CN116818810A - Welding defect detection method and welding defect detection device - Google Patents
Welding defect detection method and welding defect detection device Download PDFInfo
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- CN116818810A CN116818810A CN202310781282.2A CN202310781282A CN116818810A CN 116818810 A CN116818810 A CN 116818810A CN 202310781282 A CN202310781282 A CN 202310781282A CN 116818810 A CN116818810 A CN 116818810A
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- 238000003466 welding Methods 0.000 title claims abstract description 219
- 230000007547 defect Effects 0.000 title claims abstract description 97
- 238000001514 detection method Methods 0.000 title claims abstract description 36
- 230000007246 mechanism Effects 0.000 claims abstract description 45
- HSFWRNGVRCDJHI-UHFFFAOYSA-N Acetylene Chemical compound C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 26
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 30
- 229910052802 copper Inorganic materials 0.000 claims description 30
- 239000010949 copper Substances 0.000 claims description 30
- 229910001220 stainless steel Inorganic materials 0.000 claims description 27
- 239000010935 stainless steel Substances 0.000 claims description 27
- 238000004378 air conditioning Methods 0.000 claims description 22
- 230000015654 memory Effects 0.000 claims description 21
- 238000010438 heat treatment Methods 0.000 claims description 17
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 16
- 229910000679 solder Inorganic materials 0.000 claims description 15
- 238000005219 brazing Methods 0.000 claims description 10
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 8
- 229910052757 nitrogen Inorganic materials 0.000 claims description 8
- 239000001301 oxygen Substances 0.000 claims description 8
- 229910052760 oxygen Inorganic materials 0.000 claims description 8
- 230000007935 neutral effect Effects 0.000 claims description 7
- 238000012545 processing Methods 0.000 claims description 6
- 238000012544 monitoring process Methods 0.000 claims description 3
- 239000003507 refrigerant Substances 0.000 abstract description 11
- 238000012797 qualification Methods 0.000 abstract description 10
- 230000008439 repair process Effects 0.000 abstract description 6
- 230000035515 penetration Effects 0.000 description 11
- 230000008569 process Effects 0.000 description 8
- 238000003860 storage Methods 0.000 description 8
- 238000005493 welding type Methods 0.000 description 5
- 230000008859 change Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000000903 blocking effect Effects 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000010295 mobile communication Methods 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
- G01N23/04—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and forming images of the material
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Abstract
The invention relates to the technical field of welding, and discloses a method and a device for detecting welding defects, wherein the method comprises the following steps: before welding a workpiece, performing X-ray scanning on a welding area of the workpiece, and judging whether the workpiece is qualified to be installed or not; after the workpiece is installed to be qualified, detecting parameters of a welding wire mechanism and a welding gas mechanism; if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range, welding is carried out; after welding the workpiece, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect. According to the embodiment of the invention, the welding defects are identified through X-ray detection, so that the welding defects can be accurately detected, and further, technicians can set targeted repair measures according to the types of the welding defects, thereby avoiding the conditions of air conditioner refrigerant leakage, blockage and the like, and greatly improving the qualification rate of products.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a method and a device for detecting welding defects.
Background
In the air conditioning field, the stainless steel four-way valve gradually replaces a copper four-way valve, but the whole machine is connected with the stainless steel welding process in a welding process, and defects generated at the connecting position are not easy to be found manually. The current detection location is usually at a post-welding station, such as a leak detection station and a test station. However, the leak detection post and the test post can only detect refrigerant and welding and blocking defects, and other defects are as follows: defects such as bubbles and insufficient penetration cannot be detected manually.
Because the defects of bubble formation, insufficient penetration and the like can not be detected manually, the conditions of air conditioner refrigerant leakage, blockage and the like are extremely easy to cause.
Disclosure of Invention
In view of the above, the present invention provides a method and a device for detecting welding defects, so as to solve the problem that defects such as bubbles and insufficient penetration cannot be detected manually.
