SPOT WELDING QUALITY FUZZY CONTROL SYSTEM BASED ON MULTISENSOR INFORMATION FUSION

The multisensor information fusion technology is adopted for real time measuring the four parameters which are connected closely with the weld nugget size(welding current,electrode displacement,dynamic resistance,welding time),thus much more original information is obtained.In this way,the difficulty caused by measuring indirectly weld nugget size can be decreased in spot welding quality control,and the stability of spot welding quality can be improved.According to this method,two-dimensional fuzzy controllers are designed with the information fusion result as input and the thyristor control signal as output.The spot welding experimental results indicate that the spot welding quality intelligent control method based on multisensor information fusion technology can compensate the influence caused by variable factors in welding process and ensure the stability of welding quality.     

Intelligent diagnosis of short hydraulic signal based on improved EEMD and SVM with few low-dimensional training samples

The high accurate classification ability of an intelligent diagnosis method often needs a large amount of training samples with high-dimensional eigenvectors, however the characteristics of the signal need to be extracted accurately. Although the existing EMD(empirical mode decomposition) and EEMD(ensemble empirical mode decomposition) are suitable for processing non-stationary and non-linear signals, but when a short signal, such as a hydraulic impact signal, is concerned, their decomposition accuracy become very poor. An improve EEMD is proposed specifically for short hydraulic impact signals. The improvements of this new EEMD are mainly reflected in four aspects, including self-adaptive de-noising based on EEMD, signal extension based on SVM(support vector machine), extreme center fitting based on cubic spline interpolation, and pseudo component exclusion based on cross-correlation analysis. After the energy eigenvector is extracted from the result of the improved EEMD, the fault pattern recognition based on SVM with small amount of low-dimensional training samples is studied. At last, the diagnosis ability of improved EEMD+SVM method is compared with the EEMD+SVM and EMD+SVM methods, and its diagnosis accuracy is distinctly higher than the other two methods no matter the dimension of the eigenvectors are low or high. The improved EEMD is very propitious for the decomposition of short signal, such as hydraulic impact signal, and its combination with SVM has high ability for the diagnosis of hydraulic impact faults.     

Constant speed control for complex cross-section welding using robot based on angle self-test

Expandable profile liner（EPL） is a promising new oil well casing cementing technique, and welding is a major EPLs connection technology. Connection of EPL is still in the stage of manual welding so far, automatic welding technology is a hotspot of EPL which is one of the key technologies to be solved. A robot for automatic welding of＂8＂ type EPL is studied. Four quadrants of mathematical equations of the 8-shaped cross-section track of EPL, consisting of multiple arcs, are established. Mechanism program for complex cross-section welding of EPL based on angle detection is proposed according to characteristics of small size, small valleys, and large forming errors, etc. A welding velocity vector control model is established by linkage control of a welding vehicle, a small driven actuator, and a height tracking mechanism. A constant speed control model based on an angle and symmetrical analysis model of rectangular coordinate system for EPL is built. Constraint conditions of constant speed control between each section are analyzed with 4 sections in first quadrant as an example, and cooperation work mechanism of the welding vehicle and the small tracking actuator is established based on pressure detection. The constant speed control model using angle self-test can be used to avoid the need for a precise mathematical model for tracking control and to adapt manufacture and installation deviation of EPL workpiece. The model is able to solve constant speed and trajectory tracking problems of EPL cross-section welding. EPL seams welded by the studied robot are good in appearance, and non-destructive testing（NDT） shows the seams are good in quality with no welding defects. Bulge tests show that the maximum pressure of welded EPL is 35 MPa, which can fulfill expansion performance requirements.     

AUTOREGRESSIVE MODEL AND POWER SPECTRUM CHARATERISTICS OF CURRENT SIGNAL IN HIGH FREQUENCY GROUP PULSE MICRO-ELECTROCHEMICAL MACHINING

The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining (HGPECM) is mainly discussed. The auto-regressive(AR) model of group pulse current flowing across the cathode and the anode are created under different situations with different processing parameters and inter-electrode gap size. The AR model based on the current signals indicates that the order of the AR model is obviously different relating to the different processing conditions and the inter-electrode gap size; Moreover, it is different about the stability of the dynamic system, i.e. the white noise response of the Green's function of the dynamic system is diverse. In addition, power spectrum method is used in the analysis of the dynamic time series about the current signals with different inter-electrode gap size, the results show that there exists a strongest power spectrum peak, characteristic power spectrum(CPS), to the current signals related to the different inter-electrode gap size in the range of 0-5 kHz. Therefore, the CPS of current signals can implement the identification of the inter-electrode gap.     

