Self-adaptive laser hybrid welding system and method for single-side welding and double-side smooth transition

Abstract

The invention provides a single-side welding and double-side smooth transition self-adaptive laser hybrid welding system and method.The welding system comprises a laser welding module, a welding line collecting module, a molten pool diameter collecting module, a robot, a data processing module and a control center, and the data processing module calculates a front molten pool diameter forming value through collected welding line data; then the diameter forming value of the back melting pool is calculated according to the single-face welding double-face smooth transition constraint parameters, and then the initial laser welding power of a laser welding module is determined according to the diameter forming value of the back melting pool, the groove angle, the assembly intermittent interval, the groove truncated edge height and the thickness of the tailor-welded vertical part; then, a laser welding power compensation value is determined according to the diameter data of the front molten pool, and finally, real-time laser welding power is determined according to the initial laser welding power and the laser welding power compensation value. Single-face welding and double-face smooth transition forming can be achieved, then the stress concentration coefficient is reduced, and the fatigue load bearing capacity is improved.

Description

Technical Field

[0001] This invention relates to the field of robotic welding technology, and in particular to an adaptive laser hybrid welding system and method for single-sided welding with smooth transition between two sides. Background Technology

[0002] Currently, laser-arc hybrid welding can achieve single-sided welding and double-sided forming for corner joints. However, the laser power is fixed during laser-arc hybrid welding. When the dimensions and positional information such as assembly gap, blunt edge, misalignment, and spatial relative position fluctuate within a certain range, the ratio of the diameter of the front side of the weld pool to the diameter of the back side of the weld pool is likely to be large. When the ratio is large, the weld metal and the base metal cannot transition smoothly (the transition angle is greater than 120°), resulting in a large stress concentration factor in the welded structure, which will reduce its ability to withstand fatigue loads. Summary of the Invention

[0003] To address the technical problems in the prior art, this invention provides an adaptive laser hybrid welding system and method that enables single-sided welding with smooth double-sided transition forming.

[0004] To achieve the above-mentioned objectives, the present invention provides the following technical solution: An adaptive laser hybrid welding system for single-sided welding with smooth transition on both sides includes: Laser welding module, used for laser welding; The weld seam acquisition module is used to collect weld seam data and the thickness of welded vertical components. ; The molten pool diameter acquisition module is used to acquire molten pool diameter data from either the front or back side. Robot, with fixed laser welding module, weld seam acquisition module and molten pool diameter acquisition module; The data processing module is used to calculate the bevel angle based on the weld data collected by the weld acquisition module. Assembly interval and bevel blunt edge height The calculated forming value of the front molten pool diameter Then, the diameter forming value of the molten pool on the back side is calculated based on the constraint parameters for smooth transition between single-sided welding and double-sided welding. Then, the forming value is determined by the diameter of the back melt pool. , bevel angle Assembly interval bevel blunt edge height and the thickness of the welded vertical components Determine the initial laser welding power of the laser welding module. Then, the laser welding power compensation value is determined using the diameter data of the front or back weld pool. Finally, the initial laser welding power was used. and laser welding power compensation value Determine real-time laser welding power ; The control center connects the laser welding module, weld seam acquisition module, molten pool diameter acquisition module, robot, and data processing module. It controls the robot's movement to move the laser welding module, weld seam acquisition module, and molten pool diameter acquisition module along the weld seam. It also transmits data acquired by the weld seam acquisition module and molten pool diameter acquisition module to the data processing module and receives the real-time laser welding power calculated by the data processing module. And control the laser welding module to adjust to the real-time laser welding power. .

[0005] Preferably, it also includes an arc welding module for performing arc welding, the arc welding module being fixed to the robot to move along the weld seam under the robot's drive, and connected to a control center, which controls the arc welding power.

[0006] Preferably, the angle between the laser welding module and the welding base plate is α, where α is 15-30°; the angle between the arc welding module and the welding base plate is β, where β is 45-75°.

[0007] Preferably, the molten pool diameter acquisition module is a front molten pool diameter acquisition module, used to acquire front molten pool diameter data, and the weld acquisition module and the molten pool diameter acquisition module are located on the side of the robot close to the vertical component being welded.

[0008] Preferably, the weld seam acquisition module is a laser sensor or a vision sensor.

[0009] Preferably, the molten pool diameter acquisition module is an infrared thermal imager.

[0010] Preferably, the forming value of the front molten pool diameter The calculation formula is:

[0011] in, This is the heat input correction factor;

[0012] in, Standard coefficients for the thermal input of welding processes and welding materials can be found in welding manuals. The diameter forming value of the back melt pool The calculation formula is: .