In a first aspect, the present invention provides a method for detecting a welding defect, the method comprising:
before welding a workpiece, performing X-ray scanning on a welding area of the workpiece, and judging whether the workpiece is qualified to be installed or not;
after the workpiece is installed to be qualified, detecting parameters of a welding wire mechanism and a welding gas mechanism;
if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range, welding is carried out;
after welding the workpiece, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect.
The beneficial effects are that: according to the embodiment of the invention, the welding defects are identified through X-ray detection, so that the welding defects can be accurately detected, and further, technicians can set targeted repair measures according to the types of the welding defects, thereby avoiding the conditions of air conditioner refrigerant leakage, blockage and the like, and greatly improving the qualification rate of products.
In an alternative embodiment, the parameter detecting the welding gas mechanism includes:
acquiring the actual pressure of welding gas, oxygen and nitrogen;
judging whether the actual pressures of welding gas, oxygen and nitrogen are all in a normal pressure interval;
if yes, parameter detection is carried out on the welding wire mechanism.
In an alternative embodiment, the detecting the parameter of the welding wire mechanism includes:
acquiring the actual position of the solder;
judging whether the solder is at a preset mounting position or not;
if yes, the welding point is preheated, and welding is prepared.
In an alternative embodiment, when welding, comprising:
when starting welding, the welding gun starts to ignite;
automatically adjusting the brazing flame to be neutral flame;
and simultaneously temperature monitoring of the welded area.
In an alternative embodiment, the neutral flame has an inner flame length of 30 to 40mm.
In an alternative embodiment, the flame is uniformly heated by swinging downwards along a zigzag path.
In an alternative embodiment, when the workpiece is a stainless steel four-way valve and an air-conditioning copper pipe, the welding wire is connected when the air-conditioning copper pipe is heated to be dark red, namely, the temperature reaches 550-580 ℃.
In an alternative embodiment, when the outer diameter of the inner pipe is phi 9, the heating time is 1.5-2.5S; when the outer diameter of the inner pipe is phi 12, the heating time is 3.5-4.5S.
In a second aspect, the present invention also provides a device for detecting a welding defect, the device comprising:
the X-ray module is used for carrying out X-ray scanning on a welding area of the workpiece before welding the workpiece; after welding the workpiece, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect;
the processing module is used for judging whether the workpiece is qualified to be installed or not;
the detection module is used for detecting parameters of the welding wire mechanism and the welding gas mechanism after the workpiece is installed to be qualified;
and the welding module is used for welding if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range.
In a third aspect, the present invention also provides an electronic device, including: the detection method according to any one of the above embodiments is implemented by the processor executing the computer instructions.
In a fourth aspect, the present invention also provides a computer readable storage medium storing computer instructions for causing the computer to perform the detection method according to any one of the above embodiments.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a welding defect detecting apparatus according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a method for detecting welding defects according to an embodiment of the present invention;
FIG. 3 is a schematic illustration of a current gray scale image of a workpiece;
FIG. 4 is a schematic view of a workpiece welding area;
FIG. 5 is a gray scale image of a workpiece with large single side gap in an embodiment of the invention;
FIG. 6 is a gray scale image of a workpiece not in place in an embodiment of the invention;
FIG. 7 is a gray scale image of a workpiece having flash and bubbles therein in accordance with an embodiment of the present invention;
FIG. 8 is a gray scale image of insufficient penetration in a workpiece according to an embodiment of the invention;
fig. 9 is a gray scale image of a weld plug in a workpiece according to an embodiment of the invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the air conditioning field, the stainless steel four-way valve gradually replaces a copper four-way valve, but the whole machine is connected with the stainless steel welding process in a welding process, and defects generated at the connecting position are not easy to be found manually. The current detection location is usually at a post-welding station, such as a leak detection station and a test station. However, the leak detection post and the test post can only detect refrigerant and welding and blocking defects, and other defects are as follows: defects such as bubbles and insufficient penetration cannot be detected manually.
