Method and system for determining a pipe welding torch swing direction
By acquiring data through current sensors, voltage sensors, and angle sensors, and using a controller to calculate arc resistance and threshold values to automatically control the oscillation direction of the welding torch, the problems of low welding accuracy and visual fatigue are solved, and high-precision pipe welding is achieved.
Patent Information
- Application Number
- CN202210892193.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2022-07-27
- Publication Date
- 2026-05-15
- Estimated Expiration
- 2042-07-27
AI Technical Summary
In the pipeline welding process, the existing technology has low welding precision, the human eye has limited observation accuracy, and long-term observation leads to visual fatigue, resulting in large welding errors.
The current, voltage, and angle data of the welding torch are acquired by using current sensors, voltage sensors, and angle sensors. The controller calculates the arc resistance and arc resistance threshold, and automatically controls the swing direction of the welding torch, avoiding real-time observation by the human eye.
It improves welding precision, reduces welding errors, reduces visual fatigue for technicians, and enhances the reliability and efficiency of welding.
Smart Images
Figure CN117506070B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of pipeline welding technology, and in particular to a method and system for determining the oscillation direction of a pipeline welding torch. Background Technology
[0002] With the development of technology, automated or semi-automated welding equipment is usually used when welding pipes.
[0003] When welding pipes, due to the large diameter and wall thickness of the pipes, it is usually necessary to first bevel the pipe ends. Then, the bevels of the two pipes are placed together and welded. During the welding process, the welding torch needs to rotate both circumferentially and oscillate along the pipe's axis to keep the bevels molten, thus completing the weld between the two pipes. In related technologies, when welding pipes, technicians typically need to observe the welding torch's rotation angle and the distance between the welding torch and the bevel sidewall in real time using a display device. Then, they control the oscillation direction of the welding torch using a remote control device to complete the welding work.
[0004] On the one hand, the accuracy achievable by human visual observation is limited, which restricts the improvement of welding precision; on the other hand, the diameter of pipes is usually relatively large, and the time required for each welding operation is relatively long, which makes the workload of technicians relatively heavy and easily causes visual fatigue, resulting in welding errors and thus low welding precision. Summary of the Invention
[0005] This application provides a method and system for determining the oscillation direction of a welding torch in pipeline welding, which can solve the problem of low welding accuracy in related technologies. The technical solution is as follows:
[0006] In a first aspect, a method for determining the swing direction of a pipe welding torch is provided. The method is applied to a system for determining the swing direction of a pipe welding torch. The system includes: a current sensor, a voltage sensor, an angle sensor, a controller, and a torch motion mechanism, wherein the torch motion mechanism is equipped with a welding torch.
[0007] The method includes:
[0008] The controller controls the welding torch motion mechanism to rotate along the circumference of the pipe and move along the axial direction of the pipe;
[0009] The controller acquires the first wire feeding speed and first wire extension sent by the welding torch, the first current value sent by the current sensor, the first voltage value sent by the voltage sensor, and the first welding angle sent by the angle sensor according to a preset cycle time. The first welding angle is the angle that the welding torch rotates from a preset reference welding position along the circumference of the pipe to the current position.
[0010] The controller determines the first arc resistance corresponding to the welding torch based on the first current value, the first voltage value, and the first welding angle.
[0011] The controller determines the first arc resistance threshold corresponding to the welding torch at the current position based on the first wire feeding speed, the first wire extension, the first welding angle, and the arc resistance threshold calculation formula.
[0012] The controller determines the target swing direction of the welding torch based on the first arc resistance, the first arc resistance threshold, and the first direction.
[0013] In one possible implementation, the controller determines the first arc resistance corresponding to the welding torch based on the first current value, the first voltage value, and the first welding angle, including:
[0014] Based on the first welding angle and the correspondence between the welding angle and the angle coefficient, the first angle coefficient corresponding to the first welding angle is determined;
[0015] Calculate the first quotient of the first voltage value and the first current value, and calculate the first product of the first quotient and the first angle coefficient to obtain the first arc resistance corresponding to the welding gun.
[0016] In one possible implementation, the controller determines the target swing direction of the welding torch based on the first arc resistance, the first arc resistance threshold, and the current movement direction of the welding torch along the axial direction of the pipe, including:
[0017] If the first arc resistance is greater than the first arc resistance threshold, then the first direction that is the same as the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
[0018] If the first arc resistance is less than or equal to the first arc resistance threshold, then a second direction opposite to the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
[0019] In one possible implementation, before the controller controls the welding torch motion mechanism to rotate circumferentially along the pipe and move axially along the pipe, it further includes:
[0020] The controller acquires, according to the preset cycle time, the second wire feed speed and second wire extension sent by the welding torch, the second current value sent by the current sensor, and the second voltage value sent by the voltage sensor when welding flat standard parts; and acquires, according to the preset cycle time, the second welding angle sent by the angle sensor, the third current value sent by the current sensor, and the third voltage value sent by the voltage sensor when welding pipe standard parts.