[0013] Preferably, the initial laser welding power The calculation formula is:

[0014] in, Adjust parameters for materials; For welding speed; Factors affecting the raw materials of the vertical welding plates. , For the material's laser absorption rate, The thermal conductivity of the material; The bevel angle is an influencing factor. ; The influencing factor of assembly interval spacing. ; The influencing factor of the thickness of the vertical plate for welding. ; The factor affecting the height of the bevel blunt edge. ; The The calculation formula, obtained using the PID algorithm, is as follows:

[0015] in, , , For PID parameters; The sampling interval; For the first The difference in the diameter of the frontal molten pool at any given time. , For the first The diameter of the frontal molten pool at any given moment; , For filtering windows; The real-time laser welding power The calculation formula is: .

[0016] An adaptive laser hybrid welding method for single-sided welding with smooth transition on both sides, employing the adaptive laser hybrid welding system for single-sided welding with smooth transition on both sides as described above, the method comprising: Step 1: Place the welding base plate and the welding vertical component into the welding position. The control center controls the robot, and the control center also controls the weld seam acquisition module to move along one side of the welding vertical component. The weld seam acquisition module collects weld seam data and the thickness of the welding vertical component. ; Step 2: Weld data and thickness of vertical components for splicing The data is transmitted from the control center to the data processing module, which then calculates the bevel angle based on the weld data. Assembly interval and bevel blunt edge height Calculate the forming value of the front molten pool diameter. Calculate the diameter of the back melt pool. Then, the forming value is determined by the diameter of the back melt pool. , bevel angle Assembly interval bevel blunt edge height and the thickness of the welded vertical components Determine the laser welding power of the laser welding module ; Step 3: The robot moves the laser welding module and the arc welding module to one side of the vertical component to be welded. The laser welding module and the arc welding module are then activated and move along the vertical component to perform welding. The laser welding module is set to its initial laser welding power. ; Step 4: Simultaneously, the molten pool diameter acquisition module acquires the diameter of the molten pool on the front side during welding. Calculate the diameter of the front molten pool With front molten pool diameter forming value Difference in diameter of the front molten pool According to the laser welding power compensation value Calculate the laser welding power compensation value of the laser welding module Then adjust the laser welding power compensation value. Add initial laser welding power Real-time laser welding power is obtained ; Step 5: The control center adjusts the laser welding module to the real-time laser welding power. Continue welding; Step Six: Repeat Steps Four and Five until the welding is complete.

[0017] Preferably, in step four, the forming value of the front molten pool diameter... The calculation formula is:

[0018] in, This is the heat input correction factor;

[0019] in, Standard coefficients for the thermal input of welding processes and welding materials can be found in welding manuals. The diameter forming value of the back melt pool The calculation formula is: ; The initial laser welding power The calculation formula is:

[0020] in, Adjust parameters for materials; For welding speed; Factors affecting the raw materials of the vertical welding plates. , For the material's laser absorption rate, The thermal conductivity of the material; The bevel angle is an influencing factor. ; The influencing factor of assembly interval spacing. ; The influencing factor of the thickness of the vertical plate for welding. ; The factor affecting the height of the bevel blunt edge. ; The The calculation formula, obtained using the PID algorithm, is as follows:

[0021] in, , , For PID parameters; The sampling interval; For the first The difference in the diameter of the frontal molten pool at any given time. , For the first The diameter of the frontal molten pool at any given moment; , For filtering windows; The real-time laser welding power The calculation formula is: .

[0022] Compared with existing technologies, the adaptive laser hybrid welding system and method for single-sided welding with smooth transition on both sides provided by this invention calculates the diameter forming value of the front molten pool based on collected weld data, then calculates the diameter forming value of the back molten pool based on the constraint parameters for smooth transition on both sides. Next, the initial laser welding power of the laser welding module is determined using the back molten pool diameter forming value, bevel angle, assembly interval, bevel blunt edge height, and thickness of the welded vertical components. Then, the laser welding power compensation value is determined using the front molten pool diameter data. Finally, the real-time laser welding power is confirmed using the initial laser welding power and the laser welding power compensation value. This invention enables real-time adjustment of the laser welding power, which facilitates single-sided welding with equal diameter forming on both sides in laser-arc hybrid welding, thereby achieving smooth transition on both sides, reducing the stress concentration factor, and improving the ability to withstand fatigue loads. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a block diagram of an adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition provided in one embodiment of the present invention; Figure 2 for Figure 1 A three-dimensional view of an adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition is shown. Figure 3 for Figure 1 The image shows another perspective of the adaptive laser hybrid welding system with a smooth transition between single-sided and double-sided welding. Figure 4 for Figure 1 The image shows a front view of an adaptive laser hybrid welding system with a smooth transition between single-sided and double-sided welding.

