Ultrasonic-assisted laser cladding control method and system

Abstract

The invention provides an ultrasonic-assisted laser cladding control method and system, and relates to the technical field of laser cladding, the method comprises the following steps: according to the invention, setting initial working parameters of a cladding system, and carrying out cladding according to the initial working parameters; a molten pool image is obtained through image acquisition equipment arranged on the laser cladding head; acquiring a light spot position; according to the molten pool image, real-time molten pool key parameters are determined; according to the real-time molten pool key parameters, a molten pool state abnormal coefficient and a core deviation coefficient are determined; according to the position of the light spot, a cladding channel completion result is determined; if the cladding channel completion result is 0, a real-time first instruction and a real-time second instruction are generated according to the core deviation coefficient and the molten pool state abnormal coefficient; and adjusting the cladding system according to the real-time first instruction and the real-time second instruction. According to the invention, the accuracy of laser cladding control can be improved.

Description

Technical Field

[0001] This invention relates to the field of laser cladding technology, and in particular to an ultrasonic-assisted laser cladding control method and system. Background Technology

[0002] In related technologies, laser cladding can be controlled by relying on a preset process parameter library or by evaluating quality through offline testing after processing (such as measuring the size of the cladding layer or performing metallographic analysis), and then adjusting the parameters for the next round. Therefore, these technologies are unable to respond to transient defects that occur during the cladding process, i.e., it is difficult to guarantee the timeliness and accuracy of laser cladding control.

[0003] The information disclosed in the background section of this application is intended only to enhance the understanding of the general background of this application and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0004] This invention provides an ultrasonic-assisted laser cladding control method and system, which can solve the technical problem that related technologies cannot guarantee the timeliness and accuracy of laser cladding control.

[0005] According to a first aspect of the present invention, an ultrasonic-assisted laser cladding control method is provided, comprising:

[0006] At the beginning of the work cycle, set the initial working parameters of the cladding system and perform cladding according to the initial working parameters;

[0007] At multiple points in the work cycle, images of the molten pool are acquired using an image acquisition device mounted on the laser cladding head;

[0008] Acquire the position of the light spot at multiple points in the work cycle;

[0009] Based on the molten pool image, key parameters of the real-time molten pool are determined, including: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient.

[0010] Based on the real-time key parameters of the molten pool, determine the molten pool state anomaly coefficient and the core deviation coefficient;

[0011] The completion result of the cladding process is determined based on the position of the light spot;

[0012] If the cladding completion result is 0, then a real-time first instruction and a real-time second instruction are generated based on the core deviation coefficient and the molten pool state anomaly coefficient.

[0013] The cladding system is adjusted according to the real-time first instruction and the real-time second instruction.

[0014] According to the present invention, determining key parameters of the molten pool in real time based on the molten pool image includes:

[0015] Based on the molten pool image, determine the total number of molten pool outline pixels, the maximum length of the molten pool, the maximum width of the molten pool, and the tail temperature change rate;

[0016] The real-time molten pool area is determined based on the total number of pixels in the molten pool outline.

[0017] The real-time molten pool shape ratio is determined based on the maximum length and the maximum width of the molten pool.

[0018] The real-time tail temperature gradient is determined based on the tail temperature change rate.

[0019] According to the present invention, determining the real-time molten pool morphology ratio based on the maximum length and the maximum width of the molten pool includes: according to the formula: Determine the real-time molten pool morphology ratio at the i-th moment of the work cycle. ,in, Let be the maximum length of the molten pool at the i-th moment of the work cycle. The maximum width of the molten pool at the i-th moment of the working cycle.

[0020] According to the present invention, the determination of the molten pool state anomaly coefficient and the core deviation coefficient based on the real-time molten pool key parameters includes:

[0021] Obtain the preset melt pool area threshold, the preset melt pool shape ratio threshold, and the preset tail temperature gradient threshold;

[0022] A first difference coefficient is determined based on the preset melt pool area threshold and the real-time melt pool area;

[0023] The second difference coefficient and the core deviation coefficient are determined based on the preset melt pool morphology ratio threshold and the real-time melt pool morphology ratio.

[0024] A third difference coefficient is determined based on the preset tail temperature gradient threshold and the real-time tail temperature gradient;

[0025] The abnormality coefficient of the molten pool state is determined based on the first difference coefficient, the second difference coefficient, and the third difference coefficient.

