WO2023197623A1 - 一种窄间隙焊接方法、装置及系统 - Google Patents
一种窄间隙焊接方法、装置及系统 Download PDFInfo
- Publication number
- WO2023197623A1 WO2023197623A1 PCT/CN2022/136466 CN2022136466W WO2023197623A1 WO 2023197623 A1 WO2023197623 A1 WO 2023197623A1 CN 2022136466 W CN2022136466 W CN 2022136466W WO 2023197623 A1 WO2023197623 A1 WO 2023197623A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- current
- difference
- welding
- average value
- threshold
- Prior art date
Links
- 238000003466 welding Methods 0.000 title claims abstract description 340
- 238000000034 method Methods 0.000 title claims abstract description 61
- 230000008569 process Effects 0.000 claims abstract description 31
- 230000007246 mechanism Effects 0.000 claims description 49
- 238000004364 calculation method Methods 0.000 claims description 10
- 238000011156 evaluation Methods 0.000 claims description 9
- 230000003247 decreasing effect Effects 0.000 abstract 1
- 230000000875 corresponding effect Effects 0.000 description 32
- 238000010586 diagram Methods 0.000 description 7
- 238000012360 testing method Methods 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000002596 correlated effect Effects 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Images
Classifications
-
- 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
-
- 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
- B23K9/124—Circuits or methods for feeding welding wire
- B23K9/125—Feeding of electrodes
-
- 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
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
Definitions
- the present invention relates to the field of welding technology, and in particular to a narrow gap welding method, device and system.
- Narrow gap MAG welding has the advantages of high welding efficiency and low metal filling volume, and is widely used in offshore engineering, pressure vessels, nuclear power and other fields.
- the purpose of the invention is to improve the existing narrow gap groove welding method, track the welding process of the weld seam and perform dynamic adjustment, and improve the welding accuracy so that the workpiece meets the use requirements.
- the present invention provides a narrow gap groove welding method, which includes:
- first difference and the second difference are both greater than the preset first threshold, then reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold, then increase The conical swing amplitude of the welding wire;
- the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then move parallel to the first direction.
- Welding gun if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the second Move the welding gun parallel to the direction.
- the angle of the conical swing of the welding wire is determined by the pulse signal fed back by the servo motor of the conical swing mechanism, and the position of the welding wire is determined according to the angle of the welding wire;
- start time end time and the corresponding information between current and time, the left wall current evaluation value and the right wall current average value within several swing cycles are obtained.
- the collected corresponding information of current and time and pulse signal are denoised and input to the controller through the data acquisition card, and the corresponding relationship between the corresponding information of current and time and the pulse signal is established through the controller.
- the invention also discloses a narrow gap groove welding method, which includes:
- the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then move parallel to the first direction.
- Welding gun if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the second Move the welding gun in parallel direction;
- first difference and the second difference are both greater than the preset first threshold, then reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold, then increase The conical swing amplitude of the welding wire.
- the invention also discloses a narrow gap groove welding device, which includes: a first collection module, a second collection module, a first judgment module and a second judgment module;
- the first acquisition module is used to obtain the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire;
- the second acquisition module is used to obtain the first difference between the average value of the left side wall current and the preset welding current, and obtain the second difference between the average value of the right side wall current and the preset welding current;
- the first judgment module is used to reduce the conical swing amplitude of the welding wire if both the first difference and the second difference are greater than the preset first threshold; if the negative first difference and the negative second difference If the values are all greater than the first threshold, the conical swing amplitude of the welding wire will be increased;
- the second judgment module is used to determine if the first difference is greater than the first threshold, the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, move the welding gun parallel to the first direction; if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, the welding gun is moved parallel to the second direction.
- the angle of the conical swing of the welding wire is determined by the pulse signal fed back by the servo motor of the conical swing mechanism, and the position of the welding wire is determined according to the angle of the welding wire;
- start time end time and the corresponding information between current and time, the left wall current evaluation value and the right wall current average value within several swing cycles are obtained.
- the invention also discloses a narrow gap groove welding system, which includes: a transverse swing mechanism, a conical swing structure, a current sensor and a controller;
- the lateral swing mechanism is used to adjust the lateral position of the welding gun according to the first command of the control system
- the conical swing mechanism is used to adjust the conical swing amplitude of the welding wire according to the second control command of the control system; the servo motor of the conical swing mechanism feeds back a pulse signal to the controller so that the controller determines the position of the welding wire based on the pulse signal;
- the current sensor is used to collect the corresponding information of current and time during the welding process, and feedback the collected corresponding information of current and time to the controller;
- the controller is used to obtain the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire according to the corresponding information of current and time and the position of the welding wire; the controller is also used to obtain the average value of the left wall current and the average value of the right wall current.
- the first difference between the preset welding current and the second difference between the right side wall current average and the preset welding current is obtained; if both the first difference and the second difference are greater than the preset first threshold, then The cone swing amplitude of the welding wire is reduced through the cone swing mechanism; if the negative first difference and the negative second difference are both greater than the first threshold, the cone swing amplitude of the welding wire is increased through the cone swing mechanism; if the first If the difference is greater than the first threshold, the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then the lateral swing mechanism is used to move parallel to the first direction.
- the angle of the conical swing of the welding wire is determined by the pulse signal fed back by the servo motor of the conical swing mechanism, and the position of the welding wire is determined according to the angle of the welding wire;
- start time end time and the corresponding information between current and time, the left wall current evaluation value and the right wall current average value within several swing cycles are obtained.
- the invention also discloses a narrow gap groove welding method, which includes:
- first difference and the second difference are both greater than the preset first threshold, then reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold, then increase The conical swing amplitude of the welding wire.
