Method for manufacturing submerged arc welding wire based on drawing and copper plating integration

Abstract

This invention relates to the field of welding material preparation technology, and particularly to a method for preparing submerged arc welding wire based on integrated drawing and copper plating. The method involves coating the copper-plated surface of the welding wire with fluorescent marking grids after copper plating and drying. Dynamic images of the markings on the copper-plated surface are continuously acquired using an imaging system. Quantitative parameters of the two orthogonal diagonals of each fluorescent marking grid are extracted in real time. The presence of pre-existing signs of drawing instability in the corresponding region of the fluorescent marking grid is determined by calculating the elongation parameters of the drawn wire. A sequence of drawing instability evolution directions along the welding wire axis is constructed, and the instability state of the copper plating layer is determined based on the spatial consistency of this sequence. Finally, differentiated fine-drawing process control is implemented for different instability states. This method enables online detection of pre-existing relative slippage between the copper plating layer and the welding wire core during the drawing process. By distinguishing the drawing instability state of the copper plating layer, the preparation process can be adjusted accordingly.

Description

Technical Field

[0001] This invention relates to the field of welding material preparation technology, and in particular to a method for preparing submerged arc welding wire based on integrated copper plating during drawing. Background Technology

[0002] Submerged arc welding wire, as a core category of welding materials, is widely used in the manufacturing of major equipment such as engineering machinery. The quality of its surface copper plating directly determines the wire's conductivity, wire feeding stability, rust prevention performance, and final welding quality. The integrated drawing and copper plating process, with its advantages of high production efficiency, low energy consumption, and good plating adhesion, has become the mainstream technology for submerged arc welding wire preparation. However, during the precision drawing and sizing process, due to factors such as differences in the mechanical properties of the copper layer and the substrate, uneven interface bonding, and fluctuations in lubrication conditions, shear slippage at the interface between the copper plating and the welding wire body can easily occur, leading to defects such as plating peeling and exposed iron. This not only severely reduces the yield but also causes problems such as unstable arc, increased spatter, and poor weld formation during welding.

[0003] Existing solutions for copper plating quality control mainly fall into two categories: post-production inspection techniques, including finished product plating thickness testing, adhesion cross-cut adhesion testing, and salt spray rust prevention testing. These methods can only perform sampling inspections on finished products and cannot achieve online real-time monitoring during the production process. Another approach is process parameter optimization techniques, which improve plating quality by adjusting macroscopic process parameters such as plating solution composition, copper plating current, drawing speed, and overall tension. However, this method cannot precisely control the local interface instability state on the surface of the welding wire, and cannot respond effectively in a timely manner when problems such as insufficient local lubrication occur.

[0004] Existing technologies cannot detect the signs of relative slippage between the copper plating layer and the solder wire core during the drawing process online, making it difficult to distinguish the state of copper plating layer instability during drawing. This results in a lack of targeted adjustment of the manufacturing process and difficulty in ensuring drawing stability and the bonding quality of the copper plating layer. Summary of the Invention

[0005] To address this, the present invention provides a method for preparing submerged arc welding wire based on integrated drawing and copper plating, which overcomes the problems of existing technologies being unable to detect the relative slippage signs between the copper plating layer and the welding wire core during the drawing process online, making it difficult to distinguish the state of copper plating layer instability during drawing, resulting in a lack of targeted adjustment of the preparation process and difficulty in ensuring drawing stability and the bonding quality of the copper plating layer.

[0006] To achieve the above objectives, the present invention provides a method for preparing submerged arc welding wire based on integrated copper plating during drawing, comprising: After the copper plating and drying process, the copper-plated surface of the welding wire is coated with a grid of fluorescent markers that are connected end to end. An imaging acquisition system is set up in front of the precision drawing mold entrance to continuously acquire dynamic images of the markings on the copper-plated surface, extract the quantization parameters of the two orthogonal diagonals of each fluorescent marking grid in real time, and construct a quantization feature dataset. Based on the quantized feature dataset, the elongation performance parameters of the welding wire are calculated, and based on the elongation performance parameters, it is determined whether there are signs of drawing instability in the region corresponding to the fluorescent marker grid. Extract the instability direction vectors corresponding to the fluorescent marker grids that show signs of pull-out instability, construct a sequence of pull-out instability evolution directions along the welding wire axis, and determine the instability state of the copper plating layer of the welding wire based on the spatial consistency of the pull-out instability evolution direction sequence. Differentiated fine drawing process control is implemented for different instability states, including determining the global stretching direction vector and adjusting the input parameters of the fine drawing inlet guide mechanism based on the global stretching direction vector. Alternatively, the spatial coordinates of adjacent fluorescent marker grids corresponding to inconsistent performance in the direction of instability evolution during positioning are determined, the lubricant compensation application point of the precision drawing die is determined based on the spatial coordinates, and quality traceability information containing the spatial coordinates is generated.