[0026] According to the present invention, determining the cladding completion result based on the position of the light spot includes:

[0027] Obtain the endpoint of the preset cladding path;

[0028] If the position of the light spot has left the end point of the preset cladding track, the cladding track completion result is 1;

[0029] If the position of the light spot does not leave the end point of the preset cladding track, the cladding track completion result is 0.

[0030] According to the present invention, if the cladding completion result is 0, then based on the core deviation coefficient and the molten pool state anomaly coefficient, a real-time first instruction and a real-time second instruction are generated, including:

[0031] Based on the core deviation coefficient and the molten pool state anomaly coefficient, determine the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount;

[0032] Based on the real-time ultrasonic amplitude adjustment and the real-time laser power adjustment, a real-time first command and a real-time second command are generated.

[0033] According to the present invention, determining the real-time ultrasonic amplitude adjustment and the real-time laser power adjustment based on the core deviation coefficient and the molten pool state anomaly coefficient includes:

[0034] Obtain the laser power PID parameters and the ultrasonic amplitude PID parameters;

[0035] The real-time ultrasonic amplitude adjustment amount is determined based on the core deviation coefficient, the molten pool state anomaly coefficient, and the ultrasonic amplitude PID parameter.

[0036] The real-time laser power adjustment amount is determined based on the core deviation coefficient, the molten pool state abnormality coefficient, and the laser power PID parameter.

[0037] According to the present invention, real-time first instructions and real-time second instructions are generated based on the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount, including:

[0038] The target ultrasonic amplitude is determined based on the real-time ultrasonic amplitude adjustment amount;

[0039] The target laser power is determined based on the real-time laser power adjustment amount;

[0040] Based on the target ultrasonic amplitude, generate a real-time first command;

[0041] A real-time second command is generated based on the target laser power.

[0042] According to a second aspect of the present invention, an ultrasonic-assisted laser cladding control system is provided, comprising:

[0043] The initial parameter module sets the initial operating parameters of the cladding system at the beginning of the working cycle and performs cladding according to the initial operating parameters;

[0044] The image data module acquires images of the molten pool at multiple points in the working cycle through an image acquisition device set on the laser cladding head;

[0045] The spot position module acquires the spot position at multiple moments during the working cycle;

[0046] The real-time parameter module determines key parameters of the molten pool based on the molten pool image. These key parameters include: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient.

[0047] The anomaly coefficient module determines the molten pool state anomaly coefficient and core deviation coefficient based on the real-time key parameters of the molten pool.

[0048] The completion result module determines the completion result of the cladding channel based on the position of the light spot;

[0049] If the cladding completion result is 0, the instruction generation module generates a real-time first instruction and a real-time second instruction based on the core deviation coefficient and the molten pool state abnormality coefficient.

[0050] The system adjustment module adjusts the cladding system according to the real-time first instruction and the real-time second instruction.

[0051] Technical Effects: According to the present invention, images of the molten pool during the cladding process can be accurately acquired, and the real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient can be determined based on the molten pool images. Furthermore, abnormal conditions during the cladding process can be accurately analyzed based on the real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient, determining the molten pool state anomaly coefficient and core deviation coefficient. The cladding system can then be adjusted in real-time based on the molten pool state anomaly coefficient, core deviation coefficient, and cladding channel completion results, improving the timeliness and accuracy of laser cladding control. When determining the real-time molten pool morphology ratio, it can be determined based on the maximum molten pool length and maximum molten pool width. During the calculation process, the real-time molten pool morphology ratio can fully reflect the abnormal morphological conditions of the molten pool, improving the accuracy of the real-time molten pool morphology ratio.

[0052] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the invention. Other features and aspects of the invention will become clearer from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0053] To more clearly illustrate the technical solutions in the embodiments of the present invention 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 the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0054] Figure 1 An exemplary flowchart of an ultrasonic-assisted laser cladding control method according to an embodiment of the present invention is shown.

[0055] Figure 2 A schematic diagram illustrating the determination of key parameters of the real-time molten pool according to an embodiment of the present invention is shown;

[0056] Figure 3 An exemplary schematic diagram illustrating the determination of the molten pool state anomaly coefficient and the core deviation coefficient according to an embodiment of the present invention is shown;

[0057] Figure 4 A schematic diagram illustrating the determination of the cladding completion result according to an embodiment of the present invention is shown;

[0058] Figure 5 A schematic diagram illustrating the generation of a real-time first instruction and a real-time second instruction according to an embodiment of the present invention is shown exemplarily.

