Welding rod eccentricity on-line measuring system based on fusion of electromagnetic induction and infrared distance measurement

Abstract

The invention discloses a welding rod eccentricity on-line measuring system based on electromagnetic induction and infrared distance measurement fusion. The system comprises a measuring frame which is provided with an annular mounting frame and a welding rod channel; the plurality of electromagnetic induction positioning units are uniformly distributed along the circumferential direction of the annular mounting frame; the plurality of infrared distance measurement positioning units are uniformly distributed along the circumferential direction of the annular mounting frame; the data synchronization and fusion processing module is used for synchronously acquiring an electromagnetic response signal of the electromagnetic induction positioning unit and distance measurement data of the infrared distance measurement positioning unit; and the eccentricity calculation and result output module comprises an eccentricity calculation module and a result output module. The invention discloses a welding rod eccentricity on-line measurement system based on electromagnetic induction and infrared distance measurement fusion, and aims to solve the technical problems that an existing welding rod eccentricity detection method cannot perform on-line continuous measurement, the detection accuracy is limited, and the real space position relation between a welding core and a coating is difficult to obtain.

Description

Technical Field

[0001] This invention belongs to the field of quality inspection technology in the manufacturing process of welding materials, and specifically relates to an online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging. Background Technology

[0002] Welding electrodes consist of a coating and a core. The core is made of metal, while the coating is a mixture of various minerals, ferroalloys, and organic substances in a specific ratio, covering the outside of the core. It serves to protect the electric arc and improve weld performance during welding. Electrode eccentricity refers to the misalignment between the core axis and the outer axis of the coating. This misalignment can cause arc deviation and unstable combustion during welding, thus reducing weld quality. Therefore, accurate detection of electrode eccentricity is crucial for ensuring welding quality.

[0003] Existing methods for detecting electrode eccentricity mainly include mechanical rotation contact measurement, optical measurement based on outer diameter runout, and destructive section analysis. Among these, the mechanical rotation contact measurement method requires rotating the electrode, the optical measurement method based on outer diameter runout infers the eccentricity from changes in the outer diameter, and the destructive section analysis method is an offline detection method. These methods generally suffer from the following problems: 1. Difficulty in achieving online inspection on the production line: Mechanical rotary contact measurement method requires the welding rod to be rotated, and destructive section analysis method requires stopping the machine to take samples, neither of which can meet the continuous inspection requirements of the production line; 2. Limited detection accuracy: The optical measurement method based on outer diameter runout can only infer eccentricity through changes in outer diameter. When the outer diameter of the flux coating is uniform but the core electrode is offset, accurate detection cannot be achieved. 3. Inability to obtain the true spatial position relationship: Existing methods have difficulty obtaining the true spatial position of the outer diameter of the welding core and the coating at the same time, resulting in incomplete physical meaning of the eccentricity detection and insufficient comprehensiveness of the detection results. Summary of the Invention

[0004] The main objective of this invention is to provide an online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging, aiming to solve the technical problems of existing electrode eccentricity detection methods, such as the inability to perform continuous online measurement, limited detection accuracy, and difficulty in obtaining the true spatial positional relationship between the electrode core and the flux coating.

[0005] To achieve the above objectives, the present invention provides an online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging, comprising: Measuring frame: It has an annular mounting frame and a welding rod channel. The center line of the welding rod channel is collinear with the center of the annular mounting frame to ensure that the measuring section is perpendicular to the welding rod axis. Multiple electromagnetic induction positioning units are evenly distributed along the circumference of the annular mounting frame, maintaining a non-contact induction distance from the welding rod. Each electromagnetic induction positioning unit includes an electromagnetic field generating unit and a sensing unit. The electromagnetic field generating unit is used to generate an alternating electromagnetic field, and the sensing unit is used to receive the electromagnetic response signal generated by the welding core of the welding rod. Multiple infrared ranging and positioning units: The same number of infrared ranging and positioning units as the electromagnetic induction positioning units are arranged in a one-to-one correspondence and are evenly distributed along the circumference of the annular mounting frame. Each infrared ranging and positioning unit includes an infrared emitting unit and an infrared receiving unit. The infrared emitting unit is used to emit infrared ranging signals, and the infrared receiving unit is used to receive reflected infrared signals and generate ranging data related to the position of the outer surface of the drug coating. Data synchronization and fusion processing module: used to synchronously collect the electromagnetic response signal of the electromagnetic induction positioning unit and the ranging data of the infrared ranging positioning unit, and map the two sets of data to the same reference section coordinate system to establish the positional correspondence between the welding core and the coating. Eccentricity Calculation and Result Output Module: Includes an eccentricity calculation module and a result output module. The eccentricity calculation module is used to solve for the eccentricity and eccentricity direction based on the coordinates of the welding core center and the outer circle center of the flux coating. The result output module is used to output the eccentricity parameters and their changing trends in real time.

