JP2002178148A - Method for detecting burn through in arc welding - Google Patents
Method for detecting burn through in arc weldingInfo
- Publication number
- JP2002178148A JP2002178148A JP2000382524A JP2000382524A JP2002178148A JP 2002178148 A JP2002178148 A JP 2002178148A JP 2000382524 A JP2000382524 A JP 2000382524A JP 2000382524 A JP2000382524 A JP 2000382524A JP 2002178148 A JP2002178148 A JP 2002178148A
- Authority
- JP
- Japan
- Prior art keywords
- burn
- arc
- arc welding
- arc voltage
- detecting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000003466 welding Methods 0.000 title claims abstract description 30
- 238000000034 method Methods 0.000 title claims description 13
- 239000000463 material Substances 0.000 claims abstract description 6
- 238000012544 monitoring process Methods 0.000 claims abstract 2
- 238000001514 detection method Methods 0.000 claims description 12
- 238000010586 diagram Methods 0.000 description 8
- 239000011324 bead Substances 0.000 description 3
- 230000003760 hair shine Effects 0.000 description 2
- 230000001360 synchronised effect Effects 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
Landscapes
- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明はアーク溶接における
溶け落ち検出方法に関し、特に溶け落ち現象を、発生と
同期して確実に検出することができる溶け落ち検出方法
に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a burn-through detection method in arc welding, and more particularly to a burn-through detection method capable of reliably detecting a burn-through phenomenon in synchronization with occurrence.
【０００２】[0002]
【従来の技術】アーク溶接において、重大な溶接不良で
ある溶け落ちをリアルタイムに検出する方法が幾つか提
案されている。例えば、特開昭６３−２５２６７４号公
報（「アーク溶接における溶け落ち検出方法」）では、
溶接部分の上方にテレビカメラを設置して溶接状況（ア
ーク光の形状）を撮像し、通常の溶接時は強烈なアーク
光のために輪郭しか識別できないが、溶け落ちが生じる
と、溶け落ち部の輪郭が輝く特徴を利用して、アーク光
及び溶け落ちた部分の光が特異な形状を呈した個所を解
析することにより溶け落ちを検出する方法を開示してい
る。2. Description of the Related Art In arc welding, several methods for detecting burn-through, which is a serious welding defect, in real time have been proposed. For example, Japanese Patent Application Laid-Open No. 63-252677 (“Method of detecting burn-through in arc welding”)
A television camera is installed above the welded part to image the welding situation (shape of the arc light). During normal welding, only the outline can be identified due to the intense arc light, but if burn-through occurs, the burn-through part Discloses a method of detecting burn-through by analyzing a location where the arc light and the light of the burned-off portion have a unique shape by using the feature that the outline of shines.
【０００３】図４は上記の従来の検出方法を実施するた
めのトーチとカメラの関係の説明図であり、図５は上記
の従来の検出方法の説明図である。図４において、１１
はトーチ、１２はテレビカメラ、１３はワイヤ、１４及
び１５は被溶接材、１６はビードである。図示のよう
に、被溶接材１４，１５との溶接部分をテレビカメラ１
２によりアーク光の形状を撮像する。そして、図５に示
すように、撮像した画像について、図示の矢印方向にラ
イン走査を繰り返し、黒が連続した後、白の連続（アー
ク部）、黒の連続（溶け落ち部）、白の連続（溶け落ち
で強く輝いている部分）を検出することで溶け落ちを検
出する。この際に、予め実験により求めた定数ａ，ｂ，
ｃを設定し、白の連続（アーク部）を定数ａと比較し、
黒の連続（溶け落ち部）を定数ｂと比較し、白の連続
（溶け落ちで強く輝いている部分）を定数ｃと比較し、
各々、これらの定数を超えている場合に、「連続してい
る」と判定する。FIG. 4 is an explanatory diagram of a relationship between a torch and a camera for implementing the above-mentioned conventional detecting method, and FIG. 5 is an explanatory diagram of the above-mentioned conventional detecting method. In FIG. 4, 11
Is a torch, 12 is a television camera, 13 is a wire, 14 and 15 are materials to be welded, and 16 is a bead. As shown in the figure, the portion to be welded to the workpieces 14 and 15 is
2, the shape of the arc light is imaged. Then, as shown in FIG. 5, the line scan is repeated in the direction of the arrow shown in the figure for the captured image, and after black is continuous, white continuation (arc portion), black continuation (burn-through portion), and white continuation are performed. Detects burn-through by detecting (a part that is strongly shined by burn-through). At this time, constants a, b,
c is set, white continuation (arc part) is compared with a constant a,
The continuation of black (burned-out part) is compared with a constant b, and the continuation of white (burned-out part strongly shined) is compared with a constant c.
