CN204621366U - A kind of pipeline all-position laser-arc hybrid welding process welding system - Google Patents
A kind of pipeline all-position laser-arc hybrid welding process welding system Download PDFInfo
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- CN204621366U CN204621366U CN201520185348.2U CN201520185348U CN204621366U CN 204621366 U CN204621366 U CN 204621366U CN 201520185348 U CN201520185348 U CN 201520185348U CN 204621366 U CN204621366 U CN 204621366U
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- 238000003466 welding Methods 0.000 title claims abstract description 149
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- 230000008859 change Effects 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 239000004411 aluminium Substances 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000007789 gas Substances 0.000 description 20
- 239000002893 slag Substances 0.000 description 12
- 238000001931 thermography Methods 0.000 description 11
- 210000001503 joint Anatomy 0.000 description 9
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- 229910000679 solder Inorganic materials 0.000 description 6
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Abstract
The utility model provides a kind of pipeline all-position laser-arc hybrid welding process welding system, comprising: laser sensor gathers primary importance image information and the second place image information of weld seam; Pattern process computer calculates lateral deviation, the longitudinal bias of weld seam according to primary importance image information and second place image information; Lateral deviation is converted to lateral deviation voltage, longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to advanced amount of delay, lateral deviation voltage and longitudinal bias voltage are sent to controller; Controller according to lateral deviation voltage correction lateral deviation, according to longitudinal bias voltage correction longitudinal bias; Actuator welds after keeping accurate Shaft alignment state according to revised lateral deviation, longitudinal bias control Combined Welding welding torch and weld seam; Deflector, in welding process, changes air draught direction, eliminates the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole, ensures welding quality.
Description
Technical field
The utility model belongs to oil and gas pipes welding technology field, particularly relates to pipeline all-position laser-arc hybrid welding process welding system.
Background technology
Laser-arc hybrid welding process technology has that speed of welding is fast, welding penetration is large, bridging capability is good, weld properties is good, layer is thick, save the advantages such as wlding, is the developing direction of the automatic all-position welding technical field of research of heavy caliber long-distance pipe.In laser-arc hybrid welding process welding process; produce stronger welding slag sometimes to splash; especially the 6:00 position when all-position welding; the welding slag gravitate splashed can produce serious ejecta pollution to the focus lamp protective lens of laser torch; when the protective lens in focused light passages is infected with welding slag, small welding slag dust, even if welding slag dust diameter also sharply can absorb the energy of welding laser at below 0.1mm; make the beam quality degradation of laser, thus affect welding quality.Further, after being attached to the energy of the welding slag dirt absorption laser in focus lamp protective lens, temperature sharply rises, and causes focus lamp protective lens melt and be out of shape, and forms larger energy absorption point, causes vicious circle.
In prior art, by designing horizontal gases at high pressure gas curtain before laser condensing lens protective lens, blow away the welding slag of splashing, but the method is only applicable to pure laser torch, is not suitable for hybrid welding torch.Mainly because pure laser weld is splashed less, higher gas curtain air pressure can be adopted to reach and to prevent welding slag from splashing.
And in laser-arc hybrid welding process welding system; only have the gas curtain air pressure of more than 4MPa effectively could blow away welding slag and splash (comprising 6:00 position); and air-flow velocity now due to gas curtain is excessive; upset the shielding gas flow of arc welding; cause the phenomenon occurring honeycomb or pore during appearance of weld, cause welding quality defective.If reduce the pressure of gas curtain when being less than 2MPa, shielding gas flow can be unaffected, but due to the pressure of gas curtain too low, air-flow is too little can not effectively blow away welding slag dust, focuses on protective lens still by welding slag ejecta pollution, needs frequently to change protective lens.Like this, not only increase welding cost but also have a strong impact on welding quality and welding efficiency.
Utility model content
For prior art Problems existing; the utility model embodiment provides a kind of pipeline all-position laser-arc hybrid welding process welding system; for solving in prior art, during welding, the shielding gas flow of arc torch is easily disturbed, and causes the technical problem occurring honeycomb or pore during appearance of weld.
The utility model provides a kind of pipeline all-position laser-arc hybrid welding process welding system, and described system comprises:
Laser sensor, described laser sensor gathers primary importance image information and the second place image information of weld seam;
Pattern process computer, the first port of described pattern process computer is connected with described laser sensor, for calculating lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information;
Described lateral deviation is converted to lateral deviation voltage, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to advanced amount of delay, described lateral deviation voltage and described longitudinal bias voltage are sent to controller;
Controller, described controller is connected with the second port of described pattern process computer, for lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage;
Actuator, described actuator is connected with the 3rd port of described controller, welds after described Combined Welding welding torch and described weld seam keep accurate Shaft alignment state for controlling according to revised described lateral deviation, described longitudinal bias;
Deflector; one end of described deflector is arranged on below the focusing lens of laser torch; the other end is connected with one end of described laser sensor; for in welding process; change compressed air direction; eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole, ensure welding quality.
