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JP-7856445-B2 - Defect monitoring device, defect monitoring method, welding support system, and welding system

JP7856445B2JP 7856445 B2JP7856445 B2JP 7856445B2JP-7856445-B2

Inventors

  • 片岡 保人
  • 吉川 旭則
  • 佐藤 伸志
  • 黄 碩
  • 田村 栄一
  • 椿 翔太

Assignees

  • 株式会社神戸製鋼所

Dates

Publication Date
20260511
Application Date
20220214
Priority Date
20210709

Claims (11)

  1. A defect monitoring device that predicts the occurrence of welding defects from the history information of the welding bead formation by the welding device when a structure is formed by stacking multiple welding beads, which are formed by melting and solidifying filler material by a welding device, A shape profile acquisition unit that acquires the shape profile of an existing welding bead, A feature extraction unit that extracts feature quantities of recess shapes formed by a plurality of existing welding beads included in the shape profile, A defect location identification unit identifies candidate defect locations where welding defects are expected to occur, based on the extracted feature quantities. The welding apparatus comprises a control unit which, when it forms a new weld bead, causes the shape profile acquisition unit to update the shape profile, and repeatedly performs the extraction of feature quantities by the feature quantity extraction unit and the identification of candidate defect locations by the defect location identification unit, A defect monitoring device in which the characteristic quantity includes at least one of the following: the root angle, which is the angle on the welding bead side, of the intersection angle between the tangent line at the position where the existing welding bead is in contact with the underlying surface of the welding bead in a cross section perpendicular to the bead formation direction of the welding bead, and the width of the bead formation region in the area where the new welding bead is planned to be formed.
  2. A defect monitoring device that predicts the occurrence of welding defects from the history information of the welding bead formation by the welding device when a structure is formed by stacking multiple welding beads, which are formed by melting and solidifying filler material by a welding device, A shape profile acquisition unit that acquires the shape profile of an existing welding bead, A feature extraction unit that extracts feature quantities of recess shapes formed by a plurality of existing welding beads included in the shape profile, A defect location identification unit identifies candidate defect locations where welding defects are expected to occur, based on the extracted feature quantities. The welding apparatus comprises a control unit which, when it forms a new weld bead, causes the shape profile acquisition unit to update the shape profile, and repeatedly performs the extraction of feature quantities by the feature quantity extraction unit and the identification of candidate defect locations by the defect location identification unit, A defect monitoring device in which the characteristic quantity includes at least one of the following: the distance between the bead crests of a pair of existing welding beads that are arranged adjacent to each other and form a valley in a cross section perpendicular to the bead formation direction of the welding bead, the valley depth from the bead crest to the valley bottom, and the distance between the bottoms of the welding beads at the valley bottom.
  3. The defect monitoring device according to claim 2, wherein the feature quantities include the cross-sectional area of the recess shape calculated using at least one of the feature quantities.
  4. The defect monitoring device according to any one of claims 1 to 3, further comprising a formation area identification unit that identifies whether the existing welding bead is a wall-like continuous wall portion or a filled portion within a region surrounded by the wall portion.
  5. A defect monitoring device according to any one of claims 1 to 4, further comprising a defect size prediction unit that predicts the defect size from the location information of the candidate defect location or the magnitude of the feature quantity.
  6. A defect monitoring method for predicting the occurrence of welding defects when forming a structure by layering multiple weld beads formed by melting and solidifying filler material with a welding device, based on the history information of the welding bead formation by the welding device, The process of obtaining the shape profile of the existing weld bead, A step of extracting characteristic quantities of recess shapes formed by a plurality of existing weld beads included in the shape profile, A step of identifying candidate defect locations where welding defects are expected to occur according to the extracted feature quantities, The welding apparatus updates the shape profile when it newly forms the weld bead, and repeatedly performs the extraction of feature quantities and the identification of candidate defect locations. A defect monitoring method that distinguishes whether the existing welding bead is a wall-like continuous wall portion or a filled portion within a region surrounded by the wall portion, and determines the characteristic quantity only when the filled portion is formed.
  7. The defect monitoring method according to claim 6 , further comprising the step of predicting the defect size from the location information of the candidate defect location or the magnitude of the feature quantity.
  8. A defect monitoring device according to any one of claims 1 to 5, An instruction information generating device that generates instruction information to improve the welding defect at the identified candidate defect location, A welding support system equipped with the following features.
  9. The welding support system according to claim 8, wherein the instruction information generation device includes a post-processing condition setting unit that sets conditions for repairing the candidate defect location by machining or remelting.
  10. The instruction information generation device includes a welding condition setting unit that sets at least one of the welding conditions, such as welding current, welding voltage, filler material feeding rate, welding speed, and torch holding angle, when forming the welding bead at the candidate defect location. The welding support system according to claim 8 or 9.
  11. A welding support system according to any one of claims 8 to 10, The welding apparatus that forms the welding bead, A bead processing device for processing potential defect locations in the welded bead of the formed structure, A welding system equipped with [the following features].

