GTAW longitudinal swing wire feeding intelligent control system based on magnetic control

Abstract

The present application relates to the field of GTAW welding, and is a kind of magnetic control GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system and method.Aiming at the problems of non-fusion of sidewall, weld protrusion, poor adaptability of filler wire amount and groove size and insufficient coordination of hot wire heating and wire feeding speed in asymmetric narrow gap GTAW thick plate welding, a kind of magnetic control GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system and method is proposed.The asymmetric narrow gap weld self-adaptive welding path planning method based on structured light camera is used to control the reference motion trajectory of welding torch and the target action position of electric arc.The electric arc motion trajectory control method based on magnetic field is used to control the electric arc swing mode and sidewall residence time.The GTAW asymmetric narrow gap weld dynamic quantitative wire feeding control method based on visual sensing is used to control the filler wire amount and liquid bridge stability.The hot wire closed-loop control method with adaptive filler wire speed is used to control the coordination of hot wire temperature, heating current and wire feeding speed.

Description

Technical Field

[0001] This invention belongs to the field of asymmetric narrow gap welding technology, specifically a magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system. Background Technology

[0002] Asymmetric narrow gap GTAW (Gas Tungsten Arc Welding) is a thick plate welding process. Its core feature is the use of asymmetric bevel design. By precisely controlling the arc oscillation, filler wire operation and heat input, it can achieve high-quality welding of thick-walled components.

[0003] Existing asymmetric narrow gap welding technologies generally suffer from the following drawbacks: When the bevel sidewalls are irregular or the gap width varies significantly, traditional arcs struggle to stably cover both sides of the bevel, easily leading to defects such as poor sidewall fusion and incomplete fusion. Simultaneously, the arc dwell time in the middle of the weld cannot be precisely controlled, easily causing excessive weld buildup, surface bulges, and uneven weld formation. Furthermore, traditional equipment lacks real-time weld width detection and adaptive adjustment capabilities, failing to dynamically match arc oscillation parameters according to the actual gap width. It relies solely on fixed welding processes, exhibiting poor adaptability to different gap widths, easily resulting in insufficient penetration, unstable weld formation, and low weld quality consistency, making it difficult to meet the requirements of high-precision, high-reliability asymmetric narrow gap welding. This invention discloses a magnetically controlled GTAW dynamic quantitative hot wire feeding welding system for asymmetric narrow gap welds. By setting up a welding torch magnetically controlled actuator, a structured light camera, a molten pool vision inspection component, a hot wire feeding mechanism, and an industrial control computer, it can realize real-time monitoring and control of the asymmetric narrow gap welding state, and achieve coordinated regulation of the arc position, filler wire amount, and hot wire temperature during the asymmetric narrow gap welding process, so as to improve the sidewall fusion state and weld formation stability. Summary of the Invention

[0004] A magnetically controlled GTAW (Gross-Fire Asymmetric Narrow Gap) dynamic quantitative hot wire feeding welding system for asymmetric narrow gap GTAW welding of thick plate components is characterized by comprising: a welding torch triaxial motion support mechanism, a welding torch magnetically controlled actuator, a hot wire feeding mechanism, a structured light camera, a weld pool vision inspection component, a GTAW welding power supply, an electrical control cabinet, an industrial computer, and a PLC; the hot wire feeding mechanism includes a wire feeding unit and a hot wire heating unit, wherein the wire feeding unit continuously feeds the welding wire to the welding area, and the hot wire heating unit adjusts the position of the welding wire end, the wire feeding angle, and induction heating the welding wire; the welding torch... The three-axis motion support mechanism consists of a frame, a welding table, X-axis electric guide rails, Y-axis electric guide rails, Z-axis electric guide rails, and slide rails; the welding torch magnetic control actuator includes a mounting frame, a welding torch, and a magnetic field generator; the magnetic field generator includes an excitation power supply, an excitation coil, and a magnetic pole assembly, with the excitation coil arranged on both sides of the welding torch, and the magnetic pole assembly connected below the excitation coil and facing the welding torch; the structured light camera is set on the front side of the welding direction via a first linkage-type adjustable camera bracket, used to acquire the profile of the bevel section to be welded; the structured light camera includes a line laser and a CCD camera; the molten pool visual inspection component is set on the rear side of the welding torch, used to acquire images of the welding wire end, liquid bridge, and molten pool. The molten pool visual inspection assembly includes a second linkage-type adjustable camera bracket and a visual inspection camera. Both the first linkage-type adjustable camera bracket and the second linkage-type adjustable camera bracket include a fixed base, a connecting rod, a camera mounting base, and a locking component. One end of the connecting rod is connected to the fixed base, and the other end is connected to the camera mounting base. The camera mounting base is used to fix the structured light camera or the visual inspection camera. An angle adjustment structure is provided between the connecting rod, the fixed base, and the camera mounting base, and is fixed after adjustment by the locking component to adjust the installation position, working distance, and shooting angle of the camera relative to the welding torch, the weld bevel, and the molten pool area. The wire feeding unit includes a mounting frame, a wire spool, a servo motor, a wire feeding wheel assembly, and a wire guide nozzle; the hot wire heating unit consists of a Z-axis precision guide rail, a Y-axis precision guide rail, a wire feeding angle adjuster, a wire feeding tube, an electromagnetic induction heater, and a temperature sensor; the industrial control computer is used to perform image processing, bevel parameter calculation, oscillation parameter calculation, wire feeding speed correction, and hot wire temperature control parameter calculation, and sends control commands to the PLC; the PLC drives the X-axis electric guide rail, Y-axis electric guide rail, Z-axis electric guide rail, servo motor in the wire feeding unit, excitation power supply, and electromagnetic induction heater to perform corresponding actions according to the control commands output by the industrial control computer; the structured light camera, weld pool vision inspection component, and temperature sensor establish a data interaction channel with the industrial control computer through a communication bus. The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system is as follows: Figure 1 As shown.

