CN108723550B - Feedforward compensation GTA filler wire additive manufacturing forming height feedback control method - Google Patents
Feedforward compensation GTA filler wire additive manufacturing forming height feedback control method Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- 239000000654 additive Substances 0.000 title claims abstract description 22
- 230000000996 additive effect Effects 0.000 title claims abstract description 22
- 238000000034 method Methods 0.000 title claims abstract description 22
- 239000000945 filler Substances 0.000 title claims abstract description 15
- 238000001514 detection method Methods 0.000 claims abstract description 20
- 229910052751 metal Inorganic materials 0.000 claims abstract description 20
- 239000002184 metal Substances 0.000 claims abstract description 20
- 238000010891 electric arc Methods 0.000 claims abstract description 17
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 23
- 229910052721 tungsten Inorganic materials 0.000 claims description 23
- 239000010937 tungsten Substances 0.000 claims description 23
- 238000007711 solidification Methods 0.000 claims description 6
- 230000008023 solidification Effects 0.000 claims description 6
- 230000003044 adaptive effect Effects 0.000 claims description 3
- 230000003287 optical effect Effects 0.000 claims description 3
- 238000005070 sampling Methods 0.000 claims description 3
- 230000011218 segmentation Effects 0.000 claims description 3
- 238000000605 extraction Methods 0.000 claims 1
- 238000007493 shaping process Methods 0.000 claims 1
- 238000009825 accumulation Methods 0.000 abstract description 7
- 230000000007 visual effect Effects 0.000 abstract description 3
- 239000007787 solid Substances 0.000 abstract 3
- 238000003466 welding Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 238000003708 edge detection Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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- G06T7/0004—Industrial image inspection
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- G06T7/00—Image analysis
- G06T7/10—Segmentation; Edge detection
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- G—PHYSICS
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- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/10—Segmentation; Edge detection
- G06T7/136—Segmentation; Edge detection involving thresholding
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
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Abstract
The invention discloses a feedforward compensation GTA filler wire additive manufacturing forming height feedback control method, which comprises the following steps: the visual sensor collects images of a GTA electric arc, solid metal in front of the electric arc and a molten pool behind the electric arc; detecting the solid metal surface in front of the electric arc and the solid metal surface at the tail part of the molten pool behind the electric arc by an image processing algorithm; respectively calculating the deviation of a feedforward detection point and the deviation of a feedback detection point; compensating the deviation of the feedforward detection point into the deviation of the accumulated feedback detection point, taking the deviation as the input of a feedback controller, and calculating the variation of the control parameter; the method of the invention introduces the height deviation of feedforward detection into the height deviation of feedback detection, effectively overcomes the interference of the accumulation layer on the current accumulation layer height by using the advanced prediction function of the feedforward detection, solves the problem of large height fluctuation of the traditional pure feedback detection control, and lays a strong foundation for the high-precision control of the GTA filler wire additive manufacturing forming height.
Description
Technical Field
The invention belongs to the technical field of electric arc wire filling additive manufacturing, and particularly relates to a feed-forward compensation tungsten electrode inert Gas (GTA) wire filling additive manufacturing forming height feedback control method.
Background
The GTA filler wire additive manufacturing adopts GTA electric arc as a heat source, and auxiliary wire materials as filler materials to build and form the metal component layer by layer. At present, the technology has good application prospect in the manufacture of titanium alloy, nickel-based high-temperature alloy and high-strength aluminum alloy components. However, there are many interference factors in the GTA filler wire additive manufacturing, such as heat dissipation of the deposition layer, disturbance of process parameters, etc., so that the forming height of the current deposition layer is not consistent with the set height for lifting the GTA welding gun. After multilayer accumulation, the distance change of the tungsten needle to the surface of the accumulation layer is obvious. If the distance is too large, the energy of the electric arc is dispersed, and the formation of a deposited layer is deteriorated; if the distance is too small, the tungsten needle contacts the molten pool, so that the molten pool is polluted.