Description

This invention relates to a defect monitoring device, a defect monitoring method, a welding support system, and a welding system. In arc welding, techniques are known for detecting defects in welded structures and determining whether proper welding has been performed. For example, Patent Document 1 discloses a technique for determining the quality of welding by acquiring multiple pieces of information, such as the welder's behavior, molten pool shape, and wire protrusion length, during semi-automatic welding (Patent Document 1). Japanese Patent Publication No. 2008-110388 Figure 1 is an overall diagram of the welding system.Figure 2 is a schematic functional block diagram of the control unit.Figure 3 is a flowchart showing the procedure for monitoring the occurrence of defects.Figure 4 is a schematic diagram showing the welding torch and shape detection unit, and the bead formation trajectory of the weld bead.Figure 5A schematically shows the cross-sectional shape of adjacent existing weld beads, and is a cross-sectional view when the existing weld beads B are properly spaced apart from each other.Figure 5B schematically shows the cross-sectional shape of adjacent existing weld beads, and is a cross-sectional view when existing weld beads are placed close together.Figure 6 is an explanatory diagram showing an example of information about potential defect locations displayed on the display unit.Figure 7 is a graph showing an example of the defect candidate location determination results along the bead formation trajectory.Figure 8 is an explanatory diagram showing examples of other feature quantities in a cross-section perpendicular to the bead formation direction of an existing welded bead.Figure 9 is an explanatory diagram showing how the spacing between the existing welded beads shown in Figure 8 is changed.Figure 10 is an explanatory diagram showing how the spacing between the existing weld beads shown in Figure 8 is changed.Figure 11 is an explanatory diagram showing examples of other feature quantities in a cross-section perpendicular to the bead formation direction of an existing welded bead.Figure 12 is an explanatory diagram showing an example of feature quantities when an existing weld bead is approximated as a trapezoid in a cross-section perpendicular to the bead formation direction of the existing weld bead.Figure 13 is an explanatory diagram showing an example of characteristic quantities of an existing weld bead in a cross-section perpendicular to the bead formation direction of the existing weld bead.Figure 14 is an explanatory diagram showing an example of characteristic quantities when a welding bead is formed in the filling portion inside the wall of an existing welding bead in a cross-section perpendicular to the bead formation direction.Figure 15 is an explanatory diagram showing the pitch of each welding bead when multiple welding beads are stacked in a cross-section perpendicular to the bead formation direction of an existing welding bead.Figure 16 is an explanatory diagram showing how the shape profile is approximated by a curve.Figure 17 is an explanatory diagram showing the results of predicting the shape of a fabricated object with existing weld beads layered on top of it.Figure 18 is an explanatory diagram showing the factors influencing defects.Figure 19 is a plan view showing the existing weld bead and the planned surface for bead formation of the new weld bead.Figure 20 is a cross-sectional view along the line XX-XX shown in Figure 19.Figure 21 is a cross-sectional view along the line XXI-XXI shown in Figure 19.Figure 22 is a plan view illustrating an example of post-processing.Figure 23 is a cross-sectional view along the line XXIII-XXIII shown in Figure 22.Figure 24 is a plan view showing the process of remelting the protruding portion.Figure 25 is a cross-sectional view along the line XXV-XXV in Figure 24. The configuration examples of the present invention will be described in detail below with reference to the drawings. Here, additive manufacturing, which creates a laminated object by accumulating welding beads, will be used as an example; however, the present invention can also be applied to general welding methods such as fillet welding and butt welding. <Configuration of the welding system> Figure 1 is an overall diagram of the welding system. The welding system 100 comprises a welding apparatus 110, a bead processing apparatus 130, and a welding support system 150. Here, the welding support system 150 is exemplified as being included in the control unit 11 of the welding apparatus 110, but it may be configured separately from the welding apparatus 110. (Welding equipment) First, let me explain the configuration of the welding apparatus 110. The welding apparatus 110 comprises a control unit 11, welding robots 13 each connected to the control unit 11, a robot drive unit 15, a filler material supply unit 17, a welding power supply unit 19, a shape detection unit 21, a di