emission detection technology mainly comprises the steps that when different welding quality differences are generated, stress waves are generated and then released by acoustic waves due to plastic deformation of welding spots in the spot welding process and defects such as cracks in the second welding half process, and the association between acoustic signals and welding quality is established by collecting acoustic signals. However, in the actual welding process, complicated environmental factors are often involved, and when the acoustic sensor is singly arranged at a certain position, noise is also mixed in the acquired acoustic signal, so that the accuracy of the result is greatly affected. Therefore, the art lacks a detection device and a detection method based on acoustic signals, which can accurately and effectively feed back welding quality.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a device for detecting welding quality by arranging a plurality of acoustic sensors on a resistance welding device with a welding spot as a center at equal distance and a method for detecting the welding spot quality by adopting the device.
The technical scheme of the invention is as follows:
the method for detecting the quality of the resistance welding spot based on the acoustic emission sensor is characterized by comprising the following steps of:
step one: providing a welding device for resistance spot welding and a set of acoustic emission sensing acquisition system; the acoustic emission sensing acquisition system comprises at least 2 acoustic sensors, wherein the acoustic sensors are fixed on the welding device, and the distance between each acoustic sensor and the end face of the electrode cap is the same;
step two: providing a resistance spot welding workpiece, welding by using the resistance spot welding device, and collecting an acoustic signal in the welding process;
step three: collecting acoustic signals collected by each acoustic sensor, wherein the acoustic signals are respectively marked as N1, N2, … … and Nn, and N is the number of the acoustic sensors;
step four: performing data comparison on the acoustic signals N1, N2 … … Nn in the same time domain and extracting common frequency spectrum information Nx;
step five: establishing the association relation between the spectrum information Nx and the quality of the welding spot comprises the following steps:
step 5.1, establishing a one-to-one correspondence between the spectrum information Nx and the welding time t in the welding process;
step 5.2, defining that the welding time t comprises a welding spot growing stage and a solidification cooling stage, and defining that the energy reaching peak value of a single time period in the frequency spectrum information Nx is the moment when the nugget reaches the peak value; the event of an abrupt energy change in the cooling phase after the energy peak is defined as a spot of weld that produces a weld defect
And 5.3, establishing a one-to-one correspondence between the frequency spectrum information Nx and the melting area s, and establishing a relationship between Q and d based on a mathematical statistics method by taking the total energy output of sound waves in the whole welding time period as Q and the size of a welded core detected after welding as d.
A resistance weld quality detection system based on acoustic emission sensors, the system comprising:
the welding device for resistance spot welding, an acoustic signal acquisition system composed of at least 2 acoustic emission sensors and software for connecting the resistance spot welding device with the acoustic signal acquisition system. The acoustic emission sensors are equidistantly arranged on the welding device by taking the center of the end face of the welding electrode cap on any welding electrode arm of the resistance welding as the center of a circle; the software comprises a noise filtering system and an analysis system, the noise filtering system can extract and collect the sound signal information collected by the plurality of acoustic sensors based on common information in the same time domain, and the sound signal information is used as input information to be input to the analysis system, and the analysis system establishes the association between the sound signal information and the quality of welding spots according to the input information.
Compared with the prior art, the invention has the following technical effects:
1. the invention can effectively prevent interference caused by external sound waves in the welding process, simplify the filtering process and improve the detection accuracy.
2. The sensor is low in price without destructive detection, and the detection cost is greatly reduced.
3. The space occupancy rate of the welding area is reduced, the mechanical arm does not need to increase path planning so as to avoid collision with the sensing device, and the welding efficiency is improved.
4. The sensor has the advantages of simple structure, no limitation of external conditions in installation, debugging, experiments and the like, and flexible adjustment of the number, sensitivity and the like of the sensors.
5. Real-time detection, no need of post-welding measurement, high automation degree and further realization of intelligent manufacturing.
Drawings
FIG. 1 is a schematic view of a prior art electric resistance welding apparatus;
FIG. 2 is a state diagram of the use of the acoustic emission sensor based resistance weld quality detection system of the present invention;
FIG. 3 is a schematic diagram of a system for detecting quality of a resistance welding spot based on an acoustic emission sensor according to an embodiment of the present invention;
fig. 4 is a welding quality inspection method.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the invention. 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.
Referring first to fig. 1, fig. 1 shows a resistance welding apparatus without acoustic sensor, which is composed of the welding bodies 61, 62, the upper and lower electrodes 31, 32 and the welding members 21, 22.
