WO2016090903A1 - 窄间隙焊接电弧摇动的适应控制方法及装置 - Google Patents

窄间隙焊接电弧摇动的适应控制方法及装置 Download PDF

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Publication number
WO2016090903A1
WO2016090903A1 PCT/CN2015/082903 CN2015082903W WO2016090903A1 WO 2016090903 A1 WO2016090903 A1 WO 2016090903A1 CN 2015082903 W CN2015082903 W CN 2015082903W WO 2016090903 A1 WO2016090903 A1 WO 2016090903A1
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Prior art keywords
groove
arc
image
welding
width
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English (en)
French (fr)
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王加友
朱杰
苏娜
杨茂森
黎文航
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Jiangsu University of Science and Technology
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Jiangsu University of Science and Technology
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Priority to US15/534,005 priority Critical patent/US10870162B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127—Means for tracking lines during arc welding or cutting
    • B23K9/1272—Geometry oriented, e.g. beam optical trading
    • B23K9/1274—Using non-contact, optical means, e.g. laser means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/02—Seam welding; Backing means; Inserts
    • B23K9/0213—Narrow gap welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/02—Seam welding; Backing means; Inserts
    • B23K9/022—Welding by making use of electrode vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1087—Arc welding using remote control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/164—Arc welding or cutting making use of shielding gas making use of a moving fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode

Definitions

  • the invention relates to the field of welding technology, and particularly relates to a method and a device for adaptively controlling a narrow gap welding arc motion under conditions of varying groove width.
  • Narrow gap MIG welding is an efficient, high quality, low cost welding method.
  • the groove width and the center position of the weld will be changed, even if the arc welding method is adopted.
  • the high-speed rotating arc welding method, the serpentine welding method and the like the new process of controlling the penetration of the sidewall of the groove can not ensure that the arc always uniformly and effectively heats the sidewall of the groove, and it is also difficult to ensure a stable weld height, thereby affecting the welding. quality.
  • Japanese Patent No. JP55048475A entitled “Narrow Gap Automatic Welding Method” discloses the use of a wheel-type wire-cutting mechanism to cause arc-shaped bending deformation in advance, and the motor drives the door-plate rocking mechanism through the worm gear device to drive the
  • the arc of the end of the wire in the arc-shaped curved state of the straight guide wire tube is reciprocatingly shaken in the narrow gap groove; at the same time, the groove width is detected by the tapered roller contact probe, and
  • the potentiometer connected to the roller probe mechanism converts the change of the groove width into an electric signal, and finally controls the wire swinging angle by the door plate type shaking mechanism to automatically adapt to the change of the groove width.
  • the disadvantages are as follows: 1) The wheel type bending mechanism and the worm-and-worm type rocking mechanism are complicated, and it is inconvenient to adjust the wire bending degree and the arc shaking radius; 2) the wire pre-deformation and the rocking guiding mechanism are away from the protruding end of the wire, so that the wire is from the contact tip After the sending, the shaking rule is not strong; 3) the contact groove width sensing probe is easy to wear, and the sensing detection point is not synchronized with the welding arc position, so the sensing precision is low; 4) the rocking control device has poor controllability , resulting in reduced accuracy of arc shaking control.
  • the Chinese patent number is ZL200810236274.5, the name is “shaking arc narrow gap melting gas protection welding method and device”, and the hollow shaft motor directly drives the microbend conductive rod to reciprocate around the central axis of the welding torch, driving from the center of the straight conductive nozzle
  • the arc sent from the end of the wire is arc-shaped in the narrow gap welding groove to realize the narrow arc welding of the shaking arc.
  • the invention overcomes the above-mentioned deficiencies of the prior art, and does not need to remotely pre-deform the welding wire, but directly provides the end bending guide for the welding wire by bending the conductive rod, thereby simplifying the design of the arc shaking mechanism and making the welding wire have strong regularity.
  • the arc directivity is good, and the arc shaking control precision is high; in addition, by using curved conductive rods with different bending angles and bending lengths, the arc shaking radius can be conveniently adjusted to adapt to welding applications with different groove widths.
  • the disadvantage is that for the common narrow groove gap welding application, no specific technical solutions are involved, and it is difficult to make the variable gap narrow gap welding process practical.
  • the narrow gap groove width extraction precision is low, the arc shaking control precision is not high, the welding environment adaptability is not strong, and the like, the invention provides a control precision, engineering practicability, good environmental adaptability, implementation Convenient narrow gap welding arc shaking adaptive control method and device, detecting the groove width information according to the infrared vision sensor, and adjusting the arc shaking angle in real time by bending the conductive rod type shaking arc torch to realize arc shaking according to the change of the groove width Adaptive control of the angle.
  • the technical solution adopted by the adaptive control device for narrow gap welding arc shaking proposed by the invention comprises: a narrow gap welding torch, an arc shaking parameter control system, a computer image processing system and an infrared camera system; wherein the bending conduction in the narrow gap welding torch One end of the rod is connected to the motor drive and the feeding mechanism, and the other end is connected with the straight conductive nozzle.
  • the welding wire passing through the narrow gap welding torch extends into the groove to be welded whose groove width varies, and the welding arc is generated;
  • the infrared camera system includes digital Infrared camera and infrared filter system;
  • the computer image processing system comprises an image acquisition card, a groove width extraction module and a shaking angle calculation module which are sequentially connected, the image acquisition card is connected with the infrared camera through a video line; the output of the shaking angle calculation module is connected to the arc
  • the parameter control system is shaken; the arc shaking parameter control system is connected to the motor drive and the feeding mechanism in the welding torch through the control line, and the infrared camera and the image acquisition card are respectively connected through the signal line.
  • the technical solution adopted by the control method for the narrow gap welding arc shaking adaptive control device is: the infrared camera system acquires the infrared image of the welding area by the arc position external triggering mode, and after the computer image processing, extracts the groove width information in real time, And calculating the target value of the arc shaking angle according to the width of the groove; then, the arc shaking parameter control system controls the motor driving and the feeding mechanism to directly rotate the bending conductive rod, and controls the arc to be in the position to be welded with the target rocking angle as the welding torch The arc-shaped trajectory is shaken to realize adaptive control of the arc shaking angle according to the change of the groove width.
  • control method of the adaptive control device for narrow-gap welding arc shaking of the present invention specifically includes the following steps:
  • the preset rocking arc radius r, the reservation process gap g, the groove width variation determination threshold value TH w, and the initial value of the groove width G s0, calculated by the initial groove width G s0 (regarded The initial rocking angle ⁇ 0 corresponding to the sampling value at the actual width A 0 B 0 of the groove; then the torch moves forward with the infrared camera system at the welding speed V w while the arc shaking parameter control system is controlled by the welding torch
  • the arc is oscillated in a reciprocating arc-shaped trajectory with a rocking angle of ⁇ 0 in the groove to be welded;
  • the arc shaking parameter control system sends an arc shooting and image to the infrared camera and the image acquisition card according to the motor rotation position detection signal P M when the arc is biased to the left or right side wall of the to-be-welded groove (or at the center of the groove)
  • the computer image processing system acquires the welding area image, and the width extraction module extracts the groove width in real time through image processing;
  • the groove width extraction module extracts the current detected value G i of the groove width in real time, and Find the total n (n ⁇ 1) or i together with the nearest (n-1) (i ⁇ n) or (i-1) (i ⁇ n) groove width detection values acquired at other positions.
  • the median or average value of the groove width detection values is taken as the current sample value G si of the groove width at A i B i , and then input into the shaking angle calculation module;
  • the shaking angle calculation module compares the current sampling value G si of the groove width with the previous sampling value G s(i-1) , and if the absolute value of the difference ⁇ G si ⁇ TH w , the actual width of the groove is not adjusted.
  • a i B i is the arc at a rocking angle ⁇ i; otherwise, by the swing angle computing module according to a groove width of the current sample value G si, the reservation process and the gap g rocking arc radius r, is calculated to obtain the arc a i B i
  • the arc shaking parameter control system drives the bending conductive rod through the motor driving and feeding mechanism to control the arc to oscillate in a circular arc shape with an angle ⁇ i so that the arc stays at the side wall D i
  • the distance from the side of the M i to the edge of the groove is equal to the set reserved process gap g; the above steps 2 to 4 are repeated until the end of the welding process.
  • the control method further includes:
  • the method for extracting the width of the groove in real time by the width extraction module is: when the arc is biased to the left side wall of the groove to be welded, the image intercepting window on the right side of the groove is adjusted according to the change of the lateral position of the right edge line of the groove.
  • the method for extracting the groove width in real time by the width extraction module is: extracting the position coordinates of the highest point of the arc region by processing the global welding image, and determining the left and right of the groove according to the vertical coordinate value of the highest point.
  • the detection point has the same ordinate value, which is the median or average value of m (m ⁇ 1) position detection values on the groove edge line in the position adaptive moving image capturing window; intercepted in the processing image intercepting window
  • the median method is firstly filtered, then the gray image of the global image image is analyzed, and the peak and valley points of the molten pool image and the background image gray distribution are automatically searched for and the threshold point is determined, and the Dajin method is performed on the full window image.
  • Adaptive threshold segmentation processing finally using the Canny edge detection operator to extract the edge line of the groove; in the processing of the global welding image, first adopt the median method filtering and contrast stretching processing, and then perform global fixed threshold segmentation on the welding image.
  • Arc contour after morphological corrosion treatment of the arc region contour, extract the position coordinates of the highest point of the arc region; according to arc shooting and image acquisition
  • the pulse trigger signal P A or the abscissa value of the highest point of the arc region identifies and confirms that the arc is biased to the left side wall of the groove or to the right side wall of the groove or at the center of the groove.
  • the infrared camera is used to detect the narrow gap groove width in real time in non-contact mode.
  • the detection point and the arc position have good synchronism, the detection sensitivity and detection precision are high, and the resistance to welding spatter, smoke and arc arc light is strong.
  • the welding image can be acquired, and the multiple detection of the groove width can be realized in one shaking period, thereby improving the real-time performance of the groove width sensing detection and the arc shaking angle control.
  • Figure 1 is a block diagram of the adaptive control system for narrow gap welding arc shaking.
  • Figure 2 is a schematic diagram of the adaptive control process for narrow gap welding arc shaking.
  • Figure 3 is a schematic diagram of the calculation of the arc shaking radius and the arc shaking angle.
  • FIG. 4 is a schematic diagram of the principle of the method for extracting the width of the groove; wherein, FIG. 4(a) is a schematic diagram of the position extraction of the right edge of the groove when the arc is biased to the left side wall of the groove, and FIG. 4(b) is the right side of the arc biased to the groove.
  • the schematic diagram of the left edge position of the groove at the edge of the wall is extracted.
  • FIG. 5 is a schematic diagram of the principle of the second method for extracting the groove width; wherein, FIG. 5(a) is before the arc is biased to the left side wall of the groove.
  • the schematic diagram of the secondary groove width extraction is shown in Fig. 5(b), which is the schematic diagram of the current groove width extraction when the arc is deflected to the right side wall of the groove.
  • FIG. 6 is a flow chart of width extraction using the groove width extraction method 1.
  • FIG. 7 is a flow chart of width extraction using the groove width extraction method 2.
  • FIG. 8 is a view showing an embodiment of a method for extracting a narrow gap groove width.
  • Fig. 9 is a view showing an embodiment of a method for extracting a narrow gap groove width.
