CN105499772B - A kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint - Google Patents
A kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint Download PDFInfo
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- CN105499772B CN105499772B CN201610053551.3A CN201610053551A CN105499772B CN 105499772 B CN105499772 B CN 105499772B CN 201610053551 A CN201610053551 A CN 201610053551A CN 105499772 B CN105499772 B CN 105499772B
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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
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
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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
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/006—Control circuits therefor
Abstract
The invention provides a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint, including the coaxial telecentricity visual sensing system of MICROBEAM PLASMA WELDING system, precision welding workbench, monocular and MPAW shaping real-time controlling units；The molten bath front transient images of thin-walled areola ring longitudinal joint MICROBEAM PLASMA WELDING are obtained using the coaxial telecentricity visual sensing system of monocular, synchronously obtained and the online real-time estimate of appearance of weld characteristic parameter using many electrical parameters of MPAW shaping real-time controlling unit execution welding processes, shape the real-time regulation for the control instruction execution welding condition that real-time controlling unit is sent according to MPAW by MICROBEAM PLASMA WELDING system and precision welding workbench.The present invention can improve the reliability and a solder yield of welding product, it can be applied to during the MICROBEAM PLASMA WELDINGs of field thin-wall metal precision component such as Aero-Space manufacture, the precision welding occasion of the flexible member such as the ultra-thin-wall that is particularly suitable for use in bellows and bellows.
Description
Technical field
The invention belongs to welding quality control technology field.It is related to a kind of MICROBEAM PLASMA WELDING of thin-walled areola ring longitudinal joint
Shaping control system, can be widely applied to the MICROBEAM PLASMA WELDING mistake of the field thin-wall metal precision components such as Aero-Space manufacture
Cheng Zhong.
Background technology
Thin-wall metal precision component is the high-end dress such as Aero-Space, military issue weapons, nuclear industry, medicine equipment and biomedicine
The indispensable important component of a class in the field of making is prepared, it is strict to weldquality and joint mechanical performance requirement.Pulse microbeam
Plasma welding method (P-MPAW, Pulsed Micro-plasma Arc Welding) with energy density because concentrating, hot shadow
The advantages of area is narrow, arc stability is high and can realize the accurate control of heat input is rung, is heat-resisting thin steel strip, Thin Stainless Steel
The important welding forming manufacture method of the thin-wall metal precision component such as wall pipe, metal bellows and bellows.
Welding forming quality control is to maintain welding process stability, ensure the key of weldquality and joint performance,
It is the premise for realizing intelligent welding.China not yet realizes automation and the robot of thin-wall metal precision component comprehensively at this stage
Change welding production, the automatic weld mode of production of human assistance is still depended at present, exist welding process it is unstable,
Appearance of weld is uneven, stability of the welding quality is difficult to ensure, the low serious problems of once welding success rate of product, especially exists
In Aero-Space manufacture field, traditional welding production mode is faced with severe challenge：It is huge with demand in aerospace industry
Exemplified by the thin-wall metal shell class components such as welding bellows, welding bellows, its weld seam is large number of (when most nearly 100), and
Weldquality is both needed to reach the I grades of requirements of aerospace industry standard, while need to ensure none leak source and by hydraulic pressure, airtight, helium mass spectrum
Leak detection and fatigue life test.Therefore, the precision welding shaping On-line Control system for target with " high-precision weld seam control shape " is developed
System and technology, are the key contents that key breakthrough is needed in thin-wall metal precision component manufacture field badly.
Welding forming control technology based on molten bath back side visual sensing is the important hair of welding quality control technology field
Open up one of direction, but due in the manufacture of thin-wall metal precision component widely used docking, crimping or edge joint vacantly weld
Technique, forming quality information sensing and control to its welding process propose great challenge：Thin-wall metal precision component is welded
With mother metal wall is thin, fine weld seam and the features such as small welding pool, it is desirable to welding process vision detection system is with big times
Ensure high accuracy of detection, real-time and stability while rate and high-resolution optical characteristics.Traditional vision-based detection
System depends on the high-resolution miniature object of standard industry Shot Detection of big multiplying power, exists that the depth of field is small and enlargement ratio is with thing
The inherent optics imaging characteristic changed away from change, it is difficult to which the dynamic for directly applying to the fine weld seam precision welding of superthin structure melts
Detect that weldment manufacturing and positioning errors, molten bath self-oscillation phenomenon, the weldment especially in actual welding production are become by heat in pond
Shape and external disturbance are difficult to evade, to micro- depth of field vision system realize molten bath blur-free imaging and follow-up image procossing with
Feature extraction brings difficulty；In addition, in many welding production occasions, being difficult to directly monitor weld seam due to being limited by welding condition
Back-welding shape state, how in welding process time lag, Multivariable Coupling and under conditions of being difficult to set up accurate welding process model
Implement accurate control to quality of weld seam molding, be the key issue of thin-wall metal precision component welding manufacture urgent need to resolve.
