GrooveComputerTool.cs
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using HHECS.BllModel;
using HHECS.RobotTool.Dto;
using System.Numerics;
namespace HHECS.RobotTool.Utils
{
/// <summary>
/// 坡口计算工具
/// </summary>
internal static class GrooveComputerTool
{
/// <summary>
/// 获取计算结果
/// </summary>
/// <param name="parameter">输入参数</param>
/// <returns>[2024/11/29]</returns>
public static BllResult<RobotOutputParameter> GetComputedData(RobotInputParameter parameter)
{
try
{
var output = new RobotOutputParameter();
double WeldAttitudeAngle = 0;
var layermod = (parameter.GrooveDepth + parameter.WeldHeight) % parameter.OneWeldHeight;//计算层数的余数
//总层数
var layerValue = (parameter.GrooveDepth + parameter.WeldHeight) / parameter.OneWeldHeight;
//如果剩余高度大于四，则向上取整，否则向下
output.Layers = (int)(layermod >= 4 ? Math.Ceiling(layerValue) : Math.Floor(layerValue));
//多层多道算法
if (parameter.GrooveWidth > 30)
{
//遍历每层进行计算
for (int i = 1; i <= output.Layers; i++)
{
var layerModel = new LayerModel
{
CurrentLayer = i, //当前层
};
var weldTotal = GetWeldTotal(i, parameter, layermod);
var iLayerWeldUpTotal = GetWeldUpTotal(i, output.Layers, parameter, layermod);
layerModel.WeldTotal = weldTotal;
layerModel.WeldUpTotal = iLayerWeldUpTotal;
var zCompensation = 0f;
if (layermod < 4)
{
zCompensation = layermod;
}
//第一层
if (i == 1)
{
//一层一道
var channelModel = new ChannelModel
{
CurrentChannel = 1,
StartingPoint = new Vector3(0, 0, 0),
EndingPoint = new Vector3(parameter.WeldLength, 0, 0),
WeldAttitudeAngle = 0,
WeldWidth = layerModel.WeldTotal / i,
};
layerModel.LayerHeight = parameter.OneWeldHeight + zCompensation;
//焊接截面积
channelModel.WeldArea = parameter.GrooveWidth * Math.Pow(parameter.OneWeldHeight + zCompensation, 2) / (2 * parameter.GrooveDepth);
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.OneLayerWireFeedingSpeed / (channelModel.WeldArea * 4));
//振幅为三角形焊缝的上底
var weldAmplitude = layerModel.WeldUpTotal / 2 - 2;
channelModel.WeldAmplitude = weldAmplitude;
//频率、左右停留时间
layerModel.LeftAndRightDwellTime = GetLeftAndRightDwellTime(weldAmplitude);
layerModel.WeldSwingFrequency = GetWeldSwingFrequency(weldAmplitude);
layerModel.ChannelModels.Add(channelModel);
output.LayerModels.Add(layerModel);
continue;
}
//其他层
if (i >= 2 && i < output.Layers)
{
layerModel.LayerHeight = parameter.OneWeldHeight;
//遍历每层每个焊缝进行计算
for (int j = 1; j <= i; j++)
{
var oneWeldWidth = weldTotal / i; //第i层有i条焊缝，且每条焊缝宽度相同 di
var channelModel = new ChannelModel
{
CurrentChannel = j,
WeldWidth = oneWeldWidth,
};
if (j == 1)//梯形焊缝
{
//起点和终点
var startingPoint = new Vector3(0, -weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
var endingPoint = new Vector3(parameter.WeldLength, -weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
channelModel.StartingPoint = startingPoint;
channelModel.EndingPoint = endingPoint;
//姿态角计算
double k1 = -2 * parameter.GrooveDepth / parameter.GrooveWidth; //AB所在直线的斜率k1
double k2 = 2 * parameter.GrooveDepth / parameter.GrooveWidth; //AC所在直线的斜率k2
double kijB = (i * parameter.OneWeldHeight - parameter.GrooveDepth) / (parameter.GrooveWidth / (2 - weldTotal / 2 + (j - 1) * oneWeldWidth)); //起点与点B连线所在直线的斜率kijB