  • Figure 1 1 - arc; 2 - straight conductive nozzle; 3 - bent conductive rod; 4 - motor drive and feed mechanism; 5 - welding wire; 6 - wire feeder; 7 - workpiece; Shake trajectory; 9—beveled to be welded; 10—arc vibration parameter control system; 11—computer image processing system; 12—infrared camera; 13—infrared filter system; 14—image acquisition card; 15—groove width extraction Module; 16—shake angle calculation module; V w — welding speed, P M — motor rotation position detection signal, P A — arc shooting and image acquisition trigger signal.
  • FIG. 2 A 0 B 0 — the actual width of the narrow gap groove at the arc opening; ⁇ 0 — the initial rocking angle of the arc at the actual width A 0 B 0 of the groove; the arc M 0 O 10 D 0 — the actual width of the groove
  • ⁇ the bending angle of the bent conductive rod 3
  • h the height of the torch, that is, the height of the contact tip 2 to the workpiece
  • O 4j O 1j the centerline of the groove 9
  • O 1j the actual width of the groove A j B j at the midpoint of the arc trajectory
  • O 4j the actual width of the groove A j B j at the center of the torch
  • Figure 4 and Figure 5 17 - right image capture window; 18 - left image capture window; 19 - groove right edge; 20 - groove left edge; 21 - molten pool trailing edge; 22 - molten pool front; L 1i — the current distance from the right edge 19 of the groove to the left edge of the global image, L 2i — the current distance from the left edge 20 of the groove to the left edge of the global image, G i — the current detected value of the groove width; D w1 — right The positioning point of the image capturing window 17, D w2 - the positioning point of the left image capturing window 18; C 1 - the highest point of the arc area in the previous detection, C 2 - the highest point of the arc area in the current detection; L 1 (i- 1) - the previous distance from the right edge 19 of the groove to the left edge of the global image; L 2(i-1) - the previous distance from the left edge 20 of the groove to the left edge of the global image; G i-1 - the width of the
  • the adaptive control system for narrow gap welding arc shaking includes: a narrow gap welding torch, an arc shaking parameter control system 10, a computer image processing system 11 and an infrared camera system.
  • the narrow gap welding torch is composed of a motor driving and feeding mechanism 4, a bending conductive rod 3, a straight conductive nozzle 2, a nozzle mechanism, etc.
  • the motor driving and feeding mechanism 4 can be directly driven by a hollow shaft motor, or can be ordinary
  • the motor is indirectly driven by the drive pair and is preferably driven directly by the hollow shaft motor.
  • the straightened welding wire 5 passes through the wire feeder 6, and sequentially passes through the center hole of the motor driving and feeding mechanism 4, the bent conductive rod 3 and the straight conductive tip 2, and is sent out to reach the bevel 9 to be welded.
  • Welding arc 1 The bevel 9 to be welded is a narrow gap welding groove whose groove width varies.
  • the brush in the motor drive and feed mechanism 4 directs the welding current into the welding arc 1 circuit to realize the welding feeding without the winding of the welding cable;
  • the gas supply system provides the welding area where the arc 1 is located through the nozzle mechanism in the welding torch Active or inert protective gas, but does not require a nozzle mechanism when welding with a self-shielded flux cored wire, nor does it need to provide a shielding gas to the weld area.
  • This bent conductive rod type rocking mechanism provides better arc directivity and simplifies the design of the torch mechanism.
  • the infrared camera system includes a digital infrared camera 12 and an infrared filter system 13.
  • the infrared filter system 13 is coaxially connected to the infrared camera 12 and is installed directly in front of the infrared camera 12.
  • the infrared camera 12 may be of a charge coupled device (CCD) type or a complementary metal oxide semiconductor (CMOS) type, and is preferably of a CMOS type.
  • CMOS complementary metal oxide semiconductor
  • the infrared camera 12 is fixedly connected in front of or directly behind the welding torch, so that the infrared camera 12 and the bottom surface of the bevel 9 to be welded are at an angle ⁇ , so that the infrared camera 12 can capture the image of the welding area in the bevel 9 to be welded.
  • the infrared camera 12 with a zoom range of 18 to 45 mm and an aperture of 5.6 to 32 is selected to obtain an image of the welding area in the external trigger mode.
  • the filter system 13 includes a narrow band filter, a neutral dimming plate, and a cover glass (ie, a UV mirror), wherein the narrow band filter has a center wavelength of 700 to 1100 nm, and the neutral dimming plate has a transmittance of 1 to 50%.
  • the UV mirror is used to prevent welding splashes.
  • the arc 1 arc and the molten pool self-radiation light are used as the light source, the neutral light reduction sheet is used to adjust the light intensity, and the filter system 13 filters out the arc, smoke, splash and the like, and the clear welding can be collected. Area image.
  • the computer image processing system 11 mainly includes an image capturing card 14 connected in sequence, a groove width extracting module 15 and a rocking angle calculating module 16, and is also provided with hardware devices suitable for a general computer such as a display and a memory.
  • the image capture card 14 is placed in the card slot of the computer image processing system 11 and connected to the infrared camera 12 through a video line.
  • the image of the soldering area captured by the infrared camera 12 is sent to the computer image processing system 11 via the image capture card 14 for processing. Displayed on a display in computer image processing system 11 for monitoring.
  • the output of the rocking angle calculation module 16 is coupled to the arc rocking parameter control system 10.
  • the arc rocking parameter control system 10 connects the welding torch through the control line, inputs arc shaking parameters to the torch, and controls the motor drive and the feed mechanism 4 to rotate.
  • the arc shaking parameter control system 10 is also connected to the infrared through signal lines Camera 12 and image capture card 14.
  • the method for adapting and controlling the narrow gap welding arc shaking of the present invention is as follows: the infrared camera system acquires the welding area image by the arc position external triggering mode, and performs real-time sensing on the welding groove width; then, the computer image processing system 11 passes After the image processing extracts the groove width value, the arc shaking angle target value is calculated. Finally, the arc shaking parameter control system 10 controls the motor driving and feeding mechanism 4 to directly drive the bending conductive rod 3 to drive the straight conductive tip 2 to be sent out.
  • the arc 1 at the end of the welding wire 5 is oscillated in the to-be-welded groove 9 with respect to the circular arc-shaped trajectory 8 of the welding torch at the target rocking angle, so as to achieve adaptive control of the arc shaking angle according to the change of the groove width.
  • the specific steps are:
  • Step 1 Referring to Figure 1, Figure 2 and Figure 3, specifically:
  • a represents the length of the bent portion O 3 E of the bent conductive rod 3
  • b represents the length of the straight contact tip 2
  • h represents the height of the torch
  • ⁇ represents the bending angle of the bent conductive rod 3.
  • the calculation result of the arc shaking radius r should satisfy the condition r ⁇ (G max -2g)/2, where G max represents the maximum possible width of the groove and g represents the reserved process gap.
  • the sampled value at 0 and, in order to obtain sufficient symmetry for the two sidewalls of the groove, it is necessary to select a suitable reserved process gap g: the arc of the arc relative to the torch at A 0 B 0
  • the projection of the shaking track 8 intersects the A 0 B 0 line segment at two points M 0 and D 0 (the M 0 point is close to the left A 0 point, the D 0 point is close to the right B 0 point), and the line segments A 0 M 0 and D 0
  • the reserved process gap g is the arc axis to the left and right sides of the groove in the direction perpendicular to the welding speed V w .
  • the shortest distance of the wall is generally 0.5 to 2 mm.
  • the rocking angle calculation module 16 calculates the initial rocking angle ⁇ at the actual width of the groove A 0 B 0 by the following formula (3). 0 , and the calculated initial shaking angle ⁇ 0 is output to the arc shaking parameter control system 10.
  • the actual width of the groove in an arc swing at an angle A j B j ⁇ j the actual width of the groove in an arc swing at an angle A j B j ⁇ j:
  • Step 2 During the movement of the torch, the photoelectric (or electromagnetic) detecting device in the motor driving and feeding mechanism 4 detects the rotational position of the motor in real time, and inputs the generated motor rotational position detecting signal P M to the arc shaking parameter control system. 10, thereby indirectly detecting the position of the arc 1 in the to-be-weld groove 9 relative to the groove center line O 2 O 1i .
  • the arc shaking parameter control system 10 is simultaneously directed to the infrared camera 12 according to the input motor rotational position detecting signal P M when the arc 1 is biased toward the left side wall or the right side wall (or the center of the groove) of the bevel 9 to be welded.
  • the external trigger signal input terminal and the welding image acquisition card 14 output an arc shooting and image acquisition trigger signal P A , so that the computer image processing system 11 can acquire the welding area image at any time.
  • the arc shaking parameter control system 10 outputs an arc shooting and image acquisition pulse signal P A , and the computer image processing system 11 acquires a frame welding area image, which is then sent to the width extraction module 15 for image processing and real time groove Width extraction (the specific method of real-time extraction of groove width, see later).
  • Step 3 When the torch moves from the groove width A 0 B 0 to the arc, it reaches the position where the actual width of the groove is A i B i (see Figure 2), correspondingly the torch center projection from the original O At 40 o'clock, the O 4i point is moved, and the projection of the arc arc-shaped trajectory 8 intersects the A i B i line segment at two points M i and D i .
  • the groove width extraction module 15 processes the welding area image at the groove actual width A i B i (the actual sampling point number i ⁇ 1), and extracts the current detection value G i of the groove width at A i B i in real time, Then, the current detected value G i is obtained together with the nearest (n-1) (i ⁇ n) or (i-1) (i ⁇ n) groove width detection values previously acquired at other positions.
  • the groove width extraction module 15 inputs the current sample value Gsi of the groove width at A i B i into the shaking angle calculation module 16.
  • the arc shaking parameter control system 10 controls the motor driving and feeding mechanism 4 to drive the bending conductive rod 3 in real time, and drives the welding arc 1 at the end of the welding wire 5 to make a circular arc of angle ⁇ i , so that the arc 1 is on the side.
  • the distance between the wall dwelling points D i and M i to the edge of the groove is equal to the set reserved process gap g, respectively, so that the adaptive adjustment and control of the narrow gap welding arc shaking is realized, so as to be on both sides of the bevel 9 to be welded A uniform penetration is formed on the wall; steps 2 through 4 above are repeated until the end of the welding process.
  • the previous sampling value G s0 of the groove width is actually the groove actual The initial value of the groove width at the width A 0 B 0 .
  • the arc rocking angle target value ⁇ i is not adaptively controlled, the arc 1 is tilted to the side of the groove D i or M i , and the arc 1 axis to the side of the groove 9
  • the wall distance A i M i or D i B i will change continuously; when the distance is too large, the sidewall melting depth of the groove 9 will be reduced, and when it is too small, the undercut defect and/or the sidewall arcing may occur.
  • the phenomenon causes the weld forming quality to deteriorate and the joint performance to decrease.
  • the invention adopts the infrared camera to detect the width of the narrow gap groove in a non-contact manner, the detection point is synchronized with the arc position, the detection sensitivity is good, the detection precision is high, the anti-arc, spatter and smoke dust interference ability is strong, and the arc can be improved
  • the precision of the control of the shaking angle enables precise control of the penetration depth of the two side walls of the groove 9; if the invention is used in conjunction with the welding seam tracking and welding deposition amount control system, the welding of the narrow gap welding groove can be realized Through the simultaneous control of the amount of penetration and welding, a high-quality narrow gap welded joint with uniform penetration of the bevel sidewall and uniform weld height can be obtained.
  • the groove width extraction module 15 When the groove width extraction module 15 performs real-time extraction of the groove width, there are two methods for extracting the groove width, wherein the groove mouth
  • the principle of the width extraction method 1 is as shown in FIG. 4, and specifically has the following steps:
  • the groove is adjusted right according to the change of the last two detection values of the lateral position of the right edge line 19 of the groove.
  • the side image capturing window 17 locates the abscissa value X 1i of the point D w1 , and then uses the image capturing window 17 on the right side of the groove to intercept the right side image of the groove which is not subject to arc interference, and then extracts the groove in the image intercepting window 17 After the right edge line 19, the current distance L 1i of the right edge line 19 of the groove to the left boundary of the global image is obtained;
  • the groove is left adaptively according to the change of the last two detection values of the lateral position of the left edge line 20 of the groove.
  • the side image capture window 18 locates the abscissa value X 2i of the point D w2 , and then uses the left side image intercepting window 18 to intercept the left side image of the groove that is not subject to arc interference, and then intercepts the image intercept window window 18 on the left side of the groove.
  • the current distance L 1i or L 2i of the groove right edge line 19 or the groove left edge line 20 to the left edge of the global image is determined in steps A) and B). It can be reversed (in this case, the edge of the groove extracted in step C) also changes accordingly, and preferably step A), step B) is used in combination with step C).
  • the image can extract 2 times of the narrow gap groove width (excluding the initial extraction); if the welding image during the arc motion is collected, at least 4 welding images can be obtained, but the 4 images are “arc Left-right-right-right-leftward or "arc-right-left-left-left-right” arrangement, not head-to-tail, then only 2 extractions of the groove width (without initial extraction).
  • the sampling frequency of the groove width extraction can be improved by adopting the preferred scheme or the width extraction according to the welding image during the arc motion, thereby improving the real-time performance of the groove width sensing detection and the arc shaking angle control.
  • the positional moving image capturing small window 17 or 18 intercepts the image of the groove edge region away from the arc side for processing, which can effectively avoid the motion arc interference, and further improve the sensing detection precision of the narrow gap groove width.
  • the principle of the real-time extraction method of the groove width obtained by the groove width extraction module 15 is as shown in FIG. 5 .
  • the image edge intercepting window 17 on the right side of the movable groove and the image capturing window 18 on the left side of the groove are simultaneously present, and specifically include the following step:
  • P) global (i.e. overall) welding image is processed to extract the arc region of highest point C position coordinate 1 or C 2, and according to the highest point of the arc region C ordinate value Y C1 or Y C2 1 or C 2, and determines an image
  • the ordinate value of the intercepting window 17 or 18 locating point D w1 or D w2 is Y C1 or Y C2 ; at the same time, the image capturing window of the right side of the groove is adaptively adjusted according to the change of the detected value of the lateral position of the groove edge line 19 or 20 17 or left side image capture window 18 positioning point D w1 or D w2 of the abscissa value X 1i or X 2i ;
  • the left image intercepting window 18 is used to intercept the image including the information of the left edge line 20 of the groove, and then the current distance L 2i of the left edge line 20 of the groove to the left boundary of the global image is obtained.
  • the order of the groove edge line 19 or 20 to the current boundary L 1i or L 2i of the global image may be determined in step Q) and step R). Upside down, and preferably the groove width information is extracted from the welding image when the arc is moved to the middle point O 1i of the shaking, and the step P) may be omitted at this time. Similarly, in the previous extraction as shown in Fig.
  • the groove width extraction method 2 the groove width can be extracted multiple times in one shaking period, wherein for the preferred embodiment, the arcing point O 1i is twice when the arc is shaken in one shaking period. Correspondingly, the groove width can be extracted twice. Moreover, in the groove width extraction method 2, the detection point of the groove left edge 20 or the right edge 19 to the global image left boundary distance L 2i or L 1i is preferably located in the left image capture window 18 or the right image capture At half the height of the window 17 and above, to minimize arc arc interference.
  • the right edge line 19 to the global image left boundary distance L 1i or L 1 (i-1) has the same detection point ordinate value; and, L 1i , L 2i , L 1(i-1) and L 2(i-1 ) the final detection value, may be taken as a small image window value m (m ⁇ 1) position detected value 19 or 20 or 17 or 18 average groove edge lines, the width of the groove to improve detection reliability.
  • the key to realize the function of the groove width extraction module 15 is image processing.
  • the groove width extraction method 1 uses the image processing technology to extract the groove width.
  • the main steps include the following two steps:
  • the method further comprises: 1 adapting and correcting the horizontal coordinate value X 1i or X 2i of the positioning point D w1 or D w2 of the moving image capturing window 17 or 18 according to the change of the lateral coordinate position of the groove edge line 19 or 20;
  • the image capture window position 2 for the real-time welding image collected by the digital infrared camera 12, using the mobile image intercepting window 17 or 18 to intercept the image of the area near the right side wall edge 19 or the left side wall edge 20 of the groove, and as much as possible Intercept the image of the edge of the groove away from the arc side; 3 use the median method to smooth the image of the moving small window 17 or 18; 4 to the full window image of the Otsu method ( ⁇ , translation, "Digital Image Processing (third Edition), Electronic Industry Press, 2011, p.
  • Figure 7 shows the process of extracting the groove width by using the image processing technology to extract the groove width. The following three steps are included:
  • the method further comprises: 1 using the arc shooting and image acquisition trigger signal P A input into the computer image processing system 11 , and also identifying and confirming according to the abscissa value X C1 or X C2 of the highest point C 1 or C 2 of the arc region;
  • the arc is biased to the left side wall of the groove or to the right side wall of the groove or at the center of the groove;
  • the algorithm for adaptively correcting the position of the moving image intercepting small window is:
  • Mobile image capture window 17 or 18 positioning point D w1 or D w2 ordinate adaptive correction algorithm in the groove width extraction method 2, according to the position of the arc point highest point C 1 or C 2 ordinate Y C1 or Y C2 , determining that the ordinate value of the point D w1 or D w2 of the moving image capturing window 17 or 18 is Y C1 or Y C2 .
  • the correction algorithm can also be applied to the method for extracting the groove width.
  • FIG. 8 is a view showing an embodiment of a method for detecting a narrow gap groove width.
  • the image capture small window 17 and the left image capture small window 18 locate the horizontal coordinate values of the points D w1 and D w2 , and the resulting image capture small window is at the position indicated by the white line frame in FIGS.
  • FIG. 9 is a view showing an embodiment of the method for extracting the narrow gap groove width, and the imaging conditions and the shaking arc welding test conditions are the same as those in the first embodiment.
  • Figure 9 (a) is a welding image obtained by the computer image processing system 11 when the arc is shaken to the right wall of the groove, and for the sake of expression, two small white lines are used to indicate the highest point C 2 according to the arc area. And the position of the groove edge lines 19 and 20 on the abscissa, the position of the adaptive small window 17, 18 is adaptively determined; FIG.
  • FIG. 9(b) is the image of the arc shape after fixed threshold segmentation and morphological corrosion, thereby extracting the arc The highest point C 2 position coordinates, and determine the ordinate position of the mobile small windows 17 and 18 (as shown in Figure 9 (a)); for the global image after median filtering and contrast stretching processing, in Figure 9 ( a) and (b) at the position indicated by the white line frame, the small window image of the edge area of the groove obtained by the movable small windows 17 and 18 respectively is as shown in Figs. 9(c) and (d); The small window image is processed by the Otsu method for full window adaptive threshold segmentation.
  • the obtained edge edge region image is shown in Fig. 9(e) and (f), where the white area represents the molten pool area; the Canny edge operator is used to extract The image of the edge of the groove, as shown by the white lines in Figures 9(g) and (h) .
  • G max is the maximum value that may occur during the change of the groove gap
  • control system 10 including the completion of shaking frequency F, the residence time sidewalls t s, an initial swing arc ⁇ 0 of the three swinging arc of preset parameters.
  • the arc shaking parameter control system 10 controls the motor drive and the feeding mechanism 4 to rotate into the bent conductive rod 3 of the groove 9 to drive the welding wire.
  • the arc shaking parameter control system 10 controls the motor drive and the feeding mechanism 4 to rotate into the bent conductive rod 3 of the groove 9 to drive the welding wire.
  • the groove width extraction module 15 extracts the slope according to the groove width extraction method similar to that in the first embodiment.
  • the range of the arc rocking angle adjustment is 38.9 ° to 180.0 °.
  • a control method similar to the flat position narrow gap welding arc shaking control according to the third embodiment is employed.
  • the vertical groove width varying in the range of 8 to 16 mm
  • the arc shaking angle is changed from 50.8° to 180.0°
  • the arc is inclined.
  • the range of variation during adjustment is 44.0° ⁇ 122.1°
  • the range of arc angle adjustment is 38.9° ⁇ 102.1°
  • the arc swing angle is adjusted.
  • the range of variation is 34.9 ° ⁇ 88.9 °.
  • the arc shaking angle is adjusted from small to large in real time, so that the two sides of the narrow gap vertical welding groove are uniformly and stably melted. Deep, guarantees the quality of narrow gap vertical welding.

