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CN-116237616-B - Welding arc physical characteristic detection system and method

CN116237616BCN 116237616 BCN116237616 BCN 116237616BCN-116237616-B

Abstract

The invention discloses a welding arc physical characteristic detection system and method, wherein the detection system comprises a PLC, a touch screen, an A/D module, a welding power supply, an adjustable resistor box, a current sensor, a voltage sensor, a pressure sensor, a temperature sensor, a water-cooling welding gun, a water-cooling copper mechanism and the like, wherein system parameters and functions are set through the touch screen, then welding arcs between refractory alloy electrodes of the water-cooling welding gun and the water-cooling copper mechanism are ignited, the PLC receives arc physical signal sampling values transmitted by the A/D module, the welding arc physical characteristic detection values are transmitted to the touch screen for numerical value or graph display after digital filtering, and meanwhile, the adjustable resistor box periodically adjusts welding current and arc voltage to realize cyclic detection and display of the welding arc physical characteristics. The detection system has the advantages of simple structure, convenient operation and rich functions, can detect the static characteristic, the dynamic characteristic, the length, the temperature of a heat affected zone and the arc force of the arc, and has strong practicability.

Inventors

  • ZHU JIE
  • CHEN GUOYI
  • WANG WEI
  • WANG JIAYOU
  • Qian Haoxuan
  • WANG KAI
  • Wu Guanyue

Assignees

  • 江苏科技大学
  • 南通德众科技发展有限公司

Dates

Publication Date
20260512
Application Date
20230209

Claims (10)

