Adjustable ring laser welding system and method based on intelligent laser-assisted wire filling

Abstract

The embodiment of the invention discloses an adjustable ring laser welding system and method based on intelligent laser-assisted wire filling. According to the method, a laser emitting module is used for emitting a corresponding laser beam to the surface of a welding piece, and the shape of the laser beam is adjustable and annular; the wire filling module is used for conveying welding wires to the welding part; and the feedback module is used for acquiring the temperature and morphology in a molten pool corresponding to a welding part in the welding process to generate corresponding real-time monitoring data, and determining a feedback signal of the laser emission module and a feedback signal of the wire filling module based on the real-time monitoring data. According to the embodiment of the invention, intelligent and self-adaptive adjustment of the welding process can be realized through multi-dimensional information fusion and closed-loop control, the dependence on skills of operators is reduced while the welding quality is improved, and the production efficiency and the product yield are improved.

Description

Technical Field

[0001] The present application relates to the field of welding technology, and in particular to an adjustable ring laser welding system and method based on intelligent laser-assisted wire filling. Background Art

[0002] Light alloys are widely used in the aerospace industry due to their lightweight, corrosion-resistant, and excellent processability. However, compared to traditional materials, light alloys exhibit inferior weldability, primarily due to high thermal conductivity, low melting point, tendency to thermal cracking, and weld metal brittleness. These issues make light alloys susceptible to defects during welding, such as porosity, cracks, and weld pool instability, severely impacting the quality and reliability of welded joints.

[0003] Traditional light alloy welding methods, such as argon arc welding and laser welding, cannot achieve both high efficiency and high quality. The molten pool of single-heat-source welding is easily disturbed by external factors, leading to defects such as porosity and slag inclusions during the welding process. Adjustable ring laser welding reduces porosity and spatter during the welding process by adding an outer ring laser to expand the keyhole, thereby improving weld formation quality. Filler wire can be used to adjust the weld metallurgy, refine the grain structure, and optimize welding efficiency. However, the current process optimization of adjustable ring laser welding with filler wire is relatively complex, and it is impossible to accurately control the welding heat input, optimize the molten pool morphology, and precisely control the filler wire process according to the real-time welding situation. Summary of the Invention

[0004] To solve the above technical problems, the embodiments of the present application provide an adjustable ring laser welding system, method, electronic device, computer-readable storage medium and computer program product based on intelligent laser-assisted wire filling.

[0005] According to one aspect of an embodiment of the present application, an adjustable ring laser welding system based on intelligent laser-assisted wire filling is provided, characterized in that the device includes: a laser emission module, used to emit a corresponding laser beam to the surface of the weldment, wherein the shape of the laser beam is an adjustable ring; a wire filling module, used to convey welding wire to the weldment; a feedback module, used to obtain the temperature and morphology in the molten pool corresponding to the weldment during the welding process to generate corresponding real-time monitoring data, and determine the feedback signal of the laser emission module and the feedback signal of the wire filling module based on the real-time monitoring data.

[0006] According to one aspect of an embodiment of the present application, the feedback module includes: a monitoring unit for monitoring real-time observation data of the molten pool during welding, wherein the real-time observation data includes the temperature corresponding to the molten pool and the position information of the welding wire; a feedback unit for generating feedback adjustment signals corresponding to the filler wire module and the laser module based on the temperature and the position information of the welding wire.

[0007] According to one aspect of the embodiment of the present application, the laser emission module further includes: a laser source for emitting a corresponding annular laser beam toward the surface of the weldment; a laser adjustment module for adjusting the operating parameters of the laser based on the feedback signal, the operating parameters including the laser beam output form, the laser beam power distribution, and the laser beam focus position.

[0008] According to one aspect of an embodiment of the present application, the filler wire module further includes: a wire fine-tuning unit for adjusting the operating parameters of the welding wire based on the feedback signal, the operating parameters including the welding wire current, the welding wire feed trajectory and the welding wire feed rate.