[0005] A magnetically controlled GTAW (Ground-Tight Asymmetric Narrow Gap Welding) dynamic quantitative hot wire feeding welding system is characterized by the following: In this system, the welding torch's reference motion trajectory and the arc target's position are determined using an adaptive path planning method for asymmetric narrow gap welds based on a structured light camera. This method acquires bevel profile information using a structured light camera, and the industrial control computer calculates the bevel size, plans the welding torch's reference motion trajectory, and determines the arc target's position based on this information. Before welding begins, the welding torch moves forward, and the line laser in the structured light camera projects a line laser perpendicular to the welding direction onto the bevel area. The CCD camera acquires the deformed stripe image formed by the line laser on the bevel surface. The industrial control computer calculates the bevel profile based on the deformed stripe image and extracts the current bevel width W and the slopes of both sides of the bevel. and The asymmetric bevel has inconsistent inclination angles on both sides. The industrial control computer calculates the bevel width W, the bevel cross-sectional profile, and the slopes of the left and right bevels. , Plan the reference motion trajectory of the welding torch in three-dimensional space and determine the target position on the left side wall. and the target position on the right side wall ;in, and This refers to the target area near the left and right side walls where the electric arc acts. The industrial control computer calculates the target lateral oscillation amplitude required for the arc to deflect towards the left and right side walls, respectively, based on the welding torch reference trajectory. , The target's lateral swing amplitude , Used to determine the corresponding excitation current amplitude. The excitation current amplitude is calibrated in advance through welding tests. Excitation frequency A calibration table for swing parameters is formed by establishing the correspondence between the arc's lateral swing amplitude A and the response time τ required for the arc to reach the target swing position; the industrial control computer then uses the target lateral swing amplitude... , The excitation current amplitude during the left deflection phase is determined in the swing parameter calibration table. Excitation current amplitude during the right deflection phase and the corresponding arc response time , The lateral oscillation amplitude of the electric arc is related to the bevel width W and the target positions on the left and right side walls. , The process is matched. The industrial control computer determines the basic dwell time of the arc at the target positions on the left and right side walls based on the bevel cross-sectional profile, the target positions on the left and right side walls, the preset side wall fusion requirements, and a pre-established dwell time process parameter table. During welding, the industrial control computer corrects the basic dwell time based on the molten pool images acquired by the molten pool vision inspection component. Simultaneously, the industrial control computer calculates the dynamic filler wire amount based on the bevel cross-sectional area and welding speed. Preset bevel width threshold and ,and < ,in, The maximum bevel width is required to ensure that the maximum lateral oscillation amplitude of the magnetically controlled arc can meet the target position requirements on the left and right side walls without superimposed mechanical lateral displacement. The maximum bevel width that can meet the target position requirements of the left and right side walls after the combination of magnetic swing and lateral mechanical displacement of Y-axis electric guide rail.

