等离子熔积熔池与焊道的可视化研究
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摘要
Q等离子熔积快速制造技术是采用等离子弧作为热源熔化焊材,在数控机床控制下,根据工艺路径直接快速堆积成形金属原型或零件的快速成形新技术。目前,该技术,在快速制造梯度功能材料方面和高温硬质合金零件方面具有独特优势,是目前解决快速制造高温合金零件的最热门的研究方向,也是最重要的发展方向。焊接的质量控制一直以来都是焊接领域最困难的问题,也是最研究的最多问题。如何保证等离子熔积的成形质量,保证焊道的均匀性是本文研究的重点。质量控制中最关键的技术是焊道的形貌检测,通过检测焊道的几何尺寸,直接有效的反馈给控制器,实现焊道宽度偏差的实时反馈,实现工艺参数的在线调整,从而达到工艺优化,堆积出尺寸符合预设要求的均匀的焊道,为最终的成形零件提供精度与质量保证。本文从机器视觉传感的角度出发,研究了图像检测技术在等离子加工中的应用。
等离子熔积工艺复杂,加工环境极为恶劣。尤其是弧光干扰和飞溅造成了大量的噪声。给图像处理带来极大的困难。本文利用外加可见光窄带滤光镜的方法,滤除紫外光和部分可见长,其它弧光成分作光源,通过CCD获取清晰的焊道图像。图像处理软件通过Adlink公司的RTV-24图像采集卡获取图像数据。并在内存中实现图像预处理、特征识别、宽度偏差计算、图像保存与数据输出等任务。图像检测的关键在于图像处理算法。在焊道图像检测中,边缘提取是焊道尺寸计算的前提。
本文在Windows XP系统下运用VC++6.0开发平台进行软件模块划分和代码编写。通过调用图像采集卡的提供的库函数实现了图像的采集功能。本文根据最优边缘提取的原理编写边缘提取算法程序,通过图像加窗处理方法进一步抑制背景的影响,提取出了清晰的焊道边缘。整个边缘提取算法的思想是:通过高斯滤波器平滑图象、用一阶偏导的有限差分来计算梯度的幅值和方向、对梯度幅值进行非极大值抑制、用双阈值算法检测和连接边缘。在计算机软件上,通过用户指定宽度测量方向,实现了焊道宽度的手动与自动测量。
Plasma Arc Welding technology, using rapid plasma arc as a source of heat melting and using NC machine’s control technology to follow the direct path of manufacture process, is a new kind of technology for rapidly forming metal parts or prototyping manufactur.At present, this kind of technology has unique advantages in the field of the rapid manufacturing of functionally gradient materials and high temperature carbide parts. Because it provides a good solution to the rapid manufacture of high temperature alloy parts , more and more reseach plans were carried on how to use of this technology as the same time it becomes the most popular and most important development direction of Rapid Prototyping Mafuture technology. Welding quality control has always been the most difficult problem in welding field, and also the most problematic area in the study. That How to conrtol the plasma forming welding quality to ensure uniformity of weld is the focus of this paper. weld morphology detection technology is the most critical technology in quality control application. Throught detecting the weld beam geometry shape and sending the width deviation of weld bem directly and effectively to the controller, to work out a real-time feedback and control to make online adjustment of process parameters to reach the process optimization, for forming components to provide the ultimate precision and quality assurance. In this paper, the vison sensor applications was studied, and a a passsive vision detection technology was applied in plasma processing successfully.
Plasma welding is a complexity process and the welding environment is extremely worse. In particular the arc and splash disturbance cause a large amount of noise. These interference cause trouble and great difficulties to Image process In this paper, using a narrow-band filter method of visible light, UV filter and the rest lights reached the CCD were used as light source, then we can use a CCD cammera to grab a clear image of the weld beam. Image processing software can obtain image data. From Adlink's RTV-24 frame grabber And in memory to work out many tasks. Such as image preprocessing, feature recognition, the width of deviation, the image data output. The key factor to work a good job lies in the image detection image processing algorithms. During the weld vision detection, edge detection is the premise of the weld size calculation.