[0021] The controller calculates a second quotient of the second voltage value and the second current value to obtain a second arc resistance corresponding to the second wire feeding speed and the second dry extension;
[0022] The controller fits multiple sets of the second wire feeding speed, the second dry extension, and the second arc resistance to obtain a first function;
[0023] The controller determines the second angle coefficient corresponding to the second welding angle based on the second welding angle and the correspondence between the welding angle and the angle coefficient.
[0024] The controller calculates a third quotient of the third voltage value and the third current value, and calculates a second product of the third quotient and the second angle coefficient to obtain a third arc resistance corresponding to the second welding angle;
[0025] The controller fits multiple sets of the second welding angles and the third arc resistance to obtain a second function;
[0026] The controller calculates the third product of the first function and the second function to obtain the formula for calculating the arc resistance threshold.
[0027] Secondly, a system for determining the swing direction of a welding torch for pipeline welding is provided. The system includes: a current sensor, a voltage sensor, an angle sensor, a controller, and a welding torch motion mechanism, wherein the welding torch motion mechanism is equipped with a welding torch.
[0028] The controller is used to control the welding torch motion mechanism to rotate along the circumferential direction of the pipe and move along the axial direction of the pipe.
[0029] The welding torch is used to send a first wire feeding speed and a first wire extension to the controller according to a preset cycle duration;
[0030] The current sensor is used to: detect a first current value passing through the welding torch according to the preset period duration, and send the first current value to the controller;
[0031] The voltage sensor is used to: detect a first voltage value at the welding torch according to the preset period duration, and send the first voltage value to the controller;
[0032] The angle sensor is used to: detect the first welding angle corresponding to the welding torch according to the preset period, and send the first welding angle to the controller, wherein the first welding angle is the angle traversed by the welding torch as it rotates from the preset reference welding position along the circumferential direction of the pipe to the current position;
[0033] The controller is used for:
[0034] Based on the first current value, the first voltage value, and the first welding angle, the first arc resistance corresponding to the welding torch is determined;
[0035] Based on the first wire feeding speed, the first wire extension, the first welding angle, and the arc resistance threshold calculation formula, the first arc resistance threshold corresponding to the welding torch at the current position is determined.
[0036] Based on the first arc resistance, the first arc resistance threshold, and the first direction, the target swing direction corresponding to the welding torch is determined.
[0037] In one possible implementation, the controller is configured to:
[0038] Based on the first welding angle and the correspondence between the welding angle and the angle coefficient, the first angle coefficient corresponding to the first welding angle is determined;
[0039] Calculate the first quotient of the first voltage value and the first current value, and calculate the first product of the first quotient and the first angle coefficient to obtain the first arc resistance corresponding to the welding gun.
[0040] In one possible implementation, the controller is configured to:
[0041] If the first arc resistance is greater than the first arc resistance threshold, then the first direction that is the same as the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
[0042] If the first arc resistance is less than or equal to the first arc resistance threshold, then a second direction opposite to the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
[0043] In one possible implementation, the controller is further configured to:
[0044] The second wire feed speed and second wire extension sent by the welding torch, the second current value sent by the current sensor, and the second voltage value sent by the voltage sensor are acquired according to the preset cycle time when welding flat standard parts; the second welding angle sent by the angle sensor, the third current value sent by the current sensor, and the third voltage value sent by the voltage sensor are acquired according to the preset cycle time when welding pipe standard parts.
[0045] Calculate the second quotient of the second voltage value and the second current value to obtain the second arc resistance corresponding to the second wire feeding speed and the second dry extension;
[0046] The first function is obtained by fitting multiple sets of the second wire feeding speed, the second dry extension, and the second arc resistance.
[0047] Based on the second welding angle and the correspondence between the welding angle and the angle coefficient, the second angle coefficient corresponding to the second welding angle is determined;
[0048] Calculate the third quotient of the third voltage value and the third current value, and calculate the second product of the third quotient and the second angle coefficient to obtain the third arc resistance corresponding to the second welding angle;
[0049] A second function is obtained by fitting multiple sets of the second welding angles and the third arc resistance;
[0050] Calculate the third product of the first function and the second function to obtain the formula for calculating the arc resistance threshold.
[0051] Thirdly, a computer device is provided, the computer device including a processor and a memory, the memory storing at least one instruction, the instruction being loaded and executed by the processor to perform the operation performed by the method for determining the oscillation direction of a pipe welding torch.
[0052] Fourthly, a computer-readable storage medium is provided, wherein at least one instruction is stored in the storage medium, the instruction being loaded and executed by a processor to perform the operation performed by the method for determining the oscillation direction of a pipe welding torch.
