Laser composite welding gap overproof adaptive adjustment system

Abstract

The application provides a laser composite welding gap over-tolerance self-adaptive adjusting system, which comprises a laser tracker, an integrated box, a welding machine, a welding gun and a welding parameter calculation unit; the laser tracker is installed on the integrated box and is used for measuring the actual groove gap at the front end of the unwelded section in real time and transmitting the actual groove gap to the welding parameter calculation unit; the welding parameter calculation unit is used for receiving the pre-input theoretical parameters and the actual groove gap and calculating the required actual wire feeding speed and actual welding parameters according to the actual groove gap; the welding machine is used for receiving the actual wire feeding speed and actual welding parameters sent by the welding parameter calculation unit; and the welding gun is integrated on the integrated box and receives the instruction of the welding machine to perform welding. The whole system can change the welding parameters in real time by detecting the gap change at the front end of the welding pool in real time and combining the actual groove gap, change the welding parameters while changing the wire feeding speed, and ensure the stability of the weld forming.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of mechanical processing, in particular to a laser composite welding gap over-difference self-adaptive adjusting system. BACKGROUND

[0002] As an advanced welding process, laser composite welding has the characteristics of fast welding speed and small deformation in the domestic ship field, but it is very harsh to the working conditions, and the groove gap usually needs to be controlled within 0.5mm, but in actual engineering construction, the gap over-difference phenomenon is very common, that is, the groove gap is too large, which will have a great impact on the welding quality. At the same time, uneven gap over-difference will also cause unstable weld forming quality.

[0003] Therefore, it is necessary to provide a welding system to adjust the welding parameters in real time to adapt to the change of the groove gap during welding. SUMMARY

[0004] In view of the above-mentioned shortcomings of the prior art, the purpose of the present application is to provide a laser composite welding gap over-difference self-adaptive adjusting system to solve the problems of large groove gap and unstable weld forming in the prior art.

[0005] To achieve the above-mentioned purposes and other related purposes, the present application provides a laser composite welding gap over-difference self-adaptive adjusting system, which comprises a laser tracker, an integrated box, a welding machine, a welding gun and a welding parameter calculation unit.

[0006] The laser tracker is installed on the integrated box, used to measure the actual groove gap in front of the unwelded section in real time, and transmit the actual groove gap to the welding parameter calculation unit through the integrated box and the circuit.

[0007] The welding parameter calculation unit is used to receive the pre-input theoretical parameters and the actual groove gap G0 collected by the laser tracker, and calculate the required actual wire feeding speed Vs1 and actual welding parameters according to the actual groove gap, and send the actual wire feeding speed and actual welding parameters to the welding machine; the actual welding parameters include real-time welding current I1 and real-time welding voltage U1.

[0008] The signal source of the welding machine is integrated on the integrated box, used to accept the actual wire feeding speed and actual welding parameters sent by the welding parameter calculation unit.

[0009] The welding gun is integrated on the integrated box, receiving the instructions of the welding machine to perform welding.

[0010] Preferably, the pre-input theoretical parameters include: welding speed Vh, laser power P, theoretical wire feed speed Vs0, defocusing amount, laser power P, wire dry elongation, light-wire spacing, workpiece thickness T, theoretical groove gap G, wire diameter d, and theoretical sum of reinforcement H of the front and back welds; wherein H refers to the sum of the thickness a of the weld protruding from the upper surface of the workpiece and the thickness b of the weld protruding from the lower surface of the workpiece, H = a + b.

[0011] Preferably, the welding parameter calculation unit calculates the actual wire feed speed Vs1 by:

[0012] (1) According to the actual groove gap G0 at the front end of the unwelded section, the required actual wire filling volume Eactual is calculated:

[0013] ΔG = G - G0;

[0014] The change amount of the unwelded section compared to the theoretical wire filling amount: ΔE = (T + H) × ΔG × L; L is the length of the unwelded section;

[0015] Theoretical wire filling amount: Etheoretical = Vs0 × (L / Vh) × π × (d / 2) 2 ;

[0016] Actual wire filling amount: Eactual = Etheoretical + ΔE;

[0017] (2) Then, according to the actual wire filling amount Eactual, the corresponding actual wire feed speed Vs1 is derived:

[0018] Vs1 = Vh × Eactual / (π × (d / 2)2 × L).

