JP2006181578A - Welding operation assisting device and welding operation assisting method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a welding operation assisting device and a welding operation assisting method which enable a welder to easily perform the welding operation and realize a constantly consistent penetration welding. <P>SOLUTION: The welding operation assisting device to assist the welding operation by monitoring the state of penetration of the gap welding and the insert ring welding of two base materials to be welded is provided with: a CCD camera 3 to image the image of the state of penetration via a mirror installed at a part to be welded which cannot be seen directly by a welder; an image analyzing device 21 to analyze the image of the molten state of the penetration imaged up by the CCD camera 3; a molten state diagnosis device 22 which defines a molten area of penetration processed by the image analyzing device 21 to judge whether the present molten state is adequate or not. The result of judgment of the molten state diagnosis device 22 is transmitted to the welder performing welding as visual information, audible information or tactile information. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a welding work support apparatus and a welding work support method that support a welder's construction work in back wave welding such as gap back wave welding and insert ring welding.

  Conventionally, when performing manual welding, a welder can obtain experience level and skill level by receiving welding support using a manual welding support device (for example, Patent Document 1 and Patent Document 2) recently proposed. We are trying to improve.

  The above-mentioned manual welding support device, for example, forms a molten pool in the groove by the heat of the arc generated between the groove formed by two base materials to be welded and the torch, and the generation location of this molten pool It is intended to generate welding strips in the direction of movement by continuously moving the wire and to support welding work to weld two base materials. For example, back wave welding such as gap back wave welding and insert ring welding. Is not applicable because the welder cannot directly observe the back wave behavior.

  For this reason, when constructing gap backside welding or insert ring welding, the welder is required to have a high level of skill, and the welder performing the product construction is required to have a high level of skill.

This is because the welder needs to be able to guess the back wave state from the state of the molten pool in the groove that is visible. Especially in insert ring welding, it is difficult to grasp the back wave state. At the time of welding, a supervisor who looks directly at the back wave is placed and welded with two workers to weld the back wave state. In some cases, welding may be carried out.
JP2004-90041 JP 2001-71140 A

As described above, in order to perform gap back wave welding and insert ring welding in a stable state, advanced skills are required, or a back wave monitor is required in addition to the welder. It was made in view of the above, and it is possible to accurately transmit important back-wave conditions that cannot be seen directly, such as gap back-wave welding and insert ring welding, to the welder, and always carry out stable back-wave welding. It is an object of the present invention to provide a welding work support device and a welding work support method capable of performing the above.

  In order to achieve the above object, the present invention supports welding work by the following means and method.

  The invention corresponding to claim 1 is a welding work support device that supports the welding work by monitoring the back-wave state of gap welding or insert ring welding of two base materials to be welded, and can be directly viewed by the welder. Welding support information transmission that has a visual sensor such as a CCD camera that captures the state of the back wave through a mirror installed at a welding target site that cannot be performed, and that transmits image information captured by this visual sensor to the welder who is performing the construction Consists of means.

  According to a second aspect of the present invention, there is provided a welding work support device according to the first aspect of the present invention, wherein the welding support information transmission means performs image analysis of image analysis of the melting state of the back wave collected by the visual sensor. And a determination means for determining whether or not the current melting state is appropriate or not, and visually determining the result of the determination by the image analysis means. This information is transmitted to the welder under construction as information, auditory information, or tactile information.

  The invention corresponding to claim 3 is the welding work support apparatus according to claim 2 or claim 3, wherein the determination means determines the back wave state based on the back surface area amount.

  The invention corresponding to claim 4 is characterized in that, in the welding work support device of the invention corresponding to claim 2 or claim 3, the area amount of the back wave is used as a judgment criterion as a method for judging the molten state.

  The invention corresponding to claim 5 is the welding work support device of the invention corresponding to claim 2 or claim 5, wherein the determination means determines the state of the back wave using the dimensions related to the width and length of the back wave as a judgment criterion. To do.

  The invention corresponding to claim 6 is a welding work support device for supporting gap welding of two base materials to be welded or reverse wave welding at the time of insert ring welding, and a visual sensor such as a CCD camera attached to a welding torch. And image analysis means for processing the image information captured by the visual sensor to measure the molten pool state and comparing the result with past data to estimate the back wave state. It consists of welding support information transmission means for transmitting the estimated information of the back wave information to the welder.

  The invention corresponding to claim 7 is the welding work support device according to claim 6, wherein the welding support information transmission means is adapted to the current molten state from the back wave state estimated by the image analysis means. A determination unit that determines whether the image is present or inappropriate is provided, and a determination result obtained by the determination unit is transmitted as visual information or auditory information to the welder under construction.

