电阻点焊参数与焊接质量的相关性研究
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摘要
电阻点焊过程的动态信号与焊接质量密切相关。本文以Q235钢板为焊接试件,进行了点焊试验,在试验过程中,对焊接电流、电极间电压、电极力以及电极相对位移信号进行了同步采集。用LabVIEW编写了数据采集程序,以焊点的拉剪力作为焊接质量的评定指标。对各种焊接工况下的动态信号提取了特征值,并以其为输入参数,相应的焊点剪切强度为输出参数,建立了BP神经网络模型,得出了各动态信号对焊接质量的影响关系,结果可为点焊过程的在线监控及质量的无损检测提供依据。
The dynamic welding parameters in the process of resistance spot welding are closely related to the weld quality. In this paper, spot welding tests were carried out and dynamic process parameters of welding current, electrode voltage, electrode force, as well as electrode relative displacement were measured simultaneously by taking low carbon steel as the specimens. The data acquisition program was written in LabVIEW and the weld quality of the welded joint was checked in tensiling stress. The eigenvalues, abstracted for each signals in every welding conditions, were taken as the input, and the shearing strength as the output, a BP neural network model was established. The results show the effect of each dynamic welding parameter on weld quality, provided a basis on on-line welding quality monitoring and non-destructive welding quality examination.
The dynamic welding parameters in the process of resistance spot welding are closely related to the weld quality. In this paper, spot welding tests were carried out and dynamic process parameters of welding current, electrode voltage, electrode force, as well as electrode relative displacement were measured simultaneously by taking low carbon steel as the specimens. The data acquisition program was written in LabVIEW and the weld quality of the welded joint was checked in tensiling stress. The eigenvalues, abstracted for each signals in every welding conditions, were taken as the input, and the shearing strength as the output, a BP neural network model was established. The results show the effect of each dynamic welding parameter on weld quality, provided a basis on on-line welding quality monitoring and non-destructive welding quality examination.
引文
1 赵熹华,冯吉才.压焊方法及设备[M]. 北京:机械工业出版社,2005
2 中国机械工程学会焊接学会电阻焊(III)专业委员会.电阻焊理论与实践[M].北京: 机械工业出版社,1994:319-398
3 R. L. Cohen. Spot weld strength determined from simple electrical measurements.Weld J. 1986,64(6):17～23
4 曾鸿志,单平.电阻点焊过程及质量控制方法的研究进展.焊接技术[J],2000,29(5): l～3
5 姜以宏.光栅测热膨胀位移点焊质量实时控制装置研制.全国焊接年会论文集[J],(7),1990:37～41
6 N. T. Williams, J. D. Parker. Review of resistance spot welding of steel sheets Part 2 Factors influencing electrode life. International Materials Reviews,2004, 49 (2):77～108
7 G. Le Meur,B. Bourouga, T. Dupuy. Measurement of contact parameters at electrode/sheet interface during resistance spot welding process. Science and Technology of Welding&Joining, 2003, 8 (6):415～422
8 白钢,张勇等.点焊熔核尺寸与工艺参数关系的模型化处理.机械科学与技术[J], 2004, 23 (5):570～572
9 IRVINQ, B. The search goes on for the perfect resistance welding control, Welding Journal. Jan. 1996:63～68
10 Hao M, Osman K A. Developments in characterization of resistance spot welding of aluminum. Welding Resistance Supplement.1996(1):1～8
11 Livshits, A, G.,Universal Quality assurance method for resistance spot welding based on dynamic resistance. Welding Journal, Sept.1997:383～389
12 Tsai, C. L. et al, Modeling of resistance spot weld nugget growth. Welding Journal, Sept. 1990:47～50
