基于多极阵列电容传感空间姿态识别的焊缝跟踪方法及机理研究

The seam tracking is a key technology to realize welding automation, intelligence. But in the practical application, the results of the commonly used seam tracking sensors aren’t satisfying. For those sensors have some disadvantages such as complex system with expensive price, the finite application. Thence to design the space seam tracking sensor with low cost and high precision becomes pressing. In the present project, the capacitive sensor multi-electrodes arrayed and the space gesture recognition technology of torch are unified organically. And the capacitive sensor multi-electrodes arrayed of space seam tracking is designed. The concepts, design ideas and some key scientific issues of this sensor are also put forward. Through studying the working principles, structures and properties of this sensor, the space gesture recognition models of this sensor are established. By exploring the space gesture recognition mechanisms of the torch, the accuracy assessment programs of the space gesture recognition of the torch are also raised. After analyzing the interaction mechanisms between the gesture recognition accuracy of the torch and the real-time welding process, the laws of the space gestures of torch which are distinguished by the capacitive sensor with multi-electrode arrayed are revealed. Thus, the aim to realize the seam tracking with space complex trajectories under welding condition is achieved. To develop the space complex trajectory seam tracking technology sensed by the capacitive sensor with multi-electrodes arrayed, the theory and technology systems of the torch’s space gesture recognition, which are identified by capacitive sensor with multi-electrodes arrayed must to provide the significant theoretical basis. The research results of space seam tracking method are significant to promote the development of China’s equipment manufacturing industry.

焊缝跟踪是实现焊接自动化、智能化的关键技术之一，但目前常用的焊缝跟踪传感器在实际应用中的效果还不尽人意，或系统复杂且价格昂贵、或适用场合有限，缺乏一种低成本、高精度的空间焊缝跟踪传感器。本项目将多极阵列电容传感器和焊枪空间姿态识别技术有机结合，提出多极阵列电容式空间焊缝跟踪传感器的概念、设计思路和若干关键科学问题。研究该传感器的工作原理、结构及特性，建立该传感器的焊枪空间姿态识别模型，探索这种传感器的焊枪空间姿态识别机理，提出焊枪空间姿态识别精度评估方案，分析焊枪姿态识别精度与实时焊接过程之间的相互作用机制，揭示多极阵列电容传感器识别焊枪空间姿态的规律，达到焊接条件下实现空间复杂轨迹焊缝跟踪的目的。构建多极阵列电容传感器识别焊枪空间姿态的理论和技术体系，为多极阵列式电容传感空间复杂轨迹焊缝跟踪技术的发展提供重要理论基础，研究这种空间焊缝跟踪方法对促进我国装备制造业的发展具有重大意义。

焊缝跟踪是实现焊接自动化、智能化的关键技术之一，但目前常用的焊缝跟踪传感器在实际应用中的效果还不尽人意，或系统复杂且价格昂贵、或适用场合有限，缺乏一种低成本、高精度的空间焊缝跟踪传感器。.本项目将多极阵列电容传感器和焊枪空间姿态识别技术有机结合，提出一种新型焊缝跟踪传感器——多极阵列电容式空间焊缝跟踪传感器，采用传感器场域内不同介质的不同介电常数来准确识别焊缝形貌，并对识别的图像进行处理，提取焊缝的偏差信息并确定焊枪偏转角度。这种传感器结构简单，没有机械磨损，识别精度高，特别符合焊接过程低成本自动化的要求。.本项目研究该传感器的工作原理、结构及特性：建立该传感器的焊枪空间姿态识别模型以及焊枪空间姿态识别机理；提出焊枪空间姿态识别精度评估方案；微小电容传感信号采集和处理方法；传感器识别的焊缝波形（图像）与焊接质量的关系。构建一个多极阵列电容传感器识别焊枪空间姿态的理论和技术体系，实现复杂轨迹焊缝的实时跟踪。该研究将为智能化焊接系统的开发提供新的理论依据，同时这种空间焊缝跟踪方法对促进我国装备制造业的发展具有重大意义。