  The invention corresponding to claim 8 is the welding work support device of the invention corresponding to claim 7, wherein the welding support information transmission means performs welding if the determination means determines that the current molten state is inappropriate. Equipped with welding behavior / condition improvement instruction determination means to determine the improvement method from the welding behavior / conditions that prevent proper backside welding among welding behavior / welding conditions such as welding speed, welding current, welding voltage, etc. The improvement method determined by the welding behavior / condition improvement instruction determination means is transmitted to the welder so that the bad part can be corrected during construction.

  The invention corresponding to claim 9 is a welding work support method that supports the welding work by monitoring the back-wave state of gap welding or insert ring welding of two base materials to be welded, and can be directly viewed by the welder. The step of imaging the back wave state of the part to be welded by a visual sensor such as a CCD camera, the step of defining the melting area by performing image processing on the back wave image information imaged in this step, and the step defined by this step It consists of a step of determining whether the current molten state is appropriate or inappropriate, and a step of transmitting the result determined by this step to the welder under construction as visual information, auditory information, or tactile information. It is characterized by.

  According to a tenth aspect of the present invention, in the welding work support method according to the ninth aspect of the present invention, when it is determined by the determination step that the current molten state is inappropriate, a welding speed, welding current, The method includes a step of determining an improvement method from a welding behavior / condition that prevents proper reverse wave welding among welding behavior / welding conditions such as a welding voltage, and transmitting the improvement method to a welder. It is characterized by making it possible to correct bad parts during construction.

  The invention corresponding to claim 11 is the welding work support method of the invention corresponding to claim 9 or claim 10, wherein the determination step determines a back wave state using a back wave area amount as a criterion. And

  According to a twelfth aspect of the present invention, in the welding work support device according to the ninth or tenth aspect of the present invention, the determination step determines a back wave state based on the dimensions related to the width and length of the back wave. It is characterized by doing.

  The invention corresponding to claim 13 is a welding work support method for supporting gap welding of two base materials to be welded or back wave welding at the time of insert ring welding, wherein a visual sensor such as a CCD camera attached to a welding torch is provided. Use to measure the molten pool state, compare the result with past data to estimate the back wave state, and determine from the back wave state whether the current molten state is appropriate or inappropriate It consists of a step and the step which transmits the result determined by this step to the welder under construction.

  The invention corresponding to claim 14 is the welding work support method of the invention corresponding to claim 13, wherein if the current melting state is determined to be inappropriate by the determination step, the welding speed, welding current, It is possible to correct the bad part during construction with the step of transmitting the welding behavior / condition that prevents proper back welding in the welding behavior such as welding voltage etc. as visual information or auditory information to the welder. It is characterized by that.

  According to the present invention, the back wave state that cannot be directly seen by the welder is transmitted to the welder during welding, so that the welder can easily work, and the welder is instructed to change the welding behavior and welding conditions. By transmitting to, stable back wave welding is always possible.

  Embodiments of the present invention will be described below with reference to the drawings.

(First embodiment)
FIG. 1 is a block diagram showing a case where the first embodiment of the welding work support apparatus according to the present invention is applied to flat plate gap welding.

  In FIG. 1, reference numerals 1 and 2 denote a pair of flat plates arranged side by side on a window frame of the work table 50 through a groove. 4 are arranged in a direction orthogonal to the groove with an appropriate interval. In this case, the CCD camera 3 and the mirror 4 are each attached to a mounting plate 51 supported so as to be movable along the groove on the window frame, and the reflected surface of the mirror 4 can be imaged by the CCD camera 3 in the molten state of the back wave. It is provided in a slanted state.

  The image signal picked up by the CCD camera 3 is output to the welding support information transmission means to the welder via the cable 5. This welding support information transmission means is configured to output an image signal to a monitor (not shown) arranged in the welding surface 6 covering the face of the welder in FIG.

  Accordingly, with such a configuration, the welder can check the back wave image through the monitor disposed in the welding surface 6 during welding imaged by the CCD camera 3 via the mirror 4. Therefore, back welding can be easily performed.

  FIG. 2 is a block diagram showing a case where the first embodiment of the present invention is applied to gap welding of piping, and the same parts as those in FIG.

  2A, reference numeral 10 denotes a pipe supported by a plurality of support legs 52 on a window frame of a work table. A visual sensor such as a CCD camera 3 is provided on a central axis corresponding to a gap welding portion in the pipe 10. And the conical mirror 11 are arranged at an appropriate interval. In this case, the CCD camera 3 and the conical mirror 11 are respectively attached to members that are concentric with the pipe provided to be supported in the pipe 10.

