阅读说明：本技术 激光拼焊板气孔缺陷自动检测系统 (Automatic detection system for air hole defects of laser tailor-welded blank ) 是由 徐志力 臧远明 徐宝发 杨宁 马力 黄海航 王梦思 安思齐 金凌 于 2021-09-28 设计创作，主要内容包括：激光拼焊板气孔缺陷自动检测系统属于焊接缺陷检测技术领域,目的在于解决现有技术存在的现有设备自动检测能力差,检测效率低,检测准确性差,错边焊接中拼焊板头、尾的误报情况的发生以及存在漏检风险的问题。本发明包括：发射装置,所述发射装置以锥形发射形式发射高强度红外光；和所述发射装置相对设置的接收装置,所述接收装置至少包括和发射装置的出射光相对设置的接收镜片,所述接收镜片包括沿焊缝长度方向依次设置的三块；以及计数报警器,所述计数报警器包括计数模块、复位模块和声控模块,所述接收装置的三块接收镜片分别和计数报警器电连接,当仅有中间的接收镜片触发时,计数报警器的声控模块发出报警信号。(Laser tailor-welded blank gas pocket defect automatic check out system belongs to welding defect and detects technical field, and aim at solves the existing equipment automated inspection ability that prior art exists poor, and detection efficiency is low, and it is poor to detect the accuracy, and the emergence of the wrong report condition of tailor-welded blank head, tail and the problem that has the risk of missing examining in the wrong limit welding. The invention comprises the following steps: an emitting device that emits high-intensity infrared light in a cone emission form; the receiving device is arranged opposite to the transmitting device and at least comprises three receiving lenses arranged opposite to emergent light of the transmitting device, and the three receiving lenses are sequentially arranged along the length direction of the welding seam; and the counting alarm comprises a counting module, a resetting module and a voice control module, three receiving lenses of the receiving device are respectively electrically connected with the counting alarm, and when only the middle receiving lens is triggered, the voice control module of the counting alarm sends out an alarm signal.)

1. Laser tailor-welded blank gas pocket defect automatic check out system, its characterized in that includes:

-an emitting device (1), the emitting device (1) emitting high intensity infrared light (102) in the form of a cone emission;

the receiving device (2) is arranged opposite to the emitting device (1), the receiving device (2) at least comprises three receiving lenses arranged opposite to emergent light of the emitting device (1), and the receiving lenses comprise three pieces which are sequentially arranged along the length direction of a welding seam;

and the counting alarm (3), the counting alarm (3) comprises a counting module, a resetting module and a voice control module, three receiving lenses of the receiving device (2) are respectively electrically connected with the counting alarm (3), and when only the middle receiving lens is triggered, the voice control module of the counting alarm (3) sends an alarm signal.

2. The automatic detection system of the air hole defects of the laser tailor welded blank according to claim 1, wherein the emitting device (1) comprises:

a cylindrical launch tube (101);

the light emitter is arranged at one end of the emitting barrel (101) and penetrates through the emitting barrel (101) to emit light rays from the other end;

and a zoom ring (103) arranged at the middle position of the emission barrel (101), wherein the width of the high-intensity infrared light (102) is adjusted through the zoom ring (103).

3. The automatic detection system for the air hole defects of the laser tailor welded blank according to claim 1 or 2, wherein the surface of the emitting device (1) is sealed by a mirror surface.

4. The automatic detection system for the air hole defects of the laser tailor-welded blank according to claim 3, wherein the surface of the emitting device (1) is sealed by a mirror surface, and specifically comprises: and an emission dustproof lens (104) is arranged on one side of a light outlet of the emission device (1).

5. The automatic detection system for the air hole defects of the laser tailor welded blank according to claim 1, wherein the receiving device (2) further comprises a rectangular receiving frame (201); three receiving lenses are arranged on the surface of the receiving frame (201) opposite to the emitting device (1).

6. The automatic detection system for the air hole defects of the laser tailor welded blank according to claim 5, wherein the receiving frame (201) is made of an aluminum alloy material.

7. The automatic detection system for the air hole defects of the laser tailor welded blank according to claim 1 or 5, wherein the surface of the receiving device (2) is sealed by a mirror surface.

8. The automatic detection system for the air hole defects of the laser tailor-welded blank according to claim 7, wherein the surface of the receiving device (2) is sealed by a mirror surface, and specifically comprises: a receiving dustproof lens is arranged outside each receiving lens of the receiving device (2).

Technical Field

The invention belongs to the technical field of welding defect detection, and particularly relates to an automatic detection system for air hole defects of a laser tailor-welded blank.

Background

At present, laser tailor welded blanks have been widely used in the automotive industry, such as vehicle body stringers, frames, floors, door panels, side walls, bumpers, and the like. The quality of the laser tailor-welded blank is an important index for measuring the safety performance of the automobile body, and any quality defect of the laser tailor-welded blank is absolutely not allowed to flow into the next procedure.

At present, the laser tailor welding often has the following typical quality defects: 1. the problem of air holes is generated in the welding process; 2. the problem of misalignment of the head and the tail of the welding seam; 3. the laser welding seam deflects to a single-side plate; 4. the problem of incomplete penetration of welding seams.

The quality defects of weld joint misalignment, welding deviation and incomplete penetration are all caused by improper adjustment of welding parameters, defects in the quality of the section of a raw material, irregular plate shape and the like, and can be solved by ensuring the quality of the raw material and adjusting the technological parameters of equipment. However, the problem of the welding air holes is only solved at the source, which is relatively difficult because the problem not only relates to the quality of raw materials and the technological parameters of equipment, but also relates to the material of the plate (for example, the welding performance is affected by different proportions of elements).

The gas hole phenomenon of laser tailor-welding is mainly in welding process, tiny hole that the welding seam appears, and the diameter is: phi is different from 0.02 to 0.15, the position and the time of the air holes are irregular, however, the following problems exist according to the detection means of the laser welding line manufacturer for the welding quality defects at present:

1: the contrast color difference in the detection system parameters is set, the range is manually set according to the surface color (grey whiteness) of the plate to be welded, the set parameter range is defaulted to be the alarm standard, however, the condition that the plate color difference is similar to the weld color in the actual welding process of the plate, so that false alarm often occurs. The equipment is frequently stopped, the production efficiency is influenced, and meanwhile, the manual secondary 100 percent selection is needed.

2: during the laser tailor-welding process, many small variables occur, such as: the problems of welding smoke dust, laser light transmission, welding slag splashing and the like occur, and the small variables can be brought into a detection range along with the welding line for detection, so that the detection result can be directly influenced. Resulting in false positives and false negatives for the device.

After the equipment is mistakenly reported, the equipment can be directly influenced to stop, a lot of negative influences are generated on production organization, and after the equipment is not reported, products with default quality defects of the automatic production line are qualified products and are transferred to a finished product area, and then the products are packaged and sent to customers (unqualified products flow out). Leading to very serious consequences: 1. customer complaints; 2. affecting the overall safety performance of the whole vehicle.

In order to prevent the generation of two serious consequences, in the prior art, the automatic detection system of the laser tailor-welding machine set is comprehensively upgraded with dust removal, sealing and the like, and the automatic detection system mainly comprises: 1. the irradiation camera of the new generation of detection system is replaced, 2 dust removal ports are added (1 set of dust removal ports is added on the upper surface and the lower surface in front of the detection system respectively), and 3, the upper transmitting and receiving device and the lower transmitting and receiving device of the detection system are completely sealed (the conditions such as light transmission and the like are prevented). Meanwhile, the quality of the laser tailor-welded raw materials is improved, the control requirements are met, burrs (less than 0.05t) and straightness (less than 0.05mm/m) of a welding surface are guaranteed, and the cross section is cleaned in an all-around mode before welding (the cross section is free of foreign matters, oil stains and the like).

Meanwhile, 6 operating personnel trained professionally are additionally arranged to manually select 100% of the air hole problems of all the laser tailor-welded blanks.

And (4) selecting the products with the air hole defects by utilizing artificial vision to detect all welding seams through the irradiation light fixed at the lower end. The visual fatigue is generated by manual selection for a long time, and the following problems still exist: 1. the leakage risk and the air hole quality defect occupation ratio exist, and the existing equipment and manpower can not ensure 100 percent of the outflow risk of the tailor-welded air hole defect. 2. The automatic detection capability of the equipment has defects, a large amount of manual operation is invested, the detection efficiency is low, manpower and material resources are wasted, and 3, the false alarm condition of the head and the tail of the tailor-welded blank in the staggered welding is realized.

