A surfacing welding control system

Abstract

The invention discloses a surfacing welding control system, which relates to the technical field of surfacing welding control, and comprises a workpiece scanning unit, a path planning unit, a spacing control unit, a speed control unit and a surfacing welding execution unit; the workpiece scanning unit performs appearance scanning and recognition on the surfacing welding workpiece, obtains seven views of the surfacing welding workpiece and establishes a three-dimensional model of the workpiece, and establishes a workpiece database according to the three-dimensional model and surfacing welding data of the historical surfacing welding workpiece; in this scheme, the surfacing welding surface of the workpiece is scanned and recognized to mark the crack missing parts, and then different surfacing welding methods are used according to different positions on the surfacing welding surface to perform surfacing welding filling and covering, so that the surface of the workpiece after surfacing welding is smoother, which is beneficial to improving the quality of the workpiece after surfacing welding.

Description

Technical Field

[0001] The invention relates to the technical field of surfacing welding control, in particular to a surfacing welding control system. Background Art

[0002] Hardfacing is a welding process that accumulates one or more layers of welding material on the surface of a part to improve the surface properties of the workpiece or restore its size. Hardfacing can be done using a variety of welding methods, such as manual arc welding, submerged arc welding, gas shielded welding, etc. The selection of hardfacing materials depends on specific application requirements, such as hardness, wear resistance, corrosion resistance, etc. Hardfacing technology is widely used in machinery manufacturing, mining, metallurgy, petrochemical and other fields, and is of great significance to improving the reliability and economy of equipment.

[0003] In the process of surfacing welding, since the shapes, thicknesses and weld sizes of the surfacing workpieces are different, it is necessary to select the surfacing path and surfacing method suitable for the workpiece according to the situation of the surfacing workpiece during the welding process, so as to improve the surfacing effect of the workpiece. For example, when surfacing welding on a curved surface, it is necessary to control the distance between the welding material and the arc surface to ensure that the front and back depths of the molten pool are consistent. For example, when surfacing welding on a thinner workpiece, it is necessary to plan the surfacing path to avoid perforation due to excessive temperature of the workpiece welding point. The existing surfacing control system is difficult to achieve targeted intelligent control of surfacing methods for different workpieces. For this reason, we propose a surfacing control system. Summary of the invention

[0004] 1. Technical issues to be resolved

[0005] In view of the shortcomings of the prior art, the present invention provides a surfacing control system.

[0006] (II) Technical solution

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: a surfacing welding control system, including a workpiece scanning unit, a path planning unit, a spacing control unit, a speed control unit and a surfacing welding execution unit;

[0008] The workpiece scanning unit scans and identifies the appearance of the cladding workpiece, obtains seven views of the cladding workpiece and establishes a three-dimensional model of the workpiece, and establishes a workpiece database based on the three-dimensional model and cladding data of the historical cladding workpiece;

[0009] The path planning unit obtains the cladding surface and thickness of the workpiece, performs a flatness analysis on the cladding surface of the workpiece, marks the missing cracks in the cladding surface, sets the cladding start point and end point, selects a gap filling path according to the width of the missing cracks in the workpiece, selects a conventional path according to the thickness of the flat part of the workpiece, and obtains a cladding path by combining multiple gap filling paths and multiple conventional paths;

[0010] The spacing control unit scans the surfacing surface of the workpiece through a laser rangefinder to obtain the curvature of the surfacing surface of the workpiece, sets a preset threshold of the surfacing spacing between the welding gun head and the workpiece, and plans the moving path of the welding gun head spacing according to the curvature of the workpiece and the preset threshold of the surfacing spacing;

[0011] The speed control unit sets a preset threshold value for the moving speed of the welding gun head, determines the moving speed of the welding gun head at the flat part according to the thickness of the workpiece, obtains the volume of the missing crack of the workpiece according to the width, depth and length of the missing crack of the workpiece, and determines the moving speed of the welding gun head at the missing crack according to the volume of the missing crack of the workpiece;

[0012] The surfacing execution unit executes the surfacing operation of the workpiece according to the surfacing path, the moving path of the welding gun head and the surfacing moving speed of the welding gun head.