double kijC = (parameter.GrooveDepth - i * parameter.OneWeldHeight) / (parameter.GrooveWidth / (2 + weldTotal / 2 - (j - 1) * oneWeldWidth)); //起点与点C连线所在直线的斜率kijC
double tanValue1 = (kijB - kijC) / (1 + kijB * kijC); //起点与点B和C连线的夹角正切值；
double tanValue2 = (k1 - k2) / (1 + k1 * k2); //AB和AC夹角正切值；
double tanRadianValue1 = Math.Atan(Math.Abs(tanValue1)); //弧度值
double tanRadianValue2 = Math.Atan(Math.Abs(tanValue2)); //弧度值
double tanAngleValue1 = tanRadianValue1 / Math.PI * 180; //角度值
double tanAngleValue2 = tanRadianValue2 / Math.PI * 180; //角度值
WeldAttitudeAngle = tanAngleValue1 / 2 - tanAngleValue2 / 2;//取反中间值
channelModel.WeldAttitudeAngle = tanAngleValue1 / 2 - tanAngleValue2 / 2;
var iLayerjthWeldArea = parameter.OneWeldHeight / 2 * (2 * iLayerWeldUpTotal / i + weldTotal / 2 - iLayerWeldUpTotal / 2);
channelModel.WeldArea = iLayerjthWeldArea;
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.WireFeedingSpeed / (iLayerjthWeldArea * 4));
layerModel.ChannelModels.Add(channelModel);
continue;
}
if (j > 1 & j < i)
{
//起点和终点
var startingPoint = new Vector3(0, -iLayerWeldUpTotal / 2 + (j - 0.5f) * iLayerWeldUpTotal / i, (i - 1) * parameter.OneWeldHeight + zCompensation);
var endingPoint = new Vector3(parameter.WeldLength, -iLayerWeldUpTotal / 2 + (j - 0.5f) * iLayerWeldUpTotal / i, (i - 1) * parameter.OneWeldHeight + zCompensation);
channelModel.StartingPoint = startingPoint;
channelModel.EndingPoint = endingPoint;
//姿态角计算
channelModel.WeldAttitudeAngle = 0;
var iLayerjthWeldArea = parameter.OneWeldHeight * iLayerWeldUpTotal / i;
channelModel.WeldArea = iLayerjthWeldArea;
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.WireFeedingSpeed / (iLayerjthWeldArea * 4));
}
///最后一条梯形焊缝
else
{
//起点、终点、姿态角
var startingPoint = new Vector3(0, weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
var endingPoint = new Vector3(parameter.WeldLength, weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
channelModel.StartingPoint = startingPoint;
channelModel.EndingPoint = endingPoint;
///姿态角计算
channelModel.WeldAttitudeAngle = WeldAttitudeAngle * -1;
//焊接速度
var iLayerjthWeldArea = parameter.OneWeldHeight / 2 * (2 * iLayerWeldUpTotal / i + weldTotal / 2 - iLayerWeldUpTotal / 2);
channelModel.WeldArea = iLayerjthWeldArea;
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.WireFeedingSpeed / (iLayerjthWeldArea * 4));
}
layerModel.ChannelModels.Add(channelModel);
}
output.LayerModels.Add(layerModel);
continue;
}
//最后一层（盖面层）
else
{
//总焊接截面积（mm²）
var totalWeldArea = parameter.GrooveWidth * parameter.GrooveDepth / 2 + (parameter.GrooveWidth * 2 + parameter.WeldWidth * 2) * parameter.WeldHeight / 2;
// 总熔敷量（mm³）
var totalDepositionAmount = totalWeldArea * parameter.WeldLength; //熔敷量与焊接横截面积成正比
//最后一层实际高度
layerModel.LayerHeight = parameter.GrooveDepth + parameter.WeldHeight - ((output.Layers - 1) * parameter.OneWeldHeight + zCompensation);
//遍历每层每个焊缝进行计算
for (int j = 1; j <= i; j++)
{
var oneWeldWidth = weldTotal / i; //第i层有i条焊缝，且每条焊缝宽度相同 di
var channelModel = new ChannelModel
{
CurrentChannel = j,
WeldWidth = oneWeldWidth,
};
if (j == 1)//梯形焊缝
{
//起点和终点
var startingPoint = new Vector3(0, -weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
