CN108544068B - Welding quality control system and method for arc temperature difference before and after plasma arc perforation - Google Patents
Welding quality control system and method for arc temperature difference before and after plasma arc perforation Download PDFInfo
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- CN108544068B CN108544068B CN201810352488.2A CN201810352488A CN108544068B CN 108544068 B CN108544068 B CN 108544068B CN 201810352488 A CN201810352488 A CN 201810352488A CN 108544068 B CN108544068 B CN 108544068B
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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
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- 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
Abstract
The invention discloses a welding quality characterization and control system and a method according to the arc temperature difference of front and back sides of a variable polarity plasma arc. And filtering and symmetrizing the whole arc image, then obtaining the temperatures before and after arc perforation by using a standard temperature method, and calculating the arc temperature difference of the front side and the back side for representing the current welding quality. In addition, in the welding process, the temperature difference before and after arc perforation is collected and calculated in real time and is compared with the arc temperature difference of the qualified welding quality, and the current welding arc temperature difference is adjusted in real time to be within the error range of the qualified welding quality temperature difference, so that the implementation representation and control of the plasma arc welding quality are realized.
Description
Technical Field
The invention belongs to the field of welding quality control methods, and particularly relates to a system and a method for representing and controlling welding quality according to the front-back arc temperature difference of a variable-polarity plasma arc.
Background
The variable polarity perforation plasma arc is a novel high-efficiency zero-defect welding method developed for aluminum alloy, integrates the advantages of variable polarity TIG (non-consumable electrode gas shielded welding) and plasma high-energy beam, reasonably distributes arc energy, reduces burning loss of a tungsten electrode to the maximum extent under the condition of simultaneously melting a workpiece, removing an oxide film on the surface of the workpiece and discharging a hole in a welding joint, and can effectively utilize the characteristic of high energy density of the plasma beam to form a perforation molten pool in the welding process so as to realize single-side welding and double-side forming of the aluminum alloy medium plate.
In the welding process, the perforated molten pool as the most complicated process has important influence on the welding quality and the welding efficiency. A large number of scholars at home and abroad research the behavior of the perforation molten pool, and the results show that various welding parameters such as positive and negative polarity current, ionic gas flow, welding speed, wire filling speed and the like have important relation with the stability of the perforation molten pool. Therefore, a large number of researchers have studied controlling the stability of the piercing weld pool in order to achieve the goal of controlling the quality of the weld. However, there is currently no measure of the stability of the keyhole weld pool and no established criterion for evaluating the weld quality for the stability of the keyhole weld pool. The invention relates to a welding quality control system and a method based on arc temperature difference before and after plasma arc perforation, which are used for representing and judging welding quality in real time in the welding process. According to a large number of early tests, on the premise of ensuring the welding quality, the energy of the electric arc is absorbed by the small-hole molten pool and then passes through the small hole to reach the back of the molten pool; because the energy required for penetrating through the small hole in the stable welding is fixed, the absorbed energy is also fixed, so that the arc energy and the arc temperature difference on the front side and the back side of the perforation molten pool also have a fixed range. Based on the method, the welding quality can be represented according to the front-side and back-side arc temperature difference.
The invention realizes the real-time monitoring of the welding quality and avoids the defect that the welding quality can only be observed after the welding is finished, thereby greatly improving the welding and production efficiency and realizing high-quality and high-efficiency welding.
Disclosure of Invention
The invention aims to make up the deficiency of a method for representing the perforation plasma welding quality on line, and provides a welding quality control system and a method for the arc temperature difference before and after plasma arc perforation. The method can adapt to various working environments, realizes the online characterization and control of the welding quality, and improves the welding qualification rate and the production efficiency.
A welding quality control system and method based on the arc temperature difference before and after plasma arc perforation is characterized in that a set of visual sensing system is added along the welding direction in the welding process, the shapes and characteristics of arcs on the front side and the back side of a plasma arc are recorded in real time, the temperature difference between the arcs on the front side and the back side is obtained through on-line calculation, dynamic analysis is carried out, and the characterization and control of perforation plasma welding quality of welding process parameters are adjusted in real time.