[0025] In the diagram: 1. Robot; 2. Laser welding module; 3. Weld seam acquisition module; 4. Arc welding module; 5. Molten pool diameter acquisition module; 6. Control center; 7. Data processing module; 8. Welding base plate; 9. Welding vertical component. Detailed Implementation

[0026] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0027] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly set on the other component; when a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to the other component.

[0028] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size should still fall within the scope of the technical content disclosed in this application, provided that they do not affect the effects and purposes that this application can produce.

[0029] like Figures 1 to 4 As shown, this embodiment of the invention provides an adaptive laser hybrid welding system with single-sided welding and smooth transition on both sides, comprising: Laser welding module 2 is used for laser welding; Weld acquisition module 3 is used to collect weld data and the thickness δ of the welded vertical components; Molten pool diameter acquisition module 5 is used to acquire molten pool diameter data from the front or back side. Robot 1, fixed laser welding module 2, weld seam acquisition module 3, and molten pool diameter acquisition module 5; Data processing module 7 is used to calculate the bevel angle α, assembly interval spacing β, and bevel blunt edge height h based on the weld data collected by weld acquisition module 3, and to obtain the forming value of the front molten pool diameter. Then, the diameter forming value of the molten pool on the back side is calculated based on the constraint parameters for smooth transition between single-sided welding and double-sided welding. Then, the forming value is determined by the diameter of the back melt pool. The initial laser welding power of laser welding module 2 is determined by the bevel angle α, assembly interval β, bevel blunt edge height h, and the thickness δ of the vertical welded component. Then, the laser welding power compensation value is determined using the diameter data of the front or back weld pool. p, and finally, through the initial laser welding power p0 and the laser welding power compensation value p Determine real-time laser welding power ; Control center 6 connects laser welding module 2, weld seam acquisition module 3, molten pool diameter acquisition module 5, robot 1, and data processing module 7. It controls the movement of robot 1 to move laser welding module 2, weld seam acquisition module 3, and molten pool diameter acquisition module 5 along the weld seam, transmits the data acquired by weld seam acquisition module 3 and molten pool diameter acquisition module 5 to data processing module 7, and receives the real-time laser welding power calculated by data processing module 7. And control the laser welding module 2 to adjust to the real-time laser welding power. .

[0030] In this embodiment, the welding system further includes an arc welding module 4 for performing arc welding. The arc welding module 4 is fixed to the robot 1 and moves along the weld seam under the drive of the robot 1. It is connected to the control center 6, which controls the arc welding power. In this embodiment, the angle between the laser welding module 2 and the welding base plate 8 is 'a', where 'a' is 15-30°; the angle between the arc welding module 4 and the welding base plate 8 is 'b', where 'b' is 45-75°.

[0031] In this embodiment, the molten pool diameter acquisition module 5 is a front-facing molten pool diameter acquisition module, used to acquire front-facing molten pool diameter data. The weld seam acquisition module 3 and the molten pool diameter acquisition module 5 are located on the side of the robot 1 near the vertical component 9 being welded. The weld seam acquisition module 3 is a laser sensor or a vision sensor. The molten pool diameter acquisition module 5 is an infrared thermal imager.

[0032] In this embodiment, the forming value of the front molten pool diameter is... The calculation formula is:

[0033] in, This is the heat input correction factor;

[0034] in, Standard coefficients for the thermal input of welding processes and welding materials can be found in welding manuals. Back side molten pool diameter forming value The calculation formula is: .

[0035] In this embodiment, the initial laser welding power The calculation formula is:

[0036] in, Adjust the parameters for the materials, such as 1.2 for steel, 0.8 for aluminum, and 1.0 for stainless steel; For welding speed; Factors affecting the raw materials of the vertical welding plates. , For the material's laser absorption rate, The thermal conductivity of the material; The bevel angle is an influencing factor. ; The influencing factor of assembly interval spacing. ; The influencing factor of the thickness of the vertical plate for welding. ; The factor affecting the height of the bevel blunt edge. ; The calculation formula, obtained using the PID algorithm, is as follows:

[0037] in, , , For PID parameters; The sampling interval; For the first The difference in the diameter of the frontal molten pool at any given time. , For the first The diameter of the frontal molten pool at any given moment; , For filtering windows; Real-time laser welding power The calculation formula is: .

[0038] This embodiment also provides an adaptive laser hybrid welding method for single-sided welding with smooth transition on both sides, using the adaptive laser hybrid welding system for single-sided welding with smooth transition on both sides as described above.