- the invention also discloses a narrow gap groove welding method, which includes:
- the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then move parallel to the first direction.
- Welding gun if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the second Move the welding gun parallel to the direction.
- the narrow gap welding method, device and system of the embodiment of the present invention have the following beneficial effects:
- the welding seam will be too large or too small. If the swing amplitude of the welding wire and the position of the welding gun cannot be adjusted at this time, the welding will not be in place. question.
- the swing amplitude and the position of the welding gun are adjusted so that the swing of the welding wire can adapt to the width of the current weld seam and the left and right swings of the welding gun can be even.
- Figure 1 is a first flow diagram of a narrow gap groove welding method according to the present invention
- Figure 2 is a second flow diagram of a narrow gap groove welding method according to the present invention.
- Figure 3 is a third flow diagram of a narrow gap groove welding method according to the present invention.
- Figure 4 is an enlarged schematic diagram of the third process flow diagram in a narrow gap groove welding method of the present invention.
- Figure 5 is a schematic structural diagram of a narrow gap groove welding device according to the present invention.
- Figure 6 is a schematic structural diagram of a narrow gap groove welding system of the present invention.
- narrow gap welding requires high assembly accuracy, and assembly errors can easily cause defects such as side wall failure to fuse, welding deviation, and side wall arcing. Therefore, if the workpiece is welded using narrow gap welding, the corresponding weld tracking method needs to be used.
- the applicant conducted a large number of tests on the welding process of narrow gap grooves and found that the welding current will change periodically when the arc swings inside the narrow gap grooves.
- This change pattern is related to the arc position. There is a certain relationship. The closer the arc is to the side wall, the higher the welding current. When the arc is in the middle of the groove, the welding current is the smallest. Therefore, by establishing the relationship between the current and the welding wire position, the distance between the welding wire and the side wall can be obtained based on the welding current, thereby achieving weld seam tracking and groove width adaptation.
- the present invention provides the following narrow gap groove welding method, which includes the following steps:
- Step S1 obtain the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire;
- Step S2 obtain the first difference between the average value of the left wall current and the preset welding current, and obtain the second difference between the average value of the right wall current and the preset welding current;
- Step S3 if both the first difference and the second difference are greater than the preset first threshold, reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold , then increase the conical swing amplitude of the welding wire;
- Step S4 if the first difference is greater than the first threshold, the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the first Move the welding gun parallel in the direction; if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then Move the welding gun parallel to the second direction.
- step S1 the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire are obtained, specifically:
- the angle of the conical swing of the welding wire is determined by the pulse signal fed back by the servo motor of the conical swing mechanism, and the position of the welding wire is determined according to the angle of the welding wire;
- start time end time and the corresponding information between current and time, the left wall current evaluation value and the right wall current average value within several swing cycles are obtained.
- the welding process is a periodic swing process, after the initial swing parameters are set in the welding scheme of the prior art, the welding system can work according to the preset parameters to complete straight welding.
- One swing cycle must include the welding of the left side wall by the welding gun and the welding of the right side wall under the welding gun. Therefore, the preferred technical solution is one swing cycle or two swing cycles, or it can be an integer multiple of one swing cycle. In this field Technicians can choose according to actual needs.
- the welding wire needs to stay for a certain period of time when swinging to the side wall.
- the start and end of the stay time are determined by the position of the welding wire driven by the conical swing mechanism, that is, the angle of the welding wire, the angle of the welding wire and the conical swing.
- the pulse signal of the mechanism's servo motor has a periodic relationship.
- the average current value of the left side wall is the average current value when the welding wire stays on the left side wall
- the average current value of the right side wall is the average current value when the welding wire stays on the right side wall.
- the average current is equal to the average current when the welding wire stays on the side wall (sum of current/dwell time).
- the servo motor drives the welding wire to make a conical swing.
- the servo motor feeds back pulse signals during the rotation.
- One pulse signal corresponds to a certain angle (usually 1.8°).
- the conical swing of the welding wire is obtained from the feedback pulse signal. angle, and then calculate the angle of the conical swing of the welding wire, which is the position of the welding wire.
- the extraction process is the calculation process.
- the extraction of the distance signal from the side wall of the weld is based on the feedback from the servo motor. Pulse signal, the starting position of the welding wire is in the center, then based on the pulse signal fed back by the servo motor, calculate the distance between the welding wire and the side wall.
- the collected corresponding information of current and time and the pulse signal are denoised and input to the controller through the data acquisition card, and the corresponding relationship between the corresponding information of current and time and the pulse signal is established through the controller.
- those skilled in the art can adjust the distance between the welding wire and the side walls so that the distance between the welding wire and the side walls remains basically consistent with the set value: the current signal of the welding process is collected through the current sensor, and the encoder of the servo motor is used to collect the current signal during the welding process. Obtain the rotational position signal of the welding wire, and then transmit the signal to the host computer (or PLC) through the data acquisition card. The electrical signal is extracted on the host computer and corresponds to the welding wire position signal one-to-one, thereby obtaining the relationship between the welding wire position and the electrical signal. , set the algorithm to establish the relationship between the distance from the welding wire to the side wall and the welding current.
- those skilled in the art can pre-establish a database of current and welding wire positions during a certain narrow gap groove welding process, and then know the relative positional relationship between the welding wire and the side wall through comparison.
- the corresponding average value can be obtained based on the collected current data.
- step S2 the first difference between the average value of the left side wall current and the preset welding current is obtained, and the second difference between the average value of the right side wall current and the preset welding current is obtained.
