脉冲熔化极气体保护焊熔池的视觉传感与实时控制

Visual Sensing and Real-Time Control of Weld Pool Dynamics in Pulsed GMAW

研究对脉冲熔化极气体保护焊 (GMAW )熔池过程采用视觉传感与实时控制方法的可行性问题。由于GMAW过程的熔滴过渡现象的复杂性 ,尝试模拟焊工通过观察熔池变化等因素来调整焊接参数获取满意的焊缝成形的行为。建立了脉冲GMAW过程熔池视觉传感系统 ,宏观上将熔滴过渡对熔池特征的影响作为黑箱过程处理 ,根据脉冲GMAW弧光光谱分布和熔池图像特征提取 ,实现对脉冲GMAW熔池动态过程的实时检测。采用辨识算法建立焊接动态过程的数学模型 ,进而设计脉冲GMAW熔宽的PID控制器 ,实现对脉冲GMAW熔池宽度的实时控制。试验表明 ,建立的视觉传感系统。

The paper addresses the feasibility of visual sensing and real-time control of weld pool dynamics in pulsed GMAW. Because of the complexity of fuse dripping transition on pulsed GMAW, this method simulates welder to observe welding pool's changes and regulate the welding parameters to control welding seam figuration. The visual sensing system was established for monitoring welding pool variety. The fuse dripping transition influences on the welding pool size were considered as black-box process for simplifying complexity, and by using arc spectrum distribution of pulsed GMAW and image processing the welding pool characters are picked up, and the real-time detecting of welding pool dynamics in pulsed GMAW was realized. The model of weld pool dynamical process was be presented in this paper by identification algorithm, and then the PID controller was designed for real-time control of weld bead width during pulsed GMAW. The experiments show that the real-time and precision requirements for detecting and control of weld pool changes and bead width of pulsed GMAW could be satisfied by developed image processing and control algorithm on the established systems.