共查询到19条相似文献,搜索用时 703 毫秒
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焊接过程中焊炬自动跟踪焊缝对保证焊接质量 ,提高自动化程度有着极其重要的实际意义。焊缝自动跟踪技术的关键是焊缝位置的传感方法 ,本文在深入研究TIG焊电弧发光行为的基础上 ,结合实际的焊接工况 ,建立了一套利用电弧弧光检测焊缝位置的图像传感系统。该系统在硬件方面解决了图像采集与焊接电流的同步以及图像品质的提高等问题 ,在计算机软件方面解决了阈值与图像品质相匹配以及焊缝位置的提取等问题。生产实际应用结果表明 ,该系统在检测精度、处理速度、稳定性、可靠性及实际工况的适应性等方面完全满足高质量焊缝对焊接过程自动对中的要求。 相似文献
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针对窄间隙旋转电弧MAG焊焊缝跟踪的需要以及单一传感器的不足,采用Visual C++开发了基于电弧传感和视觉传感的多信息融合焊缝跟踪系统。电弧传感采用NIPCI-6251数据采集卡、电流/电压传感器、电弧位置传感器结合NI的measurement studio软件,实现了对每个电弧旋转周期内电弧信号的获取,进而实现积分法、极值法、粗糙集等电弧传感方法。视觉传感利用图像采集卡、电弧位置传感器和CCD摄像机,获取电弧旋转到左右坡口侧时的焊接图像,实现焊缝偏差的检测。而焊缝跟踪是综合电弧传感焊缝偏差和视觉传感焊缝偏差的基础上进行焊缝纠偏。为提高系统运行效率,采用多线程方法实现电弧传感、视觉传感的同步采集和技术;利用CTimer控件实现焊缝偏差的多信息融合分析、显示和记录。系统的构建为进一步的多信息融合控制、焊接质量控制奠定基础。 相似文献
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电弧传感直接使用焊接电信号进行焊缝跟踪,旋转电弧还可用于改善焊缝成形,具有重要的应用价值.基于气保护熔化极焊接(GMAW)的数学模型以及焊丝端部的运动学模型,对旋转电弧传感的电流信号进行了模拟.在不同焊接参数下进行了焊接试验,采集了电流波形.结果表明,数值模拟结果与实际焊接电流波形吻合.电弧传感电流波形左右半周的不对称性与焊炬偏差成正比.电弧旋转频率越高,电流变化幅度越小.旋转半径越大,电流波形的不对称性越明显.研究结果对于高速旋转电弧传感系统的设计具有指导意义. 相似文献
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《焊接技术》2021,(7)
关节机器人具有自动化程度高、运动精准等优点,被广泛应用于电弧焊接领域。但是,由于被焊接工件存在加工、装配以及安装定位误差。所以,在焊接质量要求较高、且被焊接工件一致性不好的情况下需要配套焊缝跟踪系统方能实现高质量的焊接作业。电弧传感作为焊缝跟踪的传感方式具有系统结构简单、传感位置与焊接位置重合等优点,但也具有信噪比小、精度差、跟踪参数调整困难等缺点。本研究利用电弧传感的优点,结合机器人焊接对焊缝形状位置的预知特性,利用电弧传感作为基础偏差传感器,机器人控制器根据电弧传感器测量的偏差信号,对当前焊接点进行调整的同时,还对焊缝曲线的空间方程进行调整,从而实现对焊缝曲线上未焊接点的偏移量进行预判,实现焊缝偏差的前馈调整。 相似文献
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为提高磁控电弧焊缝自动跟踪系统的稳定性与跟踪精度,引入拉丁超立方取样试验设计方法和Kriging代理模型技术,建立磁控电弧传感器的参数(励磁频率、励磁电流、磁极间隙、线圈匝数)预测模型;分析磁控电弧传感器的主要参数对焊缝跟踪信号的影响规律及其在焊接过程中的稳定性;选取传感器参数的优化设计点,试验验证磁控电弧传感器参数优化的可靠性.结果表明,优化后的焊缝跟踪传感信号波形明显,且干扰少,由于提高了信号的信噪比,从根本上提高了焊缝跟踪的准确性和稳定性. 相似文献
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水下焊接机器人视觉传感系统图像干扰因素分析 总被引:1,自引:0,他引:1
水下焊接机器人视觉传感系统在焊接过程中实时的对焊缝图像进行提取,通过一系列的图像处理算法,识别出焊缝位置,得到焊缝与焊枪之间的位置偏差,通过控制算法,实现焊缝跟踪的目的.在图像提取的过程中,会有各种各样的干扰,如泥沙干扰、弧光干扰、水泡气泡干扰、水对光的散射等各种干扰.着重分析了水下焊接机器人视觉传感系统图像提取的各种干扰因素,并对各种干扰因素产生的原理加以研究分析,并在此基础上,对如何去除各种干扰因素的方法--"二步干扰因素去除法"进行了简要的分析. 相似文献
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埋弧焊图像法焊缝自动跟踪传感系统 总被引:6,自引:0,他引:6
结合采用埋弧焊进行容器类焊接结构制造过程中的工艺特点及工况,设计了一种将微型半导体激光发生器、微型摄像机及具有滤光功能的光学系统三者集成一体的焊缝视觉传感器。该传感器结构简洁、紧凑、使用方便灵活,图像采集与处理系统具有处理速度高(100ms)、实时性强,界面显示直观、简洁、工艺可示性等特点。 相似文献
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An optical sensing system for seam tracking and weld pool control in gas metal arc welding of steel pipe 总被引:34,自引:0,他引:34
A visual sensing system was developed for automatic gas metal arc welding (GMAW) of the root pass of steel pipe. The system consisted of a vision sensor that consisted of a charge-coupled device (CCD) camera and lenses, a frame grabber, image processing algorithms, and a computer controller. A specially designed five-axis manipulator was used to position the welding torch and to provide the vision sensor with automatic access to view the welding position. During the root pass welding, an image of the weld pool and its vicinity was captured using the camera without interference of the intensive arc light by viewing at the instance of a short-circuit of the welding power. The captured image was then processed to recognize the weld pool shape. For seam tracking, the manipulator was used to adjust the torch position based upon the pool image to the groove center. The measured gap size was used to determine the appropriate welding conditions to obtain sound penetration. The welding speed was chosen using fuzzy logic with the knowledge of a skilled welder and measured gap. The automatic welding equipment demonstrated that both welding conditions and torch position could be appropriately controlled to obtain a sound weldment and a good seam tracking capability. 相似文献