[0053] Fifthly, a computer program product is provided, comprising computer program code, wherein when the computer program code is executed by a computer device, the computer device executes the method described in the first aspect and its possible implementations.
[0054] The beneficial effects of the technical solutions provided in this application are:
[0055] The scheme mentioned in this application embodiment determines the first arc resistance corresponding to the welding torch in the system for determining the oscillation direction of the welding torch. This is achieved by the controller using a first current value sent by a current sensor, a first voltage value sent by a voltage sensor, and a first welding angle sent by an angle sensor. Simultaneously, the controller determines the first arc resistance threshold corresponding to the welding torch by using the first wire feed length, first extension length, and first welding angle sent by the welding torch. Finally, the controller controls the oscillation direction of the welding torch by comparing the first arc resistance with the first arc resistance threshold. Using this scheme, the oscillation direction of the welding torch does not need to be controlled by human observation during pipeline welding; the controller can control the oscillation direction. The controller's control accuracy is significantly higher than that of human observation, and there is no visual fatigue associated with it. Therefore, this helps reduce welding errors and improves the accuracy of pipeline welding. Attached Figure Description
[0056] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0057] Figure 1 This is a schematic diagram of a system structure for determining the swing direction of a welding torch in pipeline welding, provided in an embodiment of this application.
[0058] Figure 2 This is a schematic diagram of the structure of a controller provided in an embodiment of this application;
[0059] Figure 3 This is a flowchart of a method for determining the swing direction of a welding torch in pipeline welding, provided in an embodiment of this application.
[0060] Figure 4 This is a schematic diagram of the structure of a computer device provided in an embodiment of this application. Detailed Implementation
[0061] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.
[0062] First, several terms used in the embodiments of this application will be explained:
[0063] Swing direction: During pipe welding, the welding torch needs to move along the circumference of the pipe while also moving along the axial direction of the pipe. The direction of the welding torch's movement along the axial direction of the pipe is the swing direction.
[0064] Wire feed speed: During welding, the length of the welding wire fed into the weld pool per unit time, where the liquid metal portion with a certain shape formed on the surface of the pipe is called the weld pool.
[0065] Dry extension: The distance between the end of the welding wire closest to the pipe surface and the contact tip of the welding gun.
[0066] Arc resistance: The resistance of the electric arc formed when the air between the welding torch tip and the pipe surface is broken down during the welding process.
[0067] The method for determining the oscillation direction of a pipe welding torch provided in this application embodiment is applied to a system for determining the oscillation direction of a pipe welding torch, such as... Figure 1 As shown, the system includes: a current sensor 110, a voltage sensor 120, an angle sensor 130, a controller 140, and a welding torch movement mechanism 150, wherein the welding torch movement mechanism 150 is equipped with a welding torch 1501.
[0068] The execution entity of the method for determining the oscillation direction of a pipe welding torch provided in this application embodiment can be the controller 140 in the above-mentioned system. From a hardware structure perspective, as... Figure 2 As shown, the controller 140 may include a processor 1401, a memory 1402, and a communication component 1403, etc.
[0069] The processor 1401 can be a CPU (Central Processing Unit) or a SoC (System on Chip), etc. The processor 1401 can be used to determine the first arc resistance corresponding to the welding torch, to determine the first arc resistance threshold corresponding to the welding torch at the current position, to determine the target swing direction corresponding to the welding torch, and so on.
[0070] The memory 1402 can be various volatile or non-volatile memories, such as SSD (Solid State Disk) or DRAM (Dynamic Random Access Memory). The memory can be used to store pre-stored data, intermediate data, and result data during the process of determining the oscillation direction of the welding torch in pipe welding. For example, it can store data such as the first wire feed speed, the first wire extension, the first current value, the first voltage value, the first welding angle, the first arc resistance, and the first arc resistance threshold.
[0071] The communication component 1403 can be a wired network connector, a WiFi (Wireless Fidelity) module, a Bluetooth module, a cellular network communication module, etc. The communication component 1403 can be used to transmit data with other components, such as voltage sensors, current sensors, angle sensors, welding torch moving parts, etc. The communication component can be used to receive the first wire feed speed and first wire extension sent by the welding torch, to receive the first current value sent by the current sensor, to receive the first voltage value sent by the voltage sensor, to receive the first welding angle sent by the angle sensor, and to send the target oscillation direction to the welding torch moving parts, etc.
[0072] When welding pipes, due to their large diameter and wall thickness, it is usually necessary to first bevel the pipe ends. Then, the bevels of the two pipes are placed face to face and positioned at the bevels using automated or semi-automated welding equipment. During the welding process, the welding torch needs to rotate along the circumference of the pipe and also maintain a certain width along the pipe's axis, meaning the welding torch needs to swing left and right along its axis to ensure that both pipe bevels are in a molten state. This guarantees the reliability of the weld and completes the connection between the two pipes.
