Planning and layout of V-groove welding beads based on parabolic model
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摘要: 为了提高大型相贯构件机器人焊接的焊道规划准确性，提出了抛物线模型，结合等面积与等高法研究了多层多道焊道排布方法. 首先，规划焊接工艺参数、焊道的横截面、焊接顺序以及焊枪位姿，进一步推导出焊道排布算法的公式，借助MATLAB软件进行多层多道焊道排布的仿真；最后通过机器人焊接试验验证多层多道排布的方法. 结果表明，仿真的焊道排布结果与试验的V形坡口每层每道轮廓相吻合，说明提出的基于抛物线模型的多层多道排布算法是准确可行的. 该研究成果为机器人焊接相贯构件的多层多道焊道排布提供了重要的理论基础.Abstract: In order to improve the accuracy of bead planning for robotic welding of large-scale intersecting components, a multi-layer multi-pass planning method is proposed based on the parabolic model with a method of equal area and equal height. Firstly, process parameters, cross section of weld pass, welding sequence, gun position and posture were planned, and then the algorithm formula was worked out. Secondly, MATLAB software was carried out on the multi-layer multi-pass welding beads layout. Finally, robotic welding experiments were conducted to verify the planning algorithm of welding beads. The results show that the simulated welding beads profile match with the experimental contour of each layer and pass at V-groove. This demonstrates that the proposed multi-layer multi-pass weld planning algorithm based on the parabolic model is feasible and accurate. The research has provided important theoretical basis for the layout of multi-layer multi-pass beads for robotic welding of intersecting components.
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图 4 V形坡口焊接顺序
Figure 4. Welding sequence of V groove. (a) welding from left to right; (b) welding from sides to middle
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图 5 V形坡口焊层顺序
Figure 5. Welding layer sequence of V groove. (a) welding layers with same direction; (b) welding layers with opposite directions
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图 9 抛物线模型多层多道排布示意图
Figure 9. Multi-layer multi-pass arrangement based on parabolic profile model
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图 13 V形坡口焊层焊道排布仿真图
Figure 13. Simulation diagram of bead arrangement of V-shaped groove weld. (a) weld bead for the first layer; (b) weld beads from the first to second layers; (c) weld beads from the first to third layers
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图 14 焊道横截面第一层轮廓与仿真对比
Figure 14. Comparison of the first-layer cross-sectional profile of weld with simulation
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图 15 焊道横截面一至二层轮廓与仿真对比
Figure 15. Comparison of the first to second layer cross-sectional profile of weld with simulation
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图 16 焊道横截面一至三层轮廓与仿真对比
Figure 16. Comparison of all three layers cross-sectional profile of weld with simulation
表 1 DH36钢与E501T-1L焊丝的化学成分(质量分数，%)
Table 1 Chemical compositions of DH36 steel and E501T-1L welding wire
材料 C Mn Si S P Ni Al V Ti Nb Fe DH36 0.140 1.510 0.40 0.007 0.015 0.070 0.028 0.057 0.014 0.02 余量 E501T-1L 0.04 1.30 0.35 0.015 0.018 0.45 — — — — 余量 
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表 2 因素水平表
Table 2 Factors levels
水平 焊接电压U/V 焊接电流I/A 焊接速度v/(cm·min−1) 送丝速度vf /(cm·min−1) 行进角度G/(°) 焊丝伸出长度l/mm 1 24 180 16 300 75 16 2 27 210 19 375 90 19 3 30 240 22 450 105 22
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表 3 工艺参数及输出指标
Table 3 Process parameters and output indicators
编号 焊接电压
U/V焊接电流
I/A焊接速度
v/(cm·min−1)送丝速度
vf /(cm·min−1)行进角度
G/(°)焊丝伸出长度
l/mm熔深
D/mm焊道轮廓面积
S/mm21 24 180 16 300 75 16 0. 983 45. 724 2 24 210 19 375 90 19 1. 326 43. 655 3 24 240 22 450 105 22 1. 345 38. 685 4 27 180 16 375 90 22 1. 035 47. 745 5 27 210 19 450 105 16 0. 841 47. 439 6 27 240 22 300 75 19 2. 114 48. 929 7 30 180 19 300 105 19 0. 679 35. 874 8 30 210 22 375 75 22 1. 287 46. 746 9 30 240 16 450 90 16 1. 414 72. 023 10 24 180 22 450 90 19 1. 177 34. 68 11 24 210 16 300 105 22 0. 359 51. 232 12 24 240 19 375 75 16 1. 038 48. 992 13 27 180 19 450 75 22 1. 003 41. 438 14 27 210 22 300 90 16 1. 622 44. 362 15 27 240 16 375 105 19 0. 719 52. 594 16 30 180 22 375 105 16 0. 84 33. 814 17 30 210 16 450 75 19 1. 276 59. 429 18 30 240 19 300 90 22 1.506 59.881
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