焊接机器人智能控制厚板焊接一次成形

利用CCD摄像机观察熔池图像及焊接过程,并将图像转换为数字信息,利用计算机采集并处理这些信息,控制焊接速度、焊枪摆动幅度和熔滴的过渡,使厚板焊接一次成形.     

CO2短路过渡焊接熔池图像传感器

针对CO2短路过渡焊接熔池图像实时检测的要求，研制了一种基于普通工业CCD摄像机的专用传感器。介绍了该传感器紧凑的机械结构和独特的光学设计，设计了可消除CCD摄像机固定工作时序与CO2短路过渡发生的随机性之间的矛盾的实时检测熔池图像的控制时序，给出了相应的图像检测系统的工作原理。试验表明，采用该图像传感器可以围绕焊枪轴线从不同角度快速、准确地获得清晰的熔池图像。     

连续电流TIG焊熔池图像的低成本自动化检测

改进了普通CCD摄像机镜头，使物距、放大倍数的调节范围进一步扩大。通过试验和统计的方法，调整物距、光圈、快门等光学参数，增大景深，提高对比度，拍摄出了分辨率较高的熔池图像。对大量的焊接熔池图像进行了分析，根据图像的特点，设计出了不需要滤波的图像边缘检测算法，检测出了连续电流TIG焊接熔池的整个边缘。与激光频闪视觉检测仪拍摄的熔池图像进行了对比，结果表明该低成本自动化检测装置所拍摄的熔池图像也达到了较高的清晰度与对比度。     

厚铜板焊接的计算机模拟与实验研究

基于焊接模拟前处理软件和焊接模拟后处理软件进行厚铜板三个电弧焊接过程温度场的数值模拟和实验对比研究。先利用前处理软件进行建模和划分网格等工作,再利用后处理软件完成焊接仿真模拟过程。本研究主要是用后处理软件调整焊接电流、电弧电压、焊枪间距、焊接速度,送丝速度等工艺参数,进行多组工艺参数下厚铜板焊接温度场的模拟,然后对比分析不同焊接工艺参数下的焊接温度场云图,获得最佳焊接工艺参数(焊枪间距16 mm,焊接电流300 A,TIG焊枪电压16 V,MIG焊枪电压20 V,MIG焊枪送丝速度10 mm/s),模拟结果为:MIG焊枪的熔池大小为:熔宽6.4 mm、熔深4.8 mm、熔池长度12.6 mm。     

管道全位置焊接熔池监测试验研究

在管道全位置自动焊接过程中,焊接熔池形态监测对焊接质量控制有重要意义。设计一套熔池监测试验装置,方便采集清晰的熔池图像。运用图像处理技术检测熔池边缘。用熔池长度、熔池宽度以及熔池头部轮廓二项式系数等特征参数重新定义熔池形态。应用正交试验法和极差分析法,研究在仰焊区段焊接电流、电弧电压以及焊枪摆速等因素组合变化时对熔池形态的影响程度。结果表明:采用优化的焊接工艺参数组合,可以获得良好的焊缝成形质量。     

连续电流TIG对接焊熔池形状参数的视觉检测

利用普通CCD摄像机，拍摄出了分辨率较高的TIG对接焊熔池图像，对焊接熔池图像进行分析，根据图像的特点，设计出了图像边缘检测算法，检测出连续电流TIG对接焊熔池的整个边缘，通过对熔池图像进行标定，得到了熔池实际的几何参数尺寸。     

低成本等离子弧焊缝跟踪软件系统

采用低成本CCD焊接过程视觉传感设备，实现了一种PAW焊缝实时跟踪系统，从PAW熔池后方拍摄获取图像，识别出了熔池图，识别出了熔池图像最亮点，以它作为熔池中心得到了焊缝偏差的实时曲线。设计了相应的实时控制软件，其控制周期的响应时间达到43ms.     

基于结构光的水下焊接熔池宽度在线检测

直接拍摄水下焊接熔池图像来检测焊接熔池宽度实现难度较大,提出了一种通过成形焊缝结构光条纹图像来完成水下焊接熔池宽度在线检测的方法.将装有防水罩的激光结构光视觉传感器安装在焊枪之后置于水下,针对水下成形焊缝图像特点,经图像加窗、拉普拉斯锐化、二值化以及数学形态学滤波和图像细化处理,就能够在线获得焊接熔池宽度.结果表明,处理过程速度快,检测结果精度高.当条纹检测点和熔池中心之间的距离小于35 mm时,焊接熔池宽度相对误差可控制在3%以内.     

