阅读说明：本技术 一种实时测量螺柱焊过程中偏弧的装置 (Device for measuring arc deflection in stud welding process in real time ) 是由 张德库 何思源 王克鸿 周琦 黄�俊 冯曰海 彭勇 薛鹏 于 2018-06-29 设计创作，主要内容包括：本发明公开了一种实时测量螺柱焊过程中偏弧的装置,该装置包括变位工作台,固定在工作台上的钢板,设置偏弧检测结构于钢板上；与偏弧检测装置相连的为依次设置的分流器、绝缘线、V/F变换器、控制协调计算机；所述的偏弧检测结构环绕引弧孔设置,具体包括：设置在外壁与内壁之间的上接收石墨板及下接受极石墨板,上接收石墨板固定在外壁,上接收石墨板与内壁之间设置一道环形采集缝；下接受极石墨板与外壁与内壁均固定；下接受极石墨板被n个绝缘分割带分割成均匀的n个检测区域。本发明提供的测量自动螺柱焊过程中偏弧的装置适用于绝大部分直径螺柱焊接检测；该装置具有操作简单、工作效率高、工艺稳定等优点。(The invention discloses a device for measuring the arc deflection in the stud welding process in real time, which comprises a deflection workbench, a steel plate fixed on the workbench, and an arc deflection detection structure arranged on the steel plate; the shunt, the insulated wire, the V/F converter and the control coordination computer are sequentially arranged and connected with the partial arc detection device; the structure is detected to partial arc surround the setting of arc ignition hole, specifically include: the upper receiving graphite plate and the lower receiving graphite plate are arranged between the outer wall and the inner wall, the upper receiving graphite plate is fixed on the outer wall, and an annular collecting seam is arranged between the upper receiving graphite plate and the inner wall; the lower receiving electrode graphite plate is fixed with the outer wall and the inner wall; the lower receiving electrode graphite plate is divided into n detection regions uniformly by n insulating dividing strips. The device for measuring the arc deflection in the automatic stud welding process is suitable for the stud welding detection of most diameters; the device has the advantages of simple operation, high working efficiency, stable process and the like.)

1. The device for measuring the arc deflection in the stud welding process in real time is characterized by comprising a deflection workbench (1), a steel plate (2) fixed on the workbench, and an arc deflection detection structure (3) arranged on the steel plate (2); the shunt (11), the insulated wire (9), the V/F converter (12) and the control coordination computer (13) are connected with the deflection arc detection device (3) and are arranged in sequence; partial arc detection structure (3) encircle arc ignition hole (4) and set up, specifically include: an upper receiving graphite plate (14) and a lower receiving graphite plate (17) which are arranged between the outer wall (18) and the inner wall (19), wherein the upper receiving graphite plate (14) is fixed on the outer wall (18), and an annular collecting gap (20) is arranged between the upper receiving graphite plate (14) and the inner wall (19); the lower receiving electrode graphite plate (17) is fixed with the outer wall (18) and the inner wall (19); the lower receiving electrode graphite plate (17) is divided into n detection regions uniformly by n insulating dividing belts (21).

2. The apparatus for real-time measurement of arc deflection during stud welding according to claim 1, wherein said n is at least 8.

3. The apparatus for real-time measurement of arc deflection during stud welding according to claim 1, wherein said insulating dividing strip (21) is a heat-resistant ceramic material.

4. The device for measuring the arc deviation in the stud welding process in real time according to claim 1, characterized in that a shunt (11), an insulated wire (9), a V/F converter (12) and a control coordination computer (13) are arranged in sequence; the acquisition process is as follows, the current is converted into a voltage signal by the current divider (34), the voltage signal enters the V/F converter (12) by the insulated wire (9), the conversion from analog quantity to digital quantity is completed, the output signal of the V/F converter (12) is finally collected and stored by the control coordination computer (13).

5. The apparatus for real-time measurement of arc deflection during stud welding according to claim 1, wherein said diverter (11) is of the type U2774E03, one diverter for each sensing zone.

6. The device for real-time measurement of arc deflection in stud welding process according to claim 1, characterized in that the size of the arc ignition hole (5) is matched to the stud diameter.

7. The apparatus for real-time measurement of arc deflection during stud welding according to claim 1, characterized in that the width of the annular collection slit (20) is 0.5mm-1 mm.

8. The apparatus for real time measurement of arc deflection during stud welding according to claim 1, wherein said stud welding is for studs having a diameter of more than 14 mm.

Technical Field

The invention discloses a device for measuring arc deviation in a stud welding process in real time, and belongs to the field of welding detection.

