CN107160048A - A kind of inline diagnosis method of the laser welding defect based on spectral information - Google Patents
A kind of inline diagnosis method of the laser welding defect based on spectral information Download PDFInfo
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本发明提出一种基于光谱信息的激光焊接缺陷的在线诊断方法,包括以下步骤:调整光纤探头的位置;采集光致等离子体信息以确定特征谱线;利用特征谱线计算光致等离子体的电子温度以获得电子温度时域图;根据待焊件的材料及尺寸,用不同的焊接参数焊接,选择使电子温度时域变化的标准差最小的参数为最优焊接参数;在上述参数下对N个待焊件进行焊接以获得N个电子温度时域图,进而获得SPC控制图;根据实际情况调整焊接参数,对待焊件进行焊接得到电子温度时域图记做测试时域图;将测试时域图实时绘入SPC控制图中,通过判断测试时域图中的各点是否超出SPC控制图的上下界限来判断焊接缺陷是否存在。上述方法能快速准确的判断激光焊接过程中是否存在缺陷。
The present invention proposes an online diagnostic method for laser welding defects based on spectral information, which includes the following steps: adjusting the position of the optical fiber probe; collecting photoplasma information to determine characteristic spectral lines; temperature to obtain the electronic temperature time-domain diagram; according to the material and size of the workpiece to be welded, use different welding parameters for welding, and select the parameter that minimizes the standard deviation of the electronic temperature time-domain change as the optimal welding parameter; under the above parameters, N Weld the pieces to be welded to obtain N electronic temperature time-domain diagrams, and then obtain the SPC control diagram; adjust the welding parameters according to the actual situation, and weld the parts to be welded to obtain the electronic temperature time-domain diagrams and record them as test time-domain diagrams; The domain diagram is drawn into the SPC control diagram in real time, and whether the welding defects exist is judged by judging whether each point in the test time domain diagram exceeds the upper and lower limits of the SPC control diagram. The above method can quickly and accurately judge whether there is a defect in the laser welding process.
Description
技术领域technical field
本发明涉及激光焊接质量在线诊断领域,尤其涉及一种基于光谱信息的激光焊接缺陷的在线诊断方法。The invention relates to the field of online diagnosis of laser welding quality, in particular to an online diagnosis method of laser welding defects based on spectral information.
背景技术Background technique
激光焊接以高能量密度的激光作为热源,使金属熔化形成焊接接头,是一种高效精密焊接方法。近年来,随着航空航天、汽车、微电子、轻工业、医疗等行业的迅速发展,产品零件的形状越来越复杂,对焊接构件的表面形状和变形的要求也越来越高,传统的焊接方法难以满足其需要,为此激光焊得到了广泛的重视。为了提高激光焊接的效率,减少焊接接头的缺陷,焊接缺陷在线诊断方法不可或缺,传统的离线检测方法费时费力还需要专业的设备与相关的操作人员。Laser welding uses a high-energy-density laser as a heat source to melt metals to form welded joints. It is an efficient and precise welding method. In recent years, with the rapid development of aerospace, automotive, microelectronics, light industry, medical and other industries, the shape of product parts has become more and more complex, and the requirements for the surface shape and deformation of welded components have become higher and higher. Traditional welding The method is difficult to meet its needs, so laser welding has received extensive attention. In order to improve the efficiency of laser welding and reduce the defects of welded joints, the online diagnosis method of welding defects is indispensable. The traditional offline detection method is time-consuming and laborious and requires professional equipment and related operators.
发明内容Contents of the invention
为了解决现有技术中存在的问题,本发明提出了一种基于光谱信息的激光焊接缺陷的在线诊断方法,以便快速准确的判断出激光焊接过程中是否存在焊接缺陷。In order to solve the problems existing in the prior art, the present invention proposes an online diagnosis method of laser welding defects based on spectral information, so as to quickly and accurately determine whether there are welding defects in the laser welding process.
为了实现上述目的,本发明提出了一种基于光谱信息的激光焊接缺陷的在线诊断方法,其中在线诊断装置包括光纤探头,所述光纤探头经光纤与光纤光谱仪相连接,所述光纤光谱仪还与计算机相连接,所述光纤探头经由机械万向杆固定在激光头上,所述方法包括以下步骤:In order to achieve the above object, the present invention proposes an online diagnostic method for laser welding defects based on spectral information, wherein the online diagnostic device includes an optical fiber probe, and the optical fiber probe is connected to a fiber optic spectrometer via an optical fiber, and the fiber optic spectrometer is also connected to a computer The optical fiber probe is fixed on the laser head via a mechanical universal rod, and the method includes the following steps:
步骤1、调整所述光纤探头的位置;Step 1, adjusting the position of the optical fiber probe;
步骤2、当激光焊接过程开始时,通过光纤探头采集激光焊接过程中产生的光致等离子体中的光信号,并将光纤光谱仪中形成的光谱信息传输至计算机中;Step 2. When the laser welding process starts, the optical signal in the photoplasma generated during the laser welding process is collected by the optical fiber probe, and the spectral information formed in the optical fiber spectrometer is transmitted to the computer;
步骤3、从计算机的显示界面上实时观察上述光谱信息的频域分布图中各谱线的相对强度随时间的波动情况,以确定作为分析对象的特征谱线;Step 3. Observing the fluctuation of the relative intensity of each spectral line in the frequency domain distribution diagram of the above-mentioned spectral information in real time from the display interface of the computer, so as to determine the characteristic spectral line as the analysis object;