[0009] According to one aspect of an embodiment of the present application, the wire filling module also includes: a servo motor, a pneumatic actuator, and a welding wire adjustment chamber; the servo motor is used to control the internal air pressure of the pneumatic actuator under the guidance of the operating parameters of the welding wire, thereby achieving fine-tuning of the welding wire feeding speed and position in the welding wire adjustment chamber.

[0010] According to one aspect of an embodiment of the present application, a method for adjustable ring laser welding based on intelligent laser-assisted wire filling is provided, which is applied to an adjustable ring laser welding system based on intelligent laser-assisted wire filling. The method includes: obtaining molten pool status information corresponding to the weldment, the molten pool status information including molten pool temperature, molten pool morphology and welding wire position information; determining the working parameters of the laser emission module corresponding to the ring laser based on the molten pool temperature and molten pool morphology, the working parameters including laser beam output form, laser beam power distribution and laser beam focal position; calculating the offset of the welding wire based on the welding wire position information, and adjusting the operating parameters of the wire filling module corresponding to the welding wire based on the offset.

[0011] According to one aspect of an embodiment of the present application, the offset of the welding wire is calculated based on the welding wire position information, and the operating parameters of the filling wire module corresponding to the welding wire are adjusted based on the offset, including: determining the actual position information of the welding wire based on the welding wire position information; if the real-time position information does not match the preset position information, calculating the offset of the welding wire position relative to the preset position information; and determining the operating parameters of the filling wire module based on the offset, the operating parameters including the welding wire current, the welding wire feed trajectory, and the welding wire feed rate.

[0012] According to one aspect of an embodiment of the present application, the working parameters of the laser emission module corresponding to the circumferential laser are determined based on the molten pool temperature and the molten pool morphology, including: determining the temperature deviation value between the molten pool temperature and the preset molten pool temperature and the morphology deviation value between the molten pool morphology and the preset molten pool morphology; determining the laser beam output form, laser beam power distribution and laser beam focal position of the laser emission module based on the temperature deviation value and the morphology deviation value.

[0013] According to one aspect of an embodiment of the present application, an electronic device is provided, comprising: one or more processors; a storage device for storing one or more programs, wherein when the one or more programs are executed by the one or more processors, the electronic device implements the adjustable ring laser welding method based on intelligent laser-assisted wire filling as described above.

[0014] According to one aspect of an embodiment of the present application, a computer-readable storage medium is provided, on which computer-readable instructions are stored. When the computer-readable instructions are executed by a processor of a computer, the computer executes the adjustable ring laser welding method based on intelligent laser-assisted wire filling as described above.

[0015] According to one aspect of an embodiment of the present application, a computer program product is further provided, comprising a computer program, which, when executed by a processor, implements the steps in the adjustable ring laser welding method based on intelligent laser-assisted wire filling as described above.

[0016] In the technical solution provided in the embodiments of the present application, by dynamically adjusting the operating parameters of the circumferential laser emission module (such as the laser beam output shape, power distribution and focal position) based on the temperature and morphology of the molten pool, it is possible to ensure that the laser energy is accurately matched to the welding conditions, thereby optimizing the heat input and forming quality of the molten pool, reducing welding defects (such as pores and cracks), and significantly improving the mechanical properties and appearance quality of the weld. At the same time, by calculating the offset based on the welding wire position information and adjusting the operating parameters of the filler wire module, the position deviation during the welding process can be effectively compensated, ensuring that the welding wire is stably fed into the molten pool, avoiding poor welding caused by wire deviation, and further improving the stability and consistency of the welding process. That is, through multi-dimensional information fusion and closed-loop control, the intelligent and adaptive adjustment of the welding process is realized, while improving the welding quality, reducing the dependence on the operator's skills, and improving production efficiency and product yield.