[0039] The method includes: Step 1: Place the welding base plate 8 and the welding vertical component 9 into the welding position. Control center 6 controls robot 1, and control center 6 controls weld seam acquisition module 3 to move along one side of welding vertical component 9. Weld seam acquisition module 3 collects weld seam data and the thickness of welding vertical component. ; Step 2: Weld data and thickness of vertical components for splicing The data is transmitted from the control center 6 to the data processing module 7, which calculates the bevel angle based on the weld data. Assembly interval and bevel blunt edge height Calculate the forming value of the front molten pool diameter. Calculate the diameter of the back melt pool. Then, the forming value is determined by the diameter of the back melt pool. , bevel angle Assembly interval bevel blunt edge height and the thickness of the welded vertical components Determine the laser welding power of the laser welding module ; Step 3: Robot 1 moves the laser welding module 2 and the arc welding module to one side of the vertical component 9 to be welded. The laser welding module 2 and the arc welding module are then activated and move along the vertical component 9 to perform welding. The laser welding module is set to its initial laser welding power. ; Step 4: Simultaneously with welding, the molten pool diameter acquisition module 5 acquires the diameter of the molten pool on the front side. Calculate the diameter of the front molten pool With front molten pool diameter forming value Difference in diameter of the front molten pool According to the laser welding power compensation value Calculate the laser welding power compensation value of the laser welding module Then adjust the laser welding power compensation value. Add initial laser welding power Real-time laser welding power is obtained ; Step 5: Control center 6 adjusts laser welding module 2 to real-time laser welding power. Continue welding; Step Six: Repeat Steps Four and Five until the welding is complete.

[0040] In this embodiment, in step four, the forming value of the front molten pool diameter... The calculation formula is:

[0041] in, This is the heat input correction factor;

[0042] in, Standard coefficients for the thermal input of welding processes and welding materials can be found in welding manuals. Back side molten pool diameter forming value The calculation formula is: ; Initial laser welding power The calculation formula is:

[0043] in, Adjust parameters for materials; For welding speed; Factors affecting the raw materials of the vertical welding plates. , For the material's laser absorption rate, The thermal conductivity of the material; The bevel angle is an influencing factor. ; The influencing factor of assembly interval spacing. ; The influencing factor of the thickness of the vertical plate for welding. ; The factor affecting the height of the bevel blunt edge. ; The calculation formula, obtained using the PID algorithm, is as follows:

[0044] in, , , For PID parameters; The sampling interval; For the first The difference in the diameter of the frontal molten pool at any given time. , For the first The diameter of the frontal molten pool at any given moment; , For filtering windows; Real-time laser welding power The calculation formula is: .

[0045] The above description is merely an embodiment of the present invention. It should be noted that those skilled in the art can make improvements without departing from the inventive concept of the present invention, but these improvements all fall within the protection scope of the present invention.

Claims

1. An adaptive laser hybrid welding system for single-sided welding with smooth transition on both sides, characterized in that, include: Laser welding module, used for laser welding; The weld seam acquisition module is used to collect weld seam data and the thickness of welded vertical components. ; The molten pool diameter acquisition module is used to acquire molten pool diameter data from either the front or back side. Robot, with fixed laser welding module, weld seam acquisition module and molten pool diameter acquisition module; The data processing module is used to calculate the bevel angle based on the weld data collected by the weld acquisition module. Assembly interval and bevel blunt edge height The calculated forming value of the front molten pool diameter Then, the diameter forming value of the molten pool on the back side is calculated based on the constraint parameters for smooth transition between single-sided welding and double-sided welding. Then, the forming value is determined by the diameter of the back melt pool. , bevel angle Assembly interval bevel blunt edge height and the thickness of the welded vertical components Determine the initial laser welding power of the laser welding module. Then, through the front molten pool diameter data Alternatively, the laser welding power compensation value can be determined based on the diameter of the molten pool on the back side. Finally, the initial laser welding power was used. and laser welding power compensation value Determine real-time laser welding power ; The control center connects the laser welding module, weld seam acquisition module, molten pool diameter acquisition module, robot, and data processing module. It controls the robot's movement to move the laser welding module, weld seam acquisition module, and molten pool diameter acquisition module along the weld seam. It also transmits data acquired by the weld seam acquisition module and molten pool diameter acquisition module to the data processing module and receives the real-time laser welding power calculated by the data processing module. And control the laser welding module to adjust to the real-time laser welding power. .

2. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to claim 1, characterized in that, It also includes an arc welding module for performing arc welding, which is fixed to the robot to move along the weld seam under the robot's drive, and is connected to a control center, which controls the arc welding power.

3. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to claim 2, characterized in that, The angle between the laser welding module and the welding base plate is 'a', where 'a' is 15-30°; the angle between the arc welding module and the welding base plate is 'b', where 'b' is 45-75°.

4. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to claim 2, characterized in that, The molten pool diameter acquisition module is a front molten pool diameter acquisition module, used to acquire front molten pool diameter data. The weld acquisition module and the molten pool diameter acquisition module are located on the side of the robot close to the vertical component being welded.

5. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to claim 2, characterized in that, The weld seam acquisition module is a laser sensor or a vision sensor.

6. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to claim 2, characterized in that, The molten pool diameter acquisition module is an infrared thermal imager.

7. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to any one of claims 1 to 6, characterized in that, The forming value of the front molten pool diameter The calculation formula is: ； in, This is the heat input correction factor; ； in, Standard coefficients for the thermal input of welding processes and welding materials can be found in welding manuals. The diameter forming value of the back melt pool The calculation formula is: 。 8. The adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition according to any one of claims 1 to 6, characterized in that, The initial laser welding power The calculation formula is: ； in, Adjust parameters for materials; For welding speed; Factors affecting the raw materials of the vertical welding plates. , For the material's laser absorption rate, The thermal conductivity of the material; The bevel angle is an influencing factor. ; The influencing factor of assembly interval spacing. ; The influencing factor of the thickness of the vertical plate for welding. ; The factor affecting the height of the bevel blunt edge. ; The The calculation formula, obtained using the PID algorithm, is as follows: ； in, , , For PID parameters; The sampling interval; For the first The difference in the diameter of the frontal molten pool at any given time. , For the first The diameter of the frontal molten pool at any given moment; , For filtering windows; The real-time laser welding power The calculation formula is: 。 9. An adaptive laser hybrid welding method for single-sided welding with smooth transition on both sides, characterized in that, The method employs an adaptive laser hybrid welding system with single-sided welding and smooth double-sided transition as described in any one of claims 2 to 6, the method comprising: Step 1: Place the welding base plate and the welding vertical component into the welding position. The control center controls the robot, and the control center also controls the weld seam acquisition module to move along one side of the welding vertical component. The weld seam acquisition module collects weld seam data and the thickness of the welding vertical component. ; Step 2: Weld data and thickness of vertical components for splicing The data is transmitted from the control center to the data processing module, which then calculates the bevel angle based on the weld data. Assembly interval and bevel blunt edge height Calculate the forming value of the front molten pool diameter. Calculate the diameter of the back melt pool. Then, the forming value is determined by the diameter of the back melt pool. , bevel angle Assembly interval bevel blunt edge height and the thickness of the welded vertical components Determine the laser welding power of the laser welding module ; Step 3: The robot moves the laser welding module and the arc welding module to one side of the vertical component to be welded. The laser welding module and the arc welding module are then activated and move along the vertical component to perform welding. The laser welding module is set to its initial laser welding power. ; Step 4: Simultaneously, the molten pool diameter acquisition module acquires the diameter of the molten pool on the front side during welding. Calculate the diameter of the front molten pool With front molten pool diameter forming value Difference in diameter of the front molten pool According to the laser welding power compensation value Calculate the laser welding power compensation value of the laser welding module Then adjust the laser welding power compensation value. Add initial laser welding power Real-time laser welding power is obtained ; Step 5: The control center adjusts the laser welding module to the real-time laser welding power. Continue welding; Step Six: Repeat Steps Four and Five until the welding is complete.

10. The adaptive laser hybrid welding method with single-sided welding and smooth double-sided transition according to claim 9, characterized in that, In step four, the forming value of the front molten pool diameter The calculation formula is: ； in, This is the heat input correction factor; ； in, Standard coefficients for the thermal input of welding processes and welding materials can be found in welding manuals. The diameter forming value of the back melt pool The calculation formula is: ； The initial laser welding power The calculation formula is: ； in, Adjust parameters for materials; For welding speed; Factors affecting the raw materials of the vertical welding plates. , For the material's laser absorption rate, The thermal conductivity of the material; The bevel angle is an influencing factor. ; The influencing factor of assembly interval spacing. ; The influencing factor of the thickness of the vertical plate for welding. ; The factor affecting the height of the bevel blunt edge. ; The The calculation formula, obtained using the PID algorithm, is as follows: ； in, , , For PID parameters; The sampling interval; For the first The difference in the diameter of the frontal molten pool at any given time. , For the first The diameter of the frontal molten pool at any given moment; , For filtering windows; The real-time laser welding power The calculation formula is: 。

Images