JP3274453B2 - Joint failure detection method in friction stir welding - Google Patents
Joint failure detection method in friction stir weldingInfo
- Publication number
- JP3274453B2 JP3274453B2 JP2000167054A JP2000167054A JP3274453B2 JP 3274453 B2 JP3274453 B2 JP 3274453B2 JP 2000167054 A JP2000167054 A JP 2000167054A JP 2000167054 A JP2000167054 A JP 2000167054A JP 3274453 B2 JP3274453 B2 JP 3274453B2
- Authority
- JP
- Japan
- Prior art keywords
- gap
- friction stir
- stir welding
- reference value
- image
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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- Pressure Welding/Diffusion-Bonding (AREA)
- Image Processing (AREA)
- Image Analysis (AREA)
Description
【０００１】[0001]
【産業上の利用分野】この発明は摩擦撹拌接合における
接合不良による継ぎ手不良の検知方法に関するものであ
り、接合部の隙間の増大に起因する継ぎ手不良を接合時
に検知し、この検知データに基づいて、継ぎ手補修作業
を簡便、迅速に行うことができるものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for detecting a joint failure due to a joint failure in friction stir welding, and detects a joint failure due to an increase in a gap between joints at the time of joining, based on the detected data. In addition, the joint repair work can be performed simply and quickly.
【０００２】[0002]
【従来の技術】アルミ板の接合に摩擦撹拌接合が用いら
れているが、鉄道車両の床板、側板などに使用されるア
ルミ型材等の接合継手の長さは極めて長い。他方、板材
Ｐの摩擦撹拌接合は、図１、図２に示すようにアルミ板
Ｐを支持板４上で突き合わせた状態で行われ、突合せ面
及び接合部の上面が工具Ｔのピン１及び工具本体２の肩
部３との摩擦熱で加熱軟化され、突合せ面が接合され
る。接合工具Ｔは硬質金属部材であり、その先端に突設
された比較的細いピン１が前進方向の強い抵抗を受けな
がら高速で回転するものである。アルミ板、ダブルスキ
ン型材などは型成形されるために、長尺のものほどその
直線性が低下し、これを突き合わせたとき隙間ができて
しまう。このため、支持板４上で突き合された板Ｐ，Ｐ
を万力などで横方向に押し付けて隙間を可及的に小さく
しておいて摩擦撹拌接合が行われる。また、接合工具が
隙間の中心を追跡するように接合工具の位置が制御され
るが、接合工具の隙間の中心からのずれも避けられず、
このずれの大きさも継ぎ手不良の大きな要因の一つであ
り、また、この接合工具の中心の上記ずれが隙間の許容
限界とも関連することになる。他方、摩擦撹拌接合によ
る継ぎ手については、接合不良部があると、この部分が
ウイークポイントになり、ここから亀裂が入り、この亀
裂が成長して継ぎ手破損に至る可能性がある。このため
継ぎ手全長について超音波探傷、目視検査などの検査を
行って接合不良部を特定しこれを補修するという補修作
業が行われる。摩擦撹拌接合による継ぎ手不良が発生す
る要因は一つではないが、隙間が許容値を越えることが
主な要因である場合が多い。他方、隙間が許容値を越え
ると、工具Ｔのピン１による撹拌作用で空気が巻き込ま
れるなどのために、その部分は内部欠陥、表面欠陥など
の接合不良部に必ずなると言える。例えば継ぎ手Ｊの内
部に長手方向の微細な空洞（通常「トンネル」と称され
るもの。図３（ａ）参照）ができ、あるいは、継ぎ手Ｊ
の表面に窪み（図３（ｂ）参照）ができるなどである。
継ぎ手全長を検査して不良部分を特定し、この不良部分
を補修するのであるが、その特定に手間がかかる。以上
のように、継ぎ手の検査結果から接合不良部を特定する
のではなしに接合条件から不良箇所を特定できれば、検
査コストを大幅に低減することができ、また補修した継
ぎ手の信頼度を大きく向上させることができる。2. Description of the Related Art Friction stir welding is used for joining aluminum plates. However, the length of joining joints such as aluminum members used for floor plates and side plates of railway vehicles is extremely long. On the other hand, the friction stir welding of the plate material P is performed in a state where the aluminum plate P is butted on the support plate 4 as shown in FIGS. The body 2 is heated and softened by frictional heat with the shoulder 3 and the butted surfaces are joined. The joining tool T is a hard metal member, and a relatively thin pin 1 protruding from the tip of the joining tool T rotates at high speed while receiving strong resistance in the forward direction. Since an aluminum plate, a double-skin mold material, and the like are molded, the longer the material is, the lower its linearity becomes. For this reason, the plates P, P butted on the support plate 4
Is pressed laterally with a vice or the like to make the gap as small as possible, and friction stir welding is performed. In addition, the position of the welding tool is controlled so that the welding tool tracks the center of the gap, but deviation from the center of the gap of the welding tool is inevitable,
