高压水环境旋转电弧焊接特性及其焊缝传感跟踪研究
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摘要
随着能源开发、船舶建造与维修、水上救助等许多海洋活动的展开,海洋钢结构大量涌现。水下焊接技术作为水下工程建设与维护必不可少的关键技术,急待提高与发展。旋转电弧传感器具有焊缝检测与焊接同时实现的优点,因此研究在高压水环境下采用旋转电弧进行焊缝跟踪,实现高压水环境焊接自动化具有现实的意义。目前国内外还未见这方面的研究报道。
本文采用高压舱模拟深水水下环境,采用旋转电弧作为传感进行焊缝偏差检测与跟踪,实现高压水环境水下自动焊接。研究内容主要包括:高压下旋转电弧行为及仿真研究,高压水环境旋转电弧传感信息的电流信息预处理方法,高压水环境旋转电弧传感的数学模型,高压水环境旋转电弧焊接短路过渡模型及旋转电弧参数优化,高压水环境下采用旋转电弧进行焊缝跟踪。
研究了高压旋转电弧传感焊接的电弧特征,对高压旋转电弧进行了模拟仿真计算。模拟得出的0.1MPa下的温度场与大多数文献模拟和拍摄的电弧外形是一致的,同时整个电弧由于旋转加速度的影响而偏向旋转中心轴线外侧。仿真结果表明随着气压由0.1MPa升高到1MPa,电弧温度也升高,符合随环境压力增加,电弧亮度增加的规律。随着压力升高,在施加同等电压的情况下,电流密度也增大。
研究了高压湿法旋转电弧焊接的电弧稳定性,对高压干法和湿法的电弧稳定性做了一个比较,对湿法焊接电弧稳定性差的原因做了分析。同时对影响高压水下旋转电弧焊接稳定性的因素进行了分析。这些因素包括水深,保护气流量,电压大小等。
为了消除在高压水环境下旋转电弧传感的噪声,采用了基于平面组合滤波的方法,仿真和实验表明在采用同等的组合滤波方法时,其效果比基于一维滤波效果更加好。
研究了高压水下旋转电弧传感信息的偏差识别,改进了特征谐波检测方法,深入探讨了特征谐波中焊缝偏差、焊缝倾角和初始相位、跟踪调整的相位角的关系。仿真和实验结果表明,在倾角和跟踪角B同时存在的情况下,采用基于实部的特征谐波法检测偏差比基于幅角法的特征谐波法抗干扰能力更强。
研究了高压水下旋转电弧焊接短路过渡模型及旋转电弧参数优化,对高压水下旋转电弧焊接熔滴和短路过渡状态的液桥所受到的力进行了总结分析,建立了高压水环境下旋转电弧传感焊接短路过程仿真模型。通过分析仿真结果,并与试验结果相对照,对高压水下旋转电弧焊接的旋转频率和旋转半径作了优化。
对旋转电弧焊缝跟踪方法进行了总结,最后采用模糊滑模控制器实现了高压水下旋转电弧焊缝跟踪。
With the development of energy resources exploitation, ship construction and repair, water aid etc, the sea steel structure emerges massively.
As a key technology in the underwater construction and its maintenance, the underwater welding technology needs improving and developing. The rotating arc sensor has the advantages of weld deviation detection and welding simultaneously. Therefore there is realistic meaning for the research applying the rotating arc sensor as the sensor to carry on the weld deviation detection and deep water welding automation. At present there is no such research report at home and abroad.
In this article the high-pressure tank is used to simulate the deep water environment, the rotating arc sensor is used to carry on the weld deviation detection and tracking to realize the deep water automatic welding. The research content mainly includes: The research about the arc characteristics of the high-pressure rotating arc welding;The noise elimination and deviation detection in the high-pressure rotating arc welding; the short-circuit transition model research and parameter optimization of rotating arc in the high-pressure rotating arc welding; the seam tracking in the high-pressure rotating arc welding.
To study the arc characteristics under the high-pressure rotating arc welding, the simulation calculation is carried out for the electric arc. The temperature field obtained under the 0.1MPa is consistent with the majority literature's simulations and photographys in the arc contour. At the same time the arc is influenced by rotary acceleration, so it biases towardbiases the lateral center of the rotation axis. The simulation results show that with increased pressure from 0.1MPa to 1MPa, the arc temperature rise, it is in line with the law that the arc brightness is increasing along with the pressure lifting. Along with the pressure lifting, under the circumstance of exerting the same level voltage, the current density also increases.
To study the arc stability in the high-pressure rotating arc wet welding, the dry and wet welding arc stability is compared, and the reason of the bad stability of the wet welding arc is analyzed. Meanwile the factors affecting the welding current and welding voltage are analyzed which includes the water depth, the protection gas flow rate, voltage size etc.
To study the noise elimination in the high-pressure rotating arc welding, the plane combination filtering method is used. The simulation and experimental results show that when using the equivalent filtering method, its effect is better than that of one-dimensional filtering.
To study the deviation detection in the high-pressure rotating arc welding, the relationship between deviation、oblique angle、initial phase and tracing angle are discussed, and the characteristic harmonic method is improved. The simulation and experimental results show that when the oblique angleγand tracing angleβexist at the same time, the real and imaginary method has stronger anti-interference capability than the amplitude and angle method.
To study the short circuit transition model in the high-pressure rotating arc welding and the optimization of the rotating arc parameters, the force of the melt drop in the high-pressure rotating arc welding and of fluid bridge in the short circuit transition stage is analyzed in summary, the simulation model in the high-pressure rotating arc welding is set up. The simulation results and experimental results is verified each other and the rotaing frequency and rotaing radius is optimized therefore.
