Welding process parameter real-time rapid calculation method and device and intelligent welding method and equipment

Abstract

The invention provides a welding process parameter real-time rapid calculation method and device and an intelligent welding method and equipment, and belongs to the field of welding automation. The method comprises the following steps: acquiring radiuses and intersection angles of a main pipe and a branch pipe; calculating welding seam inclination angles and welding seam rotation angles of different welding spots on the intersecting line of the main pipe and the branch pipe according to the radius and the intersection angle; according to the welding seam inclination angles and the welding seam rotation angles of the different welding spots, stress analysis is conducted on welding seam molten pools of the corresponding welding spots so that welding arc force of the corresponding welding spots can be calculated, and the welding arc force enables stress of the welding seam molten pools to be balanced in the welding direction; and calculating the welding current of the corresponding welding spot according to the welding arc force. The welding arc force of the corresponding welding spot is calculated based on the welding seam corner and the welding seam dip angle, so that the welding current needed for providing the corresponding welding arc force is calculated, the welding arc force enables a welding seam molten pool to be stressed in a balanced mode in the welding direction, and the problems and defects of welding seam forming sagging, undercut, poor weld toe transition and the like can be eliminated.

Description

Technical Field

[0001] The present invention relates to the field of welding automation, and specifically to a method for quickly calculating welding process parameters of intersecting line welds in real time, a device for quickly calculating welding process parameters of intersecting line welds in real time, an intelligent welding method for intersecting line welds, an intelligent welding device for intersecting line welds, a machine-readable storage medium and a computer program product. Background Art

[0002] There are many intersecting welds on large truss structures. Due to the large overall weight, it is impossible to use a positioner to adjust the welding position in real time. This type of intersecting weld can only be welded when the workpiece is placed horizontally. When performing single-circle continuous automated welding, there will be flat angle welding, downhill welding, horizontal welding, uphill welding, etc. according to the welding position, so the welding parameters need to be adjusted according to different positions during the welding process.

[0003] During manual welding, the welder adjusts the welding speed in real time according to the flow of the molten pool in the field of view to ensure the stability of the molten pool so that it does not flow downward. However, manual welding is affected by the position of each welder limited by the truss structure, and the welder is often required to perform half-circle welding. Half-circle welding will form two arc starting and ending points, which are prone to welding defects. In addition, manual welding requires the welder to adjust the welding speed in real time according to the flow of the molten pool, which is not conducive to improving welding efficiency. If automated welding is used, the welding equipment cannot adjust the welding process parameters according to the flow of the molten pool. This means that although automated welding has higher welding efficiency, it cannot guarantee welding quality. Summary of the invention

[0004] The purpose of the embodiments of the present invention is to provide a method and device for real-time and rapid calculation of welding process parameters, an intelligent welding method and equipment, so as to at least solve the above-mentioned problem that automated welding cannot guarantee welding quality.

[0005] In order to achieve the above-mentioned object, the first aspect of the present invention provides a method for real-time and rapid calculation of welding process parameters of an intersecting line weld, the method comprising:

[0006] Get the radius and intersection angle of the main pipe and branch pipe;

[0007] Calculate the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle;

[0008] Performing force analysis on the weld pool of the corresponding weld points according to the weld inclination angle and weld rotation angle of different weld points to calculate the welding arc force of the corresponding weld points, wherein the welding arc force makes the weld pool balanced in the welding direction;

[0009] The welding current of the corresponding welding point is calculated according to the welding arc force.

[0010] According to the above technical means, the weld inclination and weld rotation angle of different welding points on the intersection line of the branch pipe are calculated according to the radius and intersection angle of the main pipe and the branch pipe, and then the weld molten pool of the corresponding weld point is subjected to force analysis based on the weld rotation angle and the weld inclination to calculate the welding arc force of the corresponding weld point, so as to calculate the welding current required to provide the corresponding welding arc force during welding according to the welding process adopted. The welding arc force makes the weld molten pool balanced in the welding direction, which can eliminate the problems such as weld formation sagging, undercut, and poor weld toe transition. Therefore, different welding currents can be calculated according to different welding point positions, providing a control basis for high-quality and efficient automated welding.

[0011] In some feasible embodiments, calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle includes:

[0012] Calculate the first normal vector at any point on the cylindrical surface of the main tube;

[0013] Calculate the second normal vector of the branch cylinder at the same point;

[0014] Constructing the calculation equations of the first normal vector and the second normal vector based on the center rotation angle of the branch pipe, and different center rotation angles represent the positions of different welding points;

[0015] The weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe are calculated according to the calculation equation.

[0016] According to the above technical means, a calculation formula for the weld inclination and weld rotation angle based on the central rotation angle of the branch pipe was constructed according to the geometric relationship between the main pipe and the branch pipe. Therefore, by adjusting the size of the central rotation angle of the calculation formula, the weld inclination and weld rotation angle of welds in different positions can be calculated, providing a force analysis basis for calculating the welding current of different welds.

