Research On The Interactive Behavior Between Human Welders And Weld Pool Based On Welding Experience

Currently, even it is the most advanced robot of the world, the control capabilities of the shape and fluid of weld pool and defects for welding robots are far less than that of a junior welder. With the abundant welding experience and skills,skilled welders can control the shape and fluid of weld pool and detects effectively.In recent years, because of welding poor working conditions, high strength and high costs and long period of welders’ training, qualified welders become scarce human resources, resulting in the manufacture urgently increase needed for the new generation intelligent welding robots. Extracting and analysing the skilled welders’ welding experience and skills has a great significance to improve the intelligence level of welding robots, short welders’ training cycle and reduce the costs of welders’ training. In this paper, a collect system of welders’ experience and skills is built by using the attitude sensor of MPU6050 and laser vision sensing technology.The human welders’ behavior is acquired and analyzed in the welding process,details are as follows:1. A collect system of welders’ experience and skills is built by using the attitude sensor of MPU6050 and laser vision sensing technology. The true representation of three-dimensional gesture of welding torch are achieved with the welding torch model designed by the Pro/E software and the procedure of attitude data acquisition and processing developed by Lab VIEW software.2. The effect of measured gravity acceleration on the motion acceleration is texted by static and dynamic acceleration test. Preliminary tests show that the motion acceleration consisting in welding torch posture adjustment of the welding process can be neglected contrasting to the gravity acceleration.3. The Robot calibration tests and spatial geometry analysis show that the measurement accuracy of attitude angle is 0.01°. The root mean square error of angleβ and γ are C = 0.0196 °, angle α and β are C = 0.0317 °, angle α and γ are C =0.1058 °, respectively. The function of the attitude sensor is meet to the needs of the welding experiment.4. Through sensing and analyzing welding test operated by different welders, it indicates that during the welding process, welding torch of skilled welder is stable and small fluctuate. The welding torch orientation of the novice welder is instability and volatile. The skilled welder has a better maintain weld pool shape ability than that of the novice welder. When the shape and fluid of the weld pool changed, it canbe caught rapidly and responded with adjust to the welding torch attitude by the skilled welder. The novice welder has a poor performance. They only adjust one angle of the welding torch attitude. Observing the laser stripe image reflected by the weld pool surface in the skilled welder welding process, the shape and fluid of weld pool are stable and little turbulent, and the weld seam and its width are smooth and uniform. But it is opposite in the novice welder welding process, the shape and fluid of weld pool are collapse and little disorder, the weld seam shape is bad and the residual high is uneven.