[0013] Preferably, the flatness of the workpiece surfacing surface is analyzed in the path planning unit, and the crack missing parts in the surfacing surface are marked, specifically:

[0014] Step 1: obtain data of the workpiece surfacing surface scanned by a laser rangefinder, divide the workpiece surfacing surface into a plurality of square measurement grids, and determine whether each measurement grid is a curved surface or a flat surface through the scanning data of the laser rangefinder;

[0015] Step 2: If the measurement grid is a curved surface, obtain the peak and valley values ​​of the curvature of the measurement grid surface, obtain the distance fluctuation mean value through the average of the peak and valley values ​​of the curvature, obtain the distance of all points in the measurement grid to the laser rangefinder, record it as the surface point measurement value, obtain the interference removal value of each point by subtracting the surface point measurement value from the distance fluctuation mean value, set the preset threshold value of the surface flatness range, and determine whether the interference removal value of each point is within the preset threshold value of the flatness range. If the interference removal value is within the preset threshold value of the flatness range, do not mark the point. If the interference removal value is not within the preset threshold value of the flatness range, mark the point, sum and count all marked points, and if the number of marked points is greater than one-fifth of the total number of points, mark the measurement grid as a surface crack missing measurement grid;

[0016] Step 3: If the measurement grid is a plane, obtain the distances from all points in the measurement grid to the laser rangefinder, record them as plane point measurement values, take the average of all plane point measurement values ​​as the plane point mean, obtain the plane point fluctuation value by subtracting the plane point measurement value of each point from the plane point mean, set the preset threshold of the plane flatness range, and judge whether the plane point fluctuation value of each point is within the preset threshold of the plane flatness range. If the plane point fluctuation value is within the preset threshold of the plane flatness range, do not mark the point. If the plane point fluctuation value is not within the preset threshold of the plane flatness range, mark the point, sum and count all marked points, and if the number of marked points is greater than one fifth of the total number of points, mark the measurement grid as a plane crack missing measurement grid;

[0017] Step 4: Mark all the curved surface crack missing measurement grids and all the flat surface crack missing measurement grids as the crack missing locations in the cladding surface.

[0018] Preferably, in the path planning unit, a gap filling path is selected according to the width of the missing crack of the workpiece, specifically:

[0019] Step 1, obtaining the width of the missing crack of the workpiece, setting a preset crack width threshold, and determining the size relationship between the width of the missing crack of the workpiece and the preset crack width threshold. If the width of the missing crack is less than the preset crack width threshold, it is marked as a small crack. If the width of the missing crack is greater than or equal to the preset crack width threshold, it is marked as a large crack.

[0020] Step 2: determine whether the measurement grid where the large crack is located is a plane or a curved surface. If the measurement grid where the large crack is located is a curved surface, a zigzag path surfacing welding filling repair is adopted; if the measurement grid where the large crack is located is a plane, a circular path surfacing welding filling repair is adopted;

[0021] Step 3: Fill the missing parts marked as small cracks with conventional straight path welding.

[0022] Preferably, in the path planning unit, a conventional path is selected according to the thickness of the flat part of the workpiece, specifically:

[0023] Step 1, obtaining the thickness of the flat part of the workpiece, setting a preset thickness threshold, and determining the relationship between the thickness of the flat part of the workpiece and the preset thickness threshold;

[0024] Step 2: If the thickness of the flat part of the workpiece is greater than or equal to the preset thickness threshold, linear path surfacing is adopted; if the thickness of the flat part of the workpiece is less than the preset thickness threshold, linear reciprocating path surfacing is adopted by changing the speed of the welding gun head.

[0025] Preferably, in the spacing control unit, the welding gun head spacing moving path is planned by the curvature of the workpiece, the depth of the crack missing part and the preset threshold of the surfacing spacing, specifically:

[0026] Step 1, obtaining the surfacing path in the path planning unit, setting the segmentation distance, and dividing the surfacing path into multiple line segments according to the segmentation distance, which are recorded as distance adjustment line segments;

[0027] Step 2, obtaining the peak value and valley value of the curvature of each distance adjustment line segment, taking the average value of the peak value and valley value of each distance adjustment line segment, taking the average value of the peak value and valley value as the measurement starting point, taking the welding gun head as the measurement end point, and adjusting the spacing position between the welding gun head and the workpiece at each distance adjustment line segment by the preset threshold of the surfacing spacing;

[0028] Step three, connecting the positions of the welding gun heads of each adjacent spacing line segment to form a welding gun head spacing movement path.

[0029] Preferably, the segmentation distance is set as follows:

[0030] Step 1, obtaining the peak value and valley value of the curvature of the surfacing surface of the surfacing workpiece, taking the average of the peak value and valley value of the surfacing surface, recording it as the average value of the processing surface, obtaining the distance from each measuring grid on the surfacing path to the average value of the processing surface, recording it as the fluctuation difference, setting the preset threshold of the fluctuation difference range, counting the measuring grids whose fluctuation difference is not within the preset threshold of the fluctuation difference range, recording it as the number of fluctuation measuring grids;

[0031] Step 2: Count the missing cracks in the cladding surface in the path planning unit, record them as the number of missing cracks, obtain the total distance of the cladding path, and obtain the segmentation distance through the number of undulation measurement grids, the number of missing cracks and the total distance of the cladding path.