Currently, researchers propose to detect the distance from the tip of a tungsten needle to the surface of the current stacking layer by using a visual sensor and realize feedback control of the stacking height by adjusting process parameters on line. However, the stability of feedback control is poor, and the reason for the uneven control of the height of the formed part is mainly as follows: (1) the conventional feedback detection position is far away from the tip of the tungsten electrode, the detection system has large lag, and the process control belongs to lag control; (2) the non-uniformity in the height of the previous build-up layer has a greater effect on the current build-up layer. In order to improve the uniformity of the stacking height of the formed part and further improve the forming dimension precision, it is necessary to develop a detection and control method considering the interference of the previous stacking layer. Therefore, the invention provides a novel feedback control method for the forming height of GTA filler wire additive manufacturing based on feedforward compensation.
Disclosure of Invention
The invention aims to solve the problems of poor stability and low control precision of the visual feedback control height in the existing GTA additive manufacturing process, and provides a feed-forward compensation GTA filler wire additive manufacturing forming height feedback control method.
In order to achieve the aim, the invention provides a feedforward compensation GTA filler wire additive manufacturing forming height feedback control method, which comprises the following steps:
the method comprises the following steps: adjusting the position of the vision sensor to make the optical center of the vision sensor perpendicular to the plane formed by the GTA gun and the forming path, collecting images of GTA arc, solidified metal in front of the arc and molten pool behind the arc, and setting an ideal control value S from the tip of the tungsten needle to the surface of the forming layer02.5-6.5mm, and the lifting height z of the GTA gun is 0.4-1.9mm after a layer is formed;
step two: igniting GTA electric arc, setting a first rectangular area in the metal solidification area in front of the electric arc along the forming path direction, wherein the distance from the right center of the first rectangular area to the axis of the GTA gun is 6-9mm, and the GTA electric arc is electrifiedSetting a second rectangular area in a metal solidification area at the tail part of a molten pool behind the arc, wherein the distance from the positive center of the second rectangular area to the axis of the GTA gun is 5-15mm, when the sampling time is t, extracting a surface point on the solidified metal in the first rectangular area, namely a feedforward point, by using an image processing algorithm, determining the horizontal distance L from the feedforward point to the tail end of a tungsten needle in the GTA gun, and determining the vertical distance S from the tail end of the tungsten needle to the feedforward point1(t), further extracting a surface point on the solidified metal at the tail of the molten pool in the second rectangular area, namely a feedback point by using an image processing algorithm, and determining the vertical distance S from the feedback point to the tail end of a tungsten needle in the GTA gun2(t)；
Step three: determining a feedforward leading parameter d, and calculating a feedback point deviation error at the time t2(t)＝S2(t)-S0Calculating the feedforward point deviation error at the time t-d1(t-d)＝S1(t-d)-z-S0(ii) a Wherein S is1(t-d) is the vertical distance from the feed-forward point to the end of the tungsten needle at time (t-d);
step four: accumulating and compensating the deviation of the feedforward point into the deviation of the feedback point, and calculating the input deviation E (t) of the feedback controller at the time t2(t)+error1(t-d) calculating the adjustment quantity delta WFS (t) of the control parameter at the time t according to the designed controller and the size and the positive and negative of E (t);
step five: and continuously repeating the second step, the third step and the fourth step, and determining the input deviation E (t +1) of the feedback controller and the adjustment quantity delta WFS (t +1) of the control parameter at the moment (t + 1).
Preferably, the image processing algorithm step described in step two includes noise removal, edge detection, adaptive threshold segmentation, and edge point fitting.
Preferably, the feedforward lead parameter d in step three is determined by the horizontal distance L, GTA from the feedforward point to the end of the tungsten needle in the GTA gun and the detection period of the control system, and d is [ L/(V)/[sT)]Wherein V issThe unit is the moving speed of the GTA gun in mm/s, and the unit is the detection period in s, respectively]Representing a rounding symbol.
Preferably, the feedback controller described in step four is a PID controller or a fuzzy controller.
