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Detection of wire feeding speed and its influence on rotating arc welding quality

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Abstract

In order to improve the welding quality of rotating arc sensing robot, it is of great significance to study the automatic detection of wire feeding speed and its influence on the quality of rotating arc welding. According to the characteristics of the noise in the wire feeding speed signal, firstly, the signal processing method based on the characteristic of periodic change is used to eliminate the noise caused by signal loss. Secondly, a method to eliminate gross error is designed to eliminate communication noise and measurement error signal. Then, the detection method of wire feeding speed based on signal reliability can improve the detection accuracy of wire feeding speed. The detection experiments of wire feeding speed with different welding parameters were carried out, and the detection accuracy of wire feeding speed can be greater than 97% by using the designed algorithm. Moreover, the influence of system error on wire feeding speed detection can be reduced based on the method of introducing correction value. The influence of wire feeding speed on the rotating arc welding quality was tested, and the results showed that, in a certain range, the faster the wire feeding speed was, the more easily the droplet could be thrown into the molten pool. Furthermore, the experimental results showed that the wire feeding speed was also related to arc heat, arc light intensity, the fluidity of molten pool, the smoothness of weld bead, droplet growth rate, and the weld bead size. Therefore, the research content of this paper lays a foundation for the welding robot to predict and control the welding quality according to the detected wire feeding speed.

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Acknowledgements

The authors thank the reviewers for their valuable comments and suggestions.

Funding

The work is supported by the National Natural Science Foundation of China (No. 62163028), the Jiangxi Provincial Natural Science Foundation of China (No. 20224BAB212023), and the Open Fund Project of Shanghai Collaborative Innovation Center of Intelligent Manufacturing Robot Technology for Large Components (No. ZXP20211101). 

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Authors and Affiliations

  1. Key Laboratory of Robot &Welding Automation of Jiangxi, School of Information Engineering, Nanchang University, Nanchang, 330031, China

    Jian Le, Yichun Liu & Hua Zhang

  2. Shanghai Key Laboratory of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Jian Le & Xiaoqi Chen

  3. School of Resources and Environment, Nanchang University, Nanchang, 330031, China

    Yinshui He

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  1. Jian Le
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  2. Yichun Liu
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  3. Yinshui He
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  4. Hua Zhang
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Correspondence to Jian Le.

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Le, J., Liu, Y., He, Y. et al. Detection of wire feeding speed and its influence on rotating arc welding quality. Int J Adv Manuf Technol 125, 5419–5429 (2023). https://doi.org/10.1007/s00170-023-11061-5

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  • DOI: https://doi.org/10.1007/s00170-023-11061-5

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