[0006] As a further preferred technical solution to the above technical solution, the electromagnetic field generating unit and the sensing unit are integrated into a single structure or set up independently; the infrared emitting unit and the infrared receiving unit are integrated into a single structure or set up independently.

[0007] As a further preferred technical solution to the above technical solution, it also includes a welding electrode conveying mechanism, which includes a feeding roller group, a guiding component and a drive motor, to ensure that the welding electrode maintains a linear motion trajectory during the conveying process in the welding electrode channel.

[0008] As a further preferred technical solution to the above technical solution, the online measurement process for electrode eccentricity is as follows: Step S1: Construct a measurement coordinate system, with the center of the annular mounting frame of the measurement frame as the origin, and establish a reference section coordinate system; Step S2: Weld core position detection. Multiple electromagnetic induction positioning units are evenly arranged around the welding rod. The electromagnetic induction positioning units maintain a non-contact induction distance from the welding rod. An alternating electromagnetic field is generated by the electromagnetic field generating unit to induce eddy current effect in the conductive metal welding core. The electromagnetic response signal is received by the induction unit. The position information of the welding core in the coordinate system is obtained by inversion based on the negative correlation between the signal strength and the distance to the welding core. Step S3: Detection of coating position. Infrared ranging and positioning units are arranged in the circumference of the same measuring section of the welding rod, corresponding one-to-one with the electromagnetic induction positioning unit. Infrared signals are emitted by the infrared emitting unit and the infrared receiving unit receives the reflected signals from the outer surface of the coating. Ranging data is generated based on the reflected signals, and the position information of the outer circle of the coating in the coordinate system is obtained by fitting. Step S4: Data synchronization and fusion. Through the data synchronization and fusion processing module, the welding core position information and the flux coating position information are mapped to the same reference section coordinate system to establish a spatial correspondence between the two. Step S5: Calculate the eccentricity parameter. Based on the coordinates of the welding core center and the outer circle center of the flux coating, calculate the eccentricity and eccentricity direction of the welding electrode. The eccentricity is solved by the distance formula between two points, and the eccentricity direction is determined by the angular relationship of the coordinate difference.

[0009] As a further preferred embodiment of the above technical solution, the acquisition of the welding core position information in step S2 includes: acquiring projection distance data through two sets of relatively arranged electromagnetic induction positioning units, and calculating the offset of the welding core center in the x-axis and y-axis directions of the coordinate system based on the projection distance data, with the specific formula as follows: ; ; Obtain the center coordinates of the welding core: ;in, , , and The projection distance from the electromagnetic induction positioning unit to the welding core is divided into 0°, 90°, 180° and 270° directions; Obtain the measured diameter of the welding core : .

[0010] As a further preferred technical solution to the above technical solution, the acquisition of the drug coating position information in step S3 includes: acquiring ranging data through two sets of relatively arranged infrared ranging and positioning units, and calculating the offset of the outer circle center of the drug coating in the x-axis and y-axis directions of the coordinate system and the measured diameter of the drug coating based on the ranging data. The specific formula is as follows: ; ; Obtain the center coordinates of the herb skin: ;in , , and The distance from the infrared ranging and positioning unit to the drug coating surface is divided into 0°, 90°, 180° and 270° directions; The measured diameter of the drug coating was obtained. : .

[0011] As a further preferred technical solution to the above technical solution, the formula for calculating the eccentricity e in step S5 is: ; The formula for calculating the electrode eccentricity p is: .