When each of these constants is exceeded, it is determined that “continuous”.
【０００４】[0004]
【発明が解決しようとする課題】しかしながら、このよ
うな従来の方法では、溶け落ち現象の発生時に、溶け落
ち部分の輪郭の輝きがほんの一瞬であり（即ち、図５の
「白の連続（溶け落ちで強く輝いている部分）」に対応
する）、テレビカメラで撮像した後に、所定の溶け落ち
検出アルゴリズムにより溶け落ちを検出しているので、
溶け落ちの発生時点と全く同期しない非同期な検出とな
り、最悪の場合では、溶け落ちを見逃すという問題があ
った。However, in such a conventional method, when a burn-through phenomenon occurs, the outline of the burn-through portion shines only for a short time (that is, the "white continuation (melting)" in FIG. 5). The part that is strongly shining in the drop))), after shooting with a TV camera, the burn-through is detected by a predetermined burn-through detection algorithm.
As a result, the detection is asynchronous with no synchronization at the time of occurrence of the burn-through, and in the worst case, there is a problem that the burn-through is missed.
【０００５】そこで、本発明の目的は、このような従来
の問題に鑑み、アーク溶接における溶け落ち現象を、発
生と同時にリアルタイムに確実に検出する方法を提供す
ることにある。Accordingly, an object of the present invention is to provide a method for reliably detecting a burn-through phenomenon in arc welding in real time simultaneously with occurrence thereof in view of such a conventional problem.
【０００６】[0006]
【課題を解決するための手段】請求項１，２及び３の発
明によれば、被溶接材をアーク溶接する際の溶け落ちの
検出に際して、常時アーク電圧を監視してアーク電圧が
所定のしきい値を超えたか否か判定し、しきい値を超え
た時に溶け落ち発生と見なして、この時点に同期してラ
イト照射の指示を送出し、ライトの照射と同期して、Ｃ
ＣＤカメラによりアーク溶接部分を撮像し、撮像した画
像に基づいて溶け落ち発生を検出するようにしたので、
溶け落ち現象の発生と同時にリアルタイムに確実に検出
することができると共に、溶接不良の対策を迅速にとる
ことができる。また、検出した画像を保存することによ
り、さらに詳しく分析することができる。According to the first, second and third aspects of the present invention, the arc voltage is constantly monitored and the arc voltage is kept at a predetermined level when detecting the burn-through during arc welding of the workpiece. It is determined whether or not the threshold value has been exceeded. When the threshold value is exceeded, it is considered that burn-through has occurred, and a light irradiation instruction is transmitted in synchronization with this point, and in synchronization with the light irradiation, C
Since the arc welding part was imaged with a CD camera and the occurrence of burn-through was detected based on the captured image,
It is possible to reliably detect the burn-through phenomenon in real time simultaneously with the occurrence of the burn-through phenomenon, and to quickly take measures against poor welding. Further, by storing the detected image, more detailed analysis can be performed.
【０００７】[0007]
【発明の実施の形態】本発明によるアーク溶接における
溶け落ち検出方法は、溶け落ち現象が発生するときに、
アーク電圧が急激に変化することに着目し、アーク溶接
中は、このアーク電圧を常時モニターし、アーク電圧が
急激に変化したときを溶け落ち発生の同期タイミングと
し、このタイミングで溶接部分の上方に設置した光電受
光素子（例えばＣＣＤカメラ）により溶接部分を撮像
し、溶け落ち個所を検出する。BEST MODE FOR CARRYING OUT THE INVENTION The method for detecting burn-through in arc welding according to the present invention is described below.
Focusing on the sudden change in the arc voltage, during arc welding, this arc voltage is constantly monitored, and when the arc voltage changes suddenly, it is used as the synchronization timing of burn-through, and at this timing, it is above the welded part. An image of the welded portion is taken by an installed photoelectric receiving element (for example, a CCD camera), and a burned-out portion is detected.
