Welding process tuning method for adaptive laser hybrid welding, and use thereof

Abstract

A welding process tuning method for adaptive laser hybrid welding, comprising: establishing a visualized digital platform of a welding process; extracting information of a product, the information comprising: plate thickness, length, and base material; acquiring a processing status and pre-welding information of the product: within a reasonable range around a weld seam, whether a plate is polished to have metallic luster, and whether edge milling is performed; inputting initial welding data and basic welding parameters on the basis of a plate status; correcting the data to obtain basic laser parameters; setting other process parameters to obtain a passed test plate; using full-field laser to extract workpiece features, and capturing workpiece welding features to perform preliminary tuning work of adaptive welding; and arbitrarily placing a test workpiece within a certain range, and combining adaptive software and full-field laser positioning to perform tuning work of adaptive laser hybrid welding of plate seams until reliable and stable welding process parameters are obtained.

Description

An Adaptive Laser Hybrid Welding Process Debugging Method and Its Application Technical Field

[0001] This invention belongs to the field of HLW (Laser Hybid Welding) welding technology, and relates to an adaptive laser hybrid welding process debugging method and its application. Background Technology

[0002] Ship welding technology is one of the key technologies in modern shipbuilding. In shipbuilding projects, welding time accounts for approximately 30%-40% of the time spent building a single hull, and welding costs account for approximately 30%-40% of the total hull construction cost. Therefore, the level of ship welding technology directly affects the shipbuilding cycle, production costs, and product quality. In most shipyards in China, arc welding remains the primary traditional welding process, but its disadvantages are also quite obvious: it produces a lot of smoke and dust, has relatively low efficiency, and requires a large heat input, leading to severe deformation of the steel plates.

[0003] With the continuous development of the shipbuilding industry and welding technology, a high-quality and efficient welding technology is increasingly being applied in the shipbuilding industry: laser-arc hybrid welding. As one of the world's most advanced welding technologies, laser-arc hybrid welding combines numerous advantages: it utilizes the deep penetration capability of laser and the bridging ability of arc to truly achieve single-sided welding with double-sided forming, resulting in fast welding speed, high welding quality, and low welding cost; the heat-affected zone is small, effectively controlling welding deformation. This process fully leverages the advantages of both laser welding and arc welding while compensating for their respective shortcomings, improving welding quality and production processability. The application of laser hybrid welding has significantly shortened the shipbuilding cycle. However, due to technological innovation, it has also brought challenges to on-site commissioning personnel, extending the process commissioning cycle. Summary of the Invention

[0004] To address the shortcomings of the aforementioned technologies, the present invention aims to provide an advanced adaptive laser hybrid welding process method, specifically comprising the following steps:

[0005] Step 1: Establish a visualized digital platform for the welding process;

[0006] Step 2: Retrieve product information, including: sheet thickness, length, and base material;

[0007] Step 3: Obtain product pre-welding information and processing status; the product pre-welding information includes: whether the assembly work is completed, whether the grinding work is completed, and whether the product needs preheating. Among them, the splicing plate is laser-cut and only simple grinding is performed; the processing status includes: the surface grinding requirements of the plate before welding: whether the metal luster is ground out within a reasonable range around the weld, and whether the bevel is milled; the reasonable range is 20-30mm;

[0008] Step 4: Input initial welding data and basic welding parameters according to the condition of the sheet metal;

[0009] Step 5: Correct the data and obtain the basic laser parameters; the basic parameters include: initial laser power; laser emission frequency; duty cycle; pulse width; rise and fall times;

[0010] Step 6: Set other process parameters and obtain qualified test plates; the other process parameters include: setting arc welding parameters, welding torch angle; setting positioning laser parameters;

[0011] Step 7: In conjunction with full-field laser (laser positioning), capture workpiece features and welding features to perform pre-production debugging for adaptive welding;

[0012] Step 8: Place the test workpiece arbitrarily within a certain range, and combine adaptive software and full-field laser positioning to debug the adaptive laser hybrid welding of the panel seam until reliable and stable welding process parameters are obtained.

[0013] Based on the above methods, the present invention also proposes the application of the above welding process debugging method in heavy machinery manufacturing, wherein the heavy machinery is used in the fields of new energy, shipbuilding, bridges, marine engineering, and power.

[0014] The method proposed in this invention significantly shortens the debugging time and improves the progress of process development. This invention reduces the required personnel, saves manpower and time costs, and enables faster acquisition of qualified test products, thus accelerating product launch. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 is a schematic diagram of the interface of the adaptive software of the present invention.

[0017] Figure 2 is a schematic diagram of the weld surface forming of the present invention.

[0018] Figure 3 is a schematic diagram of the back-side forming of the weld of the present invention.

