钢轨窄间隙弧焊焊枪自动纠偏系统

Automatic offset correction system of narrow gap arc welding torch for rail

将窄间隙电弧焊接方法用于无缝线路钢轨焊缝的焊接,为满足焊缝两侧壁能够同时熔合,轨底窄间隙焊接采用开环控制的焊枪摆动焊接方式,导致摆动过程中焊丝端部位置出现累积误差.为消除焊枪摆动的累积误差,针对已有工艺特点,采用双视觉传感的焊枪摆动控制方法,通过采集熔池区图像,实时计算焊丝端部的摆动偏差和摆角偏差,并对焊枪摆动进行反馈控制.系统实现后进行实际焊接试验.结果表明,该方法减小了焊枪摆动偏差,较好地避免了未熔透和咬边现象发生.

Automatic narrow-gap arc welding can be used in rail welding.By oscillating and moving the bacilliform welding torch,it can join together the rails by fusing two side walls of groove.While,the swinging torch control is open-loop control,which can lead to the accumulated swing error.In order to decrease the error,a double CCD visual sensor system was used to observe the welding pool for the existing equipments and rail seam arc welding techniques.And then it calculates the position offset and oscillating angle offset of the welding wire can be calculated in real time to control the torch movement.The results show that the proposed method can effectively reduce both the position offset and the oscillating angle offset,and avoid welding defect.