CN111203639A - Double-laser-beam bilateral synchronous welding filler wire molten drop transition monitoring system and method based on high-speed camera shooting - Google Patents
Double-laser-beam bilateral synchronous welding filler wire molten drop transition monitoring system and method based on high-speed camera shooting Download PDFInfo
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
- B23K26/26—Seam welding of rectilinear seams
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/03—Observing, e.g. monitoring, the workpiece
- B23K26/032—Observing, e.g. monitoring, the workpiece using optical means
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Abstract
A double-laser-beam bilateral synchronous welding filler wire molten drop transition monitoring system and method based on high-speed camera shooting are disclosed, wherein a high-speed camera shooting system is used for monitoring the transition mode and frequency of molten drops in the double-laser-beam bilateral synchronous welding filler wire process in real time, so that the purpose of monitoring the double-laser-beam bilateral synchronous welding filler wire molten drop transition at different wire feeding speeds in the whole process is achieved. The system mainly comprises a double-laser-beam bilateral synchronous welding wire filling system, a high-speed camera shooting acquisition processing system, a full-digital wire feeding control system and an image processing system, and is characterized in that two high-speed cameras are used for simultaneously monitoring the molten drop transition on two sides of a stringer, and digital image processing software is used for rapidly processing the acquired image so as to achieve the purpose of quantitatively calculating the molten drop transition frequency. The invention can realize real-time monitoring of the molten drop transition mode and the transition frequency, thereby improving the weld quality of laser welding.
Description
Technical Field
The invention relates to a double-laser-beam bilateral synchronous welding filler molten drop transition monitoring system and method based on high-speed camera shooting, and belongs to the technical field of laser welding quality monitoring.
Background
In the fields of aerospace, mechanical manufacturing and the like, laser welding aluminum alloy is more and more widely applied due to the advantages of high energy density, small welding deformation, small processing flexibility and the like. Particularly in the field of aerospace, the most common skin-stringer structure in the cylinder section of the aircraft fuselage adopts a double-laser-beam bilateral synchronous welding technology, so that the high-efficiency connection of a T-shaped structure welding joint can be realized, and the weight of the aircraft fuselage is greatly reduced compared with riveting. At present, various airplane types such as A318, A380 and the like are successfully applied to the aluminum alloy laser welding skin-stringer T-shaped joint, so that the weight of the airplane is greatly reduced, and the integrity of the airplane body is kept.
The welding seam of the airplane body is dense, the structure is complex, the precision requirement is extremely high, and a great deal of research needs to be carried out on the double-laser-beam bilateral synchronous wire-filling welding T-shaped joint so as to ensure the precision and the welding seam quality of the welding structure. The filler wire laser welding can add beneficial elements into a molten pool, improve the weldability of a welding joint by adjusting the components of a welding seam, and inhibit the generation of pores and cracks during welding. However, the transition behavior of the droplets during the laser welding process is periodic and unstable, which is not favorable for the transition of the laser energy into the weld pool. Three typical droplet transition modes mainly exist in the double-laser-beam double-side synchronous welding process: large drop transition, spreading transition, and liquid bridge transition. The large drop transition easily causes the phenomena of rough weld formation, serious splashing and the like due to large molten drop and long forming time; in the spreading transition, because the melting and feeding of the welding wire have periodicity, the welding seam is not uniformly formed, and the defects of undercut and the like easily occur on the joint; the molten drops are transferred into the molten pool in a stable liquid bridge form in the liquid bridge transition form, the welding wire is fully melted, the influence of the fluctuation of the welding wire on the welding process is reduced, and the welding seam is well formed. Therefore, the method has important significance for accurately monitoring the quality improvement of the weld joint in the form of molten drop transition in the double-laser-beam double-side synchronous welding process.
Disclosure of Invention
In order to better monitor the molten drop transition form in the double-laser-beam double-side synchronous filler wire welding of the fuselage skin-stringer T-shaped joint under different wire feeding parameters and ensure stable wire feeding in the welding process to improve the quality of the welding joint, the invention provides a double-laser-beam double-side synchronous welding filler wire molten drop transition monitoring system and a method based on high-speed camera shooting.
In order to realize monitoring of the transition form of the filling material in the double-laser-beam bilateral synchronous wire-filling welding process, the device provided by the invention comprises four parts: the device comprises a double-laser-beam bilateral synchronous welding wire-filling system device, a high-speed camera shooting acquisition processing system device, a full-digital wire feeding control system and an image processing system device. Wherein, the welding part is composed of a YLS-10000 optical fiber laser of IGP Photonics company of Germany, a laser double-beam welding head with a focal length of 300mm, a KUKA six-axis robot is matched, and the wire filling adopts a V350 type wire feeder of LINCOLN company to fill welding wires; the high-speed camera shooting and collecting part comprises two sets of PHOTRON Fastcam1024R2 type high-speed cameras, lenses, a light filtering system and a computer system, wherein the sampling frequency of the high-speed cameras is 2000Hz, and the resolution is 256 × 256.