[0007] Furthermore, the process of coating the copper-plated surface of the solder wire after copper plating and drying with a grid of interconnected square fluorescent markers includes: The copper-plated surface is divided into several marked sections at equal intervals along the axial direction of the welding wire. Square fluorescent marker grids are sprayed in each marking section, with the vertices of adjacent fluorescent marker grids connected to form a grid structure that is connected end to end; The diagonal of the square fluorescent mark forms a 45° angle with the axis of the welding wire.

[0008] Furthermore, the process of extracting the quantization parameters of the two orthogonal diagonals of each fluorescently labeled grid includes: Obtain the coordinates of the endpoints of each diagonal, and determine the Euclidean distance between the two endpoints as the diagonal length; The lengths of the two diagonals in the same fluorescently labeled grid are denoted as the first diagonal length and the second diagonal length, respectively. The difference between the length of the first diagonal and the length of the second diagonal is determined as the distortion coefficient of the fluorescently labeled grid.

[0009] Furthermore, the process of calculating the elongation performance parameters of the welding wire pull-out and determining whether there are signs of pull-out instability in the region corresponding to the fluorescently marked grid includes: The first distortion coefficient and the second distortion coefficient of each fluorescently labeled grid at two consecutive sampling times are obtained, and the ratio of the second distortion coefficient to the first distortion coefficient is determined as the extension performance parameter. The extended performance parameters are compared with preset extended performance parameter thresholds; If the stretching performance parameter is greater than the stretching performance parameter threshold, it is determined that the region corresponding to the fluorescent marker grid has signs of pull-out instability.

[0010] Furthermore, the process of extracting the instability direction vector corresponding to the fluorescently labeled grid includes: Obtain the changes in the lengths of the first and second diagonals of a fluorescently labeled grid exhibiting signs of pull-out instability at adjacent sampling times; The diagonals with larger changes are identified as the stretching dominant diagonals; The instability direction vector is determined based on the two endpoints of the tensile dominant diagonal. The instability direction vector starts at the endpoint of the tensile dominant diagonal that is closer to the drawing inlet along the wire axis and ends at the endpoint that is farther away from the drawing inlet.

[0011] Furthermore, the process of constructing the sequence of pull-out instability evolution directions along the welding wire axis includes: The instability direction vectors corresponding to each fluorescent marker grid are obtained sequentially along the direction of wire travel. Arrange the instability direction vectors in the order of the welding wire travel direction to construct a sequence of pull-out instability evolution directions; In this sequence, each instability direction vector in the pull-out instability evolution direction is associated with the axial position index of the corresponding fluorescent marker grid.

[0012] Furthermore, the process of determining the unstable behavior of the copper plating layer on the solder wire includes: Calculate the angle between the directions of all adjacent instability direction vectors in the pull-out instability evolution direction sequence; If the included angles in all directions are less than the preset spatial consistency angle threshold, then the instability behavior state is determined to be the first instability behavior state. If at least one directional angle is greater than or equal to the spatial consistency angle threshold, then the instability behavior state is determined to be the second instability behavior state.

[0013] Furthermore, the process of implementing differentiated fine drawing process control for different unstable states includes: If the instability manifestation state is the first instability manifestation state, then the differentiated fine drawing process control is performed to determine the global stretching direction vector and adjust the import parameters of the fine drawing inlet guide mechanism based on the global stretching direction vector; If the instability state is the second instability state, then differentiated fine drawing process control is performed to locate the spatial coordinates of adjacent fluorescent marker grids corresponding to the inconsistent performance of the drawing instability evolution direction. Based on the spatial coordinates, the lubricant compensation placement point of the fine drawing die is determined, and quality traceability information containing the spatial coordinates is generated.

[0014] Furthermore, the process of determining the global stretching direction vector and adjusting the import parameters of the precision drawing inlet guide mechanism based on the global stretching direction vector includes: Vector synthesis is performed on all instability direction vectors in the pull-out instability evolution direction sequence, and the direction of the synthesized vector is determined as the global stretching direction vector. Determine the projection direction of the global stretching direction vector onto a cross section perpendicular to the welding wire axis; The direction of correction of the welding wire output by the precision drawing inlet guide mechanism on the cross section perpendicular to the welding wire axis is opposite to the projection direction.

