CN111650284A - Vibration welding state detection system and method based on acoustic emission technology - Google Patents
Vibration welding state detection system and method based on acoustic emission technology Download PDFInfo
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Abstract
The system for detecting the vibration welding state based on the acoustic emission technology comprises a vibration welding processing module, an acoustic emission signal detection module and an upper computer system; the upper computer system is connected with the vibration welding processing module; the acoustic emission signal detection module is used for acquiring an acoustic emission signal in the vibration welding process; the acoustic emission signal analysis module analyzes the acoustic emission signal collected by the acoustic emission signal detection module and extracts the characteristics of the acoustic emission signal of the welding defect in the vibration welding process of the component; the process parameter adjusting module is used for adjusting the process parameters of the vibration welding. The vibration welding state detection method based on the acoustic emission technology comprises the steps of building a vibration welding state detection system based on the acoustic emission technology; acquiring a critical threshold value of a characteristic value of an acoustic emission signal; carrying out vibration welding treatment on the welding component, and acquiring a characteristic value of an acoustic emission signal; comparing characteristics and adjusting process parameters. The invention has the advantage of improving the welding quality of the component.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a vibration welding state detection system and method based on an acoustic emission technology.
Background
Vibration welding is a new technology which is assisted by mechanical vibration in the welding process to improve the welding quality. The welding by the technology not only can effectively eliminate the residual stress of welding, but also can play a role in refining grains. In the engineering field, the weld position is usually a weak place in the structure, and the damage failure is most likely to occur, so the quality of the weld has great influence on the service life of the welded component. In addition, no matter whether vibration is applied to the component or not in the welding process, the generation of welding defects is inevitable, so when the selected process parameters are unreasonable, the vibration welding of the component does not achieve the effect of improving the welding quality, but accelerates the generation of the welding defects, and further greatly influences the welding quality of the component. The existing detection method for the welding quality of the component comprises pre-welding detection, detection in the welding process and post-welding detection, the former two methods are judged by visual observation of operators or by recognizing sound changes, the method belongs to a traditional manual detection method and has certain subjectivity, and although the post-welding detection can accurately detect the quality of a welding seam, multiple experiments are required when process parameters are determined by the detection method, so that the experiment cost is improved, and the production efficiency is reduced. Therefore, it is necessary to develop a vibration welding state detection system and method, to realize dynamic detection of the state of a component during welding, to improve the vibration welding quality of the component, and to promote and apply the assisted vibration welding technology in the field of mechanical engineering.
When a component is defective during vibration welding, strain energy is released in the form of elastic waves, a phenomenon known as acoustic emission. Since the acoustic emission signal comes from the defect itself, and the defect forms generated in the vibration welding process of the component comprise welding residual stress, welding cracks, welding blowholes, welding slag and the like, the defects belong to typical acoustic emission sources. In summary, it is easy to find that the acoustic emission technology can detect the vibration welding process in real time, so as to evaluate the quality of the vibration welding component in real time, that is, evaluate the defect evolution condition of the component in the vibration welding process in real time. Therefore, aiming at the problem that the welding state of the component is lack of real-time detection in the vibration welding process at present, the invention integrates the acoustic emission technology into the vibration welding system, and provides the vibration welding state detection system and method based on the acoustic emission technology on the basis of the acoustic emission technology.
Disclosure of Invention
In order to solve the problem that the welding state of a component is lack of real-time detection in the vibration welding process at present, the invention provides a vibration welding state detection system and a method based on an acoustic emission technology, namely, the acoustic emission technology is adopted to carry out real-time detection on the welding state of the component, and the acoustic emission signal characteristics of various welding defects are analyzed to adjust the process parameters of vibration welding, so that the welding quality is improved, a stable and ideal welding effect is favorably obtained, and the development of the vibration welding technology in the field of mechanical engineering is promoted.
