Arc stability component identification method based on rotating arc stability sensor

Abstract

This invention discloses a method for identifying arc stability components based on a rotating arc stability sensor. Utilizing the working principle of the rotating arc stability sensor, a comprehensive evaluation index of arc stability can be detected. This sensor takes arc stability as input, an arc length self-adjustment system as the sensing element, a rotating arc as the conversion element, a welding circuit as the conversion circuit, a data acquisition and processing system as the output unit, and a rotating arc sensing signal as the output. Arc stability is classified and its evaluation index is established, dividing it into three components and quantifying the magnitude of each component. The method for identifying these three arc stability components allows for the determination of their magnitudes. This invention enables robots to automatically identify the arc stability components, laying the foundation for online control of arc stability and welding quality, and improving the quality and efficiency of robot welding.

Description

Technical Field

[0001] This invention relates to the field of electronic information technology, and in particular to a method for identifying arc stability components based on a rotating arc stability sensor. Background Technology

[0002] Arc stability directly affects weld formation quality through arc heat. Furthermore, rotating arc stability sensors, as a type of sensor for detecting arc stability, use rotating arc sensing signals as input. Since arc stability determines the reliability of these signals, arc stability directly impacts the performance of the rotating arc stability sensor. Currently, visual sensors cannot directly detect welding current values ​​that reflect arc stability. Arc sensors are currently only used for welding deviation identification, but arc stability detection based on arc sensors has not been implemented. Therefore, to accurately grasp the state of arc stability during the welding process, a method for identifying arc stability components based on arc sensors needs to be developed. Summary of the Invention

[0003] To address the problems existing in the prior art, this invention provides a method for identifying arc stability components based on a rotating arc stability sensor. Utilizing the working principle of the rotating arc stability sensor, a comprehensive evaluation index of arc stability can be detected. This sensor takes arc stability as input, an arc length self-adjustment system as the sensing element, a rotating arc as the conversion element, a welding circuit as the conversion circuit, a data acquisition and processing system as the output unit, and a rotating arc sensing signal as the output. Arc stability is classified into three components based on its classification and evaluation index, and the magnitude of each component is quantified. The method for identifying these three arc stability components allows for the determination of their magnitudes. This invention enables robots to automatically identify the arc stability components, laying the foundation for online control of arc stability and welding quality, and improving the quality and efficiency of robot welding.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] The arc stability component identification method based on a rotating arc stability sensor utilizes the working principle of the sensor to detect the comprehensive evaluation index of arc stability. This rotating arc stability sensor takes arc stability as input, an arc length self-adjustment system as the sensing element, a rotating arc as the conversion element, a welding circuit as the conversion circuit, a data acquisition and processing system as the output unit, and a rotating arc sensing signal as the output. Using the classification and evaluation index of arc stability, the arc stability is divided into three components, and the magnitude of each component is quantified. The method for identifying the arc stability components then identifies the magnitudes of these three components.

[0006] Furthermore, the method utilizes the working principle of a rotating arc stability sensor to detect the comprehensive evaluation index of arc stability. This rotating arc stability sensor uses arc stability as its input, an arc length self-adjustment system as its sensing element, a rotating arc as its conversion element, a welding circuit as its conversion circuit, a data acquisition and processing system as its output unit, and the rotating arc sensing signal as its output. The specific details are as follows:

[0007] When arc stability changes, it causes variations in welding voltage or current, which in turn alters the arc length self-regulation system's adjustment capability. This self-regulation system modulates arc stability into arc length self-regulation capability. By controlling the arc rotation radius and angular velocity, the arc length during fillet welding changes according to a given magnitude and speed. The rotating arc modulates the arc length self-regulation capability into a restored arc length value. The welding circuit converts this restored arc length value into welding current. Finally, a data acquisition and processing system converts this welding current into a rotating arc sensing signal.

[0008] Based on the mechanism of arc stability's influence on rotating arc sensing signals, this study establishes several relational models: arc stability versus arc length self-regulation capability, arc length self-regulation capability versus arc length recovery value, arc length recovery value versus welding current, and welding current versus rotating arc sensing signals. Combining these models, a mapping relationship model between arc stability and rotating arc sensing signals is then established. Based on this established mapping relationship model, the comprehensive evaluation index w0 of arc stability is detected.

[0009] Furthermore, by utilizing the classification and evaluation indicators of arc stability, arc stability is divided into three components, and the magnitude of each component is quantified, as detailed below:

[0010] Arc stability is classified into three categories: unstable arc, understable arc, and stable arc. If the arc is unstable, the brightness and shape of the arc change drastically between adjacent occurrences; the arc is very dim, and sometimes it may even extinguish, exhibiting arc interruption. An arc instability index, w1, is defined to describe the degree of arc instability. The value of w1 ranges from 0 to 1; the larger the value of w1, the more unstable the arc.

