CN113510349A - Tungsten electrode welding failure pre-judgment detection device and detection method thereof - Google Patents
Tungsten electrode welding failure pre-judgment detection device and detection method thereof Download PDFInfo
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- CN113510349A CN113510349A CN202110412557.6A CN202110412557A CN113510349A CN 113510349 A CN113510349 A CN 113510349A CN 202110412557 A CN202110412557 A CN 202110412557A CN 113510349 A CN113510349 A CN 113510349A
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- tungsten electrode
- imager
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- welding
- welding gun
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- 238000003466 welding Methods 0.000 title claims abstract description 68
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 title claims abstract description 67
- 239000010937 tungsten Substances 0.000 title claims abstract description 67
- 229910052721 tungsten Inorganic materials 0.000 title claims abstract description 67
- 238000001514 detection method Methods 0.000 title claims abstract description 33
- 238000003384 imaging method Methods 0.000 claims description 14
- 230000007246 mechanism Effects 0.000 claims description 5
- 239000003086 colorant Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 238000010891 electric arc Methods 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- 230000008569 process Effects 0.000 description 4
- 239000010953 base metal Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
Images
Classifications
-
- 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
- B23K9/32—Accessories
-
- 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 application discloses tungsten utmost point welding failure is judged detection device in advance, and it includes: workstation, electronic base, imager device, operation machine and controlling means, electronic base, operation machine and controlling means install in the same face of workstation, the imager device is connected in the top of electronic base, electronic base can drive imager device rotary motion, the rotatory welder of operation machine ability centre gripping, controlling means can control operation machine and electronic base, the imager device is used for the tungsten tip of welder of shooing to whether the realization automatic feedback tungsten tip is inefficacy.
Description
Technical Field
The application relates to the field of automation equipment, in particular to a tungsten electrode welding failure pre-judgment detection device and a detection method thereof.
Background
TIG arc welding is one of the important technological processes widely used in the connection of metal materials, and it adopts tungsten electrode as electrode, under the action of external power supply, forms electric arc with workpiece, and the energy produced by the electric arc is used for melting base metal to realize firm welding seam connection. In TIG welding, arc stability is critical to ensure weld quality consistency. When the tungsten electrode is burnt by electric arc for a long time, burning loss of the end part of the tungsten electrode and pollution of molten pool metal to the end part of the tungsten electrode can be caused, the electric arc is unstable when the tungsten electrode reaches a certain degree, the capacity required by welding cannot be stably output through the tungsten electrode, the welding quality is influenced, workpieces are repaired or scrapped, the manufacturing cost is increased, and the production efficiency is reduced. In the process of the prior art, the burning loss and the pollution condition of the tungsten electrode are analyzed and judged by manual visual inspection, whether the tungsten electrode needs to be replaced or polished depends on the experience of people, and the decision cannot be judged reliably and accurately.
Disclosure of Invention
The technical problem that this application will solve lies in: the tungsten electrode welding failure prejudgment detection device and the tungsten electrode welding failure prejudgment detection method improve the stability of a welding process and reduce product repair and scrap.
On the one hand, a tungsten electrode welding failure is judged detection device in advance, and it includes: workstation, electronic base, imager device, operation machine and controlling means, electronic base, operation machine and controlling means install in the same face of workstation, the imager device is connected in the top of electronic base, electronic base can drive imager device rotary motion, the rotatory welder of operation machine ability centre gripping, controlling means can control operation machine and electronic base, the imager device is used for the tungsten tip of welder of shooing to whether the realization automatic feedback tungsten tip is inefficacy.
Compared with the prior art, the electric base of this application can drive imager device rotary motion, the enough rotatory welder of centre gripping of operating machine, through imager device shooting welder's tungsten utmost point tip, the feedback suggestion is compared automatically, and tungsten utmost point inefficacy is judged in advance to relative accuracy realization, in time changes the tungsten utmost point, improves welding process stability, reduces the product and reprocesses and scrap.
Furthermore, the imager device comprises an imager, an imaging background component and a fixed mounting bracket, wherein the imager and the imaging background component are arranged on two opposite sides of the fixed mounting bracket, the imager and the imaging background component are positioned on two opposite sides of the welding gun, the fixed mounting bracket is connected with the electric base, and the electric base can drive the fixed mounting bracket to rotate.
Furthermore, the manipulator comprises a servo motor, a rotary gear ring, a pneumatic clamping mechanism and a position sensor, and the manipulator and the imager device are arranged at a 90-degree position.
