CN112658441B - Voltage sensing method and system for monitoring metal transition state in GTA forming process - Google Patents
Voltage sensing method and system for monitoring metal transition state in GTA forming process Download PDFInfo
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- CN112658441B CN112658441B CN202010365582.9A CN202010365582A CN112658441B CN 112658441 B CN112658441 B CN 112658441B CN 202010365582 A CN202010365582 A CN 202010365582A CN 112658441 B CN112658441 B CN 112658441B
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Abstract
The invention discloses a voltage sensing method and a system for monitoring a metal transition state in a GTA forming process. In the invention, the sensing is carried out based on the filling metal and the local electric arc in the forming area, so that the obtained electric signal contains information reflecting the transition and other behaviors of the liquid filling metal, and the method is mainly used for online monitoring of the transition state of the liquid metal in the forming process of the wire filling GTA.
Description
Technical Field
The invention belongs to the technical field of information sensing and control in an electric arc forming process, and particularly relates to a real-time sensing and monitoring method for a liquid metal transition state in a forming process by using argon arc (GTA) as a heat source and filling metal.
Background
The GTA heat source is typically an arc forming heat source that is produced by forming an inert argon arc between a non-melting tungsten electrode and the metal being formed to provide a stable metal weld. The use range of the heat source can be further expanded by adopting the filling metal, such as surfacing welding deposition, surface modification, additive manufacturing and rapid forming, and the targeted addition of metal elements can change the forming structure and optimize the performance of the component, so that the related effects are not sufficient. Thus, the arc forming technique has wide application in the related industrial manufacturing field.
The automatic arc forming often has higher requirements on the consistency of local environment and working conditions, and due to the existence of dynamic randomness and external interference in the process, the stability of the state and the qualification of the quality of the automatic arc forming cannot be always guaranteed even if a reasonable forming process is adopted. Therefore, it is necessary to introduce an information sensing and online monitoring system in the automatic arc forming process, which is not only beneficial to mastering the forming direction in real time, but also is a precondition that the related forming equipment can make autonomous decision and feedback control. At present, the sensing technology applied to the real-time monitoring of the GTA forming process has various forms, such as visual sensing, arc pressure sensing, infrared sensing, ultrasonic sensing and the like. The main objects to be monitored by the sensing methods are more liquid molten pools, the sensing of dynamic fluctuation of the liquid molten pools or the measurement of geometrical shapes and the like are usually involved, and the extracted relevant information can be used as useful input for quality real-time control. In addition to the bath, the filler metal is obviously a non-negligible ring in the forming zone and participates in the forming process, and the liquid metal produced by melting is expected to be smoothly transferred into the bath all the time, so that burning loss, shaking or splashing and the like caused by interaction with the electric arc are reduced as much as possible to ensure the stability of the forming process. However, the transition state of the liquid metal is easy to change in the face of different forming poses, operation parameters, random disturbance and other specific situations, and the prior art has few suitable and convenient sensing methods for monitoring the dynamic change of the liquid metal. If a sensing method such as a sensing method based on vision and the like which needs to consider the arrangement problem is adopted to monitor the metal transition, the cost performance is not high due to the problems of relatively complex system design, occupation of space positions and the like; the characteristic signal is not very significant when the conventional method of detecting the entire arc voltage signal is used to monitor the process.
Disclosure of Invention
Aiming at overcoming the defects of the prior art, the invention provides a set of simple electric signal sensing method and system, which are mainly used for on-line monitoring of the transition state of liquid metal in the forming process of the wire-filling GTA. The sensing method is different from a method for detecting the overall arc voltage between a cathode and an anode, but the sensing is carried out based on the filling metal and the local arc in a forming area, and the obtained electric signal contains information reflecting the transition and other behaviors of the liquid filling metal.
The technical purpose of the invention is realized by the following technical scheme.