[0015] Furthermore, the process of determining the lubricant compensation injection point for the precision drawing die includes: Traverse the sequence of pull-out instability evolution directions and filter out adjacent instability direction vector groups whose direction angle is greater than or equal to the spatial consistency angle threshold; Extract the axial position indices of the two fluorescently labeled grids corresponding to adjacent unstable direction vector groups; The axial position index is mapped to spatial coordinates along the welding wire axis, and the spatial coordinates are determined as the lubricant compensation injection point of the precision drawing die.

[0016] The beneficial effects of the technical solution presented in this application include: coating the copper-plated surface of the solder wire with fluorescent marking grids after copper plating and drying; continuously acquiring dynamic images of the markings on the copper-plated surface using an imaging acquisition system; extracting the quantization parameters of the two orthogonal diagonals of each fluorescent marking grid in real time; determining whether there are signs of pull-out instability in the region corresponding to the fluorescent marking grid by calculating the extension performance parameters of the solder wire pull-out; constructing a sequence of pull-out instability evolution directions along the solder wire axis; and determining the instability state of the copper-plated layer based on the spatial consistency of the pull-out instability evolution direction sequence. Finally, differentiated fine drawing process control is performed for different instability states. This achieves online detection of relative slippage signs between the copper-plated layer and the solder wire core during the pull-out process. By distinguishing the pull-out instability state of the copper-plated layer, the preparation process is adjusted accordingly, improving pull-out stability and the bonding quality of the copper-plated layer.

[0017] Furthermore, the extension performance parameter in this invention directly reflects the dynamic change rate of the copper plating layer deformation. When the interface undergoes initial shear slip, the copper layer deformation rate will increase abruptly. By comparing with a preset threshold, the instability precursor can be accurately identified before the plating layer macroscopically peels off, thus realizing online detection of the relative slip precursor between the copper plating layer and the welding wire core during the drawing process.

[0018] Furthermore, this invention arranges all instability direction vectors according to the welding wire travel sequence and associates them with axial position indices, which can transform isolated local deformation points into a continuous spatial evolution process, intuitively presenting the propagation trend and distribution law of instability along the welding wire axis, and providing a scientific basis for precise process control and full-process quality traceability.

[0019] Furthermore, this invention employs completely different control methods for instability states caused by different factors. For the first instability state caused by overall skew, the unidirectional shear force is fundamentally eliminated by adjusting the precision drawing inlet guide mechanism. For the second instability state caused by insufficient local lubrication, the micro-slip distortion at the interface is suppressed by precisely positioning and increasing the lubricant flow rate in the corresponding area. Thus, the problem of plating peeling is effectively solved, while avoiding the increased costs caused by traditional overall speed reduction and overall lubrication enhancement methods, thereby improving drawing stability and the bonding quality of the copper plating layer. Attached Figure Description

[0020] Figure 1 This is a step diagram illustrating the preparation method of submerged arc welding wire based on integrated drawing and copper plating according to an embodiment of the present invention; Figure 2 This is a flowchart illustrating the steps for extracting quantization parameters in an embodiment of the present invention. Figure 3 A logic flowchart for determining the unstable performance state of the copper plating layer of the welding wire and performing differentiated fine drawing process control in an embodiment of the present invention; Figure 4 This is a diagram illustrating the steps of adjusting the input parameters of the precision drawing inlet guide mechanism according to an embodiment of the present invention; Figure 5 A flowchart illustrating the steps for determining the lubricant compensation application points for a precision drawing die in an embodiment of the present invention. Detailed Implementation

[0021] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0022] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0023] It should be noted that in the description of this invention, the terms "upper," "lower," "inner," "outer," etc., which indicate the direction or positional relationship, are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0024] It should be understood that although the terms "first," "second," etc., may be used in this invention to describe various types of information, these information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this invention, first information may also be referred to as second information, and similarly, second information may also be referred to as first information.

[0025] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] Please see Figure 1 The diagram shows the steps of a method for preparing a submerged arc welding wire based on integrated drawing and copper plating according to an embodiment of the present invention. The method for preparing a submerged arc welding wire based on integrated drawing and copper plating according to the present invention includes: Step S100: Coat the copper-plated surface of the solder wire after copper plating and drying with a grid of fluorescent markers connected end to end. In this invention, the side length of a single square fluorescent marker grid is 180-220 μm, preferably 200 μm; the grid line width is 45-55 μm, preferably 50 μm, to avoid the imaging breakage caused by excessively thin lines and the cover-up of micro-deformation features by excessively thick lines; and the thickness of the fluorescent marker layer is 0.6-0.9 μm, preferably 0.8 μm.