[0073] In related technologies, when welding pipes, technicians typically need to observe the distance between the welding torch and the bevel sidewall in real time using a display device. Based on this distance, they then control the direction of the welding torch's swing using a remote control to ensure the width of the weld with the two bevels. However, the accuracy of human observation is limited, and prolonged observation can lead to visual fatigue, resulting in low welding precision.
[0074] During welding, the arc resistance is positively correlated with the minimum distance between the welding torch and the bevel sidewall (the minimum distance between the two bevel sidewalls). That is, the smaller the minimum distance between the welding torch and the bevel sidewall, the lower the arc resistance generated during welding. Therefore, this application provides a method for determining the swing direction of a welding torch in pipeline welding. In this method, the controller compares the arc resistance with an arc resistance threshold to determine whether the welding torch has reached a specified distance from the bevel sidewall, thereby determining the swing direction of the welding torch. Using this method, real-time human observation is unnecessary during welding; the controller can control the movement of the welding torch, which helps improve welding accuracy.
[0075] The method for determining the oscillation direction of a pipe welding torch, as provided in the embodiments of this application, will be described below.
[0076] This application provides embodiments such as Figure 3 The process flow for determining the oscillation direction of a welding torch in pipe welding, as shown, includes the following steps.
[0077] S301, Controller 140 controls the welding torch motion mechanism 150 to rotate along the circumference of the pipe and move along the axis of the pipe.
[0078] Before welding the pipe, the welding torch 1501 at the welding torch movement mechanism 150 needs to be adjusted to a preset reference welding position, which is usually located in the direction of gravity of the pipe. Then, the technician sends a welding start command to the controller 140. The command can be sent by pressing the button or control on the controller 140 that indicates "start welding", or by clicking the button or control that indicates "start welding" on the terminal device that has established a communication connection with the controller 140, etc.
[0079] After receiving the instruction to start welding, the controller 140 controls the welding torch motion mechanism 150 to drive the welding torch 1501 to rotate along the circumference of the pipe and move along the axis of the pipe.
[0080] S302, the controller 140 acquires the first wire feeding speed and first wire extension sent by the welding torch 1501, the first current value sent by the current sensor 110, the first voltage value sent by the voltage sensor 120, and the first welding angle sent by the angle sensor 130 according to a preset cycle duration.
[0081] The first welding angle is the angle that the welding torch 1501 travels from the preset reference welding position along the circumference of the pipe to the current position.
[0082] During pipe welding, current sensor 110 detects a first current value passing through welding torch 1501 at a preset cycle time and sends the first current value to controller 140; voltage sensor 120 detects a first voltage value at welding torch 1501 at the same preset cycle time and sends the first voltage value to controller 140; angle sensor detects a first welding angle corresponding to welding torch 1501 at the same preset cycle time and sends the first welding angle to controller 140; welding torch 1501 sends a first wire feed speed and a first wire extension to controller at the same preset cycle time. The preset cycle time can be set according to actual working requirements, such as 1 microsecond, 2 milliseconds, 60 nanoseconds, 1 second, etc.
[0083] The controller 140 acquires the first wire feeding speed, first wire extension, first current value, first voltage value, and first welding angle according to the preset cycle time, for subsequent processing.
[0084] S303, the controller 140 determines the first arc resistance corresponding to the welding torch based on the first current value, the first voltage value, and the first welding angle.
[0085] The controller 140 can pre-store a correspondence table between welding angles and angle coefficients, as shown in Table 1. After obtaining the first welding angle, the controller 140 can first look up the first angle coefficient corresponding to the first welding angle in the above correspondence table. The angle coefficients a1, a2, and a3 in Table 1 are determined experimentally, such as a1 being 0.8, a2 being 0.6, and a3 being 0.5, etc., and are not limited here. Then, the controller 140 calculates the first quotient of the received first voltage value and the first current value. Next, the controller 140 calculates the first product of the first quotient and the first angle coefficient, and determines the first product as the first arc resistance of the arc generated between the welding torch 1501 and the pipe.
[0086] Table 1
[0087] Welding angle Angle coefficient [0°-60°) 1 [60°-120°) a1 [120°-160°) a2 [160°-180°] a3
[0088] Optionally, the controller 140 can pre-store a first functional relationship between the welding angle and the angle coefficient. After obtaining the first welding angle, the controller 140 can substitute the first welding angle into the aforementioned first functional relationship to obtain the first angle coefficient corresponding to the first welding angle, and use the first angle coefficient to calculate the first arc resistance. The aforementioned first functional relationship can be obtained by technicians through multiple experiments and fitting, and will not be elaborated here.