In order to observe, analyze and monitor the behavior characteristics of the molten drop during transition through a computer system, the transition shape, speed and transition mode of the molten drop are obtained by adopting a digital image processing technology, and the whole welding process is monitored and detected in real time through the computer system.
Because the transition mode of the molten drop is mainly influenced by the melting speed of the welding wire, in order to control the melting speed of the welding wire, the invention changes the wire feeding speed under the condition of ensuring that other welding parameters are not changed, thereby changing the transition mode and the frequency of the molten drop in the laser welding process.
The high-speed camera samples and images the double-laser-beam bilateral synchronous wire-filling welding process under the excitation of the sine wave generator, and transmits the images to a computer image processing system in real time for digital image processing.
Meanwhile, in order to make the picture of the molten drop transition clearer, a filtering system is used for removing the influence of laser on a high-speed camera shooting picture.
In view of the fact that the robot controls the welding gun to move and the workpiece to be fixed in the welding process, the molten drop can move along with the welding gun in the welding direction during transition. In order to minimize the error in the high-speed shooting process, the camera lens and the molten drop are required to be kept still in the welding direction as much as possible, so that the high-speed camera is fixed near the laser head and is kept on the same horizontal line all the time, so that the high-speed camera can shoot the transition mode of the molten drop in real time and calculate the molten drop transition frequency according to the image.
Because the welding process used in the invention is double-laser-beam bilateral synchronous wire-filling welding, in order to synchronously monitor the molten pools on two sides of the stringer in the synchronous welding process, two sets of high-speed camera devices are required to be connected into the same computer system, and the molten drop transition behaviors in the double-laser-beam bilateral synchronous wire-filling welding process are respectively analyzed and calculated by combining the molten pools on two sides.
The signal output ends of the two cameras are connected with the information input end of the computer, and the wire feeding speed is selected according to the test material on the basis of looking up relevant documents.
After the dual-laser beam bilateral synchronous wire filling welding starts, the following steps are required to be carried out to monitor the molten drop transition:
step one, starting a high-speed camera to perform automatic high-frequency shooting;
and secondly, in order to reduce the memory requirement of the high-speed camera and the computer system, secondary sampling is needed to be carried out on the imaging of the double-side molten drop transition, firstly, a signal is generated by using a sine wave generator, a high-speed camera is excited to carry out primary sampling, and then, the image is transmitted to a computer image processing system after the frame number is encoded and the secondary sampling is carried out.
Thirdly, preprocessing the acquired image by using digital-image processing software to improve the signal-to-noise ratio of the image;
identifying the edge profile morphology of the molten drop through an image processing algorithm, and marking the position of the molten drop in each image;
step five, by carrying out the particle coordinates (x) on the two adjacent images1，y1)、(x2，y2) Perform an operationThe transition velocity of the droplet can be expressed by the formula:
where k is the ratio of the actual length to the image length after digital-to-image processing, vwThe wire feeding speed of the welding wire in the double-laser-beam double-side synchronous wire filling welding process.
And step six, calculating and counting the molten drop transition frequency of a plurality of sampled data points by using a computer image processing system through the pictures acquired by high-speed shooting.
And step seven, analyzing and calculating the shape, the transition rate and the transition frequency of the molten drop obtained by the image pickup picture, and obtaining the optimal double-laser-beam double-side synchronous wire-filling welding molten drop transition mode and specific parameters.
The invention has the following advantages:
firstly, the invention can qualitatively judge the molten drop transition mode, quantitatively calculate the molten drop transition speed and the specific process in the transition mode and analyze the molten drop transition mode in more detail by carrying out digital processing on the high-speed camera picture.
Secondly, the invention adopts sine wave excitation primary sampling and frame number coding secondary sampling during high-speed shooting, thereby reducing the memory requirements of a high-speed camera and a computer system, accelerating the image data processing speed of the computer system and improving the memory use efficiency of the computer.
And thirdly, synchronously detecting the molten pool on two sides of the stringer by using two high-speed cameras, transmitting real-time images to the same computer system, performing comparative analysis on data of molten drop transition on two sides, and providing possibility for observing interaction between molten drop transition during double-laser-beam bilateral synchronous filler wire welding.