Disclosure of Invention

The invention aims to provide an automatic detection system for the air hole defects of a laser tailor-welded blank, which solves the problems of poor automatic detection capability, low detection efficiency, poor detection accuracy, false alarm of the head and the tail of the tailor-welded blank in staggered welding and missed detection risk of the existing equipment in the prior art.

In order to achieve the above object, the automatic detection system for the air hole defect of the laser tailor-welded blank of the present invention comprises:

an emitting device that emits high-intensity infrared light in a cone emission form;

the receiving device is arranged opposite to the transmitting device and at least comprises three receiving lenses arranged opposite to emergent light of the transmitting device, and the three receiving lenses are sequentially arranged along the length direction of the welding seam;

and the counting alarm comprises a counting module, a resetting module and a voice control module, three receiving lenses of the receiving device are respectively electrically connected with the counting alarm, and when only the middle receiving lens is triggered, the voice control module of the counting alarm sends out an alarm signal.

The transmitting device includes:

a cylindrical launch canister;

the light emitter is arranged at one end of the emitting barrel, penetrates through the emitting barrel and emits light rays from the other end of the emitting barrel;

and the zooming ring is arranged in the middle of the transmitting tube, and the width of the high-intensity infrared light is adjusted through the zooming ring.

The surface of the emitting device adopts mirror surface sealing.

The surface of the emitting device is sealed by a mirror surface, and the method specifically comprises the following steps: and a transmitting dustproof lens is arranged on one side of the light outlet of the transmitting device.

The receiving device also comprises a rectangular receiving frame; three receiving lenses are arranged on the surface of the receiving frame opposite to the emitting device.

The receiving frame is made of an aluminum alloy material.

The surface of the receiving device adopts mirror surface sealing.

The surface of the receiving device is sealed by a mirror surface, and the method specifically comprises the following steps: and a receiving dustproof lens is arranged outside each receiving lens of the receiving device.

The invention has the beneficial effects that: the automatic detection system for the air hole defects of the laser tailor-welded blank is a detection alarm device which transmits through an infrared ray conical angle, is received by a receiver after penetrating through an air hole and immediately obtains a signal. Laser tailor-welded blank gas pocket defect automatic check out system has the infrared emission device of specific wavelength, specific high strength range, the specific numerical value of specific wavelength: the wavelength is 635nm, and the specific range values of the specific high intensity range are the intensity ranges: 200-400 mw; the three groups of logic receiving chips are arranged, so that the detection of air holes with any size can be met, and the false alarm condition of the head and the tail of the tailor-welded blank can be avoided.

The installation position and space of the detection system can be completely matched with those reserved in the interior of the equipment body, and the volume of the transmitting and receiving device can not produce any negative influence on the operation of the equipment. Meanwhile, the device can automatically identify the number of the air hole defect problems through the logic programming of the detection feedback signal, and has an integral reset function. The automatic detection capability is high, the detection efficiency is high, the detection accuracy is high, the occurrence of the false alarm condition of the head and the tail of the tailor-welded blank in the staggered welding process is avoided, and the risk of missing detection is avoided.

Drawings

FIG. 1 is a schematic view of the overall structure of an automatic detection system for the air hole defects of a laser tailor-welded blank according to the present invention;

FIG. 2 is a schematic structural diagram of an emitter tube in the automatic detection system for the air hole defects of the laser tailor-welded blank according to the present invention;

FIG. 3 is a structural bottom view of a receiving device in the automatic detection system for the air hole defects of the laser tailor-welded blank according to the present invention;

FIG. 4 is a front view of a receiving device in the automatic detection system for air hole defects of a laser tailor-welded blank according to the present invention;

FIG. 5 is a structural bottom view of a counting alarm in the automatic detection system for the air hole defects of the laser tailor-welded blank of the present invention;

FIG. 6 is a front view of a counting alarm in the automatic detection system for the air hole defects of the laser tailor-welded blank of the present invention;

wherein: 1. the device comprises a transmitting device, 101, a transmitting barrel, 102, high-intensity infrared light, 103, a zooming ring, 104, a transmitting dustproof lens, 2, a receiving device, 201, a receiving frame, 3, a counting alarm, 4, a welding line, 401 and an air hole.