The magnitude of the deviation is also one of the major factors of the joint failure, and the deviation of the center of the joining tool is related to the allowable limit of the gap. On the other hand, in the case of a joint by friction stir welding, if there is a defective joint, this portion becomes a weak point, a crack is formed from this weak point, and this crack may grow and lead to joint failure. For this reason, a repair operation is performed in which an inspection such as an ultrasonic flaw detection and a visual inspection is performed on the entire joint length to identify a defective joint portion and repair the defective joint portion. The cause of joint failure due to friction stir welding is not one factor, but the main factor is that the gap exceeds the allowable value in many cases. On the other hand, if the gap exceeds the allowable value, it can be said that such a portion necessarily becomes a defective bonding portion such as an internal defect or a surface defect because air is entrained by the stirring action of the pin 1 of the tool T. For example, a fine longitudinal cavity (usually called a “tunnel”; see FIG. 3A) is formed inside the joint J, or the joint J
(See FIG. 3 (b)).
The entire length of the joint is inspected to determine a defective portion, and the defective portion is repaired, but it takes time to specify the defective portion. As described above, if a defective portion can be identified from joining conditions without identifying a defective joint from the inspection result of the joint, the inspection cost can be significantly reduced, and the reliability of the repaired joint can be greatly improved. be able to.
【０００３】[0003]
【解決しようとする課題】そこで、この発明は、摩擦撹
拌接合継ぎ手について、接合工程において接合不良部が
接合条件から特定されるように、接合不良を発生する接
合条件の変化を常時検知し、かつその良否を判別する判
別法を工夫することをその課題とするものである。SUMMARY OF THE INVENTION Accordingly, the present invention provides a friction stir welding joint that constantly detects a change in welding conditions that cause poor welding so that a poor welding portion is specified from the welding conditions in the welding process. It is an object of the present invention to devise a discriminating method for discriminating the quality.
【０００４】[0004]
【解決手段１】上記課題を解決するために講じた手段１
は次の（イ）（ロ）及び（ハ）によって構成されるもの
である。 （イ）摩擦撹拌接合装置の接合工具よりも進行方向前方
に設けたＣＣＤカメラで、接合される隙間を常時撮影す
ること、（ロ）摩擦撹拌接合開始点からの前進距離を常
時計測すること、（ハ）上記ＣＣＤカメラで撮影した隙
間映像を画像処理し、画像中の隙間の幅を演算し、この
演算値を基準値と比較して、その結果を上記前進距離と
ともにメモリに記録すること。[MEANS FOR SOLVING PROBLEMS] [Means for Solving the Problems]
Is composed of the following (a), (b) and (c). (A) A CCD camera provided forward of the welding tool of the friction stir welding apparatus in the advancing direction always photographs the gap to be welded, (b) constantly measures the forward distance from the friction stir welding start point, (C) Image processing of the gap image captured by the CCD camera, calculating the width of the gap in the image, comparing the calculated value with a reference value, and recording the result together with the advance distance in a memory.
【０００５】[0005]
【作用】ＣＣＤカメラで撮影された映像を画像処理して
撮像中の隙間の面積を測定する。そして、映像中の一定
長さ範囲の隙間の面積から、当該隙間の幅を算出する。
他方、隙間の大きさと接合不良発生との相関関係は、ア
ルミ板の厚さ、接合工具のサイズ、接合工具の回転速
度、前進速度（送り速度）など種々の要因によって左右
されるので、隙間の接合不良を生じる許容限界幅は、例
えばアルミ材の板厚、接合工具のサイズなどの一つの接
合条件との関係で一概に決まるものではないが、アルミ
板厚、接合工具のサイズ、接合工具の回転速度、前進速
度などの他の接合条件を特定した場合の、隙間の大きさ
と接合不良の発生との相関関係はほぼ一定の関係を示す
ことを実験的に確認ている。したがって、特定された条
件下での、隙間に起因する継ぎ手不良の発生に繋がる許
容限界値も実験的に特定されることである。このように
実験的に特定された隙間を基準値として設定し、上記の
ＣＣＤカメラの画像処理による隙間の演算結果を上記基
準値と比較することで、隙間に起因する継ぎ手不良の発
生を、接合部の超音波探傷などによることなしに把握す
ることができる。また、接合工具よりも進行方向前方に
配置したＣＣＤカメラの進行位置は、前進駆動モータの
エンコ−ダ等を用いて正確に検出されるから、隙間の演
算結果と基準値との比較結果を共にメモリに記録するこ
とによって、継ぎ手全長について、隙間異常及びその位
置を簡単、容易に把握することができる。The image taken by the CCD camera is processed to measure the area of the gap during image pickup. Then, the width of the gap is calculated from the area of the gap within a certain length range in the video.
