熔焊过程多信息同步采集及分析系统
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摘要
现代工业的发展对焊接电源的性能、焊缝的质量以及焊接材料,提出越来越高的要求。采用先进的信息检测技术获得焊接电弧中所包含的大量信息,是进行焊接电源性能改进、焊缝和焊接材料质量评价的基础,也为进行焊接试验和焊接设备研究提供了理论基础。
本文利用实验室已有的数据采集卡、高速摄像机以及光谱仪,在LABVIEW环境下,开发了一套适用于熔焊过程的多信息同步采集及分析系统。该系统分为采集系统和数据分析系统两个部分,采集系统可以实现焊接电信号(电弧电压和焊接电流)、高速摄像图片、光谱数据三种电弧信息的同步采集和存储;数据分析系统提供了与采集系统配套的多信息同步分析功能,可实现多信息同步回放,计算输入能量和光谱辐射强度积分等;数据分析系统还提供了针对电信号的基本分析功能,包括绘制电压电流波形图、U-I曲线、电压电流概率密度曲线,电压电流滤波,计算短路频率、短路周期方差和射滴过渡周期方差等。
通过焊接试验,对本文设计的熔焊过程多信息同步采集及分析系统进行了验证。结果表明,此系统能够实现三种信息的同步采集,并将结果记录下来,此系统对采集得到的数据能够进行有效分析,并得出相应结论。
Because of the development of modern industrial, welding performance, weldquality and welding material are facing the ever-increasing demands. Through theadvanced information-detection technology, a large amount of information containedin the welding arc can be got, which can be used as the basis of evaluating weldingperformance, weld quality and welding materials, as well as a theoretical basis for theresearch of welding equipment and welding experiment.
This paper has developed a Synchronous multi-information acquisition andanalysis system for welding process, based on the equipments in the laboratory,including the high-speed data acquisition cards, high-speed camera system and thespectrometer. MATLAB mixed LABVIEW programming technology was used in thedesign of this system. The system is divided into two parts named data acquisitionsystem and data analysis system. Through the acquisition system, welding electricsignals (arc voltage and welding current), high-speed camera image and spectral datacan be collected synchronously. The analysis system attachded to the acquisitionsystem is used to complete the analysis of the data, including locating the trigger time,calculating the input electric energy and spectral energy. Moreover, the analysissystem also provides some basic functions, including: data playback, U-I curve,voltage and current probability density curve, filtering, the calculation of frequencyand cycle variance in short-circuit transition.
Through the actual welding experiments, the function of the system has beenverified. The results show that the three kind of arc information can be collectedsimultaneously, and then be analyzed effectively, finallydraw appropriateconclusions.
本文利用实验室已有的数据采集卡、高速摄像机以及光谱仪,在LABVIEW环境下,开发了一套适用于熔焊过程的多信息同步采集及分析系统。该系统分为采集系统和数据分析系统两个部分,采集系统可以实现焊接电信号(电弧电压和焊接电流)、高速摄像图片、光谱数据三种电弧信息的同步采集和存储;数据分析系统提供了与采集系统配套的多信息同步分析功能,可实现多信息同步回放,计算输入能量和光谱辐射强度积分等;数据分析系统还提供了针对电信号的基本分析功能,包括绘制电压电流波形图、U-I曲线、电压电流概率密度曲线,电压电流滤波,计算短路频率、短路周期方差和射滴过渡周期方差等。
通过焊接试验,对本文设计的熔焊过程多信息同步采集及分析系统进行了验证。结果表明,此系统能够实现三种信息的同步采集,并将结果记录下来,此系统对采集得到的数据能够进行有效分析,并得出相应结论。
Because of the development of modern industrial, welding performance, weldquality and welding material are facing the ever-increasing demands. Through theadvanced information-detection technology, a large amount of information containedin the welding arc can be got, which can be used as the basis of evaluating weldingperformance, weld quality and welding materials, as well as a theoretical basis for theresearch of welding equipment and welding experiment.