In order to achieve the purpose, the invention adopts the following technical scheme:
a weld quality control system for a temperature differential between an arc before and after plasma arc piercing, comprising: the device comprises a plasma power supply, a plasma welding gun, a cooling water tank of a polarity-variable plasma welding system, a high-speed camera, a narrow-band filter, an image processing unit, an industrial personal computer and a display of an arc image acquisition and processing system, wherein the high-speed camera, the narrow-band filter and a welding workpiece are fixed on the same axis, the arc form is ensured to be positioned in a high-speed camera observation window in the welding process, and the arc form is ensured to be vertical to the welding workpiece so as to reduce errors in the image processing process; synchronously displaying image processing results before and after arc perforation and the arc temperature difference on a display interface in the welding process, comparing the arc temperature difference in the welding process in real time according to a preset standard arc temperature difference, and continuing welding if the temperature difference in the welding process is within an error range; if the temperature difference exceeds a preset error range in the welding process, sending a corresponding signal to a variable polarity plasma welding system through a feedback system according to the deviation of the temperature difference so as to adjust the action of a corresponding welding parameter and control the temperature difference to be within a standard error range; thereby characterizing and controlling the welding quality of the polarity-changing plasma.
Preferably, the device also comprises protective gas and ion gas with the argon purity of more than 99.99 percent, a restraint nozzle and a movement device; the high-speed camera, the narrow-band filter and the moving device are arranged at the same axial line position, so that the electric arc on the front side of the perforated molten pool and the electric arc on the back side of the perforated molten pool can be displayed in the same camera window; the image processing unit processes the arc temperature difference data in the welding process in real time and compares the arc temperature difference data with the temperature difference data of the preset qualified welding quality; if the arc temperature difference between the front side and the back side is within the error range in the welding process, continuing welding; if the temperature difference between the front side and the back side of the arc exceeds a preset error range in the welding process, sending a corresponding signal to a polarity-variable plasma welding system through a feedback system so as to adjust the wire feeding, the welding current, the movement device and the ionic gas flow and control the temperature difference between the front side and the back side of the arc to be within the error range; wherein, the plasma power supply, the cooling water tank, the plasma welding gun, the shielding gas and the ion gas, the restraint nozzle and the workpiece form a polarity-variable plasma welding control system; the narrow-band optical filter, the high-speed camera, the industrial personal computer and the display form an image acquisition system; the arc image filtering unit, the arc image deviation rectifying unit and the standard temperature method processing unit form an image processing unit; in the welding process, if the temperature difference between the front side arc and the back side arc is larger than a preset standard range, a signal is fed back to the polarity-variable plasma welding power supply and the control system to reduce the energy of an arc line, wherein the arc line energy comprises the steps of increasing the wire feeding speed, reducing the welding current and increasing the ion gas, so that the temperature difference between the front side arc and the back side arc is adjusted to be within the standard range; if the temperature difference between the front side arc and the back side arc is smaller than a preset standard range, feeding back a signal to a welding power supply and a control system to increase the energy of an arc line, wherein the energy comprises the steps of reducing the welding speed, increasing the welding current, reducing the ion gas and the like, so that the temperature difference between the front side arc and the back side arc is adjusted to be within the standard range; real-time control of arc temperature difference between the front side and the back side in the welding process is achieved, and therefore accurate control of welding heat input and weld forming is achieved.
The invention also provides a welding quality control method of the electric arc temperature difference before and after the plasma arc perforation, which comprises the following steps:
(1) setting the arc temperature difference of the front and the back sides required for reaching the qualified welding quality;
(2) monitoring the behaviors of the front and the back of the electric arc in real time in the welding process;
(3) calculating to obtain the arc temperature difference of the front and the back surfaces according to the monitored arc behavior;
(4) comparing the monitored temperature difference with the standard temperature difference range in real time, and judging whether the arc temperature difference of the ongoing welding process is within the standard temperature difference range;
(5) if the temperature difference between the front side arc and the back side arc in the monitoring is within the standard range, the step (2) is continuously executed, and the online characterization and control of the welding quality of the perforated variable-polarity plasma are realized; and (3) if the temperature difference between the front side arc and the back side arc in monitoring exceeds a standard range, judging whether the temperature difference is smaller than the standard or larger than the standard, feeding back a signal to a polarity-variable plasma welding control system, and continuously executing the step (2) after adjusting welding parameters.
And (3) monitoring the front and back behaviors of the electric arc of the molten pool in real time in the step (2) and implementing a sensed image signal for high-speed shooting.
Calculating to obtain the front and back arc temperature difference in the step (3), processing the front and back of the arc into a spectrogram by an image processing unit, and filtering and rectifying to obtain an arc front and back temperature trend graph; and then calculating the temperature difference between the front side and the back side of the electric arc.
And (4) comparing the standard temperature difference range with the standard temperature difference range in real time, and representing the current welding quality.