[0027] The fluorescent material uses Nile Red, an oil-soluble fluorescent dye that has good adhesion to the copper plating layer and does not chemically react with the calcium-sodium-based drawing powder and water-based lubricant used in the fine drawing process. Its excitation wavelength is 552nm and its emission wavelength is 636nm. It can be removed by hot air drying after fine drawing.

[0028] In practice, the coating equipment can use a non-contact piezoelectric inkjet printhead.

[0029] Step S200: Set up an imaging acquisition system in front of the fine drawing mold entrance to continuously acquire dynamic images of the markings on the copper-plated surface, extract the quantization parameters of the two orthogonal diagonals of each fluorescent marking grid in real time, and construct a quantization feature dataset. The imaging acquisition system used in this invention is an ultraviolet imaging system, which consists of a CCD camera, an ultraviolet LED ring light source, a lens, and a controller.

[0030] Step S300: Calculate the elongation performance parameters of the wire drawing based on the quantized feature dataset, and determine whether there are signs of drawing instability in the region corresponding to the fluorescent marker grid based on the elongation performance parameters. Step S400: Extract the instability direction vector corresponding to the fluorescent marker grid that shows signs of pull-out instability, construct the pull-out instability evolution direction sequence along the welding wire axis, and determine the instability performance state of the copper plating layer of the welding wire based on the spatial consistency of the pull-out instability evolution direction sequence. Step S500 involves implementing differentiated fine drawing process control for different instability states, including determining the global stretching direction vector and adjusting the input parameters of the fine drawing inlet guide mechanism based on the global stretching direction vector. Alternatively, the spatial coordinates of adjacent fluorescent marker grids corresponding to inconsistent performance in the direction of instability evolution during positioning are determined, the lubricant compensation application point of the precision drawing die is determined based on the spatial coordinates, and quality traceability information containing the spatial coordinates is generated.

[0031] The quality traceability information generated by this invention is simultaneously uploaded to the production management visualization monitoring terminal, facilitating further verification by technical personnel.

[0032] Specifically, the process of coating the copper-plated surface of the solder wire after copper plating and drying with a grid of interconnected square fluorescent markers includes: The copper-plated surface is divided into several marked sections at equal intervals along the axial direction of the welding wire. Square fluorescent marker grids are sprayed in each marking section, with the vertices of adjacent fluorescent marker grids connected to form a grid structure that is connected end to end; The diagonal of the square fluorescent mark forms a 45° angle with the axis of the welding wire.

[0033] It is understandable that when relative slippage occurs between the copper plating layer and the solder wire core, the fluorescent markings attached to the copper plating surface will deform accordingly. The two orthogonal diagonals of the square grid will produce different length changes under axial tension or shear. Connecting the fluorescent marking grid end to end with the diagonal direction forming a 45° angle with the solder wire axis allows the two diagonals to exhibit tensile and shear resistance when the copper plating layer slips along the axis. The slippage signal can be amplified by comparing the length changes of the two diagonals.

[0034] This invention employs a head-to-tail interconnected structure where adjacent grid vertices are connected, enabling full-coverage detection of the copper-plated surface of the solder wire.

[0035] Specifically, please refer to Figure 2 The diagram illustrates the steps for extracting quantization parameters according to an embodiment of the present invention. The process of extracting the quantization parameters of the two orthogonal diagonals of each fluorescently labeled grid includes: Step S201: Obtain the coordinates of the endpoints of each diagonal, and determine the Euclidean distance between the two endpoints as the diagonal length; Step S202: Record the lengths of the two diagonals in the same fluorescently labeled grid as the first diagonal length and the second diagonal length, respectively; Step S203: The difference between the length of the first diagonal and the length of the second diagonal is determined as the distortion coefficient of the fluorescent marker grid.

[0036] In this invention, the distortion coefficient is the dimensionless value of the absolute value of the difference between the length of the first diagonal and the length of the second diagonal.

[0037] Under ideal uniform stretching conditions, the two diagonals of a square fluorescent marking grid will elongate proportionally, and the distortion coefficient remains unchanged. However, when interfacial shear instability occurs, the copper layer will undergo uneven deformation, resulting in a difference in the elongation of the two diagonals and an increase in the distortion coefficient. Therefore, the distortion coefficient can reflect the degree of shear deformation at the interface between the copper plating layer and the solder wire core.