This paper has developed a Synchronous multi-information acquisition andanalysis system for welding process, based on the equipments in the laboratory,including the high-speed data acquisition cards, high-speed camera system and thespectrometer. MATLAB mixed LABVIEW programming technology was used in thedesign of this system. The system is divided into two parts named data acquisitionsystem and data analysis system. Through the acquisition system, welding electricsignals (arc voltage and welding current), high-speed camera image and spectral datacan be collected synchronously. The analysis system attachded to the acquisitionsystem is used to complete the analysis of the data, including locating the trigger time,calculating the input electric energy and spectral energy. Moreover, the analysissystem also provides some basic functions, including: data playback, U-I curve,voltage and current probability density curve, filtering, the calculation of frequencyand cycle variance in short-circuit transition.
Through the actual welding experiments, the function of the system has beenverified. The results show that the three kind of arc information can be collectedsimultaneously, and then be analyzed effectively, finallydraw appropriateconclusions.
引文
[1]姚广臣,贾涛,臧小惠.焊接技术现状与发展趋势[J].中国科技信息,2008(6):62~63
[2]杜淼.中国焊接市场发展现状[J].航空制造技术,2008(3):64~65
[3]陈邦固,李桓等.中国焊接技术的发展成就及行业概览[J].焊接,2008(1):11~16
[4]薛家祥,易志平,方平等.焊接过程电信号虚拟分析仪的研究[J].机械工程学报,2004,40(2):60~63
[5]王晓东,柳刚,范荣焕.弧焊电源检测与评价中常用的信号处理与分析方法[J].焊接技术,2001,30(2):14~16
[6]张丽玲,彭祺,张莉琴.CO2焊接过程的高速摄影与电信号分析[J].电焊机,2008,38(3):30~33
[7]刘金合,朱石刚.CO2激光焊接等离子体高速摄影照片图像处理[J].应用激光,2006,22(3):342~344
[8]张赋升,熊江涛,李京龙等.等离子体电弧现象的高速摄影及分析研究[J].光子学报,2002,31(Z2):372~377
[9]杨运强,李桓,李俊岳等.熔化极电弧焊多信息同步高速摄影[J].焊接学报,2002,23(6):29~32
[10]刘占民,李明利,薛龙.熔化极电弧焊熔滴过渡过程的高速摄像[J].激光与红外,2006,36(2):131~134
[11]李俊岳,宋永伦.电弧光谱信息及其在焊接过程测控上的应用[J].机械工程学报,1993,29(3):1~7
[12] Li Junyue, Song Yonglun. Spectral information of arc and welding automation[J].Welding in the world, 1994, 34 (9): 317~324
[13] Li Junyue, Song Yonglun. Measurement of hydrogen in a welding arc[J].Welding research abroad, 1989, 35 (6\7): 2~6, and Welding international, 1988,(12): 1122~1126
[14]柳刚,李俊岳,李桓等.焊接电弧光谱的分布特征[J].机械工程学报,2000,36(5):58~61.