The system for detecting the vibration welding state based on the acoustic emission technology comprises a vibration welding processing module, an acoustic emission signal detection module and an upper computer system; the upper computer system comprises an acoustic emission signal analysis module and a process parameter adjustment module; the upper computer system is connected with the vibration welding processing module so as to control the vibration welding processing module to carry out vibration welding processing on the welding component; the acoustic emission signal detection module is connected with the upper computer system; the acoustic emission signal detection module is used for acquiring an acoustic emission signal in a vibration welding process; the acoustic emission signal analysis module analyzes the acoustic emission signal collected by the acoustic emission signal detection module and extracts the characteristics of the acoustic emission signal of the welding defect in the vibration welding process of the component; the process parameter adjusting module is used for adjusting the process parameters of the vibration welding. Specifically, the process parameters comprise welding current, welding speed, welding voltage, vibration frequency, vibration amplitude and vibration time; the selection of welding current, welding speed and welding voltage has great influence on welding quality, and vibration frequency, vibration amplitude and vibration time directly determine the vibration energy injected into the welding component, and the vibration frequency, the vibration amplitude and the vibration time also have great influence on the welding quality.
Further, the vibration welding processing module comprises a signal source, a power amplifier, vibration excitation equipment, an acceleration sensor, a charge amplifier, an oscilloscope and welding equipment; the upper computer system is respectively connected with the signal source and the input end of the welding equipment; the output end of the signal source is connected with the input end of the power amplifier; the output end of the power amplifier is connected with the input end of the excitation equipment; the acceleration sensor is arranged on a welding component, and the output end of the acceleration sensor is connected with the input end of the charge amplifier; the output end of the charge amplifier is connected with the input end of the oscilloscope; the output end of the oscilloscope is connected with the upper computer system; the upper computer system controls the signal source to generate a sine excitation signal with independent and continuously adjustable amplitude and frequency; and the upper computer system controls the welding equipment to generate a welding heat source. Specifically, the method comprises the following steps: the upper computer system controls welding equipment to weld the welding component according to the initially set technological parameters, and controls the signal source to generate a sinusoidal excitation signal, and the sinusoidal excitation signal is amplified by the power amplifier and drives the excitation equipment to vibrate the welding component.
Furthermore, the acoustic emission signal detection module comprises an acoustic emission sensor, an acoustic emission signal amplifier and a data acquisition card; the acoustic emission sensor is arranged on the welding component; the output end of the acoustic emission sensor is connected with the input end of the acoustic emission signal amplifier; the output end of the acoustic emission signal amplifier is connected with the input end of the data acquisition card; and the output end of the data acquisition card is connected with an upper computer system.
Further, the acoustic emission signal analysis module comprises an acoustic emission signal characteristic acquisition module, an acoustic emission signal characteristic critical threshold setting module and a characteristic comparison module; the acoustic emission signal characteristic acquisition module extracts the characteristics of the acoustic emission signals acquired by the data acquisition card; the characteristic of the acoustic emission signal is the maximum Amplitude value (Amplitude) of the signal waveform; the acoustic emission signal characteristic critical threshold setting module is used for setting a critical threshold of acoustic emission signal characteristics; the characteristic comparison module is used for comparing the characteristic value of the acoustic emission signal acquired in real time with a critical threshold value.
Furthermore, the signal source is a signal generator.
Or, the signal source is an arbitrary waveform generating card.