[0038] Specifically, the process of calculating the elongation performance parameters of the welding wire and determining whether there are signs of pull-out instability in the region corresponding to the fluorescent marked grid includes: The first distortion coefficient and the second distortion coefficient of each fluorescently labeled grid at two consecutive sampling times are obtained, and the ratio of the second distortion coefficient to the first distortion coefficient is determined as the extension performance parameter. The extended performance parameters are compared with preset extended performance parameter thresholds; If the stretching performance parameter is greater than the stretching performance parameter threshold, it is determined that the area corresponding to the fluorescently marked grid has signs of pull-out instability. If the stretching performance parameter is less than or equal to the stretching performance parameter threshold, it is determined that the area corresponding to the fluorescently marked grid does not have signs of pull-out instability.

[0039] In this invention, the preset elongation performance parameter threshold is determined in advance through experiments. One hundred coils of qualified submerged arc welding wire are selected, and a precision drawing test is performed under normal process conditions. The elongation performance parameters of all fluorescently marked grids are collected, and the average elongation performance parameter μ and the standard deviation σ are calculated. The elongation performance parameter threshold is set as μ + 3σ. The preset elongation performance parameter threshold ranges from 1.2 to 1.4, and preferably, the value is 1.3.

[0040] Understandably, the elongation performance parameter reflects the dynamic rate of change of the copper plating layer deformation. When initial shear slip occurs at the interface, the deformation rate of the copper plating layer accelerates, leading to a sharp increase in the elongation performance parameter. By comparing it with a set threshold, normal drawing deformation and abnormal plastic shear deformation can be distinguished, enabling early identification of signs of interface instability.

[0041] Specifically, the process of extracting the instability direction vector corresponding to the fluorescently labeled grid includes: Obtain the changes in the lengths of the first and second diagonals of a fluorescently labeled grid exhibiting signs of pull-out instability at adjacent sampling times; The diagonals with larger changes are identified as the stretching dominant diagonals; The instability direction vector is determined based on the two endpoints of the tensile dominant diagonal. The instability direction vector starts at the endpoint of the tensile dominant diagonal that is closer to the drawing inlet along the wire axis and ends at the endpoint that is farther away from the drawing inlet.

[0042] In this invention, the elongation of the dominant diagonal is the largest, and its direction directly reflects the main stretching direction of the copper layer, which is also the propagation direction of interfacial shear instability. The starting point of the instability direction vector is defined as the endpoint near the drawing entrance, and the ending point is defined as the endpoint far from the drawing entrance. This is because the drawing deformation is transmitted sequentially from the entrance side to the exit side of the precision drawing die, and local interfacial shear instability first occurs on the entrance side and extends to the exit side as the welding wire travels. Therefore, the endpoint of the dominant diagonal near the drawing entrance is taken as the vector starting point, and the endpoint far from the drawing entrance is taken as the vector ending point, so that the instability direction vector is consistent with the slip propagation direction.

[0043] Specifically, the process of constructing the sequence of pull-out instability evolution directions along the welding wire axis includes: The instability direction vectors corresponding to each fluorescent marker grid are obtained sequentially along the direction of wire travel. Arrange the instability direction vectors in the order of the welding wire travel direction to construct a sequence of pull-out instability evolution directions; In this sequence, each instability direction vector in the pull-out instability evolution direction is associated with the axial position index of the corresponding fluorescent marker grid.

[0044] Understandably, a single instability direction vector can only reflect the slip direction at a local point and cannot determine the spatial distribution pattern of slip behavior across the entire welding wire. By arranging the instability direction vectors of all fluorescently marked grids in the order of welding wire movement to form a sequence, the changing trend of the slip direction along the axial direction can be observed intuitively.

[0045] Specifically, please refer to Figure 3 The diagram shown is a logic flowchart illustrating how an embodiment of the present invention determines the unstable state of the copper plating layer on a solder wire and performs differentiated fine drawing process control. The process for determining the unstable state of the copper plating layer on the solder wire includes: Calculate the angle between the directions of all adjacent instability direction vectors in the pull-out instability evolution direction sequence; If the included angles in all directions are less than the preset spatial consistency angle threshold, then the instability behavior state is determined to be the first instability behavior state. If at least one directional angle is greater than or equal to the spatial consistency angle threshold, then the instability behavior state is determined to be the second instability behavior state.

