CN111451604A - Repair welding monitoring feedback method and system for GTAW arc fuse material additive manufacturing arc blowout part - Google Patents
Repair welding monitoring feedback method and system for GTAW arc fuse material additive manufacturing arc blowout part Download PDFInfo
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- CN111451604A CN111451604A CN202010280366.4A CN202010280366A CN111451604A CN 111451604 A CN111451604 A CN 111451604A CN 202010280366 A CN202010280366 A CN 202010280366A CN 111451604 A CN111451604 A CN 111451604A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up 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
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
- B23K9/1272—Geometry oriented, e.g. beam optical trading
- B23K9/1274—Using non-contact, optical means, e.g. laser means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
Abstract
The invention discloses a repair welding monitoring feedback method and a repair welding monitoring feedback system at an arc blowout position in GTAW arc fuse material increase manufacturing. The method is visual and flexible, can be used for detecting and adjusting the height of the tungsten electrode, effectively overcomes the defect that the arc blowout part is fused down due to the accumulation of heat input which is difficult to solve by GTAW front wire feeding, has visual and flexible detection process and rich information, and lays a solid foundation for improving the forming quality and precision of GTAW additive manufacturing.
Description
Technical Field
The invention belongs to the field of arc fuse additive manufacturing, and particularly relates to a repair welding monitoring feedback method for an arc quenching part in GTAW arc fuse additive manufacturing.
Background
The Wire and Arc Additive Manufacturing (WAAM) is an advanced Manufacturing technology in which an Arc is used as a heat source, and a metal member is gradually built up and formed according to a solid CAD model by feeding a welding Wire by means of a numerical control technology. The GTAW additive manufacturing is an important branch of WAAM, the technology has the advantages of stable electric arc, small heat input, small splashing and high forming precision, and is widely applied to the direct manufacturing of copper alloy, aluminum alloy and nickel-based alloy components at present.
GTAW additive manufacturing generally employs a front wire feeding method for stacking. However, unidirectional deposition often causes the problem of collapse at an arc quenching position in the additive manufacturing process, and affects the morphological characteristics of a formed part, so if the collapse defect can be automatically compensated in the forming process, and the uniformity of the height of a weld bead is ensured, the morphological characteristics of the formed part can be effectively improved. Therefore, it is urgently needed to develop a method capable of monitoring the feedback collapse defect and the height of the tungsten electrode in real time.
Disclosure of Invention
The invention aims to solve the defect of arc blowout part fusion in the process of GTAW additive manufacturing accumulation, and provides a repair welding monitoring feedback method for an arc blowout part in GTAW arc fuse additive manufacturing, so that the forming morphology of the method is improved.
In order to achieve the purpose, the repair welding monitoring feedback method for the arc blowout part in the additive manufacturing of the GTAW arc fuse comprises the following steps:
step one, arranging an industrial camera on the side surface of a GTAW welding gun, and enabling the axis of the industrial camera to be perpendicular to the stacking direction and to be parallel to a substrate;
connecting an industrial camera with an industrial personal computer, placing a calibration plate below the tungsten electrode and in a plane which contains the axis of the GTAW welding gun and is vertical to the substrate, and calibrating the image;
step three, determining height information of a tungsten electrode from the substrate by an image algorithm, adjusting the distance of the tungsten electrode from the substrate, and setting a height threshold value in an industrial personal computer;
step four, starting the robot to form a welding bead, continuously acquiring welding bead images through an industrial camera, sending the welding bead images to an industrial personal computer, calculating welding bead height information through an image algorithm, comparing the welding bead height information with a preset threshold value, if the existing point height value is not within the range of the preset threshold value, sending out an arc extinguishing end collapse warning, determining the length of a welding bead height area exceeding the threshold value, determining the length of repair welding, feeding back to the robot for repair welding, and if all the point height values are within the range of the threshold value, performing step five;
step five, after the first layer is built up, the GTAW welding robot lifts the height of a welding bead by one layer;
and step six, repeating the step four and the step five until the set layer number is reached.