【０００８】ところで、アーク電圧が変化する原因に
は、上述した溶接部分の溶け落ち現象以外にも種々考え
られる。即ち、被溶接部分の表面に凹凸がある場合、ア
ークの放射が強いため溶接部分が波立つ場合、及び溶接
部分の周辺にアークが飛んだ場合、等である。このよう
な場合には、アーク長が変化するので、それに伴いアー
ク電圧が変化する。There are various possible causes of the change in the arc voltage, in addition to the above-described burn-through phenomenon of the welded portion. That is, when the surface of the portion to be welded has irregularities, when the arc radiates strongly, the welded portion undulates, and when the arc flies around the welded portion. In such a case, since the arc length changes, the arc voltage changes accordingly.
【０００９】このように、アーク電圧の変化には種々の
状況が考えられるので、「アーク電圧の変化が溶け落ち
の発生」と一義的に決めることはできず、このようにす
ると溶け落ち検出を不正確なものとしてしまう。そこ
で、本発明では、アーク溶接中の溶け落ち現象を確実に
検出するために、アーク電圧の変化を、まず溶け落ち発
生の「高い可能性」として捉え、その後に、アーク電圧
の変化に同期して撮像した溶接部分の画像を分析して溶
け落ちが発生したか否かを最終的に判定する。判定の結
果、溶け落ちが発生していれば、溶接不良としてその時
点で溶接作業を中止する。As described above, since the arc voltage change can be considered in various situations, it cannot be uniquely determined that "the change in the arc voltage causes burn-through". Make it inaccurate. Therefore, in the present invention, in order to reliably detect a burn-through phenomenon during arc welding, a change in the arc voltage is first regarded as a “high possibility” of occurrence of burn-through, and then synchronized with the change in the arc voltage. Finally, it is determined whether or not burn-through has occurred by analyzing the image of the welded portion taken. As a result of the determination, if burn-through has occurred, the welding operation is stopped at that time as welding failure.
【００１０】以下、本発明の実施形態を図面にそって具
体的に説明する。図１は、本発明のアーク溶接における
溶け落ち検出方法を適用するシステムの要部構成図であ
る。図中、１はトーチ、２はワイヤ、３は被溶接材、４
はアーク、５はビード、６はＣＣＤカメラ、７はライ
ト、８はアーク電圧モニターユニット、９は画像処理装
置、１０は外部記憶装置、である。An embodiment of the present invention will be specifically described below with reference to the drawings. FIG. 1 is a main part configuration diagram of a system to which a burn-through detection method in arc welding according to the present invention is applied. In the figure, 1 is a torch, 2 is a wire, 3 is a material to be welded, 4
Is an arc, 5 is a bead, 6 is a CCD camera, 7 is a light, 8 is an arc voltage monitor unit, 9 is an image processing device, and 10 is an external storage device.
【００１１】図示のように、トーチ１からワイヤ２を送
り出しながら被溶接材３がアーク溶接される。アーク電
圧モニターユニット８（以下、モニターユニット８）は
このようなアーク溶接中、アーク電圧を常時監視してい
る。モニターユニット８が急激なアーク電圧の変化を検
出すると、画像処理装置９に溶け落ち検出の指示を送出
し、画像処理装置９からの指示により、ライト７はアー
ク光以上の照度で溶接部分を照射するとともに、同時に
ＣＣＤカメラ６により溶接部分を撮像し、撮像された画
像が画像処理装置９に入力され、画像処理装置９により
溶け落ちの有無を検出する。そして、このときの溶け落
ちの画像は外部記憶装置１０に保存される。As shown in the drawing, a material 3 to be welded is arc-welded while sending a wire 2 from a torch 1. The arc voltage monitor unit 8 (hereinafter, monitor unit 8) constantly monitors the arc voltage during such arc welding. When the monitor unit 8 detects a rapid change in arc voltage, the monitor unit 8 sends an instruction for detecting burn-through to the image processing device 9 and, according to the instruction from the image processing device 9, the light 7 irradiates the welded portion with illuminance higher than the arc light. At the same time, the welded portion is imaged by the CCD camera 6, and the imaged image is input to the image processing device 9, and the image processing device 9 detects the presence or absence of burn-through. Then, the image of the burn-through at this time is stored in the external storage device 10.
