横向埋弧自动焊摆动跟踪系统研究
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摘要
随着我国石油储备和冶金工程建设的快速发展,以储油罐和冶金高炉为代表的大型钢结构的需求日益增长。大型钢结构的自动化焊接技术已经成为工业发展过程中不可缺少的重要研究课题。经过十几年的发展,国产自动化焊接设备已经可以取代同类进口设备,但仍然有许多的技术不够成熟,焊枪摆动技术与焊缝跟踪技术就是该领域亟待解决的课题。
本文对横向埋弧焊自动焊的应用背景做了深入的研究以作为后面焊枪摆动和焊缝跟踪系统的设计依据。并对国内外关于焊枪摆动与焊缝跟踪的设计成果进行了分析,作为后续设计的参考。根据横向埋弧焊焊枪摆动的技术要求,应用伺服控制技术,可编程控制技术,设计了焊枪摆动自动数字控制系统。解决了焊枪摆动系统在实际工作中可能遇到的问题和难点,如摆动波形控制,摆动速度自适应等。在了解了大型钢结构横向焊缝的结构特点和埋弧横向焊接的工作特点和跟踪难点的前提下,总结前人的设计经验并加入创新性设计,结合激光测距传感技术设计完成了横向埋弧自动焊接机焊缝跟踪系统的设计。通过反复试验调试解决了诸如提高检测信号精度,实时检测延时偏差补偿等跟踪难点。在前几部分的设计成果的基础上,在对所设计硬件和软件的复杂程度以及设计的实用性和经济效益的综合考虑下,提出了三种横向埋弧自动焊摆动跟踪一体机的设计方案,并最终选择一套最优方案,设计出了一台样机,将前几部分的设计成果有机地结合起来。对所设计的横向埋弧焊机摆动跟踪一体机进行了全面的模拟试验和实际焊接试验,证明了所设计的系统可以应用于实际的工程作业。最后,针对本文的研究内容和工作进行了总结,并提出了其中的不足之处和今后改进的方向。
With the rapid development of the oil reserves engineering and metallurgical engineering in our country, the requirement of large steel structure represented by oil tank and metallurgy blast furnace is growing. And the automatic welding of large steel structure has become an important research subject in the process of the development of the industry. After a decade of development, domestic welding automation equipments have already can replace the similar import equipment. But there are still many areas of technology not mature enough. Both welding torch swing technology and seam tracking technology is important research subject to be solved in the field.
The application background of transverse submerged arc welding automatic welding machine is studied deeply in this paper in order to create a foundation for the design welding torch swing and seam tracking system. The achievement of the domestic and international welding torch swing and seam tracking system are analyzed as the reference of future design. According to the technical requirements of welding torch swinging of horizontal submerged arc welding, the swinging automatic welding torch digital control system is designed with Servo control technology and programmable control technology. The potential problems in the practical work are solved by the swinging automatic welding torch digital control system such as swinging waveform controlling,swinging speed adaptive controlling, etc. The design of the horizontal submerged arc welding seam tracking system of automatic welding machine is completed. The design is completed in the premise of understanding the structure characteristics of horizontal seam of the large steel and characteristics of the work of the submerged arc welding and the difficulty of tracking. the previous design experience,the innovative design and the laser displacement sensing technology are summarized and combined in the design. The tracking difficulties such as raising the debugging signal detection accuracy, real-time detection and delay deviation compensation are solved through trial and repeated test debugging. Three design scheme of the horizontal submerged arc welding tracking equipment are proposed and the optimal scheme is chosen finally. And a prototype is designed by combining former design results organically. This part is on the basis of results in the first few parts and the comprehensive consideration of complexity of the software and hardware, the practicality and economic benefit. The simulation experiment and the actual welding test are done to the swinging tracking equipment of horizontal submerged arc welding machine, which demonstrates that the design of the system can be used in the actual work. At last, the disadvantages and improvement in the future are proposed by summarizing the work.
本文对横向埋弧焊自动焊的应用背景做了深入的研究以作为后面焊枪摆动和焊缝跟踪系统的设计依据。并对国内外关于焊枪摆动与焊缝跟踪的设计成果进行了分析,作为后续设计的参考。根据横向埋弧焊焊枪摆动的技术要求,应用伺服控制技术,可编程控制技术,设计了焊枪摆动自动数字控制系统。解决了焊枪摆动系统在实际工作中可能遇到的问题和难点,如摆动波形控制,摆动速度自适应等。在了解了大型钢结构横向焊缝的结构特点和埋弧横向焊接的工作特点和跟踪难点的前提下,总结前人的设计经验并加入创新性设计,结合激光测距传感技术设计完成了横向埋弧自动焊接机焊缝跟踪系统的设计。通过反复试验调试解决了诸如提高检测信号精度,实时检测延时偏差补偿等跟踪难点。在前几部分的设计成果的基础上,在对所设计硬件和软件的复杂程度以及设计的实用性和经济效益的综合考虑下,提出了三种横向埋弧自动焊摆动跟踪一体机的设计方案,并最终选择一套最优方案,设计出了一台样机,将前几部分的设计成果有机地结合起来。对所设计的横向埋弧焊机摆动跟踪一体机进行了全面的模拟试验和实际焊接试验,证明了所设计的系统可以应用于实际的工程作业。最后,针对本文的研究内容和工作进行了总结,并提出了其中的不足之处和今后改进的方向。
With the rapid development of the oil reserves engineering and metallurgical engineering in our country, the requirement of large steel structure represented by oil tank and metallurgy blast furnace is growing. And the automatic welding of large steel structure has become an important research subject in the process of the development of the industry. After a decade of development, domestic welding automation equipments have already can replace the similar import equipment. But there are still many areas of technology not mature enough. Both welding torch swing technology and seam tracking technology is important research subject to be solved in the field.
The application background of transverse submerged arc welding automatic welding machine is studied deeply in this paper in order to create a foundation for the design welding torch swing and seam tracking system. The achievement of the domestic and international welding torch swing and seam tracking system are analyzed as the reference of future design. According to the technical requirements of welding torch swinging of horizontal submerged arc welding, the swinging automatic welding torch digital control system is designed with Servo control technology and programmable control technology. The potential problems in the practical work are solved by the swinging automatic welding torch digital control system such as swinging waveform controlling,swinging speed adaptive controlling, etc. The design of the horizontal submerged arc welding seam tracking system of automatic welding machine is completed. The design is completed in the premise of understanding the structure characteristics of horizontal seam of the large steel and characteristics of the work of the submerged arc welding and the difficulty of tracking. the previous design experience,the innovative design and the laser displacement sensing technology are summarized and combined in the design. The tracking difficulties such as raising the debugging signal detection accuracy, real-time detection and delay deviation compensation are solved through trial and repeated test debugging. Three design scheme of the horizontal submerged arc welding tracking equipment are proposed and the optimal scheme is chosen finally. And a prototype is designed by combining former design results organically. This part is on the basis of results in the first few parts and the comprehensive consideration of complexity of the software and hardware, the practicality and economic benefit. The simulation experiment and the actual welding test are done to the swinging tracking equipment of horizontal submerged arc welding machine, which demonstrates that the design of the system can be used in the actual work. At last, the disadvantages and improvement in the future are proposed by summarizing the work.
引文
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