The vibration welding state detection method based on the acoustic emission technology comprises the following steps:
(1) fixing the welding component on the excitation equipment; mounting an acoustic emission sensor and an acceleration sensor on a welding member; connecting a signal connecting line between the upper computer system and the signal source; connecting a signal connecting line between the upper computer system and the welding equipment; connecting a signal connecting line between a signal source and a power amplifier; connecting a signal connection between the power amplifier and the excitation equipment; connecting a signal connecting line between the acceleration sensor and the charge amplifier; connecting a signal connecting line between the charge amplifier and the oscilloscope; connecting a signal connecting line between the oscilloscope and the upper computer system; connecting a signal connecting line between the acoustic emission sensor and the acoustic emission signal amplifier; connecting a signal connecting line between the acoustic emission signal amplifier and the data acquisition card; connecting a signal connecting line between the data acquisition card and the upper computer system; connecting a signal source, a power amplifier, vibration excitation equipment, welding equipment, a charge amplifier, an oscilloscope, an acoustic emission signal amplifier, a data acquisition card and a power supply of an upper computer system;
(2) carrying out destructive vibration welding tests on the component under different process parameters, simultaneously extracting the characteristic value of the collected acoustic emission signal, testing to obtain the welding residual stress of the component, obtaining the functional relation between the characteristic value of the acoustic emission signal and the welding residual stress in a curve fitting mode, and when the welding residual stress reaches the upper limit of the welding process requirement, taking the characteristic value of the acoustic emission signal at the moment as the critical threshold value of the characteristic value of the acoustic emission signal and storing the critical threshold value in a characteristic comparison module;
(3) selecting specific technological parameter values within the range of technological requirements to carry out vibration welding treatment on the welding component;
(4) the acoustic emission sensor detects the welding component vibration welding process in real time, and transmits the detected acoustic emission signals to the upper computer system, and meanwhile, an acoustic emission signal analysis module in the upper computer system extracts characteristic values of the acoustic emission signals;
(5) selecting specific technological parameter values within the range of technological requirements to carry out vibration welding treatment on the welding component, transmitting the extracted acoustic emission signal characteristic values to the characteristic comparison module for comparison, when the acoustic emission signal characteristic values exceed a critical threshold value, adjusting the technological parameters of the vibration welding by the technological parameter adjustment module, and continuously driving the vibration welding treatment module to treat the welding component by the adjusted technological parameters, namely, reducing the characteristic values of the acoustic emission signals to be below the critical threshold value by adjusting the technological parameters, so that proper technological parameters are obtained, and the welding quality is improved.
The invention has the following beneficial effects:
1. the invention provides a vibration welding state detection system and method based on an acoustic emission technology, which adopts the acoustic emission technology to detect the vibration welding process and belongs to a nondestructive detection method.
2. The acoustic emission technology adopted by the system and the method for detecting the vibration welding state based on the acoustic emission technology belongs to a dynamic real-time detection technology, can detect the development process of the welding defect in real time, and is not like the existing welding quality problem which can be found only through detection after welding, so the system and the method for detecting the vibration welding state based on the acoustic emission technology can effectively reduce the processing cost and improve the production efficiency.
3. The system and the method for detecting the vibration welding state based on the acoustic emission technology can adjust the process parameters according to the welding defects, and further improve the welding quality of the component, so that the application of the power-assisted vibration welding technology in the field of mechanical engineering is realized.
Drawings
FIG. 1 is a schematic diagram of a vibration welding state detection system based on acoustic emission technology.
FIG. 2 is a schematic diagram of a vibration welding status detection system based on acoustic emission technology.
Detailed Description
The invention is further illustrated with reference to the accompanying drawings:
the system for detecting the vibration welding state based on the acoustic emission technology comprises a vibration welding processing module, an acoustic emission signal detection module and an upper computer system; the upper computer system comprises an acoustic emission signal analysis module and a process parameter adjustment module; the upper computer system is connected with the vibration welding processing module so as to control the vibration welding processing module to carry out vibration welding processing on the welding component 1; the acoustic emission signal detection module is connected with the upper computer system; the acoustic emission signal detection module is used for acquiring an acoustic emission signal in a vibration welding process; the acoustic emission signal analysis module analyzes the acoustic emission signal collected by the acoustic emission signal detection module and extracts the characteristics of the acoustic emission signal of the welding defect in the vibration welding process of the component; the process parameter adjusting module is used for adjusting the process parameters of the vibration welding. Specifically, the process parameters comprise welding current, welding speed, welding voltage, vibration frequency, vibration amplitude and vibration time; the selection of welding current, welding speed and welding voltage has great influence on welding quality, and vibration frequency, vibration amplitude and vibration time directly determine the vibration energy injected into the welding component, and the vibration frequency, the vibration amplitude and the vibration time also have great influence on the welding quality.