And (5) monitoring the temperature difference between the front side and the back side of the electric arc, and controlling the welding quality to ensure that the temperature difference between the front side and the back side of the electric arc is within a standard range in the whole welding process.
The welding quality control system and method for the arc temperature difference before and after plasma arc perforation are used for monitoring the arc temperature difference before and after plasma perforation in the welding process and adjusting welding parameters in real time according to the temperature difference range so as to correct the temperature difference. The whole method comprises a welding power supply, image sensing, image processing, feedback adjustment and the like, welding data are monitored on line according to an image processing unit, signals are fed back to the welding power supply and a control system to adjust welding parameters in real time, the temperature difference of an electric arc is corrected, and good control over welding quality is achieved. The method can monitor and feed back the welding quality in real time so as to optimize the welding process of the variable polarity plasma and improve the welding efficiency.
Compared with the prior art, the method has the following advantages:
1. compared with the traditional polarity-variable plasma welding quality control method, the method can monitor the welding process in real time and represent the welding quality on line; the most remarkable characteristic is that welding quality information is fed back online, and corresponding information is sent to a welding system so as to adjust the welding quality online.
2. Compared with the traditional quality control method, the method can realize effective online monitoring and characterization of welding quality in the welding process, overcome the defect that the traditional plasma welding quality can only be detected after the welding action is finished, and solve the problems of time waste, low efficiency and the like of the traditional welding quality verification.
3. The method for representing and controlling the welding quality of the variable polarity plasma comprises the steps of monitoring the temperature difference between the front side and the back side of an electric arc in real time on line by presetting the temperature difference range between the front side and the back side of the electric arc which reaches the qualified welding quality, and comparing the temperature difference with a standard to judge whether the current welding quality meets the requirement; and if the temperature difference exceeds the standard range, feeding back corresponding information to the variable-polarity plasma welding power supply and the control system immediately, and controlling the temperature difference to be within the standard error range.
Drawings
FIG. 1 is a schematic diagram of the overall operation of the present weld quality characterization and control system.
FIG. 2 is a schematic diagram of the real-time processing of the present weld quality characterization and control method.
In the figure: 1. a polarity-changing plasma welding system, 2, a welding quality real-time characterization system, 3, a polarity-changing plasma welding power supply, 4, a cooling water tank, 5, a plasma welding gun, 6, an image processing unit, 7, a display, 8, a high-speed camera, 9, a narrow-band filter, 10, a motion device, 11, a welding gun protective sleeve, 12, a restraint nozzle, 13, a tungsten electrode, 14, a perforation molten pool front arc, 15, an integral welding seam, 16, a welding seam rear surface, 17, a perforation molten pool, 18, a perforation molten pool back arc, 19, a welding seam front surface, 20, a filter support, 21, a tripod, 22, a ground wire, 23, cooling water outlet, 24, cooling water inlet, 25, welding gun protective gas, 26, welding gun ionic gas, 27, welding gun cooling water outlet, 28, welding gun cooling water inlet (with a current-carrying cable), 29, an industrial personal computer, 30 and a protective gas bottle (argon), 31. an ion gas cylinder (argon), 32, an arc image filtering unit, 33, an arc image rectification unit, 34 and a standard temperature method processing unit.
Detailed Description
The embodiments of the present invention will be described below in detail with reference to the accompanying drawings, but the present invention is not limited to the following examples.
As shown in FIG. 1, the present invention provides a welding quality control system for the temperature difference between the arc before and after plasma arc piercing, comprising: the polarity-variable plasma welding system 1, the welding quality real-time representation system 2, the plasma welding gun 5, the specially-made tungsten electrode 13 and the restraint nozzle 12 provide stable welding electric arcs to avoid interfering with the quality of shot pictures; the high-speed camera 8, the specific narrow-band filter 9 and the welding arc are always kept at the same axial line position, so that errors caused by shooting angles are avoided; in the welding process, a mode that a welding gun is kept still and a workpiece moves forwards at a constant speed is adopted. The arc graphs acquired by the high-speed camera 8 in real time, the front and back temperatures of the arc processed by the image processing unit 6 are displayed on the display 7 of the industrial personal computer 29, the temperature difference is calculated and compared with the temperature difference of the preset qualified welding quality in real time, and if the front and back temperature difference of the arc in the welding process is within the error range, the welding is continued; if the temperature difference between the front side and the back side of the electric arc exceeds a preset error range in the welding process, sending a corresponding signal to the polarity-variable plasma welding system 1 through a feedback system to adjust welding parameters so that the temperature difference of the electric arc is adjusted to be within the error range; wherein the plasma welding power supply 3, the welding torch 5 and the moving device 10 form a welding system; the specific optical filter 9, the high-speed camera 8, the industrial personal computer 29 and the display 7 form an image acquisition system; the arc image filtering unit 32, the arc image rectification unit 33 and the standard temperature method processing unit 34 form an image processing unit.