Fourthly, the invention not only can instantaneously observe the molten drop transition at two sides of the molten pool, but also can dynamically monitor the wire feeding speed in real time through the computer system, so that the molten drop transition in the whole welding process is always in the monitoring of the high-speed camera and the computer system, thereby controlling the penetration and the fusion width of the welding line more strictly, and reducing the defects of welding pores, cracks, splashing and the like.
Drawings
FIG. 1 is a schematic view of a molten drop transition monitoring device of a double-laser-beam bilateral synchronous welding wire-filling process and an additional high-speed camera system;
FIG. 2 is an enlarged view of the assembly of the high speed camera;
FIG. 3 is a flow chart of double-laser beam bilateral synchronous welding filler wire molten drop transition monitoring based on high-speed image pickup;
FIG. 4 is a diagram of a high-speed camera shooting one-time sampling sine wave trigger waveform;
FIG. 5 is a schematic diagram of high-speed camera shooting sub-sampling frame number coding;
FIG. 6 is a schematic diagram of the calculation of the droplet transfer rate.
In the figure: 1-covering, 2-stringer, 3-molten pool, 4-welding wire, 5-laser beam, 6-shielding gas, 7-computer system, 8-high speed camera and 9-robot arm.
Detailed Description
The monitoring of the aluminum alloy molten drop transition of 2060/2099 double-laser-beam double-side synchronous filler wire welding based on high-speed image pickup is further explained in the following by combining the drawings and examples.
The filling material adopted during welding is 4047 aluminum alloy welding wire with the diameter of 1.2mm, the stringer is 2099 aluminum alloy, and the skin is 2060 aluminum alloy. The thicknesses of the skin and the stringer are respectively 2mm in the welding process, the joint type is a T-shaped joint, and relevant parameters of a laser beam are as follows: the laser power is 2-10 kW, the welding speed is 4-7 m/min, and the wire feeding angle is 20-55 degrees. The molten drop transition form of laser filler wire welding mainly comprises two forms of liquid bridge transition and large drop transition, wherein the liquid bridge transition molten drop transition is stable, the welding speed and the filler wire speed are good in adaptability, the large drop transition form molten drop transition presents a periodic characteristic, and the transition state is unstable, so that the liquid bridge transition is set when the optimal molten drop transition form is set. The schematic diagram of the welding device is shown in fig. 1, and the installation schematic diagram of the high-speed camera is shown in fig. 2.
As shown in fig. 3, the specific implementation steps of double-laser-beam bilateral synchronous wire-filling welding droplet transition monitoring based on high-speed image capturing are as follows:
a welding working platform is built according to the figure 1, welding parameters and a high-speed shooting position are debugged before welding starts, and molten drops are displayed in the middle of a picture as much as possible to obtain a clear and complete shooting picture.
In order to reduce the memory requirements of a computer and a high-speed camera and improve the memory efficiency of the computer, the invention adopts a secondary sampling method to ensure that the computer carries out rapid real-time image analysis and data processing in the high-speed camera shooting process. Wherein one-time sampling is as shown in FIG. 4, using a signal source of sine wave waveform as input signal, when the input signal V isinIs at the trigger upper limit signal VmAnd a trigger lower limit signal VoutIn the middle, the trigger thyristor for high-speed shooting is conducted for tjCutoff time of tmIn a conducting state, the high-speed camera shoots the behavior of molten drop transition; meanwhile, in order to further save the memory, the frame number in the primary sampling is encoded, as shown in fig. 5, the primary sampling is performed according to the encoding rule, and finally, the image after the secondary sampling is preprocessed and the image data is analyzed.
Setting the molten drop appearance and the transition rate reference value in a computer system, preprocessing a picture acquired by high-speed shooting as shown in fig. 6, fitting the outline appearance of the molten drop, and calculating the transition rate of the molten drop according to data and test parameters in the image, wherein the calculation formula is as follows:
in the present embodiment, (x)1，y1)、(x2，ya) The coordinates of the particles of the same molten drop in the two adjacent images are obtained; since the high-speed camera moves along with the laser head, when the transition rate of the molten drop is calculated, the moving rate of the high-speed camera needs to be added, and the welding rate v is usedwInstead, simultaneously for sitting in the imageThe standard proportion is consistent, and the conversion is carried out by dividing by k; k is a conversion coefficient between the actual size and the image size, and can be obtained by comparing the actual diameter of the welding wire with the diameter in the image; dt is the time interval between two adjacent pictures, dt is 0.5ms due to the high speed camera frequency of 2 kHz.
