CN102157094B - Electrode manipulation track analysis and evaluation method during manual welding simulation operation training - Google Patents
Electrode manipulation track analysis and evaluation method during manual welding simulation operation training Download PDFInfo
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Abstract
The invention relates to an electrode manipulation track analysis and evaluation method during manual welding simulation operation training, which is used for the introduction, improvement and enhancement training of the welding and electrode manipulation of welders. In the electrode manipulation track analysis and evaluation method, manipulation essentials of ensuring a welding line to be straight, controlling appropriate welding speed and welding line width, appropriately stopping on a welding line edge, and the like during the electrode manipulation are considered and the manipulative skills of the welders from the straightness, the uniformity, the homogeneous degree, the welding line width control and the welding line edge stopping time of a track and the similarity of different electrode manipulation tracks are analyzed and evaluated. By applying the electrode manipulation track analysis and evaluation method, the welders can train a series of manipulations, i.e. arc strike, electrode manipulation, ending, and the like, and manipulation tracks appear again after the manipulations are completed; and in addition, according to the invention, the learning efficiency and the learning effect are enhanced.
Description
Technical field
The invention belongs to welding analog and emulation training field, be specifically related to arc manipulation trajectory analysis and evaluation method in a kind of manual welding simulation operation training.
Background technology
It is high to tackle in traditional welding training field energy consumption, pollutes greatly, and the realistic situation that qualified teachers lack becomes the new focus in welding training field gradually based on the simulation welding training of virtual reality technology and high-precision sensor technology.The simulation welding training not only has energy-conservation, environmental protection, characteristics of high efficiency, simultaneously also through in training, introduce multimedia technology and infotech to traditional welding training reform, for having brought new approaches and new model in the welding training field.Developed country carries out early the research that virtual reality technology is applied to the welding training field in the world.In 2002; The virtual welding training system that Australia University of Wollongong (UNIVERSITY OFWOLLONGONE) publishes an article and set forth them; Their system is in the various welding operation technical ability that guarantee comprehensive training and development welder; Shorten the welders training time, reduce training cost, consumptive material and the energy.Chiba, Japan university (CHIBA UNIVERSITY) also published an article in 2002 and has described them in the achievement of simulating the welding training field.The Laurent DADALTO company of France has taken the lead in realizing the commercialization of virtual welding training equipment in the whole world.Now they produced in batches " CS-WAVE " by name virtual welding training equipment and in develop into a few days ago the 4th generation product.Than abroad, it is later relatively that the simulation welding training of domestic moulding occurs, but in technological innovation, embody very wide thinking, and also more can use the national conditions of covered arc welding to China in a large number.In March, 2008, " the welding rod space real-time positioning technology in the dull and stereotyped welding simulation of arc welding " that Shanghai Normal University proposes based on the binocular imaging principle served virtual welding training system.Xi'an Communications University's institute of welding was developed the welding operation analog training system since 2003.Related patent U.S. Patent No. was successfully developed and applied for to the former of this system in 2008, and the basic training function of elementary welders training can be provided.
Rod-moving operation is important training problem in the covered arc welding training process, its on top of degree determined a welder's weld horizontal to a great extent.Though the butt welding labour movement bar operation of simulation welding training both domestic and external system all has enough attention, does not all form a basic training and evaluation method.Xi'an Communications University in the application number of application on June 29th, 2009 is: 200910023097.7, and the patent that name is called " covered arc welding rod-moving operation analog training device and arc welding rod-moving detection method " has obtained license on February 9th, 2011.This device is used in the welder and welds crossing the threshold, improving of rod-moving operation and improve training, comprises simulated welding gun, simulation test plate (panel), image detection module, obliquity sensor, main control computer and evaluation system.Through choose reasonable, layout and the efficient data processing of sensor, realized high Precision Detection to the real time position of welder's operation simulation welding rod.This device can write down sequence of operations such as welding student striking in operating process, arc manipulation, ending, and after operation is accomplished, reappears operation trace, can improve learning efficiency and results of learning.
Summary of the invention
The object of the present invention is to provide arc manipulation trajectory analysis and evaluation method in a kind of manual welding simulation operation training.Under the guide of this method; Adopt ZL200910023097.7 covered arc welding rod-moving operation analog training device (HTS) to realize welder's operation being analyzed and being estimated from arc manipulation track aspect; And finally welder's welding operation is provided scoring, effectively instruct the welder to give training and the destination of study thereby reach.
