全熔透钨极惰性气体保护电弧焊熔池流动与传热动态过程的数值分析

针对原有钨极惰性气体保护电弧焊熔池形态模型存在的问题,采用液体分数法处理了固液相变潜热,利用完备的熔池表面变形方程组描述了熔透熔池上、下表面变形方程的耦合作用,进一步提高了熔池形状尺寸与熔池表面变形的数值计算精度。在此基础上,对全熔透GTAW焊接熔池中的流体流动与传热过程和熔池形状的动态变化过程进行了数值模拟,展示了熔池形态的瞬时演变特性。     

基于激光视觉的脉冲GTAW熔池振荡检测与分析

熔池振荡频率与焊缝全熔透状态有较为直接的物理对应关系,但熔池振荡频率的检测十分困难。针对该问题提出一种基于激光视觉的熔池振荡特征频率检测传感新方法。在介绍激光视觉法原理基础上,设计脉冲非熔化极气体保护焊(Gas tungsten arc welding, GTAW)熔池振荡激光视觉传感试验系统。采集反映熔池振荡变化的视频图像,提出激光特征条纹的图像处理算法,并利用Matlab软件编写相应的程序获得熔池振荡波形,利用快速傅里叶变换提取出熔池振荡特征频率。试验结果表明,激光视觉法不仅成功实现脉冲GTAW熔池振荡信号的检测传感,而且克服了已有的脉冲GTAW熔池振荡检测法不能被用于连续焊接的缺陷。软件系统能够较准确地提取出熔池振荡特征频率、处理时间为20 ms,满足熔池振荡信号的实时检测要求,为连续脉冲GTAW熔透控制奠定了基础。     

基于卷积神经网络的GTAW熔透预测

焊接熔池信息能反映熔透状态,但建立熔池与熔透状态的关系十分困难。针对该问题,提出一种基于卷积神经网络(Convolution neural networks,CNN)的GTAW背面熔透预测模型。通过基于被动视觉的熔池二维图像采集,建立了用于CNN网络训练和测试的训练集和测试集。其次建立了CNN背面熔透预测模型,优化了学习率、batch-size、迭代次数等网络参数。研究发现:第一层卷积核尺寸为9×9,最后一层含有64个卷积核使模型在预测准确率和训练时间上综合表现达到最佳。使用训练集数据训练模型,将训练完成的模型在测试集上对背面熔透进行预测,取得了高于96%的预测准确率。通过对预测模型的特征映射进行可视化分析,模型是通过熔池边缘,反光点位置和熔池尾部等特征来预测背面熔透情况。     

连续脉冲GTAW不同熔透状态熔池振荡 频率特征及分析*

熔池振荡频率与熔池尺寸具有直接物理对应关系,但常规弧压、弧光方法很难实现连续焊接振荡频率提取。提出一种激光视觉测量方法用于连续焊接振荡频率检测。对连续焊接条件下部分、临界及全熔透状态下的熔池振荡激光条纹进行采集,通过图像处理算法提取不同熔透状态下的频率特征,并从激光条纹变化形态、熔池表面振荡和液态金属内部流动对不同频率特征进行分析。结果表明,激光视觉法能够精确检测熔池表面金属轴向及横向的流动;在部分和全熔透状态下熔池表面及内部金属以单一模式进行振荡,存在单一特征频率;在临界熔透状态下由于熔池约束条件的变化,使其表面振荡及内部金属振荡具有部分和全熔透的振荡特征,表现出两种特征频率;不同熔透状态的振荡频率特征可为精确检测不同熔透状态提供依据。     

钨极氩弧焊熔透熔池塌陷倾向的预测

对钨极氩弧焊(GTAW)全熔透熔池进行受力分析,建立熔透熔池的力学模型,提出熔池塌陷的力学判据.利用所建立模型计算并讨论影响熔池塌陷的各个作用力的动态变化、大小和百分比组成,并预测钨极氩弧焊焊接不锈钢和低碳钢薄板时在不同焊接速度下的合适焊接电流范围.试验结果与理论预测相一致,验证了所建立模型的实用性.     

