Membrane tube panel GMAW welding gun position and welding parameter automatic adjusting method

Abstract

The invention discloses an automatic adjusting method for a GMAW welding gun position and welding parameters of a membrane tube panel, and relates to the technical field of welding processes. An existing welding mode is poor in welding stability. In the welding process, a laser tracking and positioning device is adopted to scan the spatial position of a to-be-welded weld joint at the intersection of a steel pipe and flat steel in real time, a weld pool camera is adopted to shoot a weld pool image and a weld joint image near a weld pool in real time, and a welding parameter collecting device is adopted to collect power parameters of a welding power source and wire feeding parameters of a wire feeder; the central control system adjusts the position of a welding gun in real time according to the spatial position of a to-be-welded welding seam, inputs a welding pool image and a welding seam image near a welding pool into the internally trained model in real time, and outputs a result whether power supply parameters of a welding power supply and wire feeding parameters of a wire feeder are qualified or not; and if the power supply parameter of the welding power supply or the wire feeding parameter of the wire feeder is unqualified, adjusting the power supply parameter or the wire feeding parameter into a corresponding preset parameter range interval. The device is used for adjusting the welding gun position and welding parameters.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding process. BACKGROUND

[0002] Membrane tube panel is widely used in power station boiler, pressure vessel and other equipment, and is used as a main component. At present, the GMAW welding of membrane tube panel in the industry is usually mechanical, only a few manufacturers try to use vision or laser to track the weld and guide the adjustment of the welding gun position, but it does not have the function of sensing the welding process parameters and real-time feedback of the weld quality, and cannot realize deep intelligent automatic welding. For the problems such as unstable welding process, welding parameter fluctuation, welding defects and weld deviation caused by tube panel thermal deformation, assembly error, poor consistency of base material and welding wire surface during welding, it is still not possible to respond timely and accurately, resulting in poor welding stability of the existing welding method. SUMMARY

[0003] The purpose of the present application is to solve the problem of poor welding stability of the existing welding method, and a GMAW welding gun position and welding parameter automatic adjustment method for membrane tube panel is proposed.

[0004] The GMAW welding gun position and welding parameter automatic adjustment method for membrane tube panel comprises the following contents:

[0005] Step 1, during the welding process, a laser tracking positioning device is used to scan the space position of the to-be-welded weld at the intersection of the steel pipe and the flat steel in real time, a molten pool camera is used to take real-time images of the welding state and the molten pool, and a welding parameter acquisition device is used to acquire the power parameters of the welding power supply and the wire feeding parameters of the wire feeder;

[0006] Step 2, the central control system adjusts the welding gun position in real time according to the space position of the to-be-welded weld, so that the end of the welding gun nozzle points to the space position of the to-be-welded weld, and at the same time, the central control system inputs the welding molten pool image and the weld image near the molten pool to the internally trained model in real time, outputs the result of whether the power parameters of the welding power supply and the wire feeding parameters of the wire feeder are qualified, if the power parameters of the welding power supply are unqualified, adjusts the power parameters of the welding power supply to the preset power parameter range interval, and if the wire feeding parameters of the wire feeder are unqualified, adjusts the wire feeding parameters of the wire feeder to the preset wire feeding parameter range interval.

[0007] Preferably, the obtaining process of the trained model is as follows: the welding molten pool image and the weld image near the molten pool in the welding database are used as input data, the result of whether the power parameters of the welding power supply and the wire feeding parameters of the wire feeder are qualified is labeled as output data, the input data and the output data are used to train the model, and the trained model is obtained.

[0008] Preferably, the power parameters of the welding power supply include welding current, welding voltage and pulse waveform, and the wire feeding parameters of the wire feeder include wire feeding speed.

[0009] Preferably, the central control system controls the movement of the welding torch position adjustment device according to the spatial position of the weld seam to be welded, thereby adjusting the position of the welding torch. The welding torch position adjustment device includes a crossbeam, a bracket, a welding torch holder, and vertical and horizontal electric motion devices.

[0010] The crossbeam is set on the welding equipment body, and the crossbeam is equipped with guide rails along the horizontal direction. The bracket is embedded in the guide rail and can move horizontally along the guide rail. The bracket, welding torch holder, vertical and horizontal electric motion device and welding torch are connected in sequence from top to bottom. The horizontal electric motion device can drive the welding torch to move along the horizontal and vertical directions.

[0011] Preferably, the laser wavelength of the laser tracking and positioning device is 600~1600nm.

[0012] Preferably, the frame rate of the molten pool camera is ≥50fps and the resolution is ≥720×540.

[0013] The beneficial effects of this invention are:

[0014] This invention equips GMAW (Glass Wire Welding) equipment with "eyes," "hands," and "brains" by integrating a laser tracking and positioning device, a molten pool camera, a welding parameter acquisition device, a welding torch position adjustment device, and a central control system. Through real-time detection and analysis of the welding position, molten pool and weld images, and welding process parameters, and with the help of AI technology, it formulates optimal control strategies and achieves real-time dynamic adjustment of the welding torch position, power supply parameters, and wire feeding parameters during the GMAW welding process of GMAW. This effectively solves problems such as welding process instability, power supply parameter fluctuations, wire feeding parameter fluctuations, welding defects, and weld deviations caused by thermal deformation of the GMAW, assembly errors, and differences in the surface consistency of the base material and welding wire.