For achieving the above object, the technical scheme that the present invention adopts is:
1) arc manipulation track detection
The simulation welding rod is at first got Ray Of Light to the simulation test plate (panel); Ccd video camera is a hot spot at the image that seizure light beam below the test plate (panel) is become on test plate (panel); Video camera is transferred to the image of taking in the main control computer then; Position through the position coordinates that calculates hot spot draws electrode tip stores the electrode tip position coordinates at last, is used for the reproduction of welding rod arc manipulation track;
2) optical detection
At first video camera needs initialization, and the image pixel gray-scale value of gathering is put into buffer address; Deposit the gray scale numerical value in the buffer address in array, in array, seek the maximum pixel of gray-scale value again, and compare with the striking threshold value of 200-210 gray-scale value; If max pixel value is greater than the striking threshold value, system begins to analyze the data of being gathered, and the pixel specification of the CCD chip of used video camera is 768 * 576; Drawing the pairing image coordinate of maximum gradation value pixel through CCD chip specification and the numbering of maximum gradation value pixel in array, then, is the center with the maximum gradation value; Define the tracing area of one 31 pixel * 31 pixels, the hot spot on the image necessarily is included within this zone, and be provided with the hot spot of a 170-180 gray-scale value and describe threshold value this moment; Describing threshold value to grey scale pixel value in the tracing area and hot spot compares; What describe threshold value greater than hot spot is exactly hot spot, and what describe threshold value less than hot spot is exactly the black background part, obtains all hot spot pixels thus; And according to hot spot topmost with bottom and the pixel coordinate of high order end and low order end calculate the pixel coordinate at bright spot center; At last, the pixel coordinate of bright spot is stored, be converted into the real time position that actual coordinate just can obtain welding rod simultaneously;
3) arc manipulation track reproducing
Utilize the every separated 40-120ms of timer to repeat above-mentioned optical detection; And obtain a series of coordinates on the arc manipulation track in the middle of the position coordinates that records put into array by the time order, again adjacent coordinates is coupled together the approximate arc manipulation track that obtains welder's operation with straight line;
4) pre-service of arc manipulation track
4.1) abating the noise reduces error
Find out the fluctuation range M that the simulation welding rod detects same position through observation and record, get current detection coordinates P (x y) surveys detection coordinates F (x with a last circulation at every turn; Y) compare, if the absolute value of the difference of the two is then got current detection coordinates P (x outside M; Y) be final check point coordinate, if the absolute value of the difference of the two thinks then that within scope M the change of this time testing result is caused by noise, then gets P (x; Y)=and F (x, y);
Before the arc manipulation track is analyzed, repeating among the data storage array F () a little got rid of, will go heavy data to put into new array P () then, can get rid of basically through above two steps operation and detect inaccurate coordinate in the data;
4.2) arc manipulation track coding
The arc manipulation track of simulation welding rod is made up of a series of vectors, and the shape information of arc manipulation track is kept in the middle of the direction of each vector, and the size information of arc manipulation track is kept in the middle of the size of vector; All direction vectors in [π, π] encompasses plane are with [π; π] be divided into 12 five equilibriums, be numbered { 1,2 respectively; 3......12}; Thereby make that each arc manipulation track vector can both corresponding numbering, the mode that the direction of an arc manipulation track is changed with coding shows, and also promptly the mode through coding extracts the shape information of track;
Because the arc manipulation track is cycle graph, every track is the repetition of a certain cycle graph, and then the coding that transforms out also will demonstrate periodically, accomplishes the division in arc manipulation track cycle through the track coding;
4.3) " linearity " of track
What " linearity " of simulation welding rod arc manipulation track characterized is that the welder keeps the straight ability of weld seam in operating process; Draw its mid point for the data point on the track in each cycle through computing; Through the actual flatness that reflects the mid point line of the variance of each mid point on the Y direction is " linearity "; " linearity " estimate the variance that is mid point Y coordinate, variance is estimated being converted into 100 through the mathematics conversion with interior score value, reflect the straight level of its control weld seam;
4.4) " all once " of track
" all once " is the number of unit distance intercycle on the directions X of track; At first calculate the distance C (i) between each cycle mid point on the arc manipulation track; Then C (i) is asked variance; The F that draws directly reflects " all once ", through the mathematics conversion variance is estimated being converted into 100 with interior score value at last, reflects the level of its control speed of welding;
4.5) " uniformity coefficient " of track