Because the defects of bubble formation, insufficient penetration and the like can not be detected manually, the conditions of air conditioner refrigerant leakage, blockage and the like are extremely easy to cause.
In view of the above, the present invention provides a method and a device for detecting welding defects, so as to solve the problem that defects such as bubbles and insufficient penetration cannot be detected manually.
An embodiment of the present invention is described below with reference to fig. 1 to 9.
According to an embodiment of the present invention, in one aspect, the present invention provides a method for detecting a welding defect, including:
s00, before welding a workpiece, performing X-ray scanning on a welding area of the workpiece, and judging whether the workpiece is qualified to be installed or not;
in the practical application process, first, the workpieces to be welded need to be assembled, for example, in the embodiment, a stainless steel four-way valve and an air-conditioning copper pipe are exemplified. Because stainless steel cross valve and air conditioner copper pipe are spare part, when depositing in the warehouse, can not appear the flaw, so need select stainless steel cross valve and air conditioner copper pipe before the welding among the prior art, select and pass the back and just can weld. Before the stainless steel four-way valve and the air-conditioning copper pipe are welded, the stainless steel four-way valve and the air-conditioning copper pipe are required to be assembled. The welding is performed after the assembly is completed.
And the X-ray scanning is carried out on the welding area of the workpiece before the workpiece is welded, so as to judge whether the stainless steel four-way valve and the air-conditioning copper pipe have defects, whether the assembly of the stainless steel four-way valve and the air-conditioning copper pipe is qualified, and whether the selected stainless steel four-way valve and the air-conditioning copper pipe meet the size requirement of the installed parts.
After all the conditions are met, the welding of the stainless steel four-way valve and the air conditioner copper pipe is started.
By means of the arrangement, the welding defect is identified through X-ray detection, whether the workpiece is qualified or not can be accurately detected, so that the conditions of air conditioner refrigerant leakage, blockage and the like can be avoided, and the qualification rate of products is greatly improved.
S01, after the workpiece is installed to be qualified before welding, detecting parameters of a welding wire mechanism and a welding gas mechanism;
the parameters of the welding wire mechanism and the welding gas mechanism are detected, and the parameters can be, for example, the working temperature, the working voltage of the welding wire mechanism, the gas temperature, the gas concentration, the air-fuel ratio and the like of the welding gas mechanism. Of course, the present embodiment is merely to illustrate parameters, but is not limited thereto, and those skilled in the art can change the parameters according to actual situations, and can achieve the same technical effects.
And S02, if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range, welding is carried out.
And if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range, indicating that all equipment is normal, and welding can be performed.
S03, after the workpiece is welded, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect.
After the welding is completed, the whole welded workpiece is also required to be scanned by X-rays. Likewise, the type of welding defect can be scanned directly by X-rays. The characteristic points of the welding defects can be directly scanned by X rays, so that the types of the welding defects can be obtained through the characteristic points.
By means of the arrangement, the welding defect is identified through X-ray detection, the welding defect can be accurately detected, and further, a technician can set targeted repair measures according to the type of the welding defect, so that conditions of air conditioner refrigerant leakage, blockage and the like can be avoided, and meanwhile, the qualification rate of products is greatly improved.
In an alternative embodiment, the parameter detecting the welding gas mechanism in S01 includes:
s011, acquiring the actual pressure of welding gas, oxygen and nitrogen;
s012, judging whether the actual pressures of the welding gas, oxygen and nitrogen are all in a normal pressure range;
and S013, if yes, detecting parameters of the welding wire mechanism.
The actual pressure of welding gas, oxygen and nitrogen is obtained, and whether the pressure A of liquefied gas is between 0.06Mpa and 0.1Mpa, the pressure B of oxygen is between 0.4Mpa and 0.7Mpa, and the pressure C of nitrogen filling is between 0.1Mpa and 0.2Mpa is detected. If all the welding gas mechanisms are normal, parameter detection is started on the welding wire mechanism.