13 Wei Li. Monitoring and diagnosis of resistance spot welding process. Degree of doctor of philosophy in the university of Michigan,1999
14 Darwish S M. Statistical models for spot welding of commercial alu-minum sheets[J].International Journal of Machine Tools and Manufacture, 1999.39 (10)
15 N. T. Williams, J. D. Parker. Review of resistance spot welding of steel sheets Part 1 Modelling and control of weld nugget formation. International Materials Reviews, 2004, 49(2):45～75
16 Y Chol, Y Kim2, S Rhee3. Development of a quality estimation model using multivariate analysis during resistance spot welding. Proceedings of theI MECHE Part B Journal of Engineering Manufacture,2001,215(11):1529～1538
17 杨黎峰.铝合金电阻点焊熔核形成过程的数值模拟[D].长春:吉林大学,2005
18 曹彪.点焊熔核形成过程的有限元模拟及热膨胀法实时控制[D].哈尔滨工业大学,1991
19 Javed M A, Sanders S A C. Neural Networks based learning and adaptive control for manufacturing systems. In:IEEE, 1991:242～246
20 Brown J D,Rodd M G and Williams N T, Application of artificial intelligence techniques to resistance spot welding, Ironmaking and Steelmaking,1998, 25 (3): 199～204
21 王凯,李冬青等.人工神经网络及其在焊接中的应用与展望.焊接,2005, (6) 5～9
22 张忠典,李冬青等.建立点焊质量神经网络监测模型时作用函数的选取.焊接学报,2002, 23 (3):59～62
23 马跃洲,种玉宝等.电阻点焊熔核尺寸的 RBF 网络模型.兰州理工大学学报,2004, 30 (4):1～6
24 贾贵玺,刘金涛等.模糊控制逆变弧焊电源.焊接学报,2004 (6) : 89～92
25 王永明.基于模糊算法的埋弧焊控制系统.江苏船舶,2004, 21(1) :23～25
26 杜全营,陈善本等.基于模糊逻辑的电阻点焊恒流控制系统.焊接,2003 (6):17-20
27 Yansong Zhang, Guanlong Chen, Zhongqin Lin. Study on Weld Quality Control of Resistance Spot Welding Using a Neural-Fuzzy Algorithm. Lecture Notes in Computer Science, 2004(5):544
28 朱锦洪.AduC812 微处理器模糊控制的电阻点焊装置.焊接技术,2002 (2) : 33～35
29 张波.点焊恒流模糊控制系统研究:(硕士学位论文).西安:西北 I;业大学,2002
30 彭金宁,陈丙森.焊接专家系统在我国的发展.焊接,1993, 22 (11) : 26
31 赵熹华,王衰馒.基于专家系统和人工神经网络的点焊工艺参数选择.焊接学报,1998, 19 (4):203～207
32 卢国刚.直线位移传感器发展的回顾和当今产品.世界制造技术与装备市场.2005 (O1):78
33 卢国刚.位移测量技术及其传感器的最新发展.世界制造技术与装备市场.2005(04):72～73
34 Thornton BY P H. Contact resistance in spot welding[J].Welding Journal, 1996, 76 (5):402～411
35 Waller D N.Head movement as a means of resistance welding qualitycontrol[J].British Welding Journal,1964, 11(3):118～122
36 胡德安,罗贤星等.电阻点焊电极压力的研究.南吕航空工业学院学报,1993, (1) : 65～70
37 胡德安,郑如忠等.点焊热膨胀位移质量监控的研究.江西科学,1996, 14. (4 ) : 206～210
38 南京新科研科技有限公司.ZHJ-1 型电阻焊测试仪说明书,2005
39 顺德区精悍机电有限公司.DN-25Q 交流气动电阻焊说明书,2005
40 秦皇岛市协力科技开发有限公司.XL-2102C 动态电阻应变仪使用说明书,2008
41 周开勤.机械零件手册[M]. 北京:高等教育出版社,1993
42 吴正毅.测试技术与测试信号处理[M]. 北京:清华大学出版社,1991
43 刘桂梅.电阻点焊动态参数测试系统的设计开发[D].内蒙古农业大学,2006
44 Matlab 小波分析与理论实践[M]. 电子工业出版社,2007
45 翟亮.基于MATLAB的控制系统计算机仿真[M]. 清华大学出版社,2006
46 刘普寅.模糊理论及其应用[M]. 国防科技大学出版社,1998
47 李国勇.智能控制及其MATLAB实现[M]. 电子工业出版社,2005
2 中国机械工程学会焊接学会电阻焊(III)专业委员会.电阻焊理论与实践[M].北京: 机械工业出版社,1994:319-398
3 R. L. Cohen. Spot weld strength determined from simple electrical measurements.Weld J. 1986,64(6):17～23
4 曾鸿志,单平.电阻点焊过程及质量控制方法的研究进展.焊接技术[J],2000,29(5): l～3
5 姜以宏.光栅测热膨胀位移点焊质量实时控制装置研制.全国焊接年会论文集[J],(7),1990:37～41
6 N. T. Williams, J. D. Parker. Review of resistance spot welding of steel sheets Part 2 Factors influencing electrode life. International Materials Reviews,2004, 49 (2):77～108
7 G. Le Meur,B. Bourouga, T. Dupuy. Measurement of contact parameters at electrode/sheet interface during resistance spot welding process. Science and Technology of Welding&Joining, 2003, 8 (6):415～422
