"5G+工业互联网"的焊接、切割及大数据系统的推广和应用

浅析一例基于5G通信的焊接质量远程监控系统.该系统可远程实时监控多个地点的多种焊接设备的工作状态和位置信息,获取焊接电流、焊接电压、送丝速度、气体流量等多种信息,实现监控焊接过程的实时数据、焊后追溯分析、生产质量管控、生产资源管理等作业.     

基于统计过程控制的电阻焊质量监控系统

为了增强对电阻焊过程的监控,便于焊接生产的质量管控,基于Visual Studio 2013设计了一套具有串口通信、数据记录、质量监控等多种功能的电阻焊质量监控系统。系统运用统计过程控制理论,以容易检测的焊接电流、电压、功率为监控对象,结合监控对象的最大值、最小值、平均值、标准差、频数分布等多种统计信息,实现了对焊接过程的实时监控和分析评估,依据焊接过程的稳定性来评估焊接质量。结果表明,系统能够反映焊接过程的异常情况,结合影响电阻焊的主要因素可进一步分析引起过程异常的可能原因,指导焊接过程的调整优化。     

基于IOT的焊接设备监控系统设计

设计了一种基于物联网(IOT)技术的焊接设备监控系统方案,实现了焊接设备数据的采集和监测以及远程对焊接设备的控制。该系统以瑞萨MCU为控制器、以IOT技术为核心、以云平台为基础,实现了焊接设备和云平台之间的数据传输与控制,提高了焊接过程的管理精细化。实验结果表明,该系统运行稳定,数据传输可靠,适用于各种焊接场合。     

基于GPS定位和移动互联网的焊接设备远程监控系统

为方便监控野外施工的焊接设备,有效监管焊接质量、工艺规范和工程进度,开发了一种基于GPS定位和移动互联网的焊接设备远程监控系统。系统在移动通信网络条件允许时,直接将焊接设备的多种数据上传并暂存在中转服务器内,在客户服务器开启时通过互联网将数据转发并存储到客户服务器,供客户管理终端检索。系统由专门制造的焊接设备、中转服务器、客户服务器和客户管理终端组成,客户管理终端是基于Windows的软件设计,主要涉及用户界面、数据解析、数据存储和数据传输。     

焊接生产监控中的通信技术

由于焊接生产车间往往设备数目众多、区域分散不集中,使得焊接过程的监控与管理非常困难,网络与总线技术的发展使焊接设备集中管理成为可能。针对焊接车间监控与管理系统组建的特点——要求可靠性高、实时性好、布线方便以及组网灵活等,对目前在焊接生产监控领域中常用的R S485串行总线、CAN总线、工业以太网、Zig Bee、Wifi以及3G六种通信技术进行了详细介绍和分析,分析了各自的优点、缺点和适合应用范围,并进行简单的比较,在此基础上提出了未来焊接车间组建监控与管理系统的对策:不同的数据通信技术与方案适应不同的焊接生产环境和要求,当一种通信技术难以满足时,可以采用两种或多种通信技术结合的方法实现。     

基于TwinCAT和C#的弧焊数据采集分析系统

为保证对焊接过程实现实时监控,优化焊接工艺参数,提高焊接质量,搭建了弧焊焊接过程数据采集分析系统。根据生产现场和数据采集分析的需求,构建了实时采集系统层次构架模型,提出了以传感器、倍福公司模拟量输入端子和嵌入式控制器等为主体硬件,ADS协议和实时以太网为实时通讯协议,Twin CAT PLC和C#为开发语言的分布式弧焊实时数据采集系统的设计方案。实现了弧焊焊接过程中电弧电压、电流、离子气和保护气的实时采集、显示、存储以及焊接质量分析,完成焊接设备数字化集成,提升车间管理水平。     

WMS——焊接管理软件系统

电阻焊机联网系统通过WMS焊接管理软件可实现网络系统管控一体化,解决了网络系统消息通信的实时性、确定性和可靠性问题,实现了对离散群控焊机的多点实时监控,将数据库与网络通信技术应用于该系统,实现数据采集、信息传输、参数查询和参数编程等功能.WMS是一个简单、高效率的操作系统,它适合所有的焊接控制总线.WMS可以对每日搜集到的数据进行筛选,留下有价值的部分,进行置换、调整.并将编辑好的焊接数据和程序备份,发送到客户定义的远程服务器.通过WMS焊接管理软件系统,可以有效地进行焊点质量监控、安排维修保养计划、故障诊断处理、编辑和修改程序、优化生产线资源等工作.     