- step S3 if both the first difference and the second difference are greater than the preset first threshold, the conical swing amplitude of the welding wire is reduced; if the negative first difference and the negative second difference are both greater than the A threshold value increases the conical swing amplitude of the welding wire.
- step S4 if the first difference is greater than the first threshold, the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then Move the welding gun in parallel in the first direction; if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold , then move the welding gun parallel to the second direction.
- the base material is high-strength steel, the groove depth is 80mm, the groove width is 10mm below and 16mm above.
- a narrow gap groove is a further example of a narrow gap groove:
- the current and voltage sensors collect the current and voltage parameters of the welding arc.
- the collection frequency is 2000Hz, and then use a filtering algorithm to filter and reduce noise on the original signal;
- step 4 can be executed first and then step 3.
- the present invention discloses a narrow gap groove welding method, which includes:
- the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then move parallel to the first direction.
- Welding gun if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the second Move the welding gun in parallel direction;
- first difference and the second difference are both greater than the preset first threshold, then reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold, then increase The conical swing amplitude of the welding wire.
- the present invention discloses a welding method for narrow gap grooves, which includes:
- the swing parameters of the transverse swing mechanism, the swing parameters of the conical swing mechanism and the welding parameters are set according to the narrow gap groove.
- the welding parameters include: welding current, first threshold and second threshold;
- the controller obtains the average value of the left wall current and the average value of the right wall current based on the current signal and the pulse signal;
- the controller performs data processing, judgment and instruction sending based on the average left wall current, right wall current average, welding current, first threshold and second threshold, including:
- first difference and the second difference are both greater than the preset first threshold, then reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold, then increase The conical swing amplitude of the welding wire;
- the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then move parallel to the first direction.
- Welding gun if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the second Move the welding gun parallel to the direction.
- the present invention also discloses a narrow gap groove welding device, including: a first acquisition module 101, a second acquisition module 102, a first judgment module 103 and a second judgment module 104.
- the first acquisition module 101 is used to obtain the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire;
- the second acquisition module 102 is used to obtain the first difference between the average value of the left side wall current and the preset welding current, and obtain the second difference between the average value of the right side wall current and the preset welding current;
- the first judgment module 103 is used to reduce the conical swing amplitude of the welding wire if both the first difference and the second difference are greater than the preset first threshold; if the negative first difference and the negative second If the differences are all greater than the first threshold, the conical swing amplitude of the welding wire is increased;
- the second judgment module 104 is used to determine if the first difference is greater than the first threshold, the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the first threshold.
- two thresholds move the welding gun parallel to the first direction; if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute difference between the average value of the left wall current and the average value of the right wall current is If the value is greater than the second threshold, the welding gun is moved parallel to the second direction.
- the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire are obtained, specifically:
- the angle of the conical swing of the welding wire is determined by the pulse signal fed back by the servo motor of the conical swing mechanism, and the position of the welding wire is determined according to the angle of the welding wire;
- start time end time and the corresponding information between current and time, the left wall current evaluation value and the right wall current average value within several swing cycles are obtained.
- the collected corresponding information of current and time and the pulse signal are denoised and input to the controller through the data acquisition card, and the corresponding relationship between the corresponding information of current and time and the pulse signal is established through the controller.
- Embodiment 4 is written on the basis of Embodiment 1. Those skilled in the art can implement the technical solution of Embodiment 4 according to the description of Embodiment 1, so the description and limitations of the technical solution will not be described again.
- the present invention discloses a narrow gap groove welding system, including: a transverse swing mechanism, a conical swing structure, a current sensor and a controller;
- the lateral swing mechanism is used to adjust the lateral position of the welding gun according to the first command of the control system
- the conical swing mechanism is used to adjust the conical swing amplitude of the welding wire according to the second control command of the control system; the servo motor of the conical swing mechanism feeds back a pulse signal to the controller so that the controller determines the position of the welding wire based on the pulse signal;
- the current sensor is used to collect the corresponding information of current and time during the welding process, and feedback the collected corresponding information of current and time to the controller;
- the controller is used to obtain the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire according to the corresponding information of current and time and the position of the welding wire; the controller is also used to obtain the average value of the left wall current and the average value of the right wall current.
- the first difference between the preset welding current and the second difference between the right side wall current average and the preset welding current is obtained; if both the first difference and the second difference are greater than the preset first threshold, then The cone swing amplitude of the welding wire is reduced through the cone swing mechanism; if the negative first difference and the negative second difference are both greater than the first threshold, the cone swing amplitude of the welding wire is increased through the cone swing mechanism; if the first If the difference is greater than the first threshold, the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then the lateral swing mechanism is used to move parallel to the first direction.
- the transverse swing mechanism, the conical swing structure, the current sensor and the voltage sensor are all connected to the controller.
- the welding system further includes a vertical motor, which is used to pull the transverse swing mechanism and the conical swing mechanism to move along the welding seam direction.
- the average value of the left wall current and the average value of the right wall current within several swing cycles of the welding wire are obtained, specifically:
- the angle of the conical swing of the welding wire is determined by the pulse signal fed back by the servo motor of the conical swing mechanism, and the position of the welding wire is determined according to the angle of the welding wire;
- start time end time and the corresponding information between current and time, the left wall current evaluation value and the right wall current average value within several swing cycles are obtained.
- the invention also discloses a narrow gap groove welding method, which includes:
- first difference and the second difference are both greater than the preset first threshold, then reduce the conical swing amplitude of the welding wire; if the negative first difference and the negative second difference are both greater than the first threshold, then increase The conical swing amplitude of the welding wire.
