Laser-arc hybrid welding system and welding method

Abstract

The present disclosure relates to a laser-arc hybrid welding system and a welding method, wherein the laser-arc hybrid welding system is used for welding a gap between a first workpiece (101) and a second workpiece (102), and the laser-arc hybrid welding system comprises: a laser welding gun (1) movable relative to the gap, configured to emit a laser beam (11) acting on the gap, and the laser beam (11) swings in the gap along the width direction of the gap; an arc welding gun (2) movable relative to the gap, configured to emit an electric arc following the swing of the laser beam (11) in the gap; a camera component (3) moving synchronously with the laser welding gun (1), configured to monitor the gap spacing along the width direction; and a controller (4) configured to adjust the swing amplitude and swing frequency of the laser beam (11) according to the gap spacing.

Description

Technical Field

[0001] This disclosure relates to the field of welding technology, and in particular to a laser-arc hybrid welding system and welding method. Background Technology

[0002] Laser-arc hybrid welding technology, considered one of the most promising welding technologies of the 21st century, is a precision joining method. Because it can improve weld penetration, reduce welding defects such as porosity and undercut, and is easily automated, it has been widely used in industrial production. However, among the related technologies known to the inventor, for thick plate structures, laser-arc hybrid welding technology still suffers from low welding efficiency and difficulty in controlling stress deformation, resulting in poor welding quality and effect. Summary of the Invention

[0003] The embodiments of this disclosure provide a laser-arc hybrid welding system and welding method that can improve welding quality.

[0004] According to one aspect of this disclosure, a laser-arc hybrid welding system is proposed for welding a gap between a first workpiece and a second workpiece. The laser-arc hybrid welding system includes:

[0005] The laser welding gun is movable relative to the gap and is configured to emit a laser beam that acts on the gap, and the laser beam oscillates within the gap along the width direction of the gap.

[0006] An arc welding torch, movable relative to the gap, is configured to emit an arc that follows the laser beam as it oscillates within the gap.

[0007] The camera component, moving synchronously with the laser welding torch, is configured to monitor the spacing of the gap along its width; and

[0008] The controller is configured to adjust the oscillation amplitude and oscillation frequency of the laser beam according to the spacing.

[0009] In some embodiments, the camera component is also configured to acquire welding pool information, and the controller compares the acquired data with the weld pool information in the database to adjust the position and oscillation frequency of the laser beam.

[0010] In some embodiments, the laser-arc hybrid welding system further includes:

[0011] The sensing component, connected to the arc welding torch, is configured to acquire welding current and / or welding voltage at a preset frequency. The controller compares the acquired data with the preset values ​​to adjust the welding current and / or welding voltage.

[0012] In some embodiments, the laser welding torch and the arc welding torch are movable along the extension direction of the gap.

[0013] In some embodiments, the gap extends along a first direction, and the first workpiece and the second workpiece are welded together to form a T-joint.

[0014] In some embodiments, the laser-arc hybrid welding system further includes:

[0015] The welding robot is configured to drive a laser welding gun, an arc welding gun, and a camera unit to move along the direction of the weld seam.

[0016] In some embodiments, the oscillation trajectory of the laser beam is circular.

[0017] In some embodiments, the angle between the laser beam and the arc welding torch tip in the vertical plane ranges from 15° to 50°.

[0018] In some embodiments,

[0019] The laser beam's oscillation amplitude is 2 to 3 times the slit spacing, and the oscillation frequency ranges from 60 to 120 Hz; and / or

[0020] The oscillation frequency of the laser beam decreases as the gap spacing increases.

[0021] In some embodiments, the laser-arc hybrid welding system further includes:

[0022] A laser generating device, connected to a laser welding torch, is configured to generate a laser beam;

[0023] A power source, connected to the arc welding torch, is configured to supply power to the arc welding torch; and

[0024] The gas storage device is configured to provide protective gas to the welding area.

[0025] In some embodiments, the laser-arc hybrid welding system further includes:

[0026] An electric field generating device is configured to apply an electric field to the welding area; and / or

[0027] A magnetic field generating device is configured to apply a magnetic field to the welding area.

[0028] In some embodiments, the laser-arc hybrid welding system further includes:

[0029] An ultrasonic generating device is configured to apply ultrasonic waves to the welding area.

[0030] According to another aspect of this disclosure, a welding method for a laser-arc hybrid welding system based on the above embodiments is proposed, comprising:

[0031] The laser welding gun emits a laser beam, and the arc welding gun emits an electric arc;

[0032] The camera component moves synchronously with the laser welding gun to monitor the gap spacing;

[0033] Adjust the oscillation amplitude and oscillation frequency of the laser beam according to the gap spacing;

[0034] The laser beam is oscillated within the gap by the oscillation of the laser welding gun, and the laser beam guides the arc oscillation so that two heat sources act simultaneously on the welding area to weld the molten pool.