[0006] A magnetically controlled GTAW (Gross-Fire Asymmetric Narrow Gap Welding) dynamic quantitative hot wire feeding system is characterized by: In this system, the arc oscillation mode and sidewall dwell time are controlled by a magnetic field-based arc motion trajectory control method; this method, through the linkage of excitation coils, molten pool vision inspection components, and an industrial control computer, adjusts the amplitude, polarity, frequency, and timing of the excitation current to achieve coordinated control of the arc's lateral oscillation amplitude, oscillation response time, and sidewall dwell time; the excitation coils are arranged on both sides of the welding torch, and their arrangement direction creates an alternating magnetic field in the arc region along the weld direction or its opposite direction; by changing the polarity of the excitation current, the arc deflection direction is changed, achieving alternating deflection of the arc towards the left and right sidewall target positions; a preset bevel width threshold range is established, and when the structured light camera detects the bevel width... At that time, the industrial control computer adjusts the lateral swing amplitude of the left and right targets. Call the swing parameter calibration table to determine the excitation current amplitude. and excitation frequency This allows the electric arc to reach the target positions on the left and right side walls solely through magnetic control, and to remain in place according to the base duration. Stay at the corresponding side wall target position; when At that time, the industrial control computer is based on Based on the determined excitation current amplitude, the excitation current timing is further adjusted so that the arc oscillates periodically according to the pattern of stopping at the target position on the left side wall, transitioning to the middle, and stopping at the target position on the right side wall; the oscillation period T includes the response time for the arc to deflect from the middle region to the target position on the left side wall. Dwell time on the left side wall The transition time of the electric arc from the target position on the left wall to the target position on the right wall. and the time spent on the right side wall When it is necessary to limit the heat input in the middle of the weld, the industrial control computer controls the duration of the electric arc's action in the middle region of the weld. Make individual settings or corrections; when During this process, the industrial control computer segments the oscillation period T, adjusts the lateral position of the welding torch via the Y-axis electric guide rail, and adjusts the lateral deflection of the arc relative to the welding torch via the magnetic field generator. This ensures that the lateral displacement of the welding torch and the magnetic deflection of the arc together meet the target position requirements of the left and right side walls. In the above oscillation control process, the timing start point for the side wall dwell time is either after the arc completes the corresponding lateral deflection and reaches the target position of the side wall, or it is the pre-calibrated arc response time. After completion; if the excitation frequency If the excitation frequency is too high and the arc fails to reach the target position, the industrial control computer reduces the excitation frequency or extends the corresponding transition time to ensure that the arc reaches the target position before entering the sidewall dwell stage. The molten pool vision inspection component acquires molten pool images in real time and transmits them to the industrial control computer, which then extracts the molten pool area near the sidewall. and the target molten pool area Comparison and dynamic correction of the actual residence time of the arc :when When the arc's dwell time at the target position on the corresponding sidewall is increased, the industrial control computer reduces the arc's dwell time in the middle region of the weld when the weld pool area or height trend exceeds the preset state. The workflow diagram of the magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system is as follows: Figure 5 As shown.

[0007] A magnetically controlled GTAW (Gross-Mesh Asymmetric Narrow Gap Welding) dynamic quantitative hot wire feeding welding system is characterized by: the system utilizing a hot wire feeding mechanism to achieve continuous wire feeding, wire end position adjustment, and filler wire position control, and forming a dynamic quantitative wire feeding closed-loop control through a weld pool vision inspection component, an industrial computer, and the hot wire feeding mechanism; the mounting frame of the wire feeding unit is located on one side of the frame, and the mounting frame is equipped with a wire reel, a servo motor, a wire feeding wheel assembly, and a wire guide nozzle; the wire is drawn from the wire reel, passes through the wire feeding wheel assembly and the wire guide nozzle, and enters the wire feeding tube of the hot wire heating unit; the Z-axis precision guide rail of the hot wire heating unit is fixed. A Y-axis precision guide rail is fixed to the slide of the Z-axis precision guide rail on the mounting bracket. A wire feed angle adjuster is fixed to the slide of the Y-axis precision guide rail. The wire feed tube is hinged to the wire feed angle adjuster via a rotating shaft and can rotate around this shaft to adjust the wire feed angle. An electromagnetic induction heater is fixed to the wire inlet end of the wire feed tube, and a temperature sensor is fixed to the outside of the wire feed tube. The molten pool vision inspection component acquires real-time images of the molten pool and deposited metal contour. The industrial control computer calculates the target deposited cross-sectional area based on the bevel cross-sectional area, welding speed, and preset filling ratio, and extracts the actual molten pool width based on the molten pool and deposited metal contour images. Actual molten pool height or actual weld cross-sectional area The industrial control computer will display the actual weld cross-sectional area. With the target weld cross-sectional area By comparison, the deviation of the weld cross-sectional area is obtained. The servo motor speed in the wire feeding unit is adjusted according to the weld cross-sectional area deviation ΔS to regulate the wire feeding speed. When ΔS is greater than the preset allowable deviation, the industrial control computer increases the wire feeding speed; when ΔS is less than the negative preset allowable deviation, the industrial control computer decreases the wire feeding speed; when ΔS is within the preset allowable deviation range, the industrial control computer maintains the current wire feeding speed. The welding torch magnetic control actuator, hot wire heating unit, and vision inspection component are as follows: Figure 3 As shown, the partial structure of the hot wire heating unit is as follows: Figure 4 As shown.