[0059] Figure 6 A block diagram of an ultrasonic-assisted laser cladding control system according to an embodiment of the present invention is shown as an example. Detailed Implementation

[0060] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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.

[0061] The technical solution of the present invention will be described in detail below with reference to specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments.

[0062] Figure 1 An exemplary flowchart of an ultrasonic-assisted laser cladding control method according to an embodiment of the present invention is shown, the method comprising:

[0063] Step S1: At the beginning of the work cycle, set the initial working parameters of the cladding system and perform cladding according to the initial working parameters;

[0064] Step S2: At multiple moments in the working cycle, images of the molten pool are acquired using an image acquisition device set on the laser cladding head;

[0065] Step S3: Acquire the position of the light spot at multiple moments during the work cycle;

[0066] Step S4: Based on the molten pool image, determine the key parameters of the real-time molten pool, wherein the key parameters of the real-time molten pool include: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient.

[0067] Step S5: Determine the molten pool state anomaly coefficient and core deviation coefficient based on the real-time molten pool key parameters;

[0068] Step S6: Determine the completion result of the cladding process based on the position of the light spot;

[0069] Step S7: If the cladding completion result is 0, then generate a real-time first instruction and a real-time second instruction based on the core deviation coefficient and the molten pool state abnormality coefficient.

[0070] Step S8: Adjust the cladding system according to the real-time first instruction and the real-time second instruction.

[0071] According to the ultrasonic-assisted laser cladding control method of the present invention, the molten pool image during the cladding process can be accurately acquired, and the real-time molten pool area, real-time molten pool morphology ratio and real-time tail temperature gradient can be determined based on the molten pool image. Furthermore, the abnormal conditions during the cladding process can be accurately analyzed based on the real-time molten pool area, real-time molten pool morphology ratio and real-time tail temperature gradient, and the molten pool state abnormality coefficient and core deviation coefficient can be determined. The cladding system can be adjusted in real time based on the molten pool state abnormality coefficient, core deviation coefficient and cladding channel completion result, thereby improving the timeliness and accuracy of laser cladding control.

[0072] According to one embodiment of the present invention, in step S1, at the beginning of the working cycle, the initial working parameters of the cladding system are set, and cladding is performed according to the initial working parameters.

[0073] For example, before starting the cladding operation, the initial working parameters of the cladding system are set according to the physical properties of the base material and the cladding material. For instance, when performing laser cladding of cobalt-based alloy powder on a 316 stainless steel substrate, the initial working parameters of the cladding system can be set as follows: initial laser power of 1500W, initial scanning speed of 10mm / s, initial powder feeding rate of 20g / min, and initial amplitude of ultrasonic generator of 10μm. The cladding is then performed at the beginning of the working cycle according to the initial working parameters, and the working cycle is defined as the process of completing each cladding pass.

[0074] According to one embodiment of the present invention, in step S2, at multiple moments during the working cycle, an image acquisition device disposed on the laser cladding head is used to acquire images of the molten pool.

[0075] For example, a high-speed camera and an infrared thermal imager can be coaxially integrated on the laser cladding head to simultaneously acquire images of the molten pool (e.g., visual images and thermal images) during the cladding process.

[0076] According to one embodiment of the present invention, in step S3, the position of the light spot is acquired at multiple moments in the working cycle.

[0077] For example, the position of the processing head, i.e., the position of the light spot, can be read in real time through a computer numerical control system.

[0078] According to an embodiment of the present invention, in step S4, real-time key parameters of the molten pool are determined based on the molten pool image, wherein the real-time key parameters of the molten pool include: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient.

[0079] Figure 2 A schematic diagram illustrating the determination of key parameters of a real-time molten pool according to an embodiment of the present invention is shown.

[0080] According to an embodiment of the present invention, step S4 includes:

[0081] Step S41: Based on the molten pool image, determine the total number of molten pool outline pixels, the maximum length of the molten pool, the maximum width of the molten pool, and the tail temperature change rate;

[0082] Step S42: Determine the real-time molten pool area based on the total number of pixels in the molten pool outline;

[0083] Step S43: Determine the real-time molten pool morphology ratio based on the maximum length and maximum width of the molten pool;

[0084] Step S44: Determine the real-time tail temperature gradient based on the tail temperature change rate.