[0035] In some embodiments, the welding method further includes:

[0036] Information about the weld pool is collected using a camera component;

[0037] Adjust the position and oscillation frequency of the laser beam based on the comparison results between the collected data and the database.

[0038] In some embodiments, the laser-arc hybrid welding system further includes a sensing component connected to the arc welding torch, and the welding method further includes:

[0039] Welding current and / or welding voltage are collected at a preset frequency by a sensing component;

[0040] Adjust the welding current and / or welding voltage based on the comparison between the collected data and the preset values.

[0041] In some embodiments, before adjusting the oscillation amplitude and oscillation frequency of the laser beam according to the gap spacing, the welding method further includes:

[0042] Move the laser welding gun and the arc welding gun along the direction of the gap extension.

[0043] In some embodiments, the welding method further includes, prior to the start of welding:

[0044] Laser cleaning and / or mechanical grinding are performed on the area to be welded.

[0045] Based on the above technical solutions, the laser-arc hybrid welding system of this disclosure is highly operable. While performing oscillating laser welding, the heating effect of the electric arc fully utilizes the advantages of both heat sources, resulting in a more uniform weld and higher welding quality. By employing oscillation technology, the width of the welding point or weld seam can be increased, solving the welding problem of large joint gaps. This significantly reduces the assembly accuracy requirements of the welded specimens and improves the overall welding quality of the product. Based on existing laser welding guns and arc welding guns, by adding a low-cost camera component to monitor the gap distance, the oscillation amplitude and frequency of the laser beam can be adaptively adjusted in real time. This is easy to implement, highly operable, and highly automated, improving both welding quality and welding efficiency. Attached Figure Description

[0046] The accompanying drawings, which are included to provide a further understanding of this disclosure and form part of this application, illustrate exemplary embodiments of this disclosure and are used to explain this disclosure, but do not constitute an undue limitation of this disclosure. In the drawings:

[0047] Figure 1 This is a schematic diagram of the structure of some embodiments of the laser-arc hybrid welding system disclosed herein.

[0048] Figure 2 This is an enlarged cross-sectional view of a portion of the structure of some embodiments of the laser-arc hybrid welding system disclosed herein.

[0049] Explanation of reference numerals in the attached figures

[0050] 1. Laser welding torch; 2. Arc welding torch; 3. Camera component; 4. Controller; 5. Sensor component; 6. Laser generating device; 7. Power supply; 8. Gas storage device; 11. Laser beam; 21. Arc welding torch head; 101. First workpiece; 102. Second workpiece; x, first direction; y, second direction; z, third direction. Detailed Implementation

[0051] The present disclosure is described in detail below. In the following paragraphs, different aspects of the embodiments are defined in more detail. The aspects so defined may be combined with any other aspect or aspects unless expressly stated otherwise. In particular, any feature considered preferred or advantageous may be combined with one or more other features considered preferred or advantageous.

[0052] The terms "first" and "second" used in this disclosure are merely for ease of description and to distinguish different components with the same name, and do not indicate a sequential or primary / secondary relationship.

[0053] In the description of this disclosure, it should be understood that the terms "upper," "lower," "inner," "outer," "front," or "rear," etc., indicating orientation or positional relationship, are defined based on gaps, laser welding guns, or arc welding guns, etc., and are only for the convenience of describing this disclosure, and are not intended to indicate or imply that the device referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this disclosure.

[0054] High-quality, efficient, and low-cost welding methods have always been the relentless pursuit of welding professionals. MIG welding, TIG welding, friction stir welding, vacuum electron beam welding, and laser welding are currently the most common welding methods. MIG and TIG welding are the most traditional and commonly used methods; however, their heat sources are dissipative and their energy density is low, resulting in relatively poor penetration. Laser-arc hybrid welding technology, as an emerging technology, still faces challenges such as low welding efficiency and difficulty in controlling stress and deformation, leaving room for further improvement in welding quality and effects.

[0055] First, this disclosure provides a laser-arc hybrid welding system, hereinafter referred to as the "welding system", such as... Figure 1 and Figure 2 As shown, a laser-arc hybrid welding system is used to weld the gap between the first workpiece 101 and the second workpiece 102. The system includes:

[0056] The laser welding gun 1 is movable relative to the gap and is configured to emit a laser beam 11 that acts on the gap, and the laser beam 11 oscillates within the gap along the width direction of the gap.

[0057] The arc welding torch 2 is movable relative to the gap and is configured to emit an arc that follows the laser beam 11 as it oscillates within the gap.

[0058] Camera component 3, moving synchronously with laser welding torch 1, is configured to monitor the spacing of the gap along its width direction; and

[0059] The controller 4 is configured to adjust the oscillation amplitude and oscillation frequency of the laser beam 11 according to the spacing.