[0008] A magnetically controlled GTAW (Gross-Mesh Asymmetric Narrow Gap Welding System with Dynamic Quantitative Hot Wire Feeding) is characterized by: In addition to adjusting the wire feeding speed based on the weld cross-sectional area deviation, the system further detects the liquid bridge state at the end of the welding wire using a molten pool visual inspection component, and compensates and corrects the wire feeding speed based on the stability of the liquid bridge; during welding, the industrial control computer dynamically adjusts the wire feed amount... Set initial wire feed speed The vision inspection camera in the weld pool vision inspection component detects the actual wire feeding position and the transition state of the filler metal at the end of the welding wire in real time, and uses a vision algorithm to extract the length of the liquid bridge. With liquid bridge diameter Calculate the stability evaluation value of the liquid bridge Preset liquid bridge stability threshold range ,when When the stability evaluation value of the liquid bridge falls below the lower limit of the preset stability range, the industrial control computer generates a negative speed compensation command to adjust the actual wire feeding speed. Decrease; when When the stability evaluation value of the liquid bridge exceeds the upper limit of the preset stability range, the industrial control computer generates a positive speed compensation command, causing... Increase; when At that time, the stability evaluation value of the liquid bridge was within the preset stability range, and maintained. The molten pool visual inspection component of the magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system, such as... Figure 3 As shown.

[0009] A magnetically controlled GTAW (Gross-Mesh Asymmetric Narrow Gap Welding) dynamic quantitative hot wire feeding system is characterized by the following: In this system, the synergy between hot wire temperature, heating current, and wire feeding speed is controlled by an adaptive wire feeding speed closed-loop control method. This adaptive wire feeding speed closed-loop control method adjusts the heating current using a temperature sensor, an industrial computer, and an electromagnetic induction heater to achieve closed-loop control of the hot wire temperature. The electromagnetic induction heater is fixed to the wire inlet end of the wire feeding tube, generating an alternating magnetic field on the welding wire passing through the tube, inducing eddy currents in the wire for heating. The temperature sensor is fixed to the outside of the wire feeding tube, detecting the actual temperature of the welding wire before it enters the molten pool in real time. The data is then fed back to the industrial control computer; the industrial control computer calculates the temperature difference. ,according to The heating current of the electromagnetic induction heater is adjusted by a closed-loop control system. Increase when ΔT>0 Decrease when ΔT < 0 The heating current With wire feeding speed Adaptive adjustment: when When the size increases, the industrial control computer increases synchronously. This ensures that the preheating state of the welding wire per unit length is maintained within a preset range, achieving synergy between hot wire heating and dynamic wire feeding speed.

[0010] Beneficial effects of the invention

[0011] This invention relates to the field of GTAW welding, specifically a magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system and method. Addressing the problems of incomplete sidewall fusion, weld center bulge, poor fit between filler wire amount and groove size, and insufficient coordination between hot wire heating and wire feeding speed in asymmetric narrow gap GTAW thick plate welding, this invention proposes a magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system and method. It utilizes an adaptive welding path planning method based on a structured light camera to control the welding torch's reference trajectory and the arc target position; a magnetic field-based arc trajectory control method to control the arc oscillation mode and sidewall dwell time; a vision-sensing-based dynamic quantitative wire feeding control method to control the filler wire amount and liquid bridge stability; and an adaptive filler wire speed closed-loop control method to control the coordination between hot wire temperature, heating current, and wire feeding speed. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of a magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system.

[0013] In the diagram, 1 is the industrial computer, 2 is the electrical control cabinet, 3 is the welding torch three-axis motion support mechanism, 4 is the GTAW welding power supply, 5 is the welding torch magnetic control actuator, 6 is the control cabinet, 7 is the magnetic field generator, and 8 is the wire feeding unit.

[0014] Figure 2 This is a structural diagram of the three-axis motion support mechanism for the welding torch.

[0015] In the diagram, 9 is the X-axis electric guide rail, 10 is the Z-axis electric guide rail, 11 is the Y-axis electric guide rail, 12 is the slide rail, 13 is the welding table, and 14 is the frame.

[0016] Figure 3 This is a schematic diagram of the installation structure of the welding torch magnetic actuator, hot wire heating unit, and vision inspection components.

[0017] In the figure, 15 is a narrow gap workpiece, 16 is a mounting bracket, 17 is an excitation coil, 18 is a welding torch, 19 is a magnetic pole assembly, 20 is a hot wire heating unit, 21 is a structured light camera, 22 is a molten pool visual inspection assembly, 23 is a first linkage type adjustable camera bracket, and 24 is a second linkage type adjustable camera bracket.