步骤4、在采集过程的任意时刻,利用所选特征谱线的相对强度计算光致等离子体的电子温度,以获得电子温度随时间的变化曲线;Step 4. At any point in the collection process, calculate the electron temperature of the photoplasma by using the relative intensity of the selected characteristic spectral lines, so as to obtain the change curve of the electron temperature with time;
步骤5、根据待焊件的材料以及尺寸,使用不同的焊接参数进行焊接,选择使电子温度时域变化的标准差最小的参数作为最优焊接参数;Step 5. According to the material and size of the parts to be welded, different welding parameters are used for welding, and the parameter that minimizes the standard deviation of the electronic temperature time domain change is selected as the optimal welding parameter;
步骤6、在最优焊接参数下对N个待焊件进行焊接,通过计算机记录各待焊件在激光焊接过程中产生光致等离子体的电子温度时域图;Step 6. Welding N workpieces to be welded under optimal welding parameters, and recording the electronic temperature and time-domain diagram of the photoinduced plasma generated by each workpiece to be welded during the laser welding process through a computer;
步骤7、根据步骤6中的各电子温度时域图,获得SPC控制图;Step 7, obtain the SPC control diagram according to the time-domain diagram of each electronic temperature in step 6;
步骤8、根据实际情况调整焊接参数,对待焊件进行激光焊接;Step 8. Adjust the welding parameters according to the actual situation, and perform laser welding on the parts to be welded;
步骤9、当激光焊接过程开始时,通过光纤探头采集激光焊接过程中产生的光致等离子体中的光信号,通过光纤光谱仪将形成的光谱信息传至计算机,选取步骤3中的特征谱线作为特征谱线,通过所选特征谱线计算光致等离子体的电子温度,得到电子温度时域图,将其称作测试时域图;Step 9, when the laser welding process starts, collect the optical signal in the photoplasma produced in the laser welding process through the optical fiber probe, transmit the spectral information formed to the computer through the optical fiber spectrometer, and select the characteristic spectral line in step 3 as Characteristic spectral lines, calculate the electron temperature of the photoinduced plasma through the selected characteristic spectral lines, and obtain the time-domain diagram of the electron temperature, which is called the test time-domain diagram;
步骤10、在激光焊接的过程中,通过计算机将测试时域图实时绘入SPC控制图中,判断测试时域图中的各个点是否超出SPC控制图的上下界限;Step 10, during the laser welding process, draw the test time domain diagram into the SPC control diagram in real time by the computer, and judge whether each point in the test time domain diagram exceeds the upper and lower limits of the SPC control diagram;
步骤11、如果否,则不存在焊接缺陷;Step 11, if no, there is no welding defect;
步骤12、如果是,判断是否存在连续A个点中有连续a个点超出了SPC控制图的上下界限,其中A和a的取值取决于缺陷判断的灵敏度;Step 12, if yes, judge whether there are continuous a points in the continuous A points that exceed the upper and lower limits of the SPC control chart, wherein the values of A and a depend on the sensitivity of defect judgment;
步骤13、如果否,则不存在焊接缺陷;Step 13, if no, there is no welding defect;
步骤14、如果是,则存在焊接缺陷。Step 14, if yes, there is a welding defect.
优选的是,所述光纤探头配以COL-UV/VIS准直透镜。Preferably, the optical fiber probe is equipped with a COL-UV/VIS collimating lens.
优选的是,所述光纤光谱仪的分辨率不低于0.1nm。Preferably, the resolution of the fiber optic spectrometer is not lower than 0.1 nm.
优选的是,在所述步骤1中,将所述光纤探头设置在距激光束在待焊件上的入射点15~20cm,并且高出待焊件上表面7.5~10cm的位置,同时保证所述光纤探头采集激光焊接过程中产生的光致等离子体。Preferably, in the step 1, the optical fiber probe is set at a position 15-20 cm away from the incident point of the laser beam on the workpiece to be welded, and at a position 7.5-10 cm higher than the upper surface of the workpiece to be welded, while ensuring that the The optical fiber probe mentioned above collects the photoinduced plasma generated in the laser welding process.
优选的是,在所述步骤4中,采用玻尔兹曼图法或者二谱线法计算光致等离子体的电子温度。Preferably, in the step 4, the electron temperature of the photoplasma is calculated using the Boltzmann diagram method or the two-spectrum method.
优选的是,在所述步骤7中,获得SPC控制图包括以下步骤:Preferably, in said step 7, obtaining the SPC control chart includes the following steps:
步骤71、将所述步骤6中的N个电子温度时域图的数据分为若干子组,同一时刻不同焊道的数据为一子组;Step 71. Dividing the data of the N electronic temperature time-domain diagrams in the step 6 into several subgroups, and the data of different welding passes at the same time is a subgroup;
步骤72、对各子组内的电子温度数据求取算术平均值,将该算术平均值作为每个子组的值;Step 72, calculating the arithmetic mean value for the electronic temperature data in each subgroup, and using the arithmetic mean value as the value of each subgroup;
步骤73、对各个子组的值求取算术平均值,该算术平均值即为SPC控制图中的中心线;Step 73, calculating the arithmetic mean value for the values of each subgroup, which is the center line in the SPC control chart;
步骤74、对每个子组内的电子温度数据求取标准差,称之为子组标准差;Step 74. Calculate the standard deviation of the electronic temperature data in each subgroup, which is called the subgroup standard deviation;
步骤75、对所有的子组标准差求取算术平均值,得到整体标准差;Step 75, calculating the arithmetic mean value for all subgroup standard deviations to obtain the overall standard deviation;
步骤76、通过在中心线的值上加或者减相应倍数的整体标准差以获得SPC控制图中的控制上限或控制下限的值,其中所述倍数根据子组内样本个数查SPC控制图系数表可得。Step 76, by adding or subtracting the overall standard deviation of the corresponding multiple on the value of the central line to obtain the value of the upper control limit or the lower control limit in the SPC control chart, wherein the multiple checks the coefficient of the SPC control chart according to the number of samples in the subgroup Table available.
