干扰因素下钢TIG焊电弧光谱的研究

通过对干扰因素下TIG焊电弧的光谱信息进行采集,研究了气流量变化、焊接试件表面存在锈等干扰因素对焊接过程电弧光谱分布的影响,并基于光谱分布的分析,进一步探讨了不同光谱谱段对干扰因素的反映,寻求实现焊接过程质量在线光谱测控的理论依据。研究结果表明：干扰因素在焊接电弧光谱信号不同谱段（220～300nm、300～430nm、430～520nm、530～680nm、700～900nm、900～1000nm）的分布和变化规律不同,其中220～300nm对应谱段以FeⅡ谱线的影响为主,在700～900nm对应谱段以ArⅠ谱线的影响为主,在此两个谱段干扰因素响应较明显。历史通道采集结果表明,干扰在250～350nm、700～830nm谱段,信号特征非常明显,具有很好的信噪比,并且不同干扰因素在特征谱段的反映具有自身特点,可据此对干扰因素进行分类判识。     

干扰因素下钢TIG焊电弧光谱的研究

通过对干扰因素下TIG焊电弧的光谱信息进行采集,研究了气流量变化、焊接试件表面存在锈等干扰因素对焊接过程电弧光谱分布的影响,并基于光谱分布的分析,进一步探讨了不同光谱谱段对干扰因素的反映,寻求实现焊接过程质量在线光谱测控的理论依据。研究结果表明：干扰因素在焊接电弧光谱信号不同谱段（220~300nm、300~430nm、430~520nm、530~680nm、700~900nm、900~1000nm）的分布和变化规律不同,其中 220~300nm对应谱段以FeⅡ谱线的影响为主,在700~900nm对应谱段以ArⅠ谱线的影响为主,在此两个谱段干扰因素响应较明显。历史通道采集结果表明,干扰在250~350nm、700~830nm谱段,信号特征非常明显,具有很好的信噪比,并且不同干扰因素在特征谱段的反映具有自身特点,可据此对干扰因素进行分类判识。
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焊接电弧紫外光谱信息的获取与分析

针对焊接电弧紫外光谱信息的研究 ,研制了一套焊接电弧紫外光谱计算机采集和处理系统。利用此系统对 TIG焊电弧紫外光谱进行了研究 ,成功地获得了不同焊接规范下的电弧紫外光谱频谱分布特征 ,并对此进行了分析     

电弧声信号与铝合金MIG焊缝塌陷的相关性

针对铝合金MIG焊过程热积累作用强容易产生焊缝突然塌陷从而导致焊接过程失败的问题,建立电弧声信号传感系统并以焊接电弧声为研究对象,运用小波分析方法研究焊接电弧声信号与焊缝塌陷的相关性。研究表明电弧声信号的能量变化与焊缝塌陷有着明显的对应关系,电弧声总能量随着焊缝开始塌陷而增加,对电弧声进行小波分解发现不同频带有着不同的变化规律。研究结果为铝合金MIG焊实时焊接塌陷缺陷的检测提供一种新型有效的方法。     

药芯焊丝GMAW电弧光谱的研究

通过对药芯焊丝DW-100,K-71TLF,不锈钢焊丝SQ A309L和实芯焊丝W H-50-6计4种焊丝M IG焊电弧的光谱信息进行采集,基于电弧光谱分布的分析,通过对试验采集得到GM AW焊电弧光谱信息,进行了特征谱段的选取和标定,得到了DW-100、K-71TLF、W H-50-6、SQ A309L焊丝的谱线成分,分析了4种焊丝谱线成分元素的作用。并对比了实芯焊丝W H-50-6和不锈钢焊丝SQ A309L与钛型药芯焊丝K-71TLF和DW-100焊丝光谱谱线的差异。     

以电弧光谱信号传感MIG/MAG焊熔滴过渡的工艺适应性

熔滴过渡控制的实现，取决于获得宽工艺适应性的熔滴过渡传感信号。通过试验，获取了熔化极气体保护焊电弧，在不同熔滴过渡形式下的光谱分布、谱线信号的时域波形和频域特征。对试验结果的分析表明，电弧光谱信号在上述诸方面均表现出对不同熔滴过渡形式的适应性，是一种有潜力的高品质熔滴过渡信号源。     