A voltage sensing system for monitoring metal transition state in a GTA forming process comprises a signal sensing module and a human-computer interaction module, wherein:
the signal sensing module collects an original target electric signal through a hardware loop, and the measured electric signal is transmitted to a computer; the hardware loop adopts a wiring scheme of collecting target electric signals, and filling metal is positioned in the forming area:
(1) passive type I: the voltage sensor is respectively connected to the filler metal (namely, the filler wire) and the formed metal piece (namely, the welding piece), and signals at the moment mainly originate from the forming loop, and the voltage between the filler metal and the formed metal piece is used as a target electric signal for acquisition;
(2) passive type II: the voltage sensor is respectively connected to the filler metal (namely, a filler wire) and the non-melting tungsten electrode (namely, a welding gun), and signals at the moment mainly originate from the forming loop, and the voltage between the filler metal and the non-melting tungsten electrode is taken as a target electric signal;
(3) active type I: the filling metal, the power resistor, the direct current voltage stabilizing source and the formed metal piece form an additional loop, the voltage sensor is connected to two ends of the power resistor, signals at the moment mainly originate from the loop and the direct current voltage stabilizing source, and voltages at two ends of the power resistor are used as acquisition target signals;
(4) active type II: the filling metal, the power resistor, the direct current voltage stabilizing source and the non-melting tungsten electrode form an additional loop, the voltage sensor is connected to two ends of the power resistor, signals at the moment mainly originate from the loop and the direct current voltage stabilizing source, and voltage at two ends of the power resistor is used as a collecting target signal;
the human-computer interaction module realizes the functions of real-time display, statistical analysis and data storage of the target signal through a computer.
In the technical scheme of the invention, the man-machine interaction module is established in a Matlab environment and is realized by graphical interface programming.
In the technical scheme of the invention, a frequency domain filter is adopted to filter the original signal in a man-machine interaction module.
In the technical scheme of the invention, the signal waveform shown by the man-machine interaction module in the actual forming process contains characteristic information obviously reflecting the dynamic behavior of the liquid filling metal, for example, the formation and disconnection of a short-circuit liquid bridge can cause the shown waveform to have step change similar to positive direction or negative direction.
In the technical scheme of the invention, a signal isolation module is added between the signal sensing module and the human-computer interaction module.
In the technical scheme of the invention, the analog electric signal measured by the voltage sensor is acquired by the USB data acquisition card, is subjected to A/D conversion and then is input to the computer.
In the technical scheme of the invention, the voltage sensor is a Hall voltage sensor.
In the technical scheme of the invention, the output voltage of the direct current voltage-stabilizing source is used for adjusting the amplitude of the target electric signal.
In the technical scheme of the invention, in the signal sensing module, an additional access (Hall) current sensor monitors the working current of the forming loop to ensure that the change of the target electric signal is caused by the transition behavior of the liquid filling metal and is not unstable in the working loop current.
In the technical scheme of the invention, in the wiring mode of the signal sensing module, the wiring position of the filling metal side is selected to be near the wire feeding nozzle or a position where a conductive path can be formed between the wire feeding nozzle and the filling metal inside the wire feeder.
The method for monitoring the metal transition state voltage sensing in the GTA forming process by utilizing the system senses the voltage in a forming area by using a voltage sensor, and the obtained electric signal contains information reflecting the transition behavior of the liquid filling metal, so that the online monitoring of the transition state of the liquid filling metal in the GTA forming process of the filler wire is realized:
(1) detecting the existence and disconnection state of a short circuit liquid bridge in the transition process of liquid metal to monitor the metal transition mode
(2) Detecting dynamic shaking condition of suspended molten drop in liquid metal transition process
Compared with the prior art, the beneficial effects of this technique are: the electric signal sensing method and the electric signal sensing system for on-line monitoring of the transition behavior and the state of the liquid filling metal in the forming process of the wire-filling GTA are provided, can be easily realized in general application occasions, do not need to carry out complicated sensing system design or consider the limitation of sensing space, and are easily combined with other sensing technologies
Drawings
Fig. 1 shows four alternative wiring schemes of the signal sensing module of the present invention, wherein (a) is passive type I, (b) is passive type II, (c) is active type I, and (d) is active type II.
FIG. 2 is a schematic diagram of a sensing system in an embodiment of the invention.
Fig. 3 is a waveform diagram (one) of a typical target signal collected in an embodiment of the present invention.
Fig. 4 is a waveform diagram (two) of a typical target signal collected in the embodiment of the present invention.
Detailed Description
Embodiments of the present invention are further illustrated by the following specific examples.