On the other hand, the correlation between the size of the gap and the occurrence of poor joining depends on various factors such as the thickness of the aluminum plate, the size of the joining tool, the rotation speed of the joining tool, and the forward speed (feed speed). The allowable limit width that causes poor joining is not determined unconditionally in relation to one joining condition such as the thickness of the aluminum material and the size of the joining tool, but the thickness of the aluminum plate, the size of the joining tool, It has been experimentally confirmed that the correlation between the size of the gap and the occurrence of poor joining shows a substantially constant relationship when other joining conditions such as the rotation speed and the forward speed are specified. Therefore, under the specified conditions, the allowable limit value that leads to the occurrence of the joint failure due to the gap is also experimentally specified. By setting the gap specified experimentally in this way as a reference value, and comparing the calculation result of the gap by the image processing of the CCD camera with the reference value, the occurrence of joint failure due to the gap can be determined by joining. It can be grasped without using ultrasonic flaw detection of the part. In addition, since the traveling position of the CCD camera disposed in front of the joining tool in the traveling direction is accurately detected by using an encoder of a forward drive motor, the calculation result of the gap and the comparison result of the reference value are both used. By recording in the memory, the gap abnormality and its position can be easily and easily grasped for the entire joint length.
【０００６】[0006]
【実施態様１】この実施態様１は上記解決手段１の実施
態様であり、上記隙間面積が基準値よりも大きいとき、
そのことを示す異常信号を発信させ、この異常信号が発
信される度にこれを上記前進距離とともに記録すること
である。[Embodiment 1] This embodiment 1 is an embodiment of the above-mentioned solving means 1, and when the gap area is larger than a reference value,
An abnormal signal indicating this is transmitted, and every time the abnormal signal is transmitted, this is recorded together with the forward distance.
【作用】上記の演算結果を基準値と比較して、基準値を
越えるときは、隙間異常信号を発信する。他方、接合工
具よりも進行方向前方に配置したＣＣＤカメラの進行方
向位置は、前進駆動モータのエンコ−ダ等により正確に
検出されるから、上記の隙間異常信号が出された時に、
ＣＣＤカメラの進行方向位置を読み出し、この進行方向
位置とともに隙間異常の情報を逐次メモリに記録する。
この記録を基に、隙間異常による継ぎ手不良箇所の有
無、継ぎ手不良箇所の位置を簡単、容易、かつ正確、迅
速に特定することができる。また、異常位置でのみ隙間
異常情報を記録するから、記録情報が著しく低減され、
その解読を容易、迅速に行うことができる。なお、上記
の異常情報の記録の仕方は、基準値を越えたことを示す
単純なマーク（例えは「１」）で表示するのが最も単純
であるが、演算した隙間幅の基準値に対する倍率を数値
で記録するものでもよい。The above operation result is compared with a reference value, and if it exceeds the reference value, a clearance abnormality signal is transmitted. On the other hand, the position in the traveling direction of the CCD camera disposed forward of the joining tool in the traveling direction is accurately detected by an encoder of the forward drive motor or the like.
The position of the CCD camera in the traveling direction is read out, and information of the gap abnormality is sequentially recorded in the memory together with the traveling direction position.
Based on this record, the presence or absence of a joint failure due to a gap abnormality and the position of the joint failure can be identified simply, easily, accurately, and quickly. Also, since the gap abnormality information is recorded only at the abnormal position, the recorded information is significantly reduced,
The decryption can be performed easily and quickly. Note that the simplest way of recording the above-mentioned abnormality information is to display it with a simple mark (for example, “1”) indicating that the reference value has been exceeded. May be recorded as a numerical value.
