铝合金脉冲MIG焊过程多信息分析及解耦控制
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摘要
近年来,随着铝合金在汽车、列车等运载工具中的广泛应用,对铝合金焊接结构生产的自动化、智能化及焊接质量的稳定性要求越来越高。本文针对铝合金脉冲MIG焊过程在恒定规范下铝合金热积累现象明显,参数不匹配情况下焊接过程不稳定这些关键问题,通过焊接过程中多信息传感与分析,过程建模仿真及实时解耦控制等方面对铝合金脉冲MIG焊过程进行了深入的研究。
由于铝合金脉冲MIG焊接过程中存在较多的不确定因素,实时检测和控制是保证其焊接过程稳定与焊接质量的重要方法,本文通过LabVIEW与COM技术结合的实时视觉传感,利用xPC目标实时建立了针对铝合金脉冲MIG焊的快速原型试验平台。
对于铝合金脉冲MIG焊过程,首先通过视觉传感的方法提出了一种焊丝干伸长提取算法,针对固定模板的传统微分算子边缘提取的不足,研究并利用蚁群算法、遗传算法进行熔池边缘提取。对于铝合金脉冲MIG焊过程稳定性进行了分析,得出了电弧电压概率密度、近似熵值与焊接过程稳定性的相关性。为克服已有信息对焊接过程的表征不足,对焊接过程中声音信号进行采集,分析得到不同熔滴过渡下电弧声信号特征进行熔滴过渡类型辨识,利用小波变换后得到特定频率范围的电弧声信号能量变化与焊接过程焊缝塌陷的相关性。进一步对弧焊过程多信息融合进行了初步研究,采用U-I二维相空间统计、二维近似熵信息源级多信息融合的算法确立了焊接过程电流、电压信息融合后特征与焊接过程稳定性的相关性。
本文在已有铝合金脉冲MIG焊过程辨识的基础上对其进行MIMO控制模型分析,确立了以熔宽和干伸长为目标,通过调节送丝速度与占空比来进行解耦控制的控制方案,采用经典补偿解耦控制理论、神经网络对象逆模型解耦理论进行仿真控制研究。并针对铝合金脉冲MIG焊电弧系统特点,在考虑熔滴过渡的基础上建立了焊丝熔化动态电弧模型,对所建立的模型进行了仿真,获得了与实际焊接过程相近的结果,揭示了电弧系统不稳定性的原因,并进一步在所建模型上进行了干伸长控制仿真,为电弧稳定控制提供了参考。
在传感与仿真的基础上,通过快速原型平台,首先通过送丝速度的调节来对干伸长进行单独控制,使焊接过程电弧系统稳定,接着针对以占空比来进行熔宽控制使得参数匹配困难而失稳的问题,利用双脉冲工艺方法,提出通过占空因数调节来实现热输入调节,进行焊缝熔宽控制研究,在此基础上以干伸长和熔宽为控制目标,以送丝速度、双脉冲占空因数为调节量的MIMO实时解耦控制,并在铝合金脉冲MIG焊快速原型平台的基础上,进行了不同传感方案下,不同控制器下的控制效果研究,获得了在熔宽、干伸长在视觉传感下,利用模糊PID控制器进行解耦控制,得到了焊接过程稳定,且熔宽均匀,外形美观,成形良好的焊缝。克服了铝合金脉冲MIG焊参数间强耦合关系,较好的解决了热积累问题。
In recent years, with the wide application of aluminum alloy in automobiles, trains and other means of vehicle, requirements of automation,intelligence and welding quality stability in aluminum alloy welding structures are higher and higher. In this paper, according to the key problems such as obvious heat accumulation phenomenon at constant parameters in pulsed MIG welding of aluminum alloy and unstable welding process when parameters do not match, further study on aluminum alloy welding control was done through sensing and analysis of muti-infornmation, process modeling and simulation and real-time decoupling control in welding process.
Due to many uncertain factors in pulsed MIG welding process of aluminum alloy, real-time detection and control is an important method to ensure the stability of welding process and welding quality. On the basis of vision sensing realized through combination of LabVIEW and COM technology, a rapid prototyping control platform was built with xPC target real-time environment.