The example is an on-line monitoring example of the transition state of liquid filling metal in the process of filling wire GTA surfacing, and the used forming equipment and related materials are as follows: the power supply of Magicwave4000 model from Fronius of Austria is an arc welding power supply, the robot of MOTOMAN model from Yaskawa of Japan holds a welding gun moving heat source, the base metal is Q235 steel with the thickness of 4mm, the filling metal is CHW-50C6 model welding wire with the diameter of 1.2mm, and the protective gas is argon.
The wiring scheme of the signal sensing module selected for this example is a passive type I, i.e., as shown in fig. 1 (a). The schematic diagram of an electrical signal sensing system based on the wiring scheme is shown in fig. 2, wherein a voltage sensor is respectively connected to the vicinity of a wire feeding nozzle (i.e. a welding wire) and a base metal (i.e. a welding piece), a forming loop cable passes through a current sensor coil to realize the detection of welding current, the two sensors are connected with the input end of a signal isolation module, the output end of the signal isolation module is connected with an AI port of a data acquisition card, the data acquisition card is connected with a computer, and in addition, the sensors and the isolation module are powered by a switching power supply. The related specific hardware models comprise a porphyry USB-4711AE type data acquisition card, a CHB-500SG type closed-loop Hall current sensor, a CHV-25P/50 type closed-loop Hall voltage sensor and the like.
The man-machine interaction module of the embodiment is implemented by programming an interface based on a Matlab environment, and the man-machine interaction process is carried out by clicking an interface button. The porphyry USB-4711AE type data acquisition card is provided with a software development kit aiming at the third party development and provides a function interface capable of being called for Matlab, so that the data of an AI port of the data acquisition card is set and received by compiling m language calling serial interface functions to customize sampling frequency and the like. The sampling frequency of an AI port of the data acquisition card is set to be 1024Hz, and the computer reads the data acquired by the acquisition card through an event response mechanism, namely, the computer monitors that an event is generated when the acquisition card acquires the data with the specified length and then generates a response for reading the data. Here, the collected raw data is filtered, the filter is a twelve-order Butterworth low-pass filter, the pass-band frequency is set to be 100Hz, the cut-off frequency is set to be 150Hz, and the signal attenuation is 40dB at the cut-off frequency. The filtered data can be used for oscillography, analysis, storage and other processing processes, so that a basic system framework for on-line monitoring of the transition state of the wire-filling GTA liquid filling metal is established. Typical target signal waveforms collected by the present invention during implementation of wire-filling GTA hardfacing are shown in fig. 3 and 4.
The present example detects the presence and disconnection of a short circuit liquid bridge during liquid metal transition to monitor the metal transition mode. It can be clearly observed from fig. 3 that the characteristic influence of the formation and disconnection of the liquid bridge on the target signal is observed, and then, if at the present moment, the computer reads data with a length of L in the rectangular frame in fig. 3, the evolution situation of the metal transition mode can be described by simple logic calculation, that is, the data of the target data segment is subjected to simple threshold judgment and the data length greater than the threshold is calculated, so that statistical data such as an absolute time value of the disconnection of the short-circuit liquid bridge, a percentage of the disconnection time of the short-circuit liquid bridge in the total time can be obtained.
This example detects the dynamic sloshing of a suspended droplet during the transition of liquid metal. It is obvious from fig. 4 that there is a fluctuation in the suspended droplet at the end of the filler metal during the forming process, and if the computer reads a segment of data with length L in the rectangular frame in fig. 4 at the present moment, the dynamic fluctuation of the suspended droplet can be described by calculating the variance of the segment of data and other statistics.
The above examples relate only to the wire-fill GTA surfacing process. From the above, the on-line monitoring of the transition state of the liquid filling metal in the wire filling GTA forming process can be realized based on the invention, and the detected target signal can be used for quantifying the transition process so as to accurately grasp the stability of the forming process.
The invention has been described in an illustrative manner, and it is to be understood that any simple variations, modifications or other equivalent changes which can be made by one skilled in the art without departing from the spirit of the invention fall within the scope of the invention.