【０００７】[0007]
【解決手段２】上記課題を解決するために講じた手段１
は次の（イ）（ロ）及び（ニ）によって構成されるもの
である。 （イ）摩擦撹拌接合装置の接合工具よりも進行方向前方
に設けたＣＣＤカメラで、接合される隙間を常時撮影す
ること、（ロ）摩擦撹拌接合開始点からの前進距離を常
時計測すること、（ニ）上記ＣＣＤカメラで撮影した隙
間映像を画像処理し、画像中の隙間の中心線の基準線に
対する横方向へのずれ量を演算し、当該演算値を基準値
と比較して、その結果を上記前進距離とともにメモリに
記録すること。[MEANS FOR SOLVING PROBLEMS] Means taken to solve the above problem 1
Is composed of the following (a), (b) and (d). (A) A CCD camera provided forward of the welding tool of the friction stir welding apparatus in the advancing direction always photographs the gap to be welded, (b) constantly measures the forward distance from the friction stir welding start point, (D) Image processing of the gap image captured by the CCD camera, calculating the amount of shift of the center line of the gap in the image from the reference line in the horizontal direction, comparing the calculated value with the reference value, and calculating the result. Is recorded in the memory together with the advance distance.
【０００８】[0008]
【作用】上記隙間の幅が基準値を越えていなくても、接
合工具の中心が隙間の中心から大きくずれる（偏心）と
継ぎ手不良を生じる。この中心ずれ量と基準値との比較
結果を上記前進距離とともにメモリに記録することで、
この記録と隙間の基準値との比較結果の記録とで、継ぎ
手不良箇所の有無、その位置を判別できるので、これに
より継ぎ手不良箇所を一層的確に把握することができ
る。Even if the width of the gap does not exceed the reference value, a joint failure occurs when the center of the joining tool is largely shifted (eccentric) from the center of the gap. By recording the comparison result between the center deviation amount and the reference value together with the advance distance in the memory,
The presence of the defective joint and the position of the defective joint can be determined by the recording and the recording of the comparison result with the reference value of the gap, so that the defective joint can be grasped more accurately.
【０００９】[0009]
【実施態様１】この実施態様１は上記解決手段２の実施
態様であり、上記隙間面積の横方向へのずれ量が基準値
よりも大きいとき、そのことを示す異常信号を発信さ
せ、この異常信号が発信される度にこれを上記前進距離
とともにメモリに記録することである。[Embodiment 1] Embodiment 1 is an embodiment of the above-mentioned solving means 2, and when an amount of deviation of the gap area in the lateral direction is larger than a reference value, an abnormal signal indicating that fact is transmitted, and this abnormal state is transmitted. Each time a signal is emitted, it is recorded in a memory together with the distance traveled.
【作用】上記隙間の中心と接合工具の中心との間のずれ
量が基準値を越える場合のみに、この偏心異常情報が前
進距離とともに記録されるから、記録情報が著しく低減
され、その解読を容易、迅速に行うことができる。Only when the deviation between the center of the gap and the center of the welding tool exceeds the reference value, the eccentricity abnormality information is recorded together with the forward distance. It can be done easily and quickly.
【００１０】[0010]
【実施態様２】この実施態様２は上記解決手段１と上記
解決手段２を合わせて実施することである。[Embodiment 2] Embodiment 2 is to carry out the above-mentioned means 1 and 2 together.
【作用】解決手段１による隙間異常情報と、解決手段２
による隙間異常情報とが、その隙間異常位置とともに合
わせてメモリに記録されるから、両隙間異常情報を用い
て接合不良の可能性を総合的に判断できるので、接合不
良の有無の判別、及び接合不良位置の特定をより正確に
行うことができる。The clearance abnormality information obtained by the solving means 1 and the solving means 2
The gap abnormality information is recorded in the memory together with the gap abnormality position, so that the possibility of joint failure can be comprehensively determined using both gap abnormality information. The defect position can be specified more accurately.
【００１１】[0011]
【実施態様３】解決手段１の上記実施態様１と解決手段
２の上記実施態様１とを合わせて実施することである。[Embodiment 3] The embodiment 1 of the solution 1 and the embodiment 1 of the solution 2 are implemented together.
【作用】上記実施態様２によるときは、隙間面積と隙間
中心のずれとの２つの観点からの隙間異常の有無の情
報、及びその位置の情報をメモリ記録することになるの
で、その記録情報が多大になり、その解読、評価が簡単
ではないが、この実施態様３によるときは、上記の両観
点からの隙間異常情報の記録数が極端に少なくなるの
で、その解読、評価を簡単、容易、かつ迅速に行うこと
ができる。According to the second embodiment, the information on the presence or absence of the gap abnormality and the information on the position from the two viewpoints of the gap area and the gap center are recorded in the memory. Decoding and evaluation are not easy, but according to the third embodiment, the number of recorded gap anomaly information from the above two viewpoints is extremely small, so that decoding and evaluation are simple and easy. And can be done quickly.