In such scheme, described primary importance image information specifically comprises: the image information of the initial weld position of described Combined Welding welding torch;
Described second place image information specifically comprises: in predetermined period, and described Combined Welding welding torch arrives the image information of welding position.
In such scheme, described first port is RS485 or RS232 port.
In such scheme, described second port is ethernet port.
In such scheme, the material of described deflector comprises: copper coin, aluminium sheet.
In such scheme, one end of described deflector is linear pattern, and the other end of described deflector is arc.
In such scheme, described deflector is provided with first circular hole concentric with Laser Focusing point.
The utility model provides a kind of pipeline all-position laser-arc hybrid welding process welding system, and described system comprises: laser sensor, and described laser sensor gathers primary importance image information and the second place image information of weld seam; Pattern process computer, the first port of described pattern process computer is connected with described laser sensor, for calculating lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information; Described lateral deviation is converted to lateral deviation voltage, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to advanced amount of delay, described lateral deviation voltage and described longitudinal bias voltage are sent to controller; Controller, described controller is connected with the second port of described pattern process computer, for lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage; Actuator, described actuator is connected with the 3rd port of described controller, welds after described Combined Welding welding torch and described weld seam keep accurate Shaft alignment state for controlling according to revised described lateral deviation, described longitudinal bias; Deflector, one end of described deflector is arranged on below the focusing lens of laser torch, the other end is connected with one end of described laser sensor, for in welding process, change compressed air direction, eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole, ensure welding quality; So, in welding process, the flow direction of compressed air can be guided by deflector, eliminate the phenomenon that honeycomb, pore appear in appearance of weld, improve welding quality.
Accompanying drawing explanation
The pipeline all-position laser-arc hybrid welding process welding system overall structure schematic diagram that Fig. 1 provides for the utility model embodiment;
The structural representation of the deflector that Fig. 2 provides for the utility model embodiment;
The structural representation of the protective plate that Fig. 3 provides for the utility model embodiment;
The structural representation of the pattern process computer that Fig. 4 provides for the utility model embodiment.
Description of reference numerals:
1-laser sensor; 2-pattern process computer; 3-controller; 4-actuator; 41-image processor; 42-mass analyzer; 43-memory; 51-laser torch; 52-arc torch; 6-deflector; 7-protective plate; 71-first metallic plate; 72-second metallic plate; 8-thermal infrared imager; 9-image pick-up card.
Detailed description of the invention
In order to solve laser-arc hybrid welding process in welding process, the shielding gas flow of hybrid welding torch is easily disturbed, appearance of weld is caused to occur the technical problem of honeycomb or pore, the utility model provides a kind of pipeline all-position laser-arc hybrid welding process welding system, described system comprises: laser sensor, and described laser sensor gathers primary importance image information and the second place image information of weld seam; Pattern process computer, the first port of described pattern process computer is connected with described laser sensor, for calculating lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information; Described lateral deviation is converted to lateral deviation voltage, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to advanced amount of delay, described lateral deviation voltage and described longitudinal bias voltage are sent to controller; Controller, described controller is connected with the second port of described pattern process computer, for lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage; Actuator, described actuator is connected with the 3rd port of described controller, welds after described Combined Welding welding torch and described weld seam keep accurate Shaft alignment state for controlling according to revised described lateral deviation, described longitudinal bias; Deflector; one end of described deflector is arranged on below the focusing lens of laser torch; the other end is connected with one end of described laser sensor; for in welding process; change compressed air direction; eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole, ensure welding quality.
Below by drawings and the specific embodiments, the technical solution of the utility model is described in further detail.
The present embodiment provides a kind of pipeline all-position laser-arc hybrid welding process welding system, and described system comprises: laser sensor 1, pattern process computer 2, controller 3, actuator 4, Combined Welding 5 and deflector 6; Wherein,
Described laser sensor 1 gathers primary importance image information and the second place image information of weld seam, and described primary importance image information and second place image information are sent to described pattern process computer 2; Particularly, absorb by charge coupled cell (CCD, Charge-Coupled Device) image-generating unit the image information comprising weld seam parameter after described laser sensor 1 projects the laser stripe of the CF on weld seam mating plate filters other frequency interferences light after filtration.Described weld seam parameter comprises: the lateral deviation of described weld seam, longitudinal bias, the alignment clearance of described weld seam and the unfitness of butt joint of described weld seam.