Claims (9)
1. The utility model provides a voltage sensing system of monitoring GTA shaping process metal transition state which characterized in that, includes signal sensing module, man-machine interaction module, wherein:
the signal sensing module collects an original target electric signal through a hardware loop, and the measured electric signal is transmitted to a computer; the hardware loop adopts a wiring scheme of collecting target electric signals, and filling metal is positioned in the forming area:
(1) passive type I: the voltage sensor is respectively connected to the filling metal and the formed metal part, and the signal at the moment mainly originates from a forming loop, and the voltage between the filling metal and the formed metal part is used as a target electric signal;
(2) passive type II: the voltage sensor is respectively connected to the filling metal and the non-melting tungsten electrode, and the signal at the moment mainly originates from a forming loop, and the voltage between the filling metal and the non-melting tungsten electrode is taken as a target electric signal;
(3) active type I: the filling metal, the power resistor, the direct current voltage stabilizing source and the formed metal piece form an additional loop, the voltage sensor is connected to two ends of the power resistor, signals at the moment mainly originate from the loop and the direct current voltage stabilizing source, and voltages at two ends of the power resistor are used as acquisition target signals;
(4) active type II: the filling metal, the power resistor, the direct current voltage stabilizing source and the non-melting tungsten electrode form an additional loop, the voltage sensor is connected to two ends of the power resistor, signals at the moment mainly originate from the loop and the direct current voltage stabilizing source, and voltage at two ends of the power resistor is used as a collecting target signal;
the human-computer interaction module realizes the functions of real-time display, statistical analysis and data storage of the target signal through a computer.
2. The voltage sensing system for monitoring metal transition states of a GTA forming process of claim 1, wherein the voltage sensor is a hall voltage sensor.
3. The system of claim 1, wherein the analog electrical signal measured by the voltage sensor is collected by a USB data acquisition card, a/D converted, and then input to the computer.
4. The voltage sensing system for monitoring metal transition states of a GTA forming process of claim 1 wherein the wiring position on the filler metal side in the wiring pattern of the signal sensing module is selected to be near the wire feed nozzle or inside the wire feeder where a conductive path can be formed with the filler metal.
5. The voltage sensing system for monitoring metal transition states in a GTA forming process of claim 1, wherein a signal isolation module is added between the signal sensing module and the human machine interaction module.
6. The voltage sensing system for monitoring metal transition states of a GTA forming process of claim 1, wherein the output voltage of the dc regulated supply is used to adjust the target electrical signal amplitude.
7. The voltage sensing system for monitoring metal transition state of GTA forming process according to claim 1, wherein a Hall current sensor is additionally connected to the signal sensing module to monitor the working current of the forming loop, so as to ensure that the change of the target electrical signal is caused by the transition behavior of the liquid filling metal and not the instability of the working loop current.
8. The voltage sensing system for monitoring the metal transition state in the GTA forming process according to claim 1, wherein the human-computer interaction module is built in a Matlab environment and is implemented by graphical interface programming, and a frequency-domain filter is adopted to filter the original signal.
9. The method for monitoring GTA forming process metal transition state voltage sensing using the system of any of claims 1-8, wherein voltage sensor is used to sense voltage in the forming area, and the obtained electrical signal will contain information reflecting liquid filling metal transition behavior, so as to realize on-line monitoring of liquid filling metal transition state in the wire filling GTA forming process:
(1) detecting the existence and disconnection state of a short-circuit liquid bridge in the liquid metal transition process to monitor a metal transition mode;
(2) and detecting the dynamic shaking condition of the suspended molten drop in the transition process of the liquid metal.
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| US6331694B1 (en) * | 1999-12-08 | 2001-12-18 | Lincoln Global, Inc. | Fuel cell operated welder |
| CN100475404C (en) * | 2007-01-11 | 2009-04-08 | 上海交通大学 | Control method of digital pulse consumable electrode gas protection welding |
| CN103192163B (en) * | 2012-11-17 | 2017-11-21 | 沈阳工业大学 | One kind is based on the synchronous magnetic control means of monolithic processor controlled welding and control method |
| CN104002019B (en) * | 2014-05-26 | 2018-06-22 | 中北大学 | Welding material evaluation on machinability method based on electric arc chaotic characteristic optimization algorithm |
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