Through to prior art literature and patent retrieval discovery, number of patent application is special for 200810200821.4 Chinese invention
Profit《Microbeam plasma arc welding total-system cooperative control structure》Disclose a kind of collection source of welding current control, weld joint tracking control
System, the control of welding torch travelling control, heat input, arc stability control, welding procedure are controlled in integral MICROBEAM PLASMA WELDING
System, but the system is not directed to welding pool visual sensing, it is impossible to be monitored to welding dynamic pool behavior or from molten bath table
Face obtains Molten Pool Shape characteristic information, and can not realize the online essence of MICROBEAM PLASMA WELDING process weld penetration and weld pool width
Really control；Number of patent application is 200510111327.7 Chinese invention patent《A kind of dual processor number of micro beam plasma welding
Word control system and control method》Disclose a kind of double processor communication based on MCU single-chip microcomputers and DSP Digital Signal Processing
Control system, by making full use of the respective advantage of MCU single-chip microcomputers and DSP, realizes that rapid data is transmitted
And the functions such as external characteristics optimal control are welded, but it is not directed to MICROBEAM PLASMA WELDING shaping On-line Control technology；Number of patent application
For 200610075063.9 Chinese invention patent《The digital human-computer interaction system of micro beam plasma welding》Disclose a kind of micro-
The menu mode man-machine interactive system of beam plasma welding machine, microplasma is realized using single-chip microcomputer and DSP
The man-machine interaction of welding scene, the system is also not directed to MICROBEAM PLASMA WELDING shaping On-line Control technology.
In summary, domestic and international existing MICROBEAM PLASMA WELDING (MPAW, Micro-plasma Arc Welding) system
Welding machine and host computer data communication, welding machine man-machine interaction, welding condition on-line tuning, welding bead are only related to mostly from motion tracking
Etc. function, have not yet to see online about feeding back the MICROBEAM PLASMA WELDING merged with molten bath visual information shaping based on many electricity
The research of control system and report.
The content of the invention
It is an object of the invention to overcome the deficiencies in the prior art, a kind of microplasma of thin-walled areola ring longitudinal joint is proposed
Welding forming control system, is controlled in real time online with the appearance of weld for realizing thin-wall metal shell class component ring longitudinal joint precision welding
System.
To achieve these goals, the present invention takes following technical scheme：
A kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint, including MICROBEAM PLASMA WELDING system
System, precision welding workbench, the coaxial telecentricity visual sensing system of monocular and MPAW shaping real-time controlling units；
The coaxial telecentricity visual sensing system of monocular includes LED coaxial parallel telecentricity backlight, composite filter mating plate group, work
Industry telecentric lens and high speed CCD camera；The MPAW shapings real-time controlling unit includes Molten pool image gathering control module, melted
Pond image procossing and characteristic extracting module, welding process parameter synchronous acquisition module, MPAW appearances of weld prediction module and MPAW
Appearance of weld control module；
The composite filter mating plate group includes optical filter, light damping plate and protection eyeglass, and the composite filter mating plate group is fixedly mounted on
With in the industrial telecentric lens diameter identical sleeve, one end of the sleeve is fixed on the industrial telecentric lens, institute
The other end for stating sleeve is fixedly linked with the coaxial parallel telecentricity backlights of the LED, and the industrial telecentric lens are fixedly installed on
On the high speed CCD camera, the high speed CCD camera be fixedly installed on grade in the MICROBEAM PLASMA WELDING system from
The rear of sub- welding gun, makes the coaxial parallel telecentricity backlights of the LED project directional light to micro- from the rear in the top of weldment, molten bath
Beam molten bath for plasma welding area；The Molten pool image gathering control module connects the high speed CCD camera, institute by control line
The signal output part for stating high speed CCD camera connects the molten pool and characteristic extracting module by signal wire, described
Molten pool is connected the MPAW appearances of weld prediction module with characteristic extracting module by data wire；
