A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing
Abstract
:1. Introduction
2. Principles
2.1. Filtering Method Based on Wavelet Transforms
2.2. Arc Signal Segmentation Method Based on the OTSU Algorithm
2.3. Feature Extraction Method for Droplet Transition Based on DBSCAN
2.4. Real-Time Extraction for Droplet Transfer Frequency and Droplet Transition Uniformity
2.5. Algorithm Efficiency Analysis
3. Experimental Results and Analysis
3.1. Experimental Equipment
3.2. Real-Time Monitoring Experiment of Droplet Transfer Frequency
3.3. Error Analysis
3.4. Experiments on the Relationship between the Uniformity of Droplet Transitions and the Uniformity of Weld Width
4. Conclusions
- A real-time monitoring method for droplet transfer frequency using arc sensing is proposed. In this method, the original signal acquired by a hall sensor is filtered by the wavelet transform method; the feature signal of the droplet transition is extracted by the arc signal segmentation method based on OTSU, and the feature extraction method for droplet transition based on DBSCAN is proposed. The real-time monitoring method we propose satisfies the demand for the real-time monitoring of droplet transfer frequency since the running time of the four main algorithms is 27.86 ms in total.
- We propose a concept of droplet transition uniformity. The experiments prove that weld width uniformity and droplet transition uniformity are positively correlated under conditions of uniform wire feeding and welding speeds. This principle can be used to monitor the weld bead width uniformity.
- The results of the experiments with typical parameters show that the maximal monitoring error is 0.05 Hz. This method holds promise for widespread use in monitoring and providing feedback control for droplet transfer in surface repairing and WAAM based on GTAW.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Algorithm | Running Time/ms |
---|---|
A filtering method based on wavelet transform | 3.12 |
An arc signal segmentation method based on OTSU | 6.80 |
A feature extraction method for droplet transition based on DBSCAN | 16.50 |
Calculating for droplet transfer frequency and the uniformity of transition | 1.44 |
Total | 27.86 |
Number | Welding Speed (mm/min) | Wire Feeding Speed (mm/min) | Welding Current (A) |
---|---|---|---|
50 | 1200 | 80 | |
60 | 1500 | 100 | |
70 | 1800 | 120 | |
90 | 2400 | 140 | |
110 | 2700 | 160 |
Number | Droplet Transfer Frequency (f/Hz) | The Uniformity of Droplet Transitions () |
---|---|---|
1.50 | 0.0153 | |
1.50 | 0.0098 | |
2.00 | 0.1080 | |
2.50 | 0.3879 | |
4.50 | 0.1788 |
Number | |||||
---|---|---|---|---|---|
E (Hz) | 0.02 | 0.01 | 0.01 | 0.05 | 0.05 |
Welding Speed (mm/min) | Wire Feeding Speed (mm/min) | Welding Current (A) |
---|---|---|
60 | 1500 | 100 |
Number | Droplet Transfer Frequency f (Hz) | The Uniformity of Droplet Transitions |
---|---|---|
4.0 | 0.0715 | |
4.0 | 0.2670 | |
3.0 | 0.5031 | |
5.5 | 0.5391 | |
3.5 | 0.2467 | |
11.0 | 0.7894 |
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Jia, A.; Luo, Y.; Hong, B.; Li, X.; Yin, L.; Luo, M. A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing. Sensors 2024, 24, 1924. https://doi.org/10.3390/s24061924
Jia A, Luo Y, Hong B, Li X, Yin L, Luo M. A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing. Sensors. 2024; 24(6):1924. https://doi.org/10.3390/s24061924
Chicago/Turabian StyleJia, Aiting, Yifang Luo, Bo Hong, Xiangwen Li, Li Yin, and Mina Luo. 2024. "A Real-Time Monitoring Method for Droplet Transfer Frequency in Wire-Filled GTAW Based on Arc Sensing" Sensors 24, no. 6: 1924. https://doi.org/10.3390/s24061924