【００１２】[0012]
【実施の形態】次いで図面を参照して実施の形態を説明
する。この実施の形態は、厚さ４．５ｍｍ、長さ８ｍの
アルミ板Ｐ，Ｐを接合するものであり、接合工具のピン
１の直径５．０ｍｍ、回転速度１７５０ｒｐｍ、前進速
度６００ｍｍ／分で接合するものである。摩擦撹拌接合
装置のヘッドＨの進行方向前方にＣＣＤカメラ４１を取
り付けている。このＣＣＤカメラ４１と接合工具Ｔとの
間の水平距離Ｄは２００ｍｍであるが、この距離は、余
り小さくしなくても隙間の測定精度には影響ない。ヘッ
ドＨは接合されるアルミ板Ｐ，Ｐを突き合わせた開先４
２に沿って移動し、ＣＣＤカメラ４１は開先４２を追跡
しながら常時これを撮影して映像を取り込む。このとき
に取り込まれる画像の範囲は図６（２値化画像）に示す
とおりであり、進行方向に３ｍｍ、横方向に５ｍｍの範
囲である。この画像において隙間４２ａが図示のように
現れる。ＣＣＤカメラ４１で取り込まれた画像情報は画
像処理装置５１に送られて、画像処理装置５１で画像処
理（２値化）される。画像処理情報がＣＰＵ５２に送ら
れ、隙間４２ａの面積が積分され、この隙間４２ａの面
積から隙間の幅が演算される。この例では上記画像の中
心部の進行方向１ｍｍ、横方向２ｍｍの範囲を画像処理
し、この画像処理面積４３における隙間４２ａの面積を
積分する。この画像処理面積の進行方向長さを１ｍｍに
しているので、この範囲での隙間４２ａの面積が例えば
１．５ｍｍ２であれば、この間の隙間の平均値は１．５
ｍｍである。算出された隙間の幅をメモリから呼び出さ
れた基準値を比較して、比較結果をメモリ５４に送信し
て記録させる。また、このとき、ＣＰＵは前進駆動モー
タ（サーボモータ）Ｍの回転情報をサーボアンプから呼
び出して上記メモリ５４に送信して記録させる。また、
上記の隙間面積を積分するとともに、この隙間面積の基
準線Ｓに対する重心位置を演算し、この中心位置の基準
線Ｓからのずれ量（偏心距離）ｂを演算する。そして、
この偏心距離ｂをメモリ５３から呼び出した基準値と比
較し、その比較結果をメモリ５４に送信して記録させ
る。この実施の形態での隙間についての基準値を１ｍｍ
に設定し、隙間の中心のずれについての基準値を±１ｍ
に設定し、これで全長８ｍの摩擦撹拌接合を３回行っ
た。また、隙間が基準値を越えるときだけ隙間異常信号
を発信し、そのときの隙間の基準値に対する倍率を記録
するようにした。なお、上記の基準値は、隙間と工具中
心とのずれが±１ｍｍの条件下で、実験的に確認され
た、継ぎ手不良発生の敷居値の約８０％に設定している
ので、開先隙間がこの基準値以下の箇所で隙間異常によ
る継ぎ手不良が生じる可能性は１００％ない基準値であ
る。Next, an embodiment will be described with reference to the drawings. In this embodiment, an aluminum plate P having a thickness of 4.5 mm and a length of 8 m is joined. The joining is performed at a diameter of the pin 1 of the joining tool of 5.0 mm, a rotation speed of 1750 rpm, and a forward speed of 600 mm / min. Is what you do. A CCD camera 41 is mounted in front of the head H of the friction stir welding apparatus in the traveling direction. The horizontal distance D between the CCD camera 41 and the joining tool T is 200 mm, but this distance does not affect the measurement accuracy of the gap even if it is not too small. The head H has a groove 4 in which the aluminum plates P, P to be joined are butted.
