基于微束等离子弧的焊缝跟踪传感研究
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摘要
焊缝跟踪传感技术在焊接自动化生产中具有非常重要的作用,它是保证焊缝质量的关键。目前常用的传感方式如视觉传感和电弧传感等,都存在各自的局限性。基于微束等离子弧的焊缝跟踪传感技术是焊缝跟踪领域的一个创新,它相对于传统传感方式具有一些独特的优点。
本文根据其传感原理,通过设计微束等离子弧传感器等工作,搭建起一套合适的引弧装置和相应的硬件平台,产生了可供试验测量用的稳定的等离子电弧。
针对该等离子弧系统,开发了与之配套的电压信号采集、分析软硬件系统。信号采集模块中,根据采集卡提供的接口,实现了高频率、大数据量采集,波形图实时显示和二进制或十进制数据同步保存;分析模块中,实现了数字滤波及其他一些数据分析功能。
通过静态试验,获得了等离子弧长度与测量电压之间的基本变化趋势和特点,并深入解释了电弧的五个工作状态——极限期、工作区Ⅰ、过渡区、工作区Ⅱ和导通期以及它们的形成原因;全面分析了各影响因素对传感过程可能造成的影响,其中维弧电流、离子气流量等因素对于输出电压起到决定性的作用;通过静态、动态试验等总结出适合本文硬件设备的一套最佳参数,并对微束等离子发生器进行了相应的改进,使电弧达到了更加稳定的状态。
在电弧传感器及其低层处理获取的接头表面轮廓基础上,通过多线段拟合的近似算法进行了典型焊接接头类型的识别和特征参数的提取等工作。
Weld seam tracking and sensing technology plays a very important role in welding automate production and is also a critical factor in weld seam quality. The most common sensing methods till now are vision sensor, tactile sensor and arc sensor, etc. But they all have limitations respectively. The technology of weld seam tracking based on micro plasma arc has some particular merits comparing with traditional tracking means and also is an innovation in seam tracking field. According to the principle of this seam tracking method, a suitable system which can generate non-transferred arc was built by designing a micro plasma arc sensor, an arc generating device and some corresponding equipments.
A corresponding signal collection and analysis system was developed. In the signal collection module, the collection of high frequency and large numbers of data was realized. Also, oscillogram show and binary or decimal data saving real-time were actualized. In the signal analysis module, digital filter and some other analysis functions were realized.
Through static experiments, changing trend and other properties of arc-length to voltage curve was concluded and explained, then further experiments were carried out to analyse all the influence factors. Among which non-transferred arc current and plasma gas flow were regarded as the main factors to the output. By a series of experiments, the most optimum parameters were concluded. After a summing-up of the foregoing work and results, a steadier arc was produced by making an improvement on the micro plasma arc sensor.
Afterwards, by the method of multi-line segments fitting, the work of identification of the joints type and pick-up of the characteristic parameters was performed.
本文根据其传感原理,通过设计微束等离子弧传感器等工作,搭建起一套合适的引弧装置和相应的硬件平台,产生了可供试验测量用的稳定的等离子电弧。
针对该等离子弧系统,开发了与之配套的电压信号采集、分析软硬件系统。信号采集模块中,根据采集卡提供的接口,实现了高频率、大数据量采集,波形图实时显示和二进制或十进制数据同步保存;分析模块中,实现了数字滤波及其他一些数据分析功能。
通过静态试验,获得了等离子弧长度与测量电压之间的基本变化趋势和特点,并深入解释了电弧的五个工作状态——极限期、工作区Ⅰ、过渡区、工作区Ⅱ和导通期以及它们的形成原因;全面分析了各影响因素对传感过程可能造成的影响,其中维弧电流、离子气流量等因素对于输出电压起到决定性的作用;通过静态、动态试验等总结出适合本文硬件设备的一套最佳参数,并对微束等离子发生器进行了相应的改进,使电弧达到了更加稳定的状态。
在电弧传感器及其低层处理获取的接头表面轮廓基础上,通过多线段拟合的近似算法进行了典型焊接接头类型的识别和特征参数的提取等工作。
Weld seam tracking and sensing technology plays a very important role in welding automate production and is also a critical factor in weld seam quality. The most common sensing methods till now are vision sensor, tactile sensor and arc sensor, etc. But they all have limitations respectively. The technology of weld seam tracking based on micro plasma arc has some particular merits comparing with traditional tracking means and also is an innovation in seam tracking field. According to the principle of this seam tracking method, a suitable system which can generate non-transferred arc was built by designing a micro plasma arc sensor, an arc generating device and some corresponding equipments.