【００１２】図２（Ａ），（Ｂ）は、本発明によるアー
ク電圧の急激な変化を検出する方法の説明図である。
（Ａ）に示すように、アーク電圧Ｖは、溶接が開始され
ると、微小変化があるものの、ほぼ一定電圧で時間的に
推移する（Ｔ）。しかし、溶け落ちが発生すると、図示
のＭ部のように、一時的に電圧が上昇し、しきい値Ｔｈ
を超えることになる。このときが溶け落ち発生の時間で
ある。なお、（Ｂ）は、モニターユニット８での検出を
容易にするために、アーク電圧Ｖを微分して表示したも
のである。また、しきい値Ｔｈは、多くの実験により良
／不良を判定し設定した値である。FIGS. 2A and 2B are explanatory diagrams of a method for detecting a rapid change in arc voltage according to the present invention.
As shown in (A), when welding starts, the arc voltage V changes with time at a substantially constant voltage, although there is a slight change (T). However, when burn-through occurs, the voltage temporarily rises and the threshold Th
Will be exceeded. This time is the time of occurrence of burn-through. (B) shows the arc voltage V differentiated and displayed to facilitate detection by the monitor unit 8. Further, the threshold value Th is a value set by determining good / bad by many experiments.
【００１３】図３は、本発明による溶け落ち検出方法の
処理フローチャートである。本発明では、モニターユニ
ット８により、常時アーク電圧を監視する（Ｓ１）。モ
ニターユニット８が急激なアーク電圧の変化を検出し、
しきい値Ｔｈを超えたか否か判定し（Ｓ２）、超えたと
判定すると（ＹＥＳ）、溶け落ち発生と見なして指示を
画像処理装置９に送出する（Ｓ３）。画像処理装置９
は、この指示に同期して直ちにライト７をアーク光以上
の照度で照射するように指示し（Ｓ４）、さらに、この
照射に同期してＣＣＤカメラ６を作動して撮像するよう
に指示する（Ｓ５）。そして、ＣＣＤカメラ６で撮像さ
れた画像が画像処理装置９に入力され、その画像から溶
け落ちを検出し（Ｓ６）、溶け落ち発生と認定して溶接
不良の対策をとる（Ｓ７）。そして、さらに詳細に分析
するために、検出された画像を外部記憶装置１０に保存
する（Ｓ８）。FIG. 3 is a processing flowchart of the burn-through detection method according to the present invention. In the present invention, the arc voltage is constantly monitored by the monitor unit 8 (S1). The monitor unit 8 detects a rapid change in the arc voltage,
It is determined whether or not the threshold value Th has been exceeded (S2), and if it has been determined that the threshold value has been exceeded (YES), an instruction is sent to the image processing device 9 assuming that burn-through has occurred (S3). Image processing device 9
Immediately instructs to irradiate the light 7 with an illuminance equal to or higher than the arc light in synchronization with this instruction (S4), and further instructs the CCD camera 6 to operate and capture an image in synchronization with this illumination (S4). S5). Then, the image picked up by the CCD camera 6 is input to the image processing device 9, and the burn-through is detected from the image (S6), and it is recognized that the burn-through has occurred, and measures are taken for defective welding (S7). Then, the detected image is stored in the external storage device 10 for more detailed analysis (S8).
【００１４】このように、アーク溶接中は、このアーク
電圧を常時モニターし、アーク電圧が急激に変化したと
きは、これに同期して溶接部分の上方に設置したＣＣＤ
カメラにより溶接部分を撮像し、撮像した画像から判定
するので溶け落ちをリアルタイムに検出することができ
る。さらに、保存した撮像画像を詳しく分析し、現物の
被溶接材との比較から、溶接条件を容易に決定できるば
かりか、さらに溶接強度の不良、外観不良等の検討にも
利用することもできる。As described above, during the arc welding, the arc voltage is constantly monitored, and when the arc voltage changes rapidly, the CCD installed above the welding portion is synchronized with the sudden change of the arc voltage.
Since the welded portion is imaged by the camera and the determination is made based on the imaged image, the burn-through can be detected in real time. Further, by analyzing the stored captured image in detail and comparing it with the actual workpiece to be welded, not only can welding conditions be easily determined, but it can also be used for examining poor welding strength, poor appearance, and the like.