The method of the invention has the outstanding advantages that: the invention provides a feedback control method for GTA wire-filling additive manufacturing forming height based on feedforward compensation. The method of the invention introduces the height deviation of feedforward detection into the height deviation of feedback detection, effectively overcomes the interference of the accumulation layer on the current accumulation layer height by using the advanced prediction function of the feedforward detection, solves the problem of large height fluctuation of the traditional pure feedback control, and lays a strong foundation for the high-precision control of the GTA filler wire additive manufacturing forming height.
Drawings
FIG. 1 is a block diagram of a feed-forward compensated GTA filler wire additive manufacturing forming height feedback control system;
FIG. 2 is a schematic view of a vision sensor and GTA torch position;
FIG. 3 is an acquired GTA filler wire additive manufacturing raw image;
FIG. 4 is a GTA filler wire additive manufacturing image after image processing;
FIG. 5 is a typical pile height feedback control based on feed forward compensation.
The device comprises a vision sensor 1, a GTA welding gun 2, a wire guide pipe 3, a first window 4 and a second window 5.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention.
As shown in fig. 1, a feed-forward compensated feedback control method for GTA wire-filling additive manufacturing stack height includes the following steps:
the method comprises the following steps: adjusting the position of the vision sensor to make the optical center of the vision sensor perpendicular to the plane formed by the GTA gun and the forming path direction, collecting the image of GTA arc, the solidified metal in front of the arc and the molten pool behind the arc, and setting the ideal control value S from the tip of the tungsten needle to the surface of the forming layer as shown in FIG. 302.5-6.5mm, and the lifting height z of the GTA gun is 0.4-1.9mm after a layer is formed;
step two: igniting GTA electric arc, setting a first rectangular area in a metal solidification area in front of the electric arc along the direction of a forming path, setting the distance from the center of the first rectangular area to the axis of a GTA gun to be 6-9mm, setting a second rectangular area in a metal solidification area at the tail of a molten pool behind the electric arc, setting the distance from the center of the second rectangular area to the axis of the GTA gun to be 5-15mm, when the sampling time is t, extracting a surface point, namely a feedforward point, on the solidified metal in the first rectangular area by using an image processing algorithm, determining the horizontal distance L from the feedforward point to the tail end of a tungsten needle in the GTA gun, and determining the vertical distance S from the tail end of the tungsten needle to the feedforward point1(t), further extracting a surface point on the solidified metal at the tail of the molten pool in the second rectangular area, namely a feedback point by using an image processing algorithm, and determining the vertical distance S from the feedback point to the tail end of a tungsten needle in the GTA gun2(t)；
Step three: determining a feedforward leading parameter d, and calculating a feedback point deviation error at the time t2(t)＝S2(t)-S0Calculating the feedforward point deviation error at the time t-d1(t-d)＝S1(t-d)-z-S0(ii) a Wherein S is1(t-d) is the vertical distance from the feed-forward point to the end of the tungsten needle at time (t-d);
step four: accumulating and compensating the deviation of the feedforward point into the deviation of the feedback point, and calculating the input deviation E (t) of the feedback controller at the time t2(t)+error1(t-d) calculating the adjustment quantity delta WFS (t) of the control parameter at the time t according to the designed controller and the size and the positive and negative of E (t);
step five: and continuously repeating the second step, the third step and the fourth step, and determining the input deviation E (t +1) of the feedback controller and the adjustment quantity delta WFS (t +1) of the control parameter at the moment (t + 1).
The image processing algorithm in the second step includes noise removal, edge detection, adaptive threshold segmentation and edge point fitting, and the processed image is shown in fig. 4.
The feedforward advance parameter d in the third step is determined by the horizontal distance L, GTA from the feedforward point to the tail end of the tungsten needle in the GTA gun and the detection period of the control system, and d is [ L/(V)sT)]Wherein V issThe unit is the moving speed of the GTA gun in mm/s, and the unit is the detection period in s, respectively]Representing a rounding symbol.
The feedback controller described in step four is a PID controller or a fuzzy controller, and fig. 5 is a typical stack height feedback control based on feedforward compensation.
The specific test platform of the invention is as follows: the GTA power supply is Fronius MW300, the GTA welding gun is installed at the end of the sixth shaft of the MOTOMAN robot, the robot drives the GTA welding gun to move, the filling wire material in the accumulation process is JQ.MG70-G-1 low-carbon steel welding wire, the diameter of the welding wire is 1.2mm, and the technological parameters are as follows: the current is 150A, the walking speed of a GTA welding gun is 3.3mm/s, the wire feeding speed is 1.5m/min, the protective gas is pure argon, and the gas flow is 10L/min.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (4)
1. The feed-forward compensation GTA filler wire additive manufacturing forming height feedback control method is characterized by comprising the following steps of:
the method comprises the following steps: adjusting the position of the vision sensor to make the optical center of the vision sensor perpendicular to the plane formed by the GTA gun and the forming path, collecting images of GTA arc, solidified metal in front of the arc and molten pool behind the arc, and settingIdeal control value S of tungsten needle tip to surface of shaping layer02.5-6.5mm, and the lifting height z of the GTA gun is 0.4-1.9mm after a layer is formed;
step two: igniting GTA electric arc, setting a first rectangular area in a metal solidification area in front of the electric arc along the direction of a forming path, setting the distance from the center of the first rectangular area to the axis of a GTA gun to be 6-9mm, setting a second rectangular area in a metal solidification area at the tail of a molten pool behind the electric arc, setting the distance from the center of the second rectangular area to the axis of the GTA gun to be 5-15mm, when the sampling time is t, extracting a surface point, namely a feedforward point, on the solidified metal in the first rectangular area by using an image processing algorithm, determining the horizontal distance L from the feedforward point to the tail end of a tungsten needle in the GTA gun, and determining the vertical distance S from the tail end of the tungsten needle to the feedforward point1(t), further extracting a surface point on the solidified metal at the tail of the molten pool in the second rectangular area, namely a feedback point by using an image processing algorithm, and determining the vertical distance S from the feedback point to the tail end of a tungsten needle in the GTA gun2(t)；
Step three: determining a feedforward leading parameter d, and calculating a feedback point deviation error at the time t2(t)＝S2(t)-S0Calculating the feedforward point deviation error at the time t-d1(t-d)＝S1(t-d)-z-S0(ii) a Wherein S is1(t-d) is the vertical distance from the feed-forward point to the end of the tungsten needle at time (t-d);
step four: accumulating and compensating the deviation of the feedforward point into the deviation of the feedback point, and calculating the input deviation E (t) of the feedback controller at the time t2(t)+error1(t-d) calculating the adjustment quantity delta WFS (t) of the control parameter at the time t according to the designed controller and the size and the positive and negative of E (t);
step five: and continuously repeating the second step, the third step and the fourth step, and determining the input deviation E (t +1) of the feedback controller and the adjustment quantity delta WFS (t +1) of the control parameter at the moment (t + 1).
2. The feed-forward compensated GTA wire-filling additive manufacturing forming height feedback control method of claim 1 wherein the image processing algorithm steps in step two include noise removal, solidified metal edge extraction, image adaptive threshold segmentation and edge point fitting.
3. The feed-forward compensation GTA wire-filling additive manufacturing forming height feedback control method according to claim 1, wherein the feed-forward lead parameter d in step three is determined by the horizontal distance L, GTA from the feed-forward point to the end of the tungsten needle in the GTA gun and the detection period of the control system, and d is [ L/(V) V ]sT)]Wherein V issThe unit is the moving speed of the GTA gun in mm/s, and the unit is the detection period in s, respectively]Representing a rounding symbol.
4. The feed-forward compensated GTA wire-filling additive manufacturing forming height feedback control method of claim 1, wherein the feedback controller in step four is a PID controller or a fuzzy controller.
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| CN112620652B (en) * | 2020-11-27 | 2022-09-27 | 哈尔滨工业大学 | Self-adaptive control system and method for electric arc additive manufacturing process |
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