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将旋转电弧传感器和双丝串列电弧焊结合起来,开发了旋转电弧引导的、两个电弧在同一个熔池上燃烧的双丝串列电弧焊方法,对其焊缝成形工艺进行了研究.分析了焊接电流、焊接电压、双丝间距、电弧旋转等参数对焊缝成形的影响.结果表明,随着焊接电流的增大,熔敷速度增加,焊缝成形系数呈现先增大后减少的变化规律.而焊接电压的增大则会使焊缝成形系数略有减小.对双丝间距的研究发现,当间距为15 mm时,焊接质量较好.与普通双丝串列焊相比,前置电弧旋转时熔池底部变得平坦,最大熔深有所减小,平均熔深有所增加,这将有助于减少焊缝的应力集中.与单丝旋转电弧焊相比,焊接熔敷速度显著增大,有效避免了高速焊接时的咬边现象. 相似文献
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《Science & Technology of Welding & Joining》2013,18(1):103-109
AbstractA seam tracking method is presented based on the estimation of weld position during the gas tungsten arc welding process. Kalman filtering of the weld pool images from a visual sensor is applied to compute recursively the solution to the weld position equations which are established based on an estimation of the centroid position of the weld pool images. This centroid, the position of which corresponds with the weld position, is extracted as the measurement eigenvector. The evolution of the weld position data from the weld pool images can be described through an appropriate process model, so that the weld position can be detected by applying a Kalman filter. This allows adjustment of the welding torch position in real time, which may significantly reduce processing time and promote seam tracking accuracy. Simulations and actual welding experiments have demonstrated the effectiveness of the proposed algorithm in the presence of weld pool image noise and have demonstrated the robustness of weld position detection for seam tracking. 相似文献
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The characteristics of welding currents in a rotating arc lead tandem GMAW process and the weld-seam tracking 下载免费PDF全文
Tandem gas metal arc welding (T-GMAW) process shows a high deposition rate that up to three times of the single electrode GMAW,so the welding speed could be significantly increased in this process.However,the majority of this process applications are based on the pre-programmed robotic welding,which does not allow them to track the seam real-time during welding.Rotating arc sensor,sensing the seam position by detecting the changing of welding currents,has been widely adopted in the automatic robot welding process.It is proposed in this paper to integrate the rotating arc sensor with a trailing torch to develop a new approach of rotating arc lead tandem gas metal arc welding (RLT-GMAW) process.The characteristics of the welding currents in the proposed new welding process were firstly studied,and then a self-turning fuzzy control seam tracking strategy was developed for the mobile robot automatic welding.The experimental results showed that the proposed RLT-GMAW process had an excellent seam tracking performance and high welding deposition rate.Even if there were some electromagnetic interactions between the two arcs,the deviation of the welding seam could also be reflected by the fluctuation of the welding currents on the leading arc once the correct welding parameters were selected.Based on the detected deviation,the welding tracking experiments showed that the proposed self-turning fuzzy controller had a good performance for the RLT-GMA W process seam tracking. 相似文献
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通过对管道全位置熔化极气体保护焊(gas metal arc welding,GMAW)熔池图像的研究分析,发现并验证了其根焊熔池图像尖端与焊缝坡口中心位置重合的现象,依据此规律性特征,提出了一种基于熔池图像尖端信息的焊接偏差测定方法.该方法的基本原理是,在对焊接过程熔池CCD图像进行中值滤波、小波变换、连通区域分割等图像处理后,以搜索算法测得的根焊熔池图像尖端位置信息作为焊缝坡口中心位置的坐标值,此值与焊丝中心坐标值之差即为焊接偏差量.试验证明,此方法能从根焊熔池图像中实时测定焊接偏差量,为实现机器人自动焊缝跟踪控制提供了可靠依据. 相似文献
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根据塞拉门框焊点多而短、焊接质量要求高的特点,提出一种机器人间断式弧焊视觉跟踪系统,综合运用灰度变换等方法,建立基于普通光源的视觉跟踪移动窗口图像处理体系,克服传统图像分割方法易受到工件上刀痕亮斑和暗影等噪声干扰的不足,在采集图像中移动与焊缝具有相同形状和大小的窗口,以窗口中所有像素灰度平均值最小窗口作为焊缝当前位置,能有效的滤除刀痕亮斑和暗影噪声.通过焊缝当前位置与标准位置比较,可直接计算出焊缝位置偏差.结果表明,移动窗口焊缝图像处理体系具有很强的适应性和抗干扰能力,能满足实时跟踪要求. 相似文献