Realizing precision pulse TIG welding with arc length control and visual image sensing based weld detection

Methods of arc length control and visual image based weld detection for precision pulse TIG welding were investigated. With a particular all hardware circuit, arc voltage during peak current stage is sampled and integrated to indicate arc length, deviation of arc length and adjusting parameters are calculated and output to drive a step motor directly. According to the features of welding image grabbed with CCD camera, a special algorithm was developed to detect the central line of weld fast and accurately. Then an application system were established, whose static arc length error is ±0.1 mm with 20 A average current and 1 mm given arc length, static detection precision of weld is 0.01 mm , processing time of each image is less than 120 ms . Precision pulse TIG welding of some given thin stainless steel components with complicated curved surface was successfully realized.

Research on the arc length and droplet transition control strategy for the full digital pulse MIG welding power supply

Arc length stability and droplet transition consistency are key factors for the pulse metal inert gas （MIG） welding quality. A new control strategy is proposed based on pulse current waveform adjustment to stabilize the welding process. After sufficient analysis of the droplet transition process, key current waveform parameters are refined that can affect the welding quality greatly. In order to achieve the optimal nonlinear control of parameters, the fuzzy controller is designed successfully with two inputs and three outputs in field programmable gate array （ FPGA ）, which occupies fewer resources than PID controller and has higher control performance. Experimental results show that the arc length can be adjusted fast in full range of welding current, the welding process is stable, the droplet transition has good consistency, and the welding quality is perfect.

A local pseudo arc-length method for hyperbolic conservation laws

A local pseudo arc-length method（LPALM）for solving hyperbolic conservation laws is presented in this paper.The key idea of this method comes from the original arc-length method,through which the critical points are bypassed by transforming the computational space.The method is based on local changes of physical variables to choose the discontinuous stencil and introduce the pseudo arc-length parameter,and then transform the governing equations from physical space to arc-length space.In order to solve these equations in arc-length coordinate,it is necessary to combine the velocity of mesh points in the moving mesh method,and then convert the physical variable in arclength space back to physical space.Numerical examples have proved the effectiveness and generality of the new approach for linear equation,nonlinear equation and system of equations with discontinuous initial values.Non-oscillation solution can be obtained by adjusting the parameter and the mesh refinement number for problems containing both shock and rarefaction waves.

Inverse problem of elastica of a variable-arc-length beam subjected to a concentrated load

An inverse problem of elastica of a variable-arclength beam subjected to a concentrated load is investigated. The beam is fixed at one end, and can slide freely over a hinge support at the other end. The inverse problem is to determine the value of the load when the deflection of the action point of the load is given. Based on the elasitca equations and the elliptic integrals, a set of nonlinear equations for the inverse problem are derived, and an analytical solution by means of iterations and Quasi-Newton method is presented. From the results, the relationship between the loads and deflections of the loading point is obtained.

C^2 CONTINUOUS NEARLY ARC-LENGTH PARAMETERIZED CURVE

An efficient method for C2 nearly arc-length parameterized curve is presented.An idea of approximation for the arc-length function of parametric curve which interpolates CAD data points is discussed.The parameterization is implemented by using parameter transformation.Finally,two numerical examples are given.

IMPROVEMENTS ON THE ARC-LENGTH-TYPE METHOD

Arc-length-type and energy-type methods are two main strategies used in structural nonlinear tracing analysis, but the former is widely used due to the explicitness and clarity in conception, as well as the convenience and reliability in calculation. It is very important to trace the complete load-deflection path in order to know comprehensively the characteristics of structures subjected to loads. Unfortunately, the nonlinear analysis techniques are only workable for tracing the limit-point-type equilibrium path. For the bifurcation-point-type path, most of them cannot secure a satisfactory result. In this paper, main arc-length-type methods are reviewed and compared, and the possible reasons of failures in tracing analysis are briefly discussed. Some improvements are proposed, a displacement perturbation method and a force perturbation method are presented for tracing the bifurcation-point-type paths. Finally, two examples are analyzed to verify the ideas, and some conclusions are drawn with respect to the arc-length-type methods.

AN IMPROVED ARC-LENGTH METHOD AND APPLICATION IN THE POST-BUCKLING ANALYSIS FOR COMPOSITE STRUCTURES

Based on the conventional arc-length method, an improved arc-length method with high-efficiency is proposed. The weighted modifications with respect to the variation of structural stiffness and extra-interpolation modification by using the information of known equilibrium points are introduced to improve the incremental arc-length. An approximate expansion method for the accumulated and expected arc-length is used to ensure the convergence at given load levels in large range of applications. Numerical results show that the improved arc-length method has well adaptability and higher efficiency in the post-buckling analysis of plates and shells structures for tracing whole load-deflection path and obtaining the convergence values at any specified load levels.

What Projective Angle Makes the Arc-Length of the Trajectory in a Resistive Media Maximum? A Reverse Engineering Approach

We consider the motion of a massive point-like projectile thrown with initial velocity with respect to horizontal in a two-dimensional vertical plane under the influence of gravity in a viscose media. Two different velocity-dependent resistive media models are considered—linear and quadratic. With an objective to utilizing a Computer Algebra System (CAS), specifically Mathematica [1] numerically we solve the corresponding equations of motions. For a set of compatible parameters characterizing viscose forces graphically we display comparing the trajectories explicitly showing the impact of the models. Utilizing the model-dependent trajectory equations numerically we evaluate their associated arc-lengths. What distinguishes our approach vs. the existing body of work is the notion of the “reverse engineering”. Meaning, utilizing our numeric data we establish their corresponding analytic counter parts. Ultimately, utilizing both outputs numerically and analytically we determine the matching initial projectile angles maximizing their respective arc-lengths.

A simple method to extract glacier length based on Digital Elevation Model and glacier boundaries for simple basin type glacier

Glacier length is a key morphological element that has many glaciological applications; however, it is often difficult to determine, especially for glaciers that cover larger spatial areas or those that exhibit frequent temporal change. In this paper, we describe a new Arc GIS-based method that can derive glacier flow lines for determining glacier length based on digital elevation model and glacier outlines. This method involves(1) extraction of the highest and lowest points on a glacier,(2) calculation of 10-m contour lines on the glacier from 10 m to 100 m height, and(3) connection of the midpoints of each contour line with the highest and the lowest points in order to create a flow line, which is subsequently smoothed. In order to assess the reliability of this method, we tested the algorithm's results against flow lines calculated using field measurements, analysing data from the Chinese Glacier Inventory, and manual interpretation. These data showed that the new automated method is effective in deriving glacier flow lines when contour lines are relatively large; in particular, when they are between 70 m and 100 m. Nonetheless, a key limitation of the algorithm is the requirement to automatically delete repeated and closed curves in the pre-treatment processes. In addition to calculating glacier flow lines for derivation of glacier length, this method also can be used to effectively determine glacier terminus change.

Volt-ampere characteristics of a nitrogen DC plasma arc with anode melting

The characteristics of a nitrogen arc using a graphite cathode and a melting anode in a pilot-scale plasma furnace are investigated. The voltage is examined as a function of current and apparent plasma length. The voltage increases non-linearly with the increase of apparent plasma length, with the current fixed. The experimental data so obtained are compared with the predictions of the Bowman model for the electric arc, and with numerical simulations as well. The level of agreement between the experimental data at the melting anode and the numerical predictions confirms the suitability of the proposed the Bowman model. These characteristics are relevant to the engineering design and evaluation of a DC plasma furnace and reactor for the treatment of hazardous fly ash waste.

脉冲放电破岩等离子体通道长度预测方法

针对高压脉冲放电破岩电弧等离子体通道长度难以预测的问题,构建了高压脉冲放电破岩综合试验平台,测量了花岗岩-自来水组合介质下电弧等离子体通道发展特性及典型电流、电压参数,提取了不同电极间距和脉冲放电次数下岩石表面形成的破碎区域。基于能量平衡方程建立了岩石中电弧等离子体通道的阻抗模型,采用迭代优化算法获取阻抗模型参数的近似最优解,模型计算结果与试验结果的相对误差小于7%。基于优化参数,利用实测电流电压数据预测了等离子体通道的长度。模型预测的等离子体通道长度与实测值的绝对误差均处于毫米量级,且两者的相对误差小于10%,为高压脉冲放电破岩系统电源-电极负载的匹配设计提供了理论支撑。

Numerical Simulation for Shaping Feature of Molten Pool in Twin-Arc Submerged Arc Welding

