火箭推进

针对推力室外壁焊缝坡口进行机器人焊接控制的研究,并基于主动式激光传感器获取坡口参数,通过建立坡口-参数-焊缝的模型来实现推力室外壁的自适应焊接,从而保证推力室焊接质量的一致性。在“静态”研究的基础上,进行推力室焊接过程“动态”坡口结构参数与工艺参数最优匹配的研究,建立了推力室外壁坡口自适应焊接参数模型。结合模糊控制算法搭建了焊接自适应控制系统,完成了推力室模拟件的焊接试验,验证了模型与自适应焊接系统的适用性。针对液体火箭发动机推力室专用S-06,1Cr21Ni5Ti等材料建立了热丝TIG焊接参数计算模型,可覆盖深度5～12 mm的推力室对接坡口。在SIMULINK平台下针对控制响应速度优化了焊接自适应控制系统的调节因子。自适应试验件焊缝熔合良好, X射线检测合格,强度均高于母材强度的90%。

The robot welding control is studied for the weld groove of thrust chamber outer wall. Based on the acquired groove parameters with the active laser sensor, the adaptive welding for thrust chamber outer wall is achieved and the welding quality for thrust chamber is guaranteed by building the models of groove,parameter and welding. On the basis of “static” studies,the “dynamic” control of the process parameters is studied and an adaptive welding parameter model is established for the groove of outer wall in thrust chamber. Furthermore,the welding adaptive control system is established combined with the fuzzy control algorithm and the welding experiment is accomplished for a thrust chamber simula-tor, which verified the applicability of model and the adaptive welding system. A parameter calculation model of hot wire TIG welding is established for the materials such as S-06 and 1Cr21Ni5Tiin the thrust chamber of liquid rocket engine, which can cover the thrust chamber joint with a depth of 5～12mm. The adjustment factor of the welding adaptive control system is optimized for the control response speed under the SIMULINK platform. The welds of the test joint are well welded, which passes the X-ray examination, and the strength is higher than 90% of the base metal.

引言
1 试验设备及软件
2 推力室外壁焊接参数模型建立
3 试验验证
4 结论

图1 机器人热丝TIG焊接系统<br/>Fig.1 Robot heat TIG welding system

图1 机器人热丝TIG焊接系统
Fig.1 Robot heat TIG welding system

图2 焊接熔合状态<br/>Fig.2 Fusion state of welding

图2 焊接熔合状态
Fig.2 Fusion state of welding

图3 双椭球热源模型<br/>Fig.3 Double ellipsoid heat source model

图3 双椭球热源模型
Fig.3 Double ellipsoid heat source model

图4 焊接试验试板温度场云图<br/>Fig.4 Temperature field of welding test plate

图4 焊接试验试板温度场云图
Fig.4 Temperature field of welding test plate

图5 焊缝截面区域测量图<br/>Fig.5 Measurement of welding section

图5 焊缝截面区域测量图
Fig.5 Measurement of welding section

表1 填充层数值模拟回归试验结果<br/>Tab.1 Simulated results of filling layer

表1 填充层数值模拟回归试验结果
Tab.1 Simulated results of filling layer

图6 预估焊缝截面形状计算模型示意图<br/>Fig.6 Calculation model of estimating welding section shape

图6 预估焊缝截面形状计算模型示意图
Fig.6 Calculation model of estimating welding section shape

图7 自适应焊接参数模型框图<br/>Fig.7 Block diagram of adaptive welding parameter

图7 自适应焊接参数模型框图
Fig.7 Block diagram of adaptive welding parameter

图8 锁底坡口送丝量调整示意图<br/>Fig.8 Adjustment of wire feeding amount in the groove

图8 锁底坡口送丝量调整示意图
Fig.8 Adjustment of wire feeding amount in the groove

图9 焊接自适应控制系统<br/>Fig.9 Welding adaptive control system

图9 焊接自适应控制系统
Fig.9 Welding adaptive control system

图10 焊接自适应系统仿真曲线<br/>Fig.10 Simulation curve of welding adaptive system

图10 焊接自适应系统仿真曲线
Fig.10 Simulation curve of welding adaptive system

图11 推力室坡口试板自适应焊接试验图<br/>Fig.11 Adaptive welding experiment of thrust chamber plate

图11 推力室坡口试板自适应焊接试验图
Fig.11 Adaptive welding experiment of thrust chamber plate

[1] 杨春利,张九海,王其隆.TIG焊熔池外激谐振与熔透的关系[J],焊接学报,1990,11(4):193-198.
[2] 孙龙飞, 钱喜乐, 刘琳.沉淀硬化不锈钢用于一体化贮箱工艺技术研究[J].火箭推进,2016, 42(6):62-67.
[3] 毛鹏军.弧焊机器人焊缝跟踪系统研究现状及发展趋势[J].电焊机,2001,31(10),9-12.
[4] 陈武柱,张旭东.视觉传感器与焊缝自动跟踪[J].现代制造,2002(18):58-60.
[5] 梁明龙,周凯荣.2219铝合金变极性钨极惰性气体保护焊的焊缝成形模糊控制系统[J].上海交通大学学报, 2016,28(10):42-54.
[6] 汤建锋.热丝 TIG 焊在转炉汽化冷却烟道制造中的应用[J].电焊机,2009,39(4):141-143.
[7] 李游.基于SYSWELD的汽车发动机排气歧管焊接变形数值模拟[D].南昌:南昌大学,2014.
[8] 李振江.基于SYSWELD的焊接接头温度场和残余应力场研究[D].北京:北京交通大学, 2010.
[9] 蔡志鹏.大型结构焊接变形数值模拟的研究与应用[D].北京:清华大学,2001.
[10] 王堃, 蔡强顺.电子束焊接熔池流场数值模拟研究[J].火箭推进, 2015, 41(1):98-104.
[11] GOLDAK J, CHAKRAVARTI A,BIBBV M.A double ellipsoid finite element model for welding heat sources[J].Metallurgical Transactions B,1994,15(6):299-305.
[12] 张奕.传热学[M].南京:东南大学出版社,2003.
[13] 陈楚,汪建华,罗宇.轴对称热弹塑性应力有限元分析在焊接中的应用[J].焊接学报,1987,8(4):196-203.
[14] 蔡洪能, 唐慕尧.TIG焊接温度场的有限元分析[J].焊管,1995,32(1):34-39.

备注

引言

1 试验设备及软件

2 推力室外壁焊接参数模型建立

3 试验验证

4 结论

期刊信息