FIG. 2 is a diagram showing the state of the system for detecting the quality of a welding spot of a resistance welding based on an acoustic emission sensor, wherein a signal receiver, a signal processor and a display form a signal processing system as shown in the diagram, the sensor transmits data to the signal processing system in real time in the welding process, and the signal processing system processes acoustic signals and outputs waveforms and welding quality detection results.
FIG. 3 is a schematic diagram of a system for detecting quality of a resistance welding spot based on an acoustic emission sensor according to an embodiment of the present invention; as shown, the present embodiment employs six acoustic sensors 81, 82, 83, 84, 85, 86 disposed on the welding apparatus body 61, 62, typically mechanically secured; the welding device bodies 61, 62 are two opposite electrode arms of a resistance spot welding device; and the distance between the acoustic sensor and the welding point is L, and the equidistant distance L can be set according to the actual conditions such as the size of a welding machine and the like, and is generally not less than 50mm. The detection frequency range of the acoustic sensor is 200-2MHz, the more acoustic sensors are used, the more accurate the processed data are theoretically, and the specific quantity can be adjusted according to practical conditions. The welding device bodies 61, 62 may be fixed spot welders for welding or a welding gun driven by a robot such as used in an automobile factory; in general, the welding gun is composed of symmetrical welding gun arms, the welding gun arms are provided with a pair of welding electrode caps, when welding is performed, welding spots are formed by resistance heat melting of base metal between upper and lower electrodes in the welding process, and the welding quality can be judged according to the diameter of a nugget.
During welding, the welding machine can move in the working space according to the requirement, the positions of the weldments 21 and 22 and the welding spots are not fixed, and the distances between the plurality of acoustic sensors and the welding spots are always constant and equal. After the welding of a single welding point is finished, the sound wave signals received by each acoustic sensor comprise welding signals and noise, and the received real welding signals are basically consistent and the noise is different because the acoustic sensors are close to the welding point and are always equidistant, so that the difficulty of the filtering process and the data processing is reduced, and the accuracy of the data can be effectively improved. The weldment materials include aluminum and its alloys or steel, magnesium and its alloys, and the surface may be coated or with various glue line additives such as those used for actual welding.
In an actual welding working environment, a large amount of external noise interferes with data acquisition, and as the similarity of sound wave characteristics sent by the same sound source is obviously higher than that sent by an external noise source under the same distance, a plurality of sensors are equidistantly arranged from welding spots, so that effective data can be acquired to the greatest extent, and more data can be collected by two or more sensors to improve accuracy. The sensor is arranged on the main body mechanical arm, so that the welding spot is always positioned at the center of a circle formed by a plurality of sensors, the distance is kept unchanged, the sensor can move along with the main body mechanical arm, and devices such as the sensor and the like do not need to be placed in an additional arrangement area.
Fig. 4 is a welding quality inspection method.
And when the welding process is started, welding by using the resistance spot welding device and collecting an acoustic signal of the welding process. The signal receiver collects the acoustic signals collected by the plurality of sensors and is respectively marked as N1 and N2 … … Nn; (n is the number of sensors). The signal processor performs data comparison on the signals N1 and N2 … … NN in the same time domain, extracts common spectrum information Nx, and establishes an association relation between the spectrum information Nx and the quality of welding spots based on spectrum analysis. The display displays related data, processing procedures and results in real time.
The signal processor firstly judges whether the welding process generates dangerous factors such as splashing, and if so, immediately gives an alarm and stops the welding process, and restarts after the technician processes; if the related condition is not found, welding quality detection is carried out, if the detection result is that the welding spot quality is qualified, the welding process is finished, and the subsequent welding operation can be carried out; if the detection result is unqualified, an alarm is sent out and the data is uploaded, and the alarm is processed by technicians.
The device for detecting the quality of the welding spot of the resistance welding mainly comprises more than two acoustic sensors and a signal processing system, wherein the distances from each acoustic sensor to the welding spot are equal, and the output signals of all acoustic sensors are processed by the signal processing system.
The acoustic sensor works on the principle that the acoustic wave propagating on the surface of the material or the wave in the piezoelectric sheet material is influenced by mechanical, electrical and other conditions on the boundary, the propagation characteristics of the acoustic sensor change, and the change of the characteristics such as sound velocity is detected, so that the change of related parameters such as stress, temperature, dielectric constant and the like can be detected. Acoustic sensors include magnetoelectric, resistive, capacitive, pyroelectric, and the like.
The acoustic sensor and the signal processing system can directly transmit signals, and the signals can be transmitted in a wired mode, a wireless mode and the like, and the acoustic sensor can transmit data to the processor after acquiring the signals.