In an alternative embodiment, the detecting the parameter of the wire welding mechanism in S013 includes:
s0131, acquiring the actual position of the solder;
s0132, judging whether the solder is at a preset mounting position or not;
and S0133, if yes, preheating a welding point and preparing for welding.
And detecting whether the solder is installed in place or not, and whether the operation has a clamping phenomenon or not. If the solder is actually in place, indicating that the device is normal, the solder at the solder joint may be preheated in preparation for soldering.
In an alternative embodiment, after S02, when welding, the method includes:
s03, when welding is started, a welding gun starts to ignite;
s04, automatically adjusting the brazing flame to be neutral flame;
and S05, simultaneously monitoring the temperature of the welding area.
In an alternative embodiment, the neutral flame has an inner flame length of 30 to 40mm.
In an alternative embodiment, the flame is uniformly heated by swinging downwards along a zigzag path. The area is 5mm above the solder joint to 5mm below the solder joint.
In an alternative embodiment, when the workpiece is a stainless steel four-way valve and an air-conditioning copper pipe, the welding wire is connected when the air-conditioning copper pipe is heated to be dark red, namely, the temperature reaches 550-580 ℃.
In an alternative embodiment, when the outer diameter of the inner pipe is phi 9, the heating time is 1.5-2.5S; when the outer diameter of the inner pipe is phi 12, the heating time is 3.5-4.5S.
The welding gun starts to ignite during welding, the brazing flame is automatically regulated to be neutral flame, the length of the flame inner flame is 30-40 mm, a point thermometer monitors the temperature of a welding copper area at the same time, and when copper is heated to be dark red, namely, the temperature reaches 550-580 ℃ and welding wires can be fed in; simultaneously, the flame swings downwards to uniformly heat by adopting a Z-shaped route, and the area is from 5mm at the upper side of the brazing seam to 5mm at the lower side of the brazing seam; heating time: the pipe heating time of the outer diameter phi 9 of the inner pipe is 1.5-2.5S, and the pipe heating time of the outer diameter phi 12 of the inner pipe is 3.5-4.5S.
In an alternative embodiment, the detection method further comprises:
s10, before and after welding a workpiece, performing X-ray scanning on a welding area of the workpiece to obtain a current gray level image of the workpiece;
s20, determining the type of the welding defect in the current gray level image based on the current gray level image.
In the practical application process, first, the workpieces to be welded need to be assembled, for example, in the embodiment, a stainless steel four-way valve and an air-conditioning copper pipe are exemplified. Because stainless steel cross valve and air conditioner copper pipe are spare part, when depositing in the warehouse, can not appear the flaw, so need select stainless steel cross valve and air conditioner copper pipe before the welding among the prior art, select and pass the back and just can weld. Before the stainless steel four-way valve and the air-conditioning copper pipe are welded, the stainless steel four-way valve and the air-conditioning copper pipe are required to be assembled. The welding is performed after the assembly is completed.
And the X-ray scanning is carried out on the welding area of the workpiece before the workpiece is welded, so as to judge whether the stainless steel four-way valve and the air-conditioning copper pipe have defects, whether the assembly of the stainless steel four-way valve and the air-conditioning copper pipe is qualified, and whether the selected stainless steel four-way valve and the air-conditioning copper pipe meet the size requirement of the installed parts. After the current gray level image is obtained, the current gray level image can be compared with the calibrated gray level image, and whether flaws exist, whether assembly is qualified or not and whether the size requirement is met can be directly identified from the current gray level image.
After all the conditions are met, the welding of the stainless steel four-way valve and the air conditioner copper pipe is started. After the welding is completed, the whole welded workpiece is also required to be subjected to X-ray scanning, so that the current gray level image is obtained. Likewise, after the current gray level image is obtained, the current gray level image can be compared with the calibrated gray level image to obtain the type of the welding defect. The characteristic points of the welding defects can be identified directly from the current gray level image, so that the types of the welding defects can be obtained through the characteristic points.
