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基于相关性分析和SSA-BP神经网络的铝合金电阻点焊质量预测

董建伟, 胡建明, 罗震

董建伟, 胡建明, 罗震. 基于相关性分析和SSA-BP神经网络的铝合金电阻点焊质量预测[J]. 焊接学报, 2024, 45(2): 13-18, 32. DOI: 10.12073/j.hjxb.20230226001
引用本文: 董建伟, 胡建明, 罗震. 基于相关性分析和SSA-BP神经网络的铝合金电阻点焊质量预测[J]. 焊接学报, 2024, 45(2): 13-18, 32. DOI: 10.12073/j.hjxb.20230226001
DONG Jianwei, HU Jianming, LUO Zhen. Quality prediction of aluminum alloy resistance spot welding based on correlation analysis and SSA-BP neural network[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(2): 13-18, 32. DOI: 10.12073/j.hjxb.20230226001
Citation: DONG Jianwei, HU Jianming, LUO Zhen. Quality prediction of aluminum alloy resistance spot welding based on correlation analysis and SSA-BP neural network[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(2): 13-18, 32. DOI: 10.12073/j.hjxb.20230226001

基于相关性分析和SSA-BP神经网络的铝合金电阻点焊质量预测

基金项目: 国家自然科学基金资助项目(52075378)
详细信息
    作者简介:

    董建伟,博士;主要研究方向为电阻点焊质量预测;Email: 1522991681@qq.com

    通讯作者:

    罗震,博士,教授;Email: LuoZhen8882022@126.com

  • 中图分类号: TG 453.9

Quality prediction of aluminum alloy resistance spot welding based on correlation analysis and SSA-BP neural network

  • 摘要:

    基于电阻点焊过程中工艺信号特征,在不同间距、不同间隙和不同间距与间隙3种条件下,引入相关性分析方法分析工艺信号与熔核直径之间的相关性,并建立基于麻雀搜索算法-BP神经网络(sparrow search algorithm- back propagation neural network, SSA-BP)的电阻点焊质量预测模型,将功率、焊接电流、焊接电压和动态电阻作为预测模型输入特征. 结果表明,经麻雀搜索算法优化后的BP神经网络在测试集上的决定系数R2、均方误差(mean-square error, MSE)、均方根误差(root mean square error, RMSE)和平均绝对误差(mean absolute error, MAE)分别为0.95,1.55,1.24和0.90,均优于BP模型. 获得了功率、焊接电流、焊接电压和动态电阻与熔核直径的映射关系,可为焊接的工艺参数设计提供依据.

    Abstract:

    Based on the characteristics of the process signals in the resistance spot welding process, three working conditions of different spacing, different gaps and different spacing and gaps are analyzed, and correlation analysis is introduced to extract the correlation between the process signals and the diameter of nugget. A resistance spot welding quality prediction model based on Sparrow Search Algorithm-Back Propagation Neural Network (SSA-BP) was established, and power, welding current, welding voltage and dynamic resistance are used as input features of the prediction model. The results show that the BP neural network optimized by the sparrow search algorithm outperforms the BP model on the test set with R2, MSE, RMSE and MAE of 0.95, 1.55, 1.24 and 0.90, respectively. It is also determined that there exists a mapping relationship between power, welding current, welding voltage and dynamic resistance and the diameter of the nugget, which provides a basis for the design of process parameters for welding.

  • 图  1   2219/5A06工件焊接条件(mm)

    Figure  1.   Welding conditions of 2219/5A06 workpieces. (a) fixed spacing, different gaps; (b) fixed gap, different spacing; (c) different spacing and gaps

    图  2   铝合金点焊的工艺曲线

    Figure  2.   Aluminum alloy spot welding process curves

    图  3   不同焊接条件下熔核直径分布

    Figure  3.   Nugget diameter distribution under different welding conditions

    图  4   处理后的工艺信号曲线

    Figure  4.   Processed signal curve. (a) power; (b) welding current; (c) welding voltage; (d) dynamic resistance

    图  5   BP神经网络拓扑结构

    Figure  5.   Topological structure of BP neural network

    图  6   改进SSA-BP模型预测流程

    Figure  6.   Improved SSA-BP model prediction process

    图  7   预测结果与实测值对比

    Figure  7.   Comparison of predicted results and measured values. (a) improved SSA-BP prediction model; (b) SSA-BP prediction model; (c) BP prediction model

    表  1   2219/5A06的力学性能

    Table  1   Mechanical properties of 2219/5A06

    材料抗拉强度
    Rm/MPa
    屈服强度
    Rp0.2/MPa
    断后伸长率
    A(%)
    弹性模量
    E/GPa
    22194553501073
    5A063152552071
    下载: 导出CSV

    表  2   2219/5A06的化学成分(质量分数,%)

    Table  2   Chemical composition of 2219/5A06

    材料AlSiFeCuMn
    221992.80.060.176.300.31
    5A0693.310.060.130.03
    材料VZrZnTiCr
    22190.10.150.020.07
    5A060.020.05
    下载: 导出CSV

    表  3   固定间距和不同间隙条件下焊点数量

    Table  3   Fixed spacing and corresponding welding spots number under different gaps

    装配条件间隙G/mm间距S/mm焊点数量n(个)
    10.15015
    20.25015
    30.35015
    40.45015
    50.55015
    60.65015
    70.85015
    81.05015
    91.55015
    下载: 导出CSV

    表  4   固定间隙和不同间距条件下焊点数量

    Table  4   Fixed gap and corresponding welding spots number under different spacing

    装配条件间隙G/mm间距S/mm焊点数量n(个)
    1001015
    1101515
    1202015
    1302515
    1403015
    1503515
    1604015
    1704515
    1805015
    下载: 导出CSV

    表  5   不同间距和间隙条件下焊点数量

    Table  5   The number of welding spots corresponding to different spacing and gaps

    装配条件间隙
    G/mm
    间距
    S/mm
    焊点数量
    n(个)
    1911515
    2012015
    2112515
    2213015
    231.51515
    241.52015
    251.52515
    261.53015
    2721515
    2822015
    2922515
    3023015
    下载: 导出CSV

    表  6   工艺信号与熔核直径之间的相关系数

    Table  6   Correlation coefficient between process signal and nugget diameter

    功率
    P/kW
    焊接电流
    I/kA
    焊接电压
    U/mV
    动态电阻
    R/μΩ
    0.620.950.650.54
    下载: 导出CSV

    表  7   预测模型精度指标

    Table  7   Prediction model accuracy indicators

    预测模型评价指标
    决定系数R2均方根误差 RMSE均方误差MSE平均绝对误差MAE
    改进SSA-BP0.951.241.550.90
    BP0.792.571.881.41
    SSA-BP0.851.582.521.27
    下载: 导出CSV
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出版历程
  • 收稿日期:  2023-02-25
  • 网络出版日期:  2024-01-04
  • 刊出日期:  2024-02-24

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