[15]张龙.脉冲MIG(MAG)焊熔滴过渡的弧光行为及其实时控制:[博士学位论文].哈尔滨:哈尔滨工业大学,1992
[16]云绍辉,柳刚,韩国明.熔化极气体保护焊熔滴过渡检测方法现状与展望[J].电焊机,1984(4):1~4
[17] Rehfeldt D, BollmannA. KoerbeT, et al. Computer-aided qualitycontrol byprocess analyzing, monitoring and documentation[J]. International Journal forthe Joining of Materials, 1991, 3(1): 11~16
[18]朱六妹等.CO2焊熔滴过渡特征的分析和研究[J].电焊机,2000,30(1):18~21
[19]张薇薇,刑务强.随机信号谱估计方法的Matlab实现.现代电子技术,2008,38(11):132~134
[20]朱六妹,李广辉等.基于USB总线的焊接过程瞬态信号检测[J].电焊机,2007,37(1):35~41
[21]李南.基于虚拟仪器的焊接参数测量系统设计[J].计算机测量与控制,2006,14(5)619~621
[22]王卫彬,李芳等.基于LABVIEW脉冲焊接过程稳定性评估系统[J].电焊机,2008,38(1):20~22
[23]李芳,蔡艳等.脉冲熔化极气体保护焊多信息采集分析系统[J].上海交通大学学报,2008,42(1):16~19
[24]杨运强,张军等.应用LABVIEW检测与分析焊接过程[J].电焊机,2003,33(6):19~21
[25]白岩,高洪明,路浩等.基于LABVIEW的熔化极等离子弧焊接电弧电信号分析[J].焊接学报,2006,27(8):59~62
[26]胡富仁,王国荣,石永华.LABVIEW平台中使用小波分析实现焊接电流信号的去噪[J].电焊机,2008,38(5):46~49
[27]李俊岳,杨立军,胡胜钢.脉冲MIG焊熔滴过渡光谱信息的研究[J].中国工程科学,2000,2(7):79~86
[28]薛海涛,李俊岳.焊接电弧信息测试分析系统[J].焊接学报,2003,24(1):19~22
[29]李芳,蔡艳等.脉冲熔化极气体保护焊多信息采集分析系统[J].上海交通大学学报,2008,42(1):16~19
[30] Marburger, S J. Data acquisition in GTA welding[A]. Abstracts of PapersPresented at 1987 AWS Convention: 68th American Welding SocietyAnnualMeeting and 18th International AWS Brazing Conference[C], Mami, USA: 1987.31~33
[31] Milewski J O, Dixon R.D.. Electron beam welding unit data acquisition usingpersonal computer[A].Abstracts of Papers Presented at 67th AWS AnnualMeeting[C], Mami, USA: 1986. 19~20
[32] Milewski J O. Data acquisition and analysis for EB welding in perspective[J].Welding Journal, 1988, 67(11): 256s~263s
[33] Shepard Mark E, Cook George E. A data acquisition system for arc weldingresearch[A]. Proceedings IECON '86. 1986 International Conference onIndustrial Electronic, Control and Instrumentation Industrial Applications ofMini, Micro & Personal Computers[C]. USA: 1986. 85~91
[34] Harwig D D, Dierksheide J E, Blackman S.. Arc behavior and melting rate in theVP-GMAW process [J]. Welding Journal, 2006, 85(3): 52~62
[35] Latham Wayne M, MacLauchlan Daniel T, Geier Dan P. EMAT weld inspectionand weld machine diagnostic system for continuous coil processing lines[A].Proceedings of SPIE - The International Society for Optical Engineering [C].1996, 2948(12). 252~258
[36] Matthew Miller, Bao Mi, Akio Kita. Development of automated real-time dataacquisition system for robotic weld qualitymonitoring[J]. Mechatronics,2002,12(9-10): 1259~69
[37] Barrera G. Monitoring the submerged-arc welding (SAW) process using currentand voltage transducers [J]. Welding international, 1997, 11(10): 795~801