[0085] For example, through pixel calibration, the total number of pixels in the molten pool outline within the molten pool image is calculated. Based on the molten pool image, the maximum length of the molten pool and the maximum width perpendicular to the length direction are determined. A set of temperature points are taken along the scanning direction at the solidification front at the tail of the molten pool, and the temperature change rate (the rate of temperature change with spatial distance) of this region is calculated using linear regression. Through spatial calibration, the total number of pixels in the molten pool outline is converted into the real-time molten pool area. Based on the maximum length and maximum width of the molten pool, the real-time molten pool morphology ratio is calculated. Based on the tail temperature change rate, the real-time tail temperature gradient is determined.

[0086] According to an embodiment of the present invention, step S43 includes: determining the real-time molten pool morphology ratio at the i-th moment of the working cycle according to formula (1). ,

[0087] (1)

[0088] in, Let be the maximum length of the molten pool at the i-th moment of the work cycle. The maximum width of the molten pool at the i-th moment of the working cycle.

[0089] According to one embodiment of the present invention, This is the ratio of the maximum length to the maximum width of the molten pool at the i-th moment of the working cycle. The larger this ratio (e.g., greater than 3), the thinner and longer the molten pool is. This may indicate that the scanning speed is too fast (the laser stays at a certain point for a short time, and the heat does not have time to diffuse laterally, causing the molten pool to be "stretched") and the laser power is relatively insufficient (the energy input is not enough to allow the molten pool material to flow and spread laterally). This may result in a narrower and less uniform cladding layer. The larger this ratio (e.g., less than 1.5), the shorter and thicker the molten pool is. This may indicate that the scanning speed is too slow (the laser stays in the same area for too long, and a large amount of heat accumulates and diffuses laterally) and the laser power is too high (the excessive energy input melts a large amount of metal, and the molten pool expands significantly, especially laterally). This may result in an excessively large heat-affected zone, which may damage the properties of the substrate.

[0090] In this way, the real-time molten pool shape ratio can be determined based on the maximum length and maximum width of the molten pool. During the calculation process, the abnormal molten pool shape can be fully reflected by the real-time molten pool shape ratio, thus improving the accuracy of the real-time molten pool shape ratio.

[0091] According to an embodiment of the present invention, in step S5, the molten pool state anomaly coefficient and core deviation coefficient are determined based on the real-time molten pool key parameters.

[0092] Figure 3 A schematic diagram illustrating the determination of the molten pool state anomaly coefficient and the core deviation coefficient according to an embodiment of the present invention is shown.

[0093] According to an embodiment of the present invention, step S5 includes:

[0094] Step S51: Obtain the preset molten pool area threshold, the preset molten pool shape ratio threshold, and the preset tail temperature gradient threshold.

[0095] Step S52: Determine the first difference coefficient based on the preset melt pool area threshold and the real-time melt pool area;

[0096] Step S53: Determine the second difference coefficient and the core deviation coefficient based on the preset melt pool morphology ratio threshold and the real-time melt pool morphology ratio;

[0097] Step S54: Determine the third difference coefficient based on the preset tail temperature gradient threshold and the real-time tail temperature gradient;

[0098] Step S55: Determine the molten pool state abnormality coefficient based on the first difference coefficient, the second difference coefficient, and the third difference coefficient.

[0099] For example, based on the physical properties of the base material and the cladding material, a preset molten pool area threshold, a preset molten pool morphology ratio threshold, and a preset tail temperature gradient threshold are determined. For instance, when performing laser cladding of cobalt-based alloy powder on a 316 stainless steel substrate, the preset molten pool area threshold can be set to 8 square millimeters, the preset molten pool morphology ratio threshold can be set to 2, and the preset tail temperature gradient threshold can be set to 150 degrees Celsius / mm. Based on the preset molten pool area threshold and the real-time molten pool area, a first difference coefficient is determined. Determine the first coefficient of difference; the larger the first coefficient of difference, the better. If the real-time molten pool area is too large or too small, it indicates excessive heat input, which may lead to over-melting of the substrate, an excessively large heat-affected zone, component deformation, or even material burn-out. If the real-time molten pool area is too small, it indicates insufficient heat input, which may lead to incomplete melting of the powder, poor bonding between the cladding layer and the substrate (lack of fusion), or the formation of pores. Based on the preset molten pool morphology ratio threshold and the real-time molten pool morphology ratio, the second difference coefficient and the core deviation coefficient are determined, for example, according to... The second difference coefficient is determined. The larger the second difference coefficient, the more it indicates that the real-time molten pool morphology ratio is too large or too small (the harm of the real-time molten pool morphology ratio being too large or too small is explained in detail in formula (1), and will not be repeated here). The core deviation coefficient is determined by subtracting the real-time molten pool morphology ratio from the preset molten pool morphology ratio threshold. The third difference coefficient is determined by the preset tail temperature gradient threshold and the real-time tail temperature gradient, such as, according to The third difference coefficient is determined. The larger the third difference coefficient, the larger or smaller the real-time tail temperature gradient is. When the real-time tail temperature gradient is too large, it may mean that the cooling rate is too fast. Although it may refine the grains, it may also increase the crack sensitivity. When the real-time tail temperature gradient is too small, it means that the cooling is slow, which may lead to coarse grains and reduce the mechanical properties of the material. The molten pool state anomaly coefficient is determined by summing the first difference coefficient, the second difference coefficient and the third difference coefficient.