Detailed Description

The following further describes embodiments of the present invention with reference to the drawings.

Definition of the air vent detection system of the present invention: the air hole detection system is an inspection instrument which utilizes the defect of light transmission of a leak of an air hole 4 of a laser tailor-welded product, adopts special wave frequency and high-intensity irradiation light to emit and receive and read feedback absorption signals, and is an effective detection system for any light transmission material or processing parts.

The defects of the laser tailor-welded air holes 4 are holes with different sizes which can be presented on the surface of a welding seam in the welding process, and the sizes of the holes are as follows: 0.01-0.5mm, and the internal structure of the holes is round and smooth. In actual production, the size of the product with the defect of the air hole 4 is about 0.1mm, which is common. The common characteristic of all the defects of the air holes 4 in the laser tailor-welding process is as follows: the holes are through, and the upper surface and the lower surface of the tailor-welded blank are communicated.

A light sensation feedback detection system is adopted: a light emitter and a receiver are used and are arranged in a face-to-face mode inside a designated cavity of the equipment. The light emitter emits infrared light, and the light receiver can receive light under the unobstructed condition. However, when the object to be detected passes through the cavity, the light is blocked, the receiver does not act, and no signal is output. When the object to be inspected has a hole, the receiver receives the light, and the receiver outputs a control signal to connect the load current, thereby completing a control action.

When the width of the infrared rays emitted by the emitter is too wide, the width dimension of the infrared rays on the irradiated plate is larger than 0.05mm, and the air holes 4 coincide with the light rays, the leakage points of the light rays do not completely penetrate through the air holes 4. Therefore, in order to solve the problem, the invention adds an infrared line width adjusting mechanism, namely the zoom ring 103, at the lower end of the cylindrical emitter, and the infrared line width can be directly adjusted through manual rotation. The width and intensity of the infrared ray can be adjusted to be narrow, strong or wide, weak as a whole by the zoom ring 103. This allows detection of any size of vent 4, but also non-vent 4.

Referring to fig. 1-6, the automatic detection system for the defects of the air holes 4 of the laser tailor-welded blank of the present invention comprises:

an emitting device 1, said emitting device 1 emitting high intensity infrared light 102 in a cone emission form; the intensity range in this example is 200mw to 400 mw;

the receiving device 2 is arranged opposite to the emitting device 1, the receiving device 2 at least comprises a receiving lens arranged opposite to the emergent light of the emitting device 1, and the receiving lens comprises three pieces which are sequentially arranged along the length direction of the welding seam;

and the counting alarm 3 comprises a counting module, a resetting module and a voice control module, three receiving lenses of the receiving device 2 are respectively electrically connected with the counting alarm 3, and when only the middle receiving lens is triggered, the voice control module of the counting alarm 3 sends out an alarm signal. The counting alarm 3 can adopt a counting alarm 3 of an invasive sensing technology (Zhongshan) company Limited.

The transmitting device 1 includes:

a cylindrical launch barrel 101;

a light emitter disposed at one end of the emission tube 101 and emitting light from the other end through the emission tube 101;

and a zoom ring 103 disposed at a middle position of the emission tube 101, wherein the width of the high-intensity infrared light 102 is adjusted by the zoom ring 103.

The light line width adjustment of the zoom ring 103 is to adjust focusing by rotating a knob, and the light line width is changed by adjusting the vertical distance by a concave-convex lens in the zoom ring as in the telescope principle. In this embodiment, the disclosure number CN201420244275.5 may be selected for zooming, so as to adjust the width.

The surface of the emitting device 1 adopts mirror surface sealing.

The surface of the emitting device 1 is sealed by a mirror surface, and the method specifically comprises the following steps: and a receiving dustproof lens is arranged on one side of a light outlet of the transmitting device 1.

The receiving device 2 further comprises a rectangular receiving frame 201; three receiving lenses are arranged on the surface of the receiving frame 201 opposite to the emitting device 1.