Further, the vibration welding processing module comprises a signal source, a power amplifier, vibration excitation equipment, an acceleration sensor 3, a charge amplifier, an oscilloscope and welding equipment; the upper computer system is respectively connected with the signal source and the input end of the welding equipment; the output end of the signal source is connected with the input end of the power amplifier; the output end of the power amplifier is connected with the input end of the excitation equipment; the acceleration sensor 3 is arranged on the welding component 1, and the output end of the acceleration sensor 3 is connected with the input end of the charge amplifier; the output end of the charge amplifier is connected with the input end of the oscilloscope; the output end of the oscilloscope is connected with the upper computer system; the upper computer system controls the signal source to generate a sine excitation signal with independent and continuously adjustable amplitude and frequency; and the upper computer system controls the welding equipment to generate a welding heat source. Specifically, the method comprises the following steps: the upper computer system controls welding equipment to weld the welding member 1 according to the initially set technological parameters, and controls a signal source to generate a sinusoidal excitation signal, and the sinusoidal excitation signal is amplified by a power amplifier and drives the excitation equipment to vibrate the welding member 1.
Further, the acoustic emission signal detection module comprises an acoustic emission sensor 2, an acoustic emission signal amplifier and a data acquisition card; the acoustic emission sensor 2 is arranged on the welding component 1; the output end of the acoustic emission sensor 2 is connected with the input end of the acoustic emission signal amplifier; the output end of the acoustic emission signal amplifier is connected with the input end of the data acquisition card; and the output end of the data acquisition card is connected with an upper computer system.
Further, the acoustic emission signal analysis module comprises an acoustic emission signal characteristic acquisition module, an acoustic emission signal characteristic critical threshold setting module and a characteristic comparison module; the acoustic emission signal characteristic acquisition module extracts the characteristics of the acoustic emission signals acquired by the data acquisition card; the characteristic of the acoustic emission signal is the maximum Amplitude value (Amplitude) of the signal waveform; the acoustic emission signal characteristic critical threshold setting module is used for setting a critical threshold of acoustic emission signal characteristics; the characteristic comparison module is used for comparing the characteristic value of the acoustic emission signal acquired in real time with a critical threshold value.
Furthermore, the signal source is a signal generator.
Or, the signal source is an arbitrary waveform generating card.
The vibration welding state detection method based on the acoustic emission technology comprises the following steps:
(1) fixing the welding component on the excitation equipment; mounting the acoustic emission sensor 2 and the acceleration sensor 3 on a welding member; connecting a signal connecting line between the upper computer system and the signal source; connecting a signal connecting line between the upper computer system and the welding equipment; connecting a signal connecting line between a signal source and a power amplifier; connecting a signal connection between the power amplifier and the excitation equipment; connecting a signal connecting line between the acceleration sensor 3 and the charge amplifier; connecting a signal connecting line between the charge amplifier and the oscilloscope; connecting a signal connecting line between the oscilloscope and the upper computer system; connecting a signal connecting line between the acoustic emission sensor 2 and the acoustic emission signal amplifier; connecting a signal connecting line between the acoustic emission signal amplifier and the data acquisition card; connecting a signal connecting line between the data acquisition card and the upper computer system; connecting a signal source, a power amplifier, vibration excitation equipment, welding equipment, a charge amplifier, an oscilloscope, an acoustic emission signal amplifier, a data acquisition card and a power supply of an upper computer system;
(2) carrying out destructive vibration welding tests on the component under different process parameters, simultaneously extracting the characteristic value of the collected acoustic emission signal, testing to obtain the welding residual stress of the component, obtaining the functional relation between the characteristic value of the acoustic emission signal and the welding residual stress in a curve fitting mode, and when the welding residual stress reaches the upper limit of the welding process requirement, taking the characteristic value of the acoustic emission signal at the moment as the critical threshold value of the characteristic value of the acoustic emission signal and storing the critical threshold value in a characteristic comparison module;