[0019] Preferably, the welding parameter calculation unit calculates the real-time welding current I1 and the real-time welding voltage U1 by:

[0020] ΔVs = Vs1 - Vs0;

[0021] Arc length correction M = -ΔVs / Vs0;

[0022] I1 = I0 × (1 - M), I0 is the welding current set according to the theoretical wire filling amount;

[0023] U1 = U0 × (1 - M), U0 is the welding voltage set according to the theoretical wire filling amount.

[0024] Preferably, the welding method is laser composite welding.

[0025] Preferably, the actual groove gap is less than 1 mm.

[0026] The application provides a laser composite welding gap over-adjusting system, which comprises a laser tracker, an integrated box, a welding machine, a welding gun and a welding parameter calculation unit, the laser tracker is installed on the integrated box and is used for measuring the actual groove gap of the front end of the unwelded section in real time, and the actual groove gap is transmitted to the welding parameter calculation unit through the integrated box and a circuit, the welding parameter calculation unit is used for receiving the pre-input theoretical parameters and the actual groove gap collected by the laser tracker, and the required actual wire feeding speed and actual welding parameters are calculated according to the actual groove gap, the signal source of the welding machine is integrated on the integrated box and is used for receiving the actual wire feeding speed and actual welding parameters sent by the welding parameter calculation unit, and the welding gun is integrated on the integrated box and receives the instruction of the welding machine to perform welding. The whole system can realize real-time welding parameter adjustment by detecting the gap change of the front end of the welding pool in real time, combining the actual groove gap, changing the welding parameters while changing the wire feeding speed, ensuring the stability of the weld forming and reducing the occurrence of defects.

[0027] The application can adjust the welding parameters in real time for the uneven fluctuation of the welding end surface perpendicularity reaching 90° (i.e. the contact surface of the workpiece is perpendicular to the upper and lower surfaces) and the gap after the butt welding seam is folded before welding (i.e. the groove gap is within 1mm), the gap detection device uses a laser tracker, and the welding theoretical value should be adjusted according to the gap data received by the tracker in real time to meet the requirements under specific working conditions. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 The structure of the components in the application is shown.

[0029] Figure 2 The welding groove in the application is shown.

[0030] Figure 3 The system operation flowchart in the application is shown.

[0031] Element number explanation

[0032] 11 welding gun

[0033] 12 integrated box

[0034] 13 laser tracker DETAILED DESCRIPTION

[0035] The embodiments of the application are described below through specific and concrete examples, and other advantages and effects of the application can be easily understood by those skilled in the art from the disclosure. The application can also be implemented or applied through other different embodiments, and various modifications or changes can be made to the details in the specification based on different views and applications without departing from the spirit of the application.

[0036] As will be understood by those familiar with the art, the figures to be described are not drawn to scale and that actual dimensions and shapes of the various elements can be varied. In the detailed description to follow, various embodiments are described with reference to the attached figures.

[0037] For the purposes of the description hereinafter, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", and derivatives thereof shall relate to the application as oriented in the drawing figures. However, it is to be understood that the application can assume various alternative orientations and, accordingly, such terms are not to be taken as limitations of the present application to a particular orientation.

[0038] In the context of this application, descriptions of structures where a first feature is "on" a second feature can include embodiments where the first and second features are formed in direct contact, as well as embodiments where additional features are formed between the first and second features such that the first and second features can not be in direct contact.

[0039] It is also noted that the various figures to be described are merely schematic and that actual dimensions and shapes of the various elements can be varied. In the detailed description to follow, various embodiments are described with reference to the attached figures.

[0040] As shown in FIG. 1, the present application provides a laser composite welding gap overproof self-adaptive adjustment system, the self-adaptive adjustment system comprises a laser tracker, an integrated box, a welding machine, a welding gun and a welding parameter calculation unit. Figures 1-2 The laser tracker is installed on the integrated box, and is used to measure the actual groove gap of the front end of the unwelded section in real time, and transmit the actual groove gap to the welding parameter calculation unit through the integrated box and the circuit.

[0041] The laser tracker is installed on the integrated box, and is used to measure the actual groove gap of the front end of the unwelded section in real time, and transmit the actual groove gap to the welding parameter calculation unit through the integrated box and the circuit.