The receiving frame 201 is made of aluminum alloy.

The surface of the receiving device 2 adopts mirror surface sealing.

The surface of the receiving device 2 is sealed by a mirror surface, and the method specifically comprises the following steps: a transmitting dustproof lens 104 is arranged outside each receiving lens of the receiving device 2.

The head and the tail of the laser tailor-welded blank can have the technological requirement of staggered welding in the product processing, namely, two steel plates with different thicknesses can be welded in an aligned mode or in a non-aligned mode, so that during the detection of the head and the tail, the infrared receiver can be triggered to obtain an alarm signal. Aiming at the problem of false alarm of head and tail detection, a mode of diffusion and partitioning of a receiving area is adopted for improvement.

The invention is provided with 3 equally divided receiving lenses, A, B and C in sequence, the width direction is unchanged, the length direction is evenly distributed, and the commands of adding or cutting in the program of the receiver are as follows:

the receiver is divided into three receiving modules of A/B/C, the emitter emits infrared light, and when only the middle B module is triggered, an alarm signal can be emitted, except that any triggering combination mode cannot be established. The method specifically comprises the following steps:

firstly, when the head or the tail of the receiver is in a wrong side condition, not only the point B is triggered, but also the point A or the point C on the single side is triggered, and at the moment, the receiver cannot send out an alarm signal;

when no plate exists, the A/B/C is triggered completely, and the receiver cannot send out an alarm signal;

when only the air holes 4 appear, the emitted infrared rays are blocked by the plates on the two sides, only the middle light rays can penetrate through the holes, only the middle point B is triggered at the moment, the A/C on the two sides are not triggered, and the receiver can send out an alarm signal immediately.

The alarm information of this application is integrated:

the problem of how to determine the number of the laser tailor-welded air holes 4 after the defects are detected and alarmed is considered. Therefore, the alarm is added with the quantity display function of detecting the defects of the air holes 4 and the quantity display function of welding the tailor-welded blanks, the displayed quantity is the signal sent by the receiver is programmed into a program, the welding quantity can be displayed when a single group of products are welded, and the welding quantity can be automatically displayed when the air holes 4 are detected.

When the alarm system displays the detected number of the air holes 4 or the number of the welding plates, the equipment can be stopped or automatically sorted, and then corresponding resetting and zero resetting can be carried out on the alarm if personnel continue to produce.

In the alarm, a signal for detecting the defect of the air hole 4 is directly fed back to be a sound signal, when the defect of the air hole 4 occurs, the alarm can make a harsh sound, and the sound can be heard no matter the operator is in any direction of the equipment.

Installation area and space:

1: the automatic detection system for the defects of the air holes 4 is arranged in the laser splicing and welding line unit on line, does not interfere with any operation mechanism of equipment, and is arranged between a laser welding point and a blanking area.

Receiver installation space: the length is 50mm, the height is 500mm, and the width is 100 mm. This space directly limits the size of the area of the set of receiving lenses within the receiver interior 3.

Emitter installation control: the length is 50mm, the height is 100+55mm, and the width is 90 mm. The emitters are simply cylinders 18mm x 111mm long.

All fixing supports of the air hole 4 detection system are thin-wall aluminum profiles, connecting parts are fixed in a fastening mode of embedded parts, and all fixing holes are provided with unidirectional adjustment amount.

The infrared transmitter and receiver must be completely sealed because of the internal electrical components, so mirror sealing is adopted on the surfaces of the receiver and the generator.

Installing and debugging:

the installation and debugging of the automatic air hole 4 defect detection system are carried out in a state that the equipment is completely stopped, and the specific installation steps are as follows:

the receiver is installed on the upper fixing frame through 4M 4 screws outside the line, and after no looseness is determined, the power line and the signal line are arranged along the rear end (the direction of the blanking area) of the fixing frame and bound by using an insulating binding tape.

The fixing frame which finishes the offline preparation is installed in the area reserved for the equipment, the fixing screws are fastened by using 4M 6 screws reserved in the equipment body, the horizontal state of the receiver lens is guaranteed, the distance range between the receiver and the plate is guaranteed to be adjusted to be between 100mm and 110mm, and then all the screws are fixed.