2, the CCD camera 41 constantly captures an image while tracking the groove 42 and captures an image. The range of the image captured at this time is as shown in FIG. 6 (binarized image), which is 3 mm in the traveling direction and 5 mm in the horizontal direction. In this image, the gap 42a appears as shown. The image information captured by the CCD camera 41 is sent to the image processing device 51, where the image information is subjected to image processing (binarization). The image processing information is sent to the CPU 52, the area of the gap 42a is integrated, and the width of the gap is calculated from the area of the gap 42a. In this example, image processing is performed on a range of 1 mm in the traveling direction and 2 mm in the horizontal direction at the center of the image, and the area of the gap 42 a in the image processing area 43 is integrated. Since the length of this image processing area in the traveling direction is 1 mm, if the area of the gap 42a in this range is, for example, 1.5 mm 2 , the average value of the gap between them is 1.5 mm.
mm. The calculated gap width is compared with a reference value called from the memory, and the comparison result is transmitted to the memory 54 for recording. At this time, the CPU calls the rotation information of the forward drive motor (servo motor) M from the servo amplifier, transmits it to the memory 54, and records it. Also,
The above-mentioned gap area is integrated, the position of the center of gravity of this gap area with respect to the reference line S is calculated, and the shift amount (eccentric distance) b of the center position from the reference line S is calculated. And
The eccentric distance b is compared with a reference value called from the memory 53, and the comparison result is transmitted to the memory 54 for recording. The reference value for the gap in this embodiment is 1 mm
And the reference value for the deviation of the center of the gap is ± 1 m
, And friction stir welding with a total length of 8 m was performed three times. Also, a gap abnormality signal is transmitted only when the gap exceeds a reference value, and the magnification of the gap with respect to the reference value at that time is recorded. Note that the above-mentioned reference value is set to approximately 80% of the threshold value of the occurrence of joint failure, which was experimentally confirmed under the condition that the gap between the gap and the tool center is ± 1 mm. However, there is no 100% possibility that a joint failure due to a gap abnormality will occur at a location below this reference value.
【００１３】このケースでは、長さ８ｍの３つの各摩擦
撹拌接合継ぎ手について、隙間が基準値を越える開先不
良箇所をそれぞれ３ケ所、基準値に若干満たない箇所
（基準値の８０％）をそれぞれ３ケ所設けておいて、摩
擦撹拌接合を行ったが、その結果、全ての開先不良箇所
について、隙間の基準値に対する倍率が記録された。ま
た、この基準値の倍率の実際隙間に対する誤差は±０．
２％であり、上記の基準値に若干満たない箇所につい
て、隙間異常情報が発せられることはなかった。また、
隙間の中心のずれについても同様に試験を行ったが、そ
の精度は開先隙間の幅についての上記結果とほぼ同様で
あった。そして、隙間が基準値を越える全ての箇所につ
いて、断面を検査した結果、トンネルが生じている接合
部が上記異常箇所９箇所中８箇所、継ぎ手表面に窪みを
生じたものが９箇所中１箇所であった。以上の結果か
ら、隙間異常による継ぎ手不良箇所は確実に把握される
ことが明かである。In this case, for each of the three friction stir welding joints having a length of 8 m, three groove deficient portions each having a gap exceeding the reference value and three portions slightly less than the reference value (80% of the reference value). Friction stir welding was performed at each of the three locations, and as a result, the magnification with respect to the reference value of the gap was recorded for all the groove failure locations. The error of the magnification of the reference value with respect to the actual gap is ± 0.
The gap abnormality information was not issued for a portion that was 2%, which was slightly less than the above reference value. Also,
The same test was performed for the displacement of the center of the gap, but the accuracy was almost the same as the above result for the width of the groove gap. Then, as a result of inspecting the cross section of all the places where the gap exceeds the reference value, the junction where the tunnel has occurred is eight out of the nine abnormal places and the one where the joint surface is hollow is one out of nine places. Met. From the above results, it is clear that the joint failure part due to the gap abnormality is surely grasped.