基于小波消噪与LMD的埋弧焊交流方波电弧信息提取

埋弧焊交流方波电弧电信号存在畸变,影响焊接过程电弧稳定性和焊缝成形质量,针对于此,在对采集的埋弧焊交流方波电弧电流信号进行小波包降噪后,利用局部均值分解(local mean decomposition,LMD)对电弧电流信号进行自适应分解,获得若干个具有真实物理意义的PF(product function)分量,并对PF分量集进行Hilbert变换及能量熵计算。结果表明,利用小波消噪与LMD能有效得到埋弧焊交流方波电流波形畸变的不同频率成分及其幅值在时间特征尺度上的变化特征,在此基础上通过Hilbert变换及能量熵计算可以有效提取反映焊接过程电弧稳定性和焊缝成形质量的电弧特征信息。     

基于人耳听觉模型的MIG焊熔滴过渡状态识别

针对强噪声干扰下熔化极惰性气体保护焊(Melt inert-gas,MIG)的熔滴过渡状态识别问题,提出一种基于人耳听觉模型的电弧声熔滴过渡状态识别算法。采用外耳和中耳传递函数对电弧声信号进行变换,模拟耳蜗的功能对变换后的电弧声信号进行频率分解,并求分解后各频带内信号的响度功率,根据不同频带的响度功率构建电弧声的特征矢量,采用支持向量机根据获得的特征矢量实现熔滴过渡状态的识别。试验结果表明,该算法可以很好地抑制由于焊接电流的低频变化引起的电弧声低频波动,对熔滴过渡状态的识别率达到了98%以上。为了验证算法的抗噪声干扰能力,在原始信号的基础上,分别施加了不同信噪比的白噪声和环境噪声,结果表明,所提出的算法具有优良的抗噪声干扰能力,从而为焊接质量在线监控提供了一种新方法。     

焊接电弧紫外光谱信息的计算机采集与处理系统

以焊接电弧紫外光谱的分布特征为研究对象,研制了一套焊接电弧紫外光谱计算机采集与处理系统并开发了相关软件,实现了紫外光谱采集过程的自动化、焊接电流与电弧电压的实时监测,并在电弧物理和光谱学原理的基础上,对采集的焊接电弧紫外光谱信息进行变换和处理。     

MIG焊电弧声信号与熔透状态相关性

电弧声作为焊缝熔透状态监控的潜在源信号,对焊接过程质量控制和自动化生产的实现具有重要意义.以MIG焊平板对接射流过渡过程中产生的非平稳电弧声信号为研究对象,采用小波变换技术取得了良好的信噪分离效果,达到有效抑制噪声目的.在此基础上,通过合理地选择样本数据,从时域、频域和时频联合3个角度研究分析电弧声信号与焊缝熔透状态之间的内在相关性,发现电弧声信号能量及其频谱特性与熔透状态高度相关,其中1 500～4 500 Hz频率段信号能量的变化可准确地检测出焊接过程熔透状态的改变.结果表明利用电弧声信号进行熔透状态监控是可行的,为MIG焊接过程质量监控提供了一种廉价而有效的新途径.     

熔滴过渡光谱传感与控制的研究

焊接电弧光谱是一个丰富的信息源,电弧的各种物理过程都能在电弧光谱中体现,利用电弧光谱信息能很好地检测和控制脉冲焊熔滴过渡。对电弧光谱辐射情况和对光辐射和接收系统进行了深入的研究和分析,抛弃了一般特征光谱检测设备所必需采用的光谱仪和复杂的光路系统,选用干涉滤光片,选择光谱窗口,设计并制作小型光谱传感器。对喷射过渡过程进行了熔滴过渡检测,利用光谱信息实现了脉冲焊熔滴过渡精确控制为焊接过程精确控制提供了一种新的方法和手段。     

不锈钢等离子弧焊熔池小孔行为的弧光传感研究

针对不锈钢穿孔等离子弧焊过程,熔池小孔的特征行为与弧光光谱辐射强度之间的关系进行了光谱试验研究。随着小孔的形成与闭合,弧光光谱辐射强度产生了形似于负脉冲信号的显著跃变,该跃变信号对于预测小孔的形成和闭合是极为有利的,而且通过检测敏感谱线的辐射强度可以优化传感信号品质。     