[0089] Optionally, the controller 140 can pre-store a table of correspondences between welding angles and arc resistance calculation formulas, as shown in Table 2. Here, a1, a2, a3, b1, b2, and b3 are all determined experimentally and are not limited here. After obtaining the first welding angle, the controller 140 can first look up the first arc resistance calculation formula corresponding to the first welding angle in the aforementioned table. Then, it substitutes the first voltage value and the first current value into the first arc resistance calculation formula to obtain the first arc resistance.
[0090] Table 2
[0091] Welding angle Arc resistance calculation formula [0°-60°) R = U / I [60°-120°) R = a1 × U / I [120°-160°) R = a² × U / I + b¹ [160°-180°] R = a³ × U / I + b²
[0092] Optionally, the controller 140 can pre-store a second functional relationship between the arc resistance and the welding angle, voltage value, and current value. After obtaining the first current value, the first voltage value, and the first welding angle, the controller 140 substitutes them into the second functional relationship to obtain the first arc resistance. The aforementioned second functional relationship can be obtained by technicians through multiple experiments and fitting, and will not be elaborated here.
[0093] S304, the controller 140 determines the first arc resistance threshold corresponding to the welding torch 1501 at the current position based on the first wire feeding speed, the first wire extension, the first welding angle, and the arc resistance threshold calculation formula.
[0094] While calculating the first resistive arc in step S303, the controller 140 can input the first wire feed speed, the first wire extension, and the first welding angle into a pre-set arc resistance threshold calculation formula to obtain the first arc resistance threshold corresponding to the welding torch 1501 at the current position. The arc resistance threshold calculation formula can be obtained as follows:
[0095] Before welding the pipeline using the method provided in this application, technicians need to conduct welding tests on flat standard parts and standard pipeline parts.
[0096] In the welding test of the standard flat parts (the influence of the welding angle is not considered in this test, i.e., the welding angle of the welding torch is always 0), the controller 140 acquires the second wire feed speed and second arc extension sent by the welding torch 1501, the second current value sent by the current sensor 110, and the second voltage value sent by the voltage sensor 120 within the aforementioned preset cycle time. Then, the controller 140 calculates the second quotient of the second voltage value and the second current value, and determines the second quotient as the second arc resistance corresponding to the second wire feed speed and the second arc extension. Subsequently, the controller 140 fits multiple sets of second wire feed speed, second arc extension, and second arc resistance to obtain a first function R1 = f(S,H) with respect to the wire feed speed and arc extension, where R1 is the arc resistance corresponding to the wire feed speed and arc extension, S is the wire feed speed, and H is the arc extension.
[0097] As an example, the first function mentioned above can be represented as follows: Wherein, K1, K2, C1, K3, K4, and C2 are all coefficients in the first function, obtained through the fitting process described above. Optionally, the expression for the first function can also be other forms of function, such as a sine function, a polynomial function, etc., without any limitations here.
[0098] In the welding test of standard pipe components (this test does not consider the effects of wire feed speed and wire extension, i.e., the wire feed speed and wire extension are constant), the controller acquires the second welding angle sent by the angle sensor 130, the third current value sent by the current sensor 110, and the third voltage value sent by the voltage sensor 120 within the aforementioned preset cycle time. Then, the controller 140 looks up the second angle coefficient corresponding to the second welding angle in the aforementioned correspondence table of welding angle and angle coefficient. Subsequently, the controller 140 calculates the third quotient of the third voltage value and the third current value, and calculates the second product of the third quotient and the second angle coefficient, determining the second product as the third arc resistance corresponding to the second welding angle. Then, the controller 140 fits multiple sets of second welding angles and third arc resistances to obtain a second function R2 = f(P) regarding the welding angle, where R2 is the arc resistance corresponding to the welding angle, and P is the welding angle.
[0099] Finally, the controller 140 calculates the third product of the first function f(S,H) and the second function f(P) to obtain the arc resistance threshold calculation formula R. y = f(S,H)·f(P), where R y This is the arc resistance threshold.
[0100] S305, the controller 140 determines the target swing direction of the welding torch based on the first arc resistance, the first arc resistance threshold, and the current movement direction of the welding torch in the axial direction of the pipeline.
[0101] After obtaining the first arc resistance and the first arc resistance threshold, the controller 140 compares the magnitude of the first arc resistance with that of the arc resistance threshold.
[0102] If the first arc resistance is greater than the first arc resistance threshold, then the first direction that is the same as the current movement direction of the welding torch 1501 in the axial direction of the pipe is determined as the target swing direction. For example, if the welding torch 1501 is currently moving to the left along the axial direction of the pipe, and if the first arc resistance is greater than the first arc resistance threshold at this time, then the welding torch 1501 continues to move to the left along the axial direction of the pipe.