【００１４】[0014]
【発明の効果】以上述べたとおり、この発明は、接合さ
れる板の歪みなどによる隙間を基準値と比較して、隙間
が基準値以上である箇所を隙間異常情報の記録から把握
するものであるから、超音波探傷などの内部検査を行う
ことなしに、上記記録を見るだけで摩擦撹拌接合継ぎ手
について接合手不良箇所の有無、及び不良箇所の位置を
簡単、容易、迅速かつ正確に検知することができる。し
たがって、補修を要するものと補修を要ないものとの峻
別が極めて簡単、容易であり、また、補修を要する箇所
の位置を正確、容易に特定することができる。したがっ
て、摩擦撹拌接合後の継ぎ手補修の工数、コストを大幅
に低減することができ、補修箇所の検出が自動的に光学
的に成されるので、その検出精度が高く、したがって、
接合不良箇所が補修された摩擦撹拌接合継ぎ手の信頼性
を向上させることができる。As described above, the present invention compares a gap caused by distortion of a plate to be joined with a reference value and grasps a portion where the gap is equal to or larger than the reference value from the recording of gap abnormality information. Since there is no internal inspection such as ultrasonic inspection, simply by looking at the above record, it is possible to simply, easily, quickly and accurately detect the presence or absence of a defective joint and the position of the defective joint in the friction stir welding joint. be able to. Therefore, it is extremely easy and easy to distinguish between those requiring repair and those not requiring repair, and the position of the part requiring repair can be specified accurately and easily. Therefore, the man-hour and cost for repairing the joint after friction stir welding can be greatly reduced, and the repaired portion is automatically detected optically, so that the detection accuracy is high, and
It is possible to improve the reliability of the friction stir welding joint in which the defective joint is repaired.
【図１】は摩擦撹拌接合装置の斜視図である。FIG. 1 is a perspective view of a friction stir welding apparatus.
【図２】は図１のＹ−Ｙ断面図である。FIG. 2 is a sectional view taken along line YY of FIG.
【図３】（ａ）は摩擦撹拌接合継ぎ手におけるトンネル
発生による継ぎ手不良の例示であり、（ｂ）は継ぎ手表
面のくぼみによる継ぎ手不良の例である。FIG. 3 (a) is an example of a joint failure due to the occurrence of a tunnel in a friction stir welding joint, and FIG. 3 (b) is an example of a joint failure due to a depression in the surface of the joint.
【図４】は実施の形態の斜視図である。FIG. 4 is a perspective view of the embodiment.
【図５】は実施の形態における継ぎ手不良検知システム
のブロック図である。FIG. 5 is a block diagram of a joint failure detection system according to the embodiment.
【図６】（ａ）はＣＣＤカメラによる開先隙間映像の２
値化画像であり、（ｂ）はＣＣＤカメラによる他の開先
隙間映像の２値化画像である。FIG. 6A is an image 2 of a groove gap image by a CCD camera.
(B) is a binarized image of another groove gap image by the CCD camera.
Ｈ：摩擦撹拌接合装置のヘッド Ｍ：前進駆動モータ Ｐ：アルミ板材 ｂ：開先隙間中心の基準線からのずれ量 Ｔ：摩擦撹拌接合工具 １：摩擦撹拌接合工具のピン ２：摩擦撹拌接合工具の本体 ３：摩擦撹拌接合工具の肩部 ４１：ＣＣＤカメラ ４２：開先 ４２ａ：開先の隙間４２ａ ４３：画像処理面積 ５１：画像処理装置 ５２：ＣＰＵ ５３，５４：メモリ H: Head of friction stir welding apparatus M: Forward drive motor P: Aluminum plate material b: Deviation from center line of groove gap from reference line T: Friction stir welding tool 1: Friction stir welding tool pin 2: Friction stir welding tool Main body 3: Shoulder of friction stir welding tool 41: CCD camera 42: Groove 42a: Groove 42a of groove 42: Image processing area 51: Image processing device 52: CPU 53, 54: Memory
フロントページの続き (56)参考文献 特開 平11−291067（ＪＰ，Ａ) 特開 平11−90655（ＪＰ，Ａ) 特開 平10−175089（ＪＰ，Ａ) 特開 平10−52773（ＪＰ，Ａ) 特開2000−48196（ＪＰ，Ａ) (58)調査した分野(Int.Cl.7，ＤＢ名) B23K 20/12 Continuation of the front page (56) References JP-A-11-291067 (JP, A) JP-A-11-90655 (JP, A) JP-A-10-175089 (JP, A) JP-A-10-52773 (JP) , A) JP-A-2000-48196 (JP, A) (58) Fields investigated (Int. Cl. 7 , DB name) B23K 20/12
Claims (6)
向前方に設けたＣＣＤカメラで、接合される隙間を常時
撮影し、 摩擦撹拌接合開始点からの前進距離を常時計測し、 上記ＣＣＤカメラで撮影した隙間映像を画像処理し、画
像中の隙間の幅を演算し、この演算値を基準値と比較し
て、その結果を上記前進距離とともにメモリに記録す
る、摩擦撹拌接合における継ぎ手不良検知方法。1. A CCD camera provided in front of a welding tool of a friction stir welding apparatus in the advancing direction to constantly photograph a gap to be welded, and constantly measure a forward distance from a friction stir welding start point. Image processing of the gap image taken in step 2, calculates the width of the gap in the image, compares this calculated value with the reference value, and records the result in the memory together with the above-mentioned advance distance, detection of joint failure in friction stir welding Method.