【図１】本発明のアーク溶接における溶け落ち検出方法
を適用するシステムの要部構成図である。FIG. 1 is a main part configuration diagram of a system to which a burn-through detection method in arc welding according to the present invention is applied.
【図２】（Ａ），（Ｂ）は、本発明によるアーク電圧の
急激な変化を検出する方法の説明図である。FIGS. 2A and 2B are explanatory diagrams of a method for detecting a rapid change in arc voltage according to the present invention.
【図３】本発明による溶け落ち検出方法の処理フローチ
ャートである。FIG. 3 is a processing flowchart of a burn-through detection method according to the present invention.
【図４】従来の検出方法を実施するためのトーチとカメ
ラの関係の説明図である。FIG. 4 is an explanatory diagram of a relationship between a torch and a camera for implementing a conventional detection method.
【図５】図４に示す従来の検出方法の説明図である。FIG. 5 is an explanatory diagram of the conventional detection method shown in FIG.
１…トーチ ２…ワイヤ ３…被溶接材 ４…アーク ５…ビード ６…光電受光素子 ７…ライト ８…溶接モニターユニット ９…画像処理装置 １０…外部記憶装置 DESCRIPTION OF SYMBOLS 1 ... Torch 2 ... Wire 3 ... Material to be welded 4 ... Arc 5 ... Bead 6 ... Photoelectric receiving element 7 ... Light 8 ... Weld monitor unit 9 ... Image processing device 10 ... External storage device
───────────────────────────────────────────────────── フロントページの続き (72)発明者 上甲 敬三 愛知県刈谷市昭和町１丁目１番地 株式会 社デンソー内 (72)発明者 安面 隆史 愛知県刈谷市昭和町１丁目１番地 株式会 社デンソー内 (72)発明者 高田 智 愛知県刈谷市昭和町１丁目１番地 株式会 社デンソー内 (72)発明者 川越 禎 愛知県刈谷市昭和町１丁目１番地 株式会 社デンソー内 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Keizo Kamiko 1-1-1, Showa-cho, Kariya-shi, Aichi Prefecture Inside DENSO Corporation (72) Inventor Takashi Amen 1-1-1, Showa-cho, Kariya-shi, Aichi Stock Company Inside Denso Corporation (72) Inventor Satoshi Takada 1-1-1, Showa-cho, Kariya City, Aichi Prefecture Inside Denso Corporation (72) Inventor Sada 1-1-1, Showa-cho, Kariya City, Aichi Prefecture Inside Denso Corporation
Claims (3)
検出方法において、 常時アーク電圧を監視して、前記アーク電圧が所定のし
きい値を超えたか否か判定し、 前記判定の結果、前記しきい値を超えた時に溶け落ち発
生と見なして指示を送出し、 前記指示に同期して、光電受光素子によりアーク溶接部
分を撮像し、 前記撮像した画像に基づいて溶け落ち発生を検出する、 ことを特徴とするアーク溶接における溶け落ち検出方
法。1. A method for detecting burn-through during arc welding of a material to be welded, comprising: always monitoring an arc voltage to determine whether the arc voltage exceeds a predetermined threshold value; When the threshold value is exceeded, an instruction is sent assuming that burn-through has occurred, and in synchronization with the instruction, an arc welding portion is imaged by the photoelectric receiving element, and burn-through occurrence is detected based on the captured image. A method for detecting burn-through in arc welding.
ト照射の指示を送出する請求項１に記載の溶け落ち検出
方法。2. The burn-through detection method according to claim 1, wherein a light irradiation instruction is transmitted in synchronization with a time point at which the instruction is transmitted.
存される請求項１に記載の溶け落ち検出方法。3. The method according to claim 1, wherein the captured image is stored in an external storage device.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000382524A JP2002178148A (en) | 2000-12-15 | 2000-12-15 | Method for detecting burn through in arc welding |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000382524A JP2002178148A (en) | 2000-12-15 | 2000-12-15 | Method for detecting burn through in arc welding |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2002178148A true JP2002178148A (en) | 2002-06-25 |
Family
ID=18850328
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2000382524A Pending JP2002178148A (en) | 2000-12-15 | 2000-12-15 | Method for detecting burn through in arc welding |
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