- the invention also discloses a narrow gap groove welding method, which includes:
- the second difference is less than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then move parallel to the first direction.
- Welding gun if the first difference is less than the first threshold, the second difference is greater than the first threshold, and the absolute value of the difference between the average value of the left wall current and the average value of the right wall current is greater than the second threshold, then to the second Move the welding gun parallel to the direction.
- the embodiments of the present invention provide a narrow gap welding method, device and system.
- the beneficial effects are:
- the welding seam will be too large or too small. If the swing amplitude of the welding wire and the position of the welding gun cannot be adjusted at this time, the welding will not be in place. question.
- the swing amplitude and the position of the welding gun are adjusted so that the swing of the welding wire can adapt to the width of the current weld seam and the left and right swings of the welding gun can be even.
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
一种窄间隙坡口的焊接方法，获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；根据第一差值、第二差值和第一阈值的关系，增加或降低焊丝的锥形摆动幅度；根据第一差值、第二差值、第一阈值和第二阈值的关系，横向移动焊枪的位置。该方法通过焊接过程中的左右侧壁的电流平均值和阈值进行比较，可知晓焊丝的摆动是否能适应焊缝宽度，焊枪左右摆动的距离是否相等，进而根据比较结果调整焊丝的摆动幅度以及焊枪的位置，使焊丝的摆动能够适应当前焊缝的宽度，焊枪的左右摆动均匀。还涉及一种窄间隙坡口的焊接装置及一种窄间隙坡口的焊接系统。
Description
本发明涉及焊接技术领域，特别是涉及一种窄间隙焊接方法、装置及系统。
窄间隙MAG焊接具有焊接效率高、金属填充量少等优势，在海工、压力容器及核电等领域应用广泛。
但是现有技术中的焊接方法在追踪焊接过程不能对焊接过程进行调节，造成焊接后的工件不能满足使用要求。
发明内容
本发明的目的是：对现有的窄间隙坡口的焊接方法进行改进，追踪焊缝的焊接过程并进行动态调节，提高焊接精度以使工件满足使用要求。
为了实现上述目的，本发明提供了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；
若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
进一步的，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：
通过电流传感器获取焊接过程中电流与时间的对应信息；
通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；
根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；
根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
进一步的，将采集到的电流与时间的对应信息、脉冲信号降噪后通过数据采集卡输入到控制器，通过控制器建立电流与时间的对应信息和脉冲信号的对应关系。
本发明还公开了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和 预设的焊接电流的第二差值；
若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪；
若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度。
本发明还公开了一种窄间隙坡口的焊接装置，包括：第一采集模块、第二采集模块、第一判断模块和第二判断模块；
所述第一采集模块，用于获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
所述第二采集模块，用于获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
所述第一判断模块，用于若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；
所述第二判断模块，用于若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
进一步的，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：
通过电流传感器获取焊接过程中电流与时间的对应信息；
通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；
根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；
根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
本发明还公开了一种窄间隙坡口的焊接系统，包括：横向摆动机构、锥形摆动结构、电流传感器和控制器；
所述横向摆动机构用于根据控制系统的第一命令调整焊枪的横向位置；
所述锥形摆动机构用于根据控制系统的第二控制命令调整焊丝的锥形摆动幅度；锥形摆动机构的伺服电机反馈脉冲信号到控制器以使控制器根据脉冲信号确定焊丝位置；
所述电流传感器用于采集焊接过程中电流与时间的对应信息，并将采集到的电流与时间的对应信息反馈到控制器；
所述控制器用于根据电流与时间的对应信息和焊丝位置得到焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；控制器还用于获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；若第一 差值和第二差值均大于预设的第一阈值，则通过锥形摆动机构降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则通过锥形摆动机构增加焊丝的锥形摆动幅度；若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则通过横向摆动机构向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则通过横向摆动机构向第二方向平行移动焊枪。