By means of the arrangement, the welding defect can be accurately detected by means of X-ray detection and the identification of the welding defect by combining with the current gray level image, and further, a technician can set targeted repair measures according to the type of the welding defect, so that conditions of air conditioner refrigerant leakage, blockage and the like can be avoided, and meanwhile, the qualification rate of products is greatly improved.
In an alternative embodiment, in step S10, the X-ray scanning the welding area of the workpiece includes:
s101, dividing the welding area into a plurality of image recognition areas;
s102, scanning the plurality of image recognition areas respectively.
Specifically, the welding area can emit X rays to scan through the X-ray module, the scanning area is all or part of the welding area, the scanning area can be 5mm above a pipeline welding braze joint, and the lower part is 5mm below the bottom of the matching depth of the stainless steel four-way valve and the air-conditioning copper pipe. Of course, the present embodiment is merely illustrative of the scanning area, but is not limited thereto, and those skilled in the art may change the scanning area according to actual situations, and may achieve the same technical effects.
Also, the welding area may be divided into a plurality of image recognition areas. After being divided into a plurality of image recognition areas, the X-ray module can scan each image recognition area more precisely.
So set up, because the welding defect of difference can appear in the welding region in different positions, consequently divide into a plurality of image recognition areas with the welding region, can scan each image recognition area more accurate to can carry out more accurate discernment and judgement to the welding defect, improve the rate of accuracy of discernment welding defect. And furthermore, technicians can automatically formulate targeted repair measures according to the types of welding defects, so that the situations of air conditioner refrigerant leakage, blockage and the like can be avoided, and the qualification rate of products is greatly improved.
In an alternative embodiment, in step S101, the dividing the welding area into a plurality of image recognition areas includes:
s1011, setting a region surrounded by welding solder joints at the upper end and the lower end of the workpiece as the welding region along the scanning projection surface of X rays; the scanning area is all or part of the welding area, the scanning area can be 5mm above a pipeline welding seam, and the lower part is 5mm below the bottom of the matching depth of the stainless steel four-way valve and the air-conditioning copper pipe.
S1012, setting a welding superposition part of the workpiece as a first area, and setting two side areas of the first area as second areas along the length direction of the workpiece; and setting the two side areas of the first area as a third area along the width direction of the workpiece.
As shown, the first region is a C region, the second region is a B region, and the third region is an a region.
In an alternative embodiment, in step S20, the determining, based on the current gray-scale image, a type of welding defect in the current gray-scale image includes:
s201, acquiring respective current gray level images and calibration gray level values of each of the first region, the second region and the third region;
s202, determining a current gray value of each region based on the current gray image;
s203, comparing the current gray value with the calibrated gray value to determine the type of the welding defect in the current gray image.
Specifically, after the first region, the second region and the third region are scanned respectively, the respective current gray level image of each region in the first region, the second region and the third region is obtained, and then the current gray level value of each region can be directly obtained through the existing program. Because the calibration gray values are set in advance and correspond to the welding defects one by one, the type of the welding defects in the current gray image can be directly determined by comparing the current gray value with the calibration gray values.
Thus, since the gray value of the welding defect is significantly different from the welding surface formed during normal welding, it is possible to determine whether or not the current region has the welding defect by detecting the current gray value of each region. Meanwhile, the gray value of each type of welding defect is different, so that the type of the welding defect can be judged through the gray value, the welding defect can be more accurately identified and judged, and the accuracy of identifying the welding defect is improved. And furthermore, technicians can automatically formulate targeted repair measures according to the types of welding defects, so that the situations of air conditioner refrigerant leakage, blockage and the like can be avoided, and the qualification rate of products is greatly improved.
In an alternative embodiment, in step S203, the determining the type of the welding defect in the current gray-scale image by comparing the current gray-scale value with the calibrated gray-scale value includes:
s2031, acquiring a gap gray value of a workpiece welding part before welding;
s2032, measuring a gap width based on the gap gray value;
s2033, if the gap width is within a preset gap interval, the workpiece is installed to be qualified;
and S2034, if the gap width is not within the preset gap interval, the workpiece is not installed and is qualified.