Furthermore, the control device comprises a PLC control system and an imaging analysis comparison module, the imager device can photograph the length direction of the tungsten electrode end of the welding gun, and each photographed picture is compared with the control device last time.
Further, the control device is located on one side of the imager device, and the manipulator is located on the other side of the imager device.
On the other hand, the method for prejudging and detecting the welding failure of the tungsten electrode comprises the following steps:
providing a welding gun, an operating machine, a control device, an imager device and an electric base;
an operator or a mechanical arm sends the welding gun into the detection device, when the welding gun reaches a detection height, the operator clamps the welding gun, and the operator or the mechanical arm loosens the welding gun and moves back to a safe position;
when the control device sends out detection, the imager device and the electric base cooperate to take pictures of multi-angle pictures and send the pictures to the control device;
and acquiring deviation data according to the set and compared shapes, and summarizing the displayed human-computer interface so as to prejudge the failure condition of the tungsten electrode.
Furthermore, the imaging instrument device photographs the length direction of the tungsten electrode end part of the welding gun, and compares each photographed picture with the control device last time.
Further, the manipulator clamps and rotates the welding gun, so that the imager device photographs the tungsten electrode end of the welding gun from a plurality of angles of circumference.
Further, the control device comprises control software, the control software automatically receives the shot pictures, automatically compares the pictures with the set limit failure data, displays the comparison data on an interface, and timely resembles different colors and prompts an early warning through an indicator lamp if the failure data appear.
Further, comparing the picture with a preset shape parameter and a safety limit value, and comprehensively pre-judging failure conditions; the shape parameters include:
table burn out causes bottom diameter variation;
metal vapor adheres to the conical surface;
the bottom surface of the round table is oxidized and burned to form an uneven shape.
Drawings
Fig. 1 is a perspective view of a device for predicting failure of welding of tungsten electrode according to an embodiment of the present application.
FIG. 2 is an exploded view of an embodiment of the apparatus for predicting failure of tungsten welding.
Detailed Description
Reference will now be made in detail to the exemplary embodiments, examples of which are illustrated in the accompanying drawings. When the following description refers to the accompanying drawings, like numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present application, as detailed in the appended claims.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used in this application and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It should be understood that the terms "first," "second," and the like as used in the description and in the claims, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Similarly, the use of the terms "a" or "an" and the like do not denote a limitation of quantity, but rather denote the presence of at least one; "plurality" means two or more than two. Unless otherwise indicated, "front", "rear", "lower" and/or "upper" and the like are for convenience of description and are not limited to one position or one spatial orientation. The word "comprising" or "comprises", and the like, means that the element or item listed as preceding "comprising" or "includes" covers the element or item listed as following "comprising" or "includes" and its equivalents, and does not exclude other elements or items.
The following describes exemplary embodiments of the present application in detail with reference to the drawings. The features of the following examples and embodiments can be supplemented or combined with each other without conflict.
As shown in fig. 1 and 2, a device 100 for pre-judging failure of welding of tungsten electrode according to the present application comprises: a table 11, a motorized base 12, an imager device 13, a manipulator 14, and a control device 15.
The electric base 12, the manipulator 14, and the control device 15 are mounted on the same surface of the table 11, the imager device 13 is connected above the electric base 12, the electric base 12 can drive the imager device 13 to rotate, the manipulator 14 can grip the rotating welding gun 16, and the control device 15 can control the manipulator 14 and the electric base 12.
The table 11 includes a table plate 111, four legs 112 connected to four corners of the table plate 111, respectively, two connecting bars 113 connecting the front and rear legs 112, respectively, and a cross beam 114 connecting the two connecting bars. The worktable 11 thus arranged is advantageous to the installation stability of the tungsten electrode welding failure prejudgment detecting device 100. The platen 111 is planar and is disposed parallel to the ground.
A motorized mount 12 is mounted between the table 11 and the imager device 13, the motorized mount 12 being used to rotate the imager device 13 to take pictures from different angles around the circumference of the tungsten tip 161 of the welding gun 16. The motorized base 12 may be driven by a servo motor.
The manipulator 14 includes a vertical portion 141, a horizontal portion 142, and a mounting plate 143, the horizontal portion 142 being fixed to the vertical portion 141, the vertical portion 141 being fixed to the mounting plate 143, the mounting plate 143 being fixed to the work table 11, the horizontal portion 142 being provided perpendicular to the vertical portion 141.