8 白钢,张勇等.点焊熔核尺寸与工艺参数关系的模型化处理.机械科学与技术[J], 2004, 23 (5):570～572
9 IRVINQ, B. The search goes on for the perfect resistance welding control, Welding Journal. Jan. 1996:63～68
10 Hao M, Osman K A. Developments in characterization of resistance spot welding of aluminum. Welding Resistance Supplement.1996(1):1～8
11 Livshits, A, G.,Universal Quality assurance method for resistance spot welding based on dynamic resistance. Welding Journal, Sept.1997:383～389
12 Tsai, C. L. et al, Modeling of resistance spot weld nugget growth. Welding Journal, Sept. 1990:47～50
13 Wei Li. Monitoring and diagnosis of resistance spot welding process. Degree of doctor of philosophy in the university of Michigan,1999
14 Darwish S M. Statistical models for spot welding of commercial alu-minum sheets[J].International Journal of Machine Tools and Manufacture, 1999.39 (10)
15 N. T. Williams, J. D. Parker. Review of resistance spot welding of steel sheets Part 1 Modelling and control of weld nugget formation. International Materials Reviews, 2004, 49(2):45～75
16 Y Chol, Y Kim2, S Rhee3. Development of a quality estimation model using multivariate analysis during resistance spot welding. Proceedings of theI MECHE Part B Journal of Engineering Manufacture,2001,215(11):1529～1538
17 杨黎峰.铝合金电阻点焊熔核形成过程的数值模拟[D].长春:吉林大学,2005
18 曹彪.点焊熔核形成过程的有限元模拟及热膨胀法实时控制[D].哈尔滨工业大学,1991
19 Javed M A, Sanders S A C. Neural Networks based learning and adaptive control for manufacturing systems. In:IEEE, 1991:242～246
20 Brown J D,Rodd M G and Williams N T, Application of artificial intelligence techniques to resistance spot welding, Ironmaking and Steelmaking,1998, 25 (3): 199～204
21 王凯,李冬青等.人工神经网络及其在焊接中的应用与展望.焊接,2005, (6) 5～9
22 张忠典,李冬青等.建立点焊质量神经网络监测模型时作用函数的选取.焊接学报,2002, 23 (3):59～62
23 马跃洲,种玉宝等.电阻点焊熔核尺寸的 RBF 网络模型.兰州理工大学学报,2004, 30 (4):1～6
24 贾贵玺,刘金涛等.模糊控制逆变弧焊电源.焊接学报,2004 (6) : 89～92
25 王永明.基于模糊算法的埋弧焊控制系统.江苏船舶,2004, 21(1) :23～25
26 杜全营,陈善本等.基于模糊逻辑的电阻点焊恒流控制系统.焊接,2003 (6):17-20
27 Yansong Zhang, Guanlong Chen, Zhongqin Lin. Study on Weld Quality Control of Resistance Spot Welding Using a Neural-Fuzzy Algorithm. Lecture Notes in Computer Science, 2004(5):544
28 朱锦洪.AduC812 微处理器模糊控制的电阻点焊装置.焊接技术,2002 (2) : 33～35
29 张波.点焊恒流模糊控制系统研究:(硕士学位论文).西安:西北 I;业大学,2002
30 彭金宁,陈丙森.焊接专家系统在我国的发展.焊接,1993, 22 (11) : 26
31 赵熹华,王衰馒.基于专家系统和人工神经网络的点焊工艺参数选择.焊接学报,1998, 19 (4):203～207
32 卢国刚.直线位移传感器发展的回顾和当今产品.世界制造技术与装备市场.2005 (O1):78
33 卢国刚.位移测量技术及其传感器的最新发展.世界制造技术与装备市场.2005(04):72～73
34 Thornton BY P H. Contact resistance in spot welding[J].Welding Journal, 1996, 76 (5):402～411
35 Waller D N.Head movement as a means of resistance welding qualitycontrol[J].British Welding Journal,1964, 11(3):118～122
36 胡德安,罗贤星等.电阻点焊电极压力的研究.南吕航空工业学院学报,1993, (1) : 65～70
37 胡德安,郑如忠等.点焊热膨胀位移质量监控的研究.江西科学,1996, 14. (4 ) : 206～210
38 南京新科研科技有限公司.ZHJ-1 型电阻焊测试仪说明书,2005
39 顺德区精悍机电有限公司.DN-25Q 交流气动电阻焊说明书,2005
40 秦皇岛市协力科技开发有限公司.XL-2102C 动态电阻应变仪使用说明书,2008
41 周开勤.机械零件手册[M]. 北京:高等教育出版社,1993
42 吴正毅.测试技术与测试信号处理[M]. 北京:清华大学出版社,1991
43 刘桂梅.电阻点焊动态参数测试系统的设计开发[D].内蒙古农业大学,2006
44 Matlab 小波分析与理论实践[M]. 电子工业出版社,2007
45 翟亮.基于MATLAB的控制系统计算机仿真[M]. 清华大学出版社,2006
46 刘普寅.模糊理论及其应用[M]. 国防科技大学出版社,1998
47 李国勇.智能控制及其MATLAB实现[M]. 电子工业出版社,2005