[38]王宝,宋永伦,D.Rehfeld等.汉诺威焊接材料工艺性分析系统在焊接材料领域中的应用[J].焊接,2006(10):15~18
[39]杨林,王宝,D.Rehfeldt.焊接电参数的一种新型测试方法[J].华北工学院学学报,2005,26(1):75~77
[40] Rehfeldt D, Bollmann A. Using statistical signal analysis for analyzing andmonitoring GMAW-process[A]. IIW Latin American Regional WeldingCongress[C]. 1992(2): 839~844
[41]韩喆，骆新根．虚拟仪器在焊接质量分析中的应用[J].电焊机,2007,37(12):65~68
[42]雷振山,赵晨光,魏丽等.LabVIEW 8.2基础教程[M],北京:中国铁道出版社,2008.1~3
[43]张红民,李晓峰.基于LabVIEW的多线程编程技术比较研究[J].电子技术应用,2008(10):89~91
[44]符意德,陆阳.嵌入式系统原理及接口技术[M].北京:清华大学出版社,2007.86~94
[45]王宝,杨林,王勇.焊条典型熔滴过渡形态的判读[J].焊接学报,2006,27(11):95~98
[46]刘富强,王宝.汉诺威弧焊质量分析系统及其在焊接材料测试技术中的应用[J].兵器材料科学与工程,2008,31(2):87~90
[47]陈锡辉,张银鸿.LabVIEW 8.20程序设计从入门到精通[M],北京:清华大学出版社,2007.180
[48]王宏,贾新民.信号处理基础[M],北京:机械工业出版社,2007.199
[2]杜淼.中国焊接市场发展现状[J].航空制造技术,2008(3):64~65
[3]陈邦固,李桓等.中国焊接技术的发展成就及行业概览[J].焊接,2008(1):11~16
[4]薛家祥,易志平,方平等.焊接过程电信号虚拟分析仪的研究[J].机械工程学报,2004,40(2):60~63
[5]王晓东,柳刚,范荣焕.弧焊电源检测与评价中常用的信号处理与分析方法[J].焊接技术,2001,30(2):14~16
[6]张丽玲,彭祺,张莉琴.CO2焊接过程的高速摄影与电信号分析[J].电焊机,2008,38(3):30~33
[7]刘金合,朱石刚.CO2激光焊接等离子体高速摄影照片图像处理[J].应用激光,2006,22(3):342~344
[8]张赋升,熊江涛,李京龙等.等离子体电弧现象的高速摄影及分析研究[J].光子学报,2002,31(Z2):372~377
[9]杨运强,李桓,李俊岳等.熔化极电弧焊多信息同步高速摄影[J].焊接学报,2002,23(6):29~32
[10]刘占民,李明利,薛龙.熔化极电弧焊熔滴过渡过程的高速摄像[J].激光与红外,2006,36(2):131~134
[11]李俊岳,宋永伦.电弧光谱信息及其在焊接过程测控上的应用[J].机械工程学报,1993,29(3):1~7
[12] Li Junyue, Song Yonglun. Spectral information of arc and welding automation[J].Welding in the world, 1994, 34 (9): 317~324
[13] Li Junyue, Song Yonglun. Measurement of hydrogen in a welding arc[J].Welding research abroad, 1989, 35 (6\7): 2~6, and Welding international, 1988,(12): 1122~1126
[14]柳刚,李俊岳,李桓等.焊接电弧光谱的分布特征[J].机械工程学报,2000,36(5):58~61.
[15]张龙.脉冲MIG(MAG)焊熔滴过渡的弧光行为及其实时控制:[博士学位论文].哈尔滨:哈尔滨工业大学,1992
[16]云绍辉,柳刚,韩国明.熔化极气体保护焊熔滴过渡检测方法现状与展望[J].电焊机,1984(4):1~4
[17] Rehfeldt D, BollmannA. KoerbeT, et al. Computer-aided qualitycontrol byprocess analyzing, monitoring and documentation[J]. International Journal forthe Joining of Materials, 1991, 3(1): 11~16
[18]朱六妹等.CO2焊熔滴过渡特征的分析和研究[J].电焊机,2000,30(1):18~21
[19]张薇薇,刑务强.随机信号谱估计方法的Matlab实现.现代电子技术,2008,38(11):132~134
[20]朱六妹,李广辉等.基于USB总线的焊接过程瞬态信号检测[J].电焊机,2007,37(1):35~41
[21]李南.基于虚拟仪器的焊接参数测量系统设计[J].计算机测量与控制,2006,14(5)619~621
[22]王卫彬,李芳等.基于LABVIEW脉冲焊接过程稳定性评估系统[J].电焊机,2008,38(1):20~22
[23]李芳,蔡艳等.脉冲熔化极气体保护焊多信息采集分析系统[J].上海交通大学学报,2008,42(1):16~19
[24]杨运强,张军等.应用LABVIEW检测与分析焊接过程[J].电焊机,2003,33(6):19~21
[25]白岩,高洪明,路浩等.基于LABVIEW的熔化极等离子弧焊接电弧电信号分析[J].焊接学报,2006,27(8):59~62