In step one, the position of the industrial camera along the stacking direction is the position of the weld bead length according to the arc starting point 2/3.
In the first step, the projection of the axis of the industrial camera in a plane which is vertical to the stacking direction and parallel to the substrate is 2-5mm lower than the height of the tip of the tungsten electrode of the first layer.
In the second step, the specific method of the calibration treatment is as follows:
the method comprises the following steps that firstly, an industrial camera is placed under a working condition pose, and a calibration picture meeting requirements is shot;
secondly, loading a calibration template, namely caltab _30mm.descr, by using a calibration assistant in the Halcon assistant;
and thirdly, selecting a calibration frame, loading a shot calibration picture, setting the first picture as a reference pose, selecting a required warning level, carrying out automatic calibration, solving internal parameters, external parameters and distortion coefficients of the camera, determining the mutual relation between the three-dimensional geometric position of a certain point in an acquisition range and the corresponding point in the image, and establishing a camera imaging geometric model.
In the third step and the fourth step, the specific method of the image algorithm is as follows:
the method comprises the steps of firstly, collecting a plurality of continuous images, creating an ROI and calling a reduce _ domain instruction in Halcon to segment the images;
secondly, calculating all pixel points in the ROI by adopting a median filtering method;
thirdly, performing edge extraction on the image filtered in the second step by adopting a Sobel operator;
and fourthly, measuring the edge information so as to determine the height information.
In the fourth step, the specific method for determining the repair welding length is as follows:
firstly, an industrial camera sends welding bead height information to an industrial personal computer;
secondly, setting a height threshold value in the industrial personal computer, comparing the height threshold value with the height data of each point of the welding bead, and if the height of a region exceeds the range of the height threshold value, sending an arc quenching end collapse warning;
and thirdly, calling a measure operator to determine the length of the area with the weld bead height exceeding the threshold range, namely repairing the welding length.
A repair welding monitoring feedback system for an arc quenching part in GTAW arc fuse additive manufacturing comprises a working platform and a robot, wherein a calibration plate is placed on the working platform, an industrial camera is arranged on one side of a GTAW welding gun of the robot, the axis of the industrial camera is perpendicular to the stacking direction and is parallel to the calibration plate, and the industrial camera and the robot are connected with an industrial personal computer;
the industrial camera is used for acquiring a current image in real time and sending the current image to the industrial personal computer;
the industrial personal computer is used for carrying out height calculation according to the image collected by the industrial camera, comparing the height with a threshold value, controlling the robot to stack according to the comparison result, or starting an arc end collapse warning to control the robot to carry out repair welding.
The robot is KUKA KR60HA, GTAW welding gun Magic Wave5000 argon arc welding machine, and the wire feeding mechanism adopts a Fronius wire feeding mechanism.
Compared with the prior art, the method has the advantages that the current image is collected in real time through the industrial camera and is sent to the industrial personal computer, the industrial personal computer is used for carrying out height calculation according to the image collected by the industrial camera, comparing the height calculation with the threshold value, controlling the robot to stack or starting the warning of arc end collapse according to the comparison result, and controlling the robot to carry out repair welding. The method is visual and flexible, can be used for detecting and adjusting the height of the tungsten electrode, effectively overcomes the defect that the arc blowout part is fused down due to the accumulation of heat input which is difficult to solve by GTAW front wire feeding, has visual and flexible detection process and rich information, and lays a solid foundation for improving the forming quality and precision of GTAW additive manufacturing.
Furthermore, the invention develops an image processing algorithm to determine the height of the GTAW arc fuse additive manufacturing weld bead and whether the arc blowout end has the fusion defect, and finally determines the length to be subjected to repair welding according to the set height threshold value and the height of each point of the weld bead.