Background

Stud welding is a welding method for welding a metal in a spiral or columnar shape to the surface of a metal plate. The basic principle is as follows: the top end of the stud is placed on the plane of a steel plate to be welded by a gas claw at the head of the welding gun to generate pre-welding current, the stud is lifted to generate electric arc between the stud and the steel plate, the contact part is locally melted to form a molten pool, finally the stud is pressed into the molten pool at a certain speed, and metallurgical bonding between the stud and the steel plate is realized after liquid metal is cooled. The method is widely applied to industries such as automobile manufacturing, shipbuilding, locomotives, aviation, medical appliances, boilers, chemical equipment and the like. Generally, a thread fastening method is adopted conventionally, but the method needs to open threads on a base material, so that the large-sized workpiece is difficult to machine in the machining process, and for the workpiece with high sealing requirement, the traditional thread machining method is difficult to meet the use requirement of the workpiece. Stud welding is used as a fusion welding method, compared with traditional stud machining, the method has the advantages of saving time and materials, holes do not need to be formed in the surface of a plate, and leakage accidents can be effectively avoided by stud welding in equipment requiring high sealing performance. The actual welding time of stud welding is from 2ms of energy storage welding to 3min of arc discharge welding, which shows that stud welding is a precise and stable welding method with low connection cost and high efficiency.

The partial arc detection device is composed of an acquisition circuit, an amplifier, a V/F converter, a microprocessor, a motor, a modem and the like, wherein the acquisition circuit is composed of an upper receiving graphite plate, a lower receiving graphite plate, an insulating layer, an AD574A successive comparison type A/D converter and an external resistor-capacitor part. The acquisition process is as follows, the current is converted into voltage signal by the shunt, the voltage signal enters the V/F converter after being processed by the amplifier, the microprocessor temporarily stores the output signal of the V/F converter in the memory after the conversion from analog quantity to digital quantity is completed, and finally the modem transmits the real-time measurement result to the computer.

At present, when a stud with a large diameter is used for stud welding, arc deviation is the main reason of defect generation, and the arc deviation mainly causes the following welding defects: in the stud welding process, if an obvious arc deflection phenomenon occurs in the arc drawing process, the arc is not combusted stably, the end face of the stud cannot be completely combusted, the stud is not melted uniformly, a welding molten pool is not formed uniformly, the static mechanical property of a welding joint is seriously influenced after the molten pool is solidified, finally the stud is deflected, and the welding joint cannot achieve the expected appearance effect (namely the welding joint is immersed into a base metal according to one side or the welding joint cannot be completely closed). In the welding process, air holes and thermal cracks are easily generated on a welding joint, welding stress is concentrated after welding is finished, a hard brittle phase is easily generated, cold cracks are generated on the welding joint, and the impact toughness and the dynamic mechanical property of the welding joint are seriously influenced.

Disclosure of Invention

The technical problem solved by the invention is that: the device for measuring the arc deflection in the stud welding process in real time is provided for the arc deflection phenomenon generated when the steel stud and the steel plate are welded.

The technical solution for realizing the purpose of the invention is as follows:

a device for measuring the arc deflection in the stud welding process in real time comprises a deflection workbench, a steel plate fixed on the workbench, and an arc deflection detection structure arranged on the steel plate; the shunt, the insulated wire, the V/F converter and the control coordination computer are sequentially arranged and connected with the partial arc detection device; the structure is detected to partial arc surround the setting of arc ignition hole, specifically include: the upper receiving graphite plate and the lower receiving graphite plate are arranged between the outer wall and the inner wall, the upper receiving graphite plate is fixed on the outer wall, and an annular collecting seam is arranged between the upper receiving graphite plate and the inner wall; the lower receiving electrode graphite plate is fixed with the outer wall and the inner wall; the lower receiving electrode graphite plate is divided into n detection regions uniformly by n insulating dividing strips.

Further, the number of n is at least 8.

Further, the insulating dividing tape is made of a heat-resistant ceramic material.

Furthermore, a shunt, an insulated wire, a V/F converter and a control coordination computer are arranged in sequence; the acquisition process is as follows, the current is converted into voltage signal by the shunt, the voltage signal enters the V/F converter by the insulated wire, the conversion from analog quantity to digital quantity is completed, the output signal of the V/F converter is finally collected and stored by the control coordination computer.

Further, the diverter is of the type U2774E03, one diverter for each detection zone.

Furthermore, the size of the arc striking hole is matched with the diameter of the stud.

Furthermore, the width of the annular collecting seam is 0.5mm-1 mm.

Further, stud welding is used for studs with a diameter of more than 14 mm.

Compared with the prior art, the invention has the following remarkable advantages: 1) the device for measuring the arc deflection in the automatic stud welding process is suitable for the stud welding detection of most diameters; 2) the device is rapid in post data processing and can visually reflect the current density at each position; 3) the device has the advantages of simple operation, high working efficiency, stable process and the like; 4) the device enables the data acquisition process to be displayed and monitored at any time through a microprocessor and a modem, and can store a large amount of data at a high speed for analysis.

The present invention is described in further detail below with reference to the attached drawing figures.

Drawings

FIG. 1 is a flow chart of a method of measuring arc deflection in a stud welding process in real time.

FIG. 2 is a schematic block diagram of a partial arc detection sensor.

Fig. 3 is a schematic view of acquisition region division.

Fig. 4 is a sectional view of the arc detection sensor when the arc is collected.

FIG. 5 is a process schematic of a method of measuring arc deflection in a stud welding process in real time.

Fig. 6 is a top view of the partial arc detection sensor.