  1. 1. The welding arc physical characteristic detection system is characterized by comprising a PLC (1), a touch screen (2), an A/D module (3), a D/A module (4), a welding power supply (5), a motor driver (6), an adjustable resistor box (7), a current sensor (8), a voltage sensor (9), a pressure sensor (10), a temperature sensor (11), a welding gun height/angle adjusting mechanism (12), a water-cooling welding gun (13), a circulating water cooling machine (14), a water-cooling copper mechanism (16), a workbench (17), an auxiliary power supply (21) and an auxiliary switch (22), wherein a refractory alloy electrode (19) is arranged at the lower end of the water-cooling welding gun (13), a welding arc (20) is ignited between the refractory alloy electrode (19) and the water-cooling copper mechanism (16), and welding protection gas (18) blown out from the lower end of the water-cooling welding gun (13) protects the welding arc (20) and a welding area below the welding arc; The PLC (1) is in communication connection with the touch screen (2), an output interface of the PLC (1) is respectively and electrically connected with control ports of the D/A module (4), the motor driver (6), the adjustable resistor box (7), the circulating water cooler (14) and the auxiliary switch (22), an input interface of the PLC (1) is electrically connected with an output interface of the A/D module (3), and an input interface of the A/D module (3) is respectively and electrically connected with output interfaces of the current sensor (8), the voltage sensor (9), the pressure sensor (10) and the temperature sensor (11) and is used for collecting welding current (i a ) sampling values, Arc voltage sampling value, The electric arc component force (F 1 and F 2 ) sampling values and heat affected zone temperature sampling values are output to the PLC (1), an output interface of the D/A module (4) is electrically connected with a set input interface of the welding power supply (5), two output cables of the welding power supply (5) are respectively electrically connected with an input end of the adjustable resistor box (7) and a water-cooling copper mechanism (16), an output cable of the adjustable resistor box (7) passes through the current sensor (8) and then is electrically connected with a refractory alloy electrode (19) on the water-cooling welding gun (13), the two ends of the auxiliary power supply (21) can output voltage signals of 0-24V, the two ends of the auxiliary power supply are respectively electrically connected with the auxiliary switch (22) and the refractory alloy electrode (19) on the water-cooling welding gun (13), the two input ends of the voltage sensor (9) are respectively electrically connected with the water-cooling copper mechanism (16) and the water-cooling copper mechanism (16), the two input ends of the voltage sensor (9) are respectively connected with the refractory alloy electrode (19) on the water-cooling copper mechanism (16) and the water-cooling copper mechanism (13), the auxiliary power supply (21) can output voltage signals of 0-24V, the two ends of the auxiliary power supply (22) are respectively electrically connected with the refractory alloy electrode (19) on the water-cooling copper mechanism (16), and the water-cooling copper mechanism (13), the electric sensor (161) is electrically connected with the water-cooling copper block (161) and the water-cooling device (161) and the electric sensor (16) respectively A water pipe joint (162), a transition soft water pipe (163), a water inlet pipe (164), a water outlet pipe (165), the working copper plate (166), wherein the upper surface of the copper block (161) is provided with a shallow counter bore (161-1) and a welding cable connecting threaded counter bore (161-5), the working copper plate (166) is placed in the shallow counter bore (161-1) and keeps conductive contact with the copper block (161), the upper surface of the working copper plate (166) and the upper surface of the copper block (161) are in the same horizontal plane, the lower surface of the copper block (161) is provided with a deep counter bore (161-3) corresponding to the shallow counter bore (161-1) and a pressure sensor connecting threaded counter bore (161-6), the copper block (161) is provided with a threaded through hole (161-2) between the shallow counter bore (161-1) and the deep counter bore (161-3), the temperature sensor (11) is fixedly connected to the threaded through hole (161-2) from below the copper block (161-3) and keeps static friction contact with the lower surface of the working copper block (166), the copper block (161) is internally provided with a plurality of water inlet pipes (161-162) and a plurality of water outlet pipes (162) are fixedly connected with the water inlet pipe (162) respectively, the water-cooling type water-cooling welding gun is characterized in that the rest water pipe joints (162) on the same side of the copper block (161) are fixedly connected through the transition soft water pipe (163) in a watertight manner, the upper surface of the pressure sensor (10) is fixedly connected with the water-cooling copper mechanism (16), the lower surface of the pressure sensor (10) is fixedly connected with the workbench (17), the water-cooling welding gun (13) is mechanically fixedly connected to a T-shaped flange (12-6) of the welding gun height/angle adjusting mechanism (12), the welding gun height/angle adjusting mechanism (12) is integrally and vertically fixedly connected to the workbench (17), the circulating water-cooling machine (14) comprises two water flow channels, two ends of one water flow channel are respectively and fixedly connected with a water inlet and a water outlet of the water-cooling welding gun (13), and two ends of the other water flow channel are respectively and fixedly connected with a water inlet pipe (164) and a water outlet pipe (165) of the water-cooling copper mechanism (16).
  2. 2. The welding arc physical property detection system as claimed in claim 1, wherein the refractory alloy electrode (19) is a tungsten alloy electrode.
  3. 3. The welding arc physical property detection system according to claim 1, wherein the welding gun height/angle adjusting mechanism (12) comprises a height adjusting motor (12-1), a linear motion module (12-2), an angle adjusting motor (12-3), a box-type motor seat (12-4), a transmission pair (12-5) and a T-shaped flange (12-6), the transmission pair (12-5) is arranged in the box-type motor seat (12-4), the box-type motor seat (12-4) is fixedly connected to a sliding table (12-21) of the linear motion module (12-2), the angle adjusting motor (12-3) is fixedly connected to the back surface of the box-type motor seat (12-4), an output shaft of the angle adjusting motor (12-3) is fixedly connected with a driving wheel of the transmission pair (12-5), a driven wheel of the transmission pair (12-5) is fixedly connected with the T-shaped flange (12-6), after the height adjusting motor (12-1) is rotated, the linear motion module (12-2) drives the sliding table (12-21) and the box-type motor seat (12-4) to move together with the T-shaped flange (12-6), the method comprises the steps of adjusting the distance from the lower end of a refractory alloy electrode (19) of a water-cooling welding gun (13) to the upper surface of a copper block (161) to set and adjust the height of the water-cooling welding gun (13), rotating an angle adjusting motor (12-3), driving a T-shaped flange (12-6) and the water-cooling welding gun (13) to rotate in a vertical plane after being driven by a transmission pair (12-5) to set and adjust the angle (q) of the water-cooling welding gun.
  4. 4. The welding arc physical property detection system as claimed in claim 3, wherein the transmission pair (12-5) is a gear transmission pair or a synchronous belt transmission pair or a chain transmission pair.
  5. 5. The welding arc physical property detection system according to claim 1, wherein one path of cooling water output by the circulating water cooler (14) flows into the through holes (161-4) in the copper block (161) from the water inlet pipe (164), transits through the transition soft water pipe (163) and flows back and forth through all the through holes (161-4), and flows back to the circulating water cooler (14) from the water outlet pipe (165) to cool the water cooled copper mechanism (16).
  6. 6. A method of detecting a physical characteristic of a welding arc as claimed in claim 3, comprising the steps of: the method comprises the steps of firstly, setting system parameters, namely, setting a touch button (30-6) to enter a system parameter setting sub-interface (306) through the system parameters, then setting a touch button (306-1) through A/D sampling, setting sampling function parameters of all channels of an A/D module (3), or setting rotation parameters of a height adjusting motor (12-1) through a height adjusting motor, or setting the rotation parameters of the angle adjusting motor (12-3) through an angle adjusting motor, or setting/debugging a touch button (306-4) through simulation interference, setting simulation interference parameters and performing simulation interference debugging, or setting a touch button (306-5) through welding energy, setting initial welding current (i a ) and initial arc voltage, and transmitting the set system parameters to the PLC (1) in real time for storage; In the main interface (30) of the touch screen (2), through an arc static characteristic detection touch button (30-1) or an arc dynamic characteristic detection touch button (30-2) or an arc length detection touch button (30-3) or an arc length detection touch button (30-5) or an arc force detection touch button (30-4), entering an arc static characteristic detection sub-interface (301) or an arc dynamic characteristic detection sub-interface (302) or an arc length detection sub-interface (303) or an arc force detection sub-interface (304) or an arc force detection sub-interface (305), selecting an arc static characteristic detection function or an arc dynamic characteristic detection function or an arc length detection function or an arc force detection function respectively, and simultaneously, selecting an arc static characteristic detection function or an arc length detection function or an arc force detection function in a steady state arc sampling mode or a dynamic sampling mode or an arc temperature or an arc force detection function respectively through a dynamic characteristic sampling mode touch button (302-2) or an arc length sampling mode touch button (304-2) or an arc force sampling mode touch button (305-2); Step three, self-checking before welding and welding gun posture setting, namely, in an arc static characteristic detection sub-interface (301), an arc dynamic characteristic detection sub-interface (302), an arc length detection sub-interface (303), a heat affected zone temperature detection sub-interface (304) or an arc force detection sub-interface (305), respectively detecting the tightness of a system gas path and a water path and the flow rate of welding protective gas (18) and cooling water through a gas path/water path detection touch button (31), or setting the height of the water-cooling welding gun (13) through a welding gun height setting touch button (32), or setting the angle (q) of the water-cooling welding gun (13) through a welding gun angle setting touch button (33); And fourthly, arc physical characteristic detection, namely according to a selected system detection function, the PLC (1) firstly controls and outputs the welding protection gas (18) and cooling water in advance, then fires a welding arc (20) between the refractory alloy electrode (19) and the water-cooling copper mechanism (16), acquires an arc physical signal sampling value output by a corresponding sensor through the A/D module (3), transmits a corresponding welding arc physical characteristic detection value formed after digital filtering to the touch screen (2) to display a numerical value or a graph, and simultaneously, periodically adjusts welding current (i a ) and arc voltage through the adjustable resistance box (7) to realize cyclic detection and display of the welding arc (20) physical characteristics of different welding energy parameters until the detection is finished.