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Abstract

公开一种窄间隙焊接电弧摇动的适应控制方法和装置，该控制装置由红外摄像机系统、计算机图像处理系统（11）、电弧摇动参数控制系统（10）和折弯导电杆式摇动电弧焊炬等构成；红外摄像机系统以外触发方式采集电弧（1）偏向坡口（9）左侧壁或右侧壁时的焊接区域红外图像，经过计算机图像处理后，实时提取坡口宽度信息，并计算电弧摇动角度目标值；电弧摇动参数控制系统（11）控制电机驱动机构转动折弯导电杆（3），带动焊接电弧按摇动角度目标值作圆弧形摇动，实现根据坡口宽度变化对电弧摇动角度的适应控制。该控制装置构成简单，坡口宽度检测精度高，环境适应性好，工程实用性强，可与焊缝跟踪和焊接熔敷量控制系统联合使用，达到变坡口窄间隙焊接质量适应控制的目的。

Description

窄间隙焊接电弧摇动的适应控制方法及装置 技术领域
本发明涉及焊接技术领域，特指一种在坡口宽度变化条件下对窄间隙焊接电弧运动进行适应控制的方法及装置。
背景技术
窄间隙熔化极气体保护焊是一种高效、高质量、低成本的焊接方法。在实际窄间隙焊接过程中，往往由于受坡口加工误差、工件装配误差、焊接热变形等因素的影响，会导致坡口宽度大小和焊缝中心位置发生变化，使得即使采用摇动电弧焊接法、高速旋转电弧焊接法、蛇形焊丝焊接法等控制坡口侧壁熔透的新工艺也不能保证电弧始终均匀有效地加热坡口侧壁，同时也难以保证获得稳定的焊缝高度，从而影响焊接质量。对于这种坡口宽度变化的变坡口焊接问题，需要引入针对电弧位置的适应控制机制。
日本专利号为JP55048475A、名称为“窄间隙自动焊接方法”的专利文献中，公开采用轮式弯丝机构使焊丝预先产生圆弧状弯曲变形，电机通过蜗轮蜗杆装置驱动门板式摇动机构，带动从直型导丝管中心孔送出的呈圆弧状弯曲状态的焊丝端部的电弧，在窄间隙坡口内作往复式摇动；同时，通过锥形辊轮接触式探头探测坡口宽度，并通过与辊轮探头机构相连的电位差计将坡口宽度变化转换成电信号，最后通过门板式摇动机构控制焊丝摇动角度，以自动适应坡口宽度的变化。其缺点是：1)轮式弯丝机构和蜗轮蜗杆式摇动机构复杂，不方便调节焊丝弯曲度和电弧摇动半径；2)焊丝预变形和摇动导向机构远离焊丝伸出端，使得焊丝从导电嘴送出后摇动规则性不强；3)接触式坡口宽度传感探头易磨损，且传感检测点与焊接电弧位置不同步，使得传感精度较低；4)摇动控制装置可控性较差，导致电弧摇动控制精度下降。
中国专利号为ZL200810236274.5、名称为“摇动电弧窄间隙熔化极气体保护焊接方法及装置”，采用空心轴电机直接驱动微弯导电杆绕焊炬中心轴线往复运动，带动从直型导电嘴中心孔送出焊丝端部的电弧在窄间隙焊接坡口内作圆弧形摇动，实现摇动电弧窄间隙焊接。该发明克服了上述先有技术的不足，无需对焊丝进行远程预变形处理，而是直接通过折弯导电杆为焊丝提供末端弯曲导向，从而简化了电弧摇动机构设计，并使得焊丝摇动规则性强，电弧指向性好，电弧摇动控制精度高；此外，通过采用不同折弯角度和折弯长度的弯曲导电杆，可方便地调节电弧摇动半径，以适应不同坡口宽度的焊接应用。其缺点是：对于常见的变坡口窄间隙焊接应用，未涉及具体的实施技术方案，难以使变坡口窄间隙焊接工艺实用化。
发明内容
针对现有技术存在窄间隙坡口宽度提取精度低、电弧摇动控制精度不高、焊接环境适应性不强等缺点，本发明提出一种控制精度高、工程实用性强、环境适应性好、实施方便的窄间隙焊接电弧摇动的适应控制方法及装置，根据红外视觉传感器检测坡口宽度信息，并通过折弯导电杆式摇动电弧焊炬实时调整电弧摇动角度，实现根据坡口宽度变化对电弧摇动角度的自适应控制。
本发明提出的窄间隙焊接电弧摇动的适应控制装置采用的技术方案是：包括窄间隙焊炬、电弧摇动参数控制系统、计算机图像处理系统以及红外摄像系统；其中窄间隙焊炬中的折弯导电杆一端与电机驱动及馈电机构相连、另一端与直型导电嘴相接，穿过窄间隙焊炬的焊丝伸入坡口宽度变化的待焊坡口中产生焊接电弧；红外摄像系统包括数字式红外摄像机及红外滤光系统；计算机图像处理系统包含依次连接的图像采集卡、坡口宽度提取模块和摇动角度计算模块，图像采集卡通过视频线与红外摄像机相连；摇动角度计算模块的输出连接电弧摇动参数控制系统；电弧摇动参数控制系统通过控制线与焊炬中的电机驱动及馈电机构相连，并通过信号线分别连接红外摄像机和图像采集卡。
本发明提出的窄间隙焊接电弧摇动的适应控制装置的控制方法采用的技术方案是：红外摄像系统以电弧位置外触发方式获取焊接区域红外图像，经过计算机图像处理后，实时提取坡口宽度信息，并根据坡口宽度计算出电弧摇动角度目标值；然后，电弧摇动参数控制系统控制电机驱动及馈电机构直接转动折弯导电杆，控制电弧在待焊坡口内以目标摇动角度作相对于焊炬的圆弧形轨迹摇动，实现根据坡口宽度变化对电弧摇动角度的自适应控制。
进一步地，本发明窄间隙焊接电弧摇动的适应控制装置的控制方法具体又包括如下步骤：
①在摇动角度计算模块中，预设电弧摇动半径r、预留工艺间隙g、坡口宽度变化判定阈值THw以及坡口宽度初始值Gs0后，计算出坡口初始宽度Gs0(视同为坡口实际宽度A0B0处的采样值)处所对应的初始摇动角度α0；然后焊炬与红外摄像系统一起以焊接速度Vw向前移动，同时电弧摇动参数控制系统通过焊炬控制电弧在待焊坡口内作摇动角度为α0的往复式圆弧形轨迹摇动；
②电弧摇动参数控制系统根据电机转动位置检测信号PM，在电弧偏向待焊坡口左侧壁或右侧壁(或处于坡口中心)时，向红外摄像机和图像采集卡发出电弧拍摄与图像采集触发信号PA，使计算机图像处理系统获取焊接区域图像后，宽度提取模块通过图像处理实时提取坡口宽度；
③当焊炬移动到坡口实际宽度为AiBi(实际采样点序数i≥1)的任意位置处时，坡口宽度 提取模块实时提取该处坡口宽度当前检测值Gi，并与之前在其他位置获取的最近(n-1)(i≥n时)或(i-1)(i＜n时)个坡口宽度检测值一起，求出共n(n≥1)或i(i＜n时)个坡口宽度检测值的中值或平均值，作为AiBi处坡口宽度当前采样值Gsi，再输入至摇动角度计算模块中；
④摇动角度计算模块将坡口宽度当前采样值Gsi与前次采样值Gs(i-1)进行比较，若二者差值的绝对值ΔGsi≤THw，则不调整坡口实际宽度为AiBi处的电弧摇动角度αi；否则，由摇动角度计算模块根据坡口宽度当前采样值Gsi、预留工艺间隙g和电弧摇动半径r，计算求得AiBi处电弧摇动角度目标值αi后，电弧摇动参数控制系统再通过电机驱动及馈电机构驱动折弯导电杆，控制电弧作角度为αi的圆弧形轨迹摇动，使电弧在侧壁停留点Di和Mi处至坡口侧壁距离分别与设定的预留工艺间隙g相等；重复上述步骤②至步骤④，直至焊接过程结束。
所述控制方法，其特征还包括：
在步骤①中，预留工艺间隙g是在与焊接速度Vw垂直方向上电弧轴线至坡口左右侧壁的最短距离，预设的电弧摇动半径r≥(Gmax－2g)/2，其中，r＝(a+b)sinβ+htanβ，Gmax是坡口宽度可能的最大值，a是焊炬的折弯导电杆(3)折弯部分的长度，b是焊炬的直型导电嘴(2)的长度，h是焊炬高度，β是折弯导电杆(3)的折弯角度；在步骤④中，坡口宽度变化判定阈值THw≤0.5mm，摇动角度αi＝2arcsin{(Gsi-2g)/2r}。
在所述步骤②中，宽度提取模块实时提取坡口宽度的方法一是：当电弧偏向待焊坡口左侧壁时，根据坡口右边缘线的横向位置变化调整坡口右侧图像截取窗口定位点的横坐标值，截取坡口右侧图像，提取坡口右边缘线以及坡口右边缘线至全局图像左边界的当前距离L1i；当电弧偏向待焊坡口右侧壁时，根据坡口左边缘线的横向位置变化调整坡口左侧图像截取窗口定位点的横坐标值，截取坡口左侧图像，提取坡口左边缘线以及坡口左边缘线至全局图像左边界的当前距离L2i，计算出坡口宽度当前检测值Gi＝(L1i－L2i)；
在所述步骤②中，宽度提取模块实时提取坡口宽度的方法二是：通过对全局焊接图像进行处理，提取电弧区域最高点的位置坐标，根据最高点的纵坐标值确定坡口左、右侧图像截取窗口的定位点的纵坐标值，根据坡口边缘线的横向位置变化调整图像截取窗口定位点的横坐标值；用右侧图像截取窗口截取包含坡口右边缘线信息的图像后，再求取坡口右边缘线至全局图像左边界的当前距离L1i；在同一幅图像中用坡口左侧图像截取窗口截取包含坡口左边缘线信息的图像后，再求取坡口左边缘线至全局图像左边界的当前距离L2i，计算出坡口宽度的当前检测值Gi＝(L1i－L2i)。
在所述宽度提取模块实时提取坡口宽度的方法中：坡口左边缘线至全局图像左边界距离 L2i的检测点的纵坐标值，与坡口右边缘线至全局图像左边界距离L1i的检测点的纵坐标值相同，为所述位置自适应移动式图像截取窗口内坡口边缘线上m(m≥1)个位置检测值的中值或平均值；在处理图像截取窗口截取的小窗口图像时，先进行中值法滤波，再对所全局图像图像进行灰度分析，自动寻找熔池图像与背景图像灰度分布的峰谷点并确定阈值点，对全窗口图像进行大津法自适应阈值分割处理，最后用Canny边缘检测算子提取坡口边缘线；在对全局焊接图像处理时，先采用中值法滤波和对比度拉伸处理，然后对焊接图像进行全局固定阈值分割后提取电弧区域轮廓，再对电弧区域轮廓进行形态学腐蚀处理后，提取电弧区域最高点的位置坐标；根据电弧拍摄与图像采集脉冲触发信号PA或电弧区域最高点横坐标值，辨识并确认电弧偏向坡口左侧壁或是偏向坡口右侧壁或是在坡口中心。
本发明与先有技术相比，其有益效果是：
1)采用红外摄像机以非接触方式实时检测窄间隙坡口宽度，其检测点与电弧位置同步性好，检测灵敏度和检测精度高，抗焊接飞溅、烟尘和电弧弧光干扰能力强。
2)采用电机直接(或通过传动副)驱动的折弯导电杆式摇动机构，使得电弧指向性更好，电弧摇动角度控制精度更高，同时还简化了焊炬机构设计。
3)通过小窗口截取远离电弧侧的坡口边缘区域图像进行处理，可有效避免运动电弧干扰，进一步提高了窄间隙坡口宽度的传感检测精度。
4)对焊接图像进行处理时，根据电弧和坡口边缘位置的变化，实时调整坡口边缘区域图像截取窗口的位置，提高了传感检测方法的环境适应性和工作可靠性。