[0017] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings are incorporated into and constitute a part of the specification, illustrating embodiments consistent with the present application and, together with the specification, serving to explain the principles of the present application. It is obvious that the drawings described below are merely some embodiments of the present application, and a person of ordinary skill in the art can derive other drawings based on these drawings without inventive effort. In the drawings:

[0019] Figure 11 is a schematic structural diagram of an adjustable ring laser welding system based on intelligent laser-assisted filler wire according to an exemplary embodiment of the present application;

[0020] Figure 2 is a structural schematic diagram of adjustable ring laser welding based on intelligent laser-assisted wire filling, shown in another exemplary embodiment of the present application;

[0021] Figure 3 is a flow chart of an adjustable ring laser welding method based on intelligent laser-assisted wire filling, shown in an exemplary embodiment of the present application;

[0022] Figure 4 is a flow chart of an adjustable ring laser welding method based on intelligent laser-assisted wire filling, shown in an exemplary embodiment of the present application;

[0023] Figure 5 is a flow chart of an adjustable ring laser welding method based on intelligent laser-assisted wire filling, shown in an exemplary embodiment of the present application;

[0024] Figure 6 A schematic diagram of the structure of a computer system suitable for implementing an electronic device according to an embodiment of the present application is shown. DETAILED DESCRIPTION

[0025] Exemplary embodiments will be described in detail herein, with examples illustrated in the accompanying drawings. When the following description refers to the drawings, identical numerals in different figures represent identical or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all embodiments consistent with the present application. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present application, as detailed in the appended claims.

[0026] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically separate entities. That is, these functional entities may be implemented in software, in one or more hardware modules or integrated circuits, or in different networks and / or processor devices and / or microcontroller devices.

[0027] The flowcharts shown in the accompanying drawings are for illustrative purposes only and do not necessarily include all contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps may be decomposed, while others may be combined or partially combined. Therefore, the actual execution order may vary depending on the actual situation.

[0028] In this application, "plurality" refers to two or more. "And / or" describes the relationship between related objects, indicating that three possible relationships exist. For example, "A and / or B" can mean: A exists alone, A and B exist simultaneously, and B exists alone. The character " / " generally indicates that the related objects are in an "or" relationship.

[0029] First of all, it should be noted that in high-end equipment manufacturing fields such as aerospace and automobile manufacturing, lightweighting is one of the key technical paths to achieve energy conservation and emission reduction and improve performance. Light alloy materials (such as aluminum alloys, magnesium alloys, etc.) have become an ideal choice to replace traditional steel materials due to their low density, high specific strength, strong corrosion resistance and good processing and forming properties. They have been widely used in core components such as aerospace structures, engine casings, and body frames. However, the welding performance of light alloy materials is significantly different from that of traditional steel materials. Their physical properties (such as high thermal conductivity, low melting point, high linear expansion coefficient) and metallurgical properties (such as easy oxidation, alloy element burnout, and thermal crack sensitivity) bring huge challenges to the welding process.

[0030] While hybrid heat source welding technologies (such as laser-arc hybrid welding) have improved the quality of light alloy welds to some extent in recent years, they still face challenges such as complex heat source matching and a narrow process window. Therefore, developing a light alloy welding technology that can effectively suppress weld defects and improve joint performance has become a critical issue in the aerospace industry. This technical solution aims to overcome the performance bottlenecks of traditional welding methods through innovative heat source regulation and process optimization, providing new solutions for high-quality welding of light alloy materials.