The welding process parameter synchronous acquisition module includes Hall sensor, plasma gas flow rate sensor, protection gas
Flow sensor and multi-channel data synchronous acquisition circuit；The Hall sensor, the plasma gas flow rate sensor and institute
State protection air-flow quantity sensor and the Circuit Design of Multi-channel Data is connected by signal wire respectively；The Hall sensor is installed
In in the welding main current loop of the MICROBEAM PLASMA WELDING system, the plasma gas flow rate sensor and the protection gas
Flow sensor is respectively arranged in the plasma (orifice) gas gas circuit of the MICROBEAM PLASMA WELDING system and protection gas gas circuit；The essence
Machine tool chief axis and welding pose control unit in close welding bench connect the multi-channel data acquisition electricity by signal wire
Road, the Circuit Design of Multi-channel Data connects the MPAW appearances of weld prediction module by data wire；
The MPAW appearances of weld control module includes fusion penetration molten wide controller, D/A converting circuit, signal amplification circuit
And optical coupling isolation circuit；The fusion penetration molten wide controller is sequentially connected the D/A converting circuit, the signal by signal wire
Amplifying circuit and the optical coupling isolation circuit, the optical coupling isolation circuit connect the micro beam plasma welding by signal wire respectively
The machine tool chief axis in welding machine circuit for remotely controlling, plasma gas air supply unit and the precision welding workbench in welding system
And welding pose control unit；
The MPAW appearances of weld prediction module connects molten in the MPAW appearances of weld control module by data wire
Deep molten wide controller.
In above-mentioned technical proposal, the industrial telecentric lens in the coaxial telecentricity visual sensing system of monocular are optical amplifier
Multiple is 2 to 10 times of industrial telecentric lens, and operating distance is 110.0 ± 2mm or 65.1 ± 2mm.
In above-mentioned technical proposal, the high speed CCD camera in the coaxial telecentricity visual sensing system of monocular is fixedly installed
On camera mount.
In above-mentioned technical proposal, the primary optical axis of the coaxial telecentricity visual sensing system of monocular passes through molten bath center, and this is remote
The depth of field d of heart visual sensing system meets d ＞ lcos θ, and wherein l is molten bath length, and θ is between primary optical axis and molten bath plane
Angle,
In above-mentioned technical proposal, the precision welding workbench includes machine tool chief axis and welding pose control unit, lathe
Pedestal, weldment clamping and rotating mechanism, welding torch clamping mechanism and precise motion module.
In above-mentioned technical proposal, the weldment clamping is provided with protection gas interface with rotating mechanism, and the protection gas interface leads to
Gas circuit is crossed to be connected with the protective gas air supply unit in the MICROBEAM PLASMA WELDING system.
Technique effect of the present invention with advantages below and high-lighting：The present invention is using by the coaxial parallel telecentricity backlights of LED
The coaxial telecentricity visual sensing system of monocular that source, composite filter mating plate group, industrial telecentric lens and high speed CCD camera are constituted is obtained
The molten bath front transient images of thin-walled areola ring longitudinal joint MICROBEAM PLASMA WELDING, can overcome Conventional visual sensor-based system optics into
As the problem that enlargement ratio and resolution ratio change and changed with object distance with the depth of field, enlargement ratio can not be taken into account, welding process is realized
The blur-free imaging in the small molten bath of dynamic；The many electrical parameters of welding process are performed using MPAW shaping real-time controlling units synchronously to obtain
With the online real-time estimate of appearance of weld characteristic parameter, by MICROBEAM PLASMA WELDING system and precision welding workbench according to MPAW into
The control instruction that shape real-time controlling unit is sent performs the real-time regulation of welding condition, to solve MICROBEAM PLASMA WELDING mistake
Welding process is unstable caused by situation and the uneven problem of appearance of weld for energy parameter fluctuation and radiating condition change etc. in journey
There is provided effective solution；The present invention can improve the reliability and a solder yield of welding product, can apply
During the MICROBEAM PLASMA WELDING of the field thin-wall metal precision components such as Aero-Space manufacture, the ultra-thin-wall that is particularly suitable for use in film
The precision welding occasion of the flexible member such as box and bellows.