本发明的该方案的有益效果在于上述基于光谱信息的激光焊接缺陷的在线诊断方法建立了特定的量化标准来判断焊接过程中缺陷的存在与否,该在线诊断方法可以十分准确地获得光致等离子体的光谱信息,并快速准确的判断激光焊接过程中是否存在缺陷,以便应用于工业大批量生产中缺陷的在线诊断,并为实现缺陷种类的判断和分类打下了基础。The beneficial effect of this solution of the present invention is that the above-mentioned online diagnosis method of laser welding defects based on spectral information establishes a specific quantitative standard to judge the existence of defects in the welding process. It can quickly and accurately judge whether there are defects in the laser welding process, so as to apply to the online diagnosis of defects in industrial mass production, and lay the foundation for the judgment and classification of defect types.
附图说明Description of drawings
图1示出了本发明所涉及的在线诊断装置的原理示意图以及激光焊接系统的简图。Fig. 1 shows a schematic diagram of the principle of an online diagnostic device and a schematic diagram of a laser welding system involved in the present invention.
图2示出了本发明所涉及的在线诊断方法的步骤流程图。Fig. 2 shows a flowchart of the steps of the online diagnosis method involved in the present invention.
图3(a)至图3(d)分别示出了本发明第一实施例中的焊接接头示意图、光致等离子体相对强度与时间、波长相对应的空域图、光致等离子体电子温度随时间变化的时域图、对焊接质量进行判定的SPC控制图。Fig. 3 (a) to Fig. 3 (d) respectively show the schematic diagram of the welded joint in the first embodiment of the present invention, the relative intensity of photoinduced plasma and time, the corresponding space diagram of wavelength, the temperature of photoinduced plasma electrons with Time domain diagram of time change, SPC control diagram for judging welding quality.
图4(a)至图4(d)分别示出了理想焊缝、错边、焊穿、对接间隙变动状态下的测试时域图在SPC控制图中的分布情况。Figure 4(a) to Figure 4(d) respectively show the distribution of the test time domain diagram in the SPC control diagram under the conditions of ideal weld, misalignment, weld penetration and butt gap variation.
图5示出了本发明第二实施例中焊接接头的示意图。Fig. 5 shows a schematic diagram of a welded joint in a second embodiment of the present invention.
图6(a)和图6(b)分别示出了本发明第二实施例中的焊穿、焊道分离状态下的测试时域图在SPC控制图中的分布情况。Fig. 6(a) and Fig. 6(b) respectively show the distribution of the test time-domain diagram in the SPC control diagram under the state of weld penetration and weld bead separation in the second embodiment of the present invention.
附图标记:1-光纤光谱仪,2-计算机,3-光纤探头,4-机械万向杆,5-工作台,6-待焊件,7-激光束,8-Ar保护气,9-焊缝,10-光致等离子体,11-光纤,12-激光头,A-错边区域,B-待焊件中心减薄导致的焊穿区域,C-对接间隙变动导致未焊合区域,D-垫片,E-镀锌钢板,F-焊接速度减慢导致的焊穿区域,G-焊道分离区域。Reference signs: 1-fiber optic spectrometer, 2-computer, 3-fiber optic probe, 4-mechanical universal rod, 5-workbench, 6-piece to be welded, 7-laser beam, 8-Ar shielding gas, 9-welding seam, 10-photoplasma, 11-optical fiber, 12-laser head, A-misalignment area, B-weld-through area caused by the thinning of the center of the weldment, C-unwelded area caused by the change of butt gap, D - Spacer, E - galvanized steel sheet, F - area of weld penetration caused by slowing down of welding speed, G - area of weld bead separation.
具体实施方式detailed description
下面结合附图对本发明的具体实施方式作进一步的说明。The specific embodiments of the present invention will be further described below in conjunction with the accompanying drawings.
如图1所示,本发明所涉及的在线诊断装置包括光纤探头3,所述光纤探头3经光纤11与光纤光谱仪1相连接,所述光纤光谱仪1还与计算机2相连接;其中所述光纤探头3经由机械万向杆4固定在激光头12上,所述光纤探头3的角度和高度可以根据需求调整以便对准激光焊接过程中产生的光致等离子体采集信息。As shown in Figure 1, the online diagnostic device involved in the present invention includes a fiber optic probe 3, which is connected to a fiber optic spectrometer 1 via an optical fiber 11, and the fiber optic spectrometer 1 is also connected to a computer 2; wherein the fiber optic The probe 3 is fixed on the laser head 12 via a mechanical universal rod 4, and the angle and height of the fiber optic probe 3 can be adjusted according to requirements so as to collect information in alignment with the photoplasma generated during the laser welding process.
激光焊接系统属于现有技术,在此只给出简图进行简要说明,如图1所示,激光焊接系统包括工作台5,待焊件6放置于所述工作台5上,待焊件6两侧通过夹具(图中未示出)夹紧在工作台5上,激光束7垂直照射在待焊件6表面,熔化母材金属形成接头,实现激光焊接过程,在焊接的过程中将Ar保护气8以一定的流量进行输送,以防止焊缝9及其邻近区域在激光焊接时被氧化。The laser welding system belongs to the prior art, and only a schematic diagram is given here for a brief description. As shown in FIG. Both sides are clamped on the workbench 5 by clamps (not shown in the figure), and the laser beam 7 is irradiated vertically on the surface of the workpiece 6 to be welded, and the base material metal is melted to form a joint to realize the laser welding process. During the welding process, the Ar The shielding gas 8 is delivered at a certain flow rate to prevent the weld seam 9 and its adjacent areas from being oxidized during laser welding.