[0012] The beneficial effects of this invention are as follows: 1. Enables continuous online measurement: This invention adopts a non-contact detection method, which eliminates the need for electrode rotation or machine shutdown, allowing for continuous detection of welding electrodes during production line operation without affecting the production process and significantly improving detection efficiency; 2. High detection accuracy: Based on the difference in physical properties between the core and the coating, electromagnetic induction and infrared ranging are used for positioning, which can simultaneously obtain the true spatial position relationship between the outer diameter of the core and the coating. The eccentricity is defined completely and the physical meaning is clear. Even when the outer diameter of the coating is uniform but the core is offset, accurate detection can be achieved. 3. Wide range of applications: It does not rely on changes in the outer diameter of the welding electrode to infer eccentricity, and can be applied to the eccentricity detection of welding electrodes of different specifications and different coating thicknesses, thus broadening the scope of detection applications; 4. Excellent system stability: The detection mechanisms of electromagnetic induction and infrared ranging do not interfere with each other, ensuring the reliability and stability of the detection results. At the same time, it can output the eccentricity and eccentricity direction, providing data support for quality analysis and process improvement, and helping to improve the quality and optimize the process of welding material manufacturing. Attached Figure Description

[0013] Figure 1 This is a front view of the measuring system of the present invention; Figure 2 This is a side view of the measurement system of the present invention; Figure 3 This is a schematic diagram of data transmission in the measurement system of the present invention; Figure 4 This is a schematic diagram of the coordinate system of the measurement system of the present invention. Detailed Implementation

[0014] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0015] In the preferred embodiments of the present invention, those skilled in the art should note that the welding electrodes and the like involved in the present invention can be considered as prior art.

[0016] Preferred embodiment.

[0017] like Figure 1-4 As shown, this invention discloses an online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging, comprising: Measuring frame (as an integral support component): It has an annular mounting frame and a welding rod channel (for mounting welding rods). The center line of the welding rod channel is collinear with the center of the annular mounting frame to ensure that the measuring section is perpendicular to the welding rod axis. Multiple electromagnetic induction positioning units are evenly distributed along the circumference of the annular mounting frame, maintaining a non-contact induction distance from the welding rod. Each electromagnetic induction positioning unit includes an electromagnetic field generating unit and a sensing unit. The electromagnetic field generating unit is used to generate an alternating electromagnetic field, and the sensing unit is used to receive the electromagnetic response signal generated by the welding core of the welding rod. Multiple infrared ranging and positioning units: The same number of infrared ranging and positioning units as the electromagnetic induction positioning units are arranged in a one-to-one correspondence and are evenly distributed along the circumference of the annular mounting frame. Each infrared ranging and positioning unit includes an infrared emitting unit and an infrared receiving unit. The infrared emitting unit is used to emit infrared ranging signals, and the infrared receiving unit is used to receive reflected infrared signals and generate ranging data related to the position of the outer surface of the drug coating. Data synchronization and fusion processing module (with embedded processing unit as the core): used to synchronously collect the electromagnetic response signal of the electromagnetic induction positioning unit and the ranging data of the infrared ranging positioning unit, and map the two sets of data to the same reference section coordinate system to establish the positional correspondence between the welding core and the coating. Eccentricity Calculation and Result Output Module: Includes an eccentricity calculation module and a result output module. The eccentricity calculation module is used to solve the eccentricity distance and eccentricity direction based on the coordinates of the welding core center and the outer circle center of the flux coating. The result output module is used to output the eccentricity parameters and their changing trends in real time (which can be interfaced with the production line control system).

[0018] Specifically, the electromagnetic field generating unit and the sensing unit are integrated into a single structure or set up independently; the infrared emitting unit and the infrared receiving unit are integrated into a single structure or set up independently.

[0019] More specifically, it also includes a welding electrode conveying mechanism, which includes a feeding roller group, a guide component and a drive motor, to ensure that the welding electrode maintains a straight trajectory during the conveying process in the welding electrode channel and avoids deviation or shaking.