[0032] Preferably, the specific calculation method of the segmentation distance is:

[0033]

[0034] Among them, Fj represents the segmentation distance, Dh represents the total distance of the surfacing path, Qf represents the number of undulation measurement grids, Ls represents the number of missing cracks, δ1 is the weight coefficient of the number of undulation measurement grids, 0<δ1, δ2 is the weight coefficient of the number of missing cracks, 0<δ2.

[0035] Preferably, the surfacing moving speed of the welding gun head at the flat part is determined in the speed control unit according to the thickness of the workpiece, specifically:

[0036] Step 1, obtaining the thickness of each measuring grid at a flat part of the cladding workpiece, setting a preset thickness threshold, and determining the relationship between the thickness of the measuring grid at the flat part of the workpiece and the preset thickness threshold;

[0037] Step 2: If the thickness of the measuring grid at the flat part of the workpiece is greater than or equal to the preset thickness threshold, the preset threshold of the moving speed of the welding gun head is used as the moving speed of the welding gun head in the measuring grid;

[0038] If the thickness of the measuring grid at the flat part of the workpiece is less than the preset thickness threshold, twice the preset threshold of the welding gun head moving speed is used as the moving speed of the welding gun head in the measuring grid.

[0039] Preferably, the specific calculation method of the volume of the workpiece crack missing part in the speed control unit is:

[0040]

[0041] Wherein, Rj represents the volume of the crack missing part, Kd represents the width of the crack missing part, Cd represents the length of the crack missing part, and Sd represents the depth of the crack missing part.

[0042] Preferably, in the speed control unit, the surfacing moving speed of the welding gun head at the crack missing part is determined according to the volume of the crack missing part of the workpiece, specifically:

[0043] Step 1, obtaining the volume of each measuring grid at the missing crack of the cladding workpiece, setting a preset threshold of the volume range, and determining whether the volume of the measuring grid at the missing crack of the workpiece is within the preset threshold of the volume range;

[0044] Step 2: If the volume of the measuring grid at the crack missing part of the workpiece is within the preset threshold of the volume range, half of the preset threshold of the moving speed of the welding gun head is used as the moving speed of the welding gun head in the measuring grid;

[0045] If the volume of the measuring grid at the location where the workpiece crack is missing is not within the preset threshold of the volume range, and the volume of the measuring grid at the location where the workpiece crack is missing is greater than the maximum value of the preset threshold of the volume range, then one quarter of the preset threshold of the welding gun head moving speed is used as the moving speed of the welding gun head in the measuring grid;

[0046] If the volume of the measuring grid at the location where the workpiece crack is missing is not within the preset threshold of the volume range, and the volume of the measuring grid at the location where the workpiece crack is missing is less than the minimum value of the preset threshold of the volume range, the preset threshold of the welding gun head movement speed is used as the movement speed of the welding gun head in the measuring grid.

[0047] (III) Beneficial effects

[0048] The present invention provides a surfacing control system, which has the following beneficial effects:

[0049] (1) In this scheme, the surfacing surface of the workpiece is scanned, identified and marked to identify the crack missing parts, and then different surfacing methods are used to fill and cover the surfacing according to different positions on the surfacing surface, so that the surface of the workpiece after surfacing is smoother, which is beneficial to improving the quality of the workpiece after surfacing;

[0050] (2) In this scheme, the gap filling path and the conventional path are planned according to the curvature of the surfacing surface and the situation of the crack missing part to form the surfacing path, and then the distance between the welding gun head and the workpiece surface is adjusted according to the curvature of the surfacing surface and the situation of the crack missing part to form a distance movement path, and then the moving speed of the welding gun head is planned according to the situation of the crack missing part on the workpiece surface and the thickness of the workpiece, so as to facilitate the full filling of the crack missing part during the surfacing process, and also facilitate safe surfacing of the flat part, and at the same time, it is also beneficial to make the curved surface and the flat surface surfacing smoother, and to avoid the deformation of the molten pool affecting the beauty of the workpiece after surfacing, so that the surface of the workpiece after surfacing is smoother. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 A flowchart of an operation method of a surfacing welding control system of the present invention;

[0052] Figure 2It is a structural schematic diagram of a surfacing welding control system of the present invention;

[0053] Figure 3 A schematic diagram of a zigzag line path of a surfacing welding control system of the present invention;

[0054] Figure 4 A schematic diagram of a circling path of a surfacing welding control system of the present invention;

[0055] Figure 5 It is a schematic diagram of a linear reciprocating path of a surfacing welding control system of the present invention. DETAILED DESCRIPTION

[0056] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0057] See also Figure 1-Figure 5 , the present invention provides a surfacing welding control system, including a workpiece scanning unit, a path planning unit, a spacing control unit, a speed control unit and a surfacing welding execution unit;

[0058] The workpiece scanning unit scans and identifies the appearance of the cladding workpiece, obtains seven views of the cladding workpiece and establishes a three-dimensional model of the workpiece, and establishes a workpiece database based on the three-dimensional model and cladding data of the historical cladding workpiece;