(3) selecting specific technological parameter values within the range of technological requirements to carry out vibration welding treatment on the welding component 1;
(4) the acoustic emission sensor 2 detects the welding process of the welding component 1 in real time, and transmits the detected acoustic emission signals to an upper computer system, and an acoustic emission signal analysis module in the upper computer system extracts characteristic values of the acoustic emission signals;
(5) selecting specific technological parameter values within the range of technological requirements to carry out vibration welding treatment on the welding component 1, transmitting the extracted acoustic emission signal characteristic values to the characteristic comparison module for comparison, when the acoustic emission signal characteristic values exceed a critical threshold value, adjusting the technological parameters of the vibration welding by the technological parameter adjustment module, and continuously driving the vibration welding treatment module to carry out treatment on the welding component 1 by the adjusted technological parameters, namely, reducing the characteristic values of the acoustic emission signals to be below the critical threshold value through the adjustment of the technological parameters, so that proper technological parameters are obtained, and the welding quality is improved.
The embodiments described in this specification are merely illustrative of implementations of the inventive concept and the scope of the present invention should not be considered limited to the specific forms set forth in the embodiments but rather by the equivalents thereof as may occur to those skilled in the art upon consideration of the present inventive concept.
Claims (7)
1. Vibration welding state detecting system based on acoustic emission technique its characterized in that: the device comprises a vibration welding processing module, an acoustic emission signal detection module and an upper computer system; the upper computer system comprises an acoustic emission signal analysis module and a process parameter adjustment module; the upper computer system is connected with the vibration welding processing module so as to control the vibration welding processing module to carry out vibration welding processing on the welding component; the acoustic emission signal detection module is connected with the upper computer system; the acoustic emission signal detection module is used for acquiring an acoustic emission signal in a vibration welding process; the acoustic emission signal analysis module analyzes the acoustic emission signal collected by the acoustic emission signal detection module and extracts the characteristics of the acoustic emission signal of the welding defect in the vibration welding process of the component; the process parameter adjusting module is used for adjusting the process parameters of the vibration welding.
2. A vibration welding state detection system based on acoustic emission technology as defined in claim 1, wherein: the vibration welding processing module comprises a signal source, a power amplifier, vibration excitation equipment, an acceleration sensor, a charge amplifier, an oscilloscope and welding equipment; the upper computer system is respectively connected with the signal source and the input end of the welding equipment; the output end of the signal source is connected with the input end of the power amplifier; the output end of the power amplifier is connected with the input end of the excitation equipment; the acceleration sensor is arranged on a welding component, and the output end of the acceleration sensor is connected with the input end of the charge amplifier; the output end of the charge amplifier is connected with the input end of the oscilloscope; the output end of the oscilloscope is connected with the upper computer system; the upper computer system controls the signal source to generate a sine excitation signal with independent and continuously adjustable amplitude and frequency; and the upper computer system controls the welding equipment to generate a welding heat source.
3. A vibration welding state detection system based on acoustic emission technology as defined in claim 1, wherein: the acoustic emission signal detection module comprises an acoustic emission sensor, an acoustic emission signal amplifier and a data acquisition card; the acoustic emission sensor is arranged on the welding component; the output end of the acoustic emission sensor is connected with the input end of the acoustic emission signal amplifier; the output end of the acoustic emission signal amplifier is connected with the input end of the data acquisition card; and the output end of the data acquisition card is connected with an upper computer system.
