Real-time temperature measuring device for friction stir welding
Technical Field
The invention relates to the field of welding engineering, in particular to a friction stir welding real-time temperature measuring device.
Background
Friction Stir Welding (FSW for short) was proposed by the British institute for Welding (TWI) in 1991, month 10. The friction stir welding process is mainly used for welding low-melting-point materials such as aluminum alloy and the like at first, and much research is carried out on TWI (two-way welding) about the characteristics, application and the like of the friction stir welding process.
The friction stir welding technology is a solid phase welding technology, has the advantages of low heat input, high efficiency, energy conservation, high reliability and the like, and is widely applied to the field of aerospace. And in actual processing, because reasons such as work piece machining error, work piece deformation, clamping are improper, the contact condition of stirring instrument and work piece constantly changes during the welding, leads to welding temperature fluctuation, causes welding quality unstable: (1) when the welding temperature is too low, the material is not softened enough, so that the welding defect is easy to generate and the stirring pin is broken; (2) when the welding temperature is too high, defects such as holes and tunnels are easily formed in the joints. Therefore, the stirring tool needs to be subjected to real-time temperature measurement in the welding process, so that the stirring tool can always keep a proper welding temperature, and the welding quality is ensured.
The current friction stir welding temperature measurement technology mainly comprises the following steps: (1) drilling a plurality of small holes on a welding workpiece along a welding seam, embedding a thermocouple for temperature measurement, wherein the workpiece needs to be damaged, the position of the embedded thermocouple is away from the center of the welding seam by a certain distance (generally larger than the diameter of a stirring tool and approximately equal to 2-3 times of welding thickness), otherwise, the thermocouple is stirred into the welding seam, so that the deviation between the measured temperature and the actual temperature of the center of the welding seam is large, the temperature change of discrete points can only be obtained, and the temperature of the center of the welding seam cannot be continuously obtained; (2) the welding temperature is measured by using non-contact temperature measuring devices such as infrared rays and the like, so that a real-time temperature change curve of the central surface of the welding seam can be obtained, but because the methods can only obtain the surface temperature of an object, the deviation between the measured welding seam temperature and the actual central temperature of the welding seam is large.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a friction stir welding real-time temperature measuring device.
The friction stir welding real-time temperature measuring device comprises a friction stir welding main shaft and a temperature measuring part; the temperature measuring part comprises a thermocouple, a temperature measuring bracket and a temperature measuring circuit;
the temperature measurement bracket is tightly mounted on the friction stir welding main shaft, and the temperature measurement circuit is mounted on the temperature measurement bracket; a temperature measuring hole is formed in the stirring friction welding main shaft, and a thermocouple is installed in the temperature measuring hole; the temperature measuring device comprises one or more temperature measuring holes, and the thermocouples correspond to the temperature measuring holes one to one.
Preferably, the temperature measuring circuit comprises a temperature measuring chip, a micro control unit and a communication module;
the thermocouple, the temperature measuring chip, the micro control unit and the communication module are connected in sequence.
Preferably, the temperature measuring support is provided with a containing hole, and the inner space of the containing hole forms a containing cavity; the temperature measuring circuit is installed on one or more inner wall surfaces of the object containing hole.
Preferably, the cross sections of the temperature measuring holes and the object containing holes are square;
a battery and a balancing weight are also arranged in the accommodating cavity;
the device also comprises an indicator light which is connected with the micro control unit.
Preferably, the thermocouple comprises a type K thermocouple; the temperature measuring chip comprises a MAX6675 chip; the micro control unit comprises an STM32 processor; the communication module comprises a Bluetooth transmission module.
Preferably, the temperature measuring hole comprises a blind hole;
the thermocouple is fixedly arranged in the temperature measuring hole through heat-conducting glue.
Preferably, the diameter of the temperature measuring hole is 1 mm;
at least one end face of the two end faces of the thermocouple along the axial direction has a distance less than 1mm to the outer surface of the stirring friction welding spindle.
The invention also provides a temperature measuring method using the friction stir welding real-time temperature measuring device, which comprises the following steps:
step S1: the temperature measuring chip performs cold end compensation and analog-to-digital conversion on a voltage signal of reaction temperature data obtained by the thermocouple, and converts the voltage signal into a digital signal;
step S2: the temperature measuring chip sends the digital signal as serial data to the micro control unit;
step S3: the micro control unit generates control data according to the digital signal.
Preferably, in the step S2, the temperature measuring chip outputs 16-bit 2-bit data D0 to D15 in each working timing;
D3-D14 bits correspond to 12-bit digital conversion quantity of the analog input voltage of the thermocouple, the value range is 0-4095, and the corresponding temperature value range is 0-1023.75 ℃;
the D2 bit is 0 at thermocouple normal operating conditions and jumps to 1 at thermocouple open circuit.
Preferably, the step S3 includes the steps of:
step S3.1: when the micro control unit does not receive the digital signal, outputting first fault removal reminding data;
step S3.2: when the micro control unit receives the digital signal and the D2 bit is 1, outputting second fault removal reminding data;
step S3.3: when the micro control unit receives the digital signal and the D2 bit is 0, generating temperature measuring data;
the temperature measurement method further includes step S4: the micro control unit transmits the temperature measurement data to the communication module in the form of the ACSII code.
Compared with the prior art, the invention has the following beneficial effects:
1. the thermocouple is directly embedded into the rotating stirring tool, the temperature of the center of the welding line is measured by measuring the temperature of the stirring tool during welding, the distance between the thermocouple embedded into the stirring tool and the center of the welding line is small by 1mm, and the temperature of the center of the welding line can be accurately obtained.
2. The invention advances with the stirring tool, and can obtain the real-time change curve of the central temperature of the welding seam in the whole welding process.
3. The invention uses the Bluetooth communication protocol, uses any Bluetooth signal receiving end, and can acquire and process temperature data by using equipment such as a mobile phone and the like without being equipped with additional data acquisition equipment.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a schematic structural view of a temperature measuring part mounted on a friction stir welding spindle;
FIG. 2 is a schematic view of the arrangement of the temperature measuring circuit in the temperature measuring support;
FIG. 3 is a schematic view of the location of the hole in the friction stir welding spindle;
fig. 4 is a working principle diagram of the present invention.
The figures show that: a main shaft 1 is welded in a stirring friction mode; a temperature measuring bracket 2; a battery 3; a temperature measuring chip 4; a communication module 5; a micro control unit 6.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications can be made by persons skilled in the art without departing from the spirit of the invention. All falling within the scope of the present invention.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention.
As shown in fig. 1 and 2, the friction stir welding real-time temperature measuring device provided by the invention comprises a friction stir welding spindle 1 and a temperature measuring part; the temperature measuring part comprises a thermocouple, a temperature measuring bracket 2 and a temperature measuring circuit. The temperature measurement bracket 2 is tightly installed on the friction stir welding spindle 1, and the temperature measurement circuit is installed on the temperature measurement bracket 2; a temperature measuring hole is formed in the stirring friction welding main shaft 1, and a thermocouple is installed in the temperature measuring hole. The temperature measuring device comprises one or more temperature measuring holes, and the thermocouples correspond to the temperature measuring holes one to one. The temperature measuring circuit comprises a temperature measuring chip 4, a micro control unit 6 and a communication module 5, and the thermocouple, the temperature measuring chip 4, the micro control unit 6 and the communication module 5 are connected in sequence. The temperature measuring support 2 is provided with object containing holes, the inner space of each object containing hole forms an object containing cavity, and the temperature measuring circuit is arranged on one or more inner wall surfaces of the object containing holes. The temperature measuring circuit also comprises batteries, and all parts in the temperature measuring circuit are uniformly distributed in the containing holes as much as possible when being arranged, for example, the battery 3 with larger mass is independently arranged on one side, other electronic components with smaller mass are arranged on the other side opposite to the side where the battery is arranged, so that the mass is balanced as much as possible, and when necessary, a balancing weight can be arranged in the containing cavity. Preferably, the cross sections of the temperature measuring holes and the containing holes are square.
As shown in fig. 3, the temperature measuring hole includes a blind hole, the thermocouple is fixedly installed in the temperature measuring hole through heat-conducting glue, and the blind hole is formed to prevent a workpiece material from flowing into the temperature measuring hole during welding to cause damage to the thermocouple. Preferably, the diameter of the temperature measuring hole is 1 mm; at least one end face of the two end faces of the thermocouple along the axial direction has a distance less than 1mm to the outer surface of the stirring friction welding spindle 1. During actual temperature measurement, a thermocouple needs to be embedded into the temperature measurement hole, the position of the thermocouple is fixed by adopting heat-conducting glue, and the distance between the front end of the embedded thermocouple and the surface of the stirring tool is smaller than 1mm so as to ensure the accuracy of temperature measurement.
Preferably, the thermocouple comprises a type K thermocouple; the temperature measuring chip 4 comprises an MAX6675 chip; the micro control unit 6 comprises an STM32 processor; the communication module 5 comprises a bluetooth transmission module. In addition, an indicator light is also included, which is connected to the micro-control unit 6. Of course, the types of the temperature measuring chip 4 and the micro control unit 6 can be selected according to actual working requirements, and the communication module 5 can also be a transmission module of LPWAN, WiFi, NFC, or other types.
The invention also provides a temperature measuring method using the real-time temperature measuring device for friction stir welding, which comprises the following steps: step S1: the temperature measuring chip 4 performs cold end compensation and analog-to-digital conversion on a voltage signal of reaction temperature data obtained by the thermocouple, and converts the voltage signal into a digital signal; step S2: the temperature measuring chip 4 sends the digital signal as serial data to the micro control unit 6; step S3: the micro control unit 6 generates control data from the digital signal.
In the step S2, the temperature measuring chip 4 outputs 16-bit 2-level data D0 to D15 in each working timing sequence; D3-D14 bits correspond to 12-bit digital conversion quantity of the analog input voltage of the thermocouple, the value range is 0-4095, and the corresponding temperature value range is 0-1023.75 ℃; the D2 bit is 0 at thermocouple normal operating conditions and jumps to 1 at thermocouple open circuit. The step S3 includes the steps of: step S3.1: when the micro control unit 6 does not receive the digital signal, outputting first fault removal reminding data; step S3.2: when the micro control unit 6 receives the digital signal and the D2 bit is 1, outputting second fault removal reminding data; step S3.3: when the micro control unit 6 receives the digital signal and the D2 bit is 0, temperature measurement data is generated. The temperature measurement method further includes step S4: the micro control unit 6 transmits the temperature measurement data to the communication module 5 in the form of an ACSII code.
Preferred embodiments:
as shown in fig. 1 and 2, the temperature measuring bracket 2 is mounted on any friction stir welding spindle 1 and rotates together with the friction stir welding spindle 1 during an actual welding operation. The K-type thermocouple, the MAX6675 chip, the STM32 processor, the HC-05 Bluetooth module and the battery 3 which are contained in the temperature measuring circuit are all arranged on the temperature measuring support and rotate along with the stirring friction welding spindle 1 during welding. All components arranged on the temperature measurement support can be freely arranged, the arrangement position should consider the dynamic balance of the rotation of the friction stir welding main shaft 1, and the quality is uniformly distributed as much as possible.
Particularly, the K-type thermocouple and the MAX6675 chip can be increased in a matched mode according to the requirement of a temperature measuring point, and at most two thermocouple signals can be processed by 1 STM32 processor. In this example, as shown in FIG. 3, the temperature of the shoulder of the stirring tool and the middle of the pin of the stirring tool are measured, so that a temperature measuring hole with a diameter of φ 1 needs to be drilled on the stirring tool, and the drilling position is shown in FIG. 3, so that 2K-type thermocouples and 2 MAX6675 chips are needed. When measuring temperature, the thermocouple needs to be embedded into a temperature measuring hole formed in the stirring tool, and the position of the thermocouple is fixed by adopting heat-conducting glue.
As shown in fig. 4, the thermocouple is connected to a MAX6675 chip, and the MAX6675 chip performs cold end compensation on a voltage signal obtained by the thermocouple, performs analog-to-digital conversion, and converts temperature data into a digital signal. The MAX6675 chip is connected with the STM32 processor, processes digital signals through the STM32 processor, converts the digital signals into ASCII codes and inputs the ASCII codes into the HC-05 Bluetooth module, and the HC-05 Bluetooth module converts temperature digital signals into wireless Bluetooth signals and transmits the wireless Bluetooth signals.
The MAX6675 chip is used for serial data output, a working time sequence outputs 16-bit 2-system data D0-D15, wherein D3-D14 correspond to 12-bit digital conversion quantity of thermocouple analog input voltage, the value range of the D3-D14 is 0-4095, and the corresponding temperature value range is 0-1023.75 ℃; d2 is typically 0 and jumps to 1 when the thermocouple opens.
The output ends of the two MAX6675 chips are connected with the input end of the STM32 processor, the STM32 processor is provided with two output ends, one output end is connected with an operation condition indicator lamp, and the operation condition indicator lamp lights indicator lamps with 3 colors according to different operation conditions; the other path is data output and is connected with the input end of the HC-05 Bluetooth module. The STM32 processor firstly judges the data of two receiving ends, if no data is returned on one receiving end, the data is output to be '1', the connection between the MAX6675 chip and the STM32 processor is prompted to be in a problem, the fault needs to be eliminated, and the running state indicator light is made to be red. If the two receiving ends have data to return, D2 bits of the two groups of data are judged, if the D2 bit of one receiving end is 1, the thermocouple of the receiving end is judged to be open, data "-2" is output, and meanwhile, the operating condition indicator lamp is enabled to be yellow. If the two paths of data are normal, D3-D14 bit data of the two groups of data are converted into decimal data, the decimal data are output by adopting ASCII codes and output to the HC-05 Bluetooth module, and meanwhile, the running state indicator light is green. In order to distinguish the two paths of data, when the data is output, an identification bit is added before the data is output, for example, the temperature data output by the first thermocouple is 120 ℃, the data is output as 'A120', and if the second thermocouple is in an open circuit state, the data is output as 'B-2'.
The obtained temperature data can be collected by any Bluetooth receiving end. All components are powered by batteries, and the power supply voltage is 5V. Particularly, the K-type thermocouple and the MAX6675 chip can be increased in a matched mode according to the requirement of a temperature measuring point, the number of input ends of a corresponding STM32 processor is increased, and identification bits are correspondingly increased when data are output.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.