[0059] The path planning unit obtains the cladding surface and thickness of the workpiece, performs a flatness analysis on the cladding surface of the workpiece, marks the missing cracks in the cladding surface, sets the cladding start point and end point, selects a gap filling path according to the width of the missing cracks in the workpiece, selects a conventional path according to the thickness of the flat part of the workpiece, and obtains a cladding path by combining multiple gap filling paths and multiple conventional paths;

[0060] The spacing control unit scans the surfacing surface of the workpiece through a laser rangefinder to obtain the curvature of the surfacing surface of the workpiece, sets a preset threshold of the surfacing spacing between the welding gun head and the workpiece, and plans the moving path of the welding gun head spacing according to the curvature of the workpiece and the preset threshold of the surfacing spacing;

[0061] The speed control unit sets a preset threshold value for the moving speed of the welding gun head, determines the moving speed of the welding gun head at the flat part according to the thickness of the workpiece, obtains the volume of the missing crack of the workpiece according to the width, depth and length of the missing crack of the workpiece, and determines the moving speed of the welding gun head at the missing crack according to the volume of the missing crack of the workpiece;

[0062] The specific calculation method of the volume of the workpiece crack missing in the speed control unit is:

[0063]

[0064] Wherein, Rj represents the volume of the crack missing part, Kd represents the width of the crack missing part, Cd represents the length of the crack missing part, and Sd represents the depth of the crack missing part;

[0065] The surfacing execution unit executes the surfacing operation of the workpiece according to the surfacing path, the moving path of the welding gun head and the surfacing moving speed of the welding gun head.

[0066] In this embodiment, the appearance of the surfacing workpiece is identified by scanning the surfacing workpiece, so as to prepare for the surfacing path planning of the surfacing workpiece in the later stage. By establishing a workpiece database, it is convenient to make a quick path planning response when encountering the same workpiece in the future. By analyzing the flatness of the workpiece surfacing surface, it is convenient to understand the crack missing parts and flat parts of the surfacing surface, and then it is convenient to plan the corresponding surfacing movement path according to different positions. The distance between the welding gun head and the workpiece surfacing surface is adjusted by the curvature of the workpiece surfacing surface to form the moving path of the welding gun head, which is beneficial to avoid the dripping and splashing of welding material causing the shape of the molten pool to be uneven. The moving speed of the welding gun head in the flat part is adjusted by the thickness of the workpiece, which is beneficial to avoid the workpiece welding point temperature being too high and perforation occurring. The moving speed of the welding gun head in the crack missing part is adjusted by the volume of the crack missing part, so that the molten pool formed by the welding material can fully fill the crack missing part, which is also beneficial to the flatness of the workpiece surface after surfacing.

[0067] In the path planning unit, the flatness of the workpiece cladding surface is analyzed and the cracks and missing parts in the cladding surface are marked, specifically:

[0068] Step 1: obtain data of the workpiece surfacing surface scanned by a laser rangefinder, divide the workpiece surfacing surface into a plurality of square measurement grids, and determine whether each measurement grid is a curved surface or a flat surface through the scanning data of the laser rangefinder;

[0069] Step 2: If the measurement grid is a curved surface, obtain the peak and valley values ​​of the curvature of the measurement grid surface, obtain the distance fluctuation mean value through the average of the peak and valley values ​​of the curvature, obtain the distance of all points in the measurement grid to the laser rangefinder, record it as the surface point measurement value, obtain the interference removal value of each point by subtracting the surface point measurement value from the distance fluctuation mean value, set the preset threshold value of the surface flatness range, and determine whether the interference removal value of each point is within the preset threshold value of the flatness range. If the interference removal value is within the preset threshold value of the flatness range, do not mark the point. If the interference removal value is not within the preset threshold value of the flatness range, mark the point, sum and count all marked points, and if the number of marked points is greater than one-fifth of the total number of points, mark the measurement grid as a surface crack missing measurement grid;

[0070] Step 3: If the measurement grid is a plane, obtain the distances from all points in the measurement grid to the laser rangefinder, record them as plane point measurement values, take the average of all plane point measurement values ​​as the plane point mean, obtain the plane point fluctuation value by subtracting the plane point measurement value of each point from the plane point mean, set the preset threshold of the plane flatness range, and judge whether the plane point fluctuation value of each point is within the preset threshold of the plane flatness range. If the plane point fluctuation value is within the preset threshold of the plane flatness range, do not mark the point. If the plane point fluctuation value is not within the preset threshold of the plane flatness range, mark the point, sum and count all marked points, and if the number of marked points is greater than one fifth of the total number of points, mark the measurement grid as a plane crack missing measurement grid;

[0071] Step 4: Mark all the curved surface crack missing measurement grids and all the flat surface crack missing measurement grids as the crack missing locations in the cladding surface.