The gray value is represented as 0-255, 0 is black, 255 is white, the gray value of the single-side gap is matched with the two sides of the inner pipeline and the outer pipeline before and after welding, the gap width L is measured according to the gray value of the gap, the preset gap interval is more than or equal to 0.2mm and less than or equal to 0.5mm, and if L is not in the interval, the gap interval is unqualified. And the gap between the top and the bottom of the inner and outer pipes can be synchronously detected to be completely inserted, the gap height H is calculated according to the gray value, H is more than or equal to 0mm and less than or equal to 1mm, and if H is not in the interval, the gap is unqualified.
Pipeline clearance requirement: phi 5-phi 9.52 (phi 12), single-side gap of pipeline: d=0.2 to 0.5mm, and the pipe welding depth h=9 to 10mm.
By the arrangement, the welding defect is judged through the gray value, and meanwhile, the qualification rate of the workpiece after the workpiece is installed can be judged through the gray value. Because the clearance between adjacent spare parts has strict requirements after the work piece installation is accomplished, all carry out the measurement in person through extra measuring tool or technician in prior art, lead to measuring tool many, perhaps the technician measures inaccurately, bring a lot of problems for the qualification rate of air conditioner product. According to the embodiment, the welding defects can be measured through measuring the gray value, and gaps between adjacent parts can be measured at the same time, so that additional measuring tools are not needed, technicians do not need to measure the welding defects in person, the welding defects can be obtained through the gray value, and the qualification rate of products is greatly improved.
In an alternative embodiment, in step S203, the determining the type of the welding defect in the current gray-scale image by comparing the current gray-scale value with the calibrated gray-scale value includes:
s2035, after welding, if the calibrated gray value of the first area is a first threshold value and the current gray value of the first area is greater than the first threshold value, the welding defect in the first area is a bubble; if the calibrated gray value of the first area is a first threshold value and the current gray value in the first area is smaller than the first threshold value, the welding defect in the first area is a weld flash;
s2036, after welding, if the calibrated gray value of the second area is a second threshold value and the current gray value of the second area is greater than the second threshold value, the welding defect in the second area is insufficient in penetration;
and S2037, after welding, if the calibrated gray value of the third area is a third threshold value and the current gray value in the third area is smaller than the third threshold value, the welding defect in the third area is a weld flash.
Specifically, the insufficient penetration area is actually lack of solder, the gray level is relatively light, and the current gray level value is large. Bubble defects are similar, the flash is a solder surplus, the gray level is deep, and the current gray value is small.
Further, if the first area calibration gray value is C, that is, the C area calibration gray value is C, the bubble gray value C1> C in the area is set in the same environment; the gray value c2< c of the flash area;
the calibrated gray value of the second area is B, namely the calibrated gray value of the area B is B, and the gray value B1> B with insufficient penetration in the area;
and the calibrated gray value of the third area is a, namely the calibrated gray value of the qualified welding A area is a, and the welding flash gray value a1 is less than a.
In an alternative embodiment, the detection method further comprises:
s204, dividing each of the first region, the second region and the third region into a plurality of image recognition regions;
s205, acquiring the number of welding defects in all the image recognition areas;
s206, if the number of welding defects is 0, the workpiece is qualified;
and S207, if the number of the welding defects is not 0, correcting welding parameters or eliminating the welding defects.
The segmentation may also be continued for the first region, the second region and the third region. As shown in the figure, the first area, the second area and the third area are divided into 20 small plates in total, and X-rays scan and image the 20 small plates to compare and calibrate gray values.
If the gray value of one of the small plates does not accord with the calibrated gray value, the gray value is recorded as 1 disqualification number, the total disqualification number is obtained as X,
X＝X(a)+X(b)+X(c)，
wherein: the defect number X (a) of the A area is E (0, 1,2,3 and … …), the defect number X (B) of the B area is E (0, 1,2,3 and 4), and the defect number of the C area is X (C) of the C area is E (1, 2,3 and … …).