[0017] In some feasible embodiments, constructing a calculation equation for the first normal vector and the second normal vector based on the central rotation angle of the branch pipe includes:

[0018] Constructing a parameterized equation of the cylindrical surface of the branch pipe according to the central rotation angle of the branch pipe and the intersection angle;

[0019] Determine the transformation formula for converting the main pipe cylindrical surface to the coordinate system of the branch pipe cylindrical surface;

[0020] Constructing a first calculation equation for the first normal vector based on the central rotation angle according to the transformation formula, the first normal vector and the parameterized equation;

[0021] A second calculation equation for the second normal vector based on the central rotation angle is constructed according to the transformation formula, the second normal vector and the parameterized equation.

[0022] According to the above technical means, the calculation equations related to the first normal vector and the second normal vector, respectively, with the center rotation angle can be established through the parameterized equation of the branch cylindrical surface based on the center rotation angle. When the center rotation angle changes, the first normal vector and the second normal vector also change accordingly, and there is no need to repeatedly determine the first normal vector and the second normal vector.

[0023] In some feasible embodiments, calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the calculation equation includes:

[0024] A weld feature coordinate system is established, wherein the origin of the weld feature coordinate system is the weld point, the welding direction is the Xˊaxis, and half of the angle between the two tangent planes at the weld point is the Zˊaxis;

[0025] Determine the Xˊ-axis vector according to the geometric relationship, the first calculation equation and the second calculation equation;

[0026] Determine the Z-axis vector according to the geometric relationship, the first calculation equation and the second calculation equation;

[0027] According to geometric analysis, the angle between the Xˊaxis vector and the horizontal plane is the weld inclination angle, and the angle between the Zˊaxis vector and the vertical direction is the weld rotation angle;

[0028] Calculate the weld inclination angles of different welding points based on trigonometric functions and X-axis vectors;

[0029] The weld rotation angles of different weld points are calculated based on trigonometric functions and the Z-axis vector.

[0030] According to the above technical means, the calculation relationship between the weld inclination angle, the weld rotation angle and the center rotation angle is established according to the first calculation equation and the second calculation equation. Therefore, the weld inclination angle and the weld rotation angle at different positions can be directly calculated according to different center rotation angles without repeating a large number of analysis and calculations.

[0031] In some feasible embodiments, a force analysis is performed on the weld pool of the corresponding weld point according to the weld inclination angle and weld rotation angle of different weld points to calculate the welding arc force of the corresponding weld point, including:

[0032] A weld feature coordinate system is established, wherein the origin of the weld feature coordinate system is the weld point, the welding direction is the Xˊaxis, and half of the angle between the two tangent planes at the weld point is the Zˊaxis;

[0033] Performing a force analysis on the weld pool of the intersecting line, decomposing the gravity of the weld pool to the Zˊaxis and the OˊXˊYˊplane according to the weld rotation angle of the current weld point, and obtaining the first gravity component on the OˊXˊYˊplane;

[0034] Perform force analysis on the OˊXˊYˊ plane, decompose the first gravity component into components along the welding direction and perpendicular to the welding direction according to the weld inclination angle of the current welding point, and obtain a component along the welding direction;

[0035] The welding arc force of the current welding point is calculated according to the component along the welding direction.

[0036] According to the above technical means, the tension, gravity and arc blowing force exerted on the welding molten pool of the intersecting line spatial weld are calculated and analyzed to form the intersecting line welding parameter design criteria of the molten pool equal force. The welding arc force that satisfies the force balance of the weld pool in the welding direction is determined through force analysis, which facilitates the determination of the welding current at different welding points to achieve full weld formation and avoid defects such as downward flow and weld undercut.

[0037] In some feasible embodiments, calculating the welding arc force of the current welding point according to the component along the welding direction includes:

[0038] The welding arc force at the current welding point is determined based on the fact that the sum of the component along the welding direction and the welding arc force is equal to the surface tension of the weld pool liquid.

[0039] Therefore, the welding arc force can be calculated according to the surface tension of the weld pool liquid and the component of the gravity of the weld pool along the welding direction.

[0040] A second aspect of the present application provides a device for real-time and rapid calculation of welding process parameters of an intersecting line weld, the device comprising:

[0041] A data acquisition unit, used for acquiring the radius and intersection angle of the main pipe and the branch pipe;

[0042] A weld parameter calculation unit, used for calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle;

[0043] An arc force calculation unit is used to perform force analysis on the weld pool of the corresponding weld point according to the weld inclination angle and weld rotation angle of different weld points, so as to calculate the welding arc force of the corresponding weld point, wherein the welding arc force makes the weld pool balanced in the welding direction;

[0044] The welding current calculation unit is used to calculate the welding current of the corresponding welding point according to the welding arc force.