[0060] Specifically, in the laser-arc hybrid welding process, the laser beam 11 moves before the arc. Utilizing the attraction of the oscillating laser beam 11 to the arc, the arc can be guided to oscillate within the gap along its width direction, for example, the gap width direction could be the third direction z. Specifically, while the oscillating laser beam 11 is welding, the heating effect of the arc allows both heat sources to act simultaneously on the gap for welding of the molten pool, resulting in a more uniform weld point or weld seam and higher welding quality. Optionally, the welding system can be applied to single-point welding or continuous welding scenarios.

[0061] Specifically, the laser welding torch 1 is movable relative to the gap, including both oscillation and movement along the gap's extension direction, such as continuous or intermittent movement. Correspondingly, the synchronous movement of the camera component 3 and the laser welding torch 1 also includes synchronous oscillation or synchronous movement along the gap's extension direction. Specifically, the movable nature of the arc welding torch 2 relative to the gap includes movement along the gap's extension direction, such as continuous or intermittent movement. Optionally, provided that the arc generated by the arc welding torch 2 oscillates with the laser beam 11, the arc welding torch 2 may or may not oscillate.

[0062] Specifically, the laser welding gun 1 is movable relative to the gap, causing the laser beam 11 to oscillate back and forth within the gap along its width as it moves along the extension direction of the gap, allowing weld metal to overflow. Optionally, the oscillation trajectory of the laser beam 11 can be any shape, such as a circle, a line segment, the number "8", or the infinity symbol "∞". Optionally, the movements of the laser welding gun 1, the arc welding gun 2, and the camera component 3 can be preset or adaptively adjusted by a welding robot or similar device.

[0063] Specifically, the camera component 3 can monitor the gap spacing in real time, and the controller 4 adjusts the swing amplitude and frequency of the laser beam 11 in real time according to the gap spacing, which is easy to implement and highly operable. Optionally, the camera component 3 can be a high-speed camera, etc. Specifically, when the gap spacing is large, the swing amplitude and frequency of the laser beam 11 can be increased adaptively, and when the gap spacing is small, the swing amplitude and frequency of the laser beam 11 can be decreased adaptively. Optionally, the controller 4 can be a computer or other real-time monitoring and control device.

[0064] Optionally, the laser power range can be 1400-2500W, the oscillation amplitude of the laser beam 11 can be 1-3mm, the oscillation frequency can be 60-180Hz, the arc current can be set to 150-220A, the arc voltage can be set to 16-20V, the monitoring frequency of the camera component 3 can be 24-30Hz, and the wire extension can be set to 15-20mm, wherein the wire extension is the distance from the end of the welding wire to the end of the contact tip.

[0065] Specifically, the welding system increases arc stability through the oscillating laser beam 11. Based on real-time monitoring and feedback of the gap distance by the camera component 3, welding parameters can be automatically adjusted according to the welding situation, avoiding various problems during welding. The weld points or weld seams exhibit good quality, high uniformity, and no obvious undercut, thus achieving higher welding quality and efficiency. Specifically, during the welding process, the oscillating laser-arc hybrid welding technology utilizes the oscillating laser beam 11 to induce arc deflection, increasing the welding system's adaptability to gaps. This results in more uniform weld points after spot welding or more uniform weld seams after continuous welding, leading to higher welding quality.

[0066] The welding system in this embodiment is designed for difficult-to-weld materials such as high-strength steel. By using a oscillating laser, the welding heating area can be increased, and the condensation gradient of the molten metal in the weld can be reduced. This can effectively avoid welding cracks caused by excessive cooling rate in the environment. At the same time, it can also reduce the welding preheating temperature, thereby reducing technical costs.

[0067] The welding system disclosed herein is highly operable. Simultaneously, it utilizes the heating effect of an electric arc during oscillating laser welding, fully leveraging the advantages of both heat sources to achieve more uniform welds and higher welding quality. By employing oscillation technology, the width of the welding point or weld seam can be increased, solving the welding problem of large joint gaps. This significantly reduces the assembly accuracy requirements of the welded specimens and improves the overall welding quality of the product. Based on existing laser welding torches and electric arc welding torches, by adding a low-cost camera component to monitor the gap distance, it can adaptively adjust the oscillation amplitude and frequency of the laser beam in real time. This is easy to implement, highly operable, and highly automated, improving both welding quality and welding efficiency.

[0068] In some embodiments, the camera component 3 is also configured to acquire welding pool information, and the controller 4 compares the acquired data with the pool information in the database to adjust the position and oscillation frequency of the laser beam 11.

[0069] Specifically, the camera component 3 can be a high-speed camera, etc. Specifically, the camera component 3 can identify information such as the position and shape of the molten pool, and compare the molten pool information with a database via a controller. Optionally, the molten pool information obtained by the camera component 3 can be processed by image data processing software and then compared with the molten pool information in the database. Optionally, the position and oscillation frequency of the laser beam 11 can be adjusted by a welding robot, etc.