Brief description of the drawings
Fig. 1 is the MICROBEAM PLASMA WELDING shaping control system schematic diagram of thin-walled areola ring longitudinal joint of the present invention.
In figure：The coaxial telecentric optical system of 1-monocular；2-precision welding workbench；The coaxial telecentricity vision of 3-monocular is passed
Sensing system；4-MPAW shapes real-time controlling unit；The coaxial parallel telecentricity backlights of 5-LED；6-composite filter mating plate group；7-work
Industry telecentric lens；8-high speed CCD camera；9-camera mount；10-Molten pool image gathering control module；11-molten bath figure
As processing and characteristic extracting module；12-welding process parameter synchronous acquisition module；13-MPAW appearance of weld prediction modules；
14-MPAW appearance of weld control modules；15-Hall sensor；16-plasma gas flow rate sensor；17-protection air-flow amount
Sensor；18-multi-channel data synchronous acquisition circuit；19-fusion penetration molten wide controller；20-D/A converting circuit；21-letter
Number amplifying circuit；22-optical coupling isolation circuit；23-MICROBEAM PLASMA WELDING power model；24-plasma gun；25-weldering
Machine circuit for remotely controlling；27-plasma gas air supply unit；28-protective gas air supply unit；31-machine tool chief axis and welding
Pose Control unit；42-weldment；43-molten bath；44-molten bath plane；45-primary optical axis.
Fig. 2 is MICROBEAM PLASMA WELDING system schematic described in the embodiment of the present invention.
In figure：15-Hall sensor；23-MICROBEAM PLASMA WELDING power model；24-plasma gun；25-weldering
Machine circuit for remotely controlling；26-water-cooling system；27-plasma gas air supply unit；28-protective gas air supply unit；29—
Main arc power source；30-pilot source；42-weldment.
Fig. 3 and Fig. 4 are precision welding workbench schematic diagrames described in the embodiment of the present invention.
In figure：24-plasma gun；31-machine tool chief axis and welding pose control unit；32-lathe base；33—
Weldment clamping and rotating mechanism；34-welding torch clamping mechanism；35-precise motion module；36-base body；37-the first slides
Frame；38-the second balladeur train；39-main axis head；40-rotary apparatus head bracket；41-tail end fixture；42-weldment；
46-protection gas interface.
Embodiment
Technical scheme is described in further details with reference to the accompanying drawings and examples.
Fig. 1 show the MICROBEAM PLASMA WELDING shaping control system schematic diagram of the thin-walled areola ring longitudinal joint of the present invention, bag
Include the coaxial telecentricity visual sensing system 3 of MICROBEAM PLASMA WELDING system 1, precision welding workbench 2, monocular and MPAW shapings are real-time
Control unit 4；
In the present embodiment, using MICROBEAM PLASMA WELDING system 1 as shown in Figure 2, including MICROBEAM PLASMA WELDING power
Module 23, plasma gun 24, welding machine circuit for remotely controlling 25, water-cooling system 26, plasma gas air supply unit 27 and protection
Gas air supply unit 28, wherein, MICROBEAM PLASMA WELDING power model 23 includes main arc power source 29 and pilot source 30, the master
The electric current degree of regulation of arc power 29 is 0.02A, and current pulse width degree of regulation is 0.1%；The main arc power source 29 is just
Pole is connected by welding cable through the Hall sensor 15 with weldment 42；The negative pole of the main arc power source 29 passes through sealing wire
Cable is connected with the negative pole of the pilot source 30；The negative pole of the pilot source 30 is welded by welding cable with the plasma
Tungsten electrode in rifle 24 is connected, and the positive pole of the pilot source 30 is by welding cable and the conduction in the plasma gun 24
Mouth is connected, and the protective gas air supply unit 28 is connected by gas path pipe with the protective gas air inlet of main arc power source 29
Connect, the protective gas gas outlet of the main arc power source 29 is connected by gas path pipe with the protective gas air inlet of pilot source 30
Connect, the plasma gas air supply unit 27 is connected by gas path pipe with the plasma gas inlets of pilot source 30,
The protective gas gas outlet and plasma gas gas outlet of the pilot source 30 pass through gas path pipe and plasma gun respectively
24 are connected, and the pilot source 30 is connected by pipeline with the water-cooling system 26, the cooling water of the pilot source 30
Delivery port and water inlet are connected by pipeline with plasma gun 24 respectively, and the welding machine circuit for remotely controlling 25 passes through signal
Line is connected with the main arc power source 29；
In the present embodiment, the precision welding workbench 2 of use as shown in Figure 3 and Figure 4, including machine tool chief axis and welding
Pose Control unit 31, lathe base 32, weldment clamping and rotating mechanism 33, welding torch clamping mechanism 34 and precise motion module
35, the weldment clamping is provided with protection gas interface with rotating mechanism 33, and the protection gas interface passes through gas circuit and described microbeam etc.