[0045] According to the above technical means, the device calculates the weld inclination and weld rotation angle of different welding points on the intersection line of the branch pipe according to the radius and intersection angle of the main pipe and the branch pipe, and then performs a force analysis on the weld molten pool of the corresponding weld point based on the weld rotation angle and the weld inclination to calculate the welding arc force of the corresponding weld point, thereby calculating the welding current required to provide the corresponding welding arc force during welding according to the welding process adopted. The welding arc force balances the force of the weld molten pool in the welding direction, which can eliminate problems such as weld formation sagging, undercut, and poor weld toe transition. Therefore, different welding currents can be calculated according to different welding point positions, providing a control basis for high-quality and efficient automated welding.

[0046] A third aspect of the present application provides an intelligent welding method for an intersecting line weld, the method comprising:

[0047] The welding current of each welding point is calculated by applying the real-time and fast calculation method of welding process parameters of the intersecting line weld;

[0048] The automatic welding actuator is controlled according to the welding current to weld the main pipe and the branch pipe.

[0049] The method automatically calculates the welding current of each welding point on the intersection line, and controls the automatic welding actuator to perform welding according to the welding, thereby reducing the welding heat input, making the weld formed by welding full, avoiding defects such as downward flow and weld undercut, and improving the efficiency and quality of welding work.

[0050] A fourth aspect of the present application provides an intersecting line weld intelligent welding device, the device comprising:

[0051] The controller is used to calculate the welding current of each welding point by applying the real-time and rapid calculation method of the welding process parameters of the intersecting line weld, and control the automatic welding actuator to weld the main pipe and the branch pipe according to the welding current.

[0052] The equipment can automatically calculate the welding current of each welding point on the intersection line, and control the automatic welding actuator to perform welding according to the welding, thereby reducing the welding heat input, making the weld formed by welding full, avoiding defects such as downward flow and weld undercut, and having higher work efficiency and welding quality.

[0053] A fifth aspect of the present application provides a machine-readable storage medium having instructions stored thereon, the instructions being used to enable a machine to execute the method for real-time and rapid calculation of welding process parameters of an intersecting line weld.

[0054] A sixth aspect of the present application provides a computer program product, including a computer program, which, when executed by a processor, implements the real-time and rapid calculation method of the welding process parameters of the intersection line weld.

[0055] Through the above technical solution, the weld inclination and weld rotation angle of different welding points on the intersection line of the branch pipe are calculated according to the radius and intersection angle of the main pipe and the branch pipe, and then the force analysis of the weld pool of the corresponding weld point is carried out based on the weld rotation angle and the weld inclination to calculate the welding arc force of the corresponding weld point, so as to calculate the welding current required to provide the corresponding welding arc force during welding according to the welding process adopted. The welding arc force makes the weld pool balanced in the welding direction, which can eliminate the defects of weld formation sagging, undercut, and poor weld toe transition. Therefore, different welding currents can be calculated according to different welding point positions, providing a control basis for high-quality and efficient automated welding. For the determined pipe-to-pipe intersection line joint, the range of automated welding process parameters is quickly formed, which greatly reduces the range of test parameters, avoids a large number of welding tests, and saves time.

[0056] Other features and advantages of the embodiments of the present invention will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The accompanying drawings are used to provide a further understanding of the embodiments of the present invention and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the embodiments of the present invention, but do not constitute a limitation on the embodiments of the present invention. In the accompanying drawings:

[0058] Figure 1 It is a flow chart of a method for real-time and rapid calculation of welding process parameters of an intersecting line weld provided by an embodiment of the present invention;

[0059] Figure 2 It is a schematic diagram of a main pipe and a branch pipe provided in one embodiment of the present invention;

[0060] Figure 3 It is a schematic diagram of a weld coordinate system and a reference coordinate system provided by an embodiment of the present invention;

[0061] Figure 4 It is a schematic diagram of a reference coordinate system and a branch pipe coordinate system provided by an embodiment of the present invention;

[0062] Figure 5 It is a schematic diagram of the acceptance analysis of weld pools at different positions provided by an embodiment of the present invention;

[0063] Figure 6 It is a block diagram of a device for real-time and rapid calculation of welding process parameters of an intersecting line weld provided by an embodiment of the present invention;

[0064] Figure 7 It is a flow chart of an intelligent welding method for intersecting line welds provided by one embodiment of the present invention.

[0065] Description of Reference Numerals

[0066] 1-main pipe, 2-branch pipe. DETAILED DESCRIPTION

[0067] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0068] Figure 1 This is a flow chart of a method for real-time and rapid calculation of welding process parameters of an intersecting line weld provided by an embodiment of the present invention. Figure 1 As shown, the method includes:

[0069] S1: Get the radius and intersection angle of main pipe 1 and branch pipe 2. Generally, main pipe 1 refers to a round pipe with a larger diameter, and branch pipe 2 refers to a round pipe with a smaller diameter. The intersection angle is the angle formed by the center line of main pipe 1 and the center line of branch pipe 2. In the embodiment of the present application, the intersection angle is expressed as δ, such as Figure 2 shown.