[0103] If the first arc resistance is less than or equal to the first arc resistance threshold, then the second direction opposite to the current movement direction of the welding torch 1501 in the axial direction of the pipe is determined as the target swing direction. For example, if the welding torch 1501 is currently moving to the left along the axial direction of the pipe, and if the first arc resistance is less than or equal to the first arc resistance threshold, then the welding torch 1501 will reverse direction, that is, the welding torch 1501 will move to the right along the axial direction of the pipe.
[0104] S306, the controller 140 sends the electrical signal corresponding to the target swing direction to the welding torch motion mechanism 150.
[0105] After determining the target swing direction of the welding torch 1501, the controller 140 sends a corresponding electrical signal to the welding torch motion mechanism 150 to control the welding torch motion mechanism 150 to drive the welding torch 1501 to move along the target swing direction.
[0106] The scheme mentioned in this application embodiment determines the first arc resistance corresponding to the welding torch in the system for determining the oscillation direction of the welding torch. This is achieved by the controller using a first current value sent by a current sensor, a first voltage value sent by a voltage sensor, and a first welding angle sent by an angle sensor. Simultaneously, the controller determines the first arc resistance threshold corresponding to the welding torch by using the first wire feed length, first extension length, and first welding angle sent by the welding torch. Finally, the controller controls the oscillation direction of the welding torch by comparing the first arc resistance with the first arc resistance threshold. Using this scheme, the oscillation direction of the welding torch does not need to be controlled by human observation during pipeline welding; the controller can control the oscillation direction. The controller's control accuracy is significantly higher than that of human observation, and there is no visual fatigue associated with it. Therefore, this helps reduce welding errors and improves the accuracy of pipeline welding.
[0107] This application provides a system for determining the oscillation direction of a pipe welding torch, such as... Figure 1 As shown, the system includes: a current sensor 110, a voltage sensor 120, an angle sensor 130, a controller 140, and a welding torch movement mechanism 150, wherein the welding torch movement mechanism 150 is equipped with a welding torch 1501.
[0108] The controller 140 is used to control the welding torch motion mechanism 150 to rotate along the circumference of the pipe and move along the axial direction of the pipe.
[0109] The welding torch 1501 is used to send the first wire feed speed and the first wire extension to the controller according to a preset cycle duration.
[0110] The current sensor 110 is used to: detect the first current value passing through the welding torch according to a preset period of time, and send the first current value to the controller.
[0111] Voltage sensor 120 is used to: detect the first voltage value at the welding torch according to a preset period of time, and send the first voltage value to the controller;
[0112] Angle sensor 130 is used to: detect the first welding angle corresponding to the welding torch according to a preset cycle time, and send the first welding angle to the controller, wherein the first welding angle is the angle traversed by the welding torch from the preset reference welding position along the circumferential direction of the pipe to the current position;
[0113] Controller 140 is used for:
[0114] Based on the first current value, the first voltage value, and the first welding angle, determine the first arc resistance corresponding to the welding torch;
[0115] Based on the first wire feeding speed, the first wire extension, the first welding angle, and the arc resistance threshold calculation formula, determine the first arc resistance threshold corresponding to the welding torch at the current position;
[0116] Based on the first arc resistance, the first arc resistance threshold, and the current movement direction of the welding torch along the axial direction of the pipe, the target swing direction corresponding to the welding torch is determined.
[0117] In some examples, the controller 140 is electrically connected to the current sensor 110, the voltage sensor 120, the angle sensor 130, the welding torch motion mechanism 150, and the welding torch 1501 to establish communication. This approach can improve the stability of data transmission in the system.
[0118] In other examples, the controller 140 establishes wireless communication with the current sensor 110, the voltage sensor 120, the angle sensor 130, the welding torch movement mechanism 150, and the welding torch 1501, respectively. This approach can reduce the number of wiring harnesses in the entire system and improve overall flexibility.
[0119] In one possible implementation, controller 140 is used for:
[0120] Based on the first welding angle and the correspondence between the welding angle and the angle coefficient, the first angle coefficient corresponding to the first welding angle is determined.
[0121] Calculate the first quotient of the first voltage value and the first current value, and calculate the first product of the first quotient and the first angle coefficient to obtain the first arc resistance corresponding to the welding torch.
[0122] In one possible implementation, controller 140 is used for:
[0123] If the first arc resistance is greater than the first arc resistance threshold, then the first direction that is the same as the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
[0124] If the first arc resistance is less than or equal to the first arc resistance threshold, then a second direction opposite to the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
[0125] In one possible implementation, the controller 140 is also used for:
[0126] The second wire feed speed and second wire extension sent by the welding torch 1501, the second current value sent by the current sensor 110, and the second voltage value sent by the voltage sensor 120 are acquired according to a preset cycle duration when welding standard flat parts. The second welding angle sent by the angle sensor 130, the third current value sent by the current sensor 110, and the third voltage value sent by the voltage sensor 120 are acquired according to a preset cycle duration when welding standard pipe parts.