[0011] If the electric arc is in an unstable state, the brightness and shape of the arc change significantly between adjacent intervals, but there is no arc extinction; the arc is dim, or the arc brightness changes from bright to dim. The arc instability index is defined as w2, which describes the degree to which the arc state belongs to the instability category. The value of w2 ranges from 0 to 1. The larger the value of w2, the greater the degree of arc instability. The smaller the value of w2, the less severe the arc instability, and the closer the arc is to a stable or unstable state.

[0012] If the electric arc is in a stable state, the brightness and shape of the arc change little or remain unchanged between two consecutive occurrences, there is no arc extinction, and the arc brightness is very bright. The arc stability index is defined as w3, which describes the degree to which the arc state belongs to arc stability. The value of w3 ranges from 0 to 1. The larger the value of w3, the better the arc stability.

[0013] Therefore, the arc instability index w1, the arc understability index w2, and the arc stability index w3 can be used as evaluation indicators of arc stability, and the arc stability W = [w1, w2, w3].

[0014] Furthermore, the method for identifying the arc stability components can identify the magnitudes of the three components of arc stability, as detailed below:

[0015] Using the comprehensive evaluation index of arc stability identified by the rotating arc stability sensor, three components of arc stability can be identified, which satisfy the following formula:

[0016]

[0017] In the formula, W represents arc stability, w1 represents arc instability index, w2 represents arc understability index, w3 represents arc stability index, and w0 represents arc stability comprehensive evaluation index.

[0018] Therefore, the method based on the identification of arc stability components can identify three components of arc stability: index w1, which evaluates the degree of arc instability; index w2, which evaluates the degree of arc understability; and index w3, which evaluates the degree of arc stability.

[0019] The beneficial effects of this invention are as follows:

[0020] The advantage of this invention lies in the invention of an arc stability component identification method based on a rotating arc stability sensor, which can realize online identification of arc stability components. Based on the detected arc stability components, arc stability can be monitored and adjusted in real time, which helps the welding robot to adaptively adjust according to changes in working conditions and welding parameters, and optimize the working performance of the rotating arc stability sensor and the rotating arc weld position identification sensor, thereby improving weld formation quality and weld tracking accuracy, improving the quality of robot automatic welding, and increasing the welding qualification rate. Attached Figure Description

[0021] Figure 1 This is a schematic diagram illustrating the working principle of the rotating arc stability sensor of the present invention.

[0022] Figure 2 This is a schematic diagram of the changes in the electric arc between two adjacent arcs in an unstable state according to the present invention;

[0023] Figure 3 This is a schematic diagram of the arc changes between two adjacent arcs in the understability state of the arc according to the present invention;

[0024] Figure 4 This is a schematic diagram of the arc changes between two adjacent arcs in the stable state of the arc according to the present invention;

[0025] Figure 5 This is a graph showing the relationship between the comprehensive evaluation index of arc stability and the index of arc instability in this invention;

[0026] Figure 6 This is a graph showing the relationship between the comprehensive evaluation index of arc stability and the index of arc understability in this invention.

[0027] Figure 7 This is a graph showing the relationship between the comprehensive evaluation index of arc stability and the index of arc stability state in this invention;

[0028] Figure 8 This is a curve showing the change of the arc stability component identified when the arc is unstable during the welding process, as described in this invention.

[0029] Figure 9 This is a curve showing the change of the arc stability component identified when the arc is stable during the welding process according to the present invention. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of the present invention are only used to explain the present invention and are not intended to limit the present invention.

[0031] This invention mainly includes three parts: the working principle of the rotating arc stability sensor, the classification and evaluation index of arc stability, and the identification method of arc stability components.

[0032] (1) Working principle of rotating arc stability sensor

[0033] Figure 1 This diagram illustrates the working principle of a rotating arc stability sensor. Since arc stability and the arc length self-regulation system's arc length adjustment capability are both determined by welding voltage and welding current, changes in arc stability (the measured value) cause changes in welding voltage or welding current, resulting in changes in the arc length self-regulation system's arc length adjustment capability. The arc length self-regulation system modulates the arc stability into its self-regulating capability, which is the working principle of the rotating arc stability sensor's sensing element. By controlling the arc rotation radius and angular velocity, the arc length changes according to a given magnitude and speed during fillet welding. Because the arc length self-regulation system has the ability to recover the arc length, there is a deviation between the magnitude and speed of the arc length change and the given value. The magnitude of this deviation reflects the magnitude of the arc length self-regulation capability. Therefore, the rotating arc modulates the arc length self-regulation capability into a recovered arc length value, which is the working principle of the rotating arc stability sensor's conversion element. The recovered arc length value is converted into electrical quantity (welding current) using the welding circuit, which is the working principle of the rotating arc stability sensor's conversion circuit. The welding current is converted into a rotating arc sensing signal using a data acquisition and processing system, which is also the working principle of the rotating arc stability sensor output unit.