[0018] Figure 4 This is a partial structural diagram of the hot wire heating unit.

[0019] In the diagram, 25 is the Z-axis precision guide rail, 26 is the Y-axis precision guide rail, 27 is the wire feeding angle adjuster, 28 is the electromagnetic induction heater, 29 is the wire feeding tube, and 30 is the temperature sensor.

[0020] Figure 5This is a flowchart of the dynamic quantitative hot wire feeding welding system for asymmetric narrow gap welds using magnetically controlled GTAW. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0022] The working principle of this embodiment is as follows:

[0023] Step 1: Bevel Parameter Detection and Arc Path Planning

[0024] In the dynamic quantitative hot wire feeding welding process of asymmetric narrow gap welds using magnetically controlled GTAW, it is necessary to calculate the welding torch reference trajectory, the arc target's position, the target's lateral oscillation amplitude, and the dynamic filler wire amount based on the real-time geometric parameters of the asymmetric bevel. Before welding begins, the welding torch moves forward, and the line laser in the structured light camera projects a laser perpendicular to the welding direction onto the workpiece. The CCD camera then captures the deformed laser stripe image. Figure 1 The industrial control computer in the system uses laser triangulation to calculate the profile of the bevel section and extracts the current bevel width W and the slope of the left bevel. and the slope of the right bevel The asymmetric bevel has inconsistent dip angles on both sides, i.e. The industrial control computer determines the target positions on the left and right side walls based on the bevel width W and the bevel cross-sectional profile. And calculate the target lateral swing amplitude required for the arc to deflect to the left and right sidewalls. Simultaneously, the dynamic filler wire amount is calculated based on the bevel cross-sectional area, welding speed, and preset filler ratio, and the parameters required for subsequent oscillation control and wire feeding control are preset.

[0025] Step 2: Control of arc oscillation mode and sidewall dwell time

[0026] In the dynamic quantitative hot wire feeding welding process of asymmetric narrow gap welds using magnetically controlled GTAW, the excitation parameters need to be adjusted according to the bevel width and the target lateral oscillation amplitude, and the sidewall dwell time needs to be corrected according to the molten pool state. During welding, the excitation coil forms an alternating magnetic field in the arc region along the weld direction or its opposite direction. The arc current direction is approximately along the welding torch axis. The interaction between the arc current and the alternating magnetic field generates a Lorentz force perpendicular to the weld direction, thereby causing the arc to deflect towards the target position on the left and right sidewalls along the bevel width direction. The industrial control computer determines the corresponding parameters based on the pre-calibrated relationship between the excitation current amplitude, excitation frequency, arc lateral oscillation amplitude, and arc response time. The corresponding excitation current parameters. The sidewall dwell time starts timing after the arc reaches the target position on the corresponding sidewall and is used to adjust the heat input to the sidewall, not to change the lateral oscillation amplitude of the arc. When the excitation frequency is too high and the arc fails to reach the target position, the industrial control computer reduces the excitation frequency or extends the transition time. The molten pool vision inspection component acquires molten pool images in real time, and the industrial control computer dynamically corrects the corresponding sidewall dwell time based on the comparison between the area of ​​the molten pool near the sidewall and the target molten pool area.

[0027] Step 3: Dynamic quantitative yarn feeding control

[0028] In the dynamic quantitative hot wire feeding process of magnetically controlled GTAW asymmetric narrow gap weld welding, the wire feeding speed needs to be dynamically adjusted according to the bevel size and the actual deposition state. During welding, the industrial control computer calls the dynamic filler wire amount calculated in step one to set the initial wire feeding speed. The wire feeding unit in the hot wire feeding mechanism drives the wire feeding wheel group to rotate through the servo motor, stably feeding the welding wire through the wire guide nozzle to the wire feeding tube of the hot wire heating unit. The vision inspection camera in the molten pool vision inspection component acquires real-time images of the molten pool and the contour of the deposited metal. The industrial control computer extracts the actual molten pool width, actual molten pool height, or actual deposition cross-sectional area and compares it with the target deposition amount. When the actual deposition amount is insufficient, the industrial control computer increases the wire feeding speed; when the actual deposition amount is too large, the industrial control computer decreases the wire feeding speed; when the actual deposition amount is within the allowable deviation range, the current wire feeding speed is maintained. At the same time, the industrial control computer judges the transition state of the welding wire end based on the liquid bridge length and liquid bridge diameter and compensates and corrects the wire feeding speed accordingly.