DeviceNet现场总线技术在大型横缝焊接设备中的应用

介绍一种基于DeviceNet现场总线技术的焊接设备。该设备通过控制室以及焊接系统、控制系统上的I/O终端,利用DeviceNet现场总线技术在其之间进行远程通讯和控制,简化了配线数量,降低了硬接线成本和接点故障率。人机对话界面可以将焊接数据实时传回并进行监控,实现焊接过程控制,提高自动化程度和焊接质量。控制室远离焊接施工现场,避免了焊接烟尘和弧光对操作人员的危害。     

基于蓝牙通信的焊接电源数字化控制系统

随着焊接设备的智能化、信息化、自动化和网络化的快速发展,针对以往有线和无线焊接通信系统不易安装升级、抗干扰能力弱、数据传输速度慢等问题,提出了基于蓝牙通信的焊接电源数字化控制系统的设计方案。以TMS320F28033 DSP芯片作为控制系统的核心,设计了焊接电流和电弧电压采样电路、脉宽调制信号放大电路、CAN通信等外围电路,组成了一套焊接电源数字化控制硬件系统。以片上系统CC2540作为蓝牙通信的核心,设计了采用蓝牙4.0协议传输的焊接过程信号无线通信模块,通过蓝牙无线数据传输实现人机交互。无线通信测试结果表明,DSP数字焊机控制系统能够实现焊接过程信号的远程无线传输功能,通信距离远,且数据传输稳定。     

基于nRF24L01的焊接电弧电信号实时无线监控系统

为了实现焊接现场的远程实时监控,研究焊接过程中电弧电信号对焊接质量的影响,提出了一种以射频芯片nRF24L01为收发端,DSP为运算控制核心的焊接电弧电信号实时无线监控系统,分别介绍了系统接口电路的设计以及数据采集、无线传输的软件实现。采用P-GMAW的焊接方式进行试验,试验结果表明系统稳定可靠,可实现对焊接过程的实时监控。     

Effects of Post-weld Heat Treatment on Microstructure,Mechanical Properties and the Role of Weld Reinforcement in 2219 Aluminum Alloy TIG-Welded Joints

In as-welded state, each region of 2219 aluminum alloy TIG-welded joint shows diff erent microstructure and microhardness due to the diff erent welding heat cycles and the resulting evolution of second phases. After the post-weld heat treatment, both the amount and the size of the eutectic structure or θ phases decreased. Correspondingly, both the Cu content in α-Al matrix and the microhardness increased to a similar level in each region of the joint, and the tensile strength of the entire joint was greatly improved. Post-weld heat treatment played the role of solid solution strengthening and aging strengthening. After the post-weld heat treatment, the weld performance became similar to other regions, but weld reinforcements lost their reinforcing eff ect on the weld and their existence was more of an adverse eff ect. The joint without weld reinforcements after the post-weld heat treatment had the optimal tensile properties, and the specimens randomly crack in the weld zone.     

The First Phase of the SRIF Industrialized Base in ＂West Area＂ Has Been Put into Operation

After nearly two years＇ tense construction, the first phase of industrialized base of Shenyang Research Institute of Foundry （SRIF）, located at the Tiexi Casting and Forging Industrial Park in the west of Tiexi District, has now been completed and formally put into operation.     

Thermodynamics Study on the Decomposition of Chromite with KOH

Institute of Process Engineering, Chinese Academy of Sciences, China, has proposed a method for oxidative leaching of chromite with potassium hydroxide. Understanding the mechanism of chromite decomposition, especially in the potassium hydroxide fusion, is important for the optimization of the operating parameters of the oxidative leaching process. A traditional thermodynamic method is proposed and the thermal decomposition and the reaction decomposition during the oxidative leaching of chromite with KOH and oxygen is discussed, which suggests that chromite is mainly destroyed by reactions with KOH and oxygen. Meanwhile, equilibrium of the main reactions of the above process was calculated at different temperatures and oxygen partial pressures. The stable zones of productions, namely, K2CrO4 and Fe2O3, increase with the decrease of temperature, which indicates that higher temperature is not beneficial to thermodynamic reactions. In addition, a comparison of the general alkali methods is carried out, and it is concluded that the KOH leaching process is thermodynamically superior to the conventional chromate production process.     

Influence of Heat Treatment on Damping Behaviour of the Magnesium Wrought Alloy AZ61

The effect of isochronal heat treatments for 1h on variation of damping, hardness and microstructural change of the magnesium wrought alloy AZ61 was investigated. Damping and hardness behaviour could be attributed to the evolution of precipitation process. The influence of precipitation on damping behaviour was explained in the framework of the dislocation string model of Granato and Lücke.     

Effect of Rare Earth Doping on Impedance,Modulus and Conductivity Properties of Multiferroic Composites:0.5(BiLa_xFe_(1-x)O_3)–0.5(PbTiO_3)

The Lanthanum-doped bismuth ferrite–lead titanate compositions of 0.5(Bi LaxFe1-xO3)–0.5(Pb Ti O3)(x = 0.05,0.10,0.15,0.20)(BLxF1-x-PT) were prepared by mixed oxide method.Structural characterization was performed by X-ray diffraction and shows a tetragonal structure at room temperature.The lattice parameter c/a ratio decreases with increasing of La(x = 0.05–0.20) concentration of the composites.The effect of charge carrier/ion hopping mechanism,conductivity,relaxation process and impedance parameters was studied using an impedance analyzer in a wide frequency range(102–106Hz) at different temperatures.The nature of Nyquist plot confirms the presence of bulk effects only,and non-Debye type of relaxation processes occurs in the composites.The electrical modulus exhibits an important role of the hopping mechanism in the electrical transport process of the materials.The ac conductivity and dc conductivity of the materials were studied,and the activation energy found to be 0.81,0.77,0.76 and 0.74 e V for all compositions of x = 0.05–0.20 at different temperatures(200–300 °C).     