INTELLIGENT CONTROL SYSTEM OF PULSED MAG WELDING INVERTER BASED ON DIGITAL SIGNAL PROCESSOR

A fuzzy logic intelligent control system of pulsed MAG welding inverter based on digital signal processor （DSP） is proposed to obtain the consistency of arc length in pulsed MAG welding. The proposed control system combines the merits of intelligent control with DSP digital control. The fuzzy logic intelligent control system designed is a typical two-input-single-output structure, and regards the error and the change in error of peak arc voltage as two inputs and the background time as single output. The fuzzy logic intelligent control system is realized in a look-up table （LUT） method by using MATLAB based fuzzy logic toolbox, and the implement of LUT method based on DSP is also discussed. The pulsed MAG welding experimental results demonstrate that the developed fuzzy logic intelligent control system based on DSP has strong arc length controlling ability to accomplish the stable pulsed MAG welding process and controls pulsed MAG welding inverter digitally and intelligently.     

Quantitative damage detection for planetary gear sets based on physical models

Planetary gear set is the critical component in helicopter transmission train,and an important problem in condition monitoring and health management of planetary gear set is quantitative damage detection.In order to resolve this problem,an approach based on physical models is presented to detect damage quantitatively in planetary gear set.A particular emphasis is put on a feature generation and selection method,which is used for sun gear tooth breakage damage detection quantitatively in planetary gear box of helicopter transmission system.In this feature generation procedure,the pure torsional dynamical models of 2K-H planetary gear set is established for healthy case and sun gear tooth-breakage case.Then,a feature based on the spectrum of simulation signals of the dynamical models is generated.Aiming at selecting the best feature suitable for quantitative damage detection,a two-sample Z-test procedure is used to analyze the performance of features on damage evolution tracing.A feature named SR,which had better performance in tracking damage,is proposed to detect damage in planetary gear set.Meanwhile,the sun gear tooth-chipped seeded experiments with different severity are designed to validate the method above,and then the test vibration signal is picked up and used for damage detection.With the results of several experiments for quantitative damage detection,the feasibility and the effect of this approach are verified.The proposed method can supply an effective tool for degradation state identification in condition monitoring and health management of helicopter transmission system.     

Enhanced detection of rolling element bearing fault based on stochastic resonance

Early bearing faults can generate a series of weak impacts. All the influence factors in measurement may degrade the vibration signal. Currently, bearing fault enhanced detection method based on stochastic resonance(SR) is implemented by expensive computation and demands high sampling rate, which requires high quality software and hardware for fault diagnosis. In order to extract bearing characteristic frequencies component, SR normalized scale transform procedures are presented and a circuit module is designed based on parameter-tuning bistable SR. In the simulation test, discrete and analog sinusoidal signals under heavy noise are enhanced by SR normalized scale transform and circuit module respectively. Two bearing fault enhanced detection strategies are proposed. One is realized by pure computation with normalized scale transform for sampled vibration signal, and the other is carried out by designed SR hardware with circuit module for analog vibration signal directly. The first strategy is flexible for discrete signal processing, and the second strategy demands much lower sampling frequency and less computational cost. The application results of the two strategies on bearing inner race fault detection of a test rig show that the local signal to noise ratio of the characteristic components obtained by the proposed methods are enhanced by about 50% compared with the band pass envelope analysis for the bearing with weaker fault. In addition, helicopter transmission bearing fault detection validates the effectiveness of the enhanced detection strategy with hardware. The combination of SR normalized scale transform and circuit module can meet the need of different application fields or conditions, thus providing a practical scheme for enhanced detection of bearing fault.     

Nonlinear Dynamic Characteristics of the Vectored Thruster AUV in Complex Sea Conditions

The mobility of the vectored thruster AUV in different environment is the important premise of control system design. The new type of autonomous underwater vehicle (AUV) equipped with rudders and vectored thrusters which are combined to control the course is studied. Firstly, Euler angles representation and quaternion method are applied to establish six-DOF kinematic model respectively, then Newton second law and Lagrangian approach are used to deduce the vectored thruster AUV’s nonlinear dynamic equations with six degrees of freedom (DOF) respectively in complex sea conditions based on the random wave theory according to the structural and kinetic characteristics of the vectored thruster AUV in this paper. The kinematic models and dynamic models based on different theories have the same expression and conclusion, which shows that the kinematic models and dynamic models of the vectored thruster AUV are accurate. The Runge-Kutta arithmetic is used to solve the dynamic equations, which not only can simulate the motions such as cruise and hover but also can describe the vehicle’s low-frequency and high-frequency motion. The results of computation show that the mobility of the vectored thruster AUV in interference-free environment and the integrated signals including low-frequency motion signal and high-frequency motion signal in environmental disturbance accord with practical situation, which not only solve the problem of especial singularities when the pitch angle θ = ±90° but also clears up the difficulties of computation and display of the coupled nonlinear motion equations in complex sea conditions. Moreover, the high maneuverability of the vectored thruster AUV equipped with rudders and vectored thrusters is validated, which lays a foundation for the control system design.     