[0029] Step 4: Closed-loop control of hot wire temperature

[0030] In the dynamic quantitative hot wire feeding welding process of asymmetric narrow gap welds using magnetically controlled GTAW, it is necessary to maintain coordination between the hot wire temperature and the dynamic wire feeding speed. During welding, the welding wire passes through an electromagnetic induction heater as it passes through the wire feeding tube. The electromagnetic induction heater generates an alternating magnetic field on the welding wire, inducing eddy currents and heating it. A temperature sensor detects the actual temperature of the welding wire before it enters the molten pool in real time and feeds it back to the industrial control computer. The industrial control computer compares the actual temperature with the target preheating temperature and adjusts the heating current of the electromagnetic induction heater according to the temperature difference. When the actual temperature is lower than the target preheating temperature, the heating current is increased; when the actual temperature is higher than the target preheating temperature, the heating current is decreased. Simultaneously, the heating current is adjusted synchronously with the actual wire feeding speed to maintain a relatively stable preheating state per unit length of welding wire, thus completing the dynamic quantitative hot wire feeding welding process of asymmetric narrow gap welds using magnetically controlled GTAW.

Claims

1. A magnetically controlled GTAW (Gross-Road Welding) system for asymmetric narrow-gap GTAW welding of thick plate components, characterized in that: The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system consists of a welding torch triaxial motion support mechanism, a welding torch magnetically controlled actuator, a hot wire feeding mechanism, a structured light camera, a weld pool vision inspection component, a GTAW welding power supply, an electrical control cabinet, an industrial computer, and a PLC. The hot wire feeding mechanism includes a wire feeding unit and a hot wire heating unit. The wire feeding unit continuously feeds the welding wire to the welding area, while the hot wire heating unit adjusts the position of the welding wire end, the wire feeding angle, and performs induction heating on the welding wire. The welding torch triaxial motion support mechanism consists of a frame, a welding table, an X-axis electric guide rail, and a Y-axis electric guide rail. The welding torch consists of a guide rail, a Z-axis electric guide rail, and a slide rail. The magnetic control actuator of the welding torch includes a mounting frame, a welding torch, and a magnetic field generator. The magnetic field generator includes an excitation power supply, an excitation coil, and a magnetic pole assembly. The excitation coil is arranged on both sides of the welding torch, and the magnetic pole assembly is connected below the excitation coil and faces the welding torch. The structured light camera is set on the front side of the welding direction through a first linkage-type adjustable camera bracket and is used to acquire the profile of the cross-section of the bevel to be welded. The structured light camera includes a line laser and a CCD camera. The molten pool vision inspection component is set on the rear side of the welding torch and is used to acquire images of the welding wire end, liquid bridge, and molten pool. The molten pool visual inspection assembly includes a second linkage-type adjustable camera bracket and a visual inspection camera. Both the first linkage-type adjustable camera bracket and the second linkage-type adjustable camera bracket include a fixed base, a connecting rod, a camera mounting base, and a locking component. One end of the connecting rod is connected to the fixed base, and the other end is connected to the camera mounting base. The camera mounting base is used to fix the structured light camera or the visual inspection camera. An angle adjustment structure is provided between the connecting rod, the fixed base, and the camera mounting base, and is fixed after adjustment by the locking component to adjust the installation position, working distance, and shooting angle of the camera relative to the welding torch, the weld bevel, and the molten pool area. The wire feeding unit includes a mounting frame, a wire spool, a servo motor, a wire feeding wheel assembly, and a wire guide nozzle; the hot wire heating unit consists of a Z-axis precision guide rail, a Y-axis precision guide rail, a wire feeding angle adjuster, a wire feeding tube, an electromagnetic induction heater, and a temperature sensor; the industrial control computer is used to perform image processing, bevel parameter calculation, oscillation parameter calculation, wire feeding speed correction, and hot wire temperature control parameter calculation, and sends control commands to the PLC; the PLC drives the X-axis electric guide rail, Y-axis electric guide rail, Z-axis electric guide rail, servo motor in the wire feeding unit, excitation power supply, and electromagnetic induction heater to perform corresponding actions according to the control commands output by the industrial control computer; the structured light camera, weld pool vision inspection component, and temperature sensor establish a data interaction channel with the industrial control computer through a communication bus.