The imager device 13 comprises an imager 131, an imaging background component 132 and a fixed mounting bracket 133, wherein the imager 131 and the imaging background component 132 are arranged on two opposite sides of the fixed mounting bracket 133, the imager 131 and the imaging background component 133 are arranged on two opposite sides of the welding gun 16, the fixed mounting bracket 133 is connected with the electric base 12, and the electric base 12 can drive the fixed mounting bracket 133 to rotate. The imager 131 is a high-definition imager.
The imager device 13 includes a support base 134 and a support base 135, the support base 134 is supported by the fixed mounting bracket 133, and the support base 135 is supported by the support base 134. When the tungsten tip 161 of the welding torch 16 is to be inspected, the manipulator 14 may move the tungsten tip 161 up and down and may move the tungsten tip to the support base 135 to support the tungsten tip 161, thereby facilitating the inspection of the tungsten tip 161.
The manipulator 14 includes a servo motor, a rotary gear ring, a pneumatic clamping mechanism, and a position sensor, and the manipulator 14 is installed at a 90-degree position with respect to the imager device 13. The manipulator 14 can take pictures from a plurality of angles on the circumference, and the comparison data is more comprehensive. The manipulator 14 includes automatic height detection, clamping and swiveling functions for the welding gun. The height detection is to ensure that the photographing position of the tungsten electrode is consistent with the photographing center of the imager, and reduce comparison errors. The height detection is achieved by a set of photo sensors. After the tungsten electrode reaches the detection height, a pneumatic clamping device on the slewing mechanism automatically clamps the welding gun to ensure that the height and the center are fixed. The slewing mechanism realizes arbitrary rotation according to the required photographing angle so as to acquire multi-angle pictures for comparison, and a high-precision motor with an encoder is adopted for slewing.
The control device 15 comprises a PLC control system and an imaging analysis comparison module, the imager device 13 can photograph the tungsten electrode end 161 of the welding gun in the length direction, and each photographed picture is compared with the control device in the last time. The control system of the control device 15 not only realizes the functions required by the mechanical movement, but also the control software thereof automatically receives the pictures from the scene, automatically compares the pictures with the set limit failure data, displays the comparison data on the interface, and if the failure data appears, the pictures are similar to different colors in time and prompt and early warn through an indicator light. The operator can directly check the possible reasons of failure and replace the tungsten electrode in time. Software can record and analyze failure related data frequency and make reference for more accurately setting limit failure data for operators.
The control device 15 is located on one side of the imager device 13, and the manipulator 16 is located on the other side of the imager device 13.
A prejudgment and detection method for tungsten electrode welding failure comprises the following steps:
providing a welding gun 16, an operating machine 14, a control device 15, an imager device 13 and an electric base 12;
an operator or a mechanical arm sends the welding gun 16 into the detection device, when the welding gun 16 reaches a detection height, the operator 14 clamps the welding gun, and the operator or the mechanical arm releases the welding gun 16 and moves back to a safe position;
when the control device 15 sends out detection, the imager device 13 and the electric base 12 cooperate to take pictures of multi-angle pictures and send the pictures to the control device 15;
and acquiring deviation data according to the set and compared shapes, and summarizing the displayed human-computer interface so as to prejudge the failure condition of the tungsten electrode.
The imager 13 photographs the tungsten electrode end 161 of the welding torch 16 in the longitudinal direction, and compares each photograph with the controller 15.
The manipulator 14 grips and rotates the welding gun so that the imager device 13 photographs the tungsten tip 161 of the welding gun 16 from a plurality of angles around the circumference.
The control device 15 comprises control software, the control software automatically receives the pictures from shooting, automatically compares the pictures with the set limit failure data, displays the comparison data on an interface, and timely resembles different colors and prompts early warning through an indicator light if failure data appear.
The tungsten electrode is mainly failed within the range of 5mm at the end part, the shape of the tungsten electrode is conical, the bottom part of the tungsten electrode is a circular truncated cone, and the upper part of the tungsten electrode is a conical surface with a certain angle. The tungsten electrode is failed under three conditions, namely, the diameter of the circular truncated cone is enlarged or the local part of the circular truncated cone is burnt after the end part of the tungsten electrode is burnt, so that the electric arc is deviated. One is that in the melting process, the base metal steam is attached to the conical surface to form a burr shape, and the electric arc surrounds the tungsten electrode. One is the oxidation burning loss of the bottom of the circular truncated cone of the tungsten electrode, which forms an uneven shape and influences the stability of the longitudinal distribution of the electric arc. The TIG welding arc has certain redundancy capability, and the burning loss in the three conditions within a certain limit range does not influence the quality of the welding seam. Only exceeding the limit may cause arc instability and affect the welding quality, so that in combination with experience and multiple tests, a safe limit value can be found. The failure condition can be comprehensively judged in advance by comparing the pictures with the preset shape parameters and the safety limit values from the three conditions.