[0127] Calculate the second quotient of the second voltage value and the second current value to obtain the second arc resistance corresponding to the second wire feeding speed and the second wire extension;
[0128] The first function is obtained by fitting multiple sets of second wire feeding speed, second dry extension, and second arc resistance.
[0129] Based on the second welding angle and the correspondence between the welding angle and the angle coefficient, the second angle coefficient corresponding to the second welding angle is determined.
[0130] Calculate the third quotient of the third voltage value and the third current value, and calculate the second product of the third quotient and the second angle coefficient to obtain the third arc resistance corresponding to the second welding angle;
[0131] By fitting multiple sets of second welding angles and third arc resistances, a second function is obtained;
[0132] Calculate the third product of the first function and the second function to obtain the formula for calculating the arc resistance threshold.
[0133] The scheme mentioned in this application embodiment determines the first arc resistance corresponding to the welding torch in the system for determining the oscillation direction of the welding torch. This is achieved by the controller using a first current value sent by a current sensor, a first voltage value sent by a voltage sensor, and a first welding angle sent by an angle sensor. Simultaneously, the controller determines the first arc resistance threshold corresponding to the welding torch by using the first wire feed length, first extension length, and first welding angle sent by the welding torch. Finally, the controller controls the oscillation direction of the welding torch by comparing the first arc resistance with the first arc resistance threshold. Using this scheme, the oscillation direction of the welding torch does not need to be controlled by human observation during pipeline welding; the controller can control the oscillation direction. The controller's control accuracy is significantly higher than that of human observation, and there is no visual fatigue associated with it. Therefore, this helps reduce welding errors and improves the accuracy of pipeline welding.
[0134] It should be noted that the system for determining the swing direction of a pipe welding torch provided in the above embodiments is only illustrated by the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the system can be divided into different functional modules to complete all or part of the functions described above. Furthermore, the device for determining the swing direction of a pipe welding torch and the method for determining the swing direction of a pipe welding torch provided in the above embodiments belong to the same concept, and their specific implementation process is detailed in the method embodiments, which will not be repeated here.
[0135] This application provides a computer device, which may be the controller described in the above embodiments. Figure 4 This is a schematic diagram of the computer device 400. The computer device 400 can vary significantly due to differences in configuration or performance. It may include one or more CPUs (Central Processing Units) 410 and one or more memories 420. The memories 420 store at least one instruction, which is loaded and executed by the processor 410 to implement the methods provided in the various method embodiments described above. Of course, the computer device may also have wired or wireless network interfaces, a keyboard, and input / output interfaces for input and output. The computer device may also include other components for implementing device functions, which will not be elaborated upon here.
[0136] In an exemplary embodiment, a computer-readable storage medium is also provided, such as a memory including instructions that can be executed by a processor in a terminal to complete the method for determining the oscillation direction of a pipe welding torch in the above embodiments. This computer-readable storage medium can be non-transitory. For example, the computer-readable storage medium can be ROM (Read-Only Memory), RAM (Random Access Memory), CD-ROM, magnetic tape, floppy disk, and optical data storage devices, etc.
[0137] Those skilled in the art will understand that all or part of the steps of the above embodiments can be implemented by hardware or by a program instructing related hardware. The program can be stored in a computer-readable storage medium, such as a read-only memory, a disk, or an optical disk.
[0138] The above description is merely an optional embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the principles of this application should be included within the protection scope of this application.
Claims
1. A method for determining the oscillation direction of a pipe welding torch, characterized in that, The method is applied to a system for determining the swing direction of a welding torch in pipeline welding. The system includes: a current sensor, a voltage sensor, an angle sensor, a controller, and a welding torch motion mechanism, wherein the welding torch motion mechanism is equipped with a welding torch. The method includes: The controller controls the welding torch motion mechanism to rotate along the circumference of the pipe and move along the axial direction of the pipe; The controller acquires the first wire feeding speed and first wire extension sent by the welding torch, the first current value sent by the current sensor, the first voltage value sent by the voltage sensor, and the first welding angle sent by the angle sensor according to a preset cycle time. The first welding angle is the angle that the welding torch rotates from a preset reference welding position along the circumference of the pipe to the current position. The controller determines the first angle coefficient corresponding to the first welding angle based on the first welding angle and the correspondence between the welding angle and the angle coefficient. The controller calculates a first quotient of the first voltage value and the first current value, and calculates a first product of the first quotient and the first angle coefficient to obtain the first arc resistance corresponding to the welding gun. The controller determines the first arc resistance threshold corresponding to the welding torch at the current position based on the first wire feeding speed, the first wire extension, the first welding angle, and the arc resistance threshold calculation formula. If the first arc resistance is greater than the first arc resistance threshold, the controller determines a first direction that is the same as the current direction of movement of the welding torch in the axial direction of the pipe as the target swing direction. If the first arc resistance is less than or equal to the first arc resistance threshold, the controller determines a second direction opposite to the current direction of movement of the welding torch in the axial direction of the pipe as the target swing direction.