[0015] This invention processes the spatial position of the weld to be welded, the condition of the molten pool and the weld surface, and welding parameter information in real time, makes corresponding adjustment decisions, and controls the welding torch position adjustment device and welding power supply to make corresponding adjustments, so as to ensure accurate welding position, stable welding process, and good weld formation.

[0016] This invention uses a trained model to predict whether the power supply parameters and wire feeding parameters are qualified, and adjusts them in time if they are not qualified, thereby improving processing speed and decision accuracy. Attached Figure Description

[0017] Figure 1 A schematic diagram of a welding equipment for automatically adjusting the position and welding parameters of a GMAW welding torch for membrane tube screens;

[0018] Figure 2 for Figure 1Right view of the welding torch position adjustment device;

[0019] Figure 3 for Figure 2 View from A in the middle. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the scope of the invention.

[0022] Example:

[0023] An automatic adjustment method for the position and welding parameters of the GMAW welding torch for membrane tube screens, the method comprising the following:

[0024] Step 1: During the welding process, the laser tracking and positioning device 3 is used to scan the spatial position of the weld seam at the intersection of the steel pipe 1 and the flat steel 2 in real time. The molten pool camera 4 is used to capture images of the weld pool and the weld seam near the molten pool in real time. The welding parameter acquisition device 7 is used to acquire the power parameters of the welding power source 6 and the wire feeding parameters of the wire feeder 8.

[0025] Step 2: The central control system 5 adjusts the position of the welding torch 10 in real time according to the spatial position of the weld to be welded, so that the nozzle end of the welding torch 10 points to the spatial position of the weld to be welded. At the same time, the central control system 5 inputs the image of the weld pool and the image of the weld near the weld pool into the internally trained model in real time, and outputs the results of whether the power parameters of the welding power source 6 and the wire feeding parameters of the wire feeder 8 are qualified. According to the judgment results and the preset adjustment rules, the system automatically adjusts: if the power parameters of the welding power source 6 are not qualified, the power parameters of the welding power source 6 are adjusted to the preset power parameter range; if the wire feeding parameters of the wire feeder 8 are not qualified, the wire feeding parameters of the wire feeder 8 are adjusted to the preset wire feeding parameter range.

[0026] Specifically, the central control system processes the spatial position of the weld to be welded, the surface condition of the molten pool and weld, power parameters and wire feeding parameters returned by the laser tracking and positioning device, the molten pool camera, and the welding parameter acquisition device in real time, makes corresponding adjustment decisions, and controls the welding torch position adjustment device and the welding power supply to make corresponding adjustments to ensure accurate welding position, stable welding process and good weld formation.

[0027] The molten pool camera 4 monitors the entire welding process in real time, and the captured images are transmitted to the central control system 5 in real time. The system analyzes the image information in real time to determine whether the welding is normal. If the analysis finds that the power supply parameters or wire feeding parameters are not suitable, resulting in abnormalities such as weld pool morphology, welding spatter, and weld formation, the system compares with the internal welding expert database and automatically controls the welding machine's welding power supply, welding torch position, and other hardware to adjust the power supply parameters and wire feeding parameters, forming a complete feedback system.

[0028] By integrating a laser tracking and positioning device, a molten pool camera, a welding parameter acquisition device, a welding torch position adjustment device, and a central control system, the membrane tube screen welding equipment is equipped with "eyes," "hands," and a "brain," enabling real-time dynamic adjustment of the welding torch position, power parameters, and wire feeding parameters during the GMAW welding process of the membrane tube screen.

[0029] To further define the process of obtaining the trained model: the weld pool image and the weld seam image near the weld pool in the welding database are used as input data. The results of whether the power parameters of the welding power source 6 and the wire feeding parameters of the wire feeder 8 are qualified are labeled as output data. The model is trained using the input data and the output data to obtain the trained model.

[0030] Further specifying, the power supply parameters of welding power source 6 include welding current, welding voltage and pulse waveform, and the wire feeding parameters of wire feeder 8 include wire feeding speed.

[0031] Specifically, the central control system can adjust parameters such as welding current, welding voltage, pulse waveform, and wire feed speed to achieve precise control over the welding arc and droplet transfer.

[0032] Further defining the control system 5, the central control system 5 controls the movement of the welding torch position adjustment device 9 according to the spatial position of the weld seam to be welded, thereby adjusting the position of the welding torch 10. The welding torch position adjustment device 9 includes a crossbeam 9-1, a bracket 9-2, a welding torch holder 9-3, and vertical and horizontal electric motion devices.

[0033] A crossbeam 9-1 is mounted on the welding equipment body. A guide rail is mounted on the crossbeam 9-1 along the horizontal direction. A bracket 9-2 is embedded in the guide rail and can move horizontally along the guide rail. The bracket 9-2, welding torch holder 9-3, vertical and horizontal electric motion devices, and welding torch 10 are connected in sequence from top to bottom. The horizontal electric motion device can drive the welding torch 10 to move along the horizontal and vertical directions.