[0072] In this embodiment, by dividing the workpiece surfacing surface into several measuring grids, it is convenient to more accurately measure the bending of the workpiece surfacing surface, and also convenient to accurately judge whether there are cracks missing in the measuring grid, thereby affecting the subsequent surfacing path and surfacing speed.

[0073] In the path planning unit, the gap filling path is selected according to the width of the missing crack of the workpiece, specifically:

[0074] Step 1, obtaining the width of the missing crack of the workpiece, setting a preset crack width threshold, and determining the size relationship between the width of the missing crack of the workpiece and the preset crack width threshold. If the width of the missing crack is less than the preset crack width threshold, it is marked as a small crack. If the width of the missing crack is greater than or equal to the preset crack width threshold, it is marked as a large crack.

[0075] Step 2: determine whether the measurement grid where the large crack is located is a plane or a curved surface. If the measurement grid where the large crack is located is a curved surface, a zigzag path surfacing welding filling repair is adopted; if the measurement grid where the large crack is located is a plane, a circular path surfacing welding filling repair is adopted;

[0076] Step 3: Fill the missing parts marked as small cracks with conventional straight path welding.

[0077] In this embodiment, by judging the width of the missing crack, it is convenient to distinguish between large cracks and small cracks. By judging whether the measuring grid where the large crack is located is a plane or a curved surface, the large crack whose measuring grid is a curved surface is repaired by surfacing welding according to the zigzag path, so as to leave more molten welding material at the crack, and then facilitate the molten pool formed by the welding material to fully fill the crack. If the measuring grid where the large crack is located is a plane, a circular path surfacing welding filling repair is adopted. The circular path will leave more molten welding material than the zigzag path. Since the curved surface is conducive to the flow of the molten pool and the plane is not conducive to the flow of the molten pool, more molten welding material needs to be left at the large crack on the plane to fully fill the crack. Since small cracks require very little filling welding material, a straight path filling surfacing welding can be adopted for small cracks regardless of whether they are planes or curved surfaces. Therefore, it is convenient to select different surfacing welding paths for filling according to different crack conditions, which is more beneficial to fully filling the cracks and also beneficial to a smoother surface of the workpiece after surfacing welding.

[0078] In the path planning unit, select a conventional path according to the thickness of the flat part of the workpiece, specifically:

[0079] Step 1, obtaining the thickness of the flat part of the workpiece, setting a preset thickness threshold, and determining the relationship between the thickness of the flat part of the workpiece and the preset thickness threshold;

[0080] Step 2: If the thickness of the flat part of the workpiece is greater than or equal to the preset thickness threshold, linear path surfacing is adopted; if the thickness of the flat part of the workpiece is less than the preset thickness threshold, linear reciprocating path surfacing is adopted by changing the speed of the welding gun head.

[0081] In this embodiment, a straight path can be used on the surface of a workpiece with a large thickness, and a straight reciprocating path can be used for welding on the path with a small thickness. The straight reciprocating path has a faster movement speed than the straight path welding gun head, and the dwell time at the same welding point is shorter, which is convenient for cooling the welding point, and is beneficial for avoiding perforation of the welding point. At the same time, due to the reciprocating surfacing, it is convenient to accumulate the surface of the workpiece to the same height as other positions, so that the surface of the workpiece after surfacing is smoother.

[0082] In the spacing control unit, the welding gun head spacing moving path is planned according to the curvature of the workpiece, the depth of the crack missing part and the preset threshold of the surfacing spacing, specifically:

[0083] Step 1, obtaining the surfacing path in the path planning unit, setting the segmentation distance, and dividing the surfacing path into multiple line segments according to the segmentation distance, which are recorded as distance adjustment line segments;

[0084] Step 2, obtaining the peak value and valley value of the curvature of each distance adjustment line segment, taking the average value of the peak value and valley value of each distance adjustment line segment, taking the average value of the peak value and valley value as the measurement starting point, taking the welding gun head as the measurement end point, and adjusting the spacing position between the welding gun head and the workpiece at each distance adjustment line segment by the preset threshold of the surfacing spacing;

[0085] Step three, connecting the positions of the welding gun heads of each adjacent spacing line segment to form a welding gun head spacing movement path.

[0086] In this embodiment, by dividing the surfacing path into multiple distance-adjusting line segments, it is convenient for the welding gun head to adjust the distance between the welding gun head and the workpiece surface in each distance-adjusting line segment, which is beneficial to avoid the welding gun head being too close to the workpiece surface, causing the workpiece surface temperature to be too high and melted, and also to avoid the welding gun head being too far from the workpiece surface, causing the welding material to drip and spatter, resulting in an uneven shape of the molten pool, affecting the flatness and appearance of the workpiece after surfacing.