5)根据电弧摇动位置信号以外触发方式采集焊接图像，可实现在一个摇动周期内对坡口宽度的多次检测，从而提高了坡口宽度传感检测和电弧摇动角度控制的实时性。
附图说明
下面结合附图和具体实施方式，对本发明作进一步详细说明，但本发明保护范围不限于下述实施例，凡采用等同替换或等效变换形式获得的技术方案，均在本发明保护范围之内。
图1为窄间隙焊接电弧摇动的适应控制系统原理框图。
图2为窄间隙焊接电弧摇动的适应控制过程示意图。
图3为电弧摇动半径和电弧摇动角度计算原理图。
图4为坡口宽度提取方法一的原理示意图；其中，图4(a)为电弧偏向坡口左侧壁时坡口右边缘位置提取原理图，图4(b)为电弧偏向坡口右侧壁时坡口左边缘位置提取原理图。
图5为坡口宽度提取方法二的原理示意图；其中，图5(a)为电弧偏向坡口左侧壁时前 次坡口宽度提取原理图，图5(b)为电弧偏向坡口右侧壁时当前坡口宽度提取原理图。
图6为采用坡口宽度提取方法一的宽度提取流程图。
图7为采用坡口宽度提取方法二的宽度提取流程图。
图8为窄间隙坡口宽度提取方法一的实施例图。
图9为窄间隙坡口宽度提取方法二的实施例图。
图1中：1—电弧；2—直型导电嘴；3—折弯导电杆；4—电机驱动及馈电机构；5—焊丝；6—送丝机；7—工件；8—电弧圆弧形摇动轨迹；9—待焊坡口；10—电弧摇动参数控制系统；11—计算机图像处理系统；12—红外摄像机；13—红外滤光系统；14—图像采集卡；15—坡口宽度提取模块；16—摇动角度计算模块；Vw—焊接速度，PM—电机转动位置检测信号，PA—电弧拍摄与图像采集触发信号。
图2中：A0B0—启弧处窄间隙坡口实际宽度；α0—坡口实际宽度A0B0处的电弧初始摇动角度；圆弧M0O10D0—坡口实际宽度A0B0处相对于焊炬的电弧摇动轨迹；O2O1i—坡口9中心线；O10—坡口实际宽度A0B0处电弧摇动轨迹中点；O40—坡口实际宽度A0B0处焊炬中心在坡口9底面的投影；A0M0＝D0B0＝AiMi＝DiBi＝g，表示坡口实际宽度A0B0或AiBi处在与焊接速度Vw垂直方向上电弧轴线O3Mj(j＝0或i，参见图3)至坡口侧壁距离，即预留工艺间隙；O40M0＝O40D0＝O4iMi＝O4iDi＝r，为电弧摇动半径；AiBi—任意位置窄间隙坡口实际宽度；αi—坡口实际宽度AiBi处电弧摇动角度目标值；圆弧MiO1iDi—坡口实际宽度AiBi处相对于焊炬的电弧摇动轨迹；O1i—坡口实际宽度AiBi处电弧摇动轨迹中点；O4i—坡口实际宽度AiBi处焊炬中心在坡口9底面的投影。
图3中：β—折弯导电杆3的折弯角度；h—焊炬高度，即导电嘴2至工件的高度；j—电弧在坡口内的位置序数(j＝0，...，i，…)；O4jO1j—坡口9中心线；O1j—坡口实际宽度AjBj处电弧摇动轨迹中点；O4j—坡口实际宽度AjBj处焊炬中心在坡口9底面的投影；AjMj＝DjBj＝g，表示坡口实际宽度AjBj处在与焊接速度Vw垂直方向上电弧轴线O3Mj至坡口侧壁距离，即预留工艺间隙；O4jMj＝O4jDj＝r，为电弧摇动半径。
图4和图5中：17—右侧图像截取窗口；18—左侧图像截取窗口；19—坡口右边缘；20—坡口左边缘；21—熔池后沿；22—熔池前沿；L1i—坡口右边缘19至全局图像左边界的当前距离，L2i—坡口左边缘20至全局图像左边界的当前距离，Gi—坡口宽度的当前检测值；Dw1—右侧图像截取窗口17的定位点，Dw2—左侧图像截取窗口18的定位点；C1—前次检测时电弧区域最高点，C2—本次检测时电弧区域最高点；L1(i-1)—坡口右边缘19至全局图像左边界的前次距离；L2(i-1)—坡口左边缘20至全局图像左边界的前次距离；Gi-1—坡口宽度的前次检测值。
具体实施方式
如图1所示，窄间隙焊接电弧摇动的适应控制系统包括：窄间隙焊炬、电弧摇动参数控制系统10、计算机图像处理系统11以及红外摄像系统。
窄间隙焊炬由电机驱动及馈电机构4、折弯导电杆3、直型导电嘴2、喷嘴机构等构成，电机驱动及馈电机构4可以为空心轴电机直接驱动式，也可以为普通电机通过传动副间接驱动式，并且优选空心轴电机直接驱动式。经过校直的焊丝5经过送丝机6，并依次穿过电机驱动及馈电机构4、折弯导电杆3和直型导电嘴2的中心孔后送出，伸入待焊坡口9中产生焊接电弧1。待焊坡口9是坡口宽度变化的窄间隙焊接坡口。电机驱动及馈电机构4中的电刷将焊接电流导入焊接电弧1回路，实现在焊接电缆无缠绕下的焊接馈电；供气系统通过焊炬中的喷嘴机构向电弧1所在的焊接区域提供活性或惰性保护气体，但是当采用自保护药芯焊丝焊接时则不需要喷嘴机构，也无需向焊接区域提供保护气体。这种折弯导电杆式摇动机构使得电弧指向性更好，同时还简化了焊炬机构设计。
红外摄像系统包括数字式红外摄像机12及红外滤光系统13，红外滤光系统13与红外摄像机12同轴相连，并安装在红外摄像机12的正前方。红外摄像机12可以为电荷耦合器件(CCD)式或互补金属氧化物半导体(CMOS)式，并且优选CMOS式。将红外摄像机12固定连接在焊炬的正前方或正后方，使红外摄像机12与待焊坡口9底面成一定夹角γ，便于红外摄像机12摄取到待焊坡口9内的焊接区域图像。选用变焦范围为18～45mm、光圈为5.6～32的红外摄像机12，在外触发方式下获取焊接区域图像。滤光系统13包括有窄带滤光片、中性减光片、防护玻璃(即UV镜)，其中窄带滤光片中心波长为700～1100nm，中性减光片透过率为1～50％，UV镜用于防焊接飞溅。窄间隙焊接时，利用电弧1弧光和熔池自身辐射光作为光源，采用中性减光片调节光强，并通过滤光系统13滤除弧光、烟尘、飞溅等干扰，可采集到清晰的焊接区域图像。
计算机图像处理系统11主要包含依次连接的图像采集卡14、坡口宽度提取模块15和摇动角度计算模块16，此外还配套有显示器、存储器等普通计算机应有的硬件设备。图像采集卡14置于计算机图像处理系统11的卡槽内并通过视频线与红外摄像机12相连，红外摄像机12摄取到的焊接区域图像经图像采集卡14送入计算机图像处理系统11处理，同时在计算机图像处理系统11中的显示器上显示，以便监控。摇动角度计算模块16的输出连接电弧摇动参数控制系统10，电弧摇动参数控制系统10通过控制线连接焊炬，向焊炬输入电弧摇动参数，控制电机驱动及馈电机构4转动。电弧摇动参数控制系统10还通过信号线分别连接红外 摄像机12和图像采集卡14。
本发明窄间隙焊接电弧摇动的适应控制方法，其总体技术方案是：红外摄像系统以电弧位置外触发方式获取焊接区域图像，对焊接坡口宽度进行实时传感；然后，计算机图像处理系统11通过图像处理提取出坡口宽度值后，计算出电弧摇动角度目标值；最后，电弧摇动参数控制系统10控制电机驱动及馈电机构4直接驱动折弯导电杆3，带动从直型导电嘴2送出焊丝5端部的电弧1在待焊坡口9内以目标摇动角度作相对于焊炬的圆弧形轨迹8摇动，实现根据坡口宽度变化对电弧摇动角度的自适应控制。其具体步骤是：
步骤①：参见图1、图2和图3，具体又包括：
1)选定电弧摇动半径r，或选配长度为b的直型导电嘴2。根据焊炬上安装的折弯导电杆3、直型导电嘴2以及设定的焊炬高度h，根据下式(1)计算可得到窄间隙焊接过程中电弧1的摇动半径r，其计算原理如图3所示(r＝O4jMj＝O4jDj，在A0B0处j＝0)：
r＝(a+b)sinβ+ht a nβ  (1)
其中，a表示折弯导电杆3折弯部分O3E的长度，b表示直型导电嘴2的长度，h表示焊炬高度，β表示折弯导电杆3的折弯角度。电弧摇动半径r的计算结果，应满足条件r≥(Gmax－2g)/2，这里Gmax表示坡口宽度可能的最大值，g表示预留工艺间隙。
也可以按照r≥(Gmax－2g)/2的原则，先选定电弧摇动半径r，再根据给定的折弯导电杆3的折弯长度a和折弯角度β、以及焊炬高度h，并依照式(1)配用相应长度为b的直型导电嘴2。在窄间隙焊接过程中，折弯导电杆3、直型导电嘴2以及焊炬高度h三者通常不变，因而电弧1的摇动半径r保持恒定。
2)确定坡口宽度初始值Gs0、预留工艺间隙g。焊前，用测量出窄间隙待焊坡口9启弧处的坡口宽度初始值Gs0，即A0B0线段的长度(见图2)，并视同为坡口实际宽度A0B0处的采样值；并且，为了使坡口两侧壁获得对称性好的足够熔深，需要选定合适的预留工艺间隙g：在A0B0处电弧相对于焊炬的圆弧形摇动轨迹8的投影与A0B0线段相交于M0、D0两点(M0点靠近左侧A0点、D0点靠近右侧B0点)，线段A0M0和D0B0的长度就是预留工艺间隙g，即g＝A0M0＝D0B0，该预留工艺间隙g也就是在与焊接速度Vw垂直方向上电弧轴线至坡口左、右侧壁的最短距离，一般取为0.5～2mm。
3)预设电弧摇动控制参数及工艺参数，调整焊炬初始状态。将上述坡口宽度初始值Gs0、窄间隙焊接工艺要求的预留工艺间隙g、计算得到的或选定的电弧摇动半径r、以及坡口宽度变化判定阈值THw(一般小于0.5mm)，一起预设在计算机图像处理系统11的摇动角度计算模块16中；再将焊炬连同红外摄像机12一起移至坡口实际宽度为A0B0的启弧处，并设定焊 炬高度h，此时焊炬在待焊坡口9底面的投影为O40；在电弧摇动参数控制系统10上，预设本次窄间隙焊接要求的电弧摇动频率f和电弧1在坡口两侧壁处停留时间ts等摇动工艺参数，并进行自动寻找摇动中点O10定位(见图2)。
4)确定电弧的初始摇动角度α0。根据上述预留工艺间隙g、坡口宽度初始值Gs0、以及电弧摇动半径r，摇动角度计算模块16通过下式(3)计算出坡口实际宽度为A0B0处的初始摇动角度α0，并将计算得出的初始摇动角度α0输出至电弧摇动参数控制系统10中。根据图3，在坡口实际宽度为AjBj处电弧摇动角度αj：
Figure PCTCN2015082903-appb-000001
所以，在实际宽度为A0B0处的初始摇动角度α0为：
Figure PCTCN2015082903-appb-000002
5)启动摇动电弧焊接过程。在坡口实际宽度A0B0处，引燃焊接电弧1，由电弧摇动参数控制系统10控制电机驱动及馈电机构4转动可伸入待焊坡口9的折弯导电杆3，绕焊炬中心线O3O4j(参见图3，在A0B0处j＝0)往复转动，带动从直型导电嘴2中心孔送出的焊丝5端部的焊接电弧1，以摇动轨迹中点O10为起点，在待焊坡口9内作摇动频率为f、摇动角度为α0，且相对于焊炬、关于摇动轨迹中点O10(参见图2)对称的往复式圆弧形轨迹8摇动，并在接近待焊坡口9左右两侧壁处(即M0、D0点处)作停留时间为ts的停留；同时，拖动机构带动焊炬整体与红外摄像系统一起以焊接速度Vw向前移动。