Under the Windows XP system platform ,we use VC + +6.0 programme software finished weld dectect programme modules division and code-preparation. We realize the image acquisition function with the library functions provided by Image acquisition card. In this paper, we firstly applied Canny algorithm Combined with image windowed processing method to finish task of weld edge detection successfully. The first step is to get a smooth image using Gaussian filter; the second step is to calculate the gradient through a first-order partial derivatives of the finite difference; The third step is to work out the non-maximum value suppression of Gradient amplitude; The last step is to make use of dual-threshold algorithm for edge detection and connection. Our programme can finish the manual and automatic measurements tasks through user-specified width measurement of the direction of the width of a weld
等离子熔积工艺复杂,加工环境极为恶劣。尤其是弧光干扰和飞溅造成了大量的噪声。给图像处理带来极大的困难。本文利用外加可见光窄带滤光镜的方法,滤除紫外光和部分可见长,其它弧光成分作光源,通过CCD获取清晰的焊道图像。图像处理软件通过Adlink公司的RTV-24图像采集卡获取图像数据。并在内存中实现图像预处理、特征识别、宽度偏差计算、图像保存与数据输出等任务。图像检测的关键在于图像处理算法。在焊道图像检测中,边缘提取是焊道尺寸计算的前提。
本文在Windows XP系统下运用VC++6.0开发平台进行软件模块划分和代码编写。通过调用图像采集卡的提供的库函数实现了图像的采集功能。本文根据最优边缘提取的原理编写边缘提取算法程序,通过图像加窗处理方法进一步抑制背景的影响,提取出了清晰的焊道边缘。整个边缘提取算法的思想是:通过高斯滤波器平滑图象、用一阶偏导的有限差分来计算梯度的幅值和方向、对梯度幅值进行非极大值抑制、用双阈值算法检测和连接边缘。在计算机软件上,通过用户指定宽度测量方向,实现了焊道宽度的手动与自动测量。
Plasma Arc Welding technology, using rapid plasma arc as a source of heat melting and using NC machine’s control technology to follow the direct path of manufacture process, is a new kind of technology for rapidly forming metal parts or prototyping manufactur.At present, this kind of technology has unique advantages in the field of the rapid manufacturing of functionally gradient materials and high temperature carbide parts. Because it provides a good solution to the rapid manufacture of high temperature alloy parts , more and more reseach plans were carried on how to use of this technology as the same time it becomes the most popular and most important development direction of Rapid Prototyping Mafuture technology. Welding quality control has always been the most difficult problem in welding field, and also the most problematic area in the study. That How to conrtol the plasma forming welding quality to ensure uniformity of weld is the focus of this paper. weld morphology detection technology is the most critical technology in quality control application. Throught detecting the weld beam geometry shape and sending the width deviation of weld bem directly and effectively to the controller, to work out a real-time feedback and control to make online adjustment of process parameters to reach the process optimization, for forming components to provide the ultimate precision and quality assurance. In this paper, the vison sensor applications was studied, and a a passsive vision detection technology was applied in plasma processing successfully.
Plasma welding is a complexity process and the welding environment is extremely worse. In particular the arc and splash disturbance cause a large amount of noise. These interference cause trouble and great difficulties to Image process In this paper, using a narrow-band filter method of visible light, UV filter and the rest lights reached the CCD were used as light source, then we can use a CCD cammera to grab a clear image of the weld beam. Image processing software can obtain image data. From Adlink's RTV-24 frame grabber And in memory to work out many tasks. Such as image preprocessing, feature recognition, the width of deviation, the image data output. The key factor to work a good job lies in the image detection image processing algorithms. During the weld vision detection, edge detection is the premise of the weld size calculation.
Under the Windows XP system platform ,we use VC + +6.0 programme software finished weld dectect programme modules division and code-preparation. We realize the image acquisition function with the library functions provided by Image acquisition card. In this paper, we firstly applied Canny algorithm Combined with image windowed processing method to finish task of weld edge detection successfully. The first step is to get a smooth image using Gaussian filter; the second step is to calculate the gradient through a first-order partial derivatives of the finite difference; The third step is to work out the non-maximum value suppression of Gradient amplitude; The last step is to make use of dual-threshold algorithm for edge detection and connection. Our programme can finish the manual and automatic measurements tasks through user-specified width measurement of the direction of the width of a weld
引文
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[3]张海鸥.快速制造模具技术的现状[J].机械工人:冷加工. 2002(001):27-28.
[4]单际国,董祖珏.我国熔积技术的发展及其在基础工业中的应用现状[J].中国表面工程. 2002, 15(004): 19-22.
[5]黄永军,张海鸥,王桂兰,etal.金属模具的等离子熔积直接成形及精整加工[J].航空制造技术.2004.
[6]罗勇.焊接发展史(四)——焊接过程控制[J].焊接技术.2007,36(2).
[7]刘习文,王国荣,石永华,etal.焊接熔池传感与控制系统的研究现状[J].焊接. 2005(11): 5-9.
[8]董德祥,吴林,陈定华.焊接熔深自动检测及理论研究的综述[J].压力容器. 1994(04).
[9]王志江,张广军,梁志敏,etal.熔池表面三维检测与测量技术现状及发展趋势[J].焊接. 2007(08).
[10]何德孚,李克海.焊接熔池的振荡和焊道成形的自适应控制[J].焊管.2000(04).
[11]杨春利,张九海,王其隆.薄板TIG焊熔池谐振法熔透自适应控制[J].材料科学与工艺.1991(03).
[12] SongDF,HuSS,HanJ,etal.Penetration control system for key hole pulse plasma arc welding based on reflecting plasma-flame voltage[J].Han jie Xue bao /Transactions of the China Welding Institution.2006,27(6):45-48.
[13] Mirapeix.J,Cobo.A,Conde.O,etal.Spectroscopic analysis technique for arc- welding process control[C]. Warsaw,Poland:SPIE,2005.
[14] Zhenguo S, Nian C, Qiang C. Realizing precision pulse TIG welding with arc lengthcontrol and visual image sensing based weld detection[J].Welding Research Abroad. 2004, 50(4): 27-32.
[15]高向东,黄石生,吴乃优,etal.弧焊过程焊道熔深控制技术的研究[J].华南理工大学学报(自然科学版).2000(03).
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