[0042] The welding parameter calculation unit is used for receiving the pre-input theoretical parameters and the actual groove gap collected by the laser tracker, and calculating the required actual wire feeding speed Vs1 and actual welding parameters according to the actual groove gap, and sending the actual wire feeding speed and the actual welding parameters to the welding machine; the pre-input theoretical parameters include: welding speed Vh, laser power P, theoretical wire feeding speed Vs0, defocusing amount, laser power P, wire dry elongation, light-wire spacing, workpiece thickness T, theoretical groove gap G, wire diameter d, and sum of theoretical reinforcement of the front and back welds H; wherein H refers to the sum of the thickness a of the weld protruding from the upper surface of the workpiece and the thickness b of the weld protruding from the lower surface of the workpiece, i.e. H=a+b. The actual welding parameters include real-time welding current I1 and real-time welding voltage U1.

[0043] The signal source of the welding machine is integrated on the integrated box, and is used for accepting the actual wire feeding speed and the actual welding parameters sent by the welding parameter calculation unit.

[0044] The welding gun is integrated on the integrated box, and receives the instructions of the welding machine to perform welding. It should be understood that the laser tracker is located at the front end of the welding gun, so that real-time measurement is completed first and then welding is performed.

[0045] The above-mentioned theoretical parameters are processed by the welding parameter calculation unit. The calculation method of the actual wire feeding speed Vs1 by the welding parameter calculation unit is as follows:

[0046] (1) According to the actual groove gap G0 at the front end of the unwelded section, the required actual wire filling volume Eactual is calculated:

[0047] ΔG=G-G0;

[0048] The change amount of the unwelded section compared with the theoretical wire filling amount: ΔE=(T+H)×ΔG×L; wherein L is the length of the unwelded section;

[0049] Theoretical wire filling amount: Etheoretical=Vs0×(L / Vh)×π×(d / 2) 2 ; wherein Vh is the welding speed, i.e. the forming speed of the weld;

[0050] Actual wire filling amount: Eactual=Etheoretical+ΔE.

[0051] In the above formula, L / Vh obtains the welding time required by the unwelded section, the welding time multiplied by the theoretical wire feeding speed obtains the corresponding wire length, and then multiplied by the cross-sectional area of the wire, the theoretical wire filling amount Etheoretical is obtained.

[0052] (2) Then, the corresponding actual wire feeding speed Vs1 is derived according to the actual wire filling amount Eactual:

[0053] Vs1=Vh×Eactual / (π×(d / 2) 2X L), the calculation principle refers to the calculation principle of the above-mentioned E theory;

[0054] Further, it is also needed to adjust the arc end energy in real time according to the wire feeding amount. The arc end energy change is proportional to the change of the wire feeding amount, and the increase of the wire feeding speed will increase the arc end energy at the same time. According to the percentage of the increase of the wire feeding speed, the arc length correction is calculated to keep the arc end energy conservation, and finally the real-time welding current I1 and the real-time welding voltage U1 are obtained.

[0055] ΔVs = Vs1 - Vs0;

[0056] Arc length correction M (%) = - ΔVs / Vs0

[0057] I1 = I0 x (1 - M), I0 is the welding current derived according to the theoretical wire filling amount;

[0058] U1 = U0 x (1 - M), U0 is the welding voltage derived according to the theoretical wire filling amount;

[0059] As shown in the adaptive adjustment system in the present application, the operation method is as follows: Figure 3

[0060] 1. Artificially input the theoretical parameters including the theoretical wire feeding speed Vs0, the welding speed Vh, the laser power P, the theoretical groove gap G, the workpiece thickness T, the wire diameter d, and the sum of the theoretical positive and reverse weld bead excess height H on the operation panel of the background computer, and process in the welding parameter calculation unit.

[0061] 2. Set the welding torch movement trajectory, that is, the weld seam trajectory

[0062] 3. Start the integrated box and the laser tracker

[0063] 4. The laser tracker collects the actual groove gap G0 of the front end of the unwelded section, and transmits to the welding parameter calculation unit through the integrated box and the circuit. The welding parameter calculation unit obtains the actual required wire feeding speed Vs1, the real-time welding current I1 and the real-time welding voltage U1 after calculation

[0064] 5. Start the welding machine, and the welding machine indicates the welding torch according to the calculated actual required welding parameters, and runs according to the set trajectory and speed, so that the weld is formed under the condition that the gap is out of tolerance, and the forming effect is close to the theoretical value.