var endingPoint = new Vector3(parameter.WeldLength, -weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
channelModel.StartingPoint = startingPoint;
channelModel.EndingPoint = endingPoint;
///姿态角计算
double k1 = -2 * parameter.GrooveDepth / parameter.GrooveWidth; //AB所在直线的斜率k1
double k2 = 2 * parameter.GrooveDepth / parameter.GrooveWidth; //AC所在直线的斜率k2
double kijB = (i * parameter.OneWeldHeight - parameter.GrooveDepth) / (parameter.GrooveWidth / (2 - weldTotal / 2 + (j - 1) * oneWeldWidth)); //起点与点B连线所在直线的斜率kijB
double kijC = ((float)parameter.GrooveDepth - i * (float)parameter.OneWeldHeight) / ((float)parameter.GrooveWidth / (2 + weldTotal / 2 - (j - 1) * oneWeldWidth)); //起点与点C连线所在直线的斜率kijC
double tanValue1 = (kijB - kijC) / (1 + kijB * kijC); //起点与点B和C连线的夹角正切值；
double tanValue2 = (k1 - k2) / (1 + k1 * k2); //AB和AC夹角正切值；
double tanRadianValue1 = Math.Atan(Math.Abs(tanValue1)); //弧度值
double tanRadianValue2 = Math.Atan(Math.Abs(tanValue2)); //弧度值
double tanAngleValue1 = tanRadianValue1 / Math.PI * 180; //角度值
double tanAngleValue2 = tanRadianValue2 / Math.PI * 180; //角度值
WeldAttitudeAngle = tanAngleValue1 / 2 - tanAngleValue2 / 2;
channelModel.WeldAttitudeAngle = tanAngleValue1 / 2 - tanAngleValue2 / 2;
var iLayerjthWeldArea = 0f;
//焊接速度
if (layermod >= 4)
{
iLayerjthWeldArea = layermod / 2 * (2 * iLayerWeldUpTotal / i + weldTotal / 2 - iLayerWeldUpTotal / 2);
}
else
{
iLayerjthWeldArea = (parameter.OneWeldHeight) / 2 * (2 * iLayerWeldUpTotal / i + weldTotal / 2 - iLayerWeldUpTotal / 2);
}
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.WireFeedingSpeed / (iLayerjthWeldArea * 4));
layerModel.ChannelModels.Add(channelModel);
continue;
}
if (j > 1 & j < i)
{
//起点和终点
var startingPoint = new Vector3(0, -iLayerWeldUpTotal / 2 + (j - 0.5f) * iLayerWeldUpTotal / i, (i - 1) * parameter.OneWeldHeight + zCompensation);
var endingPoint = new Vector3((float)parameter.WeldLength, Convert.ToSingle(-iLayerWeldUpTotal / 2 + (j - 0.5) * iLayerWeldUpTotal / i), (i - 1) * (float)parameter.OneWeldHeight + zCompensation);
channelModel.StartingPoint = startingPoint;
channelModel.EndingPoint = endingPoint;
///姿态角计算
channelModel.WeldAttitudeAngle = 0;
var iLayerjthWeldArea = 0f;
if (layermod >= 4)
{
iLayerjthWeldArea = layermod * iLayerWeldUpTotal / i;
}
else
{
iLayerjthWeldArea = parameter.OneWeldHeight * iLayerWeldUpTotal / i;
}
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.WireFeedingSpeed / (iLayerjthWeldArea * 4));
layerModel.ChannelModels.Add(channelModel);
}
///最后一条梯形焊缝
else
{
//起点、终点、姿态角
var startingPoint = new Vector3(0, weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
var endingPoint = new Vector3(parameter.WeldLength, weldTotal / 2, (i - 1) * parameter.OneWeldHeight + zCompensation);
channelModel.StartingPoint = startingPoint;
channelModel.EndingPoint = endingPoint;
///姿态角计算
channelModel.WeldAttitudeAngle = WeldAttitudeAngle * -1;
var iLayerjthWeldArea = 0d;
//焊接速度
if (layermod >= 4)
{
iLayerjthWeldArea = (layermod) / 2 * (2 * iLayerWeldUpTotal / i + weldTotal / 2 - iLayerWeldUpTotal / 2);
}
else
{
iLayerjthWeldArea = (parameter.OneWeldHeight) / 2 * (2 * iLayerWeldUpTotal / i + weldTotal / 2 - iLayerWeldUpTotal / 2);