  7. 7. The method for detecting the physical characteristics of the welding arc according to claim 6, wherein in the first step, the sampling function parameters of each channel of the A/D module (3) specifically comprise an upper sampling limit, a lower sampling limit, a sampling speed and a filter coefficient of the current sensor (8), the voltage sensor (9), the temperature sensor (11) and the pressure sensor (10), wherein the upper sampling limit and the lower sampling limit of the current sensor (8) are in a range of 0-450A, the upper sampling limit and the lower sampling limit of the voltage sensor (9) are in a range of 0-100V, the upper sampling limit and the lower sampling limit of the temperature sensor (11) are in a range of 0-1000 ℃, the upper sampling limit and the lower sampling limit of the pressure sensor (10) are in a range of 0-20000 g, the sampling speed ranges of all sensors are in a range of 0-200 Hz, and the filter coefficient ranges are in a range of 0-128; The rotation parameters of the height adjusting motor (12-1) and the angle adjusting motor (12-3) comprise rotation speed, rotation acceleration and deceleration time and stepping rotation angle, wherein the rotation speed range is 0-30 mm/s, the rotation acceleration and deceleration time range is 0-100 ms, and the stepping rotation angle range is 0.0144-0.9 degrees; The simulation interference parameters specifically comprise a welding gun height change amplitude, a welding gun height change speed and upper and lower side residence time, wherein the welding gun height change amplitude range is 0-10 mm, the welding gun height change speed range is 0-30 mm/s, and the upper and lower side residence time range is 0-1000 ms.
  8. 8. The method for detecting a physical characteristic of a welding arc according to claim 6, wherein in the third step, the height setting of the water-cooled welding torch (13) comprises the steps of, ①, Pressing the welding gun height setting touch button (32), wherein the PLC (1) controls the auxiliary switch (22) to be closed, and a voltage signal output by the auxiliary power supply (21) is directly applied between the refractory alloy electrode (19) and the water-cooling copper mechanism (16); ②, the PLC (1) collects voltage signals detected by the voltage sensor (9) through the A/D module (3), and simultaneously controls the motor driver (6) to drive the height adjusting motor (12-1) so that a sliding table (12-21) on the linear motion module (12-2) drives the water-cooling welding gun (13) to move downwards; ③, when the refractory alloy electrode (19) of the water-cooling welding gun (13) is in contact with the water-cooling copper mechanism (16) below the refractory alloy electrode, the A/D module (3) collects that the voltage detected by the voltage sensor (9) is just zero, and the PLC (1) immediately controls the height adjusting motor (12-1) to stop rotating and turns off the auxiliary switch (22); And ④, driving the height adjusting motor (12-1) to reversely rotate by the PLC (1) through the motor driver (6) according to the set height of the welding gun, controlling the sliding table (12-21) on the linear motion module (12-2) to drive the water-cooling welding gun (13) to vertically move upwards, and realizing the height setting of the water-cooling welding gun (13).
  9. 9. The method of claim 6, wherein in the fourth step, the PLC (1) internal digital filtering method is arithmetic mean filtering or median filtering or weighted mean filtering, in the course of arc static characteristics and arc dynamic characteristics detection, the horizontal axis represents the detected value of the welding current (i a ) and the vertical axis represents the detected value of the arc voltage when the detection result is selected to be displayed in the course of arc length detection, the horizontal axis represents the detected value of the arc voltage when the detection result is selected to be displayed in the course of arc length detection, the vertical axis represents the detected value of the arc length when the detection result is selected to be displayed in the course of heat affected zone temperature detection, the PLC (1) calculates the arc power according to the detected value of the welding current (i a ) and the detected value of the arc voltage when the detection result is selected to be displayed in the course of arc dynamic characteristics, and in the course of arc dynamic characteristics detection, the PLC (1) also uses the force sensor (3482) to express the force component of the arc pressure (32F) according to the two paths (10) under the water-cooled copper mechanism (16) The resultant operation yields a total arc force (F a ), and when the detection result is selected to be displayed in a graph, the horizontal axis represents the arc power and the vertical axis represents the total arc force (F a ) detection value.
  10. 10. The method for detecting a physical characteristic detecting system of a welding arc according to claim 6, wherein in the fourth step, when arc static characteristic detection is performed, the adjustable resistor box (7) adjusts a welding current (i a ) and an arc voltage every 5-2000 ms, when arc dynamic characteristics or arc length or heat affected zone temperature or arc force is detected in a steady-state arc sampling mode, the adjustable resistor box (7) adjusts a welding current (i a ) and an arc voltage every 10-1000 ms, when arc dynamic characteristics or arc length or heat affected zone temperature or arc force is detected in a dynamic arc sampling mode, simulation interference set previously is introduced into a detection process, the PLC (1) controls the height adjusting motor (12-1) to rotate, drives the water-cooled welding gun (13) to do vertical linear reciprocating motion with a certain speed and amplitude, enables arc length of the welding arc (20) to change, and realizes simulation interference on the welding arc (20), and meanwhile, the adjustable resistor box (7) adjusts arc current (i a ) every 10-48 ms.