[0065] ​In summary, the present application provides a laser composite welding gap over-difference self-adaptive adjusting system, which comprises a laser tracker, an integrated box, a welding machine, a welding gun and a welding parameter calculation unit, the laser tracker is installed on the integrated box, is used for measuring the actual groove gap of the front end of the unwelded section in real time, and transmits the actual groove gap to the welding parameter calculation unit through the integrated box and a circuit, the welding parameter calculation unit is used for receiving the pre-input theoretical parameters and the actual groove gap collected by the laser tracker, and calculating the required actual wire feeding speed and actual welding parameters according to the actual groove gap, the signal source of the welding machine is integrated on the integrated box, is used for receiving the actual wire feeding speed and actual welding parameters sent by the welding parameter calculation unit, the welding gun is integrated on the integrated box, receives the instruction of the welding machine, and performs welding. The whole system detects the gap change of the front end of the welding pool in real time, adjusts the welding parameters in real time in combination with the actual groove gap, changes the welding parameters while changing the wire feeding speed, guarantees the stability of the weld forming, and reduces the occurrence of defects.

[0066] The present application can adjust the welding parameters in real time for the uneven fluctuation of the welding end surface perpendicularity reaching 90° (i.e. the contact surface of the workpiece is perpendicular to the upper and lower surfaces) and the butt welding gap after folding before welding being in the range of 1mm (i.e. the groove gap is within 1mm), the gap detection device uses a laser tracker, and according to the gap data received by the tracker, how to adjust the welding theoretical value in real time is calculated to meet the requirements under specific working conditions.

[0067] The above embodiments only exemplarily illustrate the principles and effects of the present application, and are not used to limit the present application. Any person skilled in the art can modify or change the above embodiments without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes completed by those skilled in the art without departing from the spirit and technical thought disclosed by the present application should be covered by the claims of the present application.

Claims

1. A laser composite welding gap over-tolerance adaptive adjustment system, characterized in that, The adaptive adjustment system comprises a laser tracker, an integrated box, a welding machine, a welding torch and a welding parameter calculation unit; The laser tracker is installed on the integrated box and is used to measure the actual gap of the front end of the unwelded section in real time and transmit the actual gap to the welding parameter calculation unit through the integrated box and a circuit; The welding parameter calculation unit is used to receive the pre-input theoretical parameters and the actual gap G0 collected by the laser tracker and calculate the required actual wire feeding speed Vs1 and actual welding parameters according to the actual gap, and send the actual wire feeding speed and the actual welding parameters to the welding machine; the actual welding parameters include real-time welding current I1 and real-time welding voltage U1; The signal source of the welding machine is integrated on the integrated box and is used to receive the actual wire feeding speed and the actual welding parameters sent by the welding parameter calculation unit; The welding torch is integrated on the integrated box and receives the instructions of the welding machine to perform welding; The pre-input theoretical parameters include welding speed Vh, laser power P, theoretical wire feeding speed Vs0, defocusing amount, wire dry elongation, light-wire spacing, workpiece thickness T, theoretical gap G, wire diameter d and the sum H of theoretical reinforcement of the front and back welds; H refers to the sum of the thickness a of the weld protruding from the upper surface of the workpiece and the thickness b of the weld protruding from the lower surface of the workpiece, H = a + b; The welding parameter calculation unit calculates the actual wire feeding speed Vs1 as follows: (1) According to the actual gap G0 of the front end of the unwelded section, the required actual wire filling volume Eactual is calculated: ΔG = G - G0; The change amount of the unwelded section compared with the theoretical wire filling amount: ΔE = (T + H) × ΔG × L; L is the length of the unwelded section; Theoretical wire fill: Etheo = VsO x (L / Vh) x π x (d / 2) 2 ; Actual wire filling amount: Eactual = Etheoretical + ΔE; (2) Then, the corresponding actual wire feeding speed Vs1 is derived according to the actual wire filling amount Eactual: Vs1 = Vh × Eactual / (π × (d / 2)) 2 ×L).

2. The adaptive conditioning system of claim 1, wherein, The welding parameter calculation unit calculates the real-time welding current I1 and the real-time welding voltage U1 as follows: ΔVs = Vs1 - Vs0; Arc length correction M = -ΔVs / Vs0; I1 = I0 × (1 - M), I0 is the welding current set according to the theoretical wire filling amount; U1 = U0 × (1 - M), U0 is the welding voltage set according to the theoretical wire filling amount.

3. The adaptive conditioning system of claim 1, wherein: The welding method is laser composite welding.

4. The adaptive conditioning system of claim 1, wherein: The actual gap is less than 1 mm.

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