[0070] In some feasible embodiments, the main pipe radius, branch pipe radius and intersection angle input by the user may be obtained through a human-computer interaction interface.

[0071] S2: Calculate the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle, where the weld inclination angle is the angle between the welding direction and the horizontal plane; the weld rotation angle is the angle between the weld centerline and the vertical direction.

[0072] In some feasible embodiments, calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle includes:

[0073] S201: Calculate the first normal vector at any point on the cylindrical surface of the main tube. In some feasible embodiments, calculating the first normal vector at any point on the cylindrical surface of the main tube includes:

[0074] First, establish the reference coordinate system O-XYZ of the main pipe and the branch pipe. In the reference coordinate system, the origin O is located at the intersection of the center line of the main pipe and the center line of the branch pipe. The direction of the center line of the main pipe is the X axis, and the vertical direction is the Z axis. Figure 3 or Figure 4 shown.

[0075] In the reference coordinate system O-XYZ, the main cylindrical surface S can be expressed as F(x, y, z) = y 2 +z 2 -R 2 = 0, the normal vector at a point M on the main cylindrical surface S is expressed as:

[0076]

[0077] S202: Calculate the second normal vector of the branch tube cylindrical surface at the same point. In some feasible embodiments, calculating the second normal vector of the branch tube cylindrical surface at the same point includes:

[0078] First, establish the branch pipe coordinate system O1-X1Y1Z1. In the branch pipe coordinate system, the origin O1 is located at the intersection of the center line of the main pipe and the center line of the branch pipe. The direction of the branch pipe center line is the X1 axis, the vertical direction is the Z axis, and the direction perpendicular to the branch pipe center line along the horizontal plane is the Y1 axis. Figure 4 shown.

[0079] In the branch pipe coordinate system O1-X1Y1Z1, the branch pipe cylindrical surface S1 can be expressed as:

[0080] F1(x1, y1, z1) = y1 2 +z1 2 -r 2 =0.

[0081] The transformation formula for converting the branch cylindrical surface S1 to the coordinate system of the main cylindrical surface S is:

[0082]

[0083]

[0084] Substituting formula (3) into the branch cylindrical surface S1, it can be expressed as:

[0085] F1(x1, y1, z1) = y 2 +(xsinδ+zcosδ) 2 -r 2 =0.

[0086] The normal vector at a point M on the branch cylindrical surface S1 is expressed as:

[0087]

[0088] S203: Constructing calculation equations for the first normal vector and the second normal vector based on the center rotation angle of the branch pipe, where different center rotation angles represent positions of different welding points.

[0089] In some feasible embodiments, constructing a calculation equation for the first normal vector and the second normal vector based on the central rotation angle of the branch pipe includes:

[0090] First, the parameterized equation of the branch pipe cylindrical surface S1 is constructed according to the central rotation angle t of the branch pipe and the intersection angle:

[0091]

[0092] Among them, R is the radius of the main pipe, r is the radius of the branch pipe, and the size of the central rotation angle t of the branch pipe is determined according to the zero degree position selected on the branch pipe and the position of the welding point.

[0093] Then, determine the transformation formula for converting the main cylindrical surface to the coordinate system where the branch cylindrical surface is located. In some feasible embodiments, the transformation formula for converting the main cylindrical surface to the coordinate system where the branch cylindrical surface is located has been determined and obtained when calculating the second normal vector, that is, formulas (2) and (3), and can be directly applied at this time without repeated acquisition.

[0094] Then, a first calculation equation of the first normal vector based on the center rotation angle is constructed according to the transformation formula, the first normal vector and the parameterized equation. In some feasible embodiments, formula (5) can be substituted into formula (2) to obtain a conversion formula related to each coordinate of point M and the center rotation angle t, and then the conversion formula related to each coordinate of point M and the center rotation angle t is substituted into formula (1) to obtain the first calculation equation.

[0095] Finally, a second calculation equation for the second normal vector based on the center rotation angle is constructed according to the transformation formula, the second normal vector and the parameterized equation. In some feasible embodiments, formula (5) can be substituted into formula (2) to obtain a conversion formula related to each coordinate of point M and the center rotation angle t, and then the conversion formula related to each coordinate of point M and the center rotation angle t is substituted into formula (4) to obtain a second calculation equation.

[0096] Therefore, through the parameterized equation of the branch cylindrical surface based on the central rotation angle, the calculation equations related to the first normal vector and the second normal vector respectively with respect to the central rotation angle can be established. When the central rotation angle changes, the first normal vector and the second normal vector also change accordingly, and there is no need to repeatedly determine the first normal vector and the second normal vector.

[0097] S204: Calculate the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the calculation equation.