[0034] Based on the mechanism of arc stability's influence on rotating arc sensing signals, general relationship models are established for arc stability and arc length self-adjustment capability, arc length self-adjustment capability and arc length recovery value, arc length recovery value and welding current, and welding current and rotating arc sensing signals. Combining these models, a general mapping model of arc stability and rotating arc sensing signals is established. Therefore, based on the established arc stability-rotating arc sensing signal mapping model, the comprehensive evaluation index w0 of arc stability can be detected.

[0035] (2) Classification and evaluation index of arc stability

[0036] Arc stability is classified into three categories: unstable arc, understable arc, and stable arc. Figure 2This diagram illustrates the changes in the arc between two adjacent arcs when the arc is unstable. During welding, the brightness and shape of the arc change drastically between adjacent arcs; the arc becomes very dim, and sometimes it even extinguishes, exhibiting arc interruption. The arc instability index is defined as w1, which describes the degree of arc instability. The value of w1 ranges from 0 to 1; the larger the value of w1, the more unstable the arc.

[0037] Figure 3 This diagram illustrates the changes in arc brightness between two adjacent arcs during an understability state. During welding, the brightness and shape of the arc change significantly between adjacent arcs, but there is no arc extinction; the arc dims, or its brightness changes from bright to dark. The understability index is defined as w2, which describes the degree to which the arc state belongs to the understability state. The value of w2 ranges from 0 to 1. A larger w2 value indicates a greater degree of arc instability. A smaller w2 value indicates a lesser degree of arc instability, and the arc is closer to a stable or unstable state.

[0038] Figure 4 This diagram illustrates the changes in arc brightness between two consecutive arcs when the arc is in a stable state. During welding, the brightness and shape of the arc change little or remain unchanged between consecutive arcs, and there is no arc extinction; the arc brightness is very bright or very strong. The arc stability index is defined as w3, which describes the degree to which the arc state belongs to arc stability. The value of w3 ranges from 0 to 1. The larger the value of w3, the better the arc stability. The smaller the value of w3, the worse the arc stability.

[0039] Therefore, the arc instability index w1, the arc understability index w2, and the arc stability index w3 can be used as evaluation indicators of arc stability, and the arc stability W = [w1, w2, w3].

[0040] (3) Identification method of arc stability components

[0041] Figure 5 This is a graph showing the relationship between the comprehensive evaluation index of arc stability and the index of arc instability. Figure 6 This is a graph showing the relationship between the comprehensive evaluation index of arc stability and the index of arc understability. Figure 7 This diagram shows the relationship between the comprehensive evaluation index of arc stability and the arc stability state index. Using the comprehensive evaluation index of arc stability identified by the rotating arc stability sensor, three components of arc stability can be identified, which satisfy the following equation:

[0042]

[0043] In the formula, W represents arc stability, w1 represents arc instability index, w2 represents arc understability index, w3 represents arc stability index, and w0 represents arc stability comprehensive evaluation index.

[0044] Therefore, the method based on the identification of arc stability components can identify three components of arc stability: index w1, which evaluates the degree of arc instability; index w2, which evaluates the degree of arc understability; and index w3, which evaluates the degree of arc stability.

[0045] A follow-up welding experiment was conducted on a bent fillet weld with a welding current of 200A and a welding voltage of 20V. The results showed poor weld formation and an unstable arc. Figure 8 The curves showing the changes in arc stability components identified during arc instability in the welding process reveal that during welding, most arc instability indices are close to 1, while most arc understability and stability indices are close to 0, indicating that the arc is unstable during the welding process.

[0046] A follow-up welding experiment was conducted on a bent fillet weld with a welding current of 200A and a welding voltage of 25V. The results showed that the weld formation was aesthetically pleasing and the arc was stable. Figure 9 The curves showing the changes in the arc stability components identified during the arc stabilization process reveal that the arc becomes unstable within a very short time after ignition. Subsequently, the arc stability index approaches 1, while the arc instability and understability indices approach 0, indicating that the arc stability is very good during the welding process.

[0047] The results identified using the method of the present invention are consistent with the stability of the electric arc during actual welding. Therefore, the method of the present invention can correctly identify the three components of the electric arc stability.