The invention also provides a welding quality control method of the electric arc temperature difference before and after the plasma arc perforation, which comprises the following steps:
(1) setting a front and back standard arc temperature difference range which reaches the qualified welding quality;
(2) monitoring the front and back behaviors of the electric arc in real time in the welding process, and calculating the temperature difference;
(3) comparing the temperature difference range with a standard arc temperature difference range in real time, and judging whether the temperature difference of the welding in progress is within the standard range;
(4) if the temperature difference in the monitoring is within the standard range, continuing to execute the step (2); and (5) if the temperature difference in the monitoring exceeds the standard range, feeding back to the welding regulation and control unit, regulating corresponding welding parameters in real time, and continuing to execute the step (2).
Further, the front and back standard arc temperature difference range of the qualified welding quality in the step (1) is preset in advance.
Further, the arc temperature difference is monitored in real time in the step (2) and is result data processed by the image processing unit.
And further, comparing the real-time temperature difference range of the arc with the standard arc temperature difference range in the step (3), and calculating result data.
Further, judging whether the temperature difference exceeds a standard range or not in the step (4), and feeding back a signal to a regulation and control unit, wherein if the temperature difference is larger than the standard range, the energy of the arc line is reduced; and when the temperature difference is smaller than the standard range, the arc line energy is increased.
Further, the regulating and controlling unit in the step (4) is used for receiving and feeding back real-time temperature difference data in the welding process, comparing the real-time temperature difference data with a standard range, and making corresponding action.
Example 1:
firstly, the pre-welding work is ready, the adjusting optical filter 9 and the high-speed camera 8 are positioned on the same axis with the welding plane, the focal length is adjusted, and the focal length is kept unchanged in the welding process; before the ion gas cylinder 31, the protective gas cylinder 30 and the cooling water tank 4 are opened and closed, the welding gun and other necessary gas and water paths are ensured to be correctly connected during welding. Various switches of the polarity-changing plasma welding system 1 are turned on as required, while an acquisition window of the image processing unit 6 is opened. Sending out ion gas 26 in advance according to the requirements of the variable polarity perforation plasma welding strictly, and then starting direct current pilot arc through high frequency; after the pilot arc is stable, sending out protective gas 25, and starting direct current electric arc to preheat the workpiece; then starting the polarity-changed plasma main arc for welding. A high-speed camera 8 in the welding quality real-time characterization system 2 collects the arc form, and an image processing unit processes image data in real time and transmits the image data to an industrial personal computer 29 through the data; and displaying the temperature difference between the front side and the back side of the current plasma arc, and comparing with the standard temperature difference range.
As shown in fig. 1 and 2, in the welding process, if the temperature difference between the front and back sides of the arc exceeds a preset standard error range, a signal is fed back to the polarity-variable plasma welding system 1 in real time, and corresponding adjustment is made, so that the temperature difference is within the standard temperature difference range at any time. If the temperature difference between the front side and the back side of the electric arc is larger than the standard range, the energy of the electric arc line is reduced, including increasing the wire feeding speed, reducing the welding current, increasing the ion gas and the like; when the temperature difference between the front side and the back side of the electric arc is smaller than the standard range, the energy of the electric arc line is increased, including increasing welding current, reducing ion gas and the like. The invention can realize the purposes of online characterization and control of the welding quality of the polarity-variable plasma, thereby realizing the accurate control of the welding seam forming quality, improving the welding quality and achieving the purpose of improving the welding efficiency.
Claims (4)
1. A welding quality characterization and control system according to the arc temperature difference between the front and back sides of a variable polarity plasma arc is characterized by comprising: the plasma welding device comprises a plasma power supply (3), a plasma welding gun (5), a cooling water tank (4) of a polarity-variable plasma welding system (1), a high-speed camera (8), a narrow-band filter (9), an image processing unit (6), an industrial personal computer (29) and a display (7) of an arc image acquisition and processing system (2), wherein the high-speed camera (8), the narrow-band filter (9) and a welding workpiece are fixed on the same axis, the arc form is ensured to be positioned in an observation window of the high-speed camera in the welding process, and the arc form is ensured to be vertical to the welding workpiece so as to reduce errors in the image processing process; image processing results before and after arc perforation and the arc temperature difference are synchronously displayed on an interface of a display (7) in the welding process, the arc temperature difference in the welding process is compared in real time according to a preset standard arc temperature difference, and if the temperature difference in the welding process is within an error range, the welding is continued; if the temperature difference exceeds a preset error range in the welding process, sending a corresponding signal to the polarity-variable plasma welding system (1) through a feedback system according to the deviation of the temperature difference so as to adjust the action of a corresponding welding parameter and control the temperature difference to be within a standard error range; thereby characterizing and controlling the welding quality of the polarity-changing plasma.
