研究目的
Addressing the variation in welding torch to work distance (welding height) in tube-to-tubesheet welding to prevent undercuts and burn-through by introducing a machine vision system with a cross-line laser as the structured light for measurement and control.
研究成果
The cross-lines laser aided machine vision system effectively controls welding height in tube-to-tubesheet welding, with static and dynamic detection errors no more than 0.007 and 0.016 mm respectively. The compensation error for 115 tubes when WHVV = 1 mm varied from ?0.037 to +0.028 mm, demonstrating the system's reliability and stability.
研究不足
The dynamic detection error and compensation accuracy are influenced by the position deviation of cross-lines laser locating tube center, the error of image processing algorithm, and the locating error of mechanical parts. The larger the variation value of welding height, the larger the compensation error.
1：Experimental Design and Method Selection:
A machine vision system with a cross-line laser as structured light was developed to measure welding height for adaptive correction and control. An image processing algorithm was proposed to extract the ICCL (intersection coordinate of cross-lines laser) for welding height variation.
2：Sample Selection and Data Sources:
The workpiece was a tubesheet (material Q345R) with specific dimensions, and tubes of certain sizes were used. The system included a cartesian-coordinate robot, a TIG welding machine, a CCD camera, a welding torch, and a rotating assembly.
3：List of Experimental Equipment and Materials:
CCD camera (Teledyne DALSA company, Genie Nano M2420), cross-lines laser (wavelength 660 nm, laser power 100 mW), tubesheet (material Q345R), tubes (inner diameter 19 mm, wall thickness 2.5 mm, length 60 mm).
4：5 mm, length 60 mm).
Experimental Procedures and Operational Workflow:
4. Experimental Procedures and Operational Workflow: The system was tested for static and dynamic detection errors and compensation accuracy. The relationship between WHVV and ICCL was established, and welding height control was implemented based on this relationship.
5：Data Analysis Methods:
The relationship between ICCL and WHVV was analyzed using linear regression equation of least square method. Performance was evaluated based on static and dynamic detection errors and compensation accuracy.
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