[0070] Specifically, the position of the laser beam 11 can be adjusted by adjusting the position of the welding center line of the laser welding gun 1. By adjusting the position of the laser beam 11, the welding gap at the welding point or weld can be made more uniform. Specifically, by comparing the molten pool information, when the solder cladding is insufficient or the gap is large, the oscillation frequency of the laser beam 11 can be increased; when the solder cladding is reasonable or the gap is small, the oscillation frequency of the laser beam 11 can be decreased.

[0071] This embodiment enables the camera component to provide real-time feedback of welding status and quality to the controller during laser-arc hybrid welding. By monitoring the weld pool information in real time, the position and oscillation frequency of the laser beam can be automatically adjusted according to the welding status. At the same time, adaptive adjustment can automatically adjust welding parameters according to different welding conditions and workpiece materials, avoiding problems such as excessive heat effect and hot crack defects in welding. This can improve the automation level of the welding system, ensure the consistency of welding quality, and improve welding quality and efficiency.

[0072] In some embodiments, such as Figure 1 and Figure 2 As shown, the laser-arc hybrid welding system also includes:

[0073] The sensing component 5 is connected to the arc welding torch 2 and is configured to collect welding current and / or welding voltage at a preset frequency. The controller 4 compares the collected data with the preset values ​​to adjust the welding current and / or welding voltage.

[0074] Optionally, the sensing element 5 can be a Hall sensor or the like. Optionally, the acquisition frequency of the sensing element 5 can be set to 24–50 kHz. Optionally, the acquired welding current and welding voltage can be compared with preset values ​​by calculating the mean and standard deviation. Optionally, the controller 4 can adjust the welding current and welding voltage by transmitting control signals to the power supply 7 or the like.

[0075] This embodiment monitors and / or adaptively adjusts welding current and / or welding voltage data. During laser-arc hybrid welding, the welding parameters are fed back to the controller in real time using sensing components. By monitoring the welding current and welding voltage in real time and comparing them with preset values, the current and voltage can be automatically adjusted in a timely manner, ensuring the stability of the welding process and the consistency of welding quality, thereby improving welding quality and efficiency. At the same time, the adaptive adjustment can automatically adjust the current and voltage according to different welding conditions and workpiece materials, avoiding problems such as excessive heat effect and hot cracking defects in welding.

[0076] In some embodiments, the laser welding torch 1 and the arc welding torch 2 are movable along the extension direction of the gap.

[0077] Specifically, the camera component 3 moves synchronously with the laser welding torch 1. Optionally, the extension direction of the gap can also be referred to as the welding direction. Optionally, the laser welding torch 1 and the arc welding torch 2 can move along the extension direction of the gap, which can be continuous or intermittent. In the case of continuous movement, the wire feeding speed can be 8 to 10 m / min, and the welding speed can be 1.8 to 3 m / min.

[0078] This embodiment enables a more uniform weld and higher welding quality by moving the laser welding gun and the arc welding gun along the extension direction of the gap. At the same time, based on the above embodiment, the welding parameters and welding quality are fed back in real time through the camera and sensor components, which can adaptively adjust the welding parameters, resulting in a high degree of automation, high welding quality and high welding efficiency.

[0079] The inventors discovered during the production process that for welding T-joints, laser welding or arc welding alone is insufficient to address the large gaps at the joint points. Furthermore, welding methods such as manual arc welding and double-sided double-arc welding are generally used, resulting in poor welding quality and low welding efficiency. To solve the aforementioned welding problems of T-joints, in some embodiments, the gap extends along a first direction x, and the first workpiece 101 and the second workpiece 102 are welded together to form a T-joint.

[0080] Specifically, T-joints can be applied to various engineering machinery, such as cranes, rotary drilling rigs, or sweeper trucks. Specifically, the first workpiece 101 and the second workpiece 102 of the T-joint are both flat plates. The first workpiece 101 extends in the plane containing the first direction x and the third direction z, and the second workpiece 102 extends in the plane containing the first direction x and the second direction y. Specifically, the welding process of the T-joint often adopts a method of spot welding followed by continuous welding. The distance between the first workpiece 101 and the second workpiece 102 may change constantly; that is, along the first direction x, the gap between the first workpiece 101 and the second workpiece 102 in the third direction z is not uniform. Optionally, the T-joint can be a thick plate T-joint, such as a 5mm thick Q355 structure.