[0100] According to one embodiment of the present invention, in step S6, the completion result of the cladding channel is determined based on the position of the light spot.

[0101] Figure 4 A schematic diagram illustrating the determination of the cladding completion result according to an embodiment of the present invention is shown.

[0102] According to an embodiment of the present invention, step S6 includes:

[0103] Step S61: Obtain the endpoint of the preset cladding track;

[0104] Step S62: If the position of the light spot has left the end point of the preset cladding track, the cladding track completion result is 1;

[0105] Step S63: If the position of the light spot has not left the end point of the preset cladding track, the cladding track completion result is 0.

[0106] For example, laser cladding systems are typically controlled by computer numerical control (CNC) systems or robot control systems. Before processing begins, the path to be clad is programmed and input into the system. The system knows the starting and ending coordinates of the trajectory. Through the CNC system, it obtains the ending point of the preset cladding path. If the spot position has left the ending point of the preset cladding path, it indicates that the current cladding is complete, and the cladding completion result is 1. In this case, work can be stopped or the next cladding can be performed. If the spot position has not left the ending point of the preset cladding path, it indicates that the current cladding is not complete, and the cladding completion result is 0.

[0107] According to an embodiment of the present invention, in step S7, if the cladding completion result is 0, then a real-time first instruction and a real-time second instruction are generated based on the core deviation coefficient and the molten pool state abnormality coefficient.

[0108] Figure 5 A schematic diagram illustrating the generation of a real-time first instruction and a real-time second instruction according to an embodiment of the present invention is shown.

[0109] According to an embodiment of the present invention, step S7 includes:

[0110] Step S71: Determine the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount based on the core deviation coefficient and the molten pool state abnormality coefficient;

[0111] Step S72: Generate a real-time first command and a real-time second command based on the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount.

[0112] For example, if the cladding completion result is 0, it means that the cladding of this stage is not completed, and the working parameters of the cladding system need to be adjusted in real time to ensure the cladding quality; the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount are determined according to the core deviation coefficient and the molten pool state abnormality coefficient; the real-time first command and the real-time second command are generated according to the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount.

[0113] According to an embodiment of the present invention, step S71 includes:

[0114] Step S711: Obtain the laser power PID parameters and the ultrasonic amplitude PID parameters;

[0115] Step S712: Determine the real-time ultrasonic amplitude adjustment amount based on the core deviation coefficient, the molten pool state abnormality coefficient, and the ultrasonic amplitude PID parameter;

[0116] Step S713: Determine the real-time laser power adjustment amount based on the core deviation coefficient, the molten pool state abnormality coefficient, and the laser power PID parameter.

[0117] For example, laser power PID parameters and ultrasonic amplitude PID parameters can be obtained through engineering experiments or expert experience databases; real-time ultrasonic amplitude adjustment can be determined using PID control algorithms based on the core deviation coefficient, molten pool state anomaly coefficient, and ultrasonic amplitude PID parameters; and real-time laser power adjustment can be determined using PID control algorithms based on the core deviation coefficient, molten pool state anomaly coefficient, and laser power PID parameters.

[0118] According to an embodiment of the present invention, step S72 includes:

[0119] Step S721: Determine the target ultrasonic amplitude based on the real-time ultrasonic amplitude adjustment amount;

[0120] Step S722: Determine the target laser power based on the real-time laser power adjustment amount;

[0121] Step S723: Generate a real-time first command based on the target ultrasonic amplitude;

[0122] Step S724: Generate a real-time second command based on the target laser power.

