变坡口窄间隙摇动电弧脉冲焊接方法及适应控制

项目名称： 变坡口窄间隙摇动电弧脉冲焊接方法及适应控制

项目编号： No.51475218

项目类型： 面上项目

立项/批准年度： 2015

项目学科： 机械、仪表工业

项目作者： 王加友

作者单位： 江苏科技大学

项目金额： 80万元

中文摘要： 本项目提出一种变坡口窄间隙摇动电弧脉冲焊接方法，通过红外被动视觉与摇动电弧复合传感方式检测焊接坡口位置和间隙大小，实时控制电弧摇动、焊炬位置以及焊接熔敷量，使空心轴电机驱动的微弯导电杆式摇动电弧能自动适应坡口环境变化，并运用电弧摇动与脉冲焊接电流的协同控制效应，让坡口两侧壁获得足够热输入，以形成均匀稳定的焊缝高度和侧壁熔深。着重研究坡口侧壁熔深控制方法、电弧摇动和焊接熔敷量的适应控制方法、焊缝跟踪的红外视觉与摇动电弧复合传感检测方法及控制算法，研究摇动电弧产热特性和电弧力分布规律并进行数学表征，研究电弧摇动工艺参数对熔滴过渡行为、熔池流动特性、焊缝凝固成形、接头组织性能的影响规律，分析摇动电弧焊接适应控制的实时性和有效性，建立变坡口摇动电弧窄间隙GMA焊接的理论基础，促进高效及智能化焊接理论与技术的发展。

中文关键词： 窄间隙焊接；焊接自动化；摇动电弧；视觉传感；电弧传感

英文摘要： This project proposes a novel process of swing arc narrow gap pulsed welding for variable groove. A mechanism of micro-bent conductive rod, driven by hollow-axis stepping motor, is designed to weave the arc circularly. To control in real time arc swing, torch position and deposited metal volume, this system detects the position and gap value of narrow welding groove by a composite manner of infrared passive visual sensing and swing arc sensing, thus adapting the swing arc to a varying groove automatically. This adaptive control, together with the synergetic control effects of arc swing with pulsed arc current, will contribute to the enough heat input into groove sidewalls, and finally to the even and steady height and sidewall penetration of weld. This research will be focused on the control methods of sidewall penetration, arc swing and deposited metal volume, and the control algorithm and the visual and arc sensing detection techniques of seam tracking. In addition, it will reveal the characteristics and their mathematical expressions of arc heat production and arc force, investigate the effects of arc swing process parameters on the metal transfer behavior, molten metal flow, weld formation and the microstructure and properties of joint, and analyze the effectiveness and realtime performance for the adaptive control of the swing arc welding process. The above work will help to establish the theoretical fundamentals of narrow gap swing arc GMA welding for variable groove, and to promote the developments of high-efficiency and intelligent welding theory and technology.

英文关键词： narrow gap welding;welding automation;swing arc;visual sensing;arc sensing