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Penetration Estimation of GMA Backing Welding Based on Weld Pool Geometry Parameters

Chinese Journal of Mechanical Engineering 2019年第3期32卷 134-144页

作者： junfen huang Long Xue Jiqiang huang Yong Zou Ke Ma Opto-Mechatronic Equipment Technology Beijing Area Major Laboratory Beijing Institute of Petrochemical Technology

Penetration estimation is a prerequisite of the automation of backing welding based on vision sensing technology. However, the arc interference in welding process leads to the difficulties of extracting the weld pool characteristic information, which brings great challenges to the penetration estimation. At present, most researches focus on the extraction of weld pool geometry parameters, and the visual sensing systems are complex in structure and complicated in the image processing algorithms. The research of penetration estimation based on weld pool geometry parameters is still in the exploratory stage. The purpose of this paper is to research the relationship between the weld pool geometry parameters and the penetration during backing welding and to estimate penetration using the weld pool geometry parameters. A passive vision sensing test system for gas metal arc (GMA) backing welding was established. An image processing algorithm was developed to extract the weld pool geometry parameters, namely, the area, maximum width and length, half-length, length-width ratio and advancing contact angle (simplified as AWP, MWWP, MLWP, HLWP, LWR and ACA, respectively). The corresponding relationships between the weld pool geometry parameters and the penetration state were explored by analysing their changes with the welding current and speed. The distribution of the weld pool geometry parameters corresponding to penetration was determined. When the AWP of the weld pool is within a certain range and the values of LWR and ACA are close to their maximum and minimum respectively, the penetration is in good condition. A mathematical model with the weld pool geometry parameters as independent variables and the back-bead width (the indicator of the penetration state) as a dependent variable was established based on multivariable linear regression analysis, and relevant statistical tests were carried out. Multivariable linear regression equations for the weld pool geometry parameter

关键词： Welding automation Passive vision sensing Weld pool geometry parameters Penetration state Mathematical model

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Welding Polarity Effects on Weld Spatters and Bead Geometry of Hyperbaric Dry GMAW

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Chinese Journal of Mechanical Engineering 2016年第2期29卷 351-356页

作者： XUE Long WU Jinming huang junfen huang Jiqiang ZOU Yong LIU Jian Opto-Mechatronic Equipment Technology Beijing Area Major Laboratory Beijing Institute of Petrochemical Technology

Welding polarity has influence on welding stability to some extent, but the specific relationship between welding polarity and weld quality has not been found, especially under the hyperbaric environment. Based on a hyperbaric dry welding experiment system, gas metal arc welding（GMAW） experiments with direct current electrode positive（DCEP） and direct current electrode negative（DCEN） operations are carried out under the ambient pressures of 0.1 MPa, 0.4 MPa, 0.7 MPa and 1.0 MPa to find the influence rule of different welding polarities on welding spatters and weld bead geometry. The effects of welding polarities on the weld bead geometry such as the reinforcement, the weld width and the penetration are discussed. The experimental results show that the welding spatters gradually grow in quantity and size for GMAW with DCEP, while GMAW with DCEN can produce fewer spatters comparatively with the increase of the ambient pressure. Compared with DCEP, the welding current and arc voltage waveforms for DCEN is more stable and the distribution of welding current probability density for DCEN is more concentrated under the hyperbaric environment. When the ambient pressure is increased from 0.1 MPa to 1.0 MPa, the effects of welding polarities on the reinforcement, the weld width and the penetration are as follows： an increase of 0.8 mm for the weld reinforcement is produced by GMAW with DCEN and 1.3 mm by GMAW with DCEP, a decrease of 7.2 mm for the weld width is produced by DCEN and 6.1 mm by DCEP; and an increase of 3.9 mm for the penetration is produced by DCEN and 1.9 mm by DCEP. The proposed research indicates that the desirable stability in the welding procedure can be achieved by GMAW with DCEN operation under the hyperbaric environment.

关键词： welding polarity hyperbaric welding gas metal arc welding(GMAW) weld bead geometry spatter

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Constant Speed Control for Complex Cross-section Welding Using Robot Based on Angle Self-Test

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Chinese Journal of Mechanical Engineering 2014年第2期27卷 260-268页

作者： XUE Long ZOU Yong huang Jiqiang huang junfen TAO Xinghua HU Yanfeng Opto-Mechatronic Equipment Technology Beijing Area Major Laboratory Beijing Institute of Petrochemical Technology School of Automation Science and Electrical Engineering Beihang University SINOPEC Research Institute of Petroleum Engineering

Expandable profile liner（EPL） is a promising new oil well casing cementing technique, and welding is a major EPLs connection technology. Connection of EPL is still in the stage of manual welding so far, automatic welding technology is a hotspot of EPL which is one of the key technologies to be solved. A robot for automatic welding of＂8＂ type EPL is studied. Four quadrants of mathematical equations of the 8-shaped cross-section track of EPL, consisting of multiple arcs, are established. Mechanism program for complex cross-section welding of EPL based on angle detection is proposed according to characteristics of small size, small valleys, and large forming errors, etc. A welding velocity vector control model is established by linkage control of a welding vehicle, a small driven actuator, and a height tracking mechanism. A constant speed control model based on an angle and symmetrical analysis model of rectangular coordinate system for EPL is built. Constraint conditions of constant speed control between each section are analyzed with 4 sections in first quadrant as an example, and cooperation work mechanism of the welding vehicle and the small tracking actuator is established based on pressure detection. The constant speed control model using angle self-test can be used to avoid the need for a precise mathematical model for tracking control and to adapt manufacture and installation deviation of EPL workpiece. The model is able to solve constant speed and trajectory tracking problems of EPL cross-section welding. EPL seams welded by the studied robot are good in appearance, and non-destructive testing（NDT） shows the seams are good in quality with no welding defects. Bulge tests show that the maximum pressure of welded EPL is 35 MPa, which can fulfill expansion performance requirements.

关键词： expandable profile liner welding robot minitype driven actuator velocity vector model

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Welding Deviation Detection Algorithm Based on Extremum of Molten Pool Image Contour

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Chinese Journal of Mechanical Engineering 2016年第1期29卷 74-83页

作者： ZOU Yong JIANG Lipei LI Yunhua XUE Long huang junfen huang Jiqiang College of Automation Science and Electrical Engineering Beihang University Optical Electromechanical Equipment Technology Key Laboratory of Beijing Beijing Institute of Petrochemical Technology

The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding（GMAW） molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels（0.16 ram）, and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.

关键词： welding deviation welding seam tracking molten pool contour curvature extremum gas metal arc welding(GMAW)

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布里渊光子晶体光纤环形移频器

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红外与激光工程 2012年第8期41卷 2125-2129页

作者：黄民双黄军芬北京石油化工学院光机电装备技术北京市重点实验室北京102617

通过实验研究了一种光子晶体光纤环形移频器,该移频器基于布里渊频移原理,利用光子晶体光纤布里渊增益高、阈值低的特点,同时利用光纤环形腔选频放大技术获得窄线宽高增益激光输出。实验结果表明:在波长为1 548 nm单纵模光纤激光泵浦下,... 详细信息

通过实验研究了一种光子晶体光纤环形移频器,该移频器基于布里渊频移原理,利用光子晶体光纤布里渊增益高、阈值低的特点,同时利用光纤环形腔选频放大技术获得窄线宽高增益激光输出。实验结果表明:在波长为1 548 nm单纵模光纤激光泵浦下,10 m长光子晶体光纤的受激布里渊散射阈值功率约为457mW,环形腔输出的受激布里渊散射Stokes光相对于入射光移频量为9.778GHz、线宽500 kHz,并且移频量可以通过温度进行微调。该移频器可以用于分布式光纤布里渊传感器和微波发生器。

关键词：光子晶体光纤光纤环形振荡器受激布里渊散射温度特性光纤移频器

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水下高压焊接中摄像系统的离焦现象及校正

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上海交通大学学报 2016年第10期50卷 1618-1621,1626页

作者：黄继强黄军芬薛龙邹勇北京石油化工学院光机电装备技术北京市重点实验室北京102617

从折射率的角度出发,分析了水下高压焊接过程中摄像系统的焦面偏移(离焦)现象,以及温度和环境压力对折射率的影响规律;同时,结合实际的高压焊接实验设计了自动调焦系统,采用离散余弦变换方法构造频谱评价函数作为图像评判依据,以改进的... 详细信息

从折射率的角度出发,分析了水下高压焊接过程中摄像系统的焦面偏移(离焦)现象,以及温度和环境压力对折射率的影响规律;同时,结合实际的高压焊接实验设计了自动调焦系统,采用离散余弦变换方法构造频谱评价函数作为图像评判依据,以改进的爬山搜索算法作为自动调焦算法,并通过实验加以验证.结果表明,所设计的水下高压焊接摄像自动调焦系统能够解决高压焊接摄像的离焦问题,并获得较为清晰的高压焊接电弧图像.

