基于焊枪与熔池耦合模型的焊工调控行为研究

模拟解析有经验高级焊工焊接行为并实现抽象焊接行为的程序化无疑是快速发展机器人智能化焊接的优选路径之一。而同步传感测量焊工焊枪姿态和熔池状态是实现焊接行为程序化的关键。针对现有焊枪姿态和熔池特征测量系统的独立性及焊工与熔池交互过程的同步耦合分析需求，建立了传感器-万向节-焊枪钨极尖端三坐标系间的数学转换模型和熔池与焊枪钨极尖端运动坐标的双向耦合模型。通过预设机器人焊枪姿态摆动试验验证了双向耦合模型的有效性和准确性。在时空同一坐标下对比分析了不同焊接水平焊工对熔池状态的调控行为和焊缝成形质量的控制能力。结果表明，利用熔池-焊枪双向耦合模型可以获得能够表征焊工操控焊枪空间运动的较准确姿态样本数据；经模型转换的焊工操控焊枪α、β角与机器人摆动预定值的误差均小于1.2°，γ角误差约为1.5°；未经实操培训焊工操控焊枪规范性差，调控熔池动态平衡表现出调节时刻和规律的高随机性，对熔池状态动态评估能力极其匮乏，无法保证焊接过程稳定和高的焊接质量；经长期实训焊工运枪动作规范、规律性强，对熔池状态动态评估能力丰富和强的交互意识，全焊接过程能够保持熔池形态的稳定和焊缝的全熔透。

Study on Human Welder's Adjustment Behavior Based on Coupled Model of Weld Torch and Weld Pool

There is no doubt that imitating and modeling of the skilled human welder's responses as well as programming it is one of optical method for rapid developing intelligent robotic welding technology. However, it is the key step of simultaneously sensing and measuring the weld torch orientation and weld pool characteristics to realize the program of human welder's responses. Aiming at the independence of measurement system of weld torch orientation and weld pool characteristics and the synchronously coupled analyzing requirements of interaction between human welder and weld pool, a mathematical transfer model of sensor-cardon-tungsten tip and a model of the traveling weld pool coupled with the welding torch orientation was built up, respectively, and its effectiveness and accuracy was verified by robot swing experiments with given parameters. The results show that the error of weld torch orientation α and β is both less than 1.2°, and the error of γ angle is about 1.5°. The data of weld torch orientation with the received error can be obtained using the coupled model. Furthermore, the experiments that the welding torch orientation operated by different level skilled welder affects on the weld pool status were performed and analyzed. Comparison of the experimental results indicates that the untrained welder without any welding experience irregularly and randomly adjusts the welding torch and lacks the basic welding skills and the awareness interactived with the weld pool as well as cannot ensure the weld process stability and high quality. Long trained human welder can normatively operate the welding torch orientation and soundly control the weld pool morphology via his/her observations and pass-trained experience, reflecting a strange interactive awareness and guaranteeing the dynamic balance of weld pool and full penetration.