Protective gas air supply unit 28 in ion welding system 1 is connected, and gas shield is carried out to back of weld during welding for realizing；
The rotating speed continuously adjustable setting range of the precision welding workbench 2 is 0.1-99rad/min；The plasma gun 24 is rigidly fixed
On the welding torch clamping mechanism 34；The lathe base 32 includes base body 36, the first balladeur train 37 and the second balladeur train 38, institute
Stating weldment clamping and rotating mechanism 33 includes main axis head 39, rotary apparatus head bracket 40 and tail end fixture 41, the master
Axle rotates head 39 and rotary apparatus head bracket 40 is affixed, and the rotary apparatus head bracket 40 is embedded in described first with slip and slided
Accurate translator slider on frame 37 is affixed, and the tail end fixture 41 is with sliding another precision being embedded on first balladeur train 37
Translator slider is affixed, and first balladeur train 37 is fixedly mounted on the place side of main axis head 39 of the base body 36, institute
State the opposite side that the second balladeur train 38 is fixedly mounted on the base body 36；The precise motion module 35 is using five degree of freedom essence
Close motion module, including the automatically controlled microspur translation of X-axis electric controlled rotating platform, Y-axis electric controlled rotating platform, the automatically controlled microspur translation stage of X-axis, Y-axis
Platform and the automatically controlled microspur translation stage of Z axis, the accurate sliding block of the Y-axis electric controlled rotating platform and the automatically controlled microspur translation stage of the X-axis are affixed,
The automatically controlled microspur translation stage of X-axis is fixedly mounted on the accurate sliding block of the automatically controlled microspur translation stage of the Y-axis, and the Y-axis is automatically controlled
Microspur translation stage and the X-axis electric controlled rotating platform are affixed, and the X-axis electric controlled rotating platform is fixedly mounted on the automatically controlled microspur of the Z axis
On the accurate sliding block of translation stage, the precision that the automatically controlled microspur translation stage of Z axis is embedded on second balladeur train 38 with sliding is put down
Shifting sliding block is affixed, and the welding torch clamping mechanism 34 is fixedly mounted on the Y-axis electric controlled rotating platform；The machine tool chief axis and welding
Pose Control unit 31 by signal wire respectively with the main axis head 39, tail end fixture 41 and the phase of precise motion module 35
Connection, the Pose Control of handling, rotation and plasma gun 24 for realizing weldment, by the machine tool chief axis and welding pose
The output control of control unit 31 is instructed to be adjusted to the velocity of rotation of the main axis head 39, that is, realizes speed of welding
On-line Control, by the machine tool chief axis and the instruction of the output control of welding pose control unit 31 in the precise motion module 35
Motor be controlled, that is, realize welding pose control；
The coaxial telecentricity visual sensing system 3 of monocular includes LED coaxial parallel telecentricity backlight 5, composite filter mating plate group
6th, industrial telecentric lens 7 and high speed CCD camera 8；The MPAW shaping real-time controlling units 4 are controlled including Molten pool image gathering
Module 10, molten pool and characteristic extracting module 11, welding process parameter synchronous acquisition module 12, MPAW appearances of weld are pre-
Survey module 13 and MPAW appearances of weld control module 14；
The industrial telecentric lens 7 are the industrial telecentric lens that optical magnification is 2 to 10 times, and operating distance is
It is 110.0 ± 2mm's for 4 times, operating distance that optical magnification is used in 110.0 ± 2mm or 65.1 ± 2mm, the present embodiment
Industrial telecentric lens；The high speed CCD camera 8 is fixedly installed on camera mount 9, and the camera mount 9 can be fixed
Being arranged on the precision welding workbench 2 can also be independently arranged at outside the precision welding workbench 2, be adopted in the present embodiment