步骤②：在焊炬移动过程中，电机驱动及馈电机构4中的光电(或电磁)检测装置实时检测电机转动位置，并将产生的电机转动位置检测信号PM输入至电弧摇动参数控制系统10中，从而间接检测电弧1在待焊坡口9内相对坡口中心线O2O1i的位置。
然后，电弧摇动参数控制系统10根据输入的电机转动位置检测信号PM，在电弧1偏向待焊坡口9左侧壁或右侧壁(或位于坡口中心)时，同时向红外摄像机12的外触发信号输入端和焊接图像采集卡14输出电弧拍摄与图像采集触发信号PA，使计算机图像处理系统11可获取任意时刻的焊接区域图像。电弧摇动参数控制系统10每输出一个电弧拍摄与图像采集脉冲信号PA，计算机图像处理系统11就获取一帧焊接区域图像，该图像随即被送入宽度提取模块15中经过图像处理后实时坡口宽度提取(具体的坡口宽度实时提取方法，详见后文)。
步骤③：当焊炬从坡口宽度A0B0启弧处移动，到达了坡口实际宽度为AiBi(参见图2)的任意位置处，相应地焊炬中心投影从原先的O40点移至O4i点，电弧圆弧形摇动轨迹8的投影与AiBi线段相交于Mi、Di两点。
同时，坡口宽度提取模块15对坡口实际宽度AiBi(实际采样点序数i≥1)处焊接区域图像进行处理，实时提取AiBi处的坡口宽度当前检测值Gi，然后将该当前检测值Gi与先前在其他位置获取的最近(n-1)(i≥n时)或(i-1)(i＜n时)个坡口宽度检测值一起，求出共n(n≥1)或i(i＜n时)个坡口宽度检测值的中值或平均值，并将此中值或平均值作为AiBi处的坡口宽度当前采样值Gsi，以减少焊接飞溅和其他随机干扰对坡口宽度检测精度的影响；最后，坡口宽度提取模块15将AiBi处坡口宽度当前采样值Gsi输入至摇动角度计算模块16中。
步骤④：摇动角度计算模块16将AiBi处的坡口宽度当前采样值Gsi与前次在其他位置处的采样值Gs(i-1)进行比较，若二者差值的绝对值ΔGsi不大于坡口宽度变化判定阈值THw，即ΔGsi＝|Gsi－Gs(i-1)|≤THw，则不调整坡口实际宽度为AiBi处的电弧摇动角度αi；否则，摇动角度计算模块16根据坡口宽度当前采样值Gsi、预留工艺间隙g和电弧摇动半径r，并由式(2)演变得到的式(4)计算求得AiBi处电弧摇动角度目标值αi，并将其输送至电弧摇动参数控制系统10中。
Figure PCTCN2015082903-appb-000003
此时，电弧摇动参数控制系统10实时控制电机驱动及馈电机构4驱动折弯导电杆3，带动焊丝5端部的焊接电弧1作角度为αi的圆弧形摇动，使得电弧1在侧壁停留点Di和Mi处至坡口侧壁距离分别与设定的预留工艺间隙g相等，如此实现窄间隙焊接电弧摇动的自适应调整和控制，从而在待焊坡口9两侧壁上形成均匀一致的熔深；重复上述步骤②至步骤④，直至焊接过程结束。在所述步骤④中，当实际采样点序数i＝1时，即当电弧到达坡口实际宽度为A1B1处时，坡口宽度前次采样值Gs0，实际上即为坡口实际宽度A0B0处坡口宽度初始值。
在变坡口情形下，若不对电弧摇动角度目标值αi进行自适应控制，则电弧1在摇动至坡口侧壁处Di或Mi点停留时，电弧1轴线至坡口9的侧壁距离AiMi或DiBi会不断变化；当该距离过大时，会引起坡口9的侧壁熔深减小，过小时则易出现咬边缺陷和/或侧壁打弧现象，导致焊缝成形质量变差，接头性能下降。而本发明采用红外摄像机这种以非接触方式检测窄间隙坡口宽度的方法，检测点与电弧位置同步，检测灵敏度好，检测精度高，抗弧光、飞溅、烟尘干扰能力强，可提高对电弧摇动角度的控制精度，从而实现对坡口9两侧壁熔深的精确控制；若本发明与焊缝跟踪和焊接熔敷量控制系统配合使用，可实现对变坡口窄间隙焊接坡口熔透和焊接熔敷量的同时控制，从而可获得坡口侧壁熔透均匀、焊缝高度一致的高质量窄间隙焊接接头。
坡口宽度提取模块15进行坡口宽度实时提取时，具有两种坡口宽度提取方法，其中坡口 宽度提取方法一的原理如图4所示，具体有如下的步骤：
A)当电弧1偏向待焊坡口9左侧壁时，如图4(a)所示，先根据坡口右边缘线19横向位置最近两次检测值的变化量，自适应调整坡口右侧图像截取窗口17定位点Dw1的横坐标值X1i，再利用坡口右侧图像截取窗口17截取不受电弧干扰的坡口右侧图像，然后在图像截取窗口17截取图像内提取坡口右边缘线19后，再求取坡口右边缘线19至全局图像左边界的当前距离L1i；
B)当电弧1偏向待焊坡口9右侧壁时，如图4(b)所示，先根据坡口左边缘线20横向位置最近两次检测值的变化量，自适应调整坡口左侧图像截取窗口18定位点Dw2的横坐标值X2i，再利用坡口左侧图像截取窗口18截取不受电弧干扰的坡口左侧图像，然后在坡口左侧图像截取窗口窗口18截取图像内提取坡口左边缘线20后，再求取坡口左边缘线20至全局图像左边界的当前距离L2i，此时坡口宽度的当前检测值Gi＝(L1i－L2i)；
C)当电弧1再次偏向待焊坡口9左侧壁时，按照步骤A)所述方法提取坡口右边缘线19后，再提取坡口右边缘线19至全局图像左边界的下次距离L1(i+1)，此时窄间隙坡口宽度的下次检测值Gi+1＝(L1(i+1)－L2i)，以此类推。
在实施所述坡口宽度提取方法一时，步骤A)与步骤B)中求取坡口右边缘线19或坡口左边缘线20至全局图像左边界的当前距离L1i或L2i时先后顺序可以颠倒(此时步骤C)中所提取坡口边缘也相应变化)，而且优选步骤A)、步骤B)与步骤C)联合使用。
当只采用上述步骤A)与步骤B)组成的坡口宽度提取方法时，如果采集电弧在坡口两侧壁处停留期间的焊接图像，那么在一个摇动周期内可完整地获取两幅焊接图像，相应地仅能对坡口宽度值进行1次提取；如果采集电弧运动过程中的焊接图像，那么在一个摇动周期内至少可获取2对(4幅)焊接图像，相应地至少可对坡口宽度进行2次提取。当采用步骤A)、步骤B)与步骤C)联合使用的优选提取方案时，如果采集电弧在坡口两侧壁处停留期间的焊接图像，那么在一个摇动周期内可完整地获取两幅焊接图像，相应地可对窄间隙坡口宽度进行2次提取(不含初始提取)；如果采集电弧运动过程中的焊接图像，虽然也至少可获取4幅焊接图像，但是这4幅图像为“电弧偏左—偏右—偏右—偏左”或“电弧偏右—偏左—偏左—偏右”排列方式，并非头尾相连式，那么相应地也只能对坡口宽度进行2次提取(不含初始提取)。可见，采用其优选方案或者根据电弧运动过程中焊接图像进行宽度提取时，均可提高坡口宽度提取的采样频率，从而提高坡口宽度传感检测和电弧摇动角度控制的实时性。另外，通过所述位置移动式图像截取小窗口17或18截取远离电弧侧的坡口边缘区域图像进行处理，可有效避免运动电弧干扰，进一步提高了窄间隙坡口宽度的传感检测精度。
坡口宽度提取模块15实现的坡口宽度实时提取方法二的原理如图5所示，此时移动式坡口右侧图像截取窗口17、坡口左侧图像截取窗口18同时存在，具体包括如下步骤：
P)对全局(即整体)焊接图像进行处理，提取电弧区域最高点C1或C2的位置坐标，然后根据电弧区域最高点C1或C2的纵坐标值YC1或YC2，确定图像截取窗口17或18定位点Dw1或Dw2的纵坐标值为YC1或YC2；同时，根据坡口边缘线19或20横向位置检测值的变化，自适应调整坡口右侧图像截取窗口17或左侧图像截取窗口18定位点Dw1或Dw2的横坐标值X1i或X2i；
Q)用右侧图像截取窗口17截取包含坡口右边缘19信息的图像后，再求取坡口右边缘19至全局图像左边界的当前距离L1i；
R)在同一幅焊接图像中，用左侧图像截取窗口18截取包含坡口左边缘线20信息的图像后，再求取坡口左边缘线20至全局图像左边界的当前距离L2i，此时坡口宽度的当前检测值Gi＝(L1i－L2i)。
采用上述坡口宽度提取方法二进行坡口宽度提取时，其步骤Q)与步骤R)中求取坡口边缘线19或20至全局图像左边界的当前距离L1i或L2i时先后顺序可以颠倒，而且优选根据电弧运动至摇动中点O1i时的焊接图像提取坡口宽度信息，此时可省略所述步骤P)。类似地，在如图5(a)所示的前次提取中，坡口宽度的前次检测值Gi-1等于坡口右边缘线19至全局图像左边界的前次距离L1(i-1)减去坡口左边缘线20至全局图像左边界的前次距离L2(i-1)，即Gi-1＝(L1(i-1)－L2(i-1))。
采用所述坡口宽度提取方法二，在一个摇动周期内可对坡口宽度进行多次提取，其中对于其所述优选方案，在一个摇动周期内电弧摇动时两次经过摇动中点O1i，相应地可对坡口宽度进行2次提取。并且，在所述坡口宽度提取方法二中，坡口左边缘20或右边缘19至全局图像左边界距离L2i或L1i的检测点，优选位于左侧图像截取窗口18或右侧图像截取窗口17内高度的一半及以上位置处，以尽可能减少电弧弧光干扰。
在所述窄间隙坡口宽度的提取方法一和提取方法二中，坡口左边缘线20至全局图像左边界距离L2i或L2(i-1)的检测点纵坐标值，与坡口右边缘线19至全局图像左边界距离L1i或L1(i-1)的检测点纵坐标值相同；并且，L1i、L2i、L1(i-1)和L2(i-1)的最终检测值，可为图像截取小窗口17或18内坡口边缘线19或20上m(m≥1)个位置检测值的中值或平均值，以提高坡口宽度检测可靠性。
坡口宽度提取模块15功能实现的关键是图像处理，如图6所示为坡口宽度提取方法一采用图像处理技术提取坡口宽度的流程，主要包括以下两大步骤：
1)对小窗口截取图像进行处理，提取窄间隙坡口边缘。具体又包括：①根据坡口边缘线19或20横向坐标位置的变化，对移动式图像截取窗口17或18的定位点Dw1或Dw2横坐标值X1i或X2i进行适应性修正，确定图像截取窗口位置；②针对数字式红外摄像机12采集到的实时焊接图像，采用移动式图像截取窗口17或18截取坡口右侧壁边缘19或左侧壁边缘20附近区域图像，并尽可能地截取远离电弧侧的坡口边缘区域图像；③采用中值法对移动式小窗口17或18截取图像进行平滑滤波；④对全窗口图像进行大津法(阮秋琦等译，《数字图像处理(第三版)》，电子工业出版社，2011年，第479页)自适应阈值分割；⑤采用Canny边缘算子(李实英等译，《特征提取与图像处理(第二版)》，电子工业出版社，2013年，第103页)提取出熔池与坡口侧壁之间的边缘线19或20。