TIG焊接熔透熔池形状和表面变形的数值模拟

利用建立的三维TIG焊接熔池瞬时行为数值分析模型,对移动热源作用下不锈钢薄板全熔透时熔池动态行为进行了数值分析。结果表明,同时采用电弧热流和电弧压力的双椭圆分布模式,相对于高斯分布模式,计算出的熔池形状和表面变形与试验结果吻合得更好。给出运动电弧作用下熔池表面变形的动态演变,分析了与固定电弧焊接时的异同,为运动电弧作用下TIG焊接的数值模拟与智能控制提供了理论依据和试验数据。     

非熔化极气体保护焊接熔池表面形貌三维传感及其装置设计

熔池表面形貌的传感及其三维恢复在焊接机理研究和成形控制中均有着深远的意义,然而焊接过程中强弧光的干扰和熔池表面的镜面特性使得熔池表面的三维传感非常困难。利用小功率结构光条纹激光器投射激光条纹于非熔化极气体保护焊(Gas tungsten arc welding, GTAW)熔池表面,由成像屏接收熔池表面镜面反射过来的激光条纹,利用镜头前附加了与激光器波长匹配的窄带滤光片的电荷耦合器件(Charge-coupled device, CCD)摄像机观察成像屏上的条纹变化,从而获得熔池表面的高度等三维信息。为了便于研究传感规律及确定传感器结构参数间的最佳组合,设计了一套传感装置,并利用该传感装置在强弧光下获得了清晰的能够反映GTAW熔池表面形貌的激光反射条纹图像。     

穿孔型双面电弧焊的传热与小孔形成

建立了穿孔型双面电弧焊小孔形态和传热的数学模型,考虑了作用于熔池上的各种力学因素,并采用帖体曲线坐标系处理复杂的熔池表面和小孔与熔池的边界。计算结果表明,熔透是穿孔的必要条件,熔透之后穿孔的速度远远大于熔透之前的。随着板厚的增加,熔透和穿孔所需的时间增加,并且熔透到穿孔的时间间隔也增大,但熔池的最小跨距变化不大,熔池的最小跨距可作为小孔建立的评价指标。小孔的形成使得焊接能量更加集中于电弧中心线附近,从而可以采用较小的焊接热输入,不开坡口一次焊透焊件。     

熔透状态识别预测与控制技术研究现状

焊接过程中,熔透是保证焊缝质量的前提,实时监控焊缝熔透状态对实现自动化焊接和保证焊接质量具有重要的工程意义.在焊接过程中,可以通过分析熔池动态特征参数、焊接电参数、电弧声信号等识别预测熔透状态,从而实现控制熔透.近几年来,国内外专家学者在焊缝熔透方面取得了大量的研究成果.本文综述了较前沿的基于学习模型、数学建模、神经网...     

变极性等离子弧焊接熔透信息的检测与分析

通过对铝合金3003变极性等离子弧穿孔立焊熔池振荡行为的研究,发现熔池振荡频率与焊接熔透之间的内在规律。在变极性电流的作用下,焊接熔池产生振荡,可以通过对电弧电压频谱分析获得熔池固有振荡频率。分别建立变极性等离子弧穿孔立焊未熔透及完全熔透熔池模型,并分析焊接电流的变化对熔池固有振荡频率的影响,发现焊接电流大小对其影响很小,可以忽略。为了验证该模型的准确性,进行理论与实测分析,结果表明,理论值与实测值相吻合。熔池固有振荡频率主要取决于熔池宽度、深度及材料密度等参数,而其他焊接参数对其没有直接影响。因此,熔池振荡频率可间接反映焊接熔透信息,为焊接质量自动控制提供了理论支持。     

Dynamic equations of a multi-stage isolation system

Under the assumption of small vibrations, from deducing a space body’s kinetic energy, an isolator’s potential energy, damping dissipating energy and substituting into Lagrange’s equation, this paper establishes a multi-stage isolation system’s dynamic equations. A multi-stage isolation system’s dynamic equations can be described in a body’s local coordinates, as well as the system’s global coordinates. This paper proves that the two sets of equations are uniform. An example was calculated by the newly deduced equations and the finite element method. The natural frequencies of the system show that the results produced by the newly deduced equations are exact and accurate.     

转动刚体上柔性悬臂梁的动力学建模与仿真

对固结在转动刚体上柔性梁的动力学问题进行了研究。采用拉格朗日方程建立了 2种不同情形的转动刚体上柔性悬臂梁系统的动力学方程。引入了由离心力作用使柔性梁沿轴向产生变形而引起的拉伸势能所带来的广义力项,使系统产生了动力刚化效应。针对第二种情形,对不同惯量比时的系统耦合与非耦合方程进行了仿真,并通过仿真计算比较说明非耦合方程的局限性。     

Trajectory planning of mobile robots using indirect solution of optimal control method in generalized point-to-point task

This paper presents an optimal control strategy for optimal trajectory planning of mobile robots by considering nonlinear dynamic model and nonholonomic constraints of the system. The nonholonomic constraints of the system are introduced by a nonintegrable set of differential equations which represent kinematic restriction on the motion. The Lagrange’s principle is employed to derive the nonlinear equations of the system. Then, the optimal path planning of the mobile robot is formulated as an optimal control problem. To set up the problem, the nonlinear equations of the system are assumed as constraints, and a minimum energy objective function is defined. To solve the problem, an indirect solution of the optimal control method is employed, and conditions of the optimality derived as a set of coupled nonlinear differential equations. The optimality equations are solved numerically, and various simulations are performed for a nonholonomic mobile robot to illustrate effectiveness of the proposed method.     