Use latter solution；The composite filter mating plate group 6 includes optical filter, light damping plate and protection eyeglass；The composite filter mating plate group 6 fixes peace
Mounted in in the industrial diameter identical sleeve of telecentric lens 7, one end of the sleeve is fixed in the industrial telecentric lens 7
On, the other end of the sleeve is fixedly linked with the coaxial parallel telecentricity backlights 5 of the LED, and the industrial telecentric lens 7 are fixed
It is arranged on the high speed CCD camera 8, the high speed CCD camera 8 is fixedly installed on the MICROBEAM PLASMA WELDING system
The rear of plasma gun 24 in 1, makes the coaxial parallel telecentricity backlights 5 of the LED be thrown from the rear in the top of weldment, molten bath
Directional light is penetrated to MICROBEAM PLASMA WELDING molten bath area, the primary optical axis of the coaxial telecentricity visual sensing system 3 of monocular passes through molten bath
Center, the depth of field d of the telecentricity visual sensing system meets d ＞ lcos θ, and wherein l is molten bath length, and θ is primary optical axis and molten bath
Angle between plane,The Molten pool image gathering control module 10 connects the high-speed CCD by control line
Video camera 8, Molten pool image gathering control module 10 is realized at a high speed by sending start pulse signal to high speed CCD camera 8
The control of the filming frequency of ccd video camera 8, the pulse frequency of start pulse signal is typically set to MICROBEAM PLASMA WELDING current impulse
The multiple of frequency；The signal output part of the high speed CCD camera 8 connects the molten pool and feature by signal wire
Extraction module 11, the molten pool is connected the MPAW appearances of weld by data wire with characteristic extracting module 11 and predicted
Module 13；6 pairs of the composite filter mating plate group industrial telecentric lens 7 are protected and are lowered into the arc light radiation of camera lens by force
Degree, so as to ensure that the high speed CCD camera 8 obtains the clear and high crater image of signal to noise ratio；The high speed CCD camera 8
Continuous acquisition eliminates the crater image after arc light is disturbed through the composite filter mating plate group 6, and crater image is delivered into described melt
Pond image procossing and characteristic extracting module 11, the molten pool carry out image with characteristic extracting module 11 to crater image
Crater image is carried out after pretreatment successively to split and melt tank edge Detection and Extraction Molten Pool Shape characteristic information, including molten bath length,
The length of molten bath half, pool width and molten bath afterbody profile angle angle, and the Molten Pool Shape characteristic information is delivered to described
MPAW appearances of weld prediction module 13；
The welding process parameter synchronous acquisition module 12 include Hall sensor 15, plasma gas flow rate sensor 16,
Protection air-flow quantity sensor 17 and multi-channel data synchronous acquisition circuit 18；The Hall sensor 15, the plasma air-flow
Quantity sensor 16 and the protection air-flow quantity sensor 17 connect the Circuit Design of Multi-channel Data 18 by signal wire respectively；
The Hall sensor 15 is installed in the welding main current loop of the MICROBEAM PLASMA WELDING system 1, the plasma (orifice) gas
Flow sensor 16 and the protection air-flow quantity sensor 17 are respectively arranged in the plasma of the MICROBEAM PLASMA WELDING system 1
In gas gas circuit and protection gas gas circuit；Machine tool chief axis and welding pose control unit 31 in the precision welding workbench 2 pass through
Signal wire connects the Circuit Design of Multi-channel Data 18, and the Circuit Design of Multi-channel Data 18 connects described by data wire
MPAW appearances of weld prediction module 13, realizes the welding current, plasma gas flow and speed of welding number that will be collected in real time
According to transmitting to the MPAW appearances of weld prediction module 13；
The MPAW appearances of weld prediction module 13 is connected in the MPAW appearances of weld control module 14 by data wire