2)提取坡口宽度当前检测值。求取坡口右边缘19或左边缘20至全局图像左边界的当前距离为L1i或L2i，从而计算出坡口宽度的当前检测值Gi＝(L1i－L2i)。
图7所示为坡口宽度提取方法二采用图像处理技术提取坡口宽度的流程，包括以下三大步骤：
1)对整幅焊接区域红外图像进行全局图像处理，并确定图像截取小窗口位置。具体又包括：①针对数字式红外摄像机12采集到的实时焊接图像，采用中值法对全局图像(即整体图像)进行平滑滤波，以减低焊接图像中弧光、飞溅、烟尘、外部环境干扰引起的噪声；②在对图像灰度值分析的基础上，对输入图像灰度进行分段线性变换，以压缩背景区域灰度，提升熔池和电弧区域像素灰度值，增大边界处对比度，实现对图像对比度的拉伸处理，为后续阈值分割创造条件；③对全局图像进行固定阈值分割，即将包含不同灰度级的图像变为一幅二值图像，以简化图像层次，突出电弧区域轮廓；④对电弧轮廓进行形态学腐蚀处理，以消除焊丝端部反光区域的影响，提取出电弧基本形态，并求出电弧区域最高点C1或C2位置坐标值为(XC1，YC1)或(XC2，YC2)；⑤根据电弧区域最高点C1或C2的纵坐标值，确定移动式图像截取小窗口17或18的定位点Dw1或Dw2的纵坐标，同时根据坡口边缘线横向坐标位置的变化，可对移动式图像截取窗口17或18的定位点Dw1或Dw2的横坐标值X1i或X2i进行适应性修正，以提高红外视觉传感检测方法的环境适应性和工作可靠性。
2)对移动式小窗口截取的图像进行处理，提取窄间隙坡口边缘。具体又包括：①利用输入到计算机图像处理系统11中的电弧拍摄与图像采集触发信号PA，也可根据电弧区域最高点C1或C2的横坐标值XC1或XC2，辨识并确认电弧偏向坡口左侧壁或是偏向坡口右侧壁或是在坡口中心；②针对经过全局中值滤波和对比度拉伸处理过的焊接图像，采用移动式图像截取小窗口17或18截取坡口右侧壁边缘19或左侧壁边缘20附近区域图像，并尽可能地截取 远离电弧侧的坡口边缘区域图像，以减少计算机图像处理系统11的图像处理工作量，同时避免运动电弧干扰；③对所截取的全窗口图像进行灰度分析，自动寻找熔池图像与背景图像灰度分布的峰谷点并定位阈值点后，对全窗口图像进行大津法自适应阈值分割，即对图像进行黑白化处理，以突出边界，方便边缘提取；④采用Canny边缘算子对经过自适应阈值分割处理后的窗口图像进行平滑和滤波处理滤除噪声后，检测熔池与背景图像灰度发生变化的位置，在小窗口内提取出熔池与坡口侧壁之间的边缘线19或20。
3)计算坡口宽度当前检测值。计算坡口右边缘19至移动式图像截取小窗口17左边缘的当前距离Lyi、求取坡口右边缘19至全局图像左边界的当前距离为L1i＝(Lyi+X1i)，并计算坡口左边缘20至移动式图像截取小窗口18左边缘的当前距离Lzi、求取坡口左边缘20至全局图像左边界的当前距离为L2i＝(Lzi+X2i)，从而计算出坡口宽度的当前检测值Gi＝(L1i－L2i)。
在图6和图7所示的坡口宽度提取流程中，对移动式图像截取小窗口位置进行自适应修正的算法为：
1)移动式图像截取窗口17或18定位点Dw1或Dw2纵坐标自适应修正算法：在所述坡口宽度提取方法二中，根据电弧区域最高点C1或C2的位置纵坐标YC1或YC2，确定移动式图像截取窗口17或18的定位点Dw1或Dw2点的纵坐标值为YC1或YC2。该修正算法也可以推广应用于所述坡口宽度提取方法一。
2)移动式图像截取窗口17或18定位点Dw1或Dw2横坐标自适应修正算法：在所述坡口宽度提取方法一和方法二中，移动式图像截取窗口17定位点Dw1点的横坐标值X1i等于其前次设定值X1(i-1)与坡口右边缘线19位置最近两次检测值的变化量(L1(i-1)－L1(i-2))之和，即X1i＝X1(i-1)+(L1(i-1)－L1(i-2))；移动式图像截取窗口18定位点Dw2点的横坐标值X2i等于其前次设定值X2(i-1)与坡口左边缘线20位置最近两次检测值的变化量(L2(i-1)－L2(i-2))之和，即X2i＝X2(i-1)+(L2(i-1)－L2(i-2))。
以下提供本发明的4个实施例。
实施例1
图8为窄间隙坡口宽度检测方法一的实施例图。摄像条件为：数字式红外CMOS摄像机12的摄像角度γ＝25°、光圈为16，窄带滤光片中心波长为970nm、带宽25nm，中性减光片的透过率为10％；焊接条件为：采用平位置直流MAG电弧焊接，焊接电流300A，电弧电压30V，焊接速度20.3cm/min，焊炬高度h＝20mm，焊丝直径1.2mm，焊接保护气体Ar+20％CO2的流量为30L/min，Ⅰ型窄间隙低碳钢焊接坡口宽度为13mm，施焊时处于焊缝对中状态；电弧摇动工艺参数条件：摇动频率f＝2.5Hz，摇动半径r＝8.5mm，折弯导电杆3的折弯角度β＝8°, 摇动角度αj＝72°，电弧在坡口两侧壁处停留时间各为ts＝100ms，预留工艺间隙g＝1.5mm。
图8(a)和(b)分别为计算机图像处理系统11获取的电弧摇动至坡口左侧壁和右侧壁处开始停留时的焊接图像，可见电弧在坡口左右侧停留时焊丝至坡口左侧壁和右侧壁距离基本相等，说明处于焊缝对中状态；根据坡口右边缘线19和左边缘线20横向位置最近两次检测值得变化量，分别自适应调整坡口右侧图像截取小窗口17和左侧图像截取小窗口18定位点Dw1和Dw2的横坐标值，最终形成的图像截取小窗口处于图8(a)和(b)中白线框所示位置处；采用移动式小窗口17和18对焊接图像进行截取、并进行中值滤波后，获得的坡口边缘区域小窗口图像如图8(c)和(d)所示；对截取的小窗口图像采用大津法进行全窗口自适应阈值分割处理后，获得的坡口边缘区域图像如图8(e)和(f)所示，其中白色区域表示熔池区域；采用Canny边缘算子提取的坡口边缘图像，如图8(g)和(h)中的白线所示。
最后，根据坡口宽度检测方法一所述检测算法，并以移动式小窗口17或18内坡口边缘线19或20上间隔为10个像素的相邻3个(即m＝3)位置检测值的中值作为坡口宽度的当前检测值，求得坡口宽度的当前检测值Gi＝13.13mm，检测误差率为1％。
实施例2
图9为窄间隙坡口宽度提取方法二的实施例图，摄像条件和摇动电弧焊接试验条件与实施例1相同。图9(a)为计算机图像处理系统11获取的电弧摇动至坡口右侧壁处开始停留时的焊接图像，为了表达直观起见，这里用两个白线小窗口表示根据电弧区域最高点C2和坡口边缘线19和20横坐标位置变化，自适应确定的移动式小窗口17、18的位置；图9(b)为固定阈值分割和形态学腐蚀后的电弧形态图像，以此提取电弧最高点C2位置坐标，并确定移动式小窗口17和18的纵坐标位置(如图9(a)所示)；针对经过中值滤波和对比度拉伸处理后的全局图像，在图9(a)和(b)中白线框所示位置处，采用移动式小窗口17和18分别截取得到的坡口边缘区域小窗口图像如图9(c)和(d)所示；对截取的小窗口图像采用大津法进行全窗口自适应阈值分割处理后，获得的坡口边缘区域图像如图9(e)和(f)所示，其中白色区域表示熔池区域；采用Canny边缘算子提取的坡口边缘图像，如图9(g)和(h)中的白线所示。
最后，根据坡口宽度提取方法二所述检测算法，并以移动式小窗口17或18内坡口边缘线19或20上间隔为10个像素的相邻3个(即m＝3)位置检测值的中值作为坡口宽度的当前检测值，求得坡口宽度的当前检测值Gi＝13.27mm，检测误差率为2.08％。可见，对于同一个坡口宽度实际值(13.0mm)，采用检测方法二检测时，由于其移动式小窗口17中的小窗口图像受到了电弧弧光干扰，致使其检测误差比所述检测方法一的要大。
实施例3
平位置窄间隙焊接电弧摇动控制实施例。在不同的电弧摇动半径下，进行了平位置窄间隙焊接电弧摇动控制试验。试验条件包括：预留工艺间隙g＝2.0mm，摇动频率f＝2.5Hz，侧壁停留时间ts＝100ms，折弯导电杆3的折弯角度β＝8°，坡口宽度变化判定阈值THw＝0.2mm；随着坡口间隙在8～16mm范围内连续变化，焊接速度Vw对应地在30.4～15.2cm/min范围内自动调节，其余焊接试验条件同实施例1情形。
为了保证电弧摇动控制的有效性，当采用最小电弧摇动半径进行焊接时，在坡口可能的最大间隙处(即Gsi＝Gmax)，应能保证表达式(4)中的电弧摇动角度αi≤180°，因此焊前根据下式(5)确定电弧摇动的最小半径rmin：
rmin＝(Gmax-2g)/2  (5)
在表达式(5)中，Gmax为坡口间隙变化过程中可能出现的最大值，g为预留工艺间隙。相应地，在本实施例中，电弧摇动的最小半径rmin＝6mm，即电弧摇动半径r应不小于6mm。
为此，焊前选定电弧摇动半径r＝6mm，并根据已知的焊炬高度(h＝20mm)、折弯角度(β＝8°)、以及导电杆3折弯长度a＝7.3mm，依照式(1)计算出直型导电嘴2的长度b＝15.6mm，并选配相应长度的直型导电嘴2；再将摄像机12固连于准备好的焊炬上，移动焊炬至坡口实际宽度为8mm的启弧处，并将此处的坡口宽度初始值Gs0＝8.0mm、以及预留工艺间隙g＝2.0mm、坡口间隙变化判定阀值THw＝0.2mm、电弧摇动半径r＝6mm等初始控制参数，一同输入摇动角度计算模块16中；然后，在电弧摇动参数控制系统10上，设定电弧摇动频率f＝2.5Hz、电弧在坡口两侧壁处停留时间各为ts＝100ms，并在摇动角度计算模块16中，根据式(3)计算出与电弧摇动半径r相对应的电弧初始摇动角度α0＝38.9°后，将α0输入到电弧摇动参数控制系统10中，完成包括摇动频率f、侧壁停留时间ts、电弧初始摇动角度α0等三个电弧摇动参数的预设。
在对焊炬进行自动寻找电弧摇动中点O10操作后，引燃电弧1，电弧摇动参数控制系统10控制电机驱动及馈电机构4转动伸入坡口9的折弯导电杆3，带动焊丝5端部的焊接电弧1在坡口9内，按摇动频率f＝2.5Hz作相对于焊炬的、关于摇动中点O10(或O1i，参见图2)对称的往复式圆弧形轨迹8摇动，并在坡口9左右两侧壁处各停留时间ts＝100ms；同时，拖动机构带动焊炬整体与红外摄像系统一起以焊接速度Vw向前移动。