[0046] In this invention, 30 sets of samples of the first unstable performance state and 30 sets of samples of the second unstable performance state are collected respectively. The angle between adjacent unstable direction vectors in each set of samples is calculated. The maximum angle of the samples of the first unstable performance state and the minimum angle of the samples of the second unstable performance state are obtained. Based on the analysis results of the samples of the two unstable performance states, preferably, the spatial consistency angle threshold is 50°. If all direction angles are less than 50°, the unstable performance state is determined to be the first unstable performance state; if at least one direction angle is greater than or equal to 50°, the unstable performance state is determined to be the second unstable performance state.

[0047] Understandably, slip defects of different causes require different control strategies. If the angle between all adjacent instability direction vectors is very small, it means that the copper plating layer on the entire welding wire slips in almost the same direction. In actual manufacturing, this may be caused by an improper guide angle at the drawing inlet, resulting in overall force skewness, which is a global directional instability. If the angle between adjacent vectors is too large, it means that the slip direction changes abruptly in a local area, which may be caused by random instability due to poor lubrication in that area. By judging spatial consistency, the two instability modes can be automatically distinguished, providing a decision-making basis for subsequent differentiated process control.

[0048] Specifically, the process of implementing differentiated fine drawing process control for different instability states includes: If the instability manifestation state is the first instability manifestation state, then the differentiated fine drawing process control is performed to determine the global stretching direction vector and adjust the import parameters of the fine drawing inlet guide mechanism based on the global stretching direction vector; If the instability state is the second instability state, then differentiated fine drawing process control is performed to locate the spatial coordinates of adjacent fluorescent marker grids corresponding to the inconsistent performance of the drawing instability evolution direction. Based on the spatial coordinates, the lubricant compensation placement point of the fine drawing die is determined, and quality traceability information containing the spatial coordinates is generated.

[0049] Understandably, the first instability state is mainly caused by the overall skewness of the steel wire and unilateral wear of the mold. By adjusting the input parameters of the precision drawing inlet guide mechanism, the skewness of the steel wire can be corrected, fundamentally eliminating unidirectional shear force and solving the problem of plating peeling. The second instability state is mainly caused by the local rotational motion generated after the copper layer and the steel substrate undergo annular micro-debonding. Overall adjustment of the guide mechanism cannot solve the local problem. However, by accurately locating the instability area and increasing the lubricant flow at the corresponding position, the local interface friction can be reduced, and interface slip distortion can be suppressed. At the same time, the generation of quality traceability information enables full-process traceability of defective products, which is convenient for subsequent quality analysis.

[0050] Specifically, please refer to Figure 4 The diagram illustrates the steps of adjusting the input parameters of the precision drawing inlet guide mechanism according to an embodiment of the present invention. The process of determining the global stretching direction vector and adjusting the input parameters of the precision drawing inlet guide mechanism based on the global stretching direction vector includes: Step S501: Perform vector synthesis on all instability direction vectors in the pull-out instability evolution direction sequence, and determine the direction of the synthesized vector as the global stretching direction vector; Step S502: Determine the projection direction of the global stretching direction vector on the cross section perpendicular to the welding wire axis; Step S503: Adjust the direction of the correction of the welding wire output by the fine drawing inlet guide mechanism on the cross section perpendicular to the welding wire axis to be opposite to the projection direction.

[0051] In this invention, the precision drawing inlet guide mechanism consists of two mutually perpendicular adjustable guide wheels, which respectively control the inlet position of the welding wire in the horizontal and vertical directions; For example, the method for synthesizing the global stretching direction vector is as follows: If there are n instability direction vectors in the stretching instability evolution direction sequence, namely v1=(x1, y1), v2=(x2, y2), ..., v n =(x n y n If ), then the global stretching direction vector V = (Σx i , Σy i ), where i = 1, 2, ..., n; During adjustment, the projection vector V'=(x', y') of the global stretching direction vector V in the plane perpendicular to the welding wire axis is calculated. Then, the horizontal guide wheel is adjusted so that the horizontal displacement of the welding wire is -x', and the vertical guide wheel is adjusted so that the vertical displacement of the welding wire is -y', thus achieving reverse compensation.

[0052] It is understandable that by vector synthesis of all instability direction vectors, the overall deflection direction of the steel wire, i.e., the global tensile direction vector, can be obtained. Adjusting the precision drawing inlet guide mechanism so that the correction direction of the welding wire is opposite to the vertical projection direction of the global tensile direction vector can generate a reverse compensating force, counteracting the deflection tendency of the steel wire and keeping the steel wire in a centered state in the mold. This uniformly distributes the interfacial shear force and avoids coating peeling caused by local stress concentration.