The notion of ratio of width to length is proposed to describe the shaping feature of molten pool of twin-Arc submerged arc welding accurately, and analyze the law of molten pool variation and weld formation. The temperature field finite element numerical simulation model of twin arc movement is established. The loading form of twin-arc with double ellipsoid heat source is discussed. The molten pool temperature field of twin-arc submerged arc welding is calculated and analyzed under different process parameters. The law of molten pool characteristics influenced by the welding speed, current and voltage of twin-arc submerged arc welding parameters is analyzed. The relation between shaping feature of molten pool and weld formation is discussed according to the ratio of width to length. The results manifested that the width to length ratio of weld pool decreases with the improvement of welding speed, which result in gene- ration of weld defects. The width to length ratio of weld pool is increased by adjusting the proportion of the current, voltage and the distance of the two arcs, which avoids the generation of weld defects.

共旋梁单元几何非线性分析的子结构方法

采用有限元方法分析结构的非线性行为必须进行多次迭代求解,因此在保证非线性计算精度的同时提高其计算效率是关键。该文以内含2个平面梁单元的子结构为例,建立一种平面梁结构基于共旋法与子结构的几何非线性分析方法。共旋法具有将刚体位移从结构的大位移中扣除而得到准确的小变形的特点,子结构法则能将内部节点的自由度凝聚到边界节点从而大大减少结构非线性平衡方程组的阶数,该文将两者结合并利用有较好的通过荷载和位移极限点功能的修正弧长法编制了计算程序,对荷载-位移曲线具有“位移跳跃”或“荷载跌落”显著特征的数个算例进行分析,与已有文献的结果对比验证了方法及程序的正确性。

基于卡尔曼滤波的TIG焊弧长控制

【目的】TIG(Tungsten inert gas)焊过程存在钨极磨损、热变形等因素干扰,导致焊接过程焊接高度发生变化;同时前道工序焊件下料尺寸存在误差,造成焊接表面不平整,上述因素导致焊接过程中电弧长度极易发生变化,严重影响焊接质量。【方法】为了提高焊接稳定性,文中采用弧压传感方法采集弧长信息,考虑TIG焊峰值-基值交替提出TIG焊弧压预处理方法,开展弧压−弧长采集试验,确定弧压−弧长函数关系。进一步,为了克服弧压采集过程中的噪声干扰,文中采用卡尔曼滤波方法估计TIG焊弧长,建立了TIG焊卡尔曼滤波数学模型,并通过对比试验选取了卡尔曼滤波参数。在此基础上,提出了一种基于卡尔曼滤波的TIG焊弧长控制方法,准确计算弧长调节步长,并进行焊接过程弧长控制。【结果】弧长−弧压试验表明,弧长与弧压存在显著线性关系,为弧长估计提供了基础;弧长控制试验表明,通过文中基于卡尔曼滤波的弧长控制方法,焊接过程弧长标准差从0.48降低至0.305,降低36.5%。【结论】试验表明,文中所提卡尔曼滤波方法可以有效进行焊接过程弧长估计,通过焊接弧长调控可有效提高TIG焊弧长稳定性。

基于小冲杆试验的管道钢断后伸长率研究

断后伸长率是表征管材塑性的典型指标,管道局部如焊接接头处受尺寸限制无法开展单轴拉伸试验,需要借助微试样试验方法完成取样及测试。小冲杆试验作为一种微试样试验方法,能够用于获取多种力学性能参数。当前研究中,主要通过经验关联方法将载荷-位移曲线中最大位移、最大载荷对应位移及试样断后弧长等关键参量关联至材料断后伸长率。然而,上述方法对管道钢的适用性不明确,使其对管道钢材料无法直接应用。针对这一问题,首先讨论了上述基于不同特征参量的经验关联方法对管道钢的适用性,之后提供了一种断后弧长简化计算方法,并形成了适用于管道钢的基于断后弧长的经验关联公式。在此基础上,进行厚度效应修正,建立了基于小厚度试样确定管道钢材料断后伸长率的经验公式并进行可靠性验证。结果表明,基于断后弧长简化计算方法的经验关联公式确定的断后伸长率最大误差为5.08%,厚度效应修正公式对小厚度试样计算结果的最大误差为5.53%,证明建立的经验关联公式拟合效果良好且对管道钢具有良好的适用性,可为其他钢级管道局部区域断后伸长率的计算提供理论基础。