[0098] In some feasible embodiments, calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the calculation equation includes:

[0099] A weld feature coordinate system O′-X′Y′Z′ is established, where the origin O′ of the weld feature coordinate system is the weld point, the welding direction is the X′ axis, and the half of the angle between the two tangent planes at the weld point is the Z′ axis, such as Figure 3 As shown;

[0100] The X' axis vector is determined according to the geometric relationship, the first calculation equation and the second calculation equation. In some feasible embodiments, the normal vector of the horizontal plane is defined as According to the geometric relationship, it can be determined that the X′ axis vector can be expressed as:

[0101]

[0102] Substituting the first calculation equation and the second calculation equation into equation (7), we can get the expression of the X′ axis vector based on the center rotation angle t. Different center rotation angles correspond to different welding point positions.

[0103] The Z′ axis vector is determined according to the geometric relationship, the first calculation equation and the second calculation equation. According to the geometric relationship, it can be determined that the Z′ axis vector can be expressed as:

[0104]

[0105] Substituting the first calculation equation and the second calculation equation into equation (8), we can get the expression of the Z′ axis vector based on the center rotation angle t. Different center rotation angles correspond to different welding point positions.

[0106] According to geometric analysis, the angle between the X′ axis vector and the horizontal plane is the weld inclination angle, that is, the angle between the welding direction and the horizontal plane is the weld inclination angle, and the angle between the Z′ axis vector and the vertical direction is the weld rotation angle, that is, the angle between the weld centerline and the vertical direction is the weld rotation angle.

[0107] The weld inclination angles of different weld points are calculated based on trigonometric functions and the X′ axis vector. The weld inclination angle is expressed as:

[0108] Substituting equation (7) into equation (9), and then substituting the first and second calculation equations into equation (9), we can get the expression of the weld inclination based on the center rotation angle t. By changing the size of the center rotation angle t, we can get the weld inclination at different weld point positions. The range of the weld inclination is [-90°, 90°]. The weld inclination is positive when welding uphill and negative when welding downhill.

[0109] The weld rotation angles of different weld points are calculated based on trigonometric functions and the Z′ axis vector.

[0110]

[0111] Substituting equation (8) into equation (10), and then substituting the first calculation equation and the second calculation equation into equation (10), we can get the expression of the weld angle based on the center rotation angle t. By changing the size of the center rotation angle t, we can get the weld angle at different weld point positions.

[0112] Therefore, according to the first calculation equation and the second calculation equation, a calculation relationship between the weld inclination angle, the weld rotation angle and the center rotation angle is established, so that the weld inclination angle and the weld rotation angle at different positions can be directly calculated according to different center rotation angles without repeating a large number of analysis and calculations.

[0113] In the above technical means, a calculation formula for the weld inclination and weld rotation angle based on the central rotation angle of the branch pipe is constructed according to the geometric relationship between the main pipe and the branch pipe. Therefore, the weld inclination and weld rotation angle of welds in different positions can be calculated by adjusting the size of the central rotation angle of the calculation formula, which provides a force analysis basis for calculating the welding current of different welds.

[0114] S3: performing a force analysis on the weld pool of the corresponding weld point according to the weld inclination angle and weld rotation angle of different weld points to calculate the welding arc force of the corresponding weld point, wherein the welding arc force makes the weld pool balanced in the welding direction.

[0115] In some feasible embodiments, a force analysis is performed on the weld pool of the corresponding weld point according to the weld inclination angle and weld rotation angle of different weld points to calculate the welding arc force of the corresponding weld point, including:

[0116] A weld feature coordinate system is established, the origin of which is the weld point, the welding direction is the Xˊ axis, and the half of the angle between the two tangent planes at the weld point is the Zˊ axis. The weld coordinate system here is the same as the coordinate system used to calculate the weld inclination angle and weld rotation angle.

[0117] The gravity of the weld pool is decomposed in the Zˊaxis and OˊXˊYˊplane. The resultant force in the OˊXˊYˊplane will affect the appearance of the weld pool. Therefore, the overall force of the weld pool is analyzed in this plane, such as Figure 5 As shown. The reaction force (Fn), arc force (Farc), surface tension (FZ), and gravity (G) that support the molten pool. If the selected process parameters do not cause the molten pool to sag in the flat welding position, the change in spatial position will cause the molten pool to sag and the weld will appear ridge-shaped.

[0118] The force analysis of the weld pool of the intersecting line is performed, and the gravity of the weld pool is decomposed into the Zˊaxis and the OˊXˊYˊplane according to the weld rotation angle of the current weld point to obtain the first gravity component Gsinβ on the OˊXˊYˊplane.

[0119] The force analysis is performed on the OˊXˊYˊ plane, and the first gravity component is decomposed into the welding direction and the vertical welding direction according to the weld inclination angle of the current welding point to obtain the component Gsinβsinα along the welding direction.