[0087] Set the split distance, specifically:

[0088] Step 1, obtaining the peak value and valley value of the curvature of the surfacing surface of the surfacing workpiece, taking the average of the peak value and valley value of the surfacing surface, recording it as the average value of the processing surface, obtaining the distance from each measuring grid on the surfacing path to the average value of the processing surface, recording it as the fluctuation difference, setting the preset threshold of the fluctuation difference range, counting the measuring grids whose fluctuation difference is not within the preset threshold of the fluctuation difference range, recording it as the number of fluctuation measuring grids;

[0089] Step 2: Count the missing cracks in the cladding surface in the path planning unit, record them as the number of missing cracks, obtain the total distance of the cladding path, and obtain the segmentation distance through the number of undulation measurement grids, the number of missing cracks and the total distance of the cladding path;

[0090] The specific calculation method of the segmentation distance is:

[0091]

[0092] Among them, Fj represents the segmentation distance, Dh represents the total distance of the surfacing path, Qf represents the number of undulation measurement grids, Ls represents the number of missing cracks, δ1 is the weight coefficient of the number of undulation measurement grids, 0<δ1, δ2 is the weight coefficient of the number of missing cracks, 0<δ2.

[0093] In this embodiment, when the surfacing path is divided into sections, the length of each distance adjustment line segment is adjusted in combination with the total distance of the surfacing path, the number of undulation measurement grids and the number of missing cracks, so that the welding gun head can accurately control the distance from the workpiece surface at each position. The value of the weight coefficient in this scheme can be obtained by the hierarchical analysis method, which will not be elaborated here.

[0094] In the speed control unit, the moving speed of the welding gun head at the flat surface is determined according to the thickness of the workpiece, specifically:

[0095] Step 1, obtaining the thickness of each measuring grid at a flat part of the cladding workpiece, setting a preset thickness threshold, and determining the relationship between the thickness of the measuring grid at the flat part of the workpiece and the preset thickness threshold;

[0096] Step 2: If the thickness of the measuring grid at the flat part of the workpiece is greater than or equal to the preset thickness threshold, the preset threshold of the moving speed of the welding gun head is used as the moving speed of the welding gun head in the measuring grid;

[0097] If the thickness of the measuring grid at the flat part of the workpiece is less than the preset thickness threshold, twice the preset threshold of the welding gun head moving speed is used as the moving speed of the welding gun head in the measuring grid.

[0098] In this embodiment, the moving speed of the welding gun head is adjusted by the thickness of the flat part of the workpiece, so as to facilitate the surfacing welding in coordination with the straight reciprocating path, which is beneficial to avoid perforation of thinner workpieces and control the size of the molten pool, so that the surfacing welding is more flat and beautiful. The value of the preset threshold in this scheme can be obtained by the weight analysis method, which will not be elaborated here.

[0099] In the speed control unit, the surfacing moving speed of the welding gun head at the crack missing part is determined according to the volume of the crack missing part of the workpiece, specifically:

[0100] Step 1, obtaining the volume of each measuring grid at the missing crack of the cladding workpiece, setting a preset threshold of the volume range, and determining whether the volume of the measuring grid at the missing crack of the workpiece is within the preset threshold of the volume range;

[0101] Step 2: If the volume of the measuring grid at the crack missing part of the workpiece is within the preset threshold of the volume range, half of the preset threshold of the moving speed of the welding gun head is used as the moving speed of the welding gun head in the measuring grid;

[0102] If the volume of the measuring grid at the location where the workpiece crack is missing is not within the preset threshold of the volume range, and the volume of the measuring grid at the location where the workpiece crack is missing is greater than the maximum value of the preset threshold of the volume range, then one quarter of the preset threshold of the welding gun head moving speed is used as the moving speed of the welding gun head in the measuring grid;

[0103] If the volume of the measuring grid at the location where the workpiece crack is missing is not within the preset threshold of the volume range, and the volume of the measuring grid at the location where the workpiece crack is missing is less than the minimum value of the preset threshold of the volume range, the preset threshold of the welding gun head movement speed is used as the movement speed of the welding gun head in the measuring grid.

[0104] In this embodiment, when surfacing is performed on cracks, the movement of the welding gun head is controlled to facilitate the molten welding material to fully fill cracks of different sizes, thereby improving the surfacing quality and making the surface of the workpiece smoother after surfacing.

[0105] The above embodiments may be implemented in whole or in part by software, hardware, firmware or any other combination thereof. When implemented using software, the above embodiments may be implemented in whole or in part in the form of a computer program product. A person of ordinary skill in the art may appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein may be implemented in electronic hardware, or in a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution.

[0106] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0107] The above description is only a specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application.