  Here, the reason for using the conical mirror 11 is that the back wave shape of the entire circumference of the pipe is not replaced, and all the images can be captured by only one setup.

  The image signal picked up by the CCD camera 3 is output to the welding support information transmission means to the welder via the cable 5. The welding support information transmission means has the same configuration as that shown in FIG.

  Even in such gap welding of piping, the welder can check the back wave image through a monitor disposed in the welding surface 6 during welding imaged by the CCD camera 3 via the conical mirror 11. .

  In this case, since the CCD camera 3 captures the back wave of the gap welding reflected by the conical mirror 11, even if the original back wave shape is as shown in FIG. The image to be confirmed is observed in a distorted state as shown in FIG. 2C and the back wave moves on the circumference.

  Therefore, since the back wave state can be transmitted to the welder even in the gap welding of the pipe, the back wave welding can be easily performed.

(Second Embodiment)
FIG. 3 is a configuration diagram showing a case where the second embodiment of the welding work support system according to the present invention is applied to flat plate gap welding, where the same parts as in FIG. Here, different parts are described.

  In the second embodiment, as welding support information transmission means to the welder, the image data captured by the CCD camera 3 is taken into the image analysis device 21 and subjected to image analysis, and the result is given to the welding state determination device 22. Thus, it is determined whether or not the back welding state of the gap welding is possible, and the determination result is transmitted to the welder via the signal line 23.

  Here, the image analysis device 21 binarizes the back wave image as shown in FIG. 4A obtained by image analysis of the image data, thereby obtaining the back image as shown in FIG. 4B. The wave area is obtained.

  In addition, the welding state determination device 22 compares the back surface area under construction obtained by the image analysis device 21 with a standard back surface area stored in a memory (not shown) in advance, and the back surface area under construction is standard. If it is within the range of the back surface area, it is determined as “normal”, and if it is out of the standard back surface area, it is determined as “impossible”.

  With such welding support information transmission means to the welder, the welding state determination device 22 analyzes the melting state of the back wave of the member to be welded imaged by the CCD camera 3 by image analysis of the image analysis device 21. It is possible to determine whether or not the current molten state is appropriate, and to transmit the determination result as visual information to the welder under construction, so that the welder can grasp the back wave state, Not only can the welding work be facilitated, but also high quality welding can be performed.

  In the above-described embodiment, the back wave information is transmitted to the welder by outputting the determination result of the back wave state as visual information to the monitor disposed in the welding surface 6. It may be transmitted as audio information such as voice and rhythm.

  By using such a system, it becomes possible for the welder to know whether the back wave state is good during welding.

(Third embodiment)
FIG. 5 is a configuration diagram showing a case where the third embodiment of the welding work support system according to the present invention is applied to flat plate gap welding, where the same parts as those in FIG. Here, different parts are described.

  In the third embodiment, as welding support information transmission means to the welder, the image data captured by the CCD camera 3 is taken into the image analysis device 21 and subjected to image analysis, and the result is given to the welding state determination device 22. When the back wave shape of the gap welding is determined, and it is determined that the back wave shape under construction is not possible, the current back wave shape data is given to the welding condition / behavior improvement instruction determining device 24, The improvement method is determined in comparison with the appropriate back wave shape data constructed in the database, and the work improvement instruction is transmitted to the welder via the signal line 23.

  Here, since the image analysis device 21 and the welding state determination device 22 are the same as those of the second embodiment described above, the description thereof is omitted here.

  If the welding support information transmission means to such a welder is used, if the welding state determination device 22 determines that the back wave shape under construction is not possible, the welding condition / behavior improvement instruction determination device 24 determines the current situation. Comparing the wave shape data with the appropriate back wave shape data in the database, and improving the behavior and conditions that prevent proper back wave welding among welding behavior and welding conditions such as welding speed, welding current, welding voltage, etc. And the result of the improvement is transmitted to the welder, so that the welder can improve the welding conditions or the welding behavior.

  For example, when the back wave shape is small, it is determined by the welding state determination device 22 that “back wave shape is impossible”, and the welding condition / behavior improvement instruction determination device 24 sets “increase the welding current”, “ An instruction “slow welding speed” is given, and the welder responds by changing the welding conditions and behavior according to the instruction.

  As a result, when the back wave shape becomes appropriate, the welding state determination device 22 determines that the “back wave shape is normal”, and there is no instruction from the welding condition / behavior improvement instruction determining device 24, so that the welder Will continue the welding conditions / behavior being performed and wait for the next instruction.