基于能耗指标的拟人机器人步态优化与分析

通过引入基于平均功率、平均功率偏差、平均力矩损耗三个能耗指标对拟人机器人步态进行了优化与分析.基于拉格朗日方程推导了各个关节驱动力矩的计算公式,建立了拟人机器人步态优化的数学模型.使用Matlab作为优化与仿真工具,得到了一組拟人机器人步态参数最优解,分析了拟人机器人各个步态参数与拟人机器人能量消耗之间的关系.并给出了拟人机器人步态优化与分析的数值实例.     

活齿传动啮合效率的新算法与应用分析

利用第二类拉格朗日方程,建立活齿传动输入与输出力矩的关系方程式,分析运动参数对输入、输出力矩关系的影响;提出一种具有"中间体"传动方式的啮合效率计算方法,并利用活齿传动实例分析计算啮合效率.     

Modeling of heat transfer and fluid flow during gas tungsten arc welding of commercial pure aluminum

In the present study, the temperature and the velocity fields during gas tungsten arc welding of commercial pure aluminum were simulated using the solution of the equations of conversation of mass, energy and momentum in three dimensions and under steady-state heat transfer and fluid flow conditions. Then, by means of the prediction of temperature and velocity distributions, the weld pool geometry, weld thermal cycles and various solidification parameters were calculated. To verify the modeling results, welding experiments were conducted on two samples with different thicknesses and the geometry of the weld pool was measured. It is found that there is a good agreement between the predicted and the measured results. In addition, dimensional analysis was employed to understand the importance of heat transfer by convection and the roles of various driving forces in the weld pool. It is observed that the molten metal convection strongly affects on the weld pool geometry. Also the predictions make it possible to estimate the morphology and the scale of the solidified structure through solidification parameter (G/R). The result show that as the net heat input increases, the importance of convection becomes higher and the value of G/R at the weld pool centerline increases.     

Robust adaptive antiswing control of underactuated crane systems with two parallel payloads and rail length constraint

The antiswing control and accurate positioning are simultaneously investigated for underactuated crane systems in the presence of two parallel payloads on the trolley and rail length limitation. The equations of motion for the crane system in question are established via the Euler–Lagrange equation. An adaptive control strategy is proposed with the help of system energy function and energy shaping technique. Stability analysis shows that under the designed adaptive controller, the payload swings can be suppressed ultimately and the trolley can be regulated to the destination while not exceeding the pre-specified boundaries. Simulation results are provided to show the satisfactory control performances of the presented control method in terms of working efficiency as well as robustness with respect to external disturbances.     

柔性臂刚柔耦合动力方程的数值方法

在拉格朗日体系下,对同时具有关节和臂杆柔性的机械臂(下述简称柔性臂)系统进行动力学建模,从能量角度证明了传统数值积分方法求解微分方程时的不稳定性。论述了计入耗散力的拉格朗日体系转化为哈密顿体系求解时的困难,由此引入状态空间向量,得到与哈密顿模型等价的形式。采用精细时程积分算法(PIM)对所建刚柔耦合强刚性动力方程的数值求解,指出了传统PIM的局限性,并通过增维的方式将非齐次动力方程转化为齐次形式,避免了矩阵求逆造成的奇异现象,得到了逼近精确解的精细数值结果。     

Theoretical and experimental study of microstructures and weld pool geometry during GTAW of 304 stainless steel

In this work, temperature field and weld pool geometry during gas tungsten arc welding of 304 stainless steel are predicted by solving the governing equations of heat transfer and fluid flow under quasi-steady state conditions. The model is based on numerical solution of the equations of conservation of mass, momentum, and energy in the weld pool. Weld pool geometry, weld thermal cycles, and various solidification parameters are then calculated by means of the model predictions. The model considers the effects of various process parameters including welding speed and heat input. It is found that the weld pool geometry, predicted by the proposed model, is in reasonable agreement with the corresponding experimentally measured ones. In addition, the solidification behavior of the weld pool can be predicted properly by the model predictions.     

Energy scale of the average stresses and physical properties of metals in the region of reversible and irreversible deformations

Expressing the specific energy increment of a mechanical system in terms of variations of the kinematic invariants of motion equations in the Lagrange form, a hypothesis has been proposed concerning the existence of new physical properties of materials that determine the mechanism of the self-organization of reversible and irreversible deformations, as well as the variation of the mechanical properties with consideration of the previous history of deformations and variations of the ambient conditions. An energy interpretation of the notion of “generalized force” has been proposed, as well as the energy scale of average stresses by analogy with the thermodynamic scale of temperatures with an example of their calculation for certain metals.