In pulsed MIG welding of aluminum alloy, an extraction algorithm for wire extension was proposed by method of vision sensing and welding pool edge extraction was also studied using ant colony algorithm and genetic algorithm aiming at the deficiency of traditional differential operator. Analysis on stability of aluminum alloy pulsed MIG weldig process was made, and the correlation between probability density, approximate entropy value of arc voltage and the stability of welding process was obtained. In order to overcome the characterization deficiency of existing signals for welding process, sound signal in welding process was acquired, and the characteristic of arc sound signal was analyzed under different metal transfer mode to identify the mode of metal transfer, and then the relationship between welding arc sound and subsidence of aluminum alloy MIG welding bead was also studied using wavelet analysis method. Furthermore, muti-information fusion was preliminarily studied, and the correlation between characteristics after fusion of welding current, voltage and stability of welding process was established by method of U-I two-dimensional phase space, two-dimensional approximate entropy and algorithm of multi-information fusion.
In this paper, analysis on MIMO control model was made on the basis of existing process identification for pulsed MIG welding of aluminum alloy and a decoupling control scheme using pool width and wire extension as control object while using wire feed speed and duty cycle as controlled variable was selected. Simulation using classical theory of decoupling control and neural network object inverse model theory was carried out. Aiming at the characteristics of arc system and on the basis of considering the droplet transfer, dynamic arc model of wire melting was built, and the actual welding process was well reflected by simulation of the model. The reasons for the instability of arc system was also revealed. Further, wire extension control simulation was made on the built model and provided a reference for arc stability control.
On the basis of sensing and simulation, firstly, wire extension was independently controlled by adjusting wire feed speed to make arc system stable on the rapid prototyping platform. Then with double-pulse technology, heat input was changed for pool width control by regulating double-pulse duty factor. On this basis, MIMO real-time decoupling control was carried out using wire extension and pool width as control object while using wire feed speed and double-pulse duty factor as controlled variable. The control effect under different sensing methods and different controllers was also studied based on the rapid prototyping control platform. Adopting vision sensing for pool width and wire extension, decoupling control with fuzzy PID controller was carried out and obtained a stable welding process and a perfect weld, whose pool width was uniform and formation was beautiful. Therefore, the heat accumulation problem was resolved well by overcoming the strong coupling among parameters when controlling in pulsed MIG welding process.
由于铝合金脉冲MIG焊接过程中存在较多的不确定因素,实时检测和控制是保证其焊接过程稳定与焊接质量的重要方法,本文通过LabVIEW与COM技术结合的实时视觉传感,利用xPC目标实时建立了针对铝合金脉冲MIG焊的快速原型试验平台。
对于铝合金脉冲MIG焊过程,首先通过视觉传感的方法提出了一种焊丝干伸长提取算法,针对固定模板的传统微分算子边缘提取的不足,研究并利用蚁群算法、遗传算法进行熔池边缘提取。对于铝合金脉冲MIG焊过程稳定性进行了分析,得出了电弧电压概率密度、近似熵值与焊接过程稳定性的相关性。为克服已有信息对焊接过程的表征不足,对焊接过程中声音信号进行采集,分析得到不同熔滴过渡下电弧声信号特征进行熔滴过渡类型辨识,利用小波变换后得到特定频率范围的电弧声信号能量变化与焊接过程焊缝塌陷的相关性。进一步对弧焊过程多信息融合进行了初步研究,采用U-I二维相空间统计、二维近似熵信息源级多信息融合的算法确立了焊接过程电流、电压信息融合后特征与焊接过程稳定性的相关性。
本文在已有铝合金脉冲MIG焊过程辨识的基础上对其进行MIMO控制模型分析,确立了以熔宽和干伸长为目标,通过调节送丝速度与占空比来进行解耦控制的控制方案,采用经典补偿解耦控制理论、神经网络对象逆模型解耦理论进行仿真控制研究。并针对铝合金脉冲MIG焊电弧系统特点,在考虑熔滴过渡的基础上建立了焊丝熔化动态电弧模型,对所建立的模型进行了仿真,获得了与实际焊接过程相近的结果,揭示了电弧系统不稳定性的原因,并进一步在所建模型上进行了干伸长控制仿真,为电弧稳定控制提供了参考。
在传感与仿真的基础上,通过快速原型平台,首先通过送丝速度的调节来对干伸长进行单独控制,使焊接过程电弧系统稳定,接着针对以占空比来进行熔宽控制使得参数匹配困难而失稳的问题,利用双脉冲工艺方法,提出通过占空因数调节来实现热输入调节,进行焊缝熔宽控制研究,在此基础上以干伸长和熔宽为控制目标,以送丝速度、双脉冲占空因数为调节量的MIMO实时解耦控制,并在铝合金脉冲MIG焊快速原型平台的基础上,进行了不同传感方案下,不同控制器下的控制效果研究,获得了在熔宽、干伸长在视觉传感下,利用模糊PID控制器进行解耦控制,得到了焊接过程稳定,且熔宽均匀,外形美观,成形良好的焊缝。克服了铝合金脉冲MIG焊参数间强耦合关系,较好的解决了热积累问题。