[0053] Specifically, please refer to Figure 5 The diagram illustrates the steps for determining the lubricant compensation injection point of a precision drawing die according to an embodiment of the present invention. The process for determining the lubricant compensation injection point of a precision drawing die includes: Step S511: Traverse the pull-out instability evolution direction sequence and filter out adjacent instability direction vector groups whose direction angle is greater than or equal to the spatial consistency angle threshold; Step S512: Extract the axial position indices of the two fluorescent marker grids corresponding to adjacent unstable direction vector groups; Step S513: Map the axial position index to spatial coordinates along the welding wire axis, and determine the spatial coordinates as the lubricant compensation injection point of the precision drawing die.

[0054] The mapping method between axial position index and spatial coordinates is as follows: If the traveling speed of the welding wire is a, in m / s, and the acquisition frame rate of the imaging system is f, in fps, then the traveling distance of the welding wire corresponding to two adjacent frames is d = v / f, in m.

[0055] In this invention, each fluorescent marker grid is continuously captured in 10 frames during the deformation process, so the actual physical length of a single grid is 10×d.

[0056] The spatial coordinate of the center axis of the k-th fluorescent marker grid is L. k =(k-0.5)×10×d, where k is the axial position index of the grid, which increases sequentially starting from 1.

[0057] When the spatial coordinate of the central axis of the unstable region is located is L k At that time, the control system calculates the time t=L for the center of the area to reach the mold entrance based on the welding wire travel speed. k / a.

[0058] To ensure that the lubricant can accurately cover the entire unstable grid, the control system initiates flow regulation of the corresponding lubrication zone 0.3 seconds before time t, increasing the lubricant flow rate of that zone from the baseline condition of 20 mL / min to the compensation condition of 50 mL / min for a duration of 0.8 seconds.

[0059] It is understandable that the location where the angle between adjacent instability direction vectors is greater than a threshold is the core region of local vortex shear and also the region with the greatest interfacial friction. By mapping the axial position index to spatial coordinates along the welding wire axis, precise positioning of this core region can be achieved. Accurately increasing the lubricant flow rate at this location can effectively reduce local interfacial friction, prevent further debonding between the copper layer and the steel substrate, and thus avoid coating peeling.

[0060] This embodiment also provides a computer-readable storage medium storing computer program code. When the computer program code is run on a computer, the computer executes the above-mentioned method steps to realize the submerged arc welding wire preparation method based on integrated drawing and copper plating provided in the above embodiment.

[0061] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

[0062] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for preparing submerged arc welding wire based on integrated copper plating during drawing, characterized in that, include: After the copper plating and drying process, the copper-plated surface of the welding wire is coated with a grid of fluorescent markers that are connected end to end. An imaging acquisition system is set up in front of the precision drawing mold entrance to continuously acquire dynamic images of the markings on the copper-plated surface, extract the quantization parameters of the two orthogonal diagonals of each fluorescent marking grid in real time, and construct a quantization feature dataset. Based on the quantized feature dataset, the elongation performance parameters of the welding wire are calculated, and based on the elongation performance parameters, it is determined whether there are signs of drawing instability in the region corresponding to the fluorescent marker grid. Extract the instability direction vectors corresponding to the fluorescent marker grids that show signs of pull-out instability, construct a sequence of pull-out instability evolution directions along the welding wire axis, and determine the instability state of the copper plating layer of the welding wire based on the spatial consistency of the pull-out instability evolution direction sequence. Differentiated fine drawing process control is implemented for different instability states, including determining the global stretching direction vector and adjusting the input parameters of the fine drawing inlet guide mechanism based on the global stretching direction vector. Alternatively, the spatial coordinates of adjacent fluorescent marker grids corresponding to inconsistent performance in the direction of instability evolution during positioning are determined, the lubricant compensation application point of the precision drawing die is determined based on the spatial coordinates, and quality traceability information containing the spatial coordinates is generated.

2. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 1, characterized in that, The process of coating the copper-plated surface of the solder wire after copper plating and drying with a continuous square fluorescent marking grid includes: The copper-plated surface is divided into several marked sections at equal intervals along the axial direction of the welding wire. Square fluorescent marker grids are sprayed in each marking section, with the vertices of adjacent fluorescent marker grids connected to form a grid structure that is connected end to end; The diagonal of the square fluorescent mark forms a 45° angle with the axis of the welding wire.