First port of described pattern process computer 2 is connected with described laser sensor 1, for calculating lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information; The alignment clearance of weld seam and the unfitness of butt joint of described weld seam according to described second place image information acquisition, according to described alignment clearance and described unfitness of butt joint the Fitting Calculation laser output power controlled quentity controlled variable.
Particularly, described pattern process computer 2 utilizes laser power control Function Fitting to calculate laser output power controlled quentity controlled variable.
Because described Combined Welding has large fusion penetration, feature that bridging capability is good, therefore can adapt to larger unfitness of butt joint, the value of described unfitness of butt joint is specifically as follows: 0 ~ 2mm.If but described unfitness of butt joint is more than 2mm, just need the laser output power controlled quentity controlled variable increasing described Combined Welding.
In general, the two-sided 1mm root face of weldering needs the laser output power of 1KW thoroughly, therefore, when weld seam is inner shaping, and required first laser output power P
1can draw according to formula (1).
P
1＝P
0*(1+1/2*C) (1)
Wherein, in formula (1), described P
0based on power, described C is unfitness of butt joint.
Further, because the focal diameter of the laser beam of described Combined Welding is generally 0.33mm, when root face is less, the alignment clearance that described laser beam can adapt to is 0 ~ 0.3mm; And root face is when being the thicker root face of 4 ~ 10mm, the diameter of described laser beam at negative out of focus place becomes large, and the alignment clearance that can adapt to is 0 ~ 0.5mm.Wherein, described negative out of focus is the back side that the focus point of described laser beam is positioned at welding work pieces.
And alignment clearance excessive time, make laser-transmitting energy excessive, cause weld seam too high behind, therefore can adjust the second laser output power P according to formula (2) according to the alignment clearance of 0 ~ 0.5mm
2.
P
2＝P
0*(1-1/2*G) (2)
Wherein, in formula (2), described G is alignment clearance.
Therefore, the relational expression of described laser power control function can be drawn, as shown in formula (3):
P＝P
0*(1+1/2*C-1/2*G) (3)
Wherein, the corresponding 1v voltage of the 1mm of described unfitness of butt joint and described alignment clearance.
Here, described lateral deviation is described second place image information and described second place image information residual quantity in the horizontal direction; Described longitudinal bias is described second place image information and described primary importance image information residual quantity in vertical direction.Wherein,
Described primary importance image information specifically comprises: the initial weld positional information of described Combined Welding 5 welding torch;
Described second place image information specifically comprises: in predetermined period, the welding position information that described Combined Welding 5 welding torch arrives.The described default cycle is 1s.
Particularly, pattern process computer 2 carries out the image procossing such as filtering, binaryzation, Threshold segmentation and rim detection to the primary importance image information received and second place image information, Digital Image Processing algorithm is utilized to simulate the weld image with weld seam with proportionate relationship, according to the vertical and horizontal deviation of structured light principle determination welding torch and weld seam centering, add proportionality coefficient correction vertical and horizontal deviation and advanced amount of delay.
Here, the setting height(from bottom) and the proportionality coefficient that pass through the laser sensor 1 calculated have relation.Such as, the setting height(from bottom) preset is 100mm, then proportionality coefficient is 1.But can there is alignment error in installation process, or accurately can not install vision sensor in 100mm height due to the restriction of frame for movement, now need to set proportionality coefficient, such as setting height(from bottom) is 90mm, and proportionality coefficient needs to be set to 0.9; Or when setting height(from bottom) is 110mm, proportionality coefficient needs to be set to 1.1, revises with this, obtain weld seam dimensional information accurately.In sum, described proportionality coefficient is generally about 1.In use, setting height(from bottom) as far as possible close to 100mm, otherwise can should be affected for the image quality of the laser sensor 1 focused.
Secondly, described lateral deviation is converted to lateral deviation voltage, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to advanced amount of delay, described lateral deviation voltage and described longitudinal bias voltage are sent to controller 3; Here, described controller 3 is connected with the second port of described pattern process computer 2, and described lateral deviation voltage and described longitudinal bias voltage are sent to controller 3 by described 3rd port by described pattern process computer 2; Described advanced amount of delay is determined according to the leading amount of described laser sensor 1 and the speed of welding of described Combined Welding 5.Such as, when described leading amount is 1m, when described speed of welding is 1m/s, can determine that described advanced amount of delay is 1s.