Drawings
FIG. 1 is a schematic diagram of a detection feedback system according to the present invention;
FIG. 2 is a diagram of the GTAW arc fuse additive manufacturing vision system calibration operation of the present invention; (ii) a
FIG. 3 is a schematic illustration of a standard calibration plate 30 × 30 for use in the GTAW arc fuse additive manufacturing vision system of the present invention;
FIG. 4 is a flow chart of an image processing algorithm and repair welding monitoring feedback at arc quenching based on image data in accordance with the present invention;
FIG. 5 is a schematic diagram of an image extracted by an image processing algorithm according to the present invention;
the system comprises a robot 1, a GTAW welding gun 2, a tungsten electrode 3, a wire feeder 4, an industrial camera 5, a calibration plate 6, a working platform 7 and an industrial personal computer 8.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Referring to fig. 1, the repair welding monitoring feedback system at the arc blowout position of the GTAW arc fuse additive manufacturing comprises a working platform 7, a GTAW welding gun 2 perpendicular to a base plate of the working platform, a calibration plate 6 in a plane containing an axis of the GTAW welding gun and perpendicular to the base plate, a wire feeding mechanism 4 at the tail end of the GTAW welding gun and a tungsten electrode 3. The side of the working platform is provided with an industrial camera 5, and the axis of the industrial camera is vertical to the stacking direction and parallel to the substrate. And an industrial personal computer 8 for processing and feeding back information.
The specific test platform of the invention is that the GTAW power supply is a Magic Wave5000 argon arc welding machine, a welding gun is arranged at the tail end of a KUKAKR60HA mechanical arm, a Fronius wire feeding mechanism is adopted by a wire feeding mechanism 4, the robot drives the welding gun to move, a welding wire of S215 aluminum bronze is adopted in the forming process, the diameter of the welding wire is 1.2mm, the technological parameters are that the welding current is 140A, the welding speed is 0.2m/min, the wire feeding speed is 1.8m/min, the length of a welding bead is 100mm, the distance between a tungsten electrode and the welding wire is 1.2mm, the height of the tungsten electrode is kept at 3mm, the protective gas is pure argon, and the gas flow is 12L.
The repair welding monitoring feedback method for the GTAW arc fuse material additive manufacturing arc quenching part by using the system comprises the following steps:
the method comprises the following steps: the industrial camera is arranged on the side surface of the GTAW welding gun, and the axis of the industrial camera is vertical to the stacking direction and is parallel to the substrate;
step two: the industrial camera is arranged in a working condition by adopting a traditional calibration mode and is connected with an industrial personal computer in a USB3.0 mode through a data line. Placing a calibration plate under the tungsten electrode, in a plane which contains the axis of a GTAW welding gun and is vertical to the substrate, carrying out image calibration processing, and moving a camera or changing the position to carry out calibration again;
step three: adjusting the distance between the tungsten pole and the substrate according to an image algorithm;
step four: teaching a welding robot through offline programming, setting a first layer stacking path, forming a first welding bead, setting a height threshold value in a cooling process, extracting height size characteristics of each point of the stacking layer in a camera acquisition window range by adopting an image processing algorithm, feeding data back to an industrial personal computer through a flow file format, wherein the industrial personal computer is used for storing the preset height threshold value and comparing received data with the preset threshold value, if the height value of the existing point is not in the preset threshold value range, sending an arc blowout end collapse warning, determining the length of a welding bead height area exceeding the threshold value by adopting the image algorithm, determining the welding repair length, feeding the welding bead height area exceeding the threshold value to the welding robot for welding repair, and if the height value of each point is in the threshold value range, directly carrying out the next step;
step five: after the first layer is built up, the GTAW welding robot lifts the height of a welding bead by one layer;
step six: and repeating the fourth step and the fifth step until the set number of layers is reached, and detecting the total height of the stacked layers through an image processing algorithm.
In the first step, the position of the industrial camera along the stacking direction is about 2/3 weld bead lengths according to the arc starting point.