进一步的，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：
通过电流传感器获取焊接过程中电流与时间的对应信息；
通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；
根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；
根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
本发明还公开了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度。
本发明还公开了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
本发明实施例一种窄间隙焊接方法、装置及系统与现有技术相比，其有益效果在于：
(1)由于窄间隙坡口的加工精度、装配问题、或变形会导致焊缝过大或过小，此时若不能对焊丝的摆动幅度和焊枪的位置进行调节，则会导致焊接不到位的问题。本发明中，通过焊接过程中的左右侧壁的电流平均值和阈值进行比较，可以知晓焊丝的摆动是否能适应焊缝宽度，也可以知晓焊枪左右摆动的距离是否相等，进而根据比较结果调整焊丝的摆动幅度以及焊枪的位置，以使焊丝的摆动能够适应当前焊缝的宽度，使焊枪的左右摆动均匀。
(2)焊枪由于焊接过程中的变形、加工误差等原因导致焊枪不对中，会造成焊接的工件不达标，而通过本发明的横向摆动机构，可以对焊枪的位置进行调节，解决焊枪的不对 中的问题。
(3)保证侧壁熔合稳定，提升焊缝质量，降低缺陷发生几率。
图1是本发明一种窄间隙坡口的焊接方法的第一流程示意图；
图2是本发明一种窄间隙坡口的焊接方法的第二流程示意图；
图3是本发明一种窄间隙坡口的焊接方法的第三流程示意图；
图4是本发明一种窄间隙坡口的焊接方法中第三流程示意图的放大示意图；
图5是本发明一种窄间隙坡口的焊接装置的结构示意图；
图6是本发明一种窄间隙坡口的焊接系统的结构示意图。
下面结合附图和实施例，对本发明的具体实施方式作进一步详细描述。以下实施例用于说明本发明，但不用来限制本发明的范围。
实施例1：
本领域技术人员知晓，窄间隙焊接对装配精度要求高，装配误差容易引起侧壁未熔合、焊偏及侧壁起弧等缺陷。因此若采用窄间隙焊接的方法对工件进行焊接，则需要配套使用相应的焊缝追踪方法。
现有的焊缝跟踪方法包括结构光、电弧传感等方式，但均适用于常规坡口，对于窄间隙坡口还未有效的焊缝跟踪方式。
为了解决窄间隙坡口的焊接问题，申请人对窄间隙坡口的焊接过程进行了大量试验发现电弧在窄间隙坡口内部摆动时焊接电流会呈现周期性的变化，该变化规律与电弧位置具有一定的联系，电弧距离侧壁越近，焊接电流越高，电弧处于坡口中间位置时，焊接电流最小。因此建立电流与焊丝位置的关系，可以根据焊接电流获得焊丝与侧壁的距离，进而实现焊缝跟踪及坡口宽度自适应。
本领域技术人员具备相应的常规试验能力，可以依据本发明公开的技术内容，重复上述的试验过程，以得到上述的结论。或者本领域技术人员可从以公开的技术文献验证上述结论的可靠性。
基于试验得到的结论，参照图1，本发明提供了如下的窄间隙坡口的焊接方法，包括如下的步骤：
步骤S1，获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
步骤S2，获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
步骤S3，若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；
步骤S4，若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
在步骤S1中，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：
通过电流传感器获取焊接过程中电流与时间的对应信息；
通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；
根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；
根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
本领域技术人员知晓如何使用相应的传感器采集相应的数据，并且知晓传感器可以与具备数据处理能力的控制器连接，进而得到所需的数据。由于焊接过程是一个周期性摆动过程，现有技术的焊接方案在设定好初始的摆动参数后，焊接系统可以按照预设的参数进行工作，直道焊接的完成。一个摆动周期内，必然包括焊枪在左侧壁的焊接和焊枪下右侧壁的焊接，因此优先的技术方案为一个摆动周期或两个摆动周期，也可以是一个摆动周期的整数倍，本领域技术人员可以根据实际需要进行选择。
本领域技术人员知晓，焊接过程中焊丝摆动到侧壁是需要停留一定的时间，停留时间的起止有锥形摆动机构所带动的焊丝的位置确定，即焊丝的角度，焊丝的角度和锥形摆动机构的伺服电机的脉冲信号具备周期性联系。本申请中的左侧壁电流平均值为焊丝在左侧壁停留时的电流平均值，右侧壁电流平均值为焊丝在右侧壁停留时的电流平均值。电流平均值等于焊丝在侧壁停留时的平均电流(电流之和/停留时间)。
在本实施例中，伺服电机带动焊丝做锥形摆动，伺服电机在旋转过程中反馈脉冲信号，一个脉冲信号对应一定角度(一般为1.8°)，从反馈到的脉冲信号获得焊丝锥形摆动的角度，进而计算出焊丝锥形摆动的角度，这就是焊丝的位置，根据焊丝位置确定侧壁电流平均值的计算起止时间，利用该时间段内采集的电流之和除以时间段，获得侧壁停留电流平均值。
在本实施例中，设定采集频率，一般为v＝3000Hz，计算焊丝在侧壁停留时的电流信号，比如侧壁停留时间t＝0.5s，当设定在侧壁停留0.5s时，根据停留时间占摆动周期的比例，可以确定焊丝的多少角度时认为焊丝停留在侧壁。锥形摆动机构的伺服电机每经过一个脉冲信号，其摆动的角度是确定的。在此之间电流的求和为∑I
n，其中n＝1，2，3，4……[v＊t]，获得电流在侧壁的电流平均值为∑I
n/t；电弧电流与焊丝到侧壁的距离d成正相关，通过调用前期获得的焊接试验数据，建立了焊接电流与侧壁距离的模型，其中I＝I
0－a＊d，从而利用获得的电流值，得到焊缝与侧壁的距离实际值；焊缝偏差信号指的是左侧电流平均值与右侧电流平均值的差值，提取过程就是计算的过程，焊缝侧壁距离信号提取是根据伺服电机反馈的脉冲信号，起始位置焊丝在中心，那么根据伺服电机反馈的脉冲信号，计算焊丝距离侧壁的距离。
在本实施例中，将采集到的电流与时间的对应信息、脉冲信号降噪后通过数据采集卡输入到控制器，通过控制器建立电流与时间的对应信息和脉冲信号的对应关系。
在本实施例中，本领域技术人员可以调整焊丝与两侧壁的距离，使焊丝与侧壁的距离与设定值保持基本一致：通过电流传感器采集焊接过程电流信号，通过伺服电机的编 码器获取焊丝的旋转位置信号，后经数据采集卡将信号传输至上位机(或PLC)，在上位机上对电信号进行提取，并与焊丝位置信号一一对应，从而获得焊丝位置与电信号的关系，设定算法，建立焊丝到侧壁的距离与焊接电流之间的关系。
在本实施例中，本领域技术人员可以预先建立某种窄间隙坡口焊接过程中的电流、焊丝位置的数据库，进而通过比对知晓焊丝和侧壁的相对位置关系。