[0020] Furthermore, the online measurement process for electrode eccentricity is as follows: Step S1: Construct a measurement coordinate system. With the center of the annular mounting frame of the measuring frame as the origin, establish a reference section coordinate system (the reference section is perpendicular to the welding electrode axis). Step S2: Weld core position detection. Multiple electromagnetic induction positioning units are evenly arranged around the welding rod. The electromagnetic induction positioning units maintain a non-contact induction distance from the welding rod. An alternating electromagnetic field is generated by the electromagnetic field generating unit to induce eddy current effect in the conductive metal welding core. The electromagnetic response signal is received by the induction unit. The position information of the welding core in the coordinate system is obtained by inversion based on the negative correlation between the signal strength and the distance to the welding core. Step S3: Detection of coating position. Infrared ranging and positioning units are arranged in the circumference of the same measuring section of the welding rod, corresponding one-to-one with the electromagnetic induction positioning unit. Infrared signals are emitted by the infrared emitting unit and the infrared receiving unit receives the reflected signals from the outer surface of the coating. Ranging data is generated based on the reflected signals, and the position information of the outer circle of the coating in the coordinate system is obtained by fitting. Step S4: Data synchronization and fusion. Through the data synchronization and fusion processing module, the welding core position information and the flux coating position information are mapped to the same reference section coordinate system to establish a spatial correspondence between the two. Step S5: Calculate the eccentricity parameter. Based on the coordinates of the welding core center and the outer circle center of the flux coating, calculate the eccentricity and eccentricity direction of the welding electrode. The eccentricity is solved by the distance formula between two points, and the eccentricity direction is determined by the angular relationship of the coordinate difference.

[0021] Furthermore, such as Figure 4 As shown, obtaining the welding core position information in step S2 includes: acquiring projection distance data through two sets of relatively arranged electromagnetic induction positioning units, and calculating the offset of the welding core center in the x-axis and y-axis directions of the coordinate system based on the projection distance data. The specific formula is as follows: ; ; Obtain the center coordinates of the welding core: ;in, , , and The projection distance from the electromagnetic induction positioning unit to the welding core is divided into 0°, 90°, 180° and 270° directions; Obtain the measured diameter of the welding core : .

[0022] Preferably, the acquisition of the drug coating position information in step S3 includes: acquiring ranging data through two sets of relatively arranged infrared ranging and positioning units, and calculating the offset of the outer circle center of the drug coating in the x-axis and y-axis directions of the coordinate system and the measured diameter of the drug coating based on the ranging data. The specific formula is as follows: ; ; Obtain the center coordinates of the herb skin: ;in , , and The distance from the infrared ranging and positioning unit to the drug coating surface is divided into 0°, 90°, 180° and 270° directions; The measured diameter of the drug coating was obtained. : .

[0023] Preferably, the formula for calculating the eccentricity e in step S5 is: ; The formula for calculating the electrode eccentricity p is: .

[0024] Preferably, the system also includes a display connected to the result output module for real-time display of the eccentricity parameters and their changing trends.

[0025] In this embodiment, there are 4 electromagnetic induction positioning units and 4 infrared ranging positioning units. In other embodiments, the number can be set to 6 or 8 depending on the detection accuracy requirements.

[0026] Based on the physical differences between the welding core and the flux coating, this invention uses a fusion technology of electromagnetic induction and infrared ranging to achieve non-contact, online, and precise detection of electrode eccentricity. This solves the problems of existing technologies, such as the inability to perform continuous online measurement and limited detection accuracy, and provides strong support for quality control in the welding material manufacturing process.

[0027] It is worth mentioning that the technical features such as welding rods involved in this patent application should be regarded as prior art. The specific structure, working principle, and possible control methods and spatial arrangement of these technical features can be adopted using conventional choices in the field, and should not be regarded as the inventive point of this patent. This patent will not be further elaborated in detail.

[0028] For those skilled in the art, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the protection scope of this invention.

Claims

1. An online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging, characterized in that, include: Measuring frame: It has an annular mounting frame and a welding rod channel. The center line of the welding rod channel is collinear with the center of the annular mounting frame to ensure that the measuring section is perpendicular to the welding rod axis. Multiple electromagnetic induction positioning units are evenly distributed along the circumference of the annular mounting frame, maintaining a non-contact induction distance from the welding rod. Each electromagnetic induction positioning unit includes an electromagnetic field generating unit and a sensing unit. The electromagnetic field generating unit is used to generate an alternating electromagnetic field, and the sensing unit is used to receive the electromagnetic response signal generated by the welding core of the welding rod. Multiple infrared ranging and positioning units: The same number of infrared ranging and positioning units as the electromagnetic induction positioning units are arranged in a one-to-one correspondence and are evenly distributed along the circumference of the annular mounting frame. Each infrared ranging and positioning unit includes an infrared emitting unit and an infrared receiving unit. The infrared emitting unit is used to emit infrared ranging signals, and the infrared receiving unit is used to receive reflected infrared signals and generate ranging data related to the position of the outer surface of the drug coating. Data synchronization and fusion processing module: used to synchronously collect the electromagnetic response signal of the electromagnetic induction positioning unit and the ranging data of the infrared ranging positioning unit, and map the two sets of data to the same reference section coordinate system to establish the positional correspondence between the welding core and the coating. Eccentricity Calculation and Result Output Module: Includes an eccentricity calculation module and a result output module. The eccentricity calculation module is used to solve for the eccentricity and eccentricity direction based on the coordinates of the welding core center and the outer circle center of the flux coating. The result output module is used to output the eccentricity parameters and their changing trends in real time.