In the first step, the projection of the axis of the industrial camera in a plane which is vertical to the stacking direction and parallel to the substrate is 2-5mm lower than the height of the tip of the tungsten electrode in the first layer.
In the second step, the calibration plate is a 30 × 30 standard calibration plate, the number of the rows and columns of the marking points is 7 × 7, the outer frame is 30mm × 30mm, the center distance of the marking points is 3.75, the diameter of the marking points is 0.9375mm, and the cutting width is 30.75 mm.
And step two, the number of continuously acquired images is 9-16, and the image updating speed is once at 50 ms.
The calibration processing mode in the second step comprises the following steps:
(1) placing the industrial camera in a working condition pose, shooting a calibration picture, basically covering the size of a camera visual field, enabling the calibration plate to occupy about 1/4-1/3 of the visual field, and enabling the brightness of an imaging gray value of the calibration plate to be larger than 128;
(2) loading a standard 30 x 30 template, caltab _30mm. descr, using a calibration assistant in the Halcon assistant;
(3) selecting a calibration frame, loading a shot calibration picture, setting a first picture as a reference pose, selecting an alarm level 70, carrying out automatic calibration by using a calibration command, solving internal parameters, external parameters and distortion coefficients of the camera, determining the mutual relation between the three-dimensional geometric position of a certain point in an acquisition range and the corresponding point in the image, and establishing a camera imaging geometric model.
In the fourth step, the image processing algorithm is realized in the framework of Halcon software.
In step four, the image processing algorithm comprises the following steps:
1) acquiring 3-10 continuous images, creating an ROI (region of interest) and calling a reduce _ domain instruction in Halcon to segment the images;
2) calculating all pixel points in the ROI by adopting a median filtering method, and using a median _ image median filter;
3) adopting a Sobel operator to carry out edge extraction on the image after the step 2, and calling a Sobel _ amp operator to detect an edge amplitude value;
4) and calling a measure operator to measure edge information and determine welding bead height information and tungsten electrode distance substrate height information.
And adjusting the distance between the tungsten pole and the substrate in the third step, wherein the distance is set to be 3-5 mm, and the Z coordinate value of the robot is increased or decreased by acquiring the height information of the tungsten pole and the substrate extracted by the image algorithm.
The step four mentioned in the determination of repair welding length and repair welding comprises the following steps:
(a) in the welding cooling process, the welding bead height information obtained in the image processing algorithm is transmitted to an industrial personal computer through a stream file (TXT) format;
(b) setting a height threshold value in an industrial personal computer, comparing the height threshold value with the height data of each point of the welding bead, and if the height of a region exceeds the range of the height threshold value, sending an arc quenching end collapse warning;
(c) calling a measure operator to determine the length of the area with the weld bead height exceeding the threshold range, namely repairing the welding length;
(d) and (4) performing path compensation on the welding track by adopting arcswitch programming instructions in the GTAW welding robot, wherein the direction is opposite to the stacking length.
The above examples are provided only for illustrating the principles and effects of the present invention and not for limiting the present invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (8)
1. A repair welding monitoring feedback method for an arc blowout part in GTAW arc fuse material additive manufacturing is characterized by comprising the following steps:
step one, arranging an industrial camera on the side surface of a GTAW welding gun, and enabling the axis of the industrial camera to be perpendicular to the stacking direction and to be parallel to a substrate;
connecting an industrial camera with an industrial personal computer, placing a calibration plate below the tungsten electrode and in a plane which contains the axis of the GTAW welding gun and is vertical to the substrate, and calibrating the image;
step three, determining height information of a tungsten electrode from the substrate by an image algorithm, adjusting the distance of the tungsten electrode from the substrate, and setting a height threshold value in an industrial personal computer;
step four, starting the robot to form a welding bead, continuously acquiring welding bead images through an industrial camera, sending the welding bead images to an industrial personal computer, calculating welding bead height information through an image algorithm, comparing the welding bead height information with a preset threshold value, if the existing point height value is not within the range of the preset threshold value, sending out an arc extinguishing end collapse warning, determining the length of a welding bead height area exceeding the threshold value, determining the length of repair welding, feeding back to the robot for repair welding, and if all the point height values are within the range of the threshold value, performing step five;
step five, after the first layer is built up, the GTAW welding robot lifts the height of a welding bead by one layer;
and step six, repeating the step four and the step five until the set layer number is reached.