[0019] Figure 4 is a schematic diagram showing that when the weld value is below a certain range, the reverse side of the weld is not fused and not penetrated, resulting in welding defects.

[0020] Figure 5 is a schematic diagram showing the poor reverse side forming a hump when the laser power exceeds a certain range in the embodiment.

[0021] Figure 6 is a schematic diagram of the weld surface with excessively high parameter values ​​in Example 7.

[0022] Figure 7 is a schematic diagram of the weld surface with excessively low parameter values ​​in Example 7. Detailed Implementation

[0023] The invention will be further described in detail below with reference to the specific embodiments and accompanying drawings. Except for the contents specifically mentioned below, the processes, conditions, and experimental methods for implementing the invention are all common knowledge and general knowledge in the art, and the invention does not have any particular limitations.

[0024] This invention establishes a visualized digital model of process parameters: Information on the product workpiece is captured; the processing status of the panel is recorded (previous laser composite welding required grinding and milling of the panel). This application: Welding parameter data is input for the first welding verification test, with only the laser on, ensuring the welding speed is at a preset value, and other parameters set to 0; the laser welding power is continuously adjusted until the test plate is fully welded; other welding process parameters are sequentially set and modified for the second stage of welding process debugging, repeating this test until a test plate with acceptable appearance and flaw detection is produced; if the optimal result is not obtained during debugging, the second stage steps are repeated until the ideal welding result is obtained; based on the second stage, with the aid of a full-field laser, workpiece features are captured, and welding features are identified for adaptive welding pre-process debugging; the test workpiece is arbitrarily placed within a certain range, and the adaptive laser composite welding of the panel seam is debugged using Zhongxun's adaptive software and its self-developed full-field laser positioning, until reliable and stable welding process parameters are obtained.

[0025] Example

[0026] The key data and parameters in the adaptive laser hybrid welding process method of this embodiment include:

[0027] 1. An advanced, visualized data modeling platform;

[0028] 2. Key points of an advanced adaptive laser hybrid welding process: the welding position and initial state of the workpiece being welded;

[0029] 3. Key points of an advanced adaptive laser hybrid welding process: the workpiece assembly state and surface treatment status; the assembly state refers to whether the bevel has been milled and the dimensions of the gap between the assembled plates;

[0030] 4. Key points of an advanced adaptive laser hybrid welding process: inputting initial laser parameters and corresponding robot parameters based on the state of the sheet metal;

[0031] 5. Based on the qualified test plate, obtain the corrected laser data, including laser fiber power, focus information, and defocusing amount. The laser power P is generally set according to the plate thickness t. Generally, P = t * 1000W ± ΔP (laser compensation amount), the initial value of the defocusing amount D is 0mm, and the initial value of the filament spacing L is 0mm.

[0032] 6. After obtaining the corrected laser data based on the qualified test plate, continuously adjust the laser power ΔP while keeping the plate thickness t constant: the range of laser ΔP adjustment is 0%-35%.

[0033] 7. With the laser power unchanged and a qualified composite weldment already obtained, adjust the spot arc welding current I and voltage V. The adjustment range is ΔI: 0%-80%A, ΔV: 0%-20%V.

[0034] 8. With the arc welding parameters unchanged (current and voltage in step 7 remain unchanged after adjustment), adjust the arc micro-adjustment function △V in the robot and welding machine. The adjustment range △V is -0.5 to +0.5.

[0035] 9. With 6, 7, and 8 unchanged, adjust the defocusing amount D of the laser. The adjustment range is -5 to +5 mm.

[0036] 10. With 6, 7, 8, and 9 unchanged, adjust the distance between the laser dot and the arc welding filament. Adjustment range: 0-5mm.

[0037] 11. In addition to confirming the laser power, welding parameters, laser defocusing amount, wire spacing, and travel speed, it is also necessary to pay attention to the spot diameter Dl (generally 0.6-1.2mm) and the wire extension H (generally 10-15 times the wire diameter).

[0038] 12. With 6, 7, 8, 9, 10, and 11 unchanged, debug and obtain the parameters for laser positioning.

[0039] 13. With parameters 6, 7, 8, 9, 10, 11, and 12 unchanged, the adaptive technology is tested by continuously changing the spatial position of the welded workpiece, and relevant data is obtained. The relevant data refers to: obtaining reasonable parameters for laser positioning, the range of laser incident angles, suitable laser parameters, workpiece penetration depth, and suitable welding parameters. The test shows that when I, V, and speed remain constant in step 7, if P in step 5 is below the range value, incomplete fusion and incomplete penetration occur in the butt joint (Figure 4). When P is above the range value, the weld surface is concave, and a hump phenomenon appears on the back of the weld (Figure 5). When other parameter settings remain unchanged, if the parameters in step 7 are below or above the recommended range value, the weld surface has defects, poor appearance, and large spatter (Figures 6 and 7).