" uniformity coefficient " refers to the situation of the area difference in size that each cycle covered in the arc manipulation track; Every line segment two-end-point in the arc manipulation track cycle and mid point line be the some triangles of formation just; Draw the area in track cycle through calculating triangle area and then summation; Through the line method cycle graph is divided into some triangles, the three limit methods that re-use are obtained leg-of-mutton area, and summation draws the area of cycle graph again; At last the area of cycle graph is asked variance, institute's value converts the level of its control weld width of centesimal system number reflection into through mathematics;
4.6) weld width control
The width of weld seam is by each maximum of points decision in the arc manipulation track; Maximum of points and minimum point are coupled together the up-and-down boundary that obtains weld seam with connecting line respectively; The actual welds width is compared in the standard weld width; Draw the situation that butt welded seam width in welder's operating process is held, the number percent that the actual line length through the part in the basis of calculation accounts for the total line length in whole welding line edge then is that the welder is in final achievement aspect the weld width control;
4.7) the weld edge residence time
Because the detection position coordinate time is carried out by some cycles T; Thereby the sampling time of any two adjacent data coordinate points difference all is T; And dwell point one fixes on the weld edge; The number k of data point in positive and negative one millimeter around the value point on the statistics weld edge; Promptly count weld edge residence time t (n)=T * k, contrast the welder at last, account for all percentages that are worth most a little at the value point of standard in the residence time and be the last achievement of welder in the actual residence time of weld edge and standard time;
4.8) " similarity " of track
Convert every track into 1～12 track coding, form the track chain code, and each chain code value number of different arc manipulation tracks accounts for the number percent of all chain code value numbers and also can have any different, a contrast different tracks shared percentage of chain code value P (n) | n=1; 2,3...12} with Q (n) | n=1,2,3...12}; Get S=∑ Min{P (n), Q (n) | n=1,2; 3...12} be final comparing result and 0≤S≤1, S has reflected two degree that the arc manipulation track is similar in shape, two shapes are identical; The S value that the track contrast that varies in size obtains is 1, and the S that diverse track obtains is 0, and remaining most tracks all have certain similarity.
Its fidelity of arc manipulation track that described step 3) obtains depends on the frequency that detects hot spot, and it detects frequency is 20Hz.
The present invention is directed to the problem that exists in traditional welders training, operate the arc manipulation track from the welder and start with, welder's operant level is given and evaluation and guidance.Through rod-moving operation being divided into the sequence of operations main points, from " linearity ", " uniformity coefficient ", " all once ", " weld width control ", " the weld edge residence time " and the different arc manipulation track " similarity " of track welder's operative skill is carried out assay to the different operation main points.This method has characteristics: (1) applicability: this method is not limited to by the arc manipulation gimmick, is applicable to the welding arc manipulation track of Any shape; (2) comprehensive: the consideration of this method synthesis rod-moving operation main points with influence the factor of rod-moving operation, provided comprehensive assay to welding rod-moving operation.(3) science: the model that this method is set up is divided into the aspect of a plurality of investigations with the arc manipulation track of complicacy, has reflected the quality of arc manipulation track and even welder operation intuitively, has certain science.
Description of drawings
Fig. 1-a is actual serrate arc manipulation track;
Fig. 1-b is a serrate arc manipulation track under the perfect condition;
Fig. 2 is the structural representation of ZL200910023097.7 covered arc welding rod-moving operation analog training device (HTS);
Fig. 3 is a detection of code process flow diagram of the present invention;
Fig. 4 is that bright spot pixel is followed the tracks of synoptic diagram;
The track that Fig. 5 is made up of a series of vectors;
Fig. 6 is the vector coding schematic diagram;
Fig. 7-a is a standard serrate arc manipulation track;
Fig. 7-b is a standard crescent arc manipulation track;
Fig. 8 is the relevant track of the present invention's " linearity ", and wherein (a) is welder's arc manipulation track, (b) is track cycle center, (c) is the one-period in the track;
Fig. 9 is the arc manipulation track that inhomogeneous weldering speed produces, and wherein (a) is that weldering speed is crossed slow zone, (b) is weldering fast too fast zone, (c) the track cycle line of centres;
Figure 10 is the relevant track of uniformity coefficient, (a) track mid point line wherein, (b) arc manipulation track;
Figure 11 is an area computation method, (a) serrate arc manipulation track cycle wherein, (b) crescent arc manipulation track cycle;
Figure 12 is the weld seam developed width, the value point in (a) arc manipulation track wherein, (b) a value point line;
Figure 13 is the width contrast of actual welds and standard weld, (a) standard weld edge wherein, and (b) the actual welds edge exceeds the part of standard, (c) part of actual welds edge in standard;
Figure 14 is the weld edge residence time, (a) actual residence time point wherein, (b) standard residence time line;
Figure 15 is a chain code value number percent pie chart.