4. A vibration welding state detection system based on acoustic emission technology as defined in claim 1, wherein: the acoustic emission signal analysis module comprises an acoustic emission signal characteristic acquisition module, an acoustic emission signal characteristic critical threshold setting module and a characteristic comparison module; the acoustic emission signal characteristic acquisition module extracts the characteristics of the acoustic emission signals acquired by the data acquisition card; the characteristic of the acoustic emission signal is the maximum Amplitude value (Amplitude) of the signal waveform; the acoustic emission signal characteristic critical threshold setting module is used for setting a critical threshold of acoustic emission signal characteristics; the characteristic comparison module is used for comparing the characteristic value of the acoustic emission signal acquired in real time with a critical threshold value.
5. A vibration welding state detection system based on acoustic emission technology as defined in claim 1, wherein: the signal source is a signal generator.
6. A vibration welding state detection system based on acoustic emission technology as defined in claim 1, wherein: the signal source is an arbitrary waveform generating card.
7. The vibration welding state detection method based on the acoustic emission technology comprises the following steps:
(1) fixing the welding component on the excitation equipment; mounting an acoustic emission sensor and an acceleration sensor on a welding member; connecting a signal connecting line between the upper computer system and the signal source; connecting a signal connecting line between the upper computer system and the welding equipment; connecting a signal connecting line between a signal source and a power amplifier; connecting a signal connection between the power amplifier and the excitation equipment; connecting a signal connecting line between the acceleration sensor and the charge amplifier; connecting a signal connecting line between the charge amplifier and the oscilloscope; connecting a signal connecting line between the oscilloscope and the upper computer system; connecting a signal connecting line between the acoustic emission sensor and the acoustic emission signal amplifier; connecting a signal connecting line between the acoustic emission signal amplifier and the data acquisition card; connecting a signal connecting line between the data acquisition card and the upper computer system; connecting a signal source, a power amplifier, vibration excitation equipment, welding equipment, a charge amplifier, an oscilloscope, an acoustic emission signal amplifier, a data acquisition card and a power supply of an upper computer system;
(2) carrying out destructive vibration welding tests on the component under different process parameters, simultaneously extracting the characteristic value of the collected acoustic emission signal, testing to obtain the welding residual stress of the component, obtaining the functional relation between the characteristic value of the acoustic emission signal and the welding residual stress in a curve fitting mode, and when the welding residual stress reaches the upper limit of the welding process requirement, taking the characteristic value of the acoustic emission signal at the moment as the critical threshold value of the characteristic value of the acoustic emission signal and storing the critical threshold value in a characteristic comparison module;
(3) selecting specific technological parameter values within the range of technological requirements to carry out vibration welding treatment on the welding component;
(4) the acoustic emission sensor detects the welding component vibration welding process in real time, and transmits the detected acoustic emission signals to the upper computer system, and meanwhile, an acoustic emission signal analysis module in the upper computer system extracts characteristic values of the acoustic emission signals;
(5) selecting specific technological parameter values within the range of technological requirements to carry out vibration welding treatment on the welding component, transmitting the extracted acoustic emission signal characteristic values to the characteristic comparison module for comparison, when the acoustic emission signal characteristic values exceed a critical threshold value, adjusting the technological parameters of the vibration welding by the technological parameter adjustment module, and continuously driving the vibration welding treatment module to treat the welding component by the adjusted technological parameters, namely, reducing the characteristic values of the acoustic emission signals to be below the critical threshold value by adjusting the technological parameters, so that proper technological parameters are obtained, and the welding quality is improved.
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| CN204330686U (en) * | 2015-01-14 | 2015-05-13 | 湖南科技大学 | A kind of High Speed Welding fire check acoustic emission device for dynamically detecting |
| CN107389796A (en) * | 2017-09-13 | 2017-11-24 | 上海海事大学 | A kind of effect of vibration stress relief online rating system and method based on acoustic emission sensor |
| CN107931905A (en) * | 2017-12-22 | 2018-04-20 | 上海海事大学 | For improving the dither welding system and method for metal material performance |
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