[0040] 14. After the welding tests for each thickness of steel are completed (the parameters above are confirmed), continuously change the gap value of the workpiece assembly to obtain detailed laser coverage data.

[0041] 15. The robot's posture can be adjusted using adaptive software to find the optimal shape and position for the welded product, thus achieving the best welding results. For welding in different positions, the robot will automatically match different welding postures, and the posture and spatial position of the laser head and welding torch can be easily adjusted.

[0042] 16. All relevant data acquired is stored internally by the robot and uploaded to the adaptive system. This facilitates the recording, retrieval, and application of process parameters, significantly accelerating the debugging process. The progress is approximately 20-40% faster than before.

[0043] The scope of protection of this invention is not limited to the above embodiments. Any variations and advantages that can be conceived by those skilled in the art without departing from the spirit and scope of the inventive concept are included in this invention and are protected by the appended claims.

Claims

1. A method of adaptive laser hybrid welding process commissioning, characterized in that, Includes the following steps: Step 1: Establish a visualized digital platform for the welding process; Step 2: Retrieve product information, including: sheet thickness, length, and base material; Step 3: Obtain the product's processing status and pre-welding information: The pre-welding information includes whether the assembly work is completed, whether the grinding work is completed, and whether the product needs preheating; The processing status includes whether the area around the weld has been ground to a metallic luster and whether the bevel has been milled. Step 4: Input initial welding data and basic welding parameters according to the condition of the sheet metal; Step 5: Correct the data and obtain the basic laser parameters; the basic parameters include: initial laser power; laser emission frequency; duty cycle; pulse width; rise and fall times; Step 6: Set other process parameters and obtain qualified test plates; the other process parameters include: setting arc welding parameters, welding torch angle; setting positioning laser parameters; Step 7: Use full-field laser to grasp workpiece features, capture workpiece welding features, and perform pre-production debugging for adaptive welding; Step 8: Place the test workpiece arbitrarily within a certain range, and combine adaptive software and full-field laser positioning to debug the adaptive laser hybrid welding of the splice seam until reliable and stable welding process parameters are obtained.

2. The adaptive laser hybrid welding process setup method of claim 1, wherein, In step 5, the corrected laser data, including laser fiber power, focus information, and defocus information, is obtained based on the qualified test plate.

3. The method of adaptive laser hybrid welding process setup of claim 2, wherein, The laser power P is set according to the thickness t of the plate: P = t * 1000W ± ΔP; the initial value of the defocusing amount D is 0mm; the initial value of the filament spacing L is 0mm.

4. The adaptive laser hybrid welding process setup method of claim 1, wherein, Step 6 includes the following sub-steps: Step 6-1: After obtaining the corrected laser data based on the qualified test plate, continuously adjust the laser power ΔP while keeping the plate thickness t constant: the range of laser ΔP adjustment is 0%-35%; Step 6-2: With the laser power unchanged and a qualified composite weldment already obtained, adjust the arc welding current I and voltage V, with adjustment ranges △I: 0%-80%A and △V: 0%-20%V. Step 6-3: With the arc welding current and voltage unchanged, adjust the arc micro-adjustment function ΔV in the robot and welding machine. The adjustment range of ΔV is -0.5 to +0.

5. Step 6-4: With the parameters in steps 6-1 to 6-3 unchanged, adjust the defocusing amount D of the laser. The adjustment range is -5 to +5 mm. Step 6-5: With the parameters in steps 6-1 to 6-4 unchanged, adjust the distance between the laser dot and the arc welding filament. Adjustment range: 0-5mm; Step 6-6: In addition to confirming the laser power, welding parameters, laser defocusing amount, wire spacing, and travel speed, the spot diameter Dl also needs to be adjusted to 0.6-1.2mm, and the wire extension H should be 10-15 times the wire diameter. Step 6-7: With the parameters in steps 6-1 to 6-6 unchanged, debug and obtain the parameters for laser positioning.

5. The adaptive laser hybrid welding process setup method of claim 1, wherein, In step 7, the adaptive technology is tested and relevant data is obtained by constantly changing the spatial position of the welding workpiece.

6. The adaptive laser hybrid welding process setup method of claim 1, wherein, After the welding test of each thickness of steel material, the gap value of the workpiece assembly is constantly changed to obtain detailed laser coverage data.

7. The use of the welding process commissioning method according to any one of claims 1-6 in heavy machinery manufacturing.

8. The use according to claim 7, characterized in that the heavy machinery is used in the fields of new energy, ships, bridges, marine engineering, and power.

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