Comparing the gray values of the 20 small plates with the logical operation to obtain the defect number,
if X=0, the workpiece is qualified;
if X is more than or equal to 1, indicating that the workpiece is unqualified in detection, automatically correcting welding parameters or eliminating welding defects until detection data X=0.
In an alternative embodiment, the defect causes are as follows: and when the welding process is normal, the gray level change rule and the heating have a matching relationship, and when the welding process is abnormal, the gray level change rule and the heating track are against, and the abnormal situation is specifically represented as non-following gradient distribution difference, wherein the former is related to virtual welding caused by deviation of welding track, temperature, welding seam cleanliness, front and rear piping gap uniformity and the like, and the latter is related to weld flash and welding blockage caused by welding track, temperature, welding flux addition and the like.
The parameter adjustment is carried out according to the reason of forming the defect in the former, and the workpiece in the latter is sorted and removed. Specifically, in S207, the correcting the welding parameter includes:
s2071, when the welding defect is a bubble, the temperature is detected by a temperature regulator to be 555-575 ℃, and the welding gun nozzle is uniformly heated at a preset position at the upper part of the pipe orifice; the welding gun nozzle is heated evenly at the position of about 2mm above the pipe orifice. For example 1.9mm to 2.1mm.
S2072, when the welding defect is insufficient in penetration, reducing a welding heating range, heating the upper side of the brazing seam to a region of 4mm below the brazing seam, uniformly heating a welding gun nozzle at the preset position at the upper part of a pipe orifice, increasing the wire feeding speed by 0.5m/S, and increasing the heating time by 1S;
s2073, when the welding defect is weld flash, heating the area from the upper side of the brazing seam to the lower side of the brazing seam by 5mm, uniformly heating the welding gun nozzle at the preset position on the upper part of the pipe orifice, and reducing the wire feeding speed by 0.5m/S. The welding gun nozzle is heated evenly at the position of about 2mm above the pipe orifice. For example 1.9mm to 2.1mm.
Of course, the present embodiment is merely to illustrate the uniformly heated region, but is not limited thereto, and those skilled in the art may vary according to actual circumstances, and may achieve the same technical effects.
In a second aspect, the present invention also provides a device for detecting a welding defect, the device comprising:
the X-ray module is used for carrying out X-ray scanning on a welding area of the workpiece before welding the workpiece; after welding the workpiece, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect; the details of the foregoing embodiments are omitted herein.
The processing module is used for judging whether the workpiece is qualified to be installed or not; the details of the foregoing embodiments are omitted herein.
The detection module is used for detecting parameters of the welding wire mechanism and the welding gas mechanism after the workpiece is installed to be qualified; the details of the foregoing embodiments are omitted herein.
And the welding module is used for welding if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range. The details of the foregoing embodiments are omitted herein.
In a third aspect, embodiments of the present invention provide an electronic device that may include a processor and a memory, where the processor and the memory may be connected by a bus or otherwise, for example, by a bus connection.
The processor may be a central processing unit (Central Processing Unit, CPU). The processor may also be any other general purpose processor, digital signal processor (Digital Signal Processor, DSP), application specific integrated circuit (Application Specific Integrated Circuit, ASIC), field programmable gate array (Field-Programmable Gate Array, FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof.
The memory, as a non-transitory computer readable storage medium, may be used to store non-transitory software programs, non-transitory computer executable programs, and modules, such as program instructions/modules corresponding to the detection methods in the embodiments of the present invention. The processor executes various functional applications of the processor and data processing by running non-transitory software programs, instructions, and modules stored in the memory, i.e., to implement the detection methods in the method embodiments described above.
The memory may include a memory program area and a memory data area, wherein the memory program area may store an operating system, at least one application program required for a function; the storage data area may store data created by the processor, etc. In addition, the memory may include high-speed random access memory, and may also include non-transitory memory, such as at least one magnetic disk storage device, flash memory device, or other non-transitory solid state storage device. In some embodiments, the memory may optionally include memory located remotely from the processor, the remote memory being connectable to the processor through a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The one or more modules are stored in the memory that, when executed by the processor, perform the method of any of the above embodiments.
