| With the rapid development of the automobile industry and the improvement of people's environmental awareness,lightweight,safety,energy saving and environmental protection have become the mainstream direction of automobile development.In the field of automotive lightweight,wheels as an important components,have a great lightweight prospect.The lightweight of automobile wheels is mainly concentrated on the rim,and the main way is to use higher strength materials,which significantly reduces the carrying capacity while meeting the weight.In the production process of steel wheel,high strength steel rim mainly adopts flash butt welding process to realize the connection of material,and stable and reliable welding quality is the premise to ensure the safety and service life of automobile products.Flash butt welding process does not need filling materials,and simple operation,high welding efficiency,excellent welding quality.However,the flash butt welding has a short welding time and many process parameters,and the welding quality is affected by the coupling of multiple parameters,so the process development and process control are more difficult.In the process of flash welding,the secondary circuit current,clamp voltage,clamp feed displacement and speed,welding parts and matching temperature and other parameters have a great impact on the joint forming,the stability of the welding parameters and good matching between parameters become the key to guarantee the welding quality.Therefore,the development of an online monitoring and analysis system for flash butt welding process parameters,and the realization of graphical,digital measurement and calculation of the instantaneous characteristics of welding parameters and their phase relations have become an essential technical means for the process design and process analysis of new high-strength steel rim flash butt welding.In order to meet the actual engineering requirements of real-time monitoring of flash butt welding parameters in steel automobile rim production,this paper studied the butt welding process monitoring method based on multi-sensor information fusion.Through the software and hardware design of the monitoring system and the field monitoring test,the real-time collection,display,storage and analysis of the main welding parameters such as current,voltage,displacement,temperature and flash on welding are realized.The monitoring system design is mainly divided into hardware and software parts.Hardware design mainly includes sensor design and selection,signal conditioning circuit design,data acquisition card selection and conversion control,and finally realizes the real-time sensing of current,voltage,displacement and temperature.Software design is mainly using C++ programming language,the monitoring system data acquisition control,signal processing,feature value calculation,curve display,data storage and other function modules,mainly realize the following functions: the main interface to create and initialization,data acquisition card control parameter setting,analog conversion control,welding start and end of automatic judgment,monitoring data filter,signal characteristic parameter calculation,real-time display and data storage.On the basis of the monitoring system software and hardware development,this paper adopts different welding parameters,welding and monitoring experiment based on the current,voltage and displacement of the welding process,the temperature curve and its characteristic value of processing and analysis,combining with the welding sample of metallographic analysis and mechanical property test results,high strength steel rim of systemic research on the new type of flash butt welding process.Results show that the developed monitoring system,can automatically capture the beginning and end of the flash butt welding process,the real-time record the instantaneous value of main welding parameters and phase relationship,monitoring information in the form of numerical and dynamic curve visual display,the monitoring results can be a good reaction in the process of the butt welding parameters of instantaneous state as well as the matching relation between each other,It provides strong technical guarantee for flash butt welding process and quality analysis.The monitoring system developed in this paper has complete functions and can realize real-time monitoring of multiple parameters.It has the advantages of fast acquisition speed,high calculation accuracy,strong working stability,friendly humanmachine interface,low equipment cost,convenient maintenance and small volume,and is suitable for various application environments such as experimental research and production site.The system can significantly reduce the difficulty of flash butt welding process development and quality control,improve the production efficiency,and has a high practical value and a good development prospect. |
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