Research On Virtual Acquisition And Analysis System Based On Multi-sensor For Narrow Gap Welding

With the wide use of thick plates, the traditional welding method appears manylimitats. Narrow gap welding keeps the advantage and solves the limits of thetraditional methods, but the narrow gap welding wide existing sidewall fusion defects.In this paper, an arc swing narrow gap welding system has been designed based oncurrent research and a multi-sensor virtual acquisition and analysis system has beendesigned for the welding system. At last, the welding process has been comprehensiveevaluated using the fuzzy-analytic hierarchy process (FAHP) method.A swing mechanism has been designed for the Gas Metal Arc Welding torch,using the3D design software. And a computer has been used for planning the swingpath by the controller. Based on the arc swinging narrow gap welding system, a seriesof narrow gap welding welding experiments has been done. The experimental resultsshow the welding system is running well, and can effectively solve the problems ofsidewall fusion in the narrow gap welding process.A multi-sensor information acquisition and analysis system has been designedbased on the characteristics of the narrow gap welding process. First, a multi-sensorhardware system has been built; including an electrical signal system; a visual sensingsystem and a displacement sensing system. Then a virtual collection and analysissoftware system has been written using the software LabVIEW and this software cansynchronize collection, storage and analysis the information of multi-sensor. After acomprehensive analysis of the welding current; voltage; image; and displacementinformation which collected during the welding process, the stability of the electricalsignal and the arc welding process feature information can be obtained.The designed narrow-gap welding system and multi-sensor acquisition andanalysis system has been used to do a narrow gap welding experiment.5factors and4levels experiment have been designed according to the principles of the orthogonaldesign theory, to study different welding parameters and swing parameters effect onnarrow gap welds forming. Then, extracting the sidewall fusion; the smoothness of thejoint and the stability of the signal information on different parameters during thenarrow gap welding process, based on comparison of the virtual instrument result andweld forming result.Using the FAHP method for comprehensive evaluation the welding quality based on the three types of information, the sidewall fusion; the smoothness of the joint andthe stability. And the analytical result has been contrasted with the actual weld forming;the result of this comparison can specifically show the accuracy of the evaluationsystem in determining the welding quality.