In recent years, with the wide application of aluminum alloy in automobiles, trains and other means of vehicle, requirements of automation,intelligence and welding quality stability in aluminum alloy welding structures are higher and higher. In this paper, according to the key problems such as obvious heat accumulation phenomenon at constant parameters in pulsed MIG welding of aluminum alloy and unstable welding process when parameters do not match, further study on aluminum alloy welding control was done through sensing and analysis of muti-infornmation, process modeling and simulation and real-time decoupling control in welding process.
Due to many uncertain factors in pulsed MIG welding process of aluminum alloy, real-time detection and control is an important method to ensure the stability of welding process and welding quality. On the basis of vision sensing realized through combination of LabVIEW and COM technology, a rapid prototyping control platform was built with xPC target real-time environment.
In pulsed MIG welding of aluminum alloy, an extraction algorithm for wire extension was proposed by method of vision sensing and welding pool edge extraction was also studied using ant colony algorithm and genetic algorithm aiming at the deficiency of traditional differential operator. Analysis on stability of aluminum alloy pulsed MIG weldig process was made, and the correlation between probability density, approximate entropy value of arc voltage and the stability of welding process was obtained. In order to overcome the characterization deficiency of existing signals for welding process, sound signal in welding process was acquired, and the characteristic of arc sound signal was analyzed under different metal transfer mode to identify the mode of metal transfer, and then the relationship between welding arc sound and subsidence of aluminum alloy MIG welding bead was also studied using wavelet analysis method. Furthermore, muti-information fusion was preliminarily studied, and the correlation between characteristics after fusion of welding current, voltage and stability of welding process was established by method of U-I two-dimensional phase space, two-dimensional approximate entropy and algorithm of multi-information fusion.
In this paper, analysis on MIMO control model was made on the basis of existing process identification for pulsed MIG welding of aluminum alloy and a decoupling control scheme using pool width and wire extension as control object while using wire feed speed and duty cycle as controlled variable was selected. Simulation using classical theory of decoupling control and neural network object inverse model theory was carried out. Aiming at the characteristics of arc system and on the basis of considering the droplet transfer, dynamic arc model of wire melting was built, and the actual welding process was well reflected by simulation of the model. The reasons for the instability of arc system was also revealed. Further, wire extension control simulation was made on the built model and provided a reference for arc stability control.
On the basis of sensing and simulation, firstly, wire extension was independently controlled by adjusting wire feed speed to make arc system stable on the rapid prototyping platform. Then with double-pulse technology, heat input was changed for pool width control by regulating double-pulse duty factor. On this basis, MIMO real-time decoupling control was carried out using wire extension and pool width as control object while using wire feed speed and double-pulse duty factor as controlled variable. The control effect under different sensing methods and different controllers was also studied based on the rapid prototyping control platform. Adopting vision sensing for pool width and wire extension, decoupling control with fuzzy PID controller was carried out and obtained a stable welding process and a perfect weld, whose pool width was uniform and formation was beautiful. Therefore, the heat accumulation problem was resolved well by overcoming the strong coupling among parameters when controlling in pulsed MIG welding process.
引文
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