  By following the welding condition / behavior change instruction using such welding support information transmission means, the welder can keep the back wave state constant during welding.

  FIG. 6 is a block diagram showing a case where the third embodiment of the present invention is applied to gap welding of piping. The same parts as those in FIG. 2 and FIG. The action will be described.

  Now, when gap welding of the pipe 10 is performed with the welding torch 12, the melted back wave state is imaged by the CCD camera 3 through the conical mirror 11. Image data picked up by the CCD camera 3 is taken into the image analysis device 21 and subjected to image analysis.

  In this example, since the image captured by the CCD camera 3 passes through the conical mirror 11, this image becomes a molten pool image affected by the conical mirror shape as shown in FIG.

  Therefore, the image is taken and the molten pool shape is developed as a planar image (deformation correction and distance correction by a conical mirror), converted into an original shape as shown in FIG. 5B, and the image is binarized. The molten pool shape shown in FIG. The back wavelength 31 and the width 32 are calculated from the defined weld pool shape as shown in FIG.

  In this welding state diagnostic device 22, the quality of the welding state is diagnosed by comparing these two dimensions with the standard state. In addition, when it is diagnosed that the welding state is bad, the fact is transmitted to the welding behavior / condition improvement instruction determination device 23, and how is compared with the past welding behavior / conditions built in a database (not shown) It is judged whether it should be improved, and a work improvement instruction is issued to the welder.

  Even when performing gap welding of piping in this way, by following the welding condition / behavior change instruction output from the welding support information transmission means of the third embodiment, the welder can see the back wave state during welding. It can be kept constant.

(Fourth embodiment)
FIG. 8 is a block diagram showing a fourth embodiment of the welding work support apparatus according to the present invention. The same parts as those in FIG. 5 are denoted by the same reference numerals, and the description thereof is omitted. Here, different parts are described.

  In the fourth embodiment, a CCD camera 42 is attached to a torch 41 with a fixing bracket 43, and image data captured by the CCD camera 42 is converted into an image analysis device 21, a welding state diagnostic device 22 and a welding behavior similar to those shown in FIG. -It transmits to the welding surface 6 as visual information or auditory information by the welding assistance transmission means provided with the condition improvement instruction | indication determination apparatus 24. FIG.

  In this embodiment, for example, an image of the groove molten pool is collected by the CCD camera 3 attached to the torch 41, so the back wave state cannot be grasped only from the image. Therefore, a method for estimating the shape of the back wave being constructed is adopted by comparing it with a past molten pool shape having the same material, thickness, and groove shape constructed in a database (not shown) in the image analysis device 21. ing.

  This database is made up of images taken simultaneously from the front side of the molten pool and the back wave image at that time, and the back wave image can be specified if the front side image of the molten pool is known.

  Therefore, by searching in the database for a weld pool image close to the weld pool image being constructed, it is possible to identify the back wave image at that time and to estimate the back wave shape in the database for the back wave being constructed. It becomes.

The block diagram which shows the case where 1st Embodiment of the welding operation assistance system by this invention is applied to the gap welding of a flat plate. The block diagram which shows the case where the 1st Embodiment of this invention is applied to the gap welding of piping. The block diagram which shows the case where 2nd Embodiment of the welding operation assistance system by this invention is applied to the gap welding of a flat plate. In the same embodiment, it is an intermediate image displayed on the monitor for measuring a back surface area with an image analyzer. The block diagram which shows the case where 3rd Embodiment of the welding operation assistance system by this invention is applied to the gap welding of a flat plate. The block diagram which shows the case where 3rd Embodiment of the welding operation assistance system by this invention is applied to the gap welding of a flat plate. In the embodiment, it is an intermediate image displayed on a monitor for defining a back wave dimension in the image analysis apparatus. The block diagram which shows the case where 4th Embodiment of the welding operation assistance system by this invention is applied to the gap welding of a flat plate.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Material to be welded, 2 ... Material to be welded, 3 ... CCD camera, 4 ... Mirror, 5 ... Signal line, 6 ... Welding surface, 10 ... Material to be welded, 11 ... Conical mirror, 12 ... Welding torch, 21 ... Image Analyzing device, 22 ... Welding condition diagnostic device, 23 ... Cable, 24 ... Welding behavior / condition improvement instruction determining device, 31 ... Back wavelength, 32 ... Back wave width, 41 ... Welding torch, 42 ... CCD camera, 43 ... Bracket, 50 ... Workbench, 51 ... Mounting plate, 52 ... Support leg