Fusion penetration molten wide controller 19, the MPAW appearances of weld prediction module 13 joins according to molten bath visual signature parameter and welding process
Number and the Nonlinear Mapping relation of appearance of weld size carry out on-line operation, obtain weld pool width real-time estimate value and weld penetration
Real-time estimate value, then expects index with default molten wide respectively by weld pool width real-time estimate value and weld penetration real-time estimate value
It is expected that index is compared with default fusion penetration and obtain difference EdepthAnd Ewidth, and by EdepthAnd EwidthInput is molten to the fusion penetration
Wide controller 19, wherein, the non-thread of the molten bath visual signature parameter and welding process parameter and weld pool width and weld penetration
Property mapping relations are obtained by using system identifying method, in the present embodiment, are distinguished using Elman Dynamic Recurrent Neural Network systems
Knowledge method carries out off-line system identification to the MICROBEAM PLASMA WELDING process of thin-walled areola ring longitudinal joint, obtains molten bath visual signature ginseng
The Nonlinear Mapping relation of number and welding process parameter and weld pool width and weld penetration；
The MPAW appearances of weld control module 14 includes fusion penetration molten wide controller 19, D/A converting circuit 20, signal and put
Big circuit 21 and optical coupling isolation circuit 22；The fusion penetration molten wide controller 19 is sequentially connected the digital-to-analogue conversion electricity by signal wire
Road 20, the signal amplification circuit 21 and the optical coupling isolation circuit 22, the optical coupling isolation circuit 22 are distinguished by signal wire
Connect welding machine circuit for remotely controlling 25, plasma gas air supply unit 27 and the lathe in the MICROBEAM PLASMA WELDING system 1
Main shaft and welding pose control unit 31；The fusion penetration molten wide controller 19 is according to EdepthAnd Ewidth, using PID control, obscure
The control algolithms such as control, Multimode Control or MFA control calculate and obtain MICROBEAM PLASMA WELDING minor arc electric current Im-arc、
Plasma gas flow rate QplasmaOr welding speed VweldingState modulator adjustment amount Δ Im-arc、ΔQplasmaWith Δ Vwelding, point
Not by the main arc power source 29, plasma gas air supply unit 27 and machine tool chief axis and welding pose control unit 31 according to Δ
Im-arc、ΔQplasmaWith Δ VweldingPerform Im-arc、QplasmaAnd VweldingReal-time regulation, realize MICROBEAM PLASMA WELDING weld seam
The closed loop feedback control of shaping；In the present embodiment, the MPAW appearances of weld prediction module 13 is performed and described using industrial computer
The data processing and computing performed needed for fusion penetration molten wide controller 19.
Claims (6)
1. a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint, it is characterised in that：Including microbeam etc. from
Sub- welding system (1), precision welding workbench (2), the coaxial telecentricity visual sensing system (3) of monocular and the real-time control of MPAW shapings
Unit (4)；
The coaxial telecentricity visual sensing system (3) of monocular includes LED coaxial parallel telecentricity backlight (5), composite filter mating plate group
(6), industrial telecentric lens (7) and high speed CCD camera (8)；The MPAW shaping real-time controlling units (4) include crater image
Acquisition control module (10), molten pool and characteristic extracting module (11), welding process parameter synchronous acquisition module (12),
MPAW appearances of weld prediction module (13) and MPAW appearances of weld control module (14)；
The composite filter mating plate group (6) includes optical filter, light damping plate and protection eyeglass, and the composite filter mating plate group (6) is fixedly mounted
With in industrial telecentric lens (7) the diameter identical sleeve, one end of the sleeve is fixed in the industrial telecentric lens
(7) on, the other end of the sleeve is fixedly linked with the coaxial parallel telecentricity backlights (5) of the LED, the industrial telecentric lens
(7) it is fixedly installed on the high speed CCD camera (8), the high speed CCD camera (8) is fixedly installed on described microbeam etc.