Description

Welding arc physical characteristic detection system and method Technical Field The invention relates to an automatic detection system and method for a plurality of physical characteristics of welding arc, and belongs to the technical field of welding arc testing. Background Welding is widely used as an important processing technology in the field of manufacturing steel structures such as ships, pressure vessels, bridges and the like. According to the heat source in the welding metallurgical process, the conventional welding method can be classified into fusion welding, pressure welding and brazing, wherein the fusion welding method is most widely used. Among the many fusion welding methods, arc welding is most applied, and uses a welding arc as a main heat source to melt a base material and a welding material, thereby realizing connection or hot working of metal materials. Thus, the physical characteristics of the welding arc directly affect the weld formation and joint organization properties of the arc welding. Welding arcs essentially belong to a strongly lasting gas discharge phenomenon, which is a conductive process of charged particles through the gas space between the two electrodes. The welding arc may be structurally subdivided into an anode region, an arc column region, and a cathode region, each region having different conductive properties and thus more complex physical properties. The physical characteristics of the welding arc are mainly three aspects of electric characteristics, thermal characteristics and force characteristics of the arc, and specifically comprise arc static characteristics (i.e. static volt-ampere characteristics), arc dynamic characteristics (i.e. dynamic volt-ampere characteristics), arc mechanical characteristics (i.e. polar spot pressure, including anode spot behavior and cathode spot behavior), minimum voltage principle, arc heat generating characteristics, arc temperature distribution, arc spectrum and the like. Currently, researchers are mainly developing around electrical characteristics for detection studies of welding arcs. In the chinese patent publication No. CN106238870B, entitled "a device and method for detecting a forward arc characteristic", by controlling the reciprocal entering and exiting of two probes into and from a non-consumable electrode arc space, under the conditions of different probe pitches, probe heights, probe height differences and welding process parameters, the voltage signal variation between the two probes is collected, and finally the electric signal characteristics of the arc in the two probe planes are obtained. In order to obtain the spatial voltage distribution of the non-consumable electrode arc, chinese patent publication No. CN106199278B, entitled "a device and method for detecting the characteristics of a swept arc", electric signal characteristics of different spatial positions of an arc are finally obtained by controlling two probes to continuously rotate or translate and sweep through an arc space. The two Chinese patents mainly detect the characteristics of the electric arc signals, but the detection device has single function, can only detect the spatial distribution of the electric arc signals, but does not relate to other physical characteristics of welding arcs, and has complex integral structure and needs to use a special high-temperature-resistant insulating probe device. The invention discloses a Chinese patent with publication number CN102043079B, named as an arc characteristic detection device and a detection method thereof, which monitors and collects arc voltage, current and arc morphology information of a graphite electrode through devices such as a signal collection converter, a grating, a camera and the like, and analyzes the arc morphology, arc length, deflection angle and corresponding voltage and current at each moment through computer software so as to detect arc behaviors and characteristics in a metallurgical furnace. The invention solves the problem that the high-temperature electric arc characteristic in the metallurgical furnace cannot be detected due to the existence of slag and foam slag, but the device has a complex structure and cannot meet the detection of the physical characteristic of the welding electric arc. In the Chinese patent application with publication number CN113053214A, named as a welding arc static characteristic test method, system, device and application, the test of the tungsten argon arc static characteristic is realized by automatically recording the current and voltage signals of the tungsten argon arc welding detected by a Hall current sensor and a Hall voltage sensor by a computer and automatically drawing a static characteristic curve. Although the method can detect the arc static characteristic curve, the system has single function, can not comprehensively detect the physical characteristics of the welding arc, and has limited practicability. Disclosure of Invention The in