Particularly, described lateral deviation is converted to the first corresponding pixel according to the first conversion coefficient by described pattern process computer 2, and described first pixel is converted to described lateral deviation voltage;
According to the second conversion coefficient, described longitudinal bias is converted to the second corresponding pixel, described second pixel is converted to described longitudinal bias voltage.Wherein,
Described first conversion coefficient is: corresponding 100 described first pixels of described lateral deviation of 1mm, lateral deviation voltage described in 100 corresponding 1V of described first pixel;
Described second conversion coefficient is: corresponding 100 described second pixels of described longitudinal bias of 1mm, longitudinal bias voltage described in 100 corresponding 1V of described second pixel.
Here, described first conversion coefficient and described second conversion coefficient are determined according to the setting height(from bottom) of laser sensor 1.
When described pattern process computer 2 described lateral deviation is converted to described lateral deviation voltage, described longitudinal bias is converted to described longitudinal bias voltage time, described controller 3 is specifically for lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage.Regulate the output energy of described laser sensor 1 according to described laser output power controlled quentity controlled variable in real time, ensure mating of the alignment clearance of laser output power and described weld seam, unfitness of butt joint, and then guarantee welding quality.
Described actuator 4 is connected with the 3rd port of described controller 3, specifically for: control after described Combined Welding 5 welding torch and described weld seam keep accurate Shaft alignment state, to weld according to revised described lateral deviation, described longitudinal bias.
Here, described Combined Welding 5 comprises: laser torch 51, arc torch 52.
In welding process, described deflector 6 specifically for: change compressed-air actuated airflow direction, eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole, ensure welding quality.
Here, as shown in Figure 2, described deflector 6 is T-shape metallic plate, described deflector 6 is provided with first circular hole concentric with Laser Focusing point, is communicated with laser optical path.The diameter of described first circular hole can be calculated by the Gaussian beam energy dissipation of laser torch 51, makes described first circular hole assemble 86% of described Gaussian beam laser energy.
Here, the material of described deflector 6 comprises: copper coin, aluminium sheet.
One end of described deflector 6 is linear pattern, and the first width is 55mm, and the first length is 60mm; The other end of described deflector 6 is arc, and the second width is 90mm, and the second length is 150mm.The thickness of described deflector 6 is 0.1mm.
Particularly; below focusing lens one end of described deflector 6 being arranged on described laser torch 51; the other end is connected with one end of described laser sensor 1; in welding process, the high pressure air stream of horizontal air blowing curtain after the side blowout of laser torch 51, after the other end of described deflector 6 guides; be discharged to welding torch both sides remotely; eliminate the interference of high pressure air stream to Combined Welding shielding gas flow, effectively inhibit weld blowhole, improve welding quality.
In addition, in welding process, in order to the pollution enough effectively avoiding laser torch 51 focusing lens to be subject to welding slag, eliminate described laser torch 51 and protect the impact of gas curtain air-flow on shielding gas flow, improve welding quality and welding efficiency, described system is also provided with protective plate 7; Wherein,
As shown in Figure 3, described protective plate 7 is " L " type metallic plate, and described protective plate 7 comprises: the first metallic plate 71 and the second metallic plate 72; Wherein,
Described first metallic plate 71 is rectangle, and described rectangular length is 100mm, described rectangular wide be 64mm.Described first metallic plate 71 is provided with installing hole, and described installing hole comprises three rows, to adjust the setting height(from bottom) of described first metallic plate 71.
Described second metallic plate 72 is square, and the described foursquare length of side is 64mm, described second metallic plate 72 is provided with second circular hole concentric with described laser torch 51 focus point.
Particularly, before welding, described protective plate 7 is arranged on the laser head place of laser torch 51, and calculates the setting height(from bottom) h of described protective plate 7 by formula h=d/D*H; Wherein,
Described d is the diameter of described second circular hole; Described H is the focal length of laser torch 51.The diameter d of described second circular hole is 7.3 ~ 7.5mm.
Further, the welding system that the present embodiment provides can also realize the on-line monitoring of automatic welding quality, improves monitoring efficiency and quality, reduces loss, for welding quality provides reference data.。Particularly, described system also comprises: thermal infrared imager 8 and image pick-up card 9; Wherein, described in state thermal infrared imager 8 in welding process, shoot with video-corder molten bath infrared thermal imaging data and the appearance of weld process of described solder joint.