The rear of plasma gun (24) in ion welding system (1), makes the coaxial parallel telecentricity backlights (5) of the LED from weldment
Top, the rear in molten bath project directional light to MICROBEAM PLASMA WELDING molten bath area；The Molten pool image gathering control module
(10) high speed CCD camera (8) is connected by control line, the signal output part of the high speed CCD camera (8) passes through letter
Number line connects the molten pool and characteristic extracting module (11), the molten pool and characteristic extracting module (11)
The MPAW appearances of weld prediction module (13) is connected by data wire；
The welding process parameter synchronous acquisition module (12) includes Hall sensor (15), plasma gas flow rate sensor
(16), protection air-flow quantity sensor (17) and multi-channel data synchronous acquisition circuit (18)；It is the Hall sensor (15), described
Plasma gas flow rate sensor (16) and the protection air-flow quantity sensor (17) connect the multichannel by signal wire respectively
Data acquisition circuit (18)；The Hall sensor (15) is installed on the main electricity of welding of the MICROBEAM PLASMA WELDING system (1)
Flow back on road, the plasma gas flow rate sensor (16) and the protection air-flow quantity sensor (17) are respectively arranged in described micro-
In the plasma (orifice) gas gas circuit and protection gas gas circuit of beam Plasma Welding system (1)；Lathe in the precision welding workbench (2)
Main shaft and welding pose control unit (31) connect the Circuit Design of Multi-channel Data (18), the multichannel by signal wire
Data acquisition circuit (18) connects the MPAW appearances of weld prediction module (13) by data wire；
The MPAW appearances of weld control module (14) includes fusion penetration molten wide controller (19), D/A converting circuit (20), signal
Amplifying circuit (21) and optical coupling isolation circuit (22)；The fusion penetration molten wide controller (19) is sequentially connected the number by signal wire
Analog conversion circuit (20), the signal amplification circuit (21) and the optical coupling isolation circuit (22), the optical coupling isolation circuit
(22) connected respectively by signal wire welding machine circuit for remotely controlling (25) in the MICROBEAM PLASMA WELDING system (1), etc. from
Sub- gas air supply unit (27) and machine tool chief axis and welding pose control unit (31) in the precision welding workbench (2)；
The MPAW appearances of weld prediction module (13) is connected in the MPAW appearances of weld control module (14) by data wire
Fusion penetration molten wide controller (19).
2. a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint according to claim 1, it is special
Levy and be：Industrial telecentric lens (7) in the coaxial telecentricity visual sensing system (3) of monocular be optical magnification be 2 to
10 times of industrial telecentric lens, operating distance is 110.0 ± 2mm or 65.1 ± 2mm.
3. a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint according to claim 1, it is special
Levy and be：High speed CCD camera (8) in the coaxial telecentricity visual sensing system (3) of monocular is fixedly installed on video camera branch
On frame (9).
4. a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint according to claim 1, it is special
Levy and be：The primary optical axis of the coaxial telecentricity visual sensing system (3) of monocular passes through molten bath center, the telecentricity visual sensing system 1
Depth of field d meet d>Lcos θ, wherein l are molten bath length, and θ is the angle between primary optical axis and molten bath plane,
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<mi>&pi;</mi>
<mn>9</mn>
</mfrac>
<mo>&le;</mo>
<mi>&theta;</mi>
<mo>&le;</mo>
<mfrac>
<mi>&pi;</mi>
<mn>6</mn>
</mfrac>
<mo>.</mo>
</mrow>
5. a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint according to claim 1, it is special
Levy and be：The precision welding workbench (2) include machine tool chief axis and welding pose control unit (31), lathe base (32),
Weldment clamping and rotating mechanism (33), welding torch clamping mechanism (34) and precise motion module (35).
6. a kind of MICROBEAM PLASMA WELDING shaping control system of thin-walled areola ring longitudinal joint according to claim 5, it is special
Levy and be：The weldment clamping and rotating mechanism (33) are provided with protection gas interface, the protection gas interface by gas circuit with it is described
Protective gas air supply unit (28) connection in MICROBEAM PLASMA WELDING system (1).
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| CN106624266B (en) * | 2016-12-31 | 2018-08-07 | 东莞职业技术学院 | A kind of weld seam deviation and penetration signal monitoring method for Automobile Welding |
| CN107225314B (en) * | 2017-06-22 | 2022-07-26 | 华南理工大学 | Additive manufacturing system of reversed polarity plasma arc robot and implementation method thereof |
| CN108067714B (en) * | 2017-11-30 | 2020-03-20 | 清华大学 | Online monitoring and defect positioning system and method for end connection quality of thin-wall circular seam |
| CN109332957A (en) * | 2018-11-28 | 2019-02-15 | 合肥常青机械股份有限公司 | Welding robot Automation of Welding control system |
| CN112091480B (en) * | 2020-08-06 | 2022-02-11 | 苏州实创德光电科技有限公司 | Auxiliary internal lighting system for identifying axial weld joint of straight pipe and welding method |
| CN112605509B (en) * | 2020-12-09 | 2021-11-30 | 上海交通大学 | Plasma transferred arc surfacing control system and control method |
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