Research On Magnetic Control Narrow Gap Submerged Arc Welding Tracking Sensor And Weld Width Adaptive Method

With the adjustment of power structure and capacity demand in our country,the demand for high parameter and large capacity boiler is increasing.The drum is the most important part of the boiler.In the manufacture of modern drums,welding is one of the essential technologies.In order to obtain excellent welding quality,and high production efficiency,safer working environment,at the same time to reduce the labor intensity of workers,it is a good way to improve the welding intelligence and the level of automation.The seam tracking is one of the key technologies to achieve welding automation.Based on the automatic welding problem of the drum,the adaptive tracking method of the narrow gap submerged arc welding sensor and the weld width adaptive method are analyzed and studied in this paper.(1)Based on the characteristics of magnetron arc and narrow gap submerged arc welding,a new type of tracking sensor is designed,and elaborated the concept of design and scheme.Aiming at the problems such as waveform distortion and signal regulation difficulties in the excitation power module of the traditional magnetically controlled arc sensor,the waveform generator circuit and the power amplifier circuit are redesigned to reduce the distortion of the excitation waveform,enhance the anti-interference ability and simplify the signal regulation mechanism.Which is conducive to the follow-up test and analysis.(2)The structure simulation model of magnetically controlled narrow gap submerged arc welding tracking sensor is established,the COMSOL magnetic field simulation is simulated for the cross-section parameters of the magnetic core components.The tracking sensor model is optimized according to the magnetic field requirements of the arc swing;In order to solve the instability problem of sensor work,the intelligent water cooling system is designed,combined with the test,the cooling capacity of the intelligent water cooling system is verified effectively.(3)Based on the characteristics of the narrow gap groove,a mathematical model of magnetically controlled narrow gap submerged arc welding tracking arc and arc length of the sensor is established.The simulation model is built by Simulink simulation module to obtain the intrinsic relationship between the voltage characteristic signal and different groove,which can provide reference for the deviation signal identification of weld automatic tracking.(4)The second-order Butterworth filter and the VMD combined filtering method are used to filter the actual voltage characteristic signal,which proves the filtering ability of the method effectively.In order to identify and detect the narrow gap groove type,a method of voltage phase transition and mean voltage difference method is proposed.According to the characteristics of voltage characteristic signal,LM393 is designed as the core of the positioning acquisition circuit to establish the melt width adaptive seam tracking System,to achieve the purpose of melting width self-regulation and seam tracking.(5)The seam tracking test was carried out on a platform of a magnetically controlled narrow-gap submerged arc welding tracking system.The results show that the weld tracking effect is good,the melt width adaptive seam tracking system is stable,real-time is good,the weld gap width adjustment ability is strong.