焊接过程中，采用红外CMOS摄像机12实时采集焊接区域图像，在计算机图像处理系统11中对焊接图像进行处理后，坡口宽度提取模块15按类似于实施例1的坡口宽度提取方法，提取坡口宽度的当前检测值Gi，并以最近5次(即n＝5)坡口宽度检测值的中间平均值 作为坡口宽度的当前采样值Gsi。若最近两次坡口宽度采样值变化量的绝对值ΔGsi不大于其误差控制阈值THw＝0.2mm，即ΔGsi＝|Gsi－Gs(i-1)|≤0.2mm，则不调整电弧摇动角度，其中Gs(i-1)为坡口宽度的前次采样值；否则，根据焊前设定的电弧摇动半径r和预留工艺间隙g、以及坡口宽度当前采样值Gsi，再根据表达式(4)计算出电弧摇动角度的当前目标值αi，并输入电弧摇动参数控制系统10，通过电机驱动及馈电机构4驱动折弯导电杆3，控制电弧1作角度为αi的圆弧形轨迹8摇动，使电弧在坡口侧壁停留点处至坡口侧壁距离与设定的预留工艺间隙g相等，从而在坡口宽度变化下保证了电弧能均匀有效地加热坡口侧壁，获得稳定的坡口侧壁熔深和一致的焊缝高度。
本实施例中，针对8～16mm范围内变化的坡口宽度，当电弧摇动半径r＝6mm时，电弧摇动角度调节时的变化范围为38.9°～180.0°。另外，在同样焊接条件下，采用与电弧摇动半径r＝6mm时同样的控制方法，针对r＝7、8、9、10mm情形，分别实施了电弧摇动适应控制。其控制结果是：当电弧摇动半径r＝7mm时，电弧摇动角度调节时的变化范围为33.2°～118.0°；当电弧摇动半径r＝8mm时，电弧摇动角度调节时的变化范围为29.0°～97.2°；当电弧摇动半径r＝9mm时，电弧摇动角度调节时的变化范围为25.7°～83.6°；当电弧摇动半径r＝10mm时，电弧摇动角度调节时的变化范围为23.1°～73.7°。
实施例4
立向位置窄间隙焊接电弧摇动控制实施例。在不同的电弧摇动半径下，进行了立向位置窄间隙焊接电弧摇动控制试验。试验条件包括：采用脉冲MAG电弧焊接，平均焊接电流150A，平均电弧电压22V，焊接速度9.1cm/min，焊炬高度h＝20mm，焊丝直径1.2mm，焊接保护气体Ar+20％CO2的流量为20L/min，坡口间隙在8～16mm范围内连续变化；电弧摇动频率f＝0.8Hz，电弧在坡口两侧壁处停留时间各为ts＝400ms，预留工艺间隙g＝1.0mm，其余试验条件同实施例1。另外，焊前根据表达式(5)求得电弧摇动的最小半径rmin＝7mm，即电弧摇动半径r应不小于7mm。
本实施例中，采用与实施例3所涉及的平位置窄间隙焊接电弧摇动控制类似的控制方法。针对8～16mm范围内变化的立向坡口宽度，当电弧摇动半径r＝7mm时，电弧摇动角度调节时的变化范围为50.8°～180.0°；当电弧摇动半径r＝8mm时，电弧摇动角度调节时的变化范围为44.0°～122.1°；当电弧摇动半径r＝9mm时，电弧摇动角度调节时的变化范围为38.9°～102.1°；当电弧摇动半径r＝10mm时，电弧摇动角度调节时的变化范围为34.9°～88.9°。
可见，为适应坡口宽度由小到大的变化，根据式(4)所提算法，电弧摇动角度由小到大地进行实时调整，使窄间隙立焊坡口两侧壁获得了均匀稳定的熔深，保证了窄间隙立焊质量。

Claims (9)

  1. 一种窄间隙焊接电弧摇动的适应控制装置，其特征是：包括窄间隙焊炬、电弧摇动参数控制系统(10)、计算机图像处理系统(11)以及红外摄像系统；窄间隙焊炬中的折弯导电杆(3)一端与电机驱动及馈电机构(4)相连、另一端与直型导电嘴(2)相接，穿过窄间隙焊炬的焊丝(5)伸入坡口宽度变化的待焊坡口(9)中产生焊接电弧(1)；红外摄像系统包括数字式红外摄像机(12)及红外滤光系统(13)；计算机图像处理系统(11)包含依次连接的图像采集卡(14)、坡口宽度提取模块(15)和摇动角度计算模块(16)，图像采集卡(14)通过视频线与红外摄像机(12)相连；摇动角度计算模块(16)的输出连接电弧摇动参数控制系统(10)；电弧摇动参数控制系统(10)通过控制线与焊炬中的电机驱动及馈电机构(4)相连，并通过信号线分别连接红外摄像机(12)和图像采集卡(14)。
  2. 一种根据权利要求1所述窄间隙焊接电弧摇动的适应控制装置的控制方法，其特征是：红外摄像系统以电弧位置外触发方式获取焊接区域红外图像，经过计算机图像处理系统(11)处理，实时提取坡口宽度信息；计算机图像处理系统(11)根据坡口宽度计算出电弧摇动角度目标值；电弧摇动参数控制系统(10)控制电机驱动及馈电机构(4)直接转动折弯导电杆(3)，控制电弧(1)在待焊坡口(9)内以目标摇动角度作相对于焊炬的圆弧形轨迹(8)摇动，实现根据坡口宽度变化对电弧摇动角度的自适应控制。
  3. 根据权利要求2所述的控制方法，其特征是具体包括以下步骤：
    ①在摇动角度计算模块(16)中，预设电弧摇动半径r、预留工艺间隙g、坡口宽度变化判定阈值THw以及坡口宽度初始值Gs0后，计算出坡口初始宽度Gs0处所对应的初始摇动角度α0，作为坡口实际宽度A0B0处的采样值，然后焊炬与红外摄像系统一起以焊接速度Vw向前移动，同时电弧摇动参数控制系统(10)通过焊炬控制电弧(1)在待焊坡口(9)内作摇动角度为α0的往复式圆弧形轨迹(8)摇动；
    ②电弧摇动参数控制系统(10)根据电机转动位置检测信号PM，在电弧(1)偏向待焊坡口(9)左侧壁或右侧壁或处于坡口中心时，向红外摄像机(12)和图像采集卡(14)发出电弧拍摄与图像采集触发信号PA，使计算机图像处理系统(11)获取焊接区域图像后，宽度提取模块(15)通过图像处理实时提取坡口宽度；
    ③当焊炬移动到坡口实际宽度为AiBi的任意位置处时，坡口宽度提取模块(15)实时提取该处坡口宽度当前检测值Gi，并与之前在其他位置获取的最近的当i≥n时的n-1 或i<n时的i-1个坡口宽度检测值一起，求出共n≥1时共n个或当i＜n时共i个坡口宽度检测值的中值或平均值，作为AiBi处坡口宽度当前采样值Gsi，再输入至摇动角度计算模块(16)中；其中i是实际采样点序数，i≥1；
    ④摇动角度计算模块(16)将坡口宽度当前采样值Gsi与前次采样值Gs(i-1)进行比较，若二者差值的绝对值ΔGsi≤THw，则不调整坡口实际宽度为AiBi处的电弧摇动角度αi；否则，摇动角度计算模块(16)根据坡口宽度当前采样值Gsi、预留工艺间隙g和电弧摇动半径r，计算求得AiBi处电弧摇动角度目标值αi后，电弧摇动参数控制系统(10)再通过电机驱动及馈电机构(4)驱动折弯导电杆(3)，控制电弧(1)作角度为αi的圆弧形轨迹(8)摇动，使电弧在侧壁停留点Di和Mi处至坡口侧壁距离分别与设定的预留工艺间隙g相等；
    ⑤重复上述步骤②至步骤④，直至焊接过程结束。
  4. 根据权利要求3所述的控制方法，其特征是：步骤②中，宽度提取模块(15)实时提取坡口宽度的方法一是：当电弧(1)偏向待焊坡口(9)左侧壁时，根据坡口右边缘线(19)的横向位置变化调整坡口右侧图像截取窗口(17)定位点的横坐标值，截取坡口右侧图像，提取坡口右边缘线(19)以及坡口右边缘线(19)至全局图像左边界的当前距离L1i；当电弧偏向待焊坡口(9)右侧壁时，根据坡口左边缘线(20)的横向位置变化调整坡口左侧图像截取窗口(18)定位点的横坐标值，截取坡口左侧图像，提取坡口左边缘线(20)以及坡口左边缘线(20)至全局图像左边界的当前距离L2i，计算出坡口宽度当前检测值Gi＝(L1i－L2i)。
  5. 根据权利要求3所述的控制方法，其特征是：步骤②中，宽度提取模块(15)实时提取坡口宽度的方法二是：通过对全局焊接图像进行处理，提取电弧区域最高点的位置坐标，根据最高点的纵坐标值确定坡口左、右侧图像截取窗口(18、17)的定位点的纵坐标值，根据坡口边缘线(20、19)的横向位置变化调整图像截取窗口(18、17)定位点的横坐标值；用右侧图像截取窗口(17)截取包含坡口右边缘线(19)信息的图像后，再求取坡口右边缘线(19)至全局图像左边界的当前距离L1i；在同一幅图像中用坡口左侧图像截取窗口(18)截取包含坡口左边缘线(20)信息的图像后，再求取坡口左边缘线(20)至全局图像左边界的当前距离L2i，计算出坡口宽度的当前检测值Gi＝(L1i－L2i)。
  6. 根据权利要求4或5所述的控制方法，其特征是：坡口左边缘线(20)至全局 图像左边界距离L2i的检测点的纵坐标值，与坡口右边缘线(19)至全局图像左边界距离L1i的检测点的纵坐标值相同，为破口左、右侧图像截取窗口(18、17)内坡口左、右边缘线(20、19)上m个位置检测值的中值或平均值，m≥1。
  7. 根据权利要求4或5所述的控制方法，其特征是：在处理图像截取窗口(17)或(18)截取的小窗口图像时，先进行中值法滤波，再对所全局图像图像进行灰度分析，自动寻找熔池图像与背景图像灰度分布的峰谷点并确定阈值点，对全窗口图像进行大津法自适应阈值分割处理，最后用Canny边缘检测算子提取坡口边缘线(19、20)；在对全局焊接图像处理时，先采用中值法滤波和对比度拉伸处理，然后对焊接图像进行全局固定阈值分割后提取电弧区域轮廓，再对电弧区域轮廓进行形态学腐蚀处理后，提取电弧区域最高点的位置坐标。
  8. 根据权利要求4或5所述的控制方法，其特征是：根据电弧拍摄与图像采集触发信号PA或电弧区域最高点横坐标值，辨识并确认电弧偏向坡口左侧壁或是偏向坡口右侧壁或是在坡口中心。
  9. 根据权利要求3所述的控制方法，其特征是：在步骤①中，预留工艺间隙g是在与焊接速度Vw垂直方向上电弧轴线至坡口左右侧壁的最短距离，预设的电弧摇动半径r≥(Gmax－2g)/2，其中，r＝(a+b)sinβ+h tanβ，Gmax是坡口宽度可能的最大值，a是焊炬的折弯导电杆(3)折弯部分的长度，b是焊炬的直型导电嘴(2)的长度，h是焊炬高度，β是折弯导电杆(3)的折弯角度；在步骤④中，坡口宽度变化判定阈值THw≤0.5mm，摇动角度αi＝2arcsin{(Gsi-2g)/2r}。
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