当判断出焊丝在侧壁时，可以根据采集到的电流数据得到相应的平均值。
在步骤S2中，获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值。
本领域技术人员，可以根据需要设定预设的焊接电流、以及用于比较的第一阈值和第二阈值。
在步骤S3中，若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度。
在本实施中，对焊丝在左、右两侧壁的电流平均值(I
左、I
右)进行对比，若I
左、I
右与设定的焊接电流I
焊接的差值(#I
左＝I
左－I
焊接、#I
右＝I
右－I
焊接)均大于设定的阈值I
阈值1，则调整锥形摆动机构，减小焊丝摆动幅度；若－#I
左、－#I
右均大于I
阈值1，则调整锥形摆动机构，增大焊丝摆动幅度。若差值不大于设定的阈值，则说明此时焊丝的摆动是合适的，无需进行调整。
在步骤S4中，若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
在本实施例中，若#I
左大于I
阈值1且#I
右小于I
阈值1且|I
左－I
右|≥I
阈值2或者#I
左小于I
阈值1且#I
右大于I
阈值1且|I
左－I
右|≥I
阈值2，则通过横向摆动机构使焊枪整体移动，具体移动方向根据差值的正负来确定。本领域技术人员可以根据差值的正负设定第一方向和第二方向的移动方向。
母材为高强钢，坡口深度80mm，坡口宽度下10mm，上16mm，以此窄间隙坡口进行进一步的举例说明：
(1)利用控制器设定焊丝摆动幅度＝4mm，侧壁停留时间＝500ms，焊接电流I
焊接＝250A，I
阈值1＝20A，I
阈值2＝5A；
(2)设定调整步长，横向摆动调整步长为0.5mm，锥形摆动调整步长为0.5mm；
(3)设定电源参数后开始焊接，电流、电压传感器采集焊接电弧的电流、电压参数，采集频率为2000Hz，然后利用滤波算法对原始信号进行滤波降噪处理；
(4)PLC控制系统结合电机反馈的位置信号，得到焊丝在左右侧壁停留时的电流平均值(I
左、I
右)，若I
左、I
右与设定的焊接电流I
焊接的差值(#I
左＝I
左－I
焊接、#I
右＝I
右－I
焊接)均大于设定的阈值I
阈值1，则调整锥形摆动机构，减小焊丝摆动幅度；若－#I
左、－#I
右均大于I
阈值1，则调整锥形摆动机构，增大焊丝摆动幅度；若#I
左大于I
阈值1且#I
右小于I
阈值1且|I
左－I
右|≥I
阈值2或者#I
左小于I
阈值1且#I
右大于I
阈值1且|I
左－I
右|≥I
阈值2，则通过横向摆动机构使焊枪整体移动，具体移动方向根据差值的正负来确定。
实施例2：
参照图2，本发明中步骤3和步骤4的执行顺序可以进行调整，可以先执行步骤4后 执行步骤3。
在实施例1说明的基础上，本发明公开了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪；
若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度。
由于实施例2和实施例1相比，仅调整了步骤的先后顺序，因此对于其解释说明不再赘述。
实施例3：
参照图3和图4，本发明公开了一种窄间隙坡口的焊接方法，包括：
根据窄间隙坡口设定横向摆动机构的摆动参数、锥形摆动机构的摆动参数和焊接参数，所述焊接参数包括：焊接电流、第一阈值、第二阈值；
采集焊接过程的电流信号和伺服电机的脉冲信号；(对数据进行降噪处理后输入到控制器)；
控制器根据电流信号和脉冲信号得到左侧壁电流平均值和右侧壁电流平均值；
控制器根据左侧壁电流平均值、右侧壁电流平均值、焊接电流、第一阈值和第二阈值进行数据处理、判断以及指令发送，具体包括：
若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；
若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
实施例4：
参照图5，本发明还公开了一种窄间隙坡口的焊接装置，包括：第一采集模块101、第二采集模块102、第一判断模块103和第二判断模块104。
所述第一采集模块101，用于获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
所述第二采集模块102，用于获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
所述第一判断模块103，用于若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；
所述第二判断模块104，用于若第一差值大于第一阈值，第二差值小于第一阈值， 且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
在本实施例中，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：
通过电流传感器获取焊接过程中电流与时间的对应信息；
通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；
根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；
根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
在本实施例中，将采集到的电流与时间的对应信息、脉冲信号降噪后通过数据采集卡输入到控制器，通过控制器建立电流与时间的对应信息和脉冲信号的对应关系。
实施例4是在实施例1的基础上进行撰写的，本领域技术人员可以依照实施例1的说明实施实施例4的技术方案，因此不再赘述对技术方案的说明和限定。
实施例5：
参照图6，本发明公开了一种窄间隙坡口的焊接系统，包括：横向摆动机构、锥形摆动结构、电流传感器和控制器；
所述横向摆动机构用于根据控制系统的第一命令调整焊枪的横向位置；
所述锥形摆动机构用于根据控制系统的第二控制命令调整焊丝的锥形摆动幅度；锥形摆动机构的伺服电机反馈脉冲信号到控制器以使控制器根据脉冲信号确定焊丝位置；
所述电流传感器用于采集焊接过程中电流与时间的对应信息，并将采集到的电流与时间的对应信息反馈到控制器；
所述控制器用于根据电流与时间的对应信息和焊丝位置得到焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；控制器还用于获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；若第一差值和第二差值均大于预设的第一阈值，则通过锥形摆动机构降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则通过锥形摆动机构增加焊丝的锥形摆动幅度；若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则通过横向摆动机构向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则通过横向摆动机构向第二方向平行移动焊枪。
在本实施例中，横向摆动机构、锥形摆动结构、电流传感器和电压传感器均和控制器连接。
在本实施例中，所述焊接系统还包括竖向电机，所述竖向电机用于牵引横向摆动机构和锥形摆动机构沿焊缝方向移动。
在本实施例中，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：
通过电流传感器获取焊接过程中电流与时间的对应信息；
通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；