2. The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system according to claim 1, characterized in that: In this system, the welding torch reference trajectory and the arc target position are determined by an asymmetric narrow gap weld seam adaptive path planning method based on a structured light camera. This method acquires the bevel profile information using a structured light camera, and the industrial control computer calculates the bevel size, plans the welding torch reference trajectory, and determines the arc target position based on this profile information. Before welding begins, the welding torch moves forward, and the line laser in the structured light camera projects a line laser perpendicular to the welding direction onto the bevel area. The CCD camera captures the deformed stripe image formed by the line laser on the bevel surface. The industrial control computer calculates the bevel profile based on the deformed stripe image and extracts the current bevel width W and the bevel slopes on both sides. and The asymmetric bevel has inconsistent inclination angles on both sides. The industrial control computer calculates the bevel width W, the bevel cross-sectional profile, and the slopes of the left and right bevels. , Plan the reference motion trajectory of the welding torch in three-dimensional space and determine the target position on the left side wall. and the target position on the right side wall ;in, and This refers to the target area near the left and right side walls where the electric arc acts. The industrial control computer calculates the target lateral oscillation amplitude required for the arc to deflect towards the left and right side walls, respectively, based on the welding torch reference trajectory. , The target's lateral swing amplitude , Used to determine the corresponding excitation current amplitude. The excitation current amplitude is calibrated in advance through welding tests. Excitation frequency A calibration table for swing parameters is formed by establishing the correspondence between the arc's lateral swing amplitude A and the response time τ required for the arc to reach the target swing position; the industrial control computer then uses the target lateral swing amplitude... , The excitation current amplitude during the left deflection phase is determined in the swing parameter calibration table. Excitation current amplitude during the right deflection phase and the corresponding arc response time , The lateral oscillation amplitude of the electric arc is related to the bevel width W and the target positions on the left and right side walls. , The process is matched. The industrial control computer determines the basic dwell time of the arc at the target positions on the left and right side walls based on the bevel cross-sectional profile, the target positions on the left and right side walls, the preset side wall fusion requirements, and a pre-established dwell time process parameter table. During welding, the industrial control computer corrects the basic dwell time based on the molten pool images acquired by the molten pool vision inspection component. Simultaneously, the industrial control computer calculates the dynamic filler wire amount based on the bevel cross-sectional area and welding speed. Preset bevel width threshold and ,and < ,in, The maximum bevel width is required to ensure that the maximum lateral oscillation amplitude of the magnetically controlled arc can meet the target position requirements on the left and right side walls without superimposed mechanical lateral displacement. The maximum bevel width that can meet the target position requirements of the left and right side walls after the combination of magnetic swing and lateral mechanical displacement of Y-axis electric guide rail.

3. The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system according to claim 1, characterized in that: In this system, the arc oscillation mode and sidewall dwell time are controlled by a magnetic field-based arc trajectory control method. This method uses an excitation coil, a weld pool vision inspection component, and an industrial control computer to collaboratively adjust the amplitude, polarity, frequency, and timing of the excitation current, achieving coordinated control of the arc's lateral oscillation amplitude, oscillation response time, and sidewall dwell time. The excitation coil is arranged on both sides of the welding torch, and its arrangement direction creates an alternating magnetic field in the arc region along the weld direction or its opposite direction. By changing the polarity of the excitation current, the arc deflection direction is changed, achieving alternating deflection of the arc towards the left and right sidewall target positions. A preset bevel width threshold range is used; when the structured light camera detects the bevel width... At that time, the industrial control computer adjusts the lateral swing amplitude of the left and right targets. Call the swing parameter calibration table to determine the excitation current amplitude. and excitation frequency This allows the electric arc to reach the target positions on the left and right side walls solely through magnetic control, and to remain in place according to the base dwell time. Stay at the corresponding side wall target position; when At that time, the industrial control computer is based on Based on the determined excitation current amplitude, the excitation current timing is further adjusted so that the arc oscillates periodically according to the pattern of stopping at the target position on the left side wall, transitioning to the middle, and stopping at the target position on the right side wall; the oscillation period T includes the response time for the arc to deflect from the middle region to the target position on the left side wall. Dwell time on the left side wall The transition time of the electric arc from the target position on the left wall to the target position on the right wall. and the time spent on the right side wall When it is necessary to limit the heat input in the middle of the weld, the industrial control computer controls the duration of the electric arc's action in the middle region of the weld. Make individual settings or corrections; when During this process, the industrial control computer segments the oscillation period T, adjusts the lateral position of the welding torch via the Y-axis electric guide rail, and adjusts the lateral deflection of the arc relative to the welding torch via the magnetic field generator. This ensures that the lateral displacement of the welding torch and the magnetic deflection of the arc together meet the target position requirements of the left and right side walls. In the above oscillation control process, the timing start point for the side wall dwell time is either after the arc completes the corresponding lateral deflection and reaches the target position of the side wall, or it is the pre-calibrated arc response time. After completion; if the excitation frequency If the excitation frequency is too high and the arc fails to reach the target position, the industrial control computer reduces the excitation frequency or extends the corresponding transition time to ensure that the arc reaches the target position before entering the sidewall dwell stage. The molten pool vision inspection component acquires molten pool images in real time and transmits them to the industrial control computer, which then extracts the molten pool area near the sidewall. and the target molten pool area Comparison and dynamic correction of the actual residence time of the arc :when At that time, the dwell time at the target position on the corresponding side wall is increased; When the area or height of the molten pool in the middle region of the weld exceeds the preset state, the industrial control computer reduces the time the electric arc acts in the middle region of the weld.