Claims (14)

In a welding work support device that supports the welding work by monitoring the back wave state of gap welding and insert ring welding of two base materials to be welded,
A welder who has a visual sensor such as a CCD camera that captures the state of the back wave through a mirror installed at the site to be welded that cannot be directly seen by the welder, and who is working on the image information captured by this visual sensor A welding work support device comprising welding support information transmission means for transmitting to a welding work.   2. The welding operation support device according to claim 1, wherein the welding support information transmission unit includes an image analysis unit that performs image analysis on a melting state of the back wave collected by the visual sensor, and a back wave processed by the image analysis unit. And a determination means for determining whether the current molten state is appropriate or not, and welding under construction using the determination result of the determination means as visual information, auditory information, or tactile information Welding work support device characterized by transmitting to a technician.   3. The welding work support apparatus according to claim 2, wherein the information welding support information transmission means informs the welder of the welding speed, welding current, welding voltage, etc. when the determination means determines that the current molten state is inappropriate. The welding behavior / welding condition improvement instructing means determines the improvement method from the welding behavior / condition that prevents proper backside welding among the welding behavior / welding conditions of the welding. A welding work support device which transmits a determined improvement method to a welder and corrects a bad part during construction.   4. The welding work support apparatus according to claim 2, wherein the determination unit determines a back wave state using a back wave area amount as a determination criterion.   4. The welding work support apparatus according to claim 2, wherein the determination means determines the back wave state using the dimensions relating to the width and length of the back wave as a determination criterion. In the welding work support device that supports back welding at the time of gap welding and insert ring welding of two base materials to be welded,
A visual sensor such as a CCD camera attached to the welding torch, and an image that processes the image information captured by this visual sensor to measure the molten pool state and compares the result with past data to estimate the back wave state And a welding support information transmitting means for transmitting backside information estimation information estimated by the image analysis means to the welder.   7. The welding work support device according to claim 6, wherein the welding support information transmission means determines whether the current molten state is appropriate or inappropriate from the back wave state estimated by the image analysis means. And a welding work support device that transmits a result of determination by the determination means to a welder under construction as visual information or auditory information.   8. The welding work support apparatus according to claim 7, wherein the welding support information transmission means informs a welder of a welding speed, a welding current, a welding voltage, etc. when the determination means determines that the current molten state is inappropriate. Equipped with welding behavior / condition improvement instruction deciding means that decides the improvement method from the welding behavior / condition that prevents proper backside welding among welding behavior / welding conditions, etc. A welding work support device characterized in that the improved method is transmitted to the welder so that bad parts can be corrected during construction. In the welding work support method that supports the welding work by monitoring the back wave state of gap welding and insert ring welding of two base materials to be welded,
A step of imaging a back wave state of a part to be welded that cannot be directly seen by a welder with a visual sensor such as a CCD camera, and a step of defining a melting area by performing image processing on the back wave image information imaged in this step A step of determining whether the current molten state defined by this step is appropriate or inappropriate, and a welder under construction using the result determined by this step as visual information, auditory information, or tactile information A welding work support method comprising the steps of:   10. The welding work support method according to claim 9, wherein if it is determined by the determination step that the current molten state is inappropriate, the welder is informed of welding behavior such as welding speed, welding current, welding voltage, and welding conditions. The method includes determining the improvement method from the welding behavior and conditions that are preventing proper reverse wave welding and transmitting the improvement method to the welder. This step enables the welder to correct the bad part during construction. A welding work support method characterized by the above.   11. The welding work support method according to claim 9 or 10, wherein the determination step determines a back wave state using a back wave area amount as a criterion.   11. The welding work support apparatus according to claim 9 or 10, wherein the determination step determines a back wave state by using dimensions relating to the width and length of the back wave as a determination criterion. In the welding work support method that supports the back welding at the time of gap welding and insert ring welding of two base materials to be welded,
Using a visual sensor such as a CCD camera attached to the welding torch, the molten pool state is measured, the result is compared with past data, and the back wave state is estimated. A welding work support method comprising: a step of determining whether or not it is appropriate, and a step of transmitting a result determined in this step to a welder who is performing the construction.   14. The welding operation support method according to claim 13, wherein if the current melting state is determined to be inappropriate by the determination step, the welding operator is informed of welding behavior / welding conditions such as welding speed, welding current, and welding voltage. A welding work support method comprising the step of transmitting welding behavior / conditions preventing proper reverse wave welding to the welder as visual information or auditory information, and making it possible to correct bad parts during construction.

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