铝合金列车车身焊缝表面激光清洗−质量检测一体化方法

Integrated method of laser cleaning and quality inspection on weld surface of aluminum alloy train body

  • 摘要: 视觉检测是实现焊缝表面质量检测的有效手段。然而,铝合金轨道列车车身电弧焊接产生的黑灰使视觉传感器采集到的数据存在大量缺失,影响了焊缝表面质量检测的精度。为此,该文提出一种铝合金车身焊缝表面激光清洗−质量检测一体化方法,设计了“清洗−焊接−检测”一体化装置。首先采用激光清洗技术去除电弧焊接产生的黑灰,降低了数据缺失率;随后基于线结构光传感器采集焊缝表面轮廓信息,采用三次样条插值和随机抽样一致性算法建立焊缝表面动态理想轮廓模型;通过特征点提取、比较动态理想轮廓与实际轮廓差异实现了焊缝特征尺寸的测量与表面缺陷检测。结果表明,激光清洗后采集数据的缺失率相比清洗前降低了93.43%;提出的激光清洗−质量检测一体化方法实现了焊缝特征尺寸测量与表面缺陷检测。焊缝特征尺寸检测精度达0.1 mm,气孔、焊瘤、未熔合缺陷的长度检测精度达0.2 mm。

     

    Abstract: Visual inspection was an effective method of achieving weld surface quality inspection. However, the black ash generated by the arc welding of aluminum alloy bodies of rail trains caused a large amount of missing data collected by the vision sensors, which affected the accuracy of weld surface quality inspection. To this end, an integrated cleaning-inspection method for aluminum alloy body welds was proposed in the paper, designed the “cleaning-welding-detect” integration device was designed. The laser cleaning technique was used to remove the black ash produced by arc welding, it reduced the missing data rate. The weld surface contour information was collected by line structured light sensor, and the dynamic ideal contour model of weld surface was established by cubic spline interpolation and random sample consensus algorithm. By extracting feature points and comparing the difference between the dynamic ideal contour and the actual contour, the measured weld characteristic dimensions and surface defect detection were realized. The results showed that the missing rate of collected data after laser cleaning was 93.43% lower than that before cleaning. The integrated method of laser cleaning and quality inspection was proposed to realize the measurement of weld characteristic dimensions and the detection of surface defects. The detection accuracy of weld characteristic dimensions reached 0.1 mm, and the detection accuracy of porosity, overlap, lack of fusion was within 0.15 mm.

     

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