铝合金交流TIG焊接熔池动态控制图像传感方法的研究

在光谱分析的基础上，设计了全新的光学传感器，利用普通工业CCD摄像机获得了清晰的铝合金焊接熔池区域图像，为进一步控制铝合金焊接熔池动态打下了良好的基础。     

三电极高速CO_2双边角焊质量及稳定性分析

对三电极高速CO2双边角焊焊接工艺进行研究,通过LabVIEW电信号采集与高速摄影分析了焊接质量及过程稳定性.结果表明,焊接中引导电流应为最大,且引导焊枪与中间焊枪之间电流差距100A左右可获得理想的焊缝成形,中间焊枪与跟随焊枪的电流差距大小对焊接质量无明显影响,且焊枪指向位置在底板为宜.在同一工艺时,随着焊接速度增大,焊接过程变得不稳定,同一焊接速度时,试验电流400/300/300A组合时焊接过程最稳定.大电流组合时,应增大焊丝之间距离以减小电弧之间的干扰.     

Detecting and tracking of welding line in visual plasma robotic welding

The formation of stable back beads in joining of the thick materials is important in order to achieve high-quality welded metal joints. Plasma welding uses the high welding current density, which is suitable for thick materials. The keyhole in the plasma welding depends on the pilot gas and the welding current. The voltage behaviour depends on the keyhole situation. If the torch is moved away from the welding line in conventional GMA welding, the welding voltage and the welding current are changed due to variations of the arc length. But the welding voltage does not change with the arc length in plasma welding, because the welding voltage depends on the situation of the keyhole. The authors tried to observe the weld pool on the top side by using a CCD camera. The timing of the shutter in the CCD camera is investigated to take clear images of the weld pool. As a result, the clear images of the weld pool were taken when the welding current was reduced to 30 A and an interference filter of 950 nm was attached to the CCD camera. The weld pool shape was changed with the torch position in the groove. The image-processing method was developed to detect the top of the weld pool. The torch position was estimated by processing the weld pool images. The digital control was designed to trace the welding line. The performance of the controller was verified by carrying out tracking experiments.     

Sensing and seam tracking of welding line in backingless V groove welding

Abstract

The formation of stable back beads in the first layer weld during one side multilayer welding is important to achieve high quality welded metal joints. The authors tried to apply the switch back welding method to butt welding to join discs with flat metal plates without backing plates. During the welding, the gap was detected by processing the weld pool image taken with a CCD camera. Moreover, the tip of the electrode wire is changing owing to a curve of its wire extension in accordance with a rotation of the torch axis. Even though teaching is achieved before the welding, the weaving centre is shifted from the gap centre. The controller of the seam tracking was designed to prevent any steady state error.     

Application of switch back welding to V groove MAG welding

The formation of stable back beads in a root pass weld during one side multi-layer welding is important to achieve high quality welded metal joints in MAG welding. The authors employed the switch back welding method for V groove joints without backing plates. In this switch back welding method, the torch moves forward and backward with an oscillation frequency of 2.5 Hz. In order to achieve this welding, personal computers control the conventional welding robot, the power source characteristic and the wire feeder unit. During the forward, the torch is weaving on the V groove gap without the weld pool. If the weaving width becomes wider than the proper width, the tip of the wire becomes high and a good back bead cannot be obtained. The weaving width is adjusted so as to get the proper width in the switch back welding. The suitability of the welding conditions for each root gap was verified by observation of the arc, the weld pool and the external appearance of back beads. A good back bead was obtained under V groove welding in 2–4 mm gap.     

An optical sensing system for seam tracking and weld pool control in gas metal arc welding of steel pipe

A visual sensing system was developed for automatic gas metal arc welding (GMAW) of the root pass of steel pipe. The system consisted of a vision sensor that consisted of a charge-coupled device (CCD) camera and lenses, a frame grabber, image processing algorithms, and a computer controller. A specially designed five-axis manipulator was used to position the welding torch and to provide the vision sensor with automatic access to view the welding position. During the root pass welding, an image of the weld pool and its vicinity was captured using the camera without interference of the intensive arc light by viewing at the instance of a short-circuit of the welding power. The captured image was then processed to recognize the weld pool shape. For seam tracking, the manipulator was used to adjust the torch position based upon the pool image to the groove center. The measured gap size was used to determine the appropriate welding conditions to obtain sound penetration. The welding speed was chosen using fuzzy logic with the knowledge of a skilled welder and measured gap. The automatic welding equipment demonstrated that both welding conditions and torch position could be appropriately controlled to obtain a sound weldment and a good seam tracking capability.     