Contact Model of Revolute Joint with Clearance Based on Fractal Theory

The contact sti ness of a mechanical bonding surface is an important parameter in determining the normal and radial contact force. To improve the calculation accuracy of the contact force model, the surface roughness of the bonding surface and the energy loss that necessarily occurs during the impact process should be considered com?prehensively. To study the normal contact force of a revolute joint with clearance more accurately in the case of dry friction, a nonlinear sti ness coe cient model considering the surface roughness was established based on fractal theory, which considers the elastic, elastic?plastic, and plastic deformations of the asperities of the contact surface during the contact process. On this basis, a modified nonlinear spring damping model was established based on the Lankarani–Nikravesh contact force model. The laws influencing the surface roughness, recovery coe cient, initial velocity, and clearance size on the impact force were revealed, and were compared with the Lankarani–Nikravesh model and a hybrid model using MATLAB. The maximum impact force was obtained using a modified contact force model under di erent initial velocities, di erent clearances, and di erent degrees of surface roughness, and the calculated results were then compared with the experiment results. This study indicates that the modified model can be used more widely than other models, and is suitable for both large and small clearances. In particular, the modified model is more accurate when calculating the contact force of a revolute joint with a small clearance.     

Ultrasonic Nondestructive Signals Processing Based on Matching Pursuit with Gabor Dictionary

The success of ultrasonic nondestructive testing technology depends not only on the generation and measurement of the desired waveform, but also on the signal processing of the measured waves. The traditional time-domain methods have been partly successful in identifying small cracks, but not so successful in estimating crack size, especially in strong backscattering noise. Sparse signal representation can provide sparse information that represents the signal time-frequency signature, which can also be used in processing ultrasonic nondestructive signals. A novel ultrasonic nondestructive signal processing algorithm based on signal sparse representation is proposed. In order to suppress noise, matching pursuit algorithm with Gabor dictionary is selected as the signal decomposition method. Precise echoes information, such as crack location and size, can be estimated by quantitative analysis with Gabor atom. To verify the performance, the proposed algorithm is applied to computer simulation signal and experimental ultrasonic signals which represent multiple backscattered echoes from a thin metal plate with artificial holes. The results show that this algorithm not only has an excellent performance even when dealing with signals in the presence of strong noise, but also is successful in estimating crack location and size. Moreover, the algorithm can be applied to data compression of ultrasonic nondestructive signal.     

不锈钢单侧磁控电阻点焊工艺研究

为提高单侧焊接接头的质量,减少焊接缺陷,基于传统双侧轴向磁化装置,设计了一种适用于单侧电阻点焊设备的单侧径向充磁磁控装置。通过与传统电阻点焊进行对比性实验,研究了传统焊点与单侧磁控焊点随焊接电流的变化规律,揭示了单侧磁控电阻点焊装置对焊点熔核形貌、熔核尺寸、微观组织、力学性能等方面的作用机制及改善效果,验证了单侧磁控电阻点焊工艺的可行性。     

基于电极位移的点焊飞溅量化评价与自适应控制研究

飞溅是电阻点焊过程中一种常见的缺陷,严重的飞溅会显著影响焊接质量。针对典型的异常工况,通过飞溅金属量化分析与飞溅骤停实验,发现电极位移信号突变量与飞溅金属总质量之间线性相关,且电极位移信号突变量与飞溅前后熔核厚度减少量基本一致,因此电极位移信号突变量可以表征飞溅程度。在此基础上,提出了基于量化统计的点焊飞溅自适应控制策略,制定了以飞溅程度和飞溅概率为输入,以调幅系数、调幅时刻、调幅时长等电流调幅参数为输出的模糊控制策略,同时根据恒能量与恒功率补时策略确定了补时时长、补时电流等补时参数。使用两种强度的板材验证了该策略的效果。实验结果表明,与恒流焊接模式相比,该方法能有效抑制飞溅,减小压痕深度,增大熔核直径,与传统短时电流调幅策略相比,该方法减少了调幅次数和补时时间,有效提高了焊接效率。     

考虑修正平均等效应力强度因子的焊点缺陷疲劳寿命研究

提出了一种基于超声回波的焊点缺陷疲劳寿命预测评价方法。该方法采用模糊数学理论，基于超声回波特征获得损伤系数，然后综合考虑法向应力、剪切应力和初始缺陷的影响，将焊点缺陷在裂纹扩展路径上的修正平均等效应力强度因子作为疲劳评价的参量。通过对DP600GI材料的合格焊点、焊核过小焊点和烧穿焊点的接头进行疲劳试验，比较不同缺陷对焊接疲劳寿命的影响，得到一条修正平均等效应力强度因子与疲劳寿命的拟合曲线作为含初始缺陷的焊点疲劳寿命预测曲线，研究结果表明，该曲线能有效预测含初始缺陷的点焊接头的疲劳寿命。该方法有助于合理设计电阻点焊的缺陷容限。     