The specific details of the electronic device may be correspondingly understood by referring to the corresponding related descriptions and effects in any of the above embodiments, and are not repeated herein.
In a third aspect, embodiments of the present invention further provide a computer-readable storage medium storing computer instructions for causing the computer to perform any one of the detection methods.
Wherein the storage medium may be a magnetic Disk, an optical Disk, a Read-Only Memory (ROM), a random access Memory (Random Access Memory, RAM), a Flash Memory (Flash Memory), a Hard Disk (HDD), or a Solid State Drive (SSD); the storage medium may also comprise a combination of memories of the kind described above.
Although embodiments of the present invention have been described in connection with the accompanying drawings, various modifications and variations may be made by those skilled in the art without departing from the spirit and scope of the invention, and such modifications and variations fall within the scope of the invention as defined by the appended claims.
Claims (10)
1. A method of detecting a weld defect, comprising:
before welding a workpiece, performing X-ray scanning on a welding area of the workpiece, and judging whether the workpiece is qualified to be installed or not;
after the workpiece is installed to be qualified, detecting parameters of a welding wire mechanism and a welding gas mechanism;
if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range, welding is carried out;
after welding the workpiece, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect.
2. The method of claim 1, wherein the performing parameter detection on the welding gas mechanism comprises:
acquiring the actual pressure of welding gas, oxygen and nitrogen;
judging whether the actual pressures of welding gas, oxygen and nitrogen are all in a normal pressure interval;
if yes, parameter detection is carried out on the welding wire mechanism.
3. The method of claim 2, wherein the performing parameter detection on the wire bonding mechanism comprises:
acquiring the actual position of the solder;
judging whether the solder is at a preset mounting position or not;
if yes, the welding point is preheated, and welding is prepared.
4. A detection method according to claim 2 or 3, characterized in that, at the time of welding, it comprises:
when starting welding, the welding gun starts to ignite;
automatically adjusting the brazing flame to be neutral flame;
and simultaneously temperature monitoring of the welded area.
5. The method according to claim 4, wherein the inner flame length of the neutral flame is 30 to 40mm.
6. The method of claim 5, wherein the flame is uniformly heated by swinging downwards along a zigzag path.
7. The method according to claim 5 or 6, wherein when the workpiece is a stainless steel four-way valve and an air-conditioning copper pipe, the welding wire is connected when the air-conditioning copper pipe is heated to dark red, namely, the temperature reaches 550-580 ℃.
8. The detection method according to claim 7, wherein the heating time is 1.5 to 2.5S when the outer diameter of the inner pipe is Φ9; when the outer diameter of the inner pipe is phi 12, the heating time is 3.5-4.5S.
9. A welding defect detection apparatus, comprising:
the X-ray module is used for carrying out X-ray scanning on a welding area of the workpiece before welding the workpiece; after welding the workpiece, performing X-ray scanning on a welding area of the workpiece, and determining the type of the scanned welding defect;
the processing module is used for judging whether the workpiece is qualified to be installed or not;
the detection module is used for detecting parameters of the welding wire mechanism and the welding gas mechanism after the workpiece is installed to be qualified;
and the welding module is used for welding if the working parameters of the welding wire mechanism and the welding gas mechanism are in the normal range.
10. An electronic device, comprising: a memory and a processor, the memory and the processor being communicatively connected to each other, the memory having stored therein computer instructions, the processor executing the computer instructions to perform the detection method of any of claims 1 to 8.
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| CN202310781282.2A CN116818810A (en) | 2023-06-28 | 2023-06-28 | Welding defect detection method and welding defect detection device |
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| CN202310781282.2A CN116818810A (en) | 2023-06-28 | 2023-06-28 | Welding defect detection method and welding defect detection device |
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