Particularly, in welding process, after described molten bath infrared thermal imaging data and appearance of weld process have been shot with video-corder by described infrared thermography 8, described image pick-up card 9 specifically for: gather described molten bath infrared thermal imaging data and appearance of weld process, described molten bath infrared thermal imaging data appearance of weld process be sent to pattern process computer 2.
As shown in Figure 4, described pattern process computer 2 comprises: image processor 41, mass analyzer 42 and memory 43; Wherein,
In welding process, after described pattern process computer 2 receives molten bath infrared thermal imaging data, described image processor 41 specifically for: to described molten bath infrared thermal imaging data analysis, obtain welding parameter, described welding parameter is sent to described mass analyzer 42.
When described mass analyzer 42 receives described welding parameter, specifically for: by described welding parameter compared with the welding standard preset, automatic acquisition quality of welding spot assessment result; And to detecting time of abnormal solder joint, coordinate carries out record, and the time of described abnormal solder joint, coordinate are sent to memory 43.
Described memory 43 is for storing time, the coordinate data of described molten bath infrared thermal imaging data, the view data of described welding fabrication process and described Abnormal welding point.
Here, when described pattern process computer 4 detects that the welding parameter of described solder joint does not meet described welding standard, also for: extract the weld interval of described solder joint, welding position information, analyze the weld interval of described solder joint and the defect of described welding position existence, for Welding quality test provides reference data.
When operating personnel need off-line analysis, described pattern process computer 4 also for:
Read the described molten bath infrared thermal imaging data stored in described memory 43, off-line analysis is carried out to described molten bath infrared thermal imaging data, generate off-line analysis report; And play described molten bath infrared thermal imaging process and welding fabrication process by frame, the welding procedure for different materials, different parameters provides data reference.
The pipeline all-position laser-arc hybrid welding process welding system that the utility model provides, changes compressed air direction by deflector 6, eliminates the interference of compressed air to arc welding protection gas; eliminate weld blowhole; ensure welding quality, improve welding efficiency, save welding cost.
The above; be only preferred embodiment of the present utility model; be not intended to limit protection domain of the present utility model, all do within spirit of the present utility model and principle any amendment, equivalent to replace and improvement etc., all should be included within protection domain of the present utility model.
Claims (7)
1. a pipeline all-position laser-arc hybrid welding process welding system, is characterized in that, described system comprises:
Laser sensor, described laser sensor gathers primary importance image information and the second place image information of weld seam;
Pattern process computer, the first port of described pattern process computer is connected with described laser sensor, for calculating lateral deviation, the longitudinal bias of described weld seam according to described primary importance image information and described second place image information;
Described lateral deviation is converted to lateral deviation voltage, described longitudinal bias is converted to longitudinal bias voltage, after carrying out time delay calculating according to advanced amount of delay, described lateral deviation voltage and described longitudinal bias voltage are sent to controller;
Controller, described controller is connected with the second port of described pattern process computer, for lateral deviation according to the correction of described lateral deviation voltage, longitudinal bias according to the correction of described longitudinal bias voltage;
Actuator, described actuator is connected with the 3rd port of described controller, welds after described Combined Welding welding torch and described weld seam keep accurate Shaft alignment state for controlling according to revised described lateral deviation, described longitudinal bias;
Deflector; one end of described deflector is arranged on below the focusing lens of laser torch; the other end is connected with one end of described laser sensor; for in welding process; change compressed air direction; eliminate the interference of described air-flow to arc welding protective gas, avoid occurring weld blowhole, ensure welding quality.
2. the system as claimed in claim 1, is characterized in that, described primary importance image information specifically comprises: the image information of the initial weld position of described Combined Welding welding torch;
Described second place image information specifically comprises: in predetermined period, and described Combined Welding welding torch arrives the image information of welding position.
3. the system as claimed in claim 1, is characterized in that, described first port is RS485 or RS232 port.
4. the system as claimed in claim 1, is characterized in that, described second port is ethernet port.
5. the system as claimed in claim 1, is characterized in that, the material of described deflector comprises: copper coin, aluminium sheet.
6. system as claimed in claim 5, it is characterized in that, one end of described deflector is linear pattern, and the other end of described deflector is arc.
7. the system as claimed in claim 1, is characterized in that, described deflector is provided with first circular hole concentric with Laser Focusing point.
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| CN112118931A (en) * | 2018-05-18 | 2020-12-22 | 株式会社Ihi检查计测 | Composite welding device |
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| CN112118931A (en) * | 2018-05-18 | 2020-12-22 | 株式会社Ihi检查计测 | Composite welding device |
| CN112118931B (en) * | 2018-05-18 | 2022-04-12 | 株式会社Ihi检查计测 | Composite welding device |
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