[0123] For example, the historical ultrasonic amplitude of the previous moment is determined, and the target ultrasonic amplitude is determined based on the real-time ultrasonic amplitude adjustment and the historical ultrasonic amplitude; the historical laser power of the previous moment is determined, and the target laser power is determined by adding the historical laser power and the real-time laser power adjustment; based on the target ultrasonic amplitude, a real-time first command is generated, such as the controller sending a real-time first command to the ultrasonic generator to adjust its amplitude from the historical ultrasonic amplitude to the target ultrasonic amplitude; based on the target laser power, a real-time second command is generated, such as the controller sending a real-time second command to the laser to adjust its power from the historical laser power to the target laser power.

[0124] According to one embodiment of the present invention, in step S8, the cladding system is adjusted according to the real-time first instruction and the real-time second instruction.

[0125] For example, the ultrasonic generator is adjusted according to a first real-time command, and the laser is adjusted according to a second real-time command.

[0126] The ultrasonic-assisted laser cladding control method according to embodiments of the present invention can accurately acquire images of the molten pool during the cladding process, and determine the real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient based on the molten pool images. Furthermore, it can accurately analyze abnormal conditions during the cladding process based on the real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient, determine the molten pool state anomaly coefficient and core deviation coefficient, and adjust the cladding system in real time based on the molten pool state anomaly coefficient, core deviation coefficient, and cladding channel completion results, thereby improving the timeliness and accuracy of laser cladding control. When determining the real-time molten pool morphology ratio, it can be determined based on the maximum length and maximum width of the molten pool. During the calculation process, the real-time molten pool morphology ratio can fully reflect the abnormal morphological conditions of the molten pool, improving the accuracy of the real-time molten pool morphology ratio.

[0127] Figure 6 An exemplary block diagram of an ultrasonic-assisted laser cladding control system according to an embodiment of the present invention is shown, the system comprising:

[0128] The initial parameter module sets the initial operating parameters of the cladding system at the beginning of the working cycle and performs cladding according to the initial operating parameters;

[0129] The image data module acquires images of the molten pool at multiple points in the working cycle through an image acquisition device set on the laser cladding head;

[0130] The spot position module acquires the spot position at multiple moments during the working cycle;

[0131] The real-time parameter module determines key parameters of the molten pool based on the molten pool image. These key parameters include: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient.

[0132] The anomaly coefficient module determines the molten pool state anomaly coefficient and core deviation coefficient based on the real-time key parameters of the molten pool.

[0133] The completion result module determines the completion result of the cladding channel based on the position of the light spot;

[0134] If the cladding completion result is 0, the instruction generation module generates a real-time first instruction and a real-time second instruction based on the core deviation coefficient and the molten pool state abnormality coefficient.

[0135] The system adjustment module adjusts the cladding system according to the real-time first instruction and the real-time second instruction.

[0136] This invention can be a method, apparatus, system, and / or computer program product. The computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for performing various aspects of the invention.

[0137] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments, and any variations or modifications may be made to the implementation of the present invention without departing from the stated principles.

Claims

1. A method for controlling ultrasonic-assisted laser cladding, characterized in that, include: At the beginning of the work cycle, set the initial working parameters of the cladding system and perform cladding according to the initial working parameters; At multiple points in the work cycle, images of the molten pool are acquired using an image acquisition device mounted on the laser cladding head; Acquire the position of the light spot at multiple points in the work cycle; Based on the molten pool image, key parameters of the real-time molten pool are determined, including: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient. Based on the real-time key parameters of the molten pool, determine the molten pool state anomaly coefficient and the core deviation coefficient; The completion result of the cladding process is determined based on the position of the light spot; If the cladding completion result is 0, then a real-time first instruction and a real-time second instruction are generated based on the core deviation coefficient and the molten pool state anomaly coefficient. The cladding system is adjusted according to the real-time first instruction and the real-time second instruction.

2. The ultrasonic-assisted laser cladding control method according to claim 1, characterized in that, Based on the molten pool image, determine the key parameters of the real-time molten pool, including: Based on the molten pool image, determine the total number of molten pool outline pixels, the maximum length of the molten pool, the maximum width of the molten pool, and the tail temperature change rate; The real-time molten pool area is determined based on the total number of pixels in the molten pool outline. The real-time molten pool shape ratio is determined based on the maximum length and the maximum width of the molten pool. The real-time tail temperature gradient is determined based on the tail temperature change rate.