根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；
根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
实施例6：
本发明还公开了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度。
实施例7：
本发明还公开了一种窄间隙坡口的焊接方法，包括：
获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；
获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；
若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
综上，本发明实施例提供一种窄间隙焊接方法、装置及系统，有益效果在于：
(1)由于窄间隙坡口的加工精度、装配问题、或变形会导致焊缝过大或过小，此时若不能对焊丝的摆动幅度和焊枪的位置进行调节，则会导致焊接不到位的问题。本发明中，通过焊接过程中的左右侧壁的电流平均值和阈值进行比较，可以知晓焊丝的摆动是否能适应焊缝宽度，也可以知晓焊枪左右摆动的距离是否相等，进而根据比较结果调整焊丝的摆动幅度以及焊枪的位置，以使焊丝的摆动能够适应当前焊缝的宽度，使焊枪的左右摆动均匀。
(2)焊枪由于焊接过程中的变形、加工误差等原因导致焊枪不对中，会造成焊接的工件不达标，而通过本发明的横向摆动机构，可以对焊枪的位置进行调节，解决焊枪的不对中的问题。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和替换，这些改进和替换也应视为本发明的保护范围。
Claims (7)
- 一种窄间隙坡口的焊接方法，其特征在于，包括：获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
- 根据权利要求1所述的一种窄间隙坡口的焊接方法，其特征在于，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：通过电流传感器获取焊接过程中电流与时间的对应信息；通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
- 根据权利要求2所述的一种窄间隙坡口的焊接方法，其特征在于，将采集到的电流与时间的对应信息、脉冲信号降噪后通过数据采集卡输入到控制器，通过控制器建立电流与时间的对应信息和脉冲信号的对应关系。
- 一种窄间隙坡口的焊接装置，其特征在于，包括：第一采集模块、第二采集模块、第一判断模块和第二判断模块；所述第一采集模块，用于获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；所述第二采集模块，用于获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；所述第一判断模块，用于若第一差值和第二差值均大于预设的第一阈值，则降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则增加焊丝的锥形摆动幅度；所述第二判断模块，用于若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则向第二方向平行移动焊枪。
- 根据权利要求4所述的一种窄间隙坡口的焊接装置，其特征在于，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：通过电流传感器获取焊接过程中电流与时间的对应信息；通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
- 一种窄间隙坡口的焊接系统，其特征在于，包括：横向摆动机构、锥形摆动结构、电流传感器和控制器；所述横向摆动机构用于根据控制系统的第一命令调整焊枪的横向位置；所述锥形摆动机构用于根据控制系统的第二控制命令调整焊丝的锥形摆动幅度；锥形摆动机构的伺服电机反馈脉冲信号到控制器以使控制器根据脉冲信号确定焊丝位置；所述电流传感器用于采集焊接过程中电流与时间的对应信息，并将采集到的电流与时间的对应信息反馈到控制器；所述控制器用于根据电流与时间的对应信息和焊丝位置得到焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值；控制器还用于获取左侧壁电流平均值和预设的焊接电流的第一差值，获取右侧壁电流平均值和预设的焊接电流的第二差值；若第一差值和第二差值均大于预设的第一阈值，则通过锥形摆动机构降低焊丝的锥形摆动幅度；若负的第一差值和负的第二差值均大于第一阈值，则通过锥形摆动机构增加焊丝的锥形摆动幅度；若第一差值大于第一阈值，第二差值小于第一阈值，且左侧壁电流平均值和右侧壁电流平均值差值的绝对值大于第二阈值，则通过横向摆动机构向第一方向平行移动焊枪；若第一差值小于第一阈值，第二差值大于第一阈值，且左侧壁电流平均值和右侧壁电流平均值的差值的绝对值大于第二阈值，则通过横向摆动机构向第二方向平行移动焊枪。
- 根据权利要求6所述的一种窄间隙坡口的焊接系统，其特征在于，所述获取焊丝若干个摆动周期内的左侧壁电流平均值和右侧壁电流平均值，具体为：通过电流传感器获取焊接过程中电流与时间的对应信息；通过锥形摆动机构的伺服电机反馈的脉冲信号确定焊丝锥形摆动的角度，根据焊丝的角度确定焊丝的位置；根据焊丝的位置确定左侧电流平均值和右侧电流平均值计算的开始时间和结束时间；根据开始时间、结束时间以及电流与时间的对应信息得到若干个摆动周期内的左侧壁电流评价值和右侧壁电流平均值。
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210402813.8 | 2022-04-15 | ||
| CN202210402813.8A CN114619123B (zh) | 2022-04-15 | 2022-04-15 | 一种窄间隙焊接方法、装置及系统 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2023197623A1 true WO2023197623A1 (zh) | 2023-10-19 |
Family
ID=81906874
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/CN2022/136466 WO2023197623A1 (zh) | 2022-04-15 | 2022-12-05 | 一种窄间隙焊接方法、装置及系统 |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN114619123B (zh) |
| WO (1) | WO2023197623A1 (zh) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117900716A (zh) * | 2024-03-20 | 2024-04-19 | 上海飞挺管业制造有限公司 | 钢管快速自动化位置焊接的多轴联动系统 |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114619123B (zh) * | 2022-04-15 | 2022-11-11 | 广东省科学院中乌焊接研究所 | 一种窄间隙焊接方法、装置及系统 |