A corresponding signal collection and analysis system was developed. In the signal collection module, the collection of high frequency and large numbers of data was realized. Also, oscillogram show and binary or decimal data saving real-time were actualized. In the signal analysis module, digital filter and some other analysis functions were realized.
Through static experiments, changing trend and other properties of arc-length to voltage curve was concluded and explained, then further experiments were carried out to analyse all the influence factors. Among which non-transferred arc current and plasma gas flow were regarded as the main factors to the output. By a series of experiments, the most optimum parameters were concluded. After a summing-up of the foregoing work and results, a steadier arc was produced by making an improvement on the micro plasma arc sensor.
Afterwards, by the method of multi-line segments fitting, the work of identification of the joints type and pick-up of the characteristic parameters was performed.
引文
1宋天虎,李敏贤.先进制造技术的发展与焊接技术的未来.第八次全国焊接会议论文集.北京.1997:17~27
2 J. W. Kim,S. J. Na.Study On Arc Sensor Algorithm for Weld Seam Tracking in Gas Metal Arc Welding of Butt Joints.Journal of Engineering Manufacture,1991,205(4):247~255
3黄石生,高向东.焊缝跟踪技术的研究与展望.电焊机.1995,(5):1~5
4 S. Murakami,Weld-line Tracking Control of Arc Welding Robot Using Fuzzy Logic Controller.Fuzzy Sets and Systems.1989,32(2):221~237
5 T. Araya,S. Saikawa,Recent Activities on Sensing and Adaptive Control of Arc Welding.Proceedings of 3rd International Conference on Trends in Welding Research.U.S.A.1994:210~216
6 J. Yu,Y. Kim.Influence of Reflected Arc Light on Vision Sensors for Automatic GTAW Systems.Welding Journal.2003,82(2):36~42
7何景山,杨春利,林三宝.无辅助光源图像法TIG焊焊缝跟踪传感系统.焊接学报.2000,21(1): 37~408
8 Hiroshi Fujimura,Eizo Ide,Hironon Inoue.Joint Tracking Control Sensor of GMAW.Transactions of Japan Welding Society.1987,18(1):32~40.
9吴林,陈善本等.智能化焊接技术.国防工业出版社,2000:35~40
10高向东,黄石生.基于视觉传感的焊缝跟踪控制系统.焊接技术.2000,29(1):1~3
11 Tsing-Chia Kuo,Li-Jen Wu.An image tracking system for welded seams using fuzzy logic.Journal of Materials Processing Technology.2002,(120): 169~180
12齐铂金,赵晶,吴鑫,史应生.薄板焊缝视觉传感与弧焊机器人CAN总线控制.焊接技术.2000,29(12):28~30
13李鹤歧,大岛健司.用微机图像法对脉冲MAG焊接熔池进行观察和控制的研究.焊接学报.1988,9(1):37~43
14李鹤歧,大岛健司.用TV摄像机对脉冲焊接电弧长度的采样控制.焊接学报.1989,10(4):256~264
15 K. Oshima,M. Morita.Observation and Digital Control of the Molten Pool in Pulsed MIG Welding.Welding International.1988,32(3):234~240
16 K. Oshima,M. Morita.Sensing and Digital Control of Weld Pool in Pulsed MIG Welding.Transactions of the Japan Welding Society.1992,23(4):36~42
17 G. Agapiou,C. Kasiouras,A. A. Serafetinides.A detailed analysis of the MIG spectrum for the development of laser-based seam tracking sensors.Optics & Laser Technology.1999(31):157~161