3. The ultrasonic-assisted laser cladding control method according to claim 2, characterized in that, Determining the real-time molten pool morphology ratio based on the maximum length and maximum width of the molten pool includes: according to the formula: Determine the real-time molten pool morphology ratio at the i-th moment of the work cycle. ,in, Let be the maximum length of the molten pool at the i-th moment of the work cycle. The maximum width of the molten pool at the i-th moment of the working cycle.

4. The ultrasonic-assisted laser cladding control method according to claim 1, characterized in that, Based on the aforementioned real-time key parameters of the molten pool, determine the molten pool state anomaly coefficient and the core deviation coefficient, including: Obtain the preset melt pool area threshold, the preset melt pool shape ratio threshold, and the preset tail temperature gradient threshold; A first difference coefficient is determined based on the preset melt pool area threshold and the real-time melt pool area; The second difference coefficient and the core deviation coefficient are determined based on the preset melt pool morphology ratio threshold and the real-time melt pool morphology ratio. A third difference coefficient is determined based on the preset tail temperature gradient threshold and the real-time tail temperature gradient; The abnormality coefficient of the molten pool state is determined based on the first difference coefficient, the second difference coefficient, and the third difference coefficient.

5. The ultrasonic-assisted laser cladding control method according to claim 1, characterized in that, Based on the position of the light spot, the completion result of the cladding process is determined, including: Obtain the endpoint of the preset cladding path; If the position of the light spot has left the end point of the preset cladding track, the cladding track completion result is 1; If the position of the light spot does not leave the end point of the preset cladding track, the cladding track completion result is 0.

6. The ultrasonic-assisted laser cladding control method according to claim 1, characterized in that, If the cladding completion result is 0, then based on the core deviation coefficient and the molten pool state anomaly coefficient, a real-time first instruction and a real-time second instruction are generated, including: Based on the core deviation coefficient and the molten pool state anomaly coefficient, determine the real-time ultrasonic amplitude adjustment amount and the real-time laser power adjustment amount; Based on the real-time ultrasonic amplitude adjustment and the real-time laser power adjustment, a real-time first command and a real-time second command are generated.

7. The ultrasonic-assisted laser cladding control method according to claim 6, characterized in that, Based on the core deviation coefficient and the molten pool state anomaly coefficient, the real-time ultrasonic amplitude adjustment and real-time laser power adjustment are determined, including: Obtain the laser power PID parameters and the ultrasonic amplitude PID parameters; The real-time ultrasonic amplitude adjustment amount is determined based on the core deviation coefficient, the molten pool state anomaly coefficient, and the ultrasonic amplitude PID parameter. The real-time laser power adjustment amount is determined based on the core deviation coefficient, the molten pool state abnormality coefficient, and the laser power PID parameter.

8. The ultrasonic-assisted laser cladding control method according to claim 6, characterized in that, Based on the real-time ultrasonic amplitude adjustment and the real-time laser power adjustment, a real-time first command and a real-time second command are generated, including: The target ultrasonic amplitude is determined based on the real-time ultrasonic amplitude adjustment amount; The target laser power is determined based on the real-time laser power adjustment amount; Based on the target ultrasonic amplitude, generate a real-time first command; A real-time second command is generated based on the target laser power.

9. An ultrasonic-assisted laser cladding control system, characterized in that, For performing the method of any one of claims 1-8, comprising: The initial parameter module sets the initial operating parameters of the cladding system at the beginning of the working cycle and performs cladding according to the initial operating parameters; The image data module acquires images of the molten pool at multiple points in the working cycle through an image acquisition device set on the laser cladding head; The spot position module acquires the spot position at multiple moments during the working cycle; The real-time parameter module determines key parameters of the molten pool based on the molten pool image. These key parameters include: real-time molten pool area, real-time molten pool morphology ratio, and real-time tail temperature gradient. The anomaly coefficient module determines the molten pool state anomaly coefficient and core deviation coefficient based on the real-time key parameters of the molten pool. The completion result module determines the completion result of the cladding channel based on the position of the light spot; If the cladding completion result is 0, the instruction generation module generates a real-time first instruction and a real-time second instruction based on the core deviation coefficient and the molten pool state abnormality coefficient. The system adjustment module adjusts the cladding system according to the real-time first instruction and the real-time second instruction.

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