2. The GTAW arc fuse additive manufacturing arc quenching repair welding monitoring feedback method according to claim 1, wherein in the first step, the position of the industrial camera along the stacking direction is a position according to an arc starting point 2/3 for the length of the welding bead.
3. The GTAW arc fuse additive manufacturing arc quenching repair welding monitoring feedback method according to claim 1, wherein in the first step, the projection of the industrial camera axis in a plane perpendicular to the stacking direction and parallel to the substrate is 2-5mm lower than the height of the first layer tungsten electrode tip.
4. The method of claim 1, wherein in step two, the calibration process is performed by the following specific method:
the method comprises the following steps that firstly, an industrial camera is placed under a working condition pose, and a calibration picture meeting requirements is shot;
secondly, loading a calibration template, namely caltab _30mm.descr, by using a calibration assistant in the Halcon assistant;
and thirdly, selecting a calibration frame, loading a shot calibration picture, setting the first picture as a reference pose, selecting a required warning level, carrying out automatic calibration, solving internal parameters, external parameters and distortion coefficients of the camera, determining the mutual relation between the three-dimensional geometric position of a certain point in an acquisition range and the corresponding point in the image, and establishing a camera imaging geometric model.
5. The method for monitoring and feeding back the repair welding at the arc blowout position of GTAW arc fuse additive manufacturing according to claim 1, wherein in the third step and the fourth step, the specific method of the image algorithm is as follows:
the method comprises the steps of firstly, collecting a plurality of continuous images, creating an ROI and calling a reduce _ domain instruction in Halcon to segment the images;
secondly, calculating all pixel points in the ROI by adopting a median filtering method;
thirdly, performing edge extraction on the image filtered in the second step by adopting a Sobel operator;
and fourthly, measuring the edge information so as to determine the height information.
6. The GTAW arc fuse additive manufacturing arc quenching repair welding monitoring feedback method according to claim 1, wherein in the fourth step, the specific method for determining the repair welding length is as follows:
firstly, an industrial camera sends welding bead height information to an industrial personal computer;
secondly, setting a height threshold value in the industrial personal computer, comparing the height threshold value with the height data of each point of the welding bead, and if the height of a region exceeds the range of the height threshold value, sending an arc quenching end collapse warning;
and thirdly, calling a measure operator to determine the length of the area with the weld bead height exceeding the threshold range, namely repairing the welding length.
7. A system adopted by a GTAW arc fuse additive manufacturing arc extinguishing position repair welding monitoring feedback method based on claim 1 is characterized by comprising a working platform (7) and a robot (1), wherein a calibration plate (6) is placed on the working platform (7), an industrial camera (5) is arranged on one side of a GTAW welding gun (2) of the robot (1), the axis of the industrial camera (5) is perpendicular to the stacking direction and is parallel to the calibration plate (6), and the industrial camera (5) and the robot (1) are connected with an industrial personal computer (8);
the industrial camera (5) is used for acquiring a current image in real time and sending the current image to the industrial personal computer (8);
the industrial personal computer (8) is used for carrying out height calculation according to the image collected by the industrial camera (5), comparing the height calculation with a threshold value, controlling the robot (1) to stack or starting arc end collapse warning according to a comparison result, and controlling the robot (1) to carry out repair welding.
8. The system of claim 7, wherein the robot (1) is a KUKA KR60HA, the GTAW welding gun (2) is a Magic Wave5000 argon arc welding machine, and the wire feeder (4) is a Fronius wire feeder.
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