}
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.WireFeedingSpeed / (iLayerjthWeldArea * 4));
layerModel.ChannelModels.Add(channelModel);
}
}
output.LayerModels.Add(layerModel);
}
}
return BllResultFactory.Success(output);
}
//多层单道算法
//遍历每层进行计算
for (int i = 1; i <= output.Layers; i++)
{
var weldTotal = GetWeldTotal(i, parameter, layermod);
var iLayerWeldUpTotal = GetWeldUpTotal(i, output.Layers, parameter, layermod);
var zCompensation = 0f;
if (layermod < 4)
{
zCompensation = layermod;
}
var layerModel = new LayerModel
{
CurrentLayer = i,
WeldTotal = weldTotal,
WeldUpTotal = iLayerWeldUpTotal,
};
///第一层
if (i == 1)
{
layerModel.LayerHeight = parameter.OneWeldHeight + zCompensation;
var channelModel = new ChannelModel
{
CurrentChannel = 1,
StartingPoint = new Vector3(0, 0, 0),
EndingPoint = new Vector3(parameter.WeldLength, 0, 0),
WeldAttitudeAngle = 0,
};
// 第一层（打底）焊接截面积（mm²）
var oneLayerWeldArea = parameter.GrooveWidth * Math.Pow(parameter.OneWeldHeight + zCompensation, 2) / (2 * parameter.GrooveDepth);
channelModel.WeldArea = oneLayerWeldArea;
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.OneLayerWireFeedingSpeed / (oneLayerWeldArea * 4));
//振幅为上底
var weldAmplitude = iLayerWeldUpTotal / 2 - 2;
channelModel.WeldAmplitude = weldAmplitude;
//频率、左右停留时间
layerModel.LeftAndRightDwellTime = GetLeftAndRightDwellTime(weldAmplitude);
layerModel.WeldSwingFrequency = GetWeldSwingFrequency(weldAmplitude);
layerModel.ChannelModels.Add(channelModel);
output.LayerModels.Add(layerModel);
continue;
}
//其他层
if (i >= 2 && i < output.Layers)
{
var channelModel = new ChannelModel
{
CurrentChannel = 1,
WeldAttitudeAngle = 0,
StartingPoint = new Vector3(0, 0, (i - 1) * parameter.OneWeldHeight + zCompensation),
EndingPoint = new Vector3(parameter.WeldLength, 0, (i - 1) * parameter.OneWeldHeight + zCompensation)
};
layerModel.LayerHeight = parameter.OneWeldHeight;
var weldArea = (iLayerWeldUpTotal + weldTotal) * parameter.OneWeldHeight / 2;
channelModel.WeldArea = weldArea;
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.OneLayerWireFeedingSpeed / (weldArea * 4));
//振幅为上底
var weldAmplitude = iLayerWeldUpTotal / 2 - 2;
channelModel.WeldAmplitude = weldAmplitude;
//频率、左右停留时间
layerModel.LeftAndRightDwellTime = GetLeftAndRightDwellTime(weldAmplitude);
layerModel.WeldSwingFrequency = GetWeldSwingFrequency(weldAmplitude);
layerModel.ChannelModels.Add(channelModel);
}
//最后一层（盖面层）
else
{
layerModel.LayerHeight = parameter.GrooveDepth + parameter.WeldHeight - ((output.Layers - 1) * parameter.OneWeldHeight + zCompensation);
//总焊接截面积（mm²）
var totalWeldArea = parameter.GrooveWidth * parameter.GrooveDepth / 2 + (parameter.GrooveWidth * 2 + parameter.WeldWidth * 2) * parameter.WeldHeight / 2;
//总熔敷量（mm³）
var totalDepositionAmount = totalWeldArea * parameter.WeldLength; //熔敷量与焊接横截面积成正比
var channelModel = new ChannelModel
{
CurrentChannel = 1,
WeldAttitudeAngle = 0,
WeldAmplitude = 0,
StartingPoint = new Vector3(0, 0, (i - 1) * parameter.OneWeldHeight + zCompensation),
EndingPoint = new Vector3(parameter.WeldLength, 0, (i - 1) * parameter.OneWeldHeight + zCompensation)
};
var weldArea = 0d;
if (layermod >= 4)