As shown in fig. 2, the welding apparatus comprises a welding device, an acoustic sensor, a signal receiver, a signal processor, and a display, wherein the signal receiver, the signal processor, and the display may form a signal processing system.
Before welding, a plurality of positions equidistant from the weld spot are selected on the welding equipment and marked, and an acoustic sensor is mounted at the mark. And placing a weldment, checking the upper electrode and the lower electrode, adjusting the welding equipment to a working position, and finishing the preparation matters before welding. The acoustic sensor is connected with the signal receiver, the signal receiver and the signal processor are connected with the display, the running condition of each device is tested, and the normal operation of each device in the welding process is ensured.
When the welding process starts, the acoustic sensor is synchronously turned on to receive the acoustic signal, and whether the signal received by the signal receiver is in a normal range is observed, if so, the test is continued, and if not, the welding process is stopped and the equipment and the connection are checked.
In the welding process, the signal processor finishes operations such as filtering, data processing and the like, and whether the processed waveform accords with the actual welding sound signal or not is observed, if so, the test is continued, and if not, the equipment and the program are checked.
After the welding is finished, recording data on a display, carrying out damage detection on an experimental weldment to obtain accurate welding data, comparing the two data, and observing whether the deviation is in an allowable range or not, if so, finishing the welding test process, and if not, checking equipment and a program.
Claims (6)
1. The method for detecting the quality of the resistance welding spot based on the acoustic emission sensor is characterized by comprising the following steps of:
step one: providing a welding device for resistance spot welding and a set of acoustic emission sensing acquisition system; the acoustic emission sensing acquisition system comprises at least 2 acoustic sensors, wherein the acoustic sensors are fixed on the welding device, and the distance between each acoustic sensor and the end face of the electrode cap is the same;
step two: providing a resistance spot welding workpiece, welding by using the resistance spot welding device, and collecting an acoustic signal in the welding process;
step three: collecting acoustic signals collected by each acoustic sensor, wherein the acoustic signals are respectively marked as N1, N2, … … and Nn, and N is the number of the acoustic sensors;
step four: performing data comparison on the acoustic signals N1, N2 … … Nn in the same time domain and extracting common frequency spectrum information Nx;
step five: establishing the association relation between the spectrum information Nx and the quality of the welding spot comprises the following steps:
step 5.1, establishing a one-to-one correspondence between the spectrum information Nx and the welding time t in the welding process;
step 5.2, defining that the welding time t comprises a welding spot growing stage and a solidification cooling stage, and defining that the energy reaching peak value of a single time period in the frequency spectrum information Nx is the moment when the nugget reaches the peak value; the event of an abrupt energy change in the cooling phase after the energy peak is defined as a spot of weld that produces a weld defect
And 5.3, establishing a one-to-one correspondence between the frequency spectrum information Nx and the melting area s, and establishing a relationship between Q and d based on a mathematical statistics method by taking the total energy output of sound waves in the whole welding time period as Q and the size of a welded core detected after welding as d.
2. The method for detecting the quality of the resistance welding spot based on the acoustic emission sensor, as claimed in claim 1, wherein the acoustic sensors are arranged at the same interval by taking the top of the center of the end face of the electrode cap on the static arm side of the welding device as the center of a circle, and the centers of the receiving ends of the acoustic sensors face the top of the center of the electrode cap.
3. A method for detecting the quality of a resistance welding spot based on an acoustic emission sensor as claimed in claim 1, wherein the acquisition frequency of the acoustic sensor is in the range of 200HZ to 2MHZ.
4. The method for detecting the quality of a resistance welding spot based on an acoustic emission sensor as claimed in claim 1, wherein a plurality of acoustic emission sensors share a sensing system to realize unification of starting and ending of acquisition.
5. A method of detecting the quality of a resistance welding spot based on an acoustic emission sensor as claimed in claim 1.
6. A resistance weld quality detection system based on acoustic emission sensors, the system comprising: the welding device is used for resistance spot welding, the sound signal acquisition system is composed of at least 2 sound emission sensors, and software for connecting the resistance spot welding device with the sound signal acquisition system; the acoustic emission sensors are equidistantly arranged on the welding device by taking the center of the end face of the welding electrode cap on any welding electrode arm of the resistance welding as the center of a circle; the software comprises a noise filtering system and an analysis system, the noise filtering system can extract and collect the sound signal information collected by the plurality of acoustic sensors based on common information in the same time domain, and the sound signal information is used as input information to be input to the analysis system, and the analysis system establishes the association between the sound signal information and the quality of welding spots according to the input information.
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