[0081] Specifically, the welding system uses the attraction of the oscillating laser beam 11 to guide the arc to oscillate within the gap of the T-joint, which increases the stability of the arc. While the oscillating laser beam 11 is welding, the heating effect of the arc allows both heat sources to act simultaneously on the welding area of ​​the T-shaped workpiece to weld the molten pool, resulting in a more uniform weld and higher welding quality. The welding area is the area where the gap to be welded is located and the surrounding area, for example, it can be the gap and both sides along the second direction y.

[0082] Specifically, during the movement along the first direction x, the laser beam 11 can automatically adjust its swing amplitude and frequency based on the real-time monitoring and feedback of the gap spacing of the T-joint by the camera component 3, thereby avoiding various problems in welding, resulting in good weld quality, high uniformity, and no obvious undercut, thus achieving higher welding quality and efficiency.

[0083] This embodiment of the welding system targets T-joints made of difficult-to-weld materials such as high-strength steel. The use of a oscillating laser increases the welding heating area and reduces the cooling gradient of the molten weld metal, effectively preventing welding cracks caused by excessive cooling rates in the environment. It also reduces the welding preheating temperature, thus lowering costs. Furthermore, it solves the welding problem of large joint gaps, significantly reducing the assembly precision requirements of welded specimens and improving the overall welding quality of the product. Based on existing laser welding torches and arc welding torches, by adding a low-cost camera component to monitor the gap distance, the laser welding torch and arc welding torch can adaptively adjust the oscillation amplitude and frequency of the laser beam in real time during movement along the first direction. This is easy to implement, highly operable, and highly automated, improving both welding quality and efficiency.

[0084] In some embodiments, such as Figure 1 and Figure 2 As shown, the laser-arc hybrid welding system also includes:

[0085] The welding robot is configured to drive a laser welding gun 1, an arc welding gun 2, and a camera unit 3 to move along the extension direction of the gap.

[0086] Specifically, the positions or oscillation frequencies of the laser welding gun 1, the arc welding gun 2, and the camera component 3 can be adjusted by a welding robot or the like.

[0087] This embodiment uses a welding robot to drive the laser welding gun 1, the arc welding gun 2, and the camera component 3 to move along the extension direction of the gap. This can optimize the displacement accuracy of each component, improve the welding quality, and enhance the adaptive response speed and automation level of the welding system.

[0088] In some embodiments, the oscillation trajectory of the laser beam 11 is circular.

[0089] Optionally, the oscillation trajectory of the laser beam 11 can be any shape, such as a circle, a line segment, the number "8", or the infinity symbol "∞". Specifically, when the oscillation trajectory of the laser beam 11 is a line segment, if the laser welding gun 1 moves along the first direction x, the laser beam 11 will draw a pattern of sine and cosine.

[0090] This embodiment, by setting the oscillation trajectory of the laser beam to a circle, enables the solder to be uniformly melted and coated throughout the entire welding area, thereby improving the uniformity of the welding point or weld and the welding quality.

[0091] In some embodiments, such as Figure 1 and Figure 2 As shown, in the vertical plane, the angle between the laser beam 11 and the arc welding torch head 21 ranges from 15° to 50°.

[0092] Optionally, the angle between the laser beam 11 and the second workpiece 102 in the vertical plane can be 60°, and the angle between the arc welding gun head 21 and the second workpiece 102 in the vertical plane can be 45°.

[0093] This embodiment optimizes the heat transfer angle of the heat source and improves the welding quality by making the included angle between the laser beam 11 and the arc welding gun head 21 range from 15° to 50°. At the same time, it can avoid structural interference between the laser welding gun 1, the arc welding gun 2 and the camera component 3 during their movement, thereby improving the operability and reliability of the welding system.

[0094] In some embodiments, the oscillation amplitude of the laser beam 11 is 2 to 3 times the gap spacing, and the oscillation frequency ranges from 60 to 120 Hz; and / or the oscillation frequency of the laser beam 11 decreases as the gap spacing increases.

[0095] Specifically, the oscillation amplitude of the laser beam 11 is 2 to 3 times the gap spacing, and / or the oscillation frequency of the laser beam 11 decreases when the gap spacing increases, both of which ensure the filling width of the solder, allowing the solder to fully cover the gap. Specifically, the decrease in the oscillation frequency of the laser beam 11 means a decrease in the oscillation speed. Optionally, when the gap spacing increases, the oscillation frequency of the laser beam 11 can be reduced to 50% to 80% of the preset value.

[0096] Optionally, when the laser welding torch 1 and the arc welding torch 2 move continuously along the seam extension direction, the moving speed of the laser beam 11 can also decrease as the seam spacing increases. For example, the moving speed of the laser beam 11 can also decrease to 50% to 80% of a preset value.

[0097] This embodiment improves the uniformity of solder deposition by optimizing the oscillation amplitude and oscillation frequency, ensuring the consistency of the filling width and height, making the welding points or welds more uniform, and improving the welding quality.