{
weldArea = (parameter.GrooveWidth + weldTotal) * layermod / 2;
}
else
{
weldArea = (parameter.GrooveWidth + weldTotal) * parameter.OneWeldHeight / 2;
//振幅为上底
var weldAmplitude = parameter.GrooveWidth / 2 - 2;
channelModel.WeldAmplitude = weldAmplitude;
//频率、左右停留时间
layerModel.LeftAndRightDwellTime = GetLeftAndRightDwellTime(weldAmplitude);
layerModel.WeldSwingFrequency = GetWeldSwingFrequency(weldAmplitude);
}
//焊接速度
channelModel.WeldSpeed = Math.PI * Math.Pow(parameter.WeldingWire, 2) * (parameter.OneLayerWireFeedingSpeed / (weldArea * 4));
layerModel.ChannelModels.Add(channelModel);
}
output.LayerModels.Add(layerModel);
}
return BllResultFactory.Success(output);
}
catch (Exception ex)
{
return BllResultFactory.Error<RobotOutputParameter>(ex.Message);
}
}
/// <summary>
/// 获取总焊宽
/// </summary>
/// <param name="currentLayer">当前层</param>
/// <param name="totalLayer">总层数</param>
/// <param name="parameter">输入参数</param>
/// <param name="layerMod">计算层数的余数</param>
/// <remarks>1-i-1层上下焊宽算法</remarks>
/// <returns></returns>
private static float GetWeldTotal(int currentLayer, RobotInputParameter parameter, float layerMod)
{
if (currentLayer == 0)
{
return 0;
}
if (layerMod >= 4)
{
return (currentLayer - 1) * parameter.OneWeldHeight * parameter.GrooveWidth / parameter.GrooveDepth;
}
return ((currentLayer - 1) * parameter.OneWeldHeight + layerMod) * parameter.GrooveWidth / parameter.GrooveDepth;
}
/// <summary>
/// 获取上底宽
/// </summary>
/// <param name="currentLayer">当前层</param>
/// <param name="totalLayer">总层数</param>
/// <param name="parameter">输入参数</param>
/// <param name="layerMod">计算层数的余数</param>
/// <remarks>1-i-1层上下焊宽算法</remarks>
/// <returns></returns>
private static float GetWeldUpTotal(int currentLayer, int totalLayer, RobotInputParameter parameter, float layerMod)
{
if (currentLayer == 0)
{
return 0;
}
if (currentLayer != totalLayer) //1-i-1层上下焊宽算法
{
if (layerMod >= 4)
{
return currentLayer * parameter.OneWeldHeight * parameter.GrooveWidth / parameter.GrooveDepth;
}
return (currentLayer * parameter.OneWeldHeight + layerMod) * parameter.GrooveWidth / parameter.GrooveDepth;
}
return parameter.GrooveWidth + parameter.WeldWidth * 2;
}
/// <summary>
/// 获取左右停留时间
/// </summary>
/// <param name="weldAmplitude">振幅</param>
/// <returns></returns>
private static float GetWeldSwingFrequency(float weldAmplitude)
{
// 焊接频率
if (weldAmplitude == 0)
{
return 0;
}
if (5.5 / weldAmplitude >= 2.5)
{
return 2.5f;
}
if (5.5 / weldAmplitude < 1)
{
return 0.8f;
}
if (5.5 / weldAmplitude > 1 && 5.5 / weldAmplitude < 2.5)
{
return (float)Math.Round(5.5 / weldAmplitude, 1);
}
return default;
}
/// <summary>
/// 获取左右停留时间
/// </summary>
/// <param name="weldAmplitude">振幅</param>
/// <returns></returns>
private static float GetLeftAndRightDwellTime(float weldAmplitude)
{
if (weldAmplitude <= 1.5)
{
return 0;
}
if (weldAmplitude > 1.5 && weldAmplitude <= 2.5)
{
return 0.01f;
}
if (weldAmplitude > 2.5 && weldAmplitude <= 3.5)
{
return 0.02f;
}
if (weldAmplitude > 3.5 && weldAmplitude <= 4.5)
{
return 0.05f;
}
if (weldAmplitude > 4.5 && weldAmplitude <= 6)
{
return 0.1f;
}
if (weldAmplitude > 6)
{
return 0.15f;
}
return default;
}
}
}