4. The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system according to claim 1, characterized in that: The system utilizes a hot wire feeding mechanism to achieve continuous wire feeding, wire end position adjustment, and wire filling position control. It also forms a dynamic quantitative wire feeding closed-loop control system through a weld pool vision inspection component, an industrial computer, and the hot wire feeding mechanism. The mounting frame of the wire feeding unit is located on one side of the frame, and the mounting frame is equipped with a wire reel, a servo motor, a wire feeding wheel assembly, and a wire guide nozzle. The welding wire is drawn from the wire reel, passes through the wire feeding wheel assembly and the wire guide nozzle, and enters the wire feeding tube of the hot wire heating unit. The Z-axis precision guide rail of the hot wire heating unit is fixed to the mounting frame, and the Z-axis precision guide rail has a slide... A Y-axis precision guide rail is fixed, and a wire feeding angle adjuster is fixed on the slide of the Y-axis precision guide rail. The wire feeding tube is hinged to the wire feeding angle adjuster via a rotating shaft and can rotate around the shaft to adjust the wire feeding angle. An electromagnetic induction heater is fixed at the wire inlet end of the wire feeding tube, and a temperature sensor is fixed on the outside of the wire feeding tube. The molten pool vision inspection component acquires images of the molten pool and deposited metal contour in real time. The industrial control computer calculates the target deposited cross-sectional area based on the bevel cross-sectional area, welding speed, and preset filling ratio, and extracts the actual molten pool width based on the molten pool and deposited metal contour images. Actual molten pool height or actual weld cross-sectional area The industrial control computer will display the actual weld cross-sectional area. With the target weld cross-sectional area By comparison, the deviation of the weld cross-sectional area is obtained. The servo motor speed in the wire feeding unit is adjusted according to the weld cross-sectional area deviation ΔS to regulate the wire feeding speed. When ΔS is greater than the preset allowable deviation, the industrial control computer increases the wire feeding speed. When ΔS is less than the negative preset allowable deviation, the industrial control computer decreases the wire feeding speed. When ΔS is within the preset allowable deviation range, the industrial control computer maintains the current wire feeding speed.

5. The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system according to claim 1, characterized in that: The system, based on adjusting the wire feed speed according to the weld cross-sectional area deviation, further detects the liquid bridge state at the end of the welding wire using a weld pool vision inspection component, and compensates and corrects the wire feed speed according to the stability of the liquid bridge; during welding, the industrial control computer dynamically adjusts the wire feed amount. Set initial wire feed speed The vision inspection camera in the weld pool vision inspection component detects the actual wire feeding position and the transition state of the filler metal at the end of the welding wire in real time, and uses a vision algorithm to extract the length of the liquid bridge. With liquid bridge diameter Calculate the stability evaluation value of the liquid bridge ; Preset liquid bridge stability threshold range ,when When the stability evaluation value of the liquid bridge falls below the lower limit of the preset stability range, the industrial control computer generates a negative speed compensation command to adjust the actual wire feeding speed. Decrease; when When the stability evaluation value of the liquid bridge exceeds the upper limit of the preset stability range, the industrial control computer generates a positive speed compensation command, causing... Increase; when At that time, the stability evaluation value of the liquid bridge was within the preset stability range, and maintained. .

6. The magnetically controlled GTAW asymmetric narrow gap weld dynamic quantitative hot wire feeding welding system according to claim 1, characterized in that: In this system, the synergy between hot wire temperature, heating current, and wire feeding speed is controlled by an adaptive wire feeding speed closed-loop control method. This method adjusts the heating current using a temperature sensor, an industrial computer, and an electromagnetic induction heater to achieve closed-loop control of the hot wire temperature. The electromagnetic induction heater is fixed to the wire inlet end of the wire feeding tube and generates an alternating magnetic field on the welding wire passing through the tube, inducing eddy currents in the wire for heating. The temperature sensor is fixed to the outside of the wire feeding tube to detect the actual temperature of the welding wire before it enters the molten pool in real time. The data is then fed back to the industrial control computer; the industrial control computer calculates the temperature difference. ,according to The heating current of the electromagnetic induction heater is adjusted by a closed-loop control system. Increase when ΔT>0 Decrease when ΔT < 0 The heating current With wire feeding speed Adaptive adjustment: when When the size increases, the industrial control computer increases synchronously. This ensures that the preheating state of the welding wire per unit length is maintained within a preset range, achieving synergy between hot wire heating and dynamic wire feeding speed.

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