在本实施例中,所述激光束7由德国IPG Photonics公司生产的YLS-6000型光纤激光器产生,所述激光器的最大输出功率为6000W,波长为1060~1070nm,光束质量BPP≥4.0,焊接过程运动执行系统采用KUKA公司生产的KRC-60HA型六轴联动机械手,焊接时保护气体为侧向送气。所述光纤光谱仪1采用AvaSpec-ULS2048-8-USB2多通道型光纤光谱仪,该光纤光谱仪的分辨率为0.052±0.001nm,可测波长范围200~1100nm。所述光纤探头3配以COL-UV/VIS准直透镜。In this embodiment, the laser beam 7 is produced by a YLS-6000 fiber laser produced by IPG Photonics, Germany. The maximum output power of the laser is 6000W, the wavelength is 1060-1070nm, and the beam quality is BPP≥4.0. The welding process The motion execution system adopts the KRC-60HA six-axis linkage manipulator produced by KUKA Company, and the protective gas is laterally supplied during welding. The fiber optic spectrometer 1 adopts AvaSpec-ULS2048-8-USB2 multi-channel fiber optic spectrometer, the resolution of the fiber optic spectrometer is 0.052±0.001nm, and the measurable wavelength range is 200-1100nm. The fiber optic probe 3 is equipped with a COL-UV/VIS collimating lens.
本发明所涉及的基于光谱信息的激光焊接缺陷的在线诊断方法的步骤流程如图2所示,所述方法包括以下步骤:The step process of the online diagnosis method of laser welding defects based on spectral information involved in the present invention is shown in Figure 2, and the method includes the following steps:
步骤1、调整所述光纤探头3的位置。将所述光纤探头3设置在距所述激光束7在待焊件6上的入射点15~20cm,并且高出待焊件6上表面7.5~10cm的位置,同时保证所述光纤探头3的位置能够采集激光焊接过程中产生的光致等离子体10;如图2中步骤S101所示。Step 1. Adjust the position of the optical fiber probe 3 . The optical fiber probe 3 is set at a position 15-20 cm away from the incident point of the laser beam 7 on the workpiece 6 to be welded, and at a position 7.5-10 cm higher than the upper surface of the workpiece 6 to be welded, while ensuring that the optical fiber probe 3 The location is capable of collecting the photoplasma 10 generated during the laser welding process; as shown in step S101 in FIG. 2 .
步骤2、当激光焊接过程开始时,通过光纤探头3采集激光焊接过程中产生的光致等离子体10中的光信号,并将光纤光谱仪1中形成的光谱信息传输至计算机2中,如图2中步骤S102所示。在具体的采集过程中,根据待焊件6的材料以及该材料的焊接速度确定在线诊断装置的采样频率。Step 2, when the laser welding process starts, the optical signal in the photoplasma 10 generated during the laser welding process is collected by the optical fiber probe 3, and the spectral information formed in the optical fiber spectrometer 1 is transmitted to the computer 2, as shown in Figure 2 Shown in step S102. In a specific collection process, the sampling frequency of the online diagnostic device is determined according to the material of the workpiece 6 to be welded and the welding speed of the material.
步骤3、从计算机2的显示界面上实时观察上述光谱信息的频域分布图中各谱线的相对强度随时间的波动情况,以确定作为分析对象的特征谱线,如图2中步骤S103所示。其中所述特征谱线的选择有如下要求:有足够的分辨率,信噪比高,特征明显等。Step 3, observe in real time from the display interface of the computer 2 the fluctuation of the relative intensity of each spectral line in the frequency domain distribution diagram of the above-mentioned spectral information over time, so as to determine the characteristic spectral line as the analysis object, as shown in step S103 in Figure 2 Show. The selection of the characteristic spectral lines has the following requirements: sufficient resolution, high signal-to-noise ratio, and obvious features.
步骤4、在采集过程的任意时刻,利用所选特征谱线的相对强度计算光致等离子体10的电子温度,以获得电子温度随时间的变化曲线,如图2中步骤S104所示。Step 4. At any point in the collection process, calculate the electron temperature of the photoplasma 10 using the relative intensity of the selected characteristic lines to obtain a time-varying curve of the electron temperature, as shown in step S104 in FIG. 2 .
为了计算光致等离子体10的电子温度,可以采用玻尔兹曼图法或者二谱线法。其中玻尔兹曼图法是通过多条选定波长的特征谱线来计算电子温度的方法,如公式所示,其中Imn为特征谱线的相对强度(假设特征谱线由m能级向n能级的跃迁产生)、Amn为跃迁概率、gmn为统计权重、λmn为特征谱线的波长、Z为配分函数、h为普朗克常量、N为粒子的总数密度、c为光速、k为Boltzmann常数、Em为能级m的能量(以基态能级能量为零作基准)。可见以能级Em作为横坐标,以作为纵坐标,若将各选定的特征谱线的各个参数代入上述横坐标以及纵坐标,则会得到相应组数的横纵坐标(即一条特征谱线对应一组横纵坐标),用最小二乘法把这些点拟合为一条直线,其拟合出的直线斜率为这样由斜率便可以计算出电子温度T。In order to calculate the electron temperature of the photoplasma 10, the Boltzmann diagram method or the two-line method can be used. Among them, the Boltzmann diagram method is a method to calculate the electron temperature through multiple characteristic spectral lines of selected wavelengths, such as the formula , where I mn is the relative intensity of the characteristic spectral line (assuming that the characteristic spectral line is produced by the transition from m energy level to n energy level), A mn is the transition probability, g mn is the statistical weight, and λ mn is the characteristic spectral line Wavelength, Z is the partition function, h is Planck's constant, N is the total density of particles, c is the speed of light, k is the Boltzmann constant, E m is the energy of energy level m (based on the ground state energy level being zero). It can be seen that the energy level E m is taken as the abscissa, and As the ordinate, if each parameter of each selected characteristic spectral line is substituted into the above-mentioned abscissa and ordinate, the horizontal and vertical coordinates of the corresponding groups (that is, a characteristic spectral line corresponds to a group of horizontal and vertical coordinates) will be obtained. The square method fits these points into a straight line, and the slope of the fitted line is In this way, the electron temperature T can be calculated from the slope.
二谱线法是一种精度稍低但计算简单的电子温度求解方法,如公式所示,其中I为特征谱线的相对强度(其中1代表选定的第一条特征谱线,2代表选定的第二条特征谱线)、A为跃迁概率、gm为统计权重、λ为特征谱线的波长、k为Boltzmann常数、Em为能级m的能量(以基态能级能量为零作基准),可见通过二谱线法仅需同种粒子任何两条特征谱线的比值、能极差和其部分参数即可求得电子温度T。The two-spectrum method is a method of solving electron temperature with slightly lower precision but simple calculation, such as the formula , where I is the relative intensity of the characteristic spectral lines (where 1 represents the selected first characteristic spectral line, and 2 represents the selected second characteristic spectral line), A is the transition probability, g m is the statistical weight, λ is the wavelength of the characteristic spectral line, k is the Boltzmann constant, and E m is the energy of the energy level m (based on the ground state energy level being zero). It can be seen that only any two characteristic spectral lines of the same particle are required by the two-spectral method The ratio, energy range and some of its parameters can be used to obtain the electron temperature T.
步骤5、根据待焊件6的材料以及尺寸,使用不同的焊接参数进行焊接,选择使电子温度时域变化的标准差最小的参数为最优焊接参数,如图2中步骤S105所示。在最优焊接参数下进行的激光焊接能够形成良好的焊缝9,以此最优焊接参数下的激光焊接处于稳定受控状态。Step 5. According to the material and size of the workpiece 6 to be welded, different welding parameters are used for welding, and the parameter that minimizes the standard deviation of the electronic temperature time domain change is selected as the optimal welding parameter, as shown in step S105 in FIG. 2 . The laser welding performed under the optimal welding parameters can form a good weld 9, so the laser welding under the optimal welding parameters is in a stable and controlled state.
步骤6、在最优焊接参数下对N个待焊件6进行焊接,通过计算机2记录各待焊件6在激光焊接过程中产生光致等离子体10的电子温度时域图,如图2中步骤S106所示。Step 6. Weld the N pieces to be welded 6 under the optimal welding parameters, and record the electronic temperature time domain diagram of the photoinduced plasma 10 generated by each piece to be welded 6 in the laser welding process through the computer 2, as shown in Figure 2 Shown in step S106.
步骤7、根据步骤6中的各电子温度时域图,获得SPC控制图,如图2中步骤S107所示。Step 7. Obtain the SPC control diagram according to the time-domain diagram of each electron temperature in step 6, as shown in step S107 in FIG. 2 .
具体的获得SPC(Statistical Process Control,统计过程控制)控制图的过程如下:假设在最优焊接参数下对五个待焊件6进行焊接,将采集的五次焊接的电子温度时域图的数据分为若干子组,同一时刻不同焊道的数据列为一子组,从而使得不同时刻各焊道的数据分成不同的子组,从而将五次焊接得到的电子温度时域图的数据分为若干子组。例如第一次焊接采得的第一个点至第五次焊接采得的第一个点归为一子组,以此类推,在五次焊接的情况下,每个子组有五个点。The specific process of obtaining the SPC (Statistical Process Control, Statistical Process Control) control chart is as follows: Assuming that five parts to be welded 6 are welded under the optimal welding parameters, the data of the electronic temperature time-domain diagram of the five welds collected will be It is divided into several subgroups, and the data of different welding passes at the same time is listed as a subgroup, so that the data of each welding pass at different times can be divided into different subgroups, so that the data of the electronic temperature time domain map obtained by five weldings can be divided into several subgroups. For example, the first point collected in the first welding to the first point collected in the fifth welding are classified into a subgroup, and so on, in the case of five weldings, each subgroup has five points.
之后先对各子组内的电子温度数据求取算术平均值,将算术平均值作为每个子组的值,再对各个子组的值求取算术平均值,该算术平均值即为SPC控制图中的中心线;对每个子组内的数据求取标准差,称之为子组标准差,然后对所有的子组标准差求取算术平均值,可得到整体标准差。SPC控制图中的控制上限或控制下限的值通过在中心线的值上加或减一定倍数的整体标准差可得,所述倍数与子组的大小有关(子组的大小即子组内焊道的数量,在本实施例中,子组的大小为五),根据子组内样本个数(也就是焊道的个数)查SPC控制图系数表可得倍数,当子组的大小调整时,这个倍数必须随之调整,由此可得到SPC控制图的三条线。After that, calculate the arithmetic mean value of the electronic temperature data in each subgroup, use the arithmetic mean value as the value of each subgroup, and then calculate the arithmetic mean value of the values of each subgroup, and the arithmetic mean value is the SPC control chart The center line in the center line; calculate the standard deviation for the data in each subgroup, which is called the subgroup standard deviation, and then calculate the arithmetic mean for all the subgroup standard deviations to obtain the overall standard deviation. The value of the upper control limit or the lower control limit in the SPC control chart can be obtained by adding or subtracting a certain multiple of the overall standard deviation to the value of the center line, and the multiple is related to the size of the subgroup (the size of the subgroup is the weld within the subgroup The quantity of track, in the present embodiment, the size of subgroup is five), according to the number of samples in the subgroup (that is, the number of welding passes), check the SPC control chart coefficient table to get the multiple, when the size of the subgroup is adjusted , this multiple must be adjusted accordingly, and thus the three lines of the SPC control chart can be obtained.