[0120] The welding arc force of the current welding point is calculated according to the component along the welding direction. The welding arc force makes the weld pool balanced in the welding direction. According to the force analysis, when F Z >Gsinβsinα+F arc When the weld is ridge-shaped, the weld will not sag. Therefore, when the weld pool is balanced in the welding direction, the welding arc force of the current welding point is equal to the sum of the component along the welding direction and the welding arc force and the surface tension of the weld pool liquid:

[0121] F Z =Gsinβsinα+F arc (11)

[0122] Therefore, the welding arc force can be calculated according to the surface tension of the weld pool liquid and the component of the gravity of the weld pool along the welding direction.

[0123] According to the above technical means, the tension, gravity and arc blowing force exerted on the welding molten pool of the intersecting line spatial weld are calculated and analyzed to form the intersecting line welding parameter design criteria of the molten pool equal force. The welding arc force that satisfies the force balance of the weld pool in the welding direction is determined through force analysis, which facilitates the determination of the welding current at different welding points to achieve full weld formation and avoid defects such as downward flow and weld undercut.

[0124] S4: Calculate the welding current of the corresponding welding point according to the welding arc force. In some feasible embodiments, the gravity of the weld pool is expressed as:

[0125] G=ρgV(12)

[0126] Where ρ is the density of the welding wire, which can be taken as 7.85g / cm 3 ; g is the gravity constant, which is approximately 9.8N / kg; V is the molten pool volume.

[0127] The surface tension of the molten pool liquid is:

[0128] F Z =γ0(1-aT)(13)

[0129] In the formula, γ0 is the surface tension of molten steel at absolute zero, which is about 3N / m; a is a constant, which can be taken as 0.0002; and T is the molten pool temperature.

[0130] When using solid wire gas shielded welding, the arc force acting on the liquid molten pool is proportional to the square of the welding current.

[0131] F arc =kI 2 (14)

[0132] In the formula, the value of k is approximately (1.2-1.4)×10-6 N / A.

[0133] According to equations (11), (12) and (13), the arc force can be calculated, and according to equation (14), the welding current required to maintain force balance in the welding direction can be solved.

[0134] According to the above technical means, the weld inclination and weld rotation angle of different welding points on the intersection line of the branch pipe are calculated according to the radius and intersection angle of the main pipe and the branch pipe, and then the weld molten pool of the corresponding weld point is subjected to force analysis based on the weld rotation angle and the weld inclination to calculate the welding arc force of the corresponding weld point, so as to calculate the welding current required to provide the corresponding welding arc force during welding according to the welding process adopted. The welding arc force makes the weld molten pool balanced in the welding direction, which can eliminate the problems such as weld formation sagging, undercut, and poor weld toe transition. Therefore, different welding currents can be calculated according to different welding point positions, providing a control basis for high-quality and efficient automated welding.

[0135] Compared with the traditional method of manual welding or designing the welding parameters of the intersecting line according to equally divided angles, the method of the present application performs a more accurate and targeted force analysis on any position of the weld according to the weld inclination angle and weld rotation angle at different positions of the weld, and can more accurately and quickly calculate the welding arc force at any position of the weld, so as to determine the welding parameters at different positions of the weld. The method of the present application constructs a criterion for calculating and designing the welding parameters of the intersecting line according to the weld inclination angle and weld rotation angle. By adjusting the center rotation angle of the branch pipe, the welding parameters of the corresponding position can be quickly calculated, so that the single-circle automated welding has stronger continuity, fewer arc starting and ending points are formed, the weld formed by welding is smoother and fuller, the welding quality is higher, and the welding speed is faster.

[0136] The second aspect of the present application provides a device for real-time and rapid calculation of welding process parameters of an intersecting line weld, such as Figure 6 As shown, the device comprises:

[0137] A data acquisition unit, used for acquiring the radius and intersection angle of the main pipe and the branch pipe;

[0138] A weld parameter calculation unit, used for calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle;

[0139] An arc force calculation unit is used to perform force analysis on the weld pool of the corresponding weld point according to the weld inclination angle and weld rotation angle of different weld points, so as to calculate the welding arc force of the corresponding weld point, wherein the welding arc force makes the weld pool balanced in the welding direction;

[0140] The welding current calculation unit is used to calculate the welding current of the corresponding welding point according to the welding arc force.

[0141] According to the above technical means, the device calculates the weld inclination angle and weld rotation angle of different welding points on the intersection line of the branch pipe according to the radius and intersection angle of the main pipe and the branch pipe, and then performs a force analysis on the weld molten pool of the corresponding weld point based on the weld rotation angle and the weld inclination angle to calculate the welding arc force of the corresponding weld point, thereby calculating the welding current required to provide the corresponding welding arc force during welding according to the welding process adopted. The welding arc force balances the force of the weld molten pool in the welding direction, which can eliminate problems such as weld formation sagging, undercut, and poor weld toe transition. Therefore, different welding currents can be calculated according to different welding point positions, providing a control basis for high-quality and efficient automated welding.