[0098] In some embodiments, such as Figure 1 and Figure 2 As shown, the laser-arc hybrid welding system also includes:

[0099] A laser generating device 6 is connected to a laser welding gun 1 and is configured to generate a laser beam 11.

[0100] Power supply 7, connected to arc welding torch 2, is configured to supply power to arc welding torch 2; and

[0101] Gas storage device 8 is configured to provide protective gas to the welding area.

[0102] Specifically, the power supply 7 can be used to adjust the welding current and welding voltage. Optionally, the shielding gas can be high-purity Ar gas or other mixed gases, and the flow rate of the shielding gas can be set to 15-20 L / min. Optionally, the laser generating device 6 can be a laser, the power supply 7 can be an arc-controlled welding power supply, and the gas storage device 8 can be a shielding gas cylinder.

[0103] In this embodiment, the laser generating device, power supply, and gas storage device are all spaced apart from and fixedly installed in the welding area, which can reduce unnecessary moving parts, optimize the layout of the entire welding system, and improve the operability and operational reliability of the welding system.

[0104] In some embodiments, the laser-arc hybrid welding system further includes:

[0105] An electric field generating device is configured to apply an electric field to the welding area; and / or

[0106] A magnetic field generating device is configured to apply a magnetic field to the welding area.

[0107] Specifically, the welding area can be the area where the weld seam is located and the surrounding area.

[0108] This embodiment achieves greater weld penetration of composite heat source under lower laser output power conditions by applying an external electric or magnetic field to the welding area.

[0109] In some embodiments, the laser-arc hybrid welding system further includes:

[0110] An ultrasonic generating device is configured to apply ultrasonic waves to the welding area.

[0111] The ultrasonic generating device of this embodiment can use ultrasonic waves to significantly refine the grain size of the weld structure, make the alloying elements of the weld structure more uniform, reduce segregation, improve the weld strength and corrosion resistance, and further improve the post-weld performance of the product.

[0112] Secondly, this disclosure also provides a welding method based on the laser-arc hybrid welding system of the above embodiments, including:

[0113] The laser welding gun 1 emits a laser beam 11, and the arc welding gun 2 emits an electric arc;

[0114] The camera component 3 moves synchronously with the laser welding gun 1 to monitor the gap spacing;

[0115] Adjust the oscillation amplitude and oscillation frequency of the laser beam 11 according to the gap spacing;

[0116] The laser beam 11 is oscillated within the gap by the oscillation of the laser welding gun 1 along the width of the gap. The laser beam 11 guides the arc to oscillate, so that the two heat sources act on the welding area simultaneously to perform welding of the weld pool.

[0117] Specifically, the welding system increases arc stability through the oscillating laser beam 11. Based on real-time monitoring and feedback of the gap distance by the camera component 3, welding parameters can be automatically adjusted according to the welding situation, avoiding various problems during welding. The weld points or weld seams exhibit good quality, high uniformity, and no obvious undercut, thus achieving higher welding quality and efficiency. Specifically, during the welding process, the oscillating laser-arc hybrid welding technology utilizes the oscillating laser beam 11 to induce arc deflection, increasing the welding system's adaptability to gaps. This results in more uniform weld points after spot welding or more uniform weld seams after continuous welding, leading to higher welding quality.

[0118] The welding method of this embodiment increases the stability of the electric arc by inducing arc deflection with a oscillating laser beam, and makes full use of the advantages of two heat sources to increase the width and uniformity of the welding point or weld. Based on the real-time monitoring and feedback of the gap distance by the camera component, the oscillation amplitude and oscillation frequency of the laser beam can be adaptively adjusted in real time. It is easy to implement and highly operable. The welding method can be automatically completed by the controller programming, which can improve welding quality and welding efficiency at the same time.

[0119] In some embodiments, the welding method further includes:

[0120] Information about the weld pool is collected using camera component 3;

[0121] The position and oscillation frequency of the laser beam 11 are adjusted based on the comparison results between the collected data and the database.

[0122] The welding method in this embodiment uses a camera component to feed back the welding status and quality to the controller in real time. By monitoring the weld pool information in real time, the position and oscillation frequency of the laser beam can be automatically adjusted according to the welding status. At the same time, adaptive adjustment can automatically adjust the welding parameters according to different welding conditions and workpiece materials, ensuring consistent welding quality and improving welding quality and efficiency.

[0123] In some embodiments, the laser-arc hybrid welding system further includes a sensing component 5 connected to the arc welding torch 2, and the welding method further includes:

[0124] The welding current and / or welding voltage are collected by the sensing component 5 at a preset frequency;

[0125] Adjust the welding current and / or welding voltage based on the comparison between the collected data and the preset values.

[0126] The welding method of this embodiment uses sensing components to monitor welding current and / or welding voltage data and adaptively adjusts them. It can automatically adjust the current and voltage in a timely manner based on the comparison results, ensuring the stability of the welding process and the consistency of welding quality, thereby improving welding quality and efficiency.