[0031] like Figure 1 As shown, Figure 1The present invention relates to an intelligent laser-assisted wire-filling adjustable ring laser welding system, illustrated in an exemplary embodiment of the present invention. The system includes a laser emitting module 110, a wire-filling module 120, and a feedback module 130. The laser emitting module 110 is configured to emit a corresponding laser beam toward the surface of a weld, wherein the laser beam has an adjustable ring shape. The wire-filling module 120 is configured to deliver welding wire to the weld. The feedback module 130 is configured to obtain the temperature and shape of the molten pool corresponding to the weld during welding to generate corresponding real-time monitoring data, and to determine feedback signals for the laser emitting module 110 and the wire-filling module 120 based on the real-time monitoring data. The feedback module 130 includes a monitoring unit 131 for monitoring real-time observation data of the molten pool during welding, wherein the real-time observation data includes the temperature of the molten pool and the position information of the welding wire. A feedback unit 132 is configured to generate feedback adjustment signals for the wire-filling module and the laser module based on the temperature and the position information of the welding wire. The laser emission module 110 further includes: a laser source 111 for emitting a corresponding annular laser beam toward the surface of the weldment; a laser adjustment module 112 for adjusting the operating parameters of the laser based on the feedback signal, wherein the operating parameters include the laser beam output form, the laser beam power distribution, and the laser beam focal position. The wire filling module 120 further includes: a wire fine-tuning unit 121 for adjusting the operating parameters of the welding wire based on the feedback signal, wherein the operating parameters include the welding wire current, the welding wire feed trajectory, and the welding wire feed rate. The wire filling module 120 further includes: a servo motor, a pneumatic actuator, and a welding wire adjustment chamber; the servo motor is used to control the internal air pressure of the pneumatic actuator under the guidance of the operating parameters of the welding wire, thereby achieving fine-tuning of the welding wire feed speed and position in the welding wire adjustment chamber.

[0032] Preferably, the laser source of laser emitting module 110 emits an adjustable ring laser beam, adjusting the output shape, power distribution, and focal position of the laser beam according to the requirements of the welding process. A real-time monitoring device acquires temperature and topography data of the molten pool during the welding process. A real-time molten pool monitoring data processor processes this data and compares it with preset standard values. A feedback control system generates an adjustment signal based on the deviation, and the adjustable ring laser feedback control system adjusts the laser's power output, focal position, and emission mode accordingly.

[0033] The filler wire module 120 is designed to ensure stable feeding of the welding wire and efficient and stable welding process by real-time monitoring of various dynamic parameters in the welding process and precise control thereof.

[0034] Preferably, the feedback system monitors the wire position offset and molten pool status data in real time through the wire position monitoring device, the molten pool real-time monitoring data processor and the wire real-time monitoring data processor. Based on the monitoring data, the feedback control system adjusts the working parameters of the welding wire, such as wire feeding speed, wire feeding offset position and wire temperature, in real time through the control algorithm. The wire fine-tuning component is used to monitor and correct the offset of the welding wire during the feeding process in real time to ensure the accuracy and stability of the filling wire. The real-time monitoring system is responsible for acquiring and processing data on various key parameters of the welding process in real time, including the position of the welding wire, the molten pool temperature, the molten pool morphology, etc. The system usually includes multiple high-precision sensors and data processing devices to continuously monitor the feeding status of the welding wire and the changes in the molten pool during the welding process.

[0035] Preferably, the welding wire position monitoring device adopts a high-precision laser sensor array, which accurately obtains the three-dimensional position data of the welding wire through laser scanning technology, and accurately scans the position and offset of the welding wire during the welding process. The position offset of the welding wire is received and processed by the welding wire real-time monitoring data processor to monitor the offset of the welding wire relative to the welding path.

[0036] Preferably, the real-time molten pool monitoring data processor acquires real-time images and temperature data of the molten pool using a high-speed camera, infrared thermometer, or other equipment. This data is used to analyze the shape, size, and temperature distribution of the molten pool to ensure its stability and uniformity.