To realize weld seam tracking in the high-pressure rotating arc welding, the summary of the tracking methods is carried out, and at last the fuzzy-slide controller is designed to track the seam.
本文采用高压舱模拟深水水下环境,采用旋转电弧作为传感进行焊缝偏差检测与跟踪,实现高压水环境水下自动焊接。研究内容主要包括:高压下旋转电弧行为及仿真研究,高压水环境旋转电弧传感信息的电流信息预处理方法,高压水环境旋转电弧传感的数学模型,高压水环境旋转电弧焊接短路过渡模型及旋转电弧参数优化,高压水环境下采用旋转电弧进行焊缝跟踪。
研究了高压旋转电弧传感焊接的电弧特征,对高压旋转电弧进行了模拟仿真计算。模拟得出的0.1MPa下的温度场与大多数文献模拟和拍摄的电弧外形是一致的,同时整个电弧由于旋转加速度的影响而偏向旋转中心轴线外侧。仿真结果表明随着气压由0.1MPa升高到1MPa,电弧温度也升高,符合随环境压力增加,电弧亮度增加的规律。随着压力升高,在施加同等电压的情况下,电流密度也增大。
研究了高压湿法旋转电弧焊接的电弧稳定性,对高压干法和湿法的电弧稳定性做了一个比较,对湿法焊接电弧稳定性差的原因做了分析。同时对影响高压水下旋转电弧焊接稳定性的因素进行了分析。这些因素包括水深,保护气流量,电压大小等。
为了消除在高压水环境下旋转电弧传感的噪声,采用了基于平面组合滤波的方法,仿真和实验表明在采用同等的组合滤波方法时,其效果比基于一维滤波效果更加好。
研究了高压水下旋转电弧传感信息的偏差识别,改进了特征谐波检测方法,深入探讨了特征谐波中焊缝偏差、焊缝倾角和初始相位、跟踪调整的相位角的关系。仿真和实验结果表明,在倾角和跟踪角B同时存在的情况下,采用基于实部的特征谐波法检测偏差比基于幅角法的特征谐波法抗干扰能力更强。
研究了高压水下旋转电弧焊接短路过渡模型及旋转电弧参数优化,对高压水下旋转电弧焊接熔滴和短路过渡状态的液桥所受到的力进行了总结分析,建立了高压水环境下旋转电弧传感焊接短路过程仿真模型。通过分析仿真结果,并与试验结果相对照,对高压水下旋转电弧焊接的旋转频率和旋转半径作了优化。
对旋转电弧焊缝跟踪方法进行了总结,最后采用模糊滑模控制器实现了高压水下旋转电弧焊缝跟踪。
With the development of energy resources exploitation, ship construction and repair, water aid etc, the sea steel structure emerges massively.
As a key technology in the underwater construction and its maintenance, the underwater welding technology needs improving and developing. The rotating arc sensor has the advantages of weld deviation detection and welding simultaneously. Therefore there is realistic meaning for the research applying the rotating arc sensor as the sensor to carry on the weld deviation detection and deep water welding automation. At present there is no such research report at home and abroad.
In this article the high-pressure tank is used to simulate the deep water environment, the rotating arc sensor is used to carry on the weld deviation detection and tracking to realize the deep water automatic welding. The research content mainly includes: The research about the arc characteristics of the high-pressure rotating arc welding;The noise elimination and deviation detection in the high-pressure rotating arc welding; the short-circuit transition model research and parameter optimization of rotating arc in the high-pressure rotating arc welding; the seam tracking in the high-pressure rotating arc welding.
To study the arc characteristics under the high-pressure rotating arc welding, the simulation calculation is carried out for the electric arc. The temperature field obtained under the 0.1MPa is consistent with the majority literature's simulations and photographys in the arc contour. At the same time the arc is influenced by rotary acceleration, so it biases towardbiases the lateral center of the rotation axis. The simulation results show that with increased pressure from 0.1MPa to 1MPa, the arc temperature rise, it is in line with the law that the arc brightness is increasing along with the pressure lifting. Along with the pressure lifting, under the circumstance of exerting the same level voltage, the current density also increases.
To study the arc stability in the high-pressure rotating arc wet welding, the dry and wet welding arc stability is compared, and the reason of the bad stability of the wet welding arc is analyzed. Meanwile the factors affecting the welding current and welding voltage are analyzed which includes the water depth, the protection gas flow rate, voltage size etc.
To study the noise elimination in the high-pressure rotating arc welding, the plane combination filtering method is used. The simulation and experimental results show that when using the equivalent filtering method, its effect is better than that of one-dimensional filtering.
To study the deviation detection in the high-pressure rotating arc welding, the relationship between deviation、oblique angle、initial phase and tracing angle are discussed, and the characteristic harmonic method is improved. The simulation and experimental results show that when the oblique angleγand tracing angleβexist at the same time, the real and imaginary method has stronger anti-interference capability than the amplitude and angle method.
To study the short circuit transition model in the high-pressure rotating arc welding and the optimization of the rotating arc parameters, the force of the melt drop in the high-pressure rotating arc welding and of fluid bridge in the short circuit transition stage is analyzed in summary, the simulation model in the high-pressure rotating arc welding is set up. The simulation results and experimental results is verified each other and the rotaing frequency and rotaing radius is optimized therefore.
To realize weld seam tracking in the high-pressure rotating arc welding, the summary of the tracking methods is carried out, and at last the fuzzy-slide controller is designed to track the seam.
引文
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