2. The method according to claim 1, characterized in that, Before the controller controls the welding torch motion mechanism to rotate along the circumference of the pipe and move along the axial direction of the pipe, it further includes: The controller acquires, according to the preset cycle time, the second wire feed speed and second wire extension sent by the welding torch, the second current value sent by the current sensor, and the second voltage value sent by the voltage sensor when welding flat standard parts; and acquires, according to the preset cycle time, the second welding angle sent by the angle sensor, the third current value sent by the current sensor, and the third voltage value sent by the voltage sensor when welding pipe standard parts. The controller calculates a second quotient of the second voltage value and the second current value to obtain a second arc resistance corresponding to the second wire feeding speed and the second dry extension; The controller fits multiple sets of the second wire feeding speed, the second dry extension, and the second arc resistance to obtain a first function; The controller determines the second angle coefficient corresponding to the second welding angle based on the second welding angle and the correspondence between the welding angle and the angle coefficient. The controller calculates a third quotient of the third voltage value and the third current value, and calculates a second product of the third quotient and the second angle coefficient to obtain a third arc resistance corresponding to the second welding angle; The controller fits multiple sets of the second welding angles and the third arc resistance to obtain a second function; The controller calculates the third product of the first function and the second function to obtain the formula for calculating the arc resistance threshold.
3. A system for determining the oscillation direction of a pipe welding torch, characterized in that, The system includes: a current sensor, a voltage sensor, an angle sensor, a controller, and a welding torch motion mechanism, wherein the welding torch motion mechanism is equipped with a welding torch; The controller is used to control the welding torch motion mechanism to rotate along the circumferential direction of the pipe and move along the axial direction of the pipe. The welding torch is used to send a first wire feeding speed and a first wire extension to the controller according to a preset cycle duration. The current sensor is used to: detect a first current value passing through the welding torch according to the preset period duration, and send the first current value to the controller; The voltage sensor is used to: detect a first voltage value at the welding torch according to the preset period duration, and send the first voltage value to the controller; The angle sensor is used to: detect the first welding angle corresponding to the welding torch according to the preset period, and send the first welding angle to the controller, wherein the first welding angle is the angle traversed by the welding torch as it rotates from the preset reference welding position along the circumferential direction of the pipe to the current position; The controller is used for: Based on the first welding angle and the correspondence between the welding angle and the angle coefficient, the first angle coefficient corresponding to the first welding angle is determined; Calculate the first quotient of the first voltage value and the first current value, and calculate the first product of the first quotient and the first angle coefficient to obtain the first arc resistance corresponding to the welding gun; Based on the first wire feeding speed, the first wire extension, the first welding angle, and the arc resistance threshold calculation formula, the first arc resistance threshold corresponding to the welding torch at the current position is determined. If the first arc resistance is greater than the first arc resistance threshold, then the first direction that is the same as the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction. If the first arc resistance is less than or equal to the first arc resistance threshold, then a second direction opposite to the current direction of movement of the welding torch in the axial direction of the pipe is determined as the target swing direction.
4. The system according to claim 3, characterized in that, The controller is also used for: The second wire feed speed and second wire extension sent by the welding torch, the second current value sent by the current sensor, and the second voltage value sent by the voltage sensor are acquired according to the preset cycle time when welding flat standard parts; the second welding angle sent by the angle sensor, the third current value sent by the current sensor, and the third voltage value sent by the voltage sensor are acquired according to the preset cycle time when welding pipe standard parts. Calculate the second quotient of the second voltage value and the second current value to obtain the second arc resistance corresponding to the second wire feeding speed and the second dry extension; The first function is obtained by fitting multiple sets of the second wire feeding speed, the second dry extension, and the second arc resistance. Based on the second welding angle and the correspondence between the welding angle and the angle coefficient, the second angle coefficient corresponding to the second welding angle is determined; Calculate the third quotient of the third voltage value and the third current value, and calculate the second product of the third quotient and the second angle coefficient to obtain the third arc resistance corresponding to the second welding angle; A second function is obtained by fitting multiple sets of the second welding angles and the third arc resistance; Calculate the third product of the first function and the second function to obtain the formula for calculating the arc resistance threshold.
5. A computer device, characterized in that, The computer device includes a processor and a memory, the memory storing at least one instruction, which is loaded and executed by the processor to perform the operation of the method for determining the oscillation direction of a pipe welding torch as described in any one of claims 1 to 2.
6. A computer-readable storage medium, characterized in that, The storage medium stores at least one instruction, which is loaded and executed by a processor to perform the operation of the method for determining the oscillation direction of a pipe welding torch as described in any one of claims 1 to 2.