步骤8、根据实际情况调整焊接参数,对待焊件6进行激光焊接,如图2中步骤S108所示。Step 8. Adjust the welding parameters according to the actual situation, and perform laser welding on the workpiece 6 to be welded, as shown in step S108 in FIG. 2 .
步骤9、当激光焊接过程开始时,通过光纤探头3采集激光焊接过程中产生的光致等离子体10中的光信号,通过光纤光谱仪1将形成的光谱信息传至计算机2,选取步骤3中的特征谱线作为特征谱线,通过所选特征谱线计算光致等离子体10的电子温度,得到电子温度时域图,将其称作测试时域图,如图2中步骤S109所示。其中所述在线诊断装置的采样频率与步骤2中的采样频率一致。Step 9, when the laser welding process starts, collect the optical signal in the photoplasma 10 produced in the laser welding process through the optical fiber probe 3, transmit the formed spectral information to the computer 2 through the optical fiber spectrometer 1, and select the optical signal in step 3 The characteristic spectral lines are used as the characteristic spectral lines, and the electron temperature of the photoplasma 10 is calculated through the selected characteristic spectral lines to obtain a time-domain diagram of the electron temperature, which is called a test time-domain diagram, as shown in step S109 in FIG. 2 . Wherein the sampling frequency of the online diagnostic device is consistent with the sampling frequency in step 2.
步骤10、在激光焊接的过程中,通过计算机2将测试时域图实时绘入SPC控制图中;判断测试时域图中的各个点是否超出SPC控制图的上下界限,如图2中步骤S110所示。Step 10, in the process of laser welding, by computer 2, the test time domain diagram is drawn into the SPC control diagram in real time; whether each point in the test time domain diagram exceeds the upper and lower limits of the SPC control diagram, as shown in step S110 in Figure 2 shown.
步骤11、如果否,则不存在焊接缺陷,如图2中步骤S111所示。Step 11. If not, there is no welding defect, as shown in step S111 in FIG. 2 .
步骤12、如果是,判断是否存在连续A个点中有连续a个点超出了SPC控制图的上下界限,如图2中步骤S112所示。其中,A和a的取值与缺陷判断的灵敏度有关。Step 12. If yes, judge whether there are consecutive a points among the continuous A points that exceed the upper and lower limits of the SPC control chart, as shown in step S112 in FIG. 2 . Among them, the values of A and a are related to the sensitivity of defect judgment.
步骤13、如果否,则不存在焊接缺陷,如图2中步骤S113所示。Step 13. If not, there is no welding defect, as shown in step S113 in FIG. 2 .
步骤14、如果是,则存在焊接缺陷,如图2中步骤S114所示。其中缺陷的位置与越过界限的点对应的焊缝位置相同。Step 14, if yes, there is a welding defect, as shown in step S114 in FIG. 2 . The position of the defect is the same as the position of the weld corresponding to the point crossing the limit.
实施例1Example 1
在本实施例中,所述待焊件6采用304不锈钢,待焊件6的尺寸大小为100×50×3mm,焊接接头的形式及激光焊接形成的焊缝示意图如图3(a)所示,在焊接过程中用Ar保护气8进行保护。In this embodiment, the part 6 to be welded is made of 304 stainless steel, and the size of the part 6 to be welded is 100 × 50 × 3 mm. The form of the welded joint and the schematic diagram of the weld seam formed by laser welding are shown in Figure 3 (a) , Protected with Ar shielding gas 8 during the welding process.
调整光纤探头3的位置,在激光焊接过程中,使所述光纤探头3采集波长处于200~1100nm的光致等离子体中的光信号,并将光纤光谱仪1中形成的光谱信息传输至计算机2中,通过对上述光谱信息进行比较,确定采用318~420nm谱段进行分析,从而在所选谱段中采集反映波长、时间与强度关系的空域图,如图3(b)所示。对采集得到的空域图,基于分辨率高、轮廓要好、灵敏度高、相对强度适中、谱线较近等原则,选出特征谱线FeI375.8nm、FeI384.0nm、FeI385.9nm、FeI387.2nm、FeI387.8nm、FeI388.6nm,获得焊接过程中光谱的相对强度随时间变化的时域图。根据选择的特征谱线,在光谱采集的任意时刻,通过玻尔兹曼图法计算得到电子温度,从而建立起电子温度随时间的变化曲线,如图3(c)所示。Adjust the position of the fiber optic probe 3 so that during the laser welding process, the fiber optic probe 3 collects optical signals in the photoplasma with a wavelength of 200-1100 nm, and transmits the spectral information formed in the fiber optic spectrometer 1 to the computer 2 , by comparing the above spectral information, it is determined to use the 318-420nm spectral segment for analysis, so as to collect a spatial map reflecting the relationship between wavelength, time and intensity in the selected spectral segment, as shown in Figure 3(b). For the collected airspace map, based on the principles of high resolution, good profile, high sensitivity, moderate relative intensity, and close spectral lines, the characteristic spectral lines FeI375.8nm, FeI384.0nm, FeI385.9nm, FeI387.2nm, FeI387.8nm, FeI388.6nm, obtain the time domain diagram of the relative intensity of the spectrum changing with time during the welding process. According to the selected characteristic spectral lines, at any time of spectrum collection, the electron temperature is calculated by the Boltzmann diagram method, so as to establish the electron temperature change curve with time, as shown in Fig. 3(c).
固定焊接速度v=2m/min不变,采用不同的焊接参数进行焊接,通过上述方法得到不同焊接参数下电子温度随时间变化的时域图,计算电子温度随时间变化的标准差。此时,选出焊缝表面成形良好且电子温度时域变化的标准差处于最小值时的焊接参数,视为稳定受控状态下的最优焊接参数,此时激光功率P=2600W,离焦量为+0mm,Ar保护气流量为20L/min。在最优焊接参数下对五个待焊件6进行焊接,确保焊接过程中没有受到意外扰动,且焊缝成形良好,通过计算机2记录各待焊件6在激光焊接过程中产生光致等离子体10的电子温度时域图,并根据各电子温度时域图,获得SPC控制图,如图3(d)所示。The welding speed v=2m/min is fixed, and different welding parameters are used for welding. The time-domain diagram of the electronic temperature changing with time under different welding parameters is obtained by the above method, and the standard deviation of the electronic temperature changing with time is calculated. At this time, the welding parameters when the surface of the weld seam is well formed and the standard deviation of the time-domain change of the electron temperature is at the minimum value are considered as the optimal welding parameters under stable and controlled state. At this time, the laser power P=2600W, and the defocus The volume is +0mm, and the flow rate of Ar shielding gas is 20L/min. Weld the five parts 6 to be welded under the optimal welding parameters to ensure that there is no accidental disturbance during the welding process and the weld seam is well formed. The computer 2 records the photoplasma generated by each part 6 to be welded during the laser welding process. 10 electron temperature time-domain diagram, and according to each electron temperature time-domain diagram, obtain the SPC control diagram, as shown in Fig. 3(d).
得到SPC控制图之后,通过改变焊接参数或改变待焊件6的装夹状态而刻意制造焊接缺陷,以此测试SPC控制图对焊接缺陷的判别能力。After the SPC control chart is obtained, welding defects are intentionally created by changing the welding parameters or changing the clamping state of the workpiece 6 to be welded, so as to test the discrimination ability of the SPC control chart for welding defects.
如图4(a)所示,第一条焊缝是在上述最优焊接参数下焊得的,可见其表面成形良好,在SPC控制图中可见焊接过程中的电子温度始终没有连续的点超过SPC控制图的上下界限,可见没有出现焊接缺陷,因此SPC控制图与实际焊接成型实物判断一致。As shown in Figure 4(a), the first weld was welded under the above-mentioned optimal welding parameters. It can be seen that its surface is well formed. It can be seen from the SPC control chart that the electron temperature during the welding process has no continuous point exceeding The upper and lower limits of the SPC control chart show that there are no welding defects, so the SPC control chart is consistent with the actual judgment of the actual welding forming.
改变待焊件6的装夹状态,使得待焊件6右端错边形成错边区域A,然后进行激光焊接,以模拟实际生产中装夹不合适而出现错边的情况,得到的焊缝及其对应的SPC控制图如图4(b)所示,由图可见,右端错边区域A的焊缝对应的电子温度变化明显,超出SPC控制图的上下界限。Change the clamping state of the piece to be welded 6 so that the right end of the piece to be welded 6 is staggered to form a staggered side area A, and then laser welding is performed to simulate the situation that the wrong side occurs due to improper clamping in actual production, and the obtained weld and The corresponding SPC control chart is shown in Figure 4(b). It can be seen from the figure that the electronic temperature corresponding to the weld in the wrong side area A at the right end changes significantly, exceeding the upper and lower limits of the SPC control chart.
将待焊件6中心打薄,不改变焊接参数进行激光焊接,以模拟实际生产过程中工件厚度不均匀的情况,如图4(c)所示,从焊缝图像上可见,中心区域由于打薄出现了明显的焊穿现象,即形成了待焊件中心减薄导致的焊穿区域B,而在SPC控制图中对应位置的电子温度显著超出了控制下限,表明此处发生了焊接缺陷,这与实际焊接状况相对应。The center of the workpiece 6 to be welded is thinned, and laser welding is performed without changing the welding parameters to simulate the uneven thickness of the workpiece in the actual production process. As shown in Figure 4(c), it can be seen from the weld image that the central area is due to welding There is an obvious weld-through phenomenon, that is, the weld-through area B caused by the thinning of the center of the weldment is formed, and the electron temperature at the corresponding position in the SPC control chart significantly exceeds the lower limit of control, indicating that welding defects occur here. This corresponds to the actual welding conditions.
再次改变待焊件6的装夹状态,使得对接的待焊件6对接间隙发生变化,以模拟实际生产中装夹不合适造成对接间隙的变动,然后进行激光焊接,如图4(d)所示,从焊缝图像上可见,当对接间隙过大时导致未焊合的缺陷,即形成了对接间隙变动导致未焊合区域C,而SPC控制图的对应位置有连续多个点的电子温度低于控制下限,意味着发生了焊接缺陷,这与实际焊缝成形一致。Change the clamping state of the parts to be welded 6 again, so that the butt gap of the butt parts to be welded 6 changes, so as to simulate the change of the butt gap caused by improper clamping in actual production, and then perform laser welding, as shown in Figure 4(d) It can be seen from the weld seam image that when the butt gap is too large, it will cause unwelded defects, that is, the unwelded area C is formed due to the change of the butt gap, and the corresponding position of the SPC control chart has electron temperatures at multiple points in a row Below the lower control limit, it means that a welding defect has occurred, which is consistent with the actual weld formation.
