Surface Reconstruction And Automation Control Based On Magnetically Controlled Rotrary Arc Surfacing

It has been half a century since surfacing was used to repair the surface of parts and to prevent rust,enhance hardness and wear resistance on the surface of parts.However,at present,it is still in the stage of manual welding and semi-automatic welding.Although the major economies have entered the industrialization era,or even the post-industrialization era,there is still a long way to go for the realization of surfacing automation,intellectualization and flexibility.The main reason is that welding is a complex and changeable process,and many workpieces need precise fixtures,which is cheaper than using robots to realize manual welding.Therefore,it is necessary to study how to improve welding automation and reduce production costs of surfacing welding methods.Based on the previous research results of automatic welding and the difficulties encountered in actual surfacing,this paper presents a method of surface reconstruction and LabVIEW automatic control based on magnetron rotary arc surfacing,which is used to realize the automatic layout of surfacing bead and the real-time identification of welding seam deviation during welding process and the automatic adjustment of welding torch posture.Specific research contents are as follows:1)Firstly,a mechanical rotating arc sensor is designed for welding.Experiments show that the mechanical sensor is not only expensive,but also far from the expected welding effect.Therefore,a magnetically controlled rotating arc sensor is proposed,and the magnetic field distribution between magnetic poles is simulated and analyzed by COMSOL.According to the characteristics of surfacing welding,a simple and feasible magnetically controlled rotating arc sensor is designed.2)By analyzing the characteristics of LabVIEW as upper computer and gas-shielded welding automatic welding,using LabVIEW and signal acquisition card and motion control card respectively,the acquisition program for Hall signal and the automatic control program for welding process are designed,and the real-time acquisition of Hall signal and the accurate control of hardware such as motor are realized.3)Based on the analysis of the change of the position and posture of the magnetic control rotating arc welding,a mathematical model of the coordinate relationship of the arc sampling point cloud is established.The welding seam deviation is identified by extracting the feature points and fitting the feature lines.Finally,a weighted progressiveinterpolation Loop fine interpolation based on the sampling points of the magnetic control rotating arc is proposed by combining the Loop triangular subdivision algorithm.The surface reconstruction is carried out by sub-algorithm to realize the recognition of weld deviation and the adjustment of welding torch attitude.4)LabVIEW and welding automation are combined through self-built test platform and verified on the surfacing test platform based on free-form surface reconstruction algorithm.The results show that the above-mentioned method is feasible,the deviation of weld bead is identified accurately,the attitude of welding torch is adjusted accurately,and the automatic surfacing welding is realized.