2. The online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging according to claim 1, characterized in that, The electromagnetic field generating unit and the sensing unit are integrated into one structure or set up independently; the infrared emitting unit and the infrared receiving unit are integrated into one structure or set up independently.

3. The online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging according to claim 2, characterized in that, It also includes a welding electrode conveying mechanism, which includes a feeding roller group, a guide component and a drive motor, to ensure that the welding electrode maintains a linear motion trajectory during the conveying process in the welding electrode channel.

4. The online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging according to claim 3, characterized in that, The online measurement process for electrode eccentricity is as follows: Step S1: Construct a measurement coordinate system, with the center of the annular mounting frame of the measurement frame as the origin, and establish a reference section coordinate system; Step S2: Weld core position detection. Multiple electromagnetic induction positioning units are evenly arranged around the welding rod. The electromagnetic induction positioning units maintain a non-contact induction distance from the welding rod. An alternating electromagnetic field is generated by the electromagnetic field generating unit to induce eddy current effect in the conductive metal welding core. The electromagnetic response signal is received by the induction unit. The position information of the welding core in the coordinate system is obtained by inversion based on the negative correlation between the signal strength and the distance to the welding core. Step S3: Detection of coating position. Infrared ranging and positioning units are arranged in the circumference of the same measuring section of the welding rod, corresponding one-to-one with the electromagnetic induction positioning unit. Infrared signals are emitted by the infrared emitting unit and the infrared receiving unit receives the reflected signals from the outer surface of the coating. Ranging data is generated based on the reflected signals, and the position information of the outer circle of the coating in the coordinate system is obtained by fitting. Step S4: Data synchronization and fusion. Through the data synchronization and fusion processing module, the welding core position information and the flux coating position information are mapped to the same reference section coordinate system to establish a spatial correspondence between the two. Step S5: Calculate the eccentricity parameter. Based on the coordinates of the welding core center and the outer circle center of the flux coating, calculate the eccentricity and eccentricity direction of the welding electrode. The eccentricity is solved by the distance formula between two points, and the eccentricity direction is determined by the angular relationship of the coordinate difference.

5. The online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging according to claim 4, characterized in that, Step S2 involves obtaining the welding core position information by: acquiring projection distance data through two sets of relatively arranged electromagnetic induction positioning units, and calculating the offset of the welding core center in the x-axis and y-axis directions of the coordinate system based on the projection distance data. The specific formula is as follows: ； ； Obtain the center coordinates of the welding core: ;in, , , and The projection distance from the electromagnetic induction positioning unit to the welding core is divided into 0°, 90°, 180° and 270° directions; Obtain the measured diameter of the welding core : .

6. The online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging according to claim 5, characterized in that, Step S3 involves obtaining the position information of the drug coating, which includes: acquiring ranging data through two sets of relatively arranged infrared ranging and positioning units; calculating the offset of the outer circle center of the drug coating in the x-axis and y-axis directions of the coordinate system and the measured diameter of the drug coating based on the ranging data; and using the specific formulas as follows: ； ； Obtain the center coordinates of the herb skin: ;in , , and The distance from the infrared ranging and positioning unit to the drug coating surface is divided into 0°, 90°, 180° and 270° directions; The measured diameter of the drug coating was obtained. : .

7. The online electrode eccentricity measurement system based on the fusion of electromagnetic induction and infrared ranging according to claim 6, characterized in that, The formula for calculating the eccentricity e in step S5 is: ； The formula for calculating the electrode eccentricity p is: .

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