| CN117900581B (zh) * | 2024-03-20 | 2024-06-04 | 广州市市政工程试验检测有限公司 | 市政管廊供水管道焊接方法、系统、电子设备及存储介质 |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5536104A (en) * | 1978-08-31 | 1980-03-13 | Nippon Steel Corp | Automatic narrow gap welding method |
| JP2001232471A (ja) * | 2000-02-23 | 2001-08-28 | Babcock Hitachi Kk | 狭開先ｇｍａ溶接のアーク揺動振り幅異常検出方法 |
| JP2004268088A (ja) * | 2003-03-07 | 2004-09-30 | Babcock Hitachi Kk | 狭開先溶接装置 |
| CN105834554A (zh) * | 2016-04-08 | 2016-08-10 | 湘潭大学 | 一种窄间隙焊接熔宽的自适应检测控制系统及方法 |
| CN112388108A (zh) * | 2020-11-02 | 2021-02-23 | 湘潭大学 | 基于三丝交叉摆动电弧传感的中厚板折线焊缝跟踪方法 |
| CN113523503A (zh) * | 2021-07-21 | 2021-10-22 | 广东省科学院中乌焊接研究所 | 一种弯曲焊丝旋摆电弧窄间隙焊接装置及其方法 |
| CN114619123A (zh) * | 2022-04-15 | 2022-06-14 | 广东省科学院中乌焊接研究所 | 一种窄间隙焊接方法、装置及系统 |
-
2022
- 2022-04-15 CN CN202210402813.8A patent/CN114619123B/zh active Active
- 2022-12-05 WO PCT/CN2022/136466 patent/WO2023197623A1/zh unknown
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5536104A (en) * | 1978-08-31 | 1980-03-13 | Nippon Steel Corp | Automatic narrow gap welding method |
| JP2001232471A (ja) * | 2000-02-23 | 2001-08-28 | Babcock Hitachi Kk | 狭開先ｇｍａ溶接のアーク揺動振り幅異常検出方法 |
| JP2004268088A (ja) * | 2003-03-07 | 2004-09-30 | Babcock Hitachi Kk | 狭開先溶接装置 |
| CN105834554A (zh) * | 2016-04-08 | 2016-08-10 | 湘潭大学 | 一种窄间隙焊接熔宽的自适应检测控制系统及方法 |
| CN112388108A (zh) * | 2020-11-02 | 2021-02-23 | 湘潭大学 | 基于三丝交叉摆动电弧传感的中厚板折线焊缝跟踪方法 |
| CN113523503A (zh) * | 2021-07-21 | 2021-10-22 | 广东省科学院中乌焊接研究所 | 一种弯曲焊丝旋摆电弧窄间隙焊接装置及其方法 |
| CN114619123A (zh) * | 2022-04-15 | 2022-06-14 | 广东省科学院中乌焊接研究所 | 一种窄间隙焊接方法、装置及系统 |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117900716A (zh) * | 2024-03-20 | 2024-04-19 | 上海飞挺管业制造有限公司 | 钢管快速自动化位置焊接的多轴联动系统 |
| CN117900716B (zh) * | 2024-03-20 | 2024-05-24 | 上海飞挺管业制造有限公司 | 钢管快速自动化位置焊接的多轴联动系统 |
Also Published As
| Publication number | Publication date |
|---|---|
| CN114619123B (zh) | 2022-11-11 |
| CN114619123A (zh) | 2022-06-14 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| WO2023197623A1 (zh) | 一种窄间隙焊接方法、装置及系统 | |
| EP3744459A1 (en) | Systems and methods for welding torch weaving | |
| CN104588838A (zh) | 一种焊枪自动跟踪控制并在线修正系统及其控制方法 | |
| CN102615390B (zh) | 基于摆动电弧的多层多道焊焊缝跟踪系统及识别方法 | |
| US6429404B1 (en) | Method and apparatus for determining seam tracking control of arc welding | |
| US11267066B2 (en) | Weld signature analysis for weld quality determination | |
| CN102139405A (zh) | 电阻焊接方法 | |
| CN210475808U (zh) | 一种埋弧焊焊接位置自动纠偏装置 | |
| CN111843120B (zh) | 基于电弧传感和位置前馈的机器人焊缝跟踪算法 | |
| CN109304552A (zh) | 一种焊接系统及焊缝追踪方法 | |
| CN1974100A (zh) | 核电j型接头焊接复杂曲面跟踪方法 | |
| CN104475925B (zh) | 姿控发动机氩弧焊焊接电流智能控制方法 | |
| EP0139137A1 (en) | Weld line system and method for control | |
| CN111360835A (zh) | 一种焊接机械臂的焊接自动控制方法 | |
| KR100762365B1 (ko) | 아크센서의 특성이 반영된 확률적 모델을 통한 용접심 추적방법 | |
| CN110142533A (zh) | 一种基于机器视觉与ai算法的自动焊接方法及焊接装置 | |
| CN105149770A (zh) | 一种机械式激光焊接自动跟踪系统 | |
| CN210188775U (zh) | 自动焊缝跟踪控制系统 | |
| JP2023001642A (ja) | 学習済みモデルの生成方法、学習装置、溶接ロボットの制御装置、システム、学習済みモデル、およびプログラム | |
| CN109822195B (zh) | 自动焊缝跟踪控制系统 | |
| KR100373140B1 (ko) | 품질 제어가 가능한 용접선 자동 추적용 아크센서 | |
| CN112809130A (zh) | 一种智能焊缝检测和轨迹规划方法及系统 | |
| CN205614232U (zh) | 一种智能焊缝系统 | |
| CN115229303B (zh) | 基于电弧跟踪修正焊枪姿态的方法、装置、电子设备以及存储介质 | |
| US11897060B2 (en) | Systems and methods for welding torch weaving |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 22937255 Country of ref document: EP Kind code of ref document: A1 |