2. The system for the characterization and control of the welding quality according to the temperature difference between the front and back sides of the variable polarity plasma arc according to claim 1, further comprising shielding gas and ionic gas with an argon purity of 99.99% or more, a confinement nozzle (12), and a moving device (10); wherein the high-speed camera (8), the narrow-band filter (9) and the moving device (10) are positioned at the same axial line position, so that the arc (14) on the front side of the perforated molten pool and the arc (18) on the back side of the perforated molten pool can be displayed in the same camera window; the image processing unit (6) processes the arc temperature difference data in the welding process in real time and compares the arc temperature difference data with the temperature difference data of the preset qualified welding quality; if the arc temperature difference between the front side and the back side is within the error range in the welding process, continuing welding; if the temperature difference between the front side and the back side of the arc exceeds a preset error range in the welding process, sending a corresponding signal to the polarity-variable plasma welding system (1) through a feedback system so as to adjust the wire feeding, the welding current, the moving device (10) and the ion gas flow and control the temperature difference between the front side and the back side of the arc to be within the error range; wherein, a plasma power supply (3), a cooling water tank (4), a plasma welding gun (5), shielding gas and ion gas, a restraint nozzle (12) and a workpiece form a polarity-variable plasma welding system (1); the optical filter (9), the high-speed camera (8), the industrial personal computer (29) and the display (7) form an image acquisition system; the arc image filtering unit (32), the arc image rectifying unit (33) and the standard temperature method processing unit (34) form an image processing system; in the welding process, if the temperature difference between the front side arc and the back side arc is larger than a preset standard range, a signal is fed back to the polarity-variable plasma welding power supply and the control system to reduce the energy of an arc line, wherein the arc line energy comprises the steps of increasing the wire feeding speed, reducing the welding current and increasing the ion gas, so that the temperature difference between the front side arc and the back side arc is adjusted to be within the standard range; if the temperature difference between the front side arc and the back side arc is smaller than a preset standard range, feeding back a signal to a welding power supply and a control system to increase the energy of an arc line, wherein the energy comprises the steps of reducing the welding speed, increasing the welding current and reducing the ion gas, so that the temperature difference between the front side arc and the back side arc is adjusted to be within the standard range; real-time control of arc temperature difference between the front side and the back side in the welding process is achieved, and therefore accurate control of welding heat input and weld forming is achieved.
3. A method for characterizing and controlling the system of welding quality according to the temperature difference between the front and back sides of the arc of a variable polarity plasma arc according to claim 1, comprising the steps of:
(1) setting the arc temperature difference of the front and the back sides required for reaching the qualified welding quality;
(2) monitoring the behaviors of the front and the back of the electric arc in real time in the welding process;
(3) calculating to obtain the arc temperature difference of the front and the back surfaces according to the monitored arc behavior;
(4) comparing the monitored temperature difference with the standard temperature difference range in real time, and judging whether the arc temperature difference of the ongoing welding process is within the standard temperature difference range;
(5) if the temperature difference between the front side arc and the back side arc in the monitoring is within the standard range, the step (2) is continuously executed, and the online characterization and control of the welding quality of the perforated variable-polarity plasma are realized; and (3) if the temperature difference between the front side arc and the back side arc in monitoring exceeds a standard range, judging whether the temperature difference is smaller than the standard or larger than the standard, feeding back a signal to a polarity-variable plasma welding control system, and continuously executing the step (2) after adjusting welding parameters.
4. The method according to claim 3, wherein the calculation in step (3) yields front and back arc temperature differences, the front and back of the arc are processed into spectrograms for the image processing unit, and then the spectrograms are filtered and corrected to yield front and back temperature trend graphs of the arc; and then calculating the temperature difference between the front side and the back side of the electric arc.
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| CN113953634B (en) * | 2021-07-15 | 2022-10-18 | 北京工业大学 | Variable polarity plasma arc welding air hole inhibition method based on spot cluster directional movement control and quality compensation |
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