Quantitative Analysis of the Crystallographic Orientation Relationship Between the Martensite and Austenite in Quenching–Partitioning–Tempering Steels

The orientation relationships(ORs)between the martensite and the retained austenite in low-and medium-carbon steels after quenching–partitioning–tempering process were studied in this work.The ORs in the studied steels are identified by selected-area electron diffraction(SAED)as either K–S or N–W ORs.Meanwhile,the ORs were also studied based on numerical fitting of electron backscatter diffraction data method suggested by Miyamoto.The simulated K–S and N–W ORs in the low-index directions generally do not well coincide with the experimental pole figure,which may be attributed to both the orientation spread from the ideal variant orientations and high symmetry of the low-index directions.However,the simulated results coincide well with experimental pole figures in the high-index directions{123}_(bcc).A modified method with simplicity based on Miyamoto’s work was proposed.The results indicate that the ORs determined by modified method are similar to those determined by Miyamoto’method,that is,the OR is near K–S OR for the low-carbon Q–P–T steel,and with the increase of carbon content,the OR is closer to N–W OR in medium-carbon Q–P–T steel.     

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates(50 mm thick) by using finite element and contour measurement methods.A three-dimensional finite element model of 50-mmthick titanium component was proposed,in which a column–cone combined heat source model was used to simulate the temperature field and a thermo-elastic–plastic model to analyze residual stress in a weld joint based on ABAQUS software.Considering the uncertainty of welding simulation,the computation was calibrated by experimental data of contour measurement method.Both test and simulated results show that residual stresses on the surface and inside the weld zone are significantly different and present a narrow and large gradient feature in the weld joint.The peak tensile stress exceeds the yield strength of base materials inside weld,which are distinctly different from residual stress of the thin Ti-6Al-4V alloy plates presented in references before.     

Microstructures and Tensile Properties of Ultrafine-Grained Ni–(1–3.5) wt% SiC_(NP) Composites Prepared by a Powder Metallurgy Route

Silicon carbide nanoparticle-reinforced nickel-based composites(Ni–Si CNP),with a Si CNPcontent ranged from1 to 3.5 wt%,were prepared using mechanical alloying and spark plasma sintering.In addition,unreinforced pure nickel samples were also prepared for comparative purposes.To characterize the microstructural properties of both the unreinforced pure nickel and the Ni–Si CNPcomposites transmission electron microscopy(TEM) was used,while their mechanical behavior was investigated using the Vickers pyramid method for hardness measurements and a universal tensile testing machine for tensile tests.TEM results showed an array of dislocation lines decorated in the sintered pure nickel sample,whereas,for the Ni–Si CNPcomposites,the presence of nano-dispersed Si CNPand twinning crystals was observed.These homogeneously distributed Si CNPwere found located either within the matrix,between twins or on grain boundaries.For the Ni–Si CNPcomposites,coerced coarsening of the Si CNPassembly occurred with increasing Si CNPcontent.Furthermore,the grain sizes of the Ni–Si CNPcomposites were much finer than that of the unreinforced pure nickel,which was considered to be due to the composite ball milling process.In all cases,the Ni–Si CNPcomposites showed higher strengths and hardness values than the unreinforced pure nickel,likely due to a combination of dispersion strengthening(Orowan effects) and particle strengthening(Hall–Petch effects).For the Ni–Si CNPcomposites,the strength increased initially and then decreased as a function of Si CNPcontent,whereas their elongation percentages decreased linearly.Compared to all materials tested,the Ni–Si CNPcomposite containing 1.5% Si C was found more superior considering both their strength and plastic properties.     

Directional Growth of Tin Crystals Controlled by Combined Solute Concentration Gradient Field and Static Magnetic Field

A new method was introduced to achieve directional growth of Sn crystals. Microstructures in liquid(Pb)/liquid(Sn) diffusion couples were investigated under various static magnetic fields. Results show that the β-Sn crystals mainly reveal an irregular dendritic morphology without or with a relatively low static magnetic field(B0.3 T). When the magnetic field is increased to 0.5 T, the β-Sn dendrites close to the final stage of growth begin to show some directional character. With a further increase in the magnetic field to a higher level(0.8–5 T), the β-Sn dendrites have an enhanced directional growth character, but the dendrites show a certain deflection. As the magnetic field is increased to 12 T, the directional growth of the β-Sn dendrites in the center of the couple is severely destroyed. The mechanism of the directional growth of the β-Sn crystals and the deflection of the β-Sn crystals with the application of static magnetic field was tentatively discussed.     

电化学噪声数据处理方法概述

综述了常见的电化学噪声数据处理方法,介绍了直流趋势剔除、统计分析、快速傅立叶变换(FFT)法计算功率谱密度(PSD)以及小波变换处理电化学噪声信号的基本过程,并阐释了各种数学处理及所得参数的物理意义。