[26]胡富仁,王国荣,石永华.LABVIEW平台中使用小波分析实现焊接电流信号的去噪[J].电焊机,2008,38(5):46~49
[27]李俊岳,杨立军,胡胜钢.脉冲MIG焊熔滴过渡光谱信息的研究[J].中国工程科学,2000,2(7):79~86
[28]薛海涛,李俊岳.焊接电弧信息测试分析系统[J].焊接学报,2003,24(1):19~22
[29]李芳,蔡艳等.脉冲熔化极气体保护焊多信息采集分析系统[J].上海交通大学学报,2008,42(1):16~19
[30] Marburger, S J. Data acquisition in GTA welding[A]. Abstracts of PapersPresented at 1987 AWS Convention: 68th American Welding SocietyAnnualMeeting and 18th International AWS Brazing Conference[C], Mami, USA: 1987.31~33
[31] Milewski J O, Dixon R.D.. Electron beam welding unit data acquisition usingpersonal computer[A].Abstracts of Papers Presented at 67th AWS AnnualMeeting[C], Mami, USA: 1986. 19~20
[32] Milewski J O. Data acquisition and analysis for EB welding in perspective[J].Welding Journal, 1988, 67(11): 256s~263s
[33] Shepard Mark E, Cook George E. A data acquisition system for arc weldingresearch[A]. Proceedings IECON '86. 1986 International Conference onIndustrial Electronic, Control and Instrumentation Industrial Applications ofMini, Micro & Personal Computers[C]. USA: 1986. 85~91
[34] Harwig D D, Dierksheide J E, Blackman S.. Arc behavior and melting rate in theVP-GMAW process [J]. Welding Journal, 2006, 85(3): 52~62
[35] Latham Wayne M, MacLauchlan Daniel T, Geier Dan P. EMAT weld inspectionand weld machine diagnostic system for continuous coil processing lines[A].Proceedings of SPIE - The International Society for Optical Engineering [C].1996, 2948(12). 252~258
[36] Matthew Miller, Bao Mi, Akio Kita. Development of automated real-time dataacquisition system for robotic weld qualitymonitoring[J]. Mechatronics,2002,12(9-10): 1259~69
[37] Barrera G. Monitoring the submerged-arc welding (SAW) process using currentand voltage transducers [J]. Welding international, 1997, 11(10): 795~801
[38]王宝,宋永伦,D.Rehfeld等.汉诺威焊接材料工艺性分析系统在焊接材料领域中的应用[J].焊接,2006(10):15~18
[39]杨林,王宝,D.Rehfeldt.焊接电参数的一种新型测试方法[J].华北工学院学学报,2005,26(1):75~77
[40] Rehfeldt D, Bollmann A. Using statistical signal analysis for analyzing andmonitoring GMAW-process[A]. IIW Latin American Regional WeldingCongress[C]. 1992(2): 839~844
[41]韩喆，骆新根．虚拟仪器在焊接质量分析中的应用[J].电焊机,2007,37(12):65~68
[42]雷振山,赵晨光,魏丽等.LabVIEW 8.2基础教程[M],北京:中国铁道出版社,2008.1~3
[43]张红民,李晓峰.基于LabVIEW的多线程编程技术比较研究[J].电子技术应用,2008(10):89~91
[44]符意德,陆阳.嵌入式系统原理及接口技术[M].北京:清华大学出版社,2007.86~94
[45]王宝,杨林,王勇.焊条典型熔滴过渡形态的判读[J].焊接学报,2006,27(11):95~98
[46]刘富强,王宝.汉诺威弧焊质量分析系统及其在焊接材料测试技术中的应用[J].兵器材料科学与工程,2008,31(2):87~90
[47]陈锡辉,张银鸿.LabVIEW 8.20程序设计从入门到精通[M],北京:清华大学出版社,2007.180
[48]王宏,贾新民.信号处理基础[M],北京:机械工业出版社,2007.199