[0142] The third aspect of the present application provides an intelligent welding method for intersecting line welds, such as Figure 7 As shown, the method includes:

[0143] The welding current of each welding point is calculated by applying the real-time and fast calculation method of welding process parameters of the intersecting line weld;

[0144] The automatic welding actuator is controlled according to the welding current to weld the main pipe and the branch pipe.

[0145] For example, when the main chord diameter is 89 mm, the oblique belly tube is 45 mm, and the intersection angle is 66°, the inclination angle α of the uphill welding reaches a maximum value of 15.743°. At this time, the weld angle is 46.36°. The uphill welding process uses 230A, 22V, and a walking speed of 6 mm / s. According to the test, the size of the molten pool is obtained. According to formulas (12)-(14), the molten pool gravity is 9.47728 N, the arc force is 0.07406 N, and the surface tension is 1.936 N. The extreme value Gsinβsinα+F in the uphill welding stage is arc =1.935N<F Z At this time, there will be no tendency for the molten pool to sag, so when designing parameters, the process parameters in this area can be selected as 230A parameters for welding. The welding parameters in other areas are designed according to this calculation process.

[0146] The method automatically calculates the welding current of each welding point on the intersection line, and controls the automatic welding actuator to perform welding according to the welding, thereby reducing the welding heat input, making the weld formed by welding full, avoiding defects such as downward flow and weld undercut, and improving the efficiency and quality of welding work.

[0147] A fourth aspect of the present application provides an intersecting line weld intelligent welding device, the device comprising:

[0148] The controller is used to calculate the welding current of each welding point by applying the real-time and fast calculation method of the welding process parameters of the intersecting line weld, and control the automatic welding actuator to weld the main pipe and the branch pipe according to the welding current. In some feasible embodiments, the intelligent welding device can be a welding robot.

[0149] The equipment can automatically calculate the welding current of each welding point on the intersection line, and control the automatic welding actuator to perform welding according to the welding, thereby reducing the welding heat input, making the weld formed by welding full, avoiding defects such as downward flow and weld undercut, and having higher work efficiency and welding quality.

[0150] A fifth aspect of the present application provides a machine-readable storage medium having instructions stored thereon, the instructions being used to enable a machine to execute the method for real-time and rapid calculation of welding process parameters of an intersecting line weld.

[0151] A sixth aspect of the present application provides a computer program product, including a computer program, which, when executed by a processor, implements the real-time and rapid calculation method of the welding process parameters of the intersection line weld.

[0152] Through the above technical solution, the weld inclination and weld rotation angle of different welding points on the intersection line of the branch pipe are calculated according to the radius and intersection angle of the main pipe and the branch pipe, and then the welding arc force of the corresponding welding point is calculated based on the weld rotation angle and the weld inclination, so as to calculate the welding current required to provide the corresponding welding arc force during welding according to the welding process adopted, so that different welding currents can be calculated according to different welding point positions, providing a control basis for high-quality and efficient automated welding. For the determined pipe-to-pipe intersection line joint, the range of automated welding process parameters is quickly formed, which greatly narrows the range of test parameters, avoids a large number of welding tests, and saves time.

[0153] Those skilled in the art will understand that all or part of the steps in the method for implementing the above-mentioned embodiments can be completed by instructing the relevant hardware through a program, and the program is stored in a storage medium, including several instructions for making a single-chip microcomputer, a chip or a processor (processor) perform all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk and other media that can store program codes.

[0154] The optional embodiments of the present invention are described in detail above in conjunction with the accompanying drawings. However, the embodiments of the present invention are not limited to the specific details in the above embodiments. Within the technical concept of the embodiments of the present invention, the technical scheme of the embodiments of the present invention can be subjected to a variety of simple modifications, and these simple modifications all belong to the protection scope of the embodiments of the present invention. It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the embodiments of the present invention will not further describe various possible combinations.

[0155] In addition, various embodiments of the present invention may be arbitrarily combined, and as long as they do not violate the concept of the embodiments of the present invention, they should also be regarded as the contents disclosed in the embodiments of the present invention.

Claims

1. A real-time and rapid calculation method for welding process parameters of intersecting line welds, characterized in that: The method comprises: Get the radius and intersection angle of the main pipe and branch pipe; Calculate the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle; Performing force analysis on the weld pool of the corresponding weld points according to the weld inclination angle and weld rotation angle of different weld points to calculate the welding arc force of the corresponding weld points, wherein the welding arc force makes the weld pool balanced in the welding direction; The welding current of the corresponding welding point is calculated according to the welding arc force.

2. The real-time rapid calculation method of welding process parameters of intersecting line welds according to claim 1 is characterized in that: Calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle includes: Calculate the first normal vector at any point on the cylindrical surface of the main tube; Calculate the second normal vector of the branch cylinder at the same point; Constructing the calculation equations of the first normal vector and the second normal vector based on the center rotation angle of the branch pipe, and different center rotation angles represent the positions of different welding points; The weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe are calculated according to the calculation equation.

