磁控窄间隙埋弧焊跟踪传感器及熔宽自适应方法的研究

发布时间：2018-05-21 07:40

本文选题：磁控埋弧焊 + 窄间隙传感器　；参考：《湘潭大学》2017年硕士论文

【摘要】：随着我国对电力结构及容量需求的调整,导致对高参数、大容量的电站锅炉需求日益增大。其中锅筒是锅炉中最为重要的承压部件。在现代锅筒制造中,焊接是不可或缺的技术之一。为了获得优良的焊接质量,较高的生产效率,较安全的作业环境,同时要减轻工人的劳动强度,需提高焊接智能化、自动化水平。而焊缝自动跟踪是实现焊缝自动化的关键技术之一。本文针对电站锅筒的自动焊接问题,开展磁控窄间隙埋弧焊跟踪传感器和熔宽自适应方法的研究。(1)结合磁控电弧和窄间隙埋弧焊的特点,设计一种新型的跟踪传感器,并阐述了设计理念和方案;针对传统磁控电弧传感器的励磁电源模块出现的波形失真、信号调节困难等问题,重新设计波形发生电路和功率放大电路,减小激磁波形失真度,增强其抗干扰能力,简化信号调节机制,有利于后续跟踪试验的研究和分析。(2)建立磁控窄间隙埋弧焊跟踪传感器的结构仿真模型,针对导磁硅芯部件的横截面参数进行COMSOL磁场仿真,依据电弧摆动的磁场要求,优化跟踪传感器的模型;针对焊接中传感器过热问题,设计智能水冷系统,通过试验有效地验证智能水冷系统的冷却能力。(3)依据窄间隙坡口的特点,建立磁控窄间隙埋弧焊跟踪传感器的摆动电弧角和电弧弧长的数学模型,运用Simulink搭建其仿真模型,获得不同坡口的电压特征信号规律,为焊缝自动跟踪的偏差信号提供参考依据。(4)采用二阶Butterworth滤波与VMD组合滤波方法对实际电压特征信号进行滤波处理,有效地证明该滤波能力;为识别和检测窄间隙坡口类别,提出一种电压转相与均值电压差值法组合方法;依据电压特征信号的特点,设计以LM393为核心的定位采集电路,建立熔宽自适应焊缝跟踪系统,达到熔宽自调节和焊缝跟踪的要求。(5)在自行搭建的磁控窄间隙埋弧焊跟踪系统平台上进行焊缝跟踪试验,结果表明焊缝跟踪效果良好,熔宽自适应焊缝跟踪系统工作稳定,实时性好,焊缝熔宽调节能力较强。
[Abstract]:With the adjustment of power structure and capacity demand in China, the demand for high parameter and large capacity utility boilers is increasing day by day. The boiler drum is the most important pressure-bearing part in the boiler. Welding is one of the indispensable techniques in modern pot barrel manufacture. In order to obtain good welding quality, higher production efficiency, safer working environment and reduce the labor intensity of workers, it is necessary to improve the level of welding intelligence and automation. Automatic seam tracking is one of the key technologies to realize weld automation. In this paper, aiming at the problem of automatic welding of boiler tube in power station, a new type of tracking sensor is designed, which combines the characteristics of magnetically controlled arc welding and narrow gap submerged arc welding, and develops the research of magnetically controlled narrow gap submerged arc welding tracking sensor and the adaptive melting width method. Aiming at the problems of waveform distortion and signal adjustment in the excitation power supply module of traditional magnetron arc sensor, the waveform generating circuit and power amplifier circuit are redesigned to reduce the distortion of excitation waveform. Enhancing its anti-jamming ability, simplifying the signal regulation mechanism, which is helpful to the research and analysis of follow-up tracking test. (2) to establish the structural simulation model of magnetically controlled narrow gap submerged arc welding tracking sensor. According to the magnetic field requirement of arc swing, the model of tracking sensor is optimized, and the intelligent water-cooling system is designed to solve the problem of overheating of sensor in welding. According to the characteristics of narrow gap groove, the mathematical model of the swing arc angle and arc length of magnetically controlled narrow gap submerged arc welding tracking sensor is established, and the simulation model is built by Simulink. The law of voltage characteristic signal of different groove is obtained, which provides reference for the deviation signal of weld seam automatic tracking. (4) the method of combining second-order Butterworth filter and VMD filter is used to filter and process the actual voltage characteristic signal, which effectively proves the filtering ability. In order to identify and detect the type of narrow gap groove, a combination method of voltage phase shift and mean voltage difference method is proposed, and according to the characteristics of voltage characteristic signal, a positioning acquisition circuit with LM393 as the core is designed, and an adaptive weld tracking system is established. To meet the requirement of self-adjusting of weld width and seam tracking, the welding seam tracking test is carried out on the platform of magnetically controlled narrow gap submerged arc welding tracking system. The results show that the seam tracking effect is good, and the adaptive weld tracking system works stably. Good real-time, weld width adjustment ability.
【学位授予单位】：湘潭大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG409;TP212

【参考文献】