Design And Development Of A Spectrum Cooperative Sensing Device Based On Arc Additive Process

The on-line testing of molten pool quality is one of the important research contents in the field of welding.Online acquisition and analysis of diversified information in the welding process can provide real-time quality evaluation data and process control guidance for the welding manufacturing process.In the Cold Metal Transfer Plus Pulse Welding(CMT+P)process,the width of the weld pool image reflects the change of the welding speed,and the arc spectrum reflects the change of the shielding gas flow and the residual organic matter on the surface of the welding material.Therefore,the research content of this paper mainly focuses on the design and development of the arc additive process spectral synergistic sensing device based on PC+FPGA platform.Through this device,the high signal to noise ratio weld pool image and arc spectrum are obtained in the welding process.Finally,real-time monitoring and feedback of welding speed,protective gas flow,and organic residue on the surface of the welding material are realized.The details are as follows:(1)Welding speed stability monitoring based on weld pool image.We use FPGA to design a suitable filter to detect the process current signal,judge the short-circuit transition time adaptively and give the camera trigger signal to capture a clear and high signal to noise image of a weld pool with almost no arc interference.And then,the contour extraction algorithm can accurately obtain the width of the weld pool on the PC,and reflect the change of the welding speed in the welding process in real time.(2)Protection gas and organic matter monitoring based on spectral data.The spectral data with less variegated light and less noise interference is obtained by FPGA design.And then,Using the Apriori algorithm to perform data mining on the obtained spectral data,so that the association rules of different shielding gas flows are obtained.Then design the FPGA module to monitor the change of the spectral data in the welding process in real time,and realize the monitoring of the shielding gas flow and the residual organic matter on the surface of the welding material.(3)The welding feedback module besed on FPGA.This module use the powerful parallel processing function of the FPGA to collect the electrical parameters and spectral data in the welding process in real time.And then the welding speed change,the change of the shielding gas size and the residual organic matter on the surface of the welding meterial are fed back to the welding machine control system through the peripheral I/O port in real time,which the control of the welding machine's own process parameters is realized to improve the overall quality of the welding.In summary,the arc additive process spectrum synergistic sensing device is developed through the whole machine,and then the experimental design can verify the function of the device,and the online feedback and regulation of the welding parameters are realized and enhance the intelligence of the welding robot.