[0127] In some embodiments, before adjusting the oscillation amplitude and oscillation frequency of the laser beam 11 according to the gap spacing, the welding method further includes:

[0128] Move the laser welding gun 1 and the arc welding gun 2 along the extension direction of the gap.

[0129] This embodiment enables a more uniform weld by moving the laser welding torch and the arc welding torch along the extension direction of the gap, ensuring consistent and higher weld quality. The welding method can be automatically completed through controller programming, which can improve welding efficiency while improving welding quality.

[0130] In some embodiments, the welding method further includes, prior to the start of welding:

[0131] Laser cleaning and / or mechanical grinding are performed on the area to be welded.

[0132] This embodiment removes impurities such as oxide scale and oil stains from the stainless steel surface of the workpiece by performing laser cleaning and / or mechanical grinding on the area to be welded before welding, thereby reducing the fumes and toxic gases generated during welding and ensuring welding quality.

[0133] In some embodiments, before batch welding begins, the welding method may also include performing a variable gap splice test on the workpiece to verify the welding effect, for example, setting the minimum splice gap to 0 mm, the maximum splice gap to 2 mm, and the distance between splices to about 20 to 30 cm, and then putting it into production line production after the pilot test is completed.

[0134] In some specific embodiments, such as Figure 1 and Figure 2 As shown, the laser-arc hybrid welding system includes a laser welding gun 1, an arc welding gun 2, a camera component 3, a controller 4, a sensor component 5, a laser generating device 6, a power supply 7, a gas storage device 8, and a welding robot. It is used to weld the gap between the first workpiece 101 and the second workpiece 102 extending along the first direction x. The laser welding gun 1 and the arc welding gun 2 move continuously along the extension direction of the gap. After the first workpiece 101 and the second workpiece 102 are welded, a T-shaped joint is formed.

[0135] Specifically, the process parameters can be set within the following ranges: the laser power range is 1400–2500W; the oscillation amplitude of the laser beam 11 is 2–3 times the gap spacing, for example, the oscillation amplitude of the laser beam 11 can be 1–3mm; the oscillation frequency is 60–180Hz, and as the gap spacing increases, the oscillation frequency of the laser beam 11 decreases, for example, as the gap spacing increases, the oscillation frequency of the laser beam 11 can decrease to 50%–80% of the preset value; the arc current can be set to 150–220A, and the arc voltage can be set to 16–20V; the laser beam… The angle between the arc welding torch head 21 and the second workpiece 102 in the vertical plane can be 60°, and the angle between the arc welding torch head 21 and the second workpiece 102 in the vertical plane can be 45°; the monitoring frequency of the camera component 3 can be 24-30Hz, the wire extension length can be set to 15-20mm, the acquisition frequency of the sensor component 5 can be set to 24-50KHz, the wire feeding speed can be 8-10m / min, the welding speed can be 1.8-3m / min, the shielding gas can be high-purity Ar gas or other mixed gas, and the flow rate of the shielding gas can be set to 15-20L / min.

[0136] The camera component 3 is configured to collect welding pool information, and the controller 4 compares the collected data with the welding pool information in the database to adjust the position and oscillation frequency of the laser beam 11; the sensor component 5 is configured to collect welding current and / or welding voltage at a preset frequency, and the controller 4 compares the collected data with the preset value to adjust the welding current and / or welding voltage; the welding robot is configured to drive the laser welding gun 1, the arc welding gun 2 and the camera component 3 to move along the extension direction of the gap; the oscillation trajectory of the laser beam 11 is circular; before welding begins, the welding method includes laser cleaning and / or mechanical grinding of the area to be welded.

[0137] The welding system and method in this example first employ laser cleaning technology to thoroughly remove oxide scale, oil, and other impurities from the surface of the metal to be welded, thereby reducing fumes and toxic gases generated during welding and ensuring weld quality. In the hybrid welding process, a oscillating laser-arc hybrid welding technology is used. The oscillating laser beam induces arc deflection, increasing adaptability to gaps and resulting in a more uniform weld and higher weld quality. Simultaneously, based on adaptive control technology, welding parameters and quality are fed back in real time through camera and sensor components. Welding parameters such as oscillation amplitude, oscillation frequency, welding current, and voltage are adaptively adjusted to achieve higher welding quality and efficiency, resulting in well-formed, uniform welds without significant undercut.

