熔化极气体保护电弧焊(gas metal arc welding,GMAW)焊接过程存在惯性大、时滞大等非线性特征以及不确定的干扰因素.为了提高焊接质量,文章提出了一种基于扩展卡尔曼滤波器(extended kalman filter,EKF)算法的焊缝实时跟踪技术,采用霍尔电流传感器来捕捉实时焊接电流.为了实现焊枪摆动中心始终对准焊缝中心,文章通过有限长单位冲激响应滤波器(finite impulse response,FIR)对采集的电流进行滤波,并建立提取焊枪高度和水平偏差的数学模型,采用EKF实现控制焊枪.通过在有垂直和水平方向偏差的焊缝上进行实验验证,结果跟踪精度可达到±0.25 mm,所以该方法可满足机器人实时跟踪的要求.
Research on GMAW seam tracking system based on arc sensor
The welding process of gas metal arc welding(GMAW)has nonlinear characteristics such as large inertia,large time delay and uncertain interference factors.In order to improve welding quality,a real-time welding seam tracking technology based on extended kalman filter(EKF)algorithm is proposed in this paper.Hall current sensor is used to capture real-time welding current.In order to realize that the swinging center of the welding torch is always aligned with the weld center,this paper filters the collected current through finite impulse response(FIR),establishes a mathematical model for extracting the height and horizontal deviation of the welding torch,and uses EKF to control the welding torch.Through the experimental verification on the weld with vertical and horizontal deviations,the tracking accuracy can reach±0.25 mm,so the method can meet the requirements of real-time robot tracking.
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