3. The method for preparing submerged arc welding wire based on integrated drawing and copper plating according to claim 2, characterized in that, The process of extracting the quantization parameters of the two orthogonal diagonals of each fluorescently labeled grid includes: Obtain the coordinates of the endpoints of each diagonal, and determine the Euclidean distance between the two endpoints as the diagonal length; The lengths of the two diagonals in the same fluorescently labeled grid are denoted as the first diagonal length and the second diagonal length, respectively. The difference between the length of the first diagonal and the length of the second diagonal is determined as the distortion coefficient of the fluorescently labeled grid.

4. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 3, characterized in that, The process of calculating the elongation performance parameters of the welding wire pull-out and determining whether there are signs of pull-out instability in the region corresponding to the fluorescently marked grid includes: The first distortion coefficient and the second distortion coefficient of each fluorescently labeled grid at two consecutive sampling times are obtained, and the ratio of the second distortion coefficient to the first distortion coefficient is determined as the extension performance parameter. The extended performance parameters are compared with preset extended performance parameter thresholds; If the stretching performance parameter is greater than the stretching performance parameter threshold, it is determined that the region corresponding to the fluorescent marker grid has signs of pull-out instability.

5. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 4, characterized in that, The process of extracting the instability direction vector corresponding to the fluorescently labeled grid includes: Obtain the changes in the lengths of the first and second diagonals of a fluorescently labeled grid exhibiting signs of pull-out instability at adjacent sampling times; The diagonals with larger changes are identified as the stretching dominant diagonals; The instability direction vector is determined based on the two endpoints of the tensile dominant diagonal. The instability direction vector starts at the endpoint of the tensile dominant diagonal that is closer to the drawing inlet along the wire axis and ends at the endpoint that is farther away from the drawing inlet.

6. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 5, characterized in that, The process of constructing the sequence of pull-out instability evolution along the welding wire axis includes: The instability direction vectors corresponding to each fluorescent marker grid are obtained sequentially along the direction of wire travel. Arrange the instability direction vectors in the order of the welding wire travel direction to construct a sequence of pull-out instability evolution directions; In this sequence, each instability direction vector in the pull-out instability evolution direction is associated with the axial position index of the corresponding fluorescent marker grid.

7. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 6, characterized in that, The process of determining the unstable behavior of the copper plating layer on the solder wire includes: Calculate the angle between the directions of all adjacent instability direction vectors in the pull-out instability evolution direction sequence; If the included angles in all directions are less than the preset spatial consistency angle threshold, then the instability behavior state is determined to be the first instability behavior state. If at least one directional angle is greater than or equal to the spatial consistency angle threshold, then the instability behavior state is determined to be the second instability behavior state.

8. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 7, characterized in that, The process of implementing differentiated fine drawing process control for different instability states includes: If the instability manifestation state is the first instability manifestation state, then the differentiated fine drawing process control is performed to determine the global stretching direction vector and adjust the import parameters of the fine drawing inlet guide mechanism based on the global stretching direction vector; If the instability state is the second instability state, then differentiated fine drawing process control is performed to locate the spatial coordinates of adjacent fluorescent marker grids corresponding to the inconsistent performance of the drawing instability evolution direction. Based on the spatial coordinates, the lubricant compensation placement point of the fine drawing die is determined, and quality traceability information containing the spatial coordinates is generated.

9. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 8, characterized in that, The process of determining the global stretching direction vector and adjusting the import parameters of the precision drawing inlet guide mechanism based on the global stretching direction vector includes: Vector synthesis is performed on all instability direction vectors in the pull-out instability evolution direction sequence, and the direction of the synthesized vector is determined as the global stretching direction vector. Determine the projection direction of the global stretching direction vector onto a cross section perpendicular to the welding wire axis; The direction of correction of the welding wire output by the precision drawing inlet guide mechanism on the cross section perpendicular to the welding wire axis is opposite to the projection direction.

10. The method for preparing submerged arc welding wire based on integrated copper plating during drawing according to claim 8, characterized in that, The process of determining the lubricant compensation injection point for the precision drawing die includes: Traverse the sequence of pull-out instability evolution directions and filter out adjacent instability direction vector groups whose direction angle is greater than or equal to the spatial consistency angle threshold; Extract the axial position indices of the two fluorescently labeled grids corresponding to adjacent unstable direction vector groups; The axial position index is mapped to spatial coordinates along the welding wire axis, and the spatial coordinates are determined as the lubricant compensation injection point of the precision drawing die.

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