[0138] This disclosure combines laser and electric arc within the gap of a large joint, using laser to guide and control the arc's oscillation within the gap. Real-time monitoring and feedback of the welding process allow for precise control of the laser-arc hybrid welding process, improving the welding quality of T-joints. For difficult-to-weld materials such as high-strength steel, the oscillating laser of this disclosure increases the welding heating area and reduces the cooling gradient of the molten weld metal, effectively preventing welding cracks caused by excessive cooling rates in the environment. The welding method of this disclosure can reduce the welding preheating temperature, achieving cost reduction. By providing real-time feedback on welding parameters and welding quality, this disclosure adaptively adjusts welding parameters to ensure welding quality and efficiency, avoiding various problems during welding and improving both welding quality and efficiency.

[0139] The laser-arc hybrid welding system and welding method provided in this disclosure have been described in detail above. Specific embodiments have been used to illustrate the principles and implementation methods of this disclosure. The descriptions of these embodiments are merely for the purpose of helping to understand the method and its core ideas. It should be noted that those skilled in the art can make various improvements and modifications to this disclosure without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this disclosure.

Claims

1. A laser-arc hybrid welding system, characterized in that, For welding a gap between a first workpiece (101) and a second workpiece (102), the gap extending along a first direction (x), the first workpiece (101) and the second workpiece (102) forming a T-joint after welding, the laser-arc hybrid welding system includes: The laser welding gun (1) is movable relative to the gap and is configured to emit a laser beam (11) that acts on the gap, and the laser beam (11) oscillates within the gap along the width direction of the gap; the oscillation amplitude of the laser beam (11) is 2 to 3 times the gap spacing and the oscillation frequency range is 60 to 120 Hz. The arc welding gun (2) is movable relative to the gap and is configured to emit an arc that follows the laser beam (11) as it oscillates within the gap; in the vertical plane, the angle between the laser beam (11) and the arc welding gun head (21) is in the range of 15° to 50°. The camera component (3) moves synchronously with the laser welding gun (1), is configured to monitor the gap spacing along the width direction, and is configured to collect welding pool information; The sensing component (5), connected to the arc welding gun (2), is configured to acquire welding current and / or welding voltage at a preset frequency; An electric field generating device is configured to apply an electric field to the welding area; and / or a magnetic field generating device is configured to apply a magnetic field to the welding area; An ultrasonic generating device is configured to apply ultrasonic waves to the welding area; and The controller (4) is configured to adjust the oscillation amplitude and oscillation frequency of the laser beam (11) in real time according to the gap, so that the oscillation frequency of the laser beam (11) decreases as the gap gap increases; the controller (4) is also configured to compare the collected welding pool information with the pool information in the database, and increase the oscillation frequency of the laser beam (11) when the solder cladding is insufficient, and decrease the oscillation frequency of the laser beam (11) when the solder cladding is reasonable; the controller (4) is also configured to compare the collected welding current and / or welding voltage with preset values ​​to adjust the welding current and / or welding voltage.

2. The laser-arc hybrid welding system according to claim 1, characterized in that, The laser welding gun (1) and the arc welding gun (2) are movable along the extension direction of the gap.

3. The laser-arc hybrid welding system according to claim 1, characterized in that, Also includes: The welding robot is configured to drive the laser welding gun (1), the arc welding gun (2) and the camera unit (3) to move along the extension direction of the gap.

4. The laser-arc hybrid welding system according to claim 1, characterized in that, The oscillation trajectory of the laser beam (11) is circular.

5. The laser-arc hybrid welding system according to claim 1, characterized in that, Also includes: A laser generating device (6) is connected to the laser welding gun (1) and is configured to generate the laser beam (11). A power supply (7), connected to the arc welding gun (2), is configured to supply power to the arc welding gun (2); and The gas storage device (8) is configured to provide protective gas to the welding area.

6. A welding method based on the laser-arc hybrid welding system according to any one of claims 1 to 5, characterized in that, include: The laser welding gun (1) emits the laser beam (11), and the arc welding gun (2) emits an electric arc; The camera component (3) moves synchronously with the laser welding gun (1) and monitors the gap spacing. The camera component (3) collects welding pool information, and the sensor component (5) collects welding current and / or welding voltage at a preset frequency. Adjust the oscillation amplitude and oscillation frequency of the laser beam (11) according to the gap spacing, adjust the position and oscillation frequency of the laser beam (11) according to the comparison results of the collected data and the database, and adjust the welding current and / or welding voltage according to the comparison results of the collected data and the preset value. The laser beam (11) is oscillated within the gap along the width direction of the gap by the oscillation of the laser welding gun (1). The laser beam (11) guides the arc to oscillate so that two heat sources act on the welding area simultaneously for welding.

7. The welding method according to claim 6, characterized in that, Before adjusting the oscillation amplitude and oscillation frequency of the laser beam (11) according to the gap spacing, the welding method further includes: The laser welding gun (1) and the arc welding gun (2) are moved along the extension direction of the gap.

8. The welding method according to claim 6 or 7, characterized in that, Before welding begins, the welding method also includes: Laser cleaning and / or mechanical grinding are performed on the area to be welded.

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