The method for preprocessing the molten drop transition image collected by the high-speed camera comprises the following specific steps:
(1) carrying out median smoothing filtering and drying on the image by using a median filter;
(2) the image is clearer and easier to identify through gray linear transformation;
(3) enhancing the contrast of the image by using a histogram of the image;
(4) and fitting the profile curve of the molten drop in the image by adopting a least square method, and calculating the centroid coordinate of the molten drop.
And calculating the molten drop transition rate by using the data values obtained by sampling, wherein the specific mode is that 1000 data points are randomly selected from all sampling results to serve as calculation samples, the molten drop transition frequency is calculated, and an average value is obtained.
And carrying out whole-process monitoring on a molten drop transition mode in the double-laser-beam double-side synchronous welding process, and carrying out processing analysis on data such as a molten drop profile, a transition frequency, a transition speed and the like obtained by processing by a computer system, thereby providing image data for monitoring the welding quality of a weldment on line.
Claims (8)
1. A double-laser-beam bilateral synchronous welding wire-filling molten drop transition monitoring system based on high-speed camera shooting is characterized by comprising a double-laser-beam bilateral synchronous welding wire-filling system, a high-speed camera shooting acquisition processing system, a full-digital wire feeding control system and an image processing system.
2. The double-laser-beam double-side synchronous welding wire filling system according to claim 1, comprising two lasers, two wire feeders and two sets of shielding gas supply systems, wherein the two lasers, the wire feeders and the shielding gas devices are respectively arranged on two sides of a skin, and the shielding gas devices, the laser welding head and the wire feeders are arranged in sequence along a welding direction.
3. The double-laser-beam double-side synchronous welding high-speed camera shooting, collecting and processing system according to claim 1, wherein the high-speed camera shooting, collecting and processing system comprises two high-speed cameras, a filtering system and a computer processing system, the high-speed cameras are fixed on a mechanical arm for clamping a laser, the molten droplets are rapidly imaged after being selectively filtered by the filtering system, then the images are output to the computer processing system by the high-speed cameras to be digitally processed, and the internal memory is saved through secondary sampling.
4. The full digital wire feed control system for double-laser-beam double-side synchronous welding as claimed in claim 1, comprising a digital trigger, a high-speed computer digital signal processor, capable of changing the wire feed speed of the welding wire and ensuring stable wire feed.
5. A double-laser-beam bilateral synchronous welding filler wire molten drop transition monitoring method based on high-speed camera shooting is characterized by comprising the following steps:
(1) setting different wire feeding speeds by looking up data and calculating heat input parameters so as to obtain molten drop sizes and transition frequency parameters at different wire feeding speeds;
(2) starting the welding device, carrying out high-frequency sampling capture and selective imaging on the bilateral transition molten drops in the bilateral synchronous welding process of the double laser beams by the high-speed camera system, and feeding the wire feeding speed back to the computer digital signal processor by the wire feeding system;
(3) and the computer image and digital processing system carries out high-speed processing on the input signal and analyzes the transition mode and the transition frequency of the double-laser-beam bilateral synchronous welding molten drop at different wire feeding speeds.
6. The method for monitoring the double-laser-beam bilateral synchronous welding filler wire by the high-speed camera system as claimed in claim 5, wherein the two high-speed cameras are respectively arranged on the two laser heads to ensure that the high-speed cameras and the welding wire are relatively static, and the positions of the high-speed cameras are adjusted to ensure that the whole process of the molten drop transition can be captured by the cameras.
7. The method for monitoring the double-laser-beam bilateral synchronous welding filler wire droplet transition based on high-speed camera shooting according to claim 5, wherein digital image processing software in a computer system is used for preprocessing pictures acquired by high-speed camera shooting, and the method mainly comprises the following steps:
(1) carrying out median smoothing filtering and denoising on the image by using a median filter;
(2) the image is clearer and easier to identify through gray scale linear transformation;
(3) enhancing the contrast of the image by using a histogram of the image;
(4) fitting the profile curve of the droplet in the image by using a least square method, calculating the centroid coordinates (x1, y1), (x2, y2) of the droplet, and calculating the droplet transfer rate by using the following formula:
wherein k is the ratio of the actual length to the image length after the digital-image technology processing, and vw is the wire feeding speed of the welding wire in the double-laser-beam double-side synchronous wire-filling welding process.
8. According to the method for monitoring the double-laser-beam bilateral synchronous welding filler wire droplet transition based on high-speed image pickup in the claim 5, the droplet shape and the transition frequency obtained by the high-speed image pickup system are subjected to data analysis and sample observation, so that the optimal welding droplet transition mode and the optimal droplet transition frequency are obtained.
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