BASIC THEORY AND METHOD OF WELDING ARC SPECTRAL INFORMATION

Arc spectral information is a rising information source which can solve many problems thatcan not be done with arc electric information and other arc information. It is of important signficanceto develop automatic control technique of welding process. The basic theory and methods on it play animportant role in expounding and applying arc spectral information. Using concemed equation inplasma physics and spectrum theory a system of equations including 12 equations which serve as basictheory of arc spectral information is set up. Through analyzing of the 12 equations, a basic view thatarc spectral information is the reflection of arc state and state variation, and is the most abundant in-formation resource reflecting welding arc process is drawn. Furthermore, based on the basic theory thebasic methods of test and control of arc spectral information and points out some applications of it arediscussesed.     

BASIC THEORY AND APPLICATIONS OF WELDING ARC SPECTRAL INFORMATION

Welding arc spectral information is a rising welding information source.In some occa- sion,it can reflect many physical phenomena of welding process and solve many problems that cannot be done with arc electric information,acoustic information and other arc information.It is of important significance in developing automatic control technique of welding process and other similar process.Many years study work on welding are spectral information of thc anthor are dis- cussed from three aspects of theory,method and application.Basic theory,view and testing methods of welding arc spectral information has been put forward.In application aspects,many applied ex- amples,for example,monitoring of harmful gases in arc(such as hydrogen and nitrogen)with the method of welding arc spectral information;welding arc spectral imaging of the welding pool which is used in automatic seam tracking;controlling of welding droplet transfer with welding arc spectral information and so on,are introduced.Especially,the successful application in real time controlling of welding droplet transfer in pulsed GMAW is introduced too.These application examples show that the welding arc spectral information has great applied significance and development potentiali- ties.These content will play an important role in applying and spreading welding arc spectral infor- mation technology.     

Application of arc plasma spectral information in the monitor of Al–Mg alloy pulsed GTAW penetration status based on fuzzy logic system

In this paper, an intelligent fuzzy system based on arc spectral information was proposed to recognize the weld penetration status. A spectrometer and a visual sensor were used simultaneously to collect the arc spectral and visual information about the Al–Mg alloy pulsed GTAW process, respectively. Principal component analysis was utilized for spectral line identification, redundancy removal and spectral characteristic signals extraction; wavelet packet denoising technique was used to filter these signals. The relationship between the penetration status under different welding conditions and the corresponding spectral signals was discussed and clarified. Finally, a fuzzy system based on the spectral signals was developed and successfully used to estimate the percentage index of the weld penetration status. With a binary decision of penetration index, the average recognition rate for the penetration status about the specific welding conditions was no less than 82.1 %.     

陶瓷与不锈钢的焊接

用电弧焊方法焊接陶瓷与不锈钢,研究了焊接电流、电弧长度等工艺参数对焊接质量的影响。结果表明,在陶瓷金属复合材料的陶瓷层上焊接不锈钢,焊接加热不仅可以改善复合钢管中陶瓷与金属的结合方式,在焊接区实现的陶瓷与金属的微冶金结合,而且焊接后的陶瓷内衬复合钢管的压－剪强度明显增加,焊缝为柱状枝晶组织,焊接熔合区的陶瓷受焊接热作用由原来的树枝晶改变为细小的等轴晶,陶瓷与母材呈现微冶金结合方式,焊接影响区陶瓷仍保留树枝晶特征。     

Effect of laser on the welding process of short-circuiting transfer MIG welding of aluminum alloys

In this paper, the effect of laser on the welding process in metal inert gas (MIG) welding of aluminum alloys was studied exploiting high-speed imaging and welding electrical signals collecting. Bead-on-plate welding experiments were conducted using conventional short-circuiting transfer MIG welding and laser-short-circuiting transfer MIG hybrid welding. The obtained results point out that it took less time to strike the arc in laser-MIG hybrid welding, and the stability of arc striking was increased. When the laser was introduced into the arc atmosphere, the arc was compressed, and the welding energy was more concentrated. The arc cathode spot was fixed to the laser beam impinging spot, so the arc could burn stably. In laser-MIG hybrid welding, the droplet short-circuiting transfer stability and the weld appearance were improved significantly. Moreover, an analysis method of judging droplet transfer stability which bases on statistical techniques was proposed. By this method, it can be concluded that the short-circuiting transfer process became more stable in laser-MIG hybrid welding.