The emitter fixing frame is arranged in an area beside a dust removing opening of the equipment, and the used fixing screws are consistent with original screws of the dust removing box.

The wire of the transmitter is firstly sleeved into a fixing ring with the diameter of 20, and then the transmitter is fixed by using an upper M20 round nut and a lower M20 round nut.

And (4) the power line of the emitter is thrown to a 24V power supply reserved in the electric cabinet along the equipment cavity, and then the emitter is connected.

And throwing the power line and the signal line of the receiver to the employee operating platform.

The socket of the alarm is connected with the electric wire and the signal wire of the receiver, and then the alarm is connected with a power supply.

After the equipment is electrified, infrared light emitted by the emitter is oppositely emitted to the receiver, and the light is ensured to be centered but symmetrical on two sides.

And (3) actual verification:

in order to enable the functionality and accuracy of the detection system to meet expectations. The project personnel plan to carry out preliminary on-line detection test on the system:

1. 6-point gaps are automatically manufactured on the welding surface of the prepared welding raw material (holes are ensured to be generated in the welding process), and then tests show that all defects of 6-point air holes 4 give an alarm.

2. Specially, 2 products which are required to be subjected to staggered edge welding at the head and the tail are prepared for the test, and the test result is as follows: the head and the tail have no false alarm, and the effect is very good.

Practice tracking:

in 4 working days after the project is finished, 5180 products and 430 alarm air holes are welded by the laser tailor-welding machine set. In order to ensure the stability and accuracy of the detection system, 6 professional selecting personnel are specially arranged to perform secondary selection on 5150 qualified products, and the conclusion is 100% qualified. The application of the detection system in an automatic production line really meets the requirement of automation.

Automatic gas pocket 4 detecting system that laser tailor-welding unit adopted. Is the first innovative technology aiming at the defect detection of the laser tailor-welded air hole 4 at abroad at present.

The practical application result of the detection system of the invention is as follows:

1. in the time that the air hole 4 detection system is used for nearly 1 year, 56 pieces of laser tailor-welded products produced by the unit are produced, wherein 4990 pieces of air holes are produced, the detection system is completely and automatically identified successfully, no quality information feedback of the air hole 4 is sent to a client, and the condition of missing report is '0'.

2. In 990 pieces of automatically detected defective products with air holes 4, the air holes 4 are found in 100% of the products after secondary sorting, and the false alarm rate is 0.

And (3) benefit measurement:

1. economic benefits are as follows:

after the detection system is successfully put into use, 6 professional selectors can be directly replaced by the automatic system.

Wherein the labor cost is as follows: 6 persons about 5000 yuan/person/month 12 month about 36 ten thousand yuan

Auxiliary materials input in the original selection process: about 2000 yuan.

The development and manufacturing cost of the detection project is 3.5 ten thousand yuan.

The direct economic benefit all year round is 36+ 0.2-3.5-32.7 ten thousand yuan/year

2. Other benefits are as follows:

the laser tailor-welded product is mainly applied to the car body and plays a crucial role in determining the safety performance of the whole car. At present, the total number of automobiles produced in China is about 2800 thousands, and the laser tailor-welding process is applied to 95 percent of commercial automobiles. Laser tailor-welded blanks offered by Baoku occupy a large share of the market. The quality defect of the laser tailor-welding is 0.1 percent, wherein the content of the defects of the air holes 4 in the whole quality defect is 60 percent. According to the calculation, in the laser tailor-welded blank provided by Baoku, the product with the defect of the air hole 4 accounts for 0.06%, and the probability that the product with the potential defect of the air hole 4 flows out of the whole vehicle is about 160 thousands of vehicles.

The detection system is an important means for detecting the quality of laser tailor-welded blanks, and can ensure that all laser tailor-welded blank products provided by Baowu do not have the quality defect of air holes 4 in a client/automobile through online practical application. The safety performance of the whole automobile is ensured, the market competitiveness of laser tailor-welded products is improved, and the image and the credit of Baowu groups are maintained.

Secondly, the successful application of the automatic detection system follows the direction of intelligent/self /unmanned development of modern factories and enterprises, is the embodiment of another innovation in the laser tailor-welding processing field, and is another breakthrough in the intelligent unmanned field of laser tailor-welding quality control.