[0034] Specifically, the number of welding torches applicable is 1 to 40, and the applicable welding positions include, but are not limited to, flat welding (PA position) and overhead welding (PD position).

[0035] The transmission between the crossbeam, the hanger, and the welding gun holder adopts a ball screw + linear guide + servo motor transmission method to ensure transmission accuracy and response speed.

[0036] The difference in horizontal height between the weld pool camera and the tip of the welding torch nozzle should not be too large to ensure a good field of view and obtain clear and complete images of the weld pool and adjacent completed fillet welds; the weld pool camera is specially water-cooled and has the ability to operate stably in high-temperature environments.

[0037] Further specified, the laser wavelength of the laser tracking and positioning device 3 is 600~1600nm.

[0038] Specifically, to improve the ability to resist welding arc interference, the laser tracking and positioning device uses near-infrared light with a wavelength of 780~980nm.

[0039] Further restrictions are imposed: the frame rate of the molten pool camera 4 is ≥50fps, and the resolution is ≥720×540.

[0040] Specifically, to ensure the timeliness and clarity of the captured images, the frame rate of the molten pool camera should be ≥50fps and the resolution should be ≥720×540.

[0041] While the invention has been described herein with reference to specific embodiments, it should be understood that these embodiments are merely examples of the principles and applications of the invention. Therefore, it should be understood that many modifications can be made to the exemplary embodiments, and other arrangements can be designed without departing from the spirit and scope of the invention as defined by the appended claims. It should be understood that different dependent claims and features described herein can be combined in ways different from those described in the original claims. It is also understood that features described in conjunction with individual embodiments can be used in other described embodiments.

Claims

1. A method for automatic adjustment of the position and welding parameters of a membrane tube panel GMAW welding torch, characterized in that, The method comprises the following contents: Step 1, in the welding process, a laser tracking positioning device (3) is used to scan the space position of the to-be-welded weld at the intersection of the steel pipe (1) and the flat steel (2) in real time, a molten pool camera (4) is used to take real-time images of the welding state and the molten pool, and a welding parameter acquisition device (7) is used to acquire the power parameters of the welding power source (6) and the wire feeding parameters of the wire feeder (8); Step 2, the central control system (5) adjusts the position of the welding torch (10) according to the space position of the to-be-welded weld in real time, so that the nozzle end of the welding torch (10) points to the space position of the to-be-welded weld, and at the same time, the central control system (5) inputs the welding molten pool image and the weld image near the molten pool to the internally trained model in real time, outputs the result of whether the power parameters of the welding power source (6) and the wire feeding parameters of the wire feeder (8) are qualified, if the power parameters of the welding power source (6) are unqualified, adjusts the power parameters of the welding power source (6) to the preset power parameter range interval, and if the wire feeding parameters of the wire feeder (8) are unqualified, adjusts the wire feeding parameters of the wire feeder (8) to the preset wire feeding parameter range interval.

2. The membrane tube panel GMAW welding gun position and welding parameter automatic adjusting method according to claim 1, characterized in that, The obtaining process of the trained model: the welding molten pool image and the weld image near the molten pool in the welding database are used as input data, the result of whether the power parameters of the welding power source (6) and the wire feeding parameters of the wire feeder (8) are qualified is labeled as output data, the input data and the output data are used to train the model, and the trained model is obtained.

3. The membrane tube sheet GMAW welding gun position and welding parameter automatic adjustment method according to claim 1, characterized in that, The power parameters of the welding power source (6) include welding current, welding voltage and pulse waveform, and the wire feeding parameters of the wire feeder (8) include wire feeding speed.

4. The membrane tube sheet GMAW welding gun position and welding parameter automatic adjustment method according to claim 1, characterized in that, The central control system (5) controls the welding torch position adjusting device (9) to move according to the space position of the to-be-welded weld, so as to adjust the position of the welding torch (10), wherein the welding torch position adjusting device (9) comprises a crossbeam (9-1), a hanger (9-2), a welding torch seat (9-3) and vertical and horizontal electric motion devices, The crossbeam (9-1) is arranged on the welding equipment body, a guide rail is arranged on the crossbeam (9-1) in the horizontal direction, the hanger (9-2) is embedded on the guide rail and can move horizontally along the guide rail, the hanger (9-2), the welding torch seat (9-3), the vertical and horizontal electric motion devices and the welding torch (10) are connected in sequence from top to bottom, and the horizontal electric motion device can drive the welding torch (10) to move in the horizontal direction and the vertical direction.

5. The membrane tube sheet GMAW welding gun position and welding parameter automatic adjustment method according to claim 1, characterized in that, The laser wavelength of the laser tracking positioning device (3) is 600-1600 nm.

6. The membrane tube sheet GMAW welding gun position and welding parameter automatic adjustment method according to claim 1, characterized in that, The shooting frame rate of the molten pool camera (4) is ≥50 fps, and the resolution is ≥720×540.

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