Claims

1. A surfacing control system, characterized in that: It includes a workpiece scanning unit, a path planning unit, a spacing control unit, a speed control unit and a surfacing execution unit; The workpiece scanning unit scans and identifies the appearance of the cladding workpiece, obtains seven views of the cladding workpiece and establishes a three-dimensional model of the workpiece, and establishes a workpiece database based on the three-dimensional model and cladding data of the historical cladding workpiece; The path planning unit obtains the cladding surface and thickness of the workpiece, performs a flatness analysis on the cladding surface of the workpiece, marks the missing cracks in the cladding surface, sets the cladding start point and end point, selects a gap filling path according to the width of the missing cracks in the workpiece, selects a conventional path according to the thickness of the flat part of the workpiece, and obtains a cladding path by combining multiple gap filling paths and multiple conventional paths; The spacing control unit scans the surfacing surface of the workpiece through a laser rangefinder to obtain the curvature of the surfacing surface of the workpiece, sets a preset threshold of the surfacing spacing between the welding gun head and the workpiece, and plans the moving path of the welding gun head spacing according to the curvature of the workpiece and the preset threshold of the surfacing spacing; The speed control unit sets a preset threshold value for the moving speed of the welding gun head, determines the moving speed of the welding gun head at the flat part according to the thickness of the workpiece, obtains the volume of the missing crack of the workpiece according to the width, depth and length of the missing crack of the workpiece, and determines the moving speed of the welding gun head at the missing crack according to the volume of the missing crack of the workpiece; The surfacing execution unit executes the surfacing operation of the workpiece according to the surfacing path, the moving path of the welding gun head and the surfacing moving speed of the welding gun head.

2. A surfacing welding control system according to claim 1, characterized in that: In the path planning unit, the flatness of the workpiece cladding surface is analyzed and the cracks and missing parts in the cladding surface are marked, specifically: Step 1: obtain data of the workpiece surfacing surface scanned by a laser rangefinder, divide the workpiece surfacing surface into a plurality of square measurement grids, and determine whether each measurement grid is a curved surface or a flat surface through the scanning data of the laser rangefinder; Step 2: If the measurement grid is a curved surface, obtain the peak and valley values ​​of the curvature of the measurement grid surface, obtain the distance fluctuation mean value through the average of the peak and valley values ​​of the curvature, obtain the distance of all points in the measurement grid to the laser rangefinder, record it as the surface point measurement value, obtain the interference removal value of each point by subtracting the surface point measurement value from the distance fluctuation mean value, set the preset threshold value of the surface flatness range, and determine whether the interference removal value of each point is within the preset threshold value of the flatness range. If the interference removal value is within the preset threshold value of the flatness range, do not mark the point. If the interference removal value is not within the preset threshold value of the flatness range, mark the point, sum and count all marked points, and if the number of marked points is greater than one-fifth of the total number of points, mark the measurement grid as a surface crack missing measurement grid; Step 3: If the measurement grid is a plane, obtain the distances from all points in the measurement grid to the laser rangefinder, record them as plane point measurement values, take the average of all plane point measurement values ​​as the plane point mean, obtain the plane point fluctuation value by subtracting the plane point measurement value of each point from the plane point mean, set the preset threshold of the plane flatness range, and judge whether the plane point fluctuation value of each point is within the preset threshold of the plane flatness range. If the plane point fluctuation value is within the preset threshold of the plane flatness range, do not mark the point. If the plane point fluctuation value is not within the preset threshold of the plane flatness range, mark the point, sum and count all marked points, and if the number of marked points is greater than one fifth of the total number of points, mark the measurement grid as a plane crack missing measurement grid; Step 4: Mark all the curved surface crack missing measurement grids and all the flat surface crack missing measurement grids as the crack missing locations in the cladding surface.

3. A surfacing welding control system according to claim 2, characterized in that: In the path planning unit, the gap filling path is selected according to the width of the missing crack of the workpiece, specifically: Step 1, obtaining the width of the missing crack of the workpiece, setting a preset crack width threshold, and determining the size relationship between the width of the missing crack of the workpiece and the preset crack width threshold. If the width of the missing crack is less than the preset crack width threshold, it is marked as a small crack. If the width of the missing crack is greater than or equal to the preset crack width threshold, it is marked as a large crack. Step 2: determine whether the measurement grid where the large crack is located is a plane or a curved surface. If the measurement grid where the large crack is located is a curved surface, a zigzag path surfacing welding filling repair is adopted; if the measurement grid where the large crack is located is a plane, a circular path surfacing welding filling repair is adopted; Step 3: Fill the missing parts marked as small cracks with conventional straight path welding.

4. A surfacing welding control system according to claim 3, characterized in that: In the path planning unit, select a conventional path according to the thickness of the flat part of the workpiece, specifically: Step 1, obtaining the thickness of the flat part of the workpiece, setting a preset thickness threshold, and determining the relationship between the thickness of the flat part of the workpiece and the preset thickness threshold; Step 2: If the thickness of the flat part of the workpiece is greater than or equal to the preset thickness threshold, linear path surfacing is adopted; if the thickness of the flat part of the workpiece is less than the preset thickness threshold, linear reciprocating path surfacing is adopted by changing the speed of the welding gun head.

