基于电极位移的点焊飞溅量化评价与自适应控制研究

doi:10.3969/j.issn.1004-132X.2022.09.002

中国机械工程 ›› 2022, Vol. 33 ›› Issue (09): 1025-1033.DOI: 10.3969/j.issn.1004-132X.2022.09.002

基于电极位移的点焊飞溅量化评价与自适应控制研究

李欢, 吕天乐, 夏裕俊, 李永兵

上海交通大学上海市复杂薄板结构数字化制造重点实验室, 上海, 200240

收稿日期:2021-11-11 出版日期:2022-05-10 发布日期:2022-05-17
通讯作者: 夏裕俊(通信作者),男,1991年生,博士后研究人员。研究方向为电阻点焊质量在线评价与控制。发表论文12篇。E-mail:xyjdbgt6509@sjtu.edu.cn。
作者简介:李欢,女,1997年生,硕士研究生。研究方向为电阻点焊飞溅识别与管控。E-mail:qingxi@sjtu.edu.cn。
基金资助:
国家自然科学基金联合基金(U1764251);国家自然科学基金(52025058,51805323,52175345);机械系统与振动国家重点实验室开放基金课题(MSVZD202111)

Adaptive Control Research and Quantitative Evaluation of Resistance Spot Welding Expulsion Based on Electrode Displacement

LI Huan, LYU Tianle, XIA Yujun, LI Yongbing

Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240

Received:2021-11-11 Online:2022-05-10 Published:2022-05-17

摘要/Abstract

摘要： 飞溅是电阻点焊过程中一种常见的缺陷，严重的飞溅会显著影响焊接质量。针对典型的异常工况，通过飞溅金属量化分析与飞溅骤停实验，发现电极位移信号突变量与飞溅金属总质量之间线性相关，且电极位移信号突变量与飞溅前后熔核厚度减少量基本一致，因此电极位移信号突变量可以表征飞溅程度。在此基础上，提出了基于量化统计的点焊飞溅自适应控制策略，制定了以飞溅程度和飞溅概率为输入,以调幅系数、调幅时刻、调幅时长等电流调幅参数为输出的模糊控制策略，同时根据恒能量与恒功率补时策略确定了补时时长、补时电流等补时参数。使用两种强度的板材验证了该策略的效果。实验结果表明，与恒流焊接模式相比，该方法能有效抑制飞溅，减小压痕深度，增大熔核直径，与传统短时电流调幅策略相比，该方法减少了调幅次数和补时时间，有效提高了焊接效率。

关键词: 电阻点焊, 位移信号, 异常工况, 自适应控制

Abstract: Expulsion was a common problem in resistance spot welding, which seriously affected the welding quality. Aiming at the typical abnormal conditions, through the quantitative analysis of expulsion metals and expulsion sudden stop experiments, it is shown a strong linear correlation between the sudden of electrode displacement signal and the total mass of expulsion metals is found, and the sudden of electrode displacement signals is basically the same as the reduction of nugget thickness before and after expulsions. Therefore, the sudden of electrode displacement signals may characterize the degree of expulsion. Based on this, the adaptive control strategy of spot welding expulsion was proposed based on quantitative statistics. The fuzzy control strategy was formulated with expulsion degree and expulsion probability as inputs and current amplitude modulation parameters such as amplitude modulation coefficient, amplitude modulation time and amplitude modulation duration time as outputs. The time compensation parameters such as time compensation length and time compensation current were determined according to the time compensation strategy of constant energy and constant power. The effectiveness of the strategy was verified by using two kinds of strength sheets. Experimental results show that compared with constant current welding, the method herein may effectively suppress expulsion, reduce indentation depth and increase nugget diameter. Compared with the traditional short-time current amplitude modulation strategy, the method reduces the number of amplitude modulation and the time of time compensation, and effectively improves the welding efficiency.

Key words: resistance spot welding, displacement signal, abnormal condition, adaptive control

中图分类号:

TP183

李欢, 吕天乐, 夏裕俊, 李永兵. 基于电极位移的点焊飞溅量化评价与自适应控制研究[J]. 中国机械工程, 2022, 33(09): 1025-1033.

LI Huan, LYU Tianle, XIA Yujun, LI Yongbing. Adaptive Control Research and Quantitative Evaluation of Resistance Spot Welding Expulsion Based on Electrode Displacement[J]. China Mechanical Engineering, 2022, 33(09): 1025-1033.

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基于电极位移的点焊飞溅量化评价与自适应控制研究

Adaptive Control Research and Quantitative Evaluation of Resistance Spot Welding Expulsion Based on Electrode Displacement

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