基于超声参数化和熵模型的汽车焊点质量识别

汽车焊点的超声波检测过程中,超声回波为非稳态信号,特征不易提取,同时焊点缺陷类型众多,导致汽车焊点质量的自动判定与识别比较困难。因此,提出一种基于超声信号参数化和判别熵模型的汽车焊点质量智能识别方法。通过建立汽车焊点超声回波信号的参数化模型,再基于EM算法思想,提出多回波超声信号的特征参数估计算法。根据提取的超声信号时频特征值,结合判别熵对特征值的有效性进行监督,提取最优特征值子集,最终实现汽车焊点质量类型的智能识别。焊点的实际检测结果验证了方法的有效性和识别的准确性。     

Characterization of nugget nucleation quality based on the structure-borne acoustic emission signals detected during resistance spot welding process

Acoustic emission signals detected during the resistance spot welding of aluminum alloy were studied in order to assess the characterizations of welding process, the characterizations of the effect of welding parameters to nugget nucleation and the characterizations of the nugget quality by the analysis to acoustic emission signals. The results showed that the physical phases of nugget nucleation can be characterized by the acoustic emission signals detected during the resistance spot welding process. The effects of welding current and current duration to nugget nucleation can be characterized by the characteristic parameters of acoustic emission signals. The characteristic parameters of acoustic emission signals had a better relevance to nugget dimensions and weld strength, which made it possible to measure or predict the weld strength by the characteristic parameters of acoustic emission signals detected during the resistance spot welding process.     

Quality monitoring based on dynamic resistance and principal component analysis in small scale resistance spot welding process

The present study aims at solving weld quality monitoring problem in small scale resistance spot welding of titanium alloy. Typical dynamic resistance curves were divided into several stages based on the weld nugget formation process. A smaller electrode force or lower welding current was found to promote the initial resistance peak. The bulk material heating stage could not be detected under very high welding current condition. Electrode force effect on dynamic resistance and failure load was much smaller than that of welding current. Principal component analysis was made on discrete dynamic resistance values. The first principal component was selected as independent variable in regression analysis for quality estimation. A back propagation neural network model was then proposed to simultaneously predict the nugget size and failure load. The electrode force, welding current, welding time, and first five principal components were designed as network inputs. Effectiveness of the developed model was validated through data training, testing, and validation. The realtime and online quality monitoring purpose could be realized.     

Quality control based on electrode displacement and force in resistance spot welding

The behaviors of electrode displacement and force during spot welding under various conditions, such as different weld currents, electrode forces, and welding times, were studied. Tests were conducted on a 170 kVA MFDC spot welder. Data were collected via a multichannel high-speed data acquisition system and were analyzed with MATLAB. Behaviors of 5182 aluminum and mild steel in spot welding were compared. Results show that nugget expansion rate does not reach zero for aluminium as it does for mild steel as nugget grew to a certain size. A linear relationship is found between the nugget size and maximum expansion that facilitates online weld quality evaluation. An electrode force peak is observed and believed relevant to the sufficient nugget size.     

基于电极位移信号特征分析的电阻点焊质量监测

提出一种基于点焊过程信息采集和处理的焊点质量在线监测方法。通过对电极位移、动态电阻信号的实时采集和分析,利用电阻信号动态特征刻画熔核形成的不同阶段,从同步位移信号中提取12个与焊点质量相关的动态特征参量。通过对提取的特征参量与作为焊点质量评价指标的抗剪强度之间的相关性分析,选取相关性显著的特征参量作为输入和抗剪强度为输出,建立线性回归、非线性回归及径向基函数神经网络焊点质量监测模型。监测模型的有效性检验结果表明,建立的三种监测模型都可实现对焊点质量的在线监测。径向基函数神经网络模型的监测准确率高于其他两种模型,其平均验证误差为2.28%,最大验证误差低于10%。     

超声波检测焊点质量的建模方法及应用分析

介绍了两层板焊接时焊点的有限元建模方法：通过金相实验得到焊点尺寸参数,利用超声检测的回波衰减理论及超声波传播衰减信号得到焊点阻尼系数。首先建立了材料为BLD的两层板多类型焊点有限元模型,然后通过与设备检测对比的方法验证了模型的准确性,最后研究了探头在曲面检测工况下角度定位的灵敏度问题,并通过实验进行了验证,实验结果表明：对曲面焊点质量进行检测时,探头角度偏离法线10°范围内,检测结果受到的影响很小。