[0048] The above are embodiments of the present invention. The above embodiments and specific parameters are only for clearly illustrating the invention verification process and are not intended to limit the patent protection scope of the present invention. The patent protection scope of the present invention shall still be determined by its claims. Similarly, any equivalent structural changes made based on the description and drawings of the present invention shall also be included within the protection scope of the present invention.

Claims

1. A method for identifying arc stability components based on a rotating arc stability sensor, characterized in that: This paper utilizes the working principle of a rotating arc stability sensor to detect the comprehensive evaluation index w0 of arc stability. The sensor takes arc stability as input, an arc length self-adjustment system as the sensing element, a rotating arc as the conversion element, a welding circuit as the conversion circuit, a data acquisition and processing system as the output unit, and the rotating arc sensing signal as the output. Based on the classification and evaluation index of arc stability, arc stability is divided into three components: arc instability index w1, arc understability index w2, and arc stability index w3. The magnitude of each component is quantified. The magnitude of the three arc stability components is identified using an arc stability component identification method. The identification method satisfies the following formula: ； In the formula, W represents arc stability, w1 represents arc instability index, w2 represents arc understability index, w3 represents arc stability index, and w0 represents arc stability comprehensive evaluation index. Therefore, based on the method for identifying arc stability components, three components of arc stability are identified: index w1, which evaluates the degree of arc instability; index w2, which evaluates the degree of arc understability; and index w3, which evaluates the degree of arc stability.

2. The method for identifying arc stability components based on a rotating arc stability sensor as described in claim 1, characterized in that: The invention utilizes the working principle of a rotating arc stability sensor to detect a comprehensive evaluation index of arc stability. This rotating arc stability sensor takes arc stability as input, an arc length self-adjustment system as the sensing element, a rotating arc as the conversion element, a welding circuit as the conversion circuit, a data acquisition and processing system as the output unit, and a rotating arc sensing signal as the output. Its specific details are as follows: When the arc stability changes, the welding voltage or welding current changes, which in turn changes the arc length adjustment capability of the arc length self-adjustment system. The arc length self-adjustment system modulates the arc stability into the arc length self-adjustment capability. By controlling the arc rotation radius and angular velocity, the arc length during fillet welding changes according to a given size and speed. The rotating arc modulates the arc length self-adjustment capability into an arc length recovery value. The welding circuit converts the arc length recovery value into welding current. The data acquisition and processing system converts the welding current into a rotating arc sensing signal. Based on the mechanism of arc stability's influence on rotating arc sensing signals, this paper establishes a relationship model between arc stability and arc length self-regulation capability, a relationship model between arc length self-regulation capability and arc length recovery value, a relationship model between arc length recovery value and welding current, and a relationship model between welding current and rotating arc sensing signals. Combining these models, a mapping relationship model between arc stability and rotating arc sensing signals is established. Based on this established mapping relationship model, a comprehensive evaluation index for arc stability is implemented. The detection.

3. The method for identifying arc stability components based on a rotating arc stability sensor as described in claim 1, characterized in that: The method utilizes the classification and evaluation index of arc stability to divide arc stability into three components, and quantifies the magnitude of each component, as detailed below: Arc stability is divided into three categories: unstable arc, understable arc, and stable arc. If the arc is in an unstable state, the brightness and shape of the arc change drastically between two consecutive arcs, the arc is very dark, and sometimes the arc will even extinguish, resulting in arc breakage. The arc instability index is defined as w1, which describes the degree to which the arc state belongs to the arc instability. The value of w1 ranges from 0 to 1. The larger the value of w1, the more unstable the arc. If the arc is in an unstable state, the brightness and shape of the arc change significantly between two consecutive occurrences, but there is no arc extinction phenomenon; the arc is dark, or the arc brightness changes from bright to dark. The arc instability index is defined as w2, which describes the degree to which the arc state belongs to the arc instability. The value of w2 ranges from 0 to 1. The larger the value of w2, the greater the degree of arc instability; the smaller the value of w2, the less severe the degree of arc instability, and the closer the arc is to a stable or unstable state. If the electric arc is in a stable state, the brightness and shape of the electric arc change little or remain unchanged between two consecutive times, there is no phenomenon of electric arc extinction, and the electric arc brightness is very bright or bright; the electric arc stability index is defined as w3, which is used to describe the degree to which the electric arc state belongs to the electric arc stability, and the value of w3 ranges from 0 to 1; the larger the value of w3, the better the stability of the electric arc. Therefore, the arc instability index w1, the arc understability index w2, and the arc stability index w3 are used as evaluation indicators of arc stability, and the arc stability W = [w1, w2, w3].

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