实施例2Example 2
在本实施例中,所述待焊件6采用DX51D+Z镀锌钢板E,焊接接头的形式采用预留间隙的搭接接头,也就是在焊接接头的两端分别垫有垫片D,垫片D的大小根据实际需求而定,其焊接接头及激光焊接形成的焊缝示意图如图5所示,焊接过程中采用Ar保护气进行保护。In this embodiment, the part 6 to be welded is DX51D+Z galvanized steel sheet E, and the form of the welded joint is a lap joint with a reserved gap, that is, pads D are placed on both ends of the welded joint, and the pads The size of sheet D is determined according to actual needs. The schematic diagram of the welded joint and the weld seam formed by laser welding is shown in Figure 5. Ar shielding gas is used for protection during the welding process.
固定焊接速度v=2.5m/min不变,采用不同的焊接参数进行焊接,以确定最优焊接参数,此时激光功率P=3900W,间隙值为0.2mm,离焦量为+15mm,Ar保护气流量为20L/min。在最优焊接参数下对五个待焊件6进行焊接,确保焊接过程中没有受到意外扰动,且焊缝成形良好,通过计算机2记录各待焊件6在激光焊接过程中产生光致等离子体10的电子温度时域图,并根据各电子温度时域图,获得SPC控制图。The fixed welding speed v=2.5m/min is unchanged, and different welding parameters are used for welding to determine the optimal welding parameters. At this time, the laser power P=3900W, the gap value is 0.2mm, the defocus is +15mm, Ar protection The air flow is 20L/min. Weld the five parts 6 to be welded under the optimal welding parameters to ensure that there is no accidental disturbance during the welding process and the weld seam is well formed. The computer 2 records the photoplasma generated by each part 6 to be welded during the laser welding process. 10 electronic temperature time-domain diagrams, and obtain the SPC control diagram according to each electronic temperature time-domain diagram.
得到SPC控制图之后,通过改变焊接参数或者改变装夹的状态而刻意制造焊接缺陷,测试SPC控制图对焊接缺陷的判别能力。After the SPC control chart is obtained, welding defects are deliberately created by changing the welding parameters or changing the state of the clamping, and the ability of the SPC control chart to identify welding defects is tested.
改变焊接参数使得焊缝中心区域的焊接速度降低,如图6(a)所示,从焊缝图像上可见,中心区域由于降速出现了局部烧穿的现象,即形成了焊接速度减慢导致的焊穿区域F,在SPC控制图的相应区域的电子温度显著低于控制下限,表明此处发生了焊接缺陷,这与实际焊接情况吻合。Changing the welding parameters reduces the welding speed in the central area of the weld, as shown in Figure 6(a). From the image of the weld, it can be seen that the central area has a local burn-through phenomenon due to the speed reduction, that is, the welding speed slows down. The electron temperature in the corresponding area of the SPC control chart is significantly lower than the lower control limit, indicating that welding defects have occurred here, which is consistent with the actual welding situation.
将预留间隙搭接接头的间隙值调大然后进行激光焊接,如图6(b)所示,从焊缝图像上可见,由于间隙值调大,焊缝发生了明显的焊道分离,即形成了焊道分离区域G,而在SPC控制图的多处焊道分离对应位置的电子温度显著低于控制下限,这意味着发生了焊接缺陷,可见SPC控制图的判别效果良好。Increase the gap value of the lap joint with the reserved gap and then carry out laser welding, as shown in Figure 6(b), it can be seen from the weld image that due to the large gap value, the weld bead separation has occurred obviously, that is, The weld bead separation area G is formed, and the electron temperature at the positions corresponding to multiple weld bead separations in the SPC control chart is significantly lower than the lower control limit, which means that welding defects have occurred, and the discrimination effect of the SPC control chart is good.
通过以上实施例可以得出以下结论:当测试时域图始终处于SPC控制图的上下界限之间时,无焊接缺陷产生;当测试时域图波动较大,但始终没有足够连续的点超出SPC控制图的控制上限或控制下限时,此时仍然没有焊接缺陷产生;当测试时域图有足够数量连续的点超出了SPC控制图的控制上限或控制下限时,意味着此处出现了某种形式的焊接缺陷。Through the above embodiment, the following conclusions can be drawn: when the test time-domain diagram is always between the upper and lower limits of the SPC control chart, no welding defects will occur; when the test time-domain diagram fluctuates greatly, but there are not enough continuous points beyond the SPC When the upper control limit or lower control limit of the control chart is reached, there is still no welding defect at this time; when a sufficient number of continuous points in the test time domain chart exceed the upper control limit or lower control limit of the SPC control chart, it means that some kind of welding defect has occurred here. form of welding defects.
本发明所涉及的基于光谱信息的激光焊接缺陷的在线诊断方法建立了特定的量化标准来判断焊接过程中缺陷的存在与否,该在线诊断方法可以十分准确地获得光致等离子体的光谱信息,并快速准确的判断激光焊接过程中是否存在缺陷,以便应用于工业大批量生产中缺陷的在线诊断,并为实现缺陷种类的判断和分类打下了基础。The online diagnosis method of laser welding defects based on spectral information involved in the present invention establishes specific quantitative standards to judge the existence of defects in the welding process, and the online diagnosis method can obtain the spectral information of photoplasma very accurately, And quickly and accurately judge whether there are defects in the laser welding process, so as to be applied to the online diagnosis of defects in industrial mass production, and lay a foundation for realizing the judgment and classification of defect types.
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