基于杆系离散元理论的结构屈曲显式弧长法研究

基于杆系离散元理论,提出了一种显式弧长法用于结构弹性屈曲全过程分析。建立了新型接触单元-铰固接触单元的本构模型,分别采用离散元法和结构力学方法对铰固接触单元在已知端部位移工况下进行受力分析,并通过端部内力相等建立方程,推导了接触刚度系数;采用动力阻尼技术简化了颗粒运动方程的求解过程,然后引入总位移约束弧长法,详细阐述了与离散元法相结合的求解策略和实施过程,并给出了相关分析参数的计算公式;通过算例验证了该方法的准确性和适用性。在追踪结构屈曲平衡路径时,该方法无需组集刚度矩阵、不涉及矩阵奇异等不收敛问题,且参数少、稳定性好,与传统有限元弧长法相比更具优越性,为结构分析提供了新的算法工具。

海洋纤维增强柔性管压溃失效特性研究及参数敏感性分析

以一种黏结型的纤维增强柔性管作为研究对象,基于ABAQUS建立纤维增强柔性管的实体单元模型。根据二维Hashin失效判据判断柔性管失效情况,充分考虑管道内外护套层塑性及纤维增强层复合材料渐进失效,建立纤维增强柔性管的压溃数值模型。将特征值法与弧长法相结合,计算得到了较为精准的纤维增强柔性管临界压溃压力及对应的外压—椭圆度曲线;并对影响柔性管临界压溃压力的几个敏感性参数如椭圆度、纤维缠绕角度、直线度进行分析。研究结果表明椭圆度和直线度偏差的增大及纤维缠绕角度的降低均会使柔性管的临界压溃压力下降,该结果对纤维增强柔性管的设计与使用均具有一定的参考意义。

温度边界条件对平面壁板热屈曲行为的影响研究

以高超声速飞行器为代表的高速航空器在飞行过程中其壁板结构易发生屈曲失稳,这种屈曲失稳与热效应紧密相关,因此温度边界条件会对结构的屈曲行为产生影响。本文通过一套自主设计的试验夹具,结合基于热力顺序耦合方式的静力弧长算法,研究了不同温度边界条件对平板屈曲行为的影响。结果表明,边界温度会显著影响极限屈曲载荷,且影响程度与力学边界条件相关;当边界与域内存在负温差(边界温度低于域内温度)时,温度影响的敏感程度更高;相比之下,边界温度影响区的宽度对壁板屈曲行为的影响较小。本文可为复杂壁板结构热屈曲行为的深入研究提供一定的参考依据。

子午线弧长正解展开通式及数学分析

子午线弧长公式通常表示为大地纬度B的级数展开式,其系数以第一偏心率e为参数,本文利用第三扁率n对公式进行重新推导,并将其表示为三角函数的3种形式:倍角形式、指数形式和二倍角形式。重新推导的公式中各系数中的分母值都明显变小,个别高阶项系数消失,结构简单、形式简洁。基于此,对3种表示形式的8阶展开式和10阶展开式进行截断误差分析,结果表明3种表示形式的8阶展开式精度最低也有毫米级,能满足日常的使用场景,而10阶展开式精度提高了至少2个数量级,能满足高精度的使用场景。在高精度的使用场景下,不同表示形式的子午线弧长公式具有不同的实用性,分析表明在0°N—30°N低纬度地区推荐使用三角函数的指数形式,在30°N—55°N中纬度地区推荐使用三角函数的二倍角形式,而在55°N—90°N高纬度地区推荐使用三角函数的倍角形式。

船用高强钢GMAW-P脉冲焊接参数对电弧弧长的影响研究

对690 MPa级船用结构钢GMAW-P脉冲焊接过程电弧行为进行研究,分析了脉冲参数对电弧长度的影响。一脉一滴所在的弧长区间为3~6 mm,一脉多滴所在的弧长区间为5~8 mm,一脉一滴到一脉多滴的过渡区为5~6 mm,短路过渡弧长小于2 mm。脉冲时间上升,弧长增长;脉冲电流上升,弧长呈先上升后下降趋势;脉冲频率增大,弧长变长;基值电流升高,弧长减小。