TIG焊接熔池形状参数的视觉检测

在分析ＴＩＧ焊接电弧光谱的基础上,设计出复合滤光镜头,与普通ＣＣＤ摄像机组成视觉传感器,从试件正面观测熔池图像,焊接过程中根据电流大小通过软件调整采集图像亮度,得到了比较清晰的ＴＩＧ焊接熔池图像,利用自行开发的图像处理算法,检测了熔池正面的形状参数。该算法处理一幅图像同时不超过７０ｍｓ,满足实时检测的需要。     

基于视觉图像传感的精密脉冲TIG焊焊缝跟踪

针对某复杂曲面薄壁不锈钢工件精密脉冲TIG焊中的焊缝跟踪问题 ,本文研究了一种基于视觉传感的高精度、高实时性焊缝跟踪技术。根据脉冲TIG焊的工艺特点 ,该技术通过选择特定波长的滤光片及合理的曝光时刻 ,采用工业CCD摄像机获取可直接分辨出焊缝、熔池和钨极的清晰、放大的焊接区图像。采用VC语言设计的图像处理算法 ,可以快速准确地识别出焊缝中心线 ,提取钨极偏离焊缝中心线的方向和距离 ,驱动步进电机调节焊炬位置 ,实现高精度、高实时性的焊缝跟踪。试验结果表明 ,该技术的单幅图像处理周期小于 12 0ms,能实现焊炬运动方向与焊缝偏差角小于 3 0°的焊缝跟踪 ,满足了复杂曲面的薄壁不锈钢工件的精密焊接要求。     

Image processing and control of weld pool in switch-back welding without backing plate

To achieve high quality in multilayer welding, it is important to obtain stable weld results for the first layer.^1-5 For this reason, welding is usually conducted by using a backing of the same kind as the base material or a ceramic backing plate. In using a backing metal, the weight of the base material increases. Also it sometimes induces notches to occur at the weld joint between the base material and the backing. This can cause cracking. On the other hand, in using the backing plate, its removal is required after welding, and this makes the method unsuitable for automating the process. Therefore, in the authors' previous report, a proposal was made of the switch-back welding method in which welding is executed without using a backing plate, and also an investigation was made of the welding conditions for the root gap.⁶ In this welding method, it is necessary to adjust the wire feeding rate, the torch motion and the power property in accordance with the gap so that the back bead and the deposit can be controlled. Even if the gap is measured before welding, it may change owing to welding distortion. Hence, when welding is conducted by fixing the welding conditions, the change in the gap causes the back bead to become unstable. For this reason, in this study, a method is discussed to detect the gap on-line by processing images of the molten pool observed by a CCD camera. Then, using the results, the back bead was feed-forward-controlled in real time. Moreover, to examine the controlling performance, welding was conducted by varying the gap between 4.6 mm and 2.5 mm without tack welding. Very good weld results were obtained.     

基于网格激光的TIG焊熔池三维表面凹凸性分析

针对钨极惰性气体保护焊熔池三维表面测量的问题,提出了基于网格结构激光熔池表面反射的测量方法,并使用CCD采集投影在成像屏上的反射结构激光视屏图像.在此基础上,分别对标准的凹面和凸面反射激光成像进行了标定与分析,进一步对不同电流大小的TIG焊过程中的熔池表面所反射于成像屏上的激光网格信息进行了分析,分析了熔池自由表面的凹凸性.结果表明,采用网格激光能更好的反映熔池表面的凹凸情况,且随着焊接电流的增加,熔池表面由凸面慢慢开始向中间凹陷转变.     

Analysis of submerged arc welding process by three-dimensional computational fluid dynamics simulations

The effect of torch angle and current polarities on the convection heat transfer in single wire submerged arc welding is analyzed. To develop arc models such as arc heat flux, arc pressure and electromagnetic force, this study adopts the Abel inversion method with CCD camera images for direct and alternating current polarities. The heat transfer by molten slag from the flux consumption is considered as an additional boundary heat source in the numerical simulation. The variation of arc forces, the direction of droplet flight with polarity and the torch angle significantly affect the molten pool flow and the resultant weld beads. The simulated weld pool profiles are validated with corresponding experimental results and found to be in good agreement.