18 Morgan,J. S. Bromley,P. G. Davey.Visual Guidance Techniques for Robot Arc Welding.Proceeding of 3rd International conference on Robot Vision and sensory Controls.Tokyo,Japan.1987:615~619
19张炯等.实时视觉控制的弧焊机器人系统.焊接学报.1997,18(12):184~188
20 R. W. Richardson,D. A. Gutow.Coaxial Arc Weld Pool viewing for Process Monitoring and Control.Welding Journal.1984,63(3):43~50
21张裕明.TIG焊熔透正面视觉自适应控制的研究.哈尔滨工业大学博士论文.1990:25~60
22张裕明,吴林.TIG焊熔透正面检测量的确定.焊接学报.1991,12(1):39~45
23 Y. M. Zhang,R. Kovacevc,L. Wu.Closed-loop Control of Weld Penetration Using Front-Face vision Sensing . Journal of Systems and Control Engineering.1993,207(3):27~34
24 Min Young Kim,Kuk-Won Ko,Hyung Suck Cho,Jae-Hoon Kim.Visual sensing and recognition of welding environment for intelligent shipyard welding robots . Intelligent Robots and Systems(IROS 2000) . Proceedings.2000 IEEE/RSJ International Conference,Takamatsu,Japan.2000,3: 2159 ~2165
25 Y.Ogawa. Image processing for wet welding in turbid condition.Underwater Technology,2000.Proceedings of the 2000 International Symposium.Tokyo, Japan.2000:457~462
26 Karsten Haug,Gunter Pritschow.Robust laser-stripe sensor for automated weld-seam-tracking in the shipbuilding industry Industrial Electronics Society.Proceedings of the 24th Annual Conference of the IEEE (IECON '98),Aachen,Germany.1998,2:1236~1241
27 S. Jorg,J. Langwald, J. Stelter, G. Hirzinger, C. Natale.Flexible robot-assembly using a multi-sensory approach.Robotics and Automation.IEEE International Conference.San Francisco,CA,USA.2000,.4:3687~3694
28张炯等.薄板对接接头识别的视觉方法.中国机械工程.1997,8(6):104~106
29 Z. Bingul,G. E. Cook,A. M.Strauss. Application of fuzzy logic to spatial thermal control in fusion welding . Industry Applications . IEEE Transactions.2000,36:1523~1530
30 S. Amin-Nejad,J. S. Smith, J. Lucas.TMS320C40 parallel processor for high speed imaging application . Image Processing And Its Applications.Seventh International Conference.Manchester,UK.1999,1:429~434
31震宇,张华,潘际銮.电弧传感器的发展状况及应用前景.焊接技术.2001,30(5):2~6
32 K. Eguchi, S. Yamane, H. Sugi,T. Kubota, K. Oshima,Application of neural network to detection of arc length, extension length and root gap in robotic welding.Industrial Electronics Society(IECON '98).Proceedings of the 24th Annual Conference of the IEEE.Aachen,Germany.1998,2:1131~1135
33 P. U. Dilthey,J. Gollnick.Through the arc sensing in GMA-welding with high speed rotating torch.Industrial Electronics Society.Proceedings of the 24th Annual Conference of the IEEE (IECON '98).Aachen,Germany.1998, 4:2374~2377
34费跃农.电弧传感器焊缝自动跟踪系统及电弧传感基础理论研究.清华大学博士论文.1990:32~50
35陈善本等编著.焊接过程现代控制方法.哈尔滨工业大学出版社,2001:1~10
36 Zafer Bingul,George E.Dynamic modeling of GMAW process.Proceedings - IEEE International Conference on Robotics and Automation.Detroit,MI, USA.1999,4:3059~3064
37樊重建.基于微束等离子弧的焊缝跟踪传感研究.哈尔滨工业大学工学硕士学位论文.2003:6~10
38吴镛宪.等离子电弧的稳定性.上海航天.1994,4.