Embodiment
Below in conjunction with accompanying drawing the present invention is done further explain.
Three basic exercises of the general branch of arc manipulation: send to the molten bath along the welding rod center line; Move along direction of welding; Teeter.Welding rod is that the high-quality arc length is constant in the process that welding rod constantly melts to the purpose that the molten bath direction is sent to.Send the speed should be identical under the welding rod with the burn-off rate of welding rod.Otherwise, current interruption or welding rod and weldment bonding phenomenon can take place.Welding rod moves along direction of welding, is in order to control figuration of bead.Narrower, the lack of penetration or defective such as welding bead is too high, wide even occur burning of welding bead can appear in welding rod move forward excessive velocities or cross slowly.
The present invention is devoted to propose a complete welder of cover and operates arc manipulation analysis and evaluation method, through reflecting welder's operant level on this method macroscopic view, embodies the weak link of welder's operation on the microcosmic, makes the welder can weld training targetedly.Through observing, can find that the arc manipulation track of reality all is made up of a series of cycle graphs, form by a plurality of irregular little triangles like the serrate arc manipulation track that Fig. 1-a is actual.Under perfect condition, serrate arc manipulation track should present the form like Fig. 1-b, and no matter is which type of arc manipulation track, can be regarded as the combination of cycle graph.Through cycle graph is analyzed, and then reflection whole piece arc manipulation track quality is that thought is estimated in fundamental analysis of the present invention.The present invention mainly is divided into two aspects, estimates for the wall scroll trajectory analysis on the one hand; Be the comparative evaluation between the different arc manipulation tracks on the one hand in addition.
The main points of welding arc manipulation basic operation are to guarantee that weld seam is straight, control suitable weldering speed and weld width, do suitable stop at weld edge.The wall scroll trajectory analysis combines above-mentioned main points; From " linearity ", " uniformity coefficient ", " all once ", " weld width control " and " the weld edge residence time " five aspects of track assay is carried out in the arc manipulation basic operation, and which aspect of pointing out in welder's operating process that can be concrete is not controlled well.
Then mainly pay close attention to " similarity " for different arc manipulation track contrasts.Suppose in use; Generated an arc manipulation track by welding coach demonstration; The student just can oneself operate on HTS afterwards; The arc manipulation track that generates is compared with it, and its " similarity " can explain to a certain extent that then the student operates and train the gap of operation, thereby can train more targetedly.Simultaneously, after different students' arc manipulation track and same standard trajectory compared, the difference of " similarity " also can reflect the difference of operant level between the student to a certain extent.
(1) arc manipulation track detection
Accurately and efficiently welding position detection in real time is the basis that draws the arc manipulation track and carry out assay.The HTS of a new generation adopts the optical detection principle, catches the welding operation position in real time through the CCD industrial camera, and the arc manipulation track reflects the most at last.
Referring to Fig. 2; The present invention adopts ZL200910023097.7 covered arc welding rod-moving operation analog training device (HTS), and simulation welding rod 5 is at first got Ray Of Light to simulation test plate (panel) 6, and this moment, light emitting diode 8 was luminous; Ccd video camera 1 is a hot spot at the image that seizure light beam below the simulation test plate (panel) 6 is become on simulation test plate (panel) 6; Video camera 1 is transferred to main control computer 3 with the image of taking through image pick-up card 2 then, and the position through the position coordinates that calculates hot spot draws electrode tip is shown by display screen 4; At last the electrode tip position coordinates is stored, be used for the reproduction of welding rod arc manipulation track;
(2) optical detection principle
Only need pay close attention to the X-Y coordinate of welding gun end on surface level owing to accomplish the collection of arc manipulation track, therefore of the present invention focusing on carried out detection computations to the X-Y coordinate of hot spot on the simulation test plate (panel).Like figure, at first video camera needs initialization like the detection of code flow process of Fig. 3, and the image pixel gray-scale value of gathering is put into buffer address; Deposit the gray scale numerical value in the buffer address in array, in array, seek the maximum pixel of gray-scale value again, and compare with the striking threshold value of 200-210 gray-scale value.If max pixel value is greater than the striking threshold value; System begins to analyze the data of being gathered; The pixel specification of the CCD chip of used video camera is 768 * 576, draws the pairing image coordinate of maximum gradation value pixel through CCD chip specification and the numbering of maximum gradation value pixel in array, then; With the maximum gradation value pixel is the center, defines the tracing area of one 31 pixel * 31 pixels.Like Fig. 4, peripheral square frame is represented tracing area, the lattice represent pixel, and circle is represented hot spot.Among the figure, black is on behalf of the maximum pixel of brightness.Hot spot on the image necessarily is included within this zone; The hot spot that be provided with a 170-180 gray-scale value this moment is described threshold value, describes threshold value to grey scale pixel value in the tracing area and hot spot and compares, and what describe threshold value greater than hot spot is exactly hot spot; What describe threshold value less than hot spot is exactly the black background part; Obtain all hot spot pixels thus, and according to hot spot topmost with bottom and the pixel coordinate of high order end and low order end calculate the pixel coordinate at bright spot center, at last; The pixel coordinate of bright spot is stored, be converted into the real time position that actual coordinate just can obtain welding rod simultaneously;
(3) arc manipulation track reproducing
Utilize that timer is every to repeat above-mentioned optical detection at a distance from 40-120ms, and just obtained a series of coordinates on the arc manipulation track in the middle of the position coordinates that records put into array by the time order.Again adjacent coordinates is coupled together with straight line and just can be similar to the arc manipulation track that obtains welder's operation.And its fidelity of arc manipulation track that draws thus depends on that to a great extent system detects the frequency of hot spot, and it is high more to detect the high more then validity of frequency.The system that draws in the experiment detects frequency can reach 20Hz, and this frequency can satisfy the needed resolution of arc manipulation track reproducing fully, operates the arc manipulation track like Fig. 1-a for the welder who is reproduced by the HTS system.
(4) pre-service of arc manipulation track
4.1) abating the noise reduces error
Owing to adopt the method for optical detection, can cause the bias lights such as natural light in the environment to bring error for detecting as location welding rod end position.For example in actual detected, when simulation welding rod position was actionless, detected position coordinates still had small fluctuation.Find out the fluctuation range M that the simulation welding rod detects same position through observation and record, get current detection coordinates P (x y) surveys detection coordinates F (x with a last circulation at every turn; Y) compare, if the absolute value of the difference of the two is then got current detection coordinates P (x outside M; Y) be final check point coordinate, if the absolute value of the difference of the two thinks then that within scope M the change of this time testing result is caused by noise, then gets P (x; Y)=and F (x, y);
For the arc manipulation track, the data point of repetition does not have practical meaning in addition, therefore before the arc manipulation track is analyzed, need repeating among the data storage array F () a little be got rid of, and will go heavy data to put into new array P () then.Basically can get rid of inaccurate coordinate in the detection data through above two steps operation.
4.2) arc manipulation track coding
Forms by frame position coordinate line in front and back for the hot spot that the track that the present invention collects is taken by video camera, simultaneously owing to poor if having time between the frame of front and back, can think direction frame coordinate after the coordinate points of former frame of track.Therefore, arc manipulation track (Fig. 5) that can think to form by a series of vectors.Wherein Fig. 5 (a) is a vector in the track.Then can think that the shape information of arc manipulation track mainly is kept in the middle of the direction of each vector, the size information of track then is kept in the middle of the size of vector.For the analysis of wall scroll arc manipulation track, need take all factors into consideration its shape and size, but then mainly consider the similar of its profile for the Study on Similarity of different arc manipulation tracks.Therefore need a kind of method further to extract the shape information of arc manipulation track.
Therefore all direction vectors in [π, π] encompasses plane can be divided into 12 five equilibriums with [π, π] as everyone knows, be numbered respectively 1,2,3......12}.The direction of track vector is carried out correspondence according to Fig. 6, thereby make that each track vector can both corresponding numbering.Can the mode that the direction of an arc manipulation track changes with coding be showed through the method, also promptly the mode through coding extracts the shape information of track.
In addition, the arc manipulation track is a cycle graph, and every track can be regarded the repetition (like Fig. 7-a and 7-b) of a certain cycle graph as, and then the coding that transforms out also will demonstrate certain periodicity.It is one of main thought of this research that the arc manipulation track is divided into that all after dates analyze again.And can accomplish the division in arc manipulation track cycle easily through the track coding.Therefore, the track coding also is the basis of whole trajectory analysis research.
4.3) " linearity " of track
Weld seam is straight to be that the welding beginner is training an early stage required elementary object that reaches, and also is one of indispensable quality of elementary welder.In the present invention, what characterize is that the welder keeps the straight ability of weld seam in operating process to " linearity " of arc manipulation track (abbreviating " linearity " at the back as)." linearity " is that the minimum part of difficulty also is the basis of other aspect researchs in the trajectory analysis research.
Like Fig. 8, (a) be the serrate arc manipulation track of welder's practical operation, this track is similar to (c) " mountain peak " shape cycle graph by several and forms.Can draw its mid point (b) through computing for the data point on the track in each cycle.Through observing mid point the varying in size on the Y direction can find each cycle, and the actual flatness that reflects the mid point line of the variance of each mid point on the Y direction also is appreciated that to be " linearity "." linearity " estimate the variance that is mid point Y coordinate, further can variance be estimated being converted into 100, thereby give the welder with direct feedback with interior score value through the mathematics conversion, reflect the straight level of its control weld seam.
4.4) " all once " of track
" all once " can be interpreted as the number of unit distance intercycle on the directions X of track.In welder's learning process, the bad phenomenon of weldering speed control system can occur, high too high or slag inclusion, lack of penetration appears burning, thickens in some position that shows as weld seam on the macroscopic view.In view of " all once " of track, then showed as, and when weldering speed is slow excessively, too much cycle graph can on unit distance, occur; Very few cycle graph (Fig. 9) can appear on unit distance when weldering speed is too fast.Therefore, adopt " all once " tolerance can well reflect the speed control technical ability that the welder operates.Further observing (like Fig. 9), can to find to cross in the slow zone (a) the track cycle line of centres (distance) in weldering speed shorter relatively, and the track cycle line of centres (distance) is longer relatively in welding fast too fast zone (b).So the length that can adopt the cycle line of centres (c) reflects " all once " of whole piece track.
At first calculate the distance C (i) between each cycle mid point on the arc manipulation track.Then C (i) is asked variance, the F that draws directly reflects " all once ".Can variance be estimated being converted into 100 at last through the mathematics conversion, thereby give the welder, reflect the level of its control speed of welding with direct feedback with interior score value.
4.5) " uniformity coefficient " of track
When the welding arc manipulation; If each track cycle may be caused slag inclusion when institute's region covered varies in size; The problem that defective such as undercut and weld width differ, therefore outstanding welder should be able to guarantee the consistance of each cycle size in the track in rod-moving operation." uniformity coefficient " refers to the situation of the area difference in size that each cycle covered in the arc manipulation track.In addition, " uniformity coefficient " is that above-mentioned " linearity " and " all once " one is strong additional, because make discovery from observation, well weld defects (Figure 10) still possibly occur under situation at " linearity " and " all once ".Fine like Figure 10 track " linearity " and " all once ", but clearly the size differences in track cycle is very big, still can cause weld defects and weld width to differ in the case to influence weld seam attractive in appearance.Therefore, this research adopts " uniformity coefficient " to measure the size in track cycle.
The size in cycle is appreciated that the area size into cycle graph, because type of gesture is had nothing in common with each other, its cycle graph also has very big difference, selects suitable area formula to carry out planimeter emphasis at last.The arc manipulation track is that a series of coordinate points through camera acquisition are formed by connecting, and therefore no matter is that serrate arc manipulation track or crescent arc manipulation track can be regarded as by numerous line segment and form.Simultaneously; In the preceding text by the agency of how to obtain the mid point in each track cycle; And every line segment two-end-point in the cycle and mid point line can form some triangles just; Then can draw the area in track cycle through calculating triangle area and then suing for peace, and do regardless of the profile in track cycle.Like Figure 11, through the line method cycle graph is divided into some triangles, the three limit methods that re-use are obtained leg-of-mutton area, and summation just can draw the area of cycle graph again.At last the area of cycle graph is asked variance, give the welder with direct feedback, reflect the level of its control weld width thereby institute's value converts the centesimal system number into through mathematics.
4.6) weld width control
The width control of weld seam is an important skill of welders training, also is simultaneously one of key factor that guarantees weldquality and profile.Can reflect very directly easily that through welding arc manipulation track the welder controls the real standard of weld width.The width of weld seam is seen (a) among Figure 12 mainly by each is worth a decision most in the arc manipulation track, further maximum of points and minimum point is used connecting line respectively, sees among Figure 12 that (b) couples together the up-and-down boundary that just can obtain weld seam.
The purpose of taking out the actual welds width is to compare with the standard weld width, and then can draw the situation that the butt welded seam width is held in welder's operating process.Like Figure 13, the actual welds edge has been divided into two parts by the standard weld edge, exceeds part (b) and (c).The number percent that actual line length through the part in the basis of calculation accounts for the total line length in whole welding line edge then is that the welder is in final achievement aspect the weld width control.
4.7) the weld edge residence time
Because weldment is generally metal, heat conduction is very fast, and the weld edge temperature is lower when causing During normal welding, is easy to generate undercut or defective such as fusion not.Therefore when arc manipulation, need do slightly to stop to prolong heat time heating time and prevent that above-mentioned defective from producing at weld edge.What " the weld edge residence time " investigated is exactly whether the welder has kept the rational residence time at the edge of weld seam in rod-moving operation; Otherwise the time causes the defective of undercut or incomplete fusion inadequately easily, and defective such as overlong time is prone to cause burning or burn.Therefore, what need do at first is to calculate the weld edge residence time, again through comparing the rationality of weighing operation with the standard time.
HTS in the detection position coordinate time carry out by some cycles T, thereby the sampling time of any two adjacent data coordinate points difference all is T, and dwell point one fixes on the weld edge.Therefore, if on the statistics weld edge value point on every side in positive and negative one millimeter the number k of data point just can count weld edge residence time t (n)=T * k.Contrast the welder at last in the actual residence time of weld edge and standard time, account for all percentages that are worth most a little at the value point of standard in the residence time and be the last achievement of welder (like Figure 14).
4.8) " similarity " of track
Can know that by preceding text every track can convert 1～12 track coding into, forms the track chain code.And accounting for the number percent of all chain code value numbers, each chain code value number of different arc manipulation tracks also can have any different.Like Figure 15 is the shared number percent pie charts of different chain code values, and the pie chart of different arc manipulation tracks will be distinguished to some extent.A contrast different tracks shared percentage of chain code value P (n) | n=1,2,3...12} and Q (n) | n=1,2,3...12} gets S=∑ Min{P (n), Q (n) | n=1,2,3...12} is final comparing result and 0≤S≤1.S has reflected two degree that the arc manipulation track is similar in shape, and two shapes are identical, and the S value that the track contrast that varies in size obtains is 1, and the S that diverse track obtains is 0, and remaining most tracks all have certain similarity.
Claims (2)
1. arc manipulation trajectory analysis and the evaluation method in the manual welding simulation operation training is characterized in that its concrete steps are following:
1) arc manipulation track detection
The simulation welding rod is at first got Ray Of Light to the simulation test plate (panel); Ccd video camera is a hot spot at the image that seizure light beam below the test plate (panel) is become on test plate (panel); Video camera is transferred to the image of taking in the main control computer then; Position through the position coordinates that calculates hot spot draws electrode tip stores the electrode tip position coordinates at last, is used for the reproduction of welding rod arc manipulation track;
2) optical detection
Each gray values of pixel points in the two field picture of gathering is taken out from internal memory, and deposit array in, in array, seek the maximum pixel of gray-scale value; And compare with the striking threshold value of 200-210 gray-scale value, if max pixel value is greater than the striking threshold value, system begins to analyze the data of being gathered; The pixel specification of the CCD chip of used video camera is 768 * 576, draws the pairing image coordinate of maximum gradation value pixel through CCD chip specification and the numbering of maximum gradation value pixel in array, then; With bright spot is the center; Define the tracing area of one 31 pixel * 31 pixels, the hot spot on the image necessarily is included within this zone, and be provided with the hot spot of a 170-180 gray-scale value and describe threshold value this moment; Describing threshold value to grey scale pixel value in the tracing area and hot spot compares; What describe threshold value greater than hot spot is exactly hot spot, and what describe threshold value less than hot spot is exactly the black background part, obtains all hot spot pixels thus; And according to hot spot topmost with bottom and the pixel coordinate of high order end and low order end calculate the pixel coordinate at bright spot center; At last, the pixel coordinate of bright spot is stored, be converted into the real time position that actual coordinate just can obtain welding rod simultaneously;
3) arc manipulation track reproducing
Utilize the every separated 40-120ms of timer to repeat above-mentioned optical detection; And obtain a series of coordinates on the arc manipulation track in the middle of the position coordinates that records put into array by the time order, again adjacent coordinates is coupled together the approximate arc manipulation track that obtains welder's operation with straight line;
4) pre-service of arc manipulation track
4.1) abating the noise reduces error
Through observing and write down the scope M of the fluctuation of finding out the detection of simulation welding rod same position, get current detection coordinates P (x is y) with last one the survey detection coordinates F (x that circulates at every turn; Y) compare, if the absolute value of the difference of the two is then got current detection coordinates P (x outside M; Y) be final check point coordinate, if the absolute value of the difference of the two thinks then that within scope M the change of this time testing result is caused by noise, then gets P (x; Y)=and F (x, y);
Before the arc manipulation track is analyzed, repeating among the data storage array F () a little got rid of, will go heavy data to put into new array P () then, can get rid of basically through above two steps operation and detect inaccurate coordinate in the data;
4.2) arc manipulation track coding
The arc manipulation track of simulation welding rod is made up of a series of vectors, and the shape information of arc manipulation track is kept in the middle of the direction of each vector, and the size information of arc manipulation track is kept in the middle of the size of vector; All direction vectors in [π, π] encompasses plane are with [π; π] be divided into 12 five equilibriums, be numbered { 1,2 respectively; 3 ... 12 }; Thereby make that each arc manipulation track vector can both corresponding numbering, the mode that the direction of an arc manipulation track is changed with coding shows, and also promptly the mode through coding extracts the shape information of track;
Because the arc manipulation track is cycle graph, every track is the repetition of a certain cycle graph, and then the coding that transforms out also will demonstrate periodically, accomplishes the division in arc manipulation track cycle through the track coding;
4.3) " linearity " of track
What " linearity " of simulation welding rod arc manipulation track characterized is that the welder keeps the straight ability of weld seam in operating process; Draw its mid point for the data point on the track in each cycle through computing; Through the actual flatness that reflects the mid point line of the variance of each mid point on the Y direction is " linearity "; " linearity " estimate the variance that is mid point Y coordinate, variance is estimated being converted into 100 through the mathematics conversion with interior score value, reflect the straight level of its control weld seam;
4.4) " all once " of track
" all once " is the number of unit distance intercycle on the directions X of track; At first calculate the distance C (i) between each cycle mid point on the arc manipulation track; Then C (i) is asked variance; The variance F of the C that is drawn (i) directly reflects " all once ", through the mathematics conversion variance is estimated being converted into 100 with interior score value at last, reflects the level of its control speed of welding;
4.5) " uniformity coefficient " of track
" uniformity coefficient " refers to the situation of the area difference in size that each cycle covered in the arc manipulation track; Every line segment two-end-point in the arc manipulation track cycle and mid point line be the some triangles of formation just; Draw the area in track cycle through calculating triangle area and then summation; Through the line method cycle graph is divided into some triangles, the three limit methods that re-use are obtained leg-of-mutton area, and summation draws the area of cycle graph again; At last the area of cycle graph is asked variance, institute's value converts the level of its control weld width of centesimal system number reflection into through mathematics;
4.6) weld width control
The width of weld seam is by each maximum of points decision in the arc manipulation track; Maximum of points and minimum point are coupled together the up-and-down boundary that obtains weld seam with connecting line respectively; Actual welds width and standard weld width are compared; Draw the situation that butt welded seam width in welder's operating process is held, the number percent that the actual line length through the part in the basis of calculation accounts for the total line length in whole welding line edge then is that the welder is in final achievement aspect the weld width control;
4.7) the weld edge residence time
Because the detection position coordinate time is carried out by some cycles T; Thereby the sampling time of any two adjacent data coordinate points difference all is T; And dwell point one fixes on the weld edge; The number k of data point in positive and negative one millimeter around the value point on the statistics weld edge; Promptly count weld edge residence time t (n)=T * k, contrast the welder at last, account for all percentages that are worth most a little at the value point of standard in the residence time and be the last achievement of welder in the actual residence time of weld edge and standard time;
4.8) " similarity " of track
Convert every track into 1 ~ 12 track coding, form the track chain code, and each chain code value number of different arc manipulation tracks accounts for the number percent of all chain code value numbers and also can have any different, the shared percentage of contrast each chain code value of different tracks P (n) | n=1; 2,3 ... 12} with Q (n) | n=1,2,3 ... 12 }; Get S=∑ Min P (n), Q (n) | n=1,2; 3 ... 12 } be final comparing result and 0≤S≤1, S has reflected two degree that the arc manipulation track is similar in shape, and two shapes are identical; The S value that the track contrast that varies in size obtains is 1, and the S that diverse track obtains is 0, and remaining most tracks all have certain similarity.
2. arc manipulation trajectory analysis and evaluation method in the manual welding simulation operation training according to claim 1 is characterized in that: its fidelity of arc manipulation track that described step 3) obtains depends on the frequency that detects hot spot, and it detects frequency is 20Hz.
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| 李铁良等.手弧焊焊接速度测试装置研究.《焊接技术》.2000,第29卷(第06期),26-27. * |
| 王友江 等.改变层间运条方法提高焊条电弧焊质量.《电焊机》.2004,第34卷(第10期),49-51. * |
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