关键词：水下焊接高压焊接摄像系统离焦校正

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基于二维小波变换及图像模式识别的焊缝坡口识别

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机械工程学报 2005年第2期41卷 162-165页

作者：蒋力培黄军芬殷树言石油化工学院装备技术研究所北京102617 北京工业大学机电学院北京100022

采用二维小波变换及二值化方法处理初始条件下管道焊缝坡口图像,获取焊缝坡口纹理信息,作为模板。对后续坡口图像进行同样的小波变换及二值化处理,利用模式识别方法获取后续图像焊缝坡口及其中心线的基本位置信息,研究的焊缝坡口识别... 详细信息

采用二维小波变换及二值化方法处理初始条件下管道焊缝坡口图像,获取焊缝坡口纹理信息,作为模板。对后续坡口图像进行同样的小波变换及二值化处理,利用模式识别方法获取后续图像焊缝坡口及其中心线的基本位置信息,研究的焊缝坡口识别算法为实现自然光下焊缝坡口实时跟踪提供了理论依据。

关键词：二维小波变换模式识别

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三维焊缝图像传感技术

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焊接学报 2006年第8期27卷 12-14页

作者：冯音琦黄民双黄军芬蒋力培北京石油化工学院光机电装备技术北京市重点实验室北京102617

介绍一种采用光栅莫尔条纹技术的三维焊缝图像传感系统,它由交角很小的两块黑白透射光栅和CCD摄像机镜头等元件构成,根据系统的光路结构找出变形的莫尔条纹相对焊缝的上表面相对偏移量与焊缝形貌的函数关系,得到焊缝的三维信息。阐述了... 详细信息

介绍一种采用光栅莫尔条纹技术的三维焊缝图像传感系统,它由交角很小的两块黑白透射光栅和CCD摄像机镜头等元件构成,根据系统的光路结构找出变形的莫尔条纹相对焊缝的上表面相对偏移量与焊缝形貌的函数关系,得到焊缝的三维信息。阐述了实现方法以及图像处理过程,并进行了获取焊缝三维图像的试验。结果表明,这种光栅莫尔条纹三维测量技术提取图像信息简单,可以获得焊缝的边缘形状和焊缝坡口的大致形貌,适用于焊缝图像的精确特征识别和提取。

关键词：莫尔条纹三维图像焊缝

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基于多因素权重法的高压GMAW焊缝成形分析

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焊接学报 2018年第10期39卷 75-80,132页

作者：郑朋朋薛龙黄继强黄军芬北京石油化工学院光机电装备技术北京重点实验室北京102617

水下高压干式GMAW焊缝成形难以控制,影响焊接质量,通过多因素权重法对影响高压GMAW焊缝成形的参数进行分析,以确定焊接过程中主要参数与焊缝成形之间的关系.以高压GMAW焊接正交试验结果作为训练样本,利用BP神经网络建立了焊缝成形预测模... 详细信息

水下高压干式GMAW焊缝成形难以控制,影响焊接质量,通过多因素权重法对影响高压GMAW焊缝成形的参数进行分析,以确定焊接过程中主要参数与焊缝成形之间的关系.以高压GMAW焊接正交试验结果作为训练样本,利用BP神经网络建立了焊缝成形预测模型.将模型预测结果与实际焊接试验结果进行对比,验证了模型的精确度.以预测模型中的权值为基础,通过Garson算法得出各参数变量对于焊缝成形参数的权重系数,并通过高压干式GMAW试验进行验证.结果表明,不同焊接参数变化引起的焊缝成形参数变化幅度与相应焊接参数对焊缝成形的影响权重基本对应,所得权重系数对于高压GMAW焊接工程应用具有指导作用.

关键词：高压焊接多因素权重焊缝成形神经网络

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全光纤集成式焊缝图像传感系统

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焊接学报 2009年第6期30卷 63-66页

作者：黄民双黄军芬唐建蒋力培北京石油化工学院光机电装备技术北京市重点实验室北京102617

提出了一种新的全光纤集成式线结构光投影焊缝图像传感系统,其中激光线结构光投影光场由传光光纤和集成在其输出端面的微型柱面透镜产生,焊缝激光图像由光纤传像束接收.利用光线理论分析了大芯径石英光纤出射端面的近场强度分布和光纤... 详细信息

提出了一种新的全光纤集成式线结构光投影焊缝图像传感系统,其中激光线结构光投影光场由传光光纤和集成在其输出端面的微型柱面透镜产生,焊缝激光图像由光纤传像束接收.利用光线理论分析了大芯径石英光纤出射端面的近场强度分布和光纤传像束传输激光焊缝图像的特性.结果表明,激光经过大芯径光纤传输后,有利于提高投影条纹的质量;激光焊缝图像经过传像光纤传输后,由于光纤的空间滤波效应,大部分图像噪声被滤除.试验结果与理论分析基本一致.

关键词：光强分布空间滤波焊缝图像光纤传感

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