Failure mode 1: burning of the truncated cone results in a change in the diameter of the base.
Failure mode 2: the metal vapor adheres to the conical surface.
Failure mode 3: the bottom surface of the round table is oxidized and burned to form an uneven shape.
The present invention is not limited to the above-described embodiments, and those skilled in the art will be able to make various modifications without creative efforts from the above-described conception and within the scope of the present invention.
Claims (10)
1. The utility model provides a tungsten utmost point welding failure is detection device in advance which characterized in that includes: workstation, electronic base, imager device, operation machine and controlling means, electronic base, operation machine and controlling means install the same face at the workstation, the imager device is connected in the top of electronic base, electronic base can drive imager device rotary motion, the rotatory welder of operation machine ability centre gripping, controlling means can control operation machine and electronic base.
2. The tungsten electrode welding failure prejudging device according to claim 1, wherein: the imager device comprises an imager, an imaging background component and a fixed mounting support, wherein the imager and the imaging background component are arranged on two opposite sides of the fixed mounting support, the imager and the imaging background component are positioned on two opposite sides of the welding gun, the fixed mounting support is connected with the electric base, and the electric base can drive the fixed mounting support to rotate.
3. The tungsten electrode welding failure prejudgment detection device according to claim 2, characterized in that: the manipulator comprises a servo motor, a rotary gear ring, a pneumatic clamping mechanism and a position sensor, and is installed at a 90-degree position with the imager device.
4. A tungsten electrode welding failure prejudgment detection device as claimed in claim 3, wherein: the control device comprises a PLC control system and an imaging analysis comparison module, the imager device can photograph the length direction of the tungsten electrode end part of the welding gun, and each photographed picture is compared with the control device last time.
5. The tungsten electrode welding failure prejudgment detection device according to claim 4, characterized in that: the control device is positioned at one side of the imager device, and the manipulator is positioned at the other side of the imager device.
6. A prejudgment and detection method for tungsten electrode welding failure is characterized by comprising the following steps:
providing a welding gun, an operating machine, a control device, an imager device and an electric base;
an operator or a mechanical arm sends the welding gun into the detection device, when the welding gun reaches a detection height, the operator clamps the welding gun, and the operator or the mechanical arm loosens the welding gun and moves back to a safe position;
when the control device sends out detection, the imager device and the electric base cooperate to take pictures of multi-angle pictures and send the pictures to the control device;
and acquiring deviation data according to the set and compared shapes, and summarizing the displayed human-computer interface so as to prejudge the failure condition of the tungsten electrode.
7. The prejudgment detection method for the welding failure of the tungsten electrode as recited in claim 6, is characterized in that: the imaging instrument device photographs the length direction of the tungsten electrode end part of the welding gun, and compares each photographed picture with the control device last time.
8. The prejudgment detection method for the welding failure of the tungsten electrode according to claim 7, characterized by comprising the following steps: the manipulator clamps and rotates the welding gun so that the imager device photographs the end of the tungsten electrode of the welding gun from a plurality of circumferential angles.
9. The prejudgment detection method for the welding failure of the tungsten electrode according to claim 8, characterized by comprising the following steps: the control device comprises control software, the control software automatically receives the pictures from shooting, automatically compares the pictures with the set limit failure data, displays the comparison data on an interface, and timely resembles different colors and prompts early warning through an indicator lamp if failure data appear.
10. The prejudgment detection method for the welding failure of the tungsten electrode according to claim 9, characterized by comprising the following steps: comparing the picture with a preset shape parameter and a safety limit value, and comprehensively pre-judging failure conditions; the shape parameters include:
table burn out causes bottom diameter variation;
metal vapor adheres to the conical surface;
the bottom surface of the round table is oxidized and burned to form an uneven shape.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110412557.6A CN113510349A (en) | 2021-04-16 | 2021-04-16 | Tungsten electrode welding failure pre-judgment detection device and detection method thereof |
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| CN202110412557.6A CN113510349A (en) | 2021-04-16 | 2021-04-16 | Tungsten electrode welding failure pre-judgment detection device and detection method thereof |
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Cited By (1)
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