[0037] Optionally, in some possible embodiments, see Figure 2 , Figure 2is a schematic structural diagram of another exemplary embodiment of the present application, illustrating intelligent laser-assisted wire-filling-based adjustable ring laser welding. The intelligent laser-assisted wire-filling-based adjustable ring laser welding device 100 includes a wire fine-tuning assembly 102, an adjustable ring laser source 103, and other components. The adjustable ring laser source 103 is configured to emit an adjustable ring laser toward the surface of a weld 101, and the wire fine-tuning assembly 102 is configured to supply welding wire to the weld. The wire fine-tuning assembly 102 and the adjustable ring laser source 103 are simultaneously fixed to the same robotic arm, allowing them to move together along a trajectory relative to the weld 101. During welding, the infrared temperature measuring device 104, high-speed camera device 105, and welding wire position monitoring device 1021 detect the real-time status of the molten pool. Based on the feedback control system 108, instructions are sent to the adjustable ring laser feedback control system 109 and the welding wire fine-tuning assembly 102 to precisely adjust the welding parameters and achieve precise control of the welding position and temperature field. This has the significant advantages of stabilizing the molten pool, reducing spatter, and minimizing porosity defects. Specifically, the welding wire fine-tuning assembly 102 can complete the fine control of the welding wire position through the servo motor, welding wire adjustment chamber, pneumatic actuator, and wire outlet 1025, ensuring the continuity and uniformity of the weld, effectively avoiding defects (porosity, cracks, incomplete penetration, undercut, etc.) caused by uneven or excessive feeding of the welding wire and position deviation during the welding process, thereby achieving automation and efficiency of the welding process, improving production efficiency and consistency. When the wire position monitoring device detects a position deviation, the feedback system converts the feedback signal into an electrical signal and transmits it to the servo motor. The servo motor adjusts its speed to control the air intake and exhaust of the pneumatic actuator, achieving a pressure difference within the wire adjustment chamber and thus fine-tuning the wire position. In some embodiments, the emission wavelength of the center laser and the ring laser of the adjustable ring laser is 1080 nm, the core diameter of the optical fiber used to transmit the center laser is 14 μm, and the core diameter of the optical fiber used to transmit the ring laser is 100 μm. In some embodiments, the power of the adjustable ring laser source can be greater than or equal to 1 kW and less than or equal to 3 kW to ensure that the molten pool formed by the adjustable ring laser spot melting the weld 101 is more stable. The sum of the power of the center laser and the ring laser can be 1.5 kW, 2 kW, 2.5 kW, etc., without limitation. In some embodiments, the speed of the laser light source spot and the welding wire can be greater than or equal to 1 m / min and less than or equal to 4 m / min to ensure that the molten pool formed by the weld 101 is at a moderate temperature and has high welding efficiency. The speed of movement along the moving trajectory can be 1.2 m / min, 1.5 m / min, 2 m / min, 3 m / min, 3.2 m / min, etc., which are not limited here. In some embodiments, the wire feed speed can be greater than or equal to 0.01 mm / s and less than or equal to 0.04 mm / s to ensure stability during the welding process.The wire feeding speed can be 0.015mm / s, 0.02mm / s, 0.025mm / s, etc., which is not limited here. In some embodiments, the wire spacing can be greater than or equal to 1mm and less than or equal to 5mm to ensure the interaction between the welding wire and the laser and improve the weld quality. The wire spacing can be 1.5mm, 2mm, 2.5mm, 3mm, etc., which is not limited here. In some embodiments, the weld parameters may include the molten pool temperature, the molten pool morphology and the welding wire position. The monitoring component includes an infrared temperature measuring device 104, a high-speed camera device 105, and a welding wire position monitoring device. The infrared thermometer is used to measure the temperature distribution of the welding area and monitor the welding temperature in real time; the high-speed camera device is used for dynamic analysis of the welding molten pool, observation of spattering, welding arc stability analysis, etc.; the welding wire position monitoring device is mainly used to monitor the relative position of the welding wire, the wire feeding speed and the distance between the welding wire and the welding workpiece in real time during the welding process to ensure the stability of the welding process and the welding quality. The real-time molten pool monitoring data processor 106 is configured to control the adjustable ring laser source 103 to increