A Detection Method of Wire Feeding Speed Based on Filtering Algorithm of Distortion Signal

doi:10.16183/j.cnki.jsjtu.2021.270

Abstract

Abstract:

Wire feeding speed has an important effect on the welding quality. In order to realize robot intelligent welding, it is necessary to study the accurate detection method of the wire feeding speed. First, the working principle of the wire feeding speed detection is studied, thus the wire feeding speed online detection can be realized. Then, a kind of wire feeding speed detection system is designed, which wirelessly transmits the sensing signal of the welding wire to the welding robot. Finally, the detection method of the wire feeding speed based on the filtering algorithm of distortion sensing signal is studied, including the principle of no mutation of adjacent wire feeding speed sensing signal, the interference signal elimination algorithm for adjacent detection signal of multiple sensing signal loss without abrupt change, and the detection method of the wire feeding speed. The experimental results show that the main noise in the original wire feeding speed sensing signal can be eliminated by using the designed algorithm and system, and the accuracy of the wire feeding speed detection can be improved. In addition, the width of weld pass after robot welding can not be affected by the change of the welding current.

Key words: wire feeding speed, distortion signal, filtering algorithm, online detection, robot welding

CLC Number:

TG409

LE Jian, LIU Yichun, ZHANG Hua, CHEN Xiaoqi. A Detection Method of Wire Feeding Speed Based on Filtering Algorithm of Distortion Signal[J]. Journal of Shanghai Jiao Tong University, 2022, 56(10): 1334-1340.

Figures/Tables 8

Fig.1

Fig.2

Fig.3

Fig.4

Fig.5

Tab.1

Detection accuracy of wire feeding speed

U/V	I/A	$v - 2$ / (cm·s^-1)	$v - 1$ / (cm·s^-1)	δ₁/%	$v -$ / (cm·s^-1)	δ₂/%
25	170	9.43	50.08	431.07	9.51	0.8
25	210	14.2	161.86	1039.86	13.3	6.3

Tab.1

Fig.6

References 11

[1]	PU J H, ZHAO Y, JIANG Y M, et al. Influence of wire feeding speed on the melting behavior and formation of narrow-gap joint by laser welding with filler wire[J]. Journal of Laser Applications, 2020, 32(3): 032007. doi: 10.2351/7.0000043 URL
[2]	周丹, 李翠, 易鑫, 等. 送丝速度对铝/钢激光填丝熔钎焊性能的影响[J]. 焊接, 2019(3): 38-43.
	ZHOU Dan, LI Cui, YI Xin, et al. Influence of wire feeding speed on properties of laser weld-brazed joints of aluminum/steel[J]. Welding & Joining, 2019(3): 38-43.
[3]	NARSIMHACHARY D, SHARIFF S M, PADMANABHAM G, et al. Influence of wire feed rate on mechanical and microstructure characteristics of aluminum to galvanized steel laser brazed joint[J]. Journal of Manufacturing Processes, 2019, 39: 271-281. doi: 10.1016/j.jmapro.2019.02.017 URL
[4]	MILANI A M, PAIDAR M, KHODABANDEH A, et al. Influence of filler wire and wire feed speed on metallurgical and mechanical properties of MIG welding-brazing of automotive galvanized steel/5754 aluminum alloy in a lap joint configuration[J]. International Journal of Advanced Manufacturing Technology, 2016, 82(9/10/11/12): 1495-1506. doi: 10.1007/s00170-015-7505-4 URL
[5]	殷传亚, 邢彦锋, 金光灿, 等. 送丝速度对6061铝合金/DP590镀锌钢CMT点塞焊接头性能的影响[J]. 热加工工艺, 2018, 47(11): 183-185.
	YIN Chuanya, XING Yanfeng, JIN Guangcan, et al. Effects of wire feeding speed on properties of CMT spot plug welding joint of 6061 aluminum alloy and DP590 galvanized steel[J]. Hot Working Technology, 2018, 47(11): 183-185.
[6]	黄麒霖, 张延松. 送丝速度对铝合金脉冲MIG焊能量输入及温度场数值仿真的影响[J]. 热加工工艺, 2021, 50(1): 112-116.
	HUANG Qilin, ZHANG Yansong. Influence of wire feeding speed on heat input and temperature field numerical simulation of pulse MIG welding for aluminum alloy[J]. Hot Working Technology, 2021, 50(1): 112-116.
[7]	WANG J F, SUN Q J, MA J K, et al. Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding[J]. Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2019, 233(10): 2061-2073. doi: 10.1177/0954405418811783 URL
[8]	于世宝, 刘翥寰, 史涛, 等. 送丝速度对三丝间接电弧焊稳定性及焊缝成形的影响[J]. 焊接技术, 2021, 50(1): 35-39.
	YU Shibao, LIU Zhuhuan, SHI Tao, et al. Effect of wire feeding speed on the stability and weld formation of triple-wire indirect arc welding[J]. Welding Technology, 2021, 50(1): 35-39.
[9]	HUANG L, CHEN X Z, KONOVALOV S, et al. The effect of wire feeding speed on solidification cracking of CMT welding for Al-Si alloys[J]. Metals, 2021, 11(2): 267. doi: 10.3390/met11020267 URL
[10]	张栋, 陈茂爱, 武传松. 高速CMT焊送丝速度和焊接电流波形参数的优化[J]. 焊接学报, 2018, 39(1): 119-122.
	ZHANG Dong, CHEN Maoai, WU Chuansong. Optimization of waveform parameters for high speed CMT welding of steel[J]. Transactions of the China Welding Institution, 2018, 39(1): 119-122.
[11]	YAO P, XUE J X, ZHOU K. Study on the wire feed speed prediction of double-wire-pulsed MIG welding based on support vector machine regression[J]. International Journal of Advanced Manufacturing Technology, 2015, 79(9/10/11/12): 2107-2116. doi: 10.1007/s00170-015-7039-9 URL