5. A surfacing welding control system according to claim 4, characterized in that: In the spacing control unit, the welding gun head spacing moving path is planned according to the curvature of the workpiece, the depth of the crack missing part and the preset threshold of the surfacing spacing, specifically: Step 1, obtaining the surfacing path in the path planning unit, setting the segmentation distance, and dividing the surfacing path into multiple line segments according to the segmentation distance, which are recorded as distance adjustment line segments; Step 2, obtaining the peak value and valley value of the curvature of each distance adjustment line segment, taking the average value of the peak value and valley value of each distance adjustment line segment, taking the average value of the peak value and valley value as the measurement starting point, taking the welding gun head as the measurement end point, and adjusting the spacing position between the welding gun head and the workpiece at each distance adjustment line segment by the preset threshold of the surfacing spacing; Step three, connecting the positions of the welding gun heads of each adjacent spacing line segment to form a welding gun head spacing movement path.

6. A surfacing welding control system according to claim 5, characterized in that: Set the split distance, specifically: Step 1, obtaining the peak value and valley value of the curvature of the surfacing surface of the surfacing workpiece, taking the average of the peak value and valley value of the surfacing surface, recording it as the average value of the processing surface, obtaining the distance from each measuring grid on the surfacing path to the average value of the processing surface, recording it as the fluctuation difference, setting the preset threshold of the fluctuation difference range, counting the measuring grids whose fluctuation difference is not within the preset threshold of the fluctuation difference range, recording it as the number of fluctuation measuring grids; Step 2: Count the missing cracks in the cladding surface in the path planning unit, record them as the number of missing cracks, obtain the total distance of the cladding path, and obtain the segmentation distance through the number of undulation measurement grids, the number of missing cracks and the total distance of the cladding path.

7. A surfacing welding control system according to claim 6, characterized in that: The specific calculation method of the segmentation distance is: Among them, Fj represents the segmentation distance, Dh represents the total distance of the surfacing path, Qf represents the number of undulation measurement grids, Ls represents the number of missing cracks, δ1 is the weight coefficient of the number of undulation measurement grids, 0<δ1, δ2 is the weight coefficient of the number of missing cracks, 0<δ2.

8. A surfacing welding control system according to claim 7, characterized in that: In the speed control unit, the moving speed of the welding gun head at the flat surface is determined according to the thickness of the workpiece, specifically: Step 1, obtaining the thickness of each measuring grid at a flat part of the cladding workpiece, setting a preset thickness threshold, and determining the relationship between the thickness of the measuring grid at the flat part of the workpiece and the preset thickness threshold; Step 2: If the thickness of the measuring grid at the flat part of the workpiece is greater than or equal to the preset thickness threshold, the preset threshold of the moving speed of the welding gun head is used as the moving speed of the welding gun head in the measuring grid; If the thickness of the measuring grid at the flat part of the workpiece is less than the preset thickness threshold, twice the preset threshold of the welding gun head moving speed is used as the moving speed of the welding gun head in the measuring grid.

9. A surfacing welding control system according to claim 8, characterized in that: The specific calculation method of the volume of the workpiece crack missing in the speed control unit is: Wherein, Rj represents the volume of the crack missing part, Kd represents the width of the crack missing part, Cd represents the length of the crack missing part, and Sd represents the depth of the crack missing part.

10. A surfacing welding control system according to claim 9, characterized in that: In the speed control unit, the surfacing moving speed of the welding gun head at the crack missing part is determined according to the volume of the crack missing part of the workpiece, specifically: Step 1, obtaining the volume of each measuring grid at the missing crack of the cladding workpiece, setting a preset threshold of the volume range, and determining whether the volume of the measuring grid at the missing crack of the workpiece is within the preset threshold of the volume range; Step 2: If the volume of the measuring grid at the crack missing part of the workpiece is within the preset threshold of the volume range, half of the preset threshold of the moving speed of the welding gun head is used as the moving speed of the welding gun head in the measuring grid; If the volume of the measuring grid at the location where the workpiece crack is missing is not within the preset threshold of the volume range, and the volume of the measuring grid at the location where the workpiece crack is missing is greater than the maximum value of the preset threshold of the volume range, then one quarter of the preset threshold of the welding gun head moving speed is used as the moving speed of the welding gun head in the measuring grid; If the volume of the measuring grid at the location where the workpiece crack is missing is not within the preset threshold of the volume range, and the volume of the measuring grid at the location where the workpiece crack is missing is less than the minimum value of the preset threshold of the volume range, the preset threshold of the welding gun head movement speed is used as the movement speed of the welding gun head in the measuring grid.

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