39雷玉成,顾晓波.等离子弧喷嘴结构对电弧稳定性的影响.江苏理工大学学报.1994,15(4)
40张宝卿.微束等离子弧焊的应用.低压电器.1990,2.
41 Robert H.Bishop著.LabVIEW 6i使用教程.乔瑞萍,林欣等译.电子工业出版社,2003:98~130
42廖宝剑,吴士德,潘际銮.电弧传感器理论模型及信息处理.焊接学报.1996,17(4):263~272
43张光明,金庆辉.等离子弧工作气体的选择.安装.1995,20(4):4~5
44潘际銮.焊接手册第一卷焊接方法及设备.机械工业出版社,1995:131~144
45吴林,陈善本等编著.智能化焊接技术.国防工业出版社,2000:218~221
2 J. W. Kim,S. J. Na.Study On Arc Sensor Algorithm for Weld Seam Tracking in Gas Metal Arc Welding of Butt Joints.Journal of Engineering Manufacture,1991,205(4):247~255
3黄石生,高向东.焊缝跟踪技术的研究与展望.电焊机.1995,(5):1~5
4 S. Murakami,Weld-line Tracking Control of Arc Welding Robot Using Fuzzy Logic Controller.Fuzzy Sets and Systems.1989,32(2):221~237
5 T. Araya,S. Saikawa,Recent Activities on Sensing and Adaptive Control of Arc Welding.Proceedings of 3rd International Conference on Trends in Welding Research.U.S.A.1994:210~216
6 J. Yu,Y. Kim.Influence of Reflected Arc Light on Vision Sensors for Automatic GTAW Systems.Welding Journal.2003,82(2):36~42
7何景山,杨春利,林三宝.无辅助光源图像法TIG焊焊缝跟踪传感系统.焊接学报.2000,21(1): 37~408
8 Hiroshi Fujimura,Eizo Ide,Hironon Inoue.Joint Tracking Control Sensor of GMAW.Transactions of Japan Welding Society.1987,18(1):32~40.
9吴林,陈善本等.智能化焊接技术.国防工业出版社,2000:35~40
10高向东,黄石生.基于视觉传感的焊缝跟踪控制系统.焊接技术.2000,29(1):1~3
11 Tsing-Chia Kuo,Li-Jen Wu.An image tracking system for welded seams using fuzzy logic.Journal of Materials Processing Technology.2002,(120): 169~180
12齐铂金,赵晶,吴鑫,史应生.薄板焊缝视觉传感与弧焊机器人CAN总线控制.焊接技术.2000,29(12):28~30
13李鹤歧,大岛健司.用微机图像法对脉冲MAG焊接熔池进行观察和控制的研究.焊接学报.1988,9(1):37~43
14李鹤歧,大岛健司.用TV摄像机对脉冲焊接电弧长度的采样控制.焊接学报.1989,10(4):256~264
15 K. Oshima,M. Morita.Observation and Digital Control of the Molten Pool in Pulsed MIG Welding.Welding International.1988,32(3):234~240
16 K. Oshima,M. Morita.Sensing and Digital Control of Weld Pool in Pulsed MIG Welding.Transactions of the Japan Welding Society.1992,23(4):36~42
17 G. Agapiou,C. Kasiouras,A. A. Serafetinides.A detailed analysis of the MIG spectrum for the development of laser-based seam tracking sensors.Optics & Laser Technology.1999(31):157~161
18 Morgan,J. S. Bromley,P. G. Davey.Visual Guidance Techniques for Robot Arc Welding.Proceeding of 3rd International conference on Robot Vision and sensory Controls.Tokyo,Japan.1987:615~619
19张炯等.实时视觉控制的弧焊机器人系统.焊接学报.1997,18(12):184~188
20 R. W. Richardson,D. A. Gutow.Coaxial Arc Weld Pool viewing for Process Monitoring and Control.Welding Journal.1984,63(3):43~50
21张裕明.TIG焊熔透正面视觉自适应控制的研究.哈尔滨工业大学博士论文.1990:25~60
22张裕明,吴林.TIG焊熔透正面检测量的确定.焊接学报.1991,12(1):39~45
23 Y. M. Zhang,R. Kovacevc,L. Wu.Closed-loop Control of Weld Penetration Using Front-Face vision Sensing . Journal of Systems and Control Engineering.1993,207(3):27~34