隙間異常信号を発信させ、この隙間異常信号が発信され
る度にこれを上記前進距離とともにメモリに記録する、
請求項１の摩擦撹拌接合における継ぎ手不良検知方法。2. When the gap area is larger than a reference value,
A gap abnormality signal is transmitted, and each time this gap abnormality signal is transmitted, this is recorded in a memory together with the advance distance.
A method for detecting a joint failure in friction stir welding according to claim 1.
向前方に設けたＣＣＤカメラで、接合される隙間を常時
撮影し、 摩擦撹拌接合開始点からの前進距離を常時計測し、 上記ＣＣＤカメラで撮影した隙間映像を画像処理し、画
像中の隙間の中心線の基準線に対する横方向へのずれ量
を演算し、当該演算値を基準値と比較して、その結果を
上記前進距離とともにメモリに記録する、摩擦撹拌接合
における継ぎ手不良検知方法。3. A CCD camera provided in front of a welding tool of a friction stir welding apparatus in a traveling direction to constantly photograph a gap to be welded, and constantly measure a forward distance from a friction stir welding start point. Image processing of the gap image photographed in the above, calculates the amount of lateral displacement of the center line of the gap in the image with respect to the reference line, compares the calculated value with the reference value, and stores the result together with the advance distance in the memory. Method for detecting joint failure in friction stir welding recorded in
量が基準値よりも大きいとき、隙間異常信号を発信さ
せ、この異常信号が発信される度にこれを上記前進距離
とともにメモリに記録する、請求項３の摩擦撹拌接合に
おける継ぎ手不良検知方法。4. A gap abnormality signal is transmitted when the amount of deviation of the gap from the reference line in the lateral direction is larger than a reference value. Each time this abnormality signal is transmitted, this is recorded in a memory together with the advance distance. The method for detecting a joint failure in friction stir welding according to claim 3.
像処理し、画像中の隙間の中心線の基準線に対する横方
向へのずれ量を演算し、当該演算値を基準値と比較し
て、その結果を上記前進距離とともにメモリに記録す
る、請求項１の摩擦撹拌接合における継ぎ手不良検知方
法。5. A gap image photographed by said CCD camera is subjected to image processing, a shift amount of a center line of the gap in the image with respect to a reference line in a lateral direction is calculated, and the calculated value is compared with a reference value. 2. The method for detecting a joint failure in friction stir welding according to claim 1, wherein the result is recorded in a memory together with the advance distance.
よりも大きいとき、隙間異常信号を発信させ、この異常
信号が発信される度にこれを上記前進距離とともにメモ
リに記録する、請求項２の摩擦撹拌接合における継ぎ手
不良検知方法。6. When a gap amount of the gap area in the lateral direction is larger than a reference value, a gap abnormality signal is transmitted, and every time this abnormality signal is transmitted, this is recorded in a memory together with the advance distance. A method for detecting a joint failure in friction stir welding according to claim 2.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000167054A JP3274453B2 (en) | 2000-06-05 | 2000-06-05 | Joint failure detection method in friction stir welding |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000167054A JP3274453B2 (en) | 2000-06-05 | 2000-06-05 | Joint failure detection method in friction stir welding |
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| Publication Number | Publication Date |
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| JP3274453B2 true JP3274453B2 (en) | 2002-04-15 |
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| KR101564166B1 (en) | 2014-03-10 | 2015-10-28 | 세방전지(주) | Ultrasonic fusion inspection system and the method thereof |
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|---|---|---|---|---|
| JP3311590B2 (en) * | 1996-08-06 | 2002-08-05 | 株式会社日立製作所 | Friction welding method |
| JP3333411B2 (en) * | 1996-12-18 | 2002-10-15 | 株式会社日立製作所 | Friction stir welding method and friction stir welding device |
| JP3070735B2 (en) * | 1997-07-23 | 2000-07-31 | 株式会社日立製作所 | Friction stir welding method |
| JPH11291067A (en) * | 1998-04-09 | 1999-10-26 | Hitachi Ltd | Friction joining method |
| JP2000048196A (en) * | 1998-07-27 | 2000-02-18 | Miyachi Technos Corp | Method for recording welded situation and state, and device therefor |
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