3. The real-time rapid calculation method of welding process parameters of intersecting line welds according to claim 2 is characterized in that: Constructing the calculation equations of the first normal vector and the second normal vector based on the central rotation angle of the branch pipe, including: Constructing a parameterized equation of the cylindrical surface of the branch pipe according to the central rotation angle of the branch pipe and the intersection angle; Determine the transformation formula for converting the main pipe cylindrical surface to the coordinate system of the branch pipe cylindrical surface; Constructing a first calculation equation for the first normal vector based on the central rotation angle according to the transformation formula, the first normal vector and the parameterized equation; A second calculation equation for the second normal vector based on the central rotation angle is constructed according to the transformation formula, the second normal vector and the parameterized equation.

4. The real-time rapid calculation method of welding process parameters of intersecting line welds according to claim 3 is characterized in that: Calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the calculation equation includes: A weld feature coordinate system is established, wherein the origin of the weld feature coordinate system is the weld point, the welding direction is the Xˊaxis, and half of the angle between the two tangent planes at the weld point is the Zˊaxis; Determine the Xˊ-axis vector according to the geometric relationship, the first calculation equation and the second calculation equation; Determine the Z-axis vector according to the geometric relationship, the first calculation equation and the second calculation equation; According to geometric analysis, the angle between the Xˊaxis vector and the horizontal plane is the weld inclination angle, and the angle between the Zˊaxis vector and the vertical direction is the weld rotation angle; Calculate the weld inclination angles of different welding points based on trigonometric functions and X-axis vectors; The weld rotation angles of different weld points are calculated based on trigonometric functions and the Z-axis vector.

5. The real-time rapid calculation method of welding process parameters of intersecting line welds according to claim 1 is characterized in that: According to the weld inclination and weld rotation angle of different weld points, the weld pool of the corresponding weld point is subjected to stress analysis to calculate the welding arc force of the corresponding weld point, including: A weld feature coordinate system is established, wherein the origin of the weld feature coordinate system is the weld point, the welding direction is the Xˊaxis, and half of the angle between the two tangent planes at the weld point is the Zˊaxis; Performing a force analysis on the weld pool of the intersecting line, decomposing the gravity of the weld pool to the Zˊaxis and the OˊXˊYˊplane according to the weld rotation angle of the current weld point, and obtaining the first gravity component on the OˊXˊYˊplane; Perform force analysis on the OˊXˊYˊ plane, decompose the first gravity component into components along the welding direction and perpendicular to the welding direction according to the weld inclination angle of the current welding point, and obtain a component along the welding direction; The welding arc force of the current welding point is calculated according to the component along the welding direction.

6. The method for real-time and rapid calculation of welding process parameters of intersecting line welds according to claim 5 is characterized in that: Calculating the welding arc force of the current welding point according to the component along the welding direction includes: The welding arc force at the current welding point is determined based on the fact that the sum of the component along the welding direction and the welding arc force is equal to the surface tension of the weld pool liquid.

7. A device for real-time and rapid calculation of welding process parameters of intersecting line welds, characterized in that: The device comprises: A data acquisition unit, used for acquiring the radius and intersection angle of the main pipe and the branch pipe; A weld parameter calculation unit, used for calculating the weld inclination angle and weld rotation angle of different welding points on the intersection line of the main pipe and the branch pipe according to the radius and the intersection angle; An arc force calculation unit is used to perform force analysis on the weld pool of the corresponding weld point according to the weld inclination angle and weld rotation angle of different weld points, so as to calculate the welding arc force of the corresponding weld point, wherein the welding arc force makes the weld pool balanced in the welding direction; The welding current calculation unit is used to calculate the welding current of the corresponding welding point according to the welding arc force.

8. An intelligent welding method for intersecting line welds, characterized in that: The method comprises: Calculate the welding current of each welding point by using the real-time fast calculation method of welding process parameters of the intersecting line weld described in any one of claims 1 to 6; The automatic welding actuator is controlled according to the welding current to weld the main pipe and the branch pipe.

9. An intelligent welding device for intersecting line welds, characterized in that: The device comprises: The controller is used to calculate the welding current of each welding point by applying the real-time and rapid calculation method of the welding process parameters of the intersecting line weld described in any one of claims 1 to 6, and control the automatic welding actuator to weld the main pipe and the branch pipe according to the welding current.

10. A machine-readable storage medium having instructions stored thereon, characterized in that: The instruction is used to enable the machine to execute the real-time and rapid calculation method of the welding process parameters of the intersection line weld described in any one of claims 1 to 6 of the present application.

11. A computer program product, comprising a computer program, characterized in that When the computer program is executed by a processor, the computer program implements the real-time and rapid calculation method for welding process parameters of an intersection weld seam according to any one of claims 1 to 6.

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