24 Min Young Kim,Kuk-Won Ko,Hyung Suck Cho,Jae-Hoon Kim.Visual sensing and recognition of welding environment for intelligent shipyard welding robots . Intelligent Robots and Systems(IROS 2000) . Proceedings.2000 IEEE/RSJ International Conference,Takamatsu,Japan.2000,3: 2159 ~2165
25 Y.Ogawa. Image processing for wet welding in turbid condition.Underwater Technology,2000.Proceedings of the 2000 International Symposium.Tokyo, Japan.2000:457~462
26 Karsten Haug,Gunter Pritschow.Robust laser-stripe sensor for automated weld-seam-tracking in the shipbuilding industry Industrial Electronics Society.Proceedings of the 24th Annual Conference of the IEEE (IECON '98),Aachen,Germany.1998,2:1236~1241
27 S. Jorg,J. Langwald, J. Stelter, G. Hirzinger, C. Natale.Flexible robot-assembly using a multi-sensory approach.Robotics and Automation.IEEE International Conference.San Francisco,CA,USA.2000,.4:3687~3694
28张炯等.薄板对接接头识别的视觉方法.中国机械工程.1997,8(6):104~106
29 Z. Bingul,G. E. Cook,A. M.Strauss. Application of fuzzy logic to spatial thermal control in fusion welding . Industry Applications . IEEE Transactions.2000,36:1523~1530
30 S. Amin-Nejad,J. S. Smith, J. Lucas.TMS320C40 parallel processor for high speed imaging application . Image Processing And Its Applications.Seventh International Conference.Manchester,UK.1999,1:429~434
31震宇,张华,潘际銮.电弧传感器的发展状况及应用前景.焊接技术.2001,30(5):2~6
32 K. Eguchi, S. Yamane, H. Sugi,T. Kubota, K. Oshima,Application of neural network to detection of arc length, extension length and root gap in robotic welding.Industrial Electronics Society(IECON '98).Proceedings of the 24th Annual Conference of the IEEE.Aachen,Germany.1998,2:1131~1135
33 P. U. Dilthey,J. Gollnick.Through the arc sensing in GMA-welding with high speed rotating torch.Industrial Electronics Society.Proceedings of the 24th Annual Conference of the IEEE (IECON '98).Aachen,Germany.1998, 4:2374~2377
34费跃农.电弧传感器焊缝自动跟踪系统及电弧传感基础理论研究.清华大学博士论文.1990:32~50
35陈善本等编著.焊接过程现代控制方法.哈尔滨工业大学出版社,2001:1~10
36 Zafer Bingul,George E.Dynamic modeling of GMAW process.Proceedings - IEEE International Conference on Robotics and Automation.Detroit,MI, USA.1999,4:3059~3064
37樊重建.基于微束等离子弧的焊缝跟踪传感研究.哈尔滨工业大学工学硕士学位论文.2003:6~10
38吴镛宪.等离子电弧的稳定性.上海航天.1994,4.
39雷玉成,顾晓波.等离子弧喷嘴结构对电弧稳定性的影响.江苏理工大学学报.1994,15(4)
40张宝卿.微束等离子弧焊的应用.低压电器.1990,2.
41 Robert H.Bishop著.LabVIEW 6i使用教程.乔瑞萍,林欣等译.电子工业出版社,2003:98~130
42廖宝剑,吴士德,潘际銮.电弧传感器理论模型及信息处理.焊接学报.1996,17(4):263~272
43张光明,金庆辉.等离子弧工作气体的选择.安装.1995,20(4):4~5
44潘际銮.焊接手册第一卷焊接方法及设备.机械工业出版社,1995:131~144
45吴林,陈善本等编著.智能化焊接技术.国防工业出版社,2000:218~221