Fig. 7 is a schematic view of current collection for each zone.

Wherein, 1, a deflection workbench; 2.a steel plate; 3.a partial arc detection device; 4. an arc ignition hole; 5.a stud; 6.a stud welding controller; 7.a stud welding robot control arm; 8.a stud welding gun; 9.a pneumatic claw; 10. an insulated wire 11, a shunt; 12. a V/F converter; 13. a control coordination computer; 14. upper receiving graphite plates; 15 a ceramic ring; 16. a bell-jar type arc; 17. the lower part receives a graphite plate; 18. an outer wall; 19. an inner wall; 20. an annular collection slot; 21. an insulating separator; 22. a welding power supply; 23. arc in stud area; a1 zone arc; an A2 zone arc; region arc a 3; an A4 zone arc; an A5 zone arc; 29.a6 zone arc; a7 zone arc; an A8 zone arc; a1 zone diverter; a2 zone diverter; a3 zone diverter; an a4 zone diverter; a5 zone diverter; a6 zone diverter; a7 zone diverter; a8 zone diverter

Detailed Description

The invention will be further explained with reference to the drawings and the embodiments

The invention relates to a device for measuring arc deflection in the stud welding process in real time, which comprises: the device comprises a displacement workbench 1, a steel plate 2 fixed on the workbench, and a deflection arc detection structure 3 arranged on the steel plate 2; the shunt 11, the insulated wire 9, the V/F converter 12 and the control coordination computer 13 are connected with the partial arc detection device 3 and are arranged in sequence; the structure 3 is detected to partial arc encircle ignition hole 4 sets up, specifically include: an upper receiving graphite plate 14 and a lower receiving graphite plate 17 which are arranged between an outer wall 18 and an inner wall 19, wherein the upper receiving graphite plate 14 is fixed on the outer wall 18, and an annular collecting slit 20 is arranged between the upper receiving graphite plate 14 and the inner wall 19; the lower receiving electrode graphite plate 17 is fixed with the outer wall 18 and the inner wall 19; the lower receiving electrode graphite sheet 17 is divided into n detection regions uniformly by n insulating dividing strips 21.

The device specifically works as follows:

step one, as shown in fig. 1, installing a deflection arc detection sensor 3 on a deflection worktable 1;

step two, as shown in fig. 5, starting the automatic stud welding controller 6 and the partial arc detection sensor 3, wherein the sensing device consists of an upper receiving graphite plate 14, a lower receiving graphite plate 17 and a middle insulating material 21, and data are collected through a circular collecting seam 20 of the upper receiving graphite plate 14 during arc discharge;

and step three, as shown in fig. 2 and 5, when the sprayed electric arc sweeps through the circular collecting seam 20, the current passing through the upper receiving graphite plate 14 is received by the lower receiving graphite plate 17, the current value is converted into a voltage signal through the current divider 11, the obtained voltage signal is amplified through the linear amplifier, the amplified signal enters the V/F converter 12 through a collecting circuit formed by a resistance-capacitance element externally connected to the a/D converter, the conversion from analog quantity to digital quantity is completed, the microprocessor processes the output signal of the V/F converter 12 and then stores the processed signal in the memory, and finally the modem transmits the real-time measurement result to the control coordination computer 13.

Step four, as shown in fig. 3, when the signal is transmitted to the computer, the detected current value of the areas of a1, a2, A3, …, A8 and the like is I₁、I₂、I₃、…、I₈And areas S1, S2, S3, …, and S8 of the respective portions, and current densities J1, J2, J3, …, and J8 of the respective regions are calculated by an I/S computer program. Taking the area A4 as an example, the current in the area A4 collected by the current receiving and sensing device in the welding process is I₄The area of the a4 region is:

the current density in the a4 region is then:

according to the steps, current densities J1, J2, J3, … and J8 of other areas such as A1, A2, A3, … and A8 can be obtained, when the current density of one or a plurality of areas is zero, arc deflection occurs, and the degree of arc deflection is determined by the number of abnormal areas.

Referring to fig. 4, 6 and 7, the arc deflection detecting device is composed of an upper receiving graphite plate 14, an annular collecting slit 20, a lower receiving graphite plate 17 fixed on an outer wall 18 and an inner wall 19, an insulating material 21 and an arc ignition hole 4. When the bell jar type arc 16 ignited on the stud 5 is received by the lower receiving graphite plate 17 through the annular collecting slit 20, the arc falls into the arc 24 of the A1 region, the arc 25 of the A2 region, the arc 26 of the A3 region, the arc 27 of the A4 region, the arc 28 of the A5 region, the arc 29 of the A6 region, the arc 30 of the A7 region and the arc 31 of the A8 region, and the arc is converted into voltage signals by the corresponding A1 region shunt 32, the A2 region shunt 33, the A3 region shunt 34, the A4 region shunt 35, the A5 region shunt 36, the A6 region shunt 37, the A7 region shunt 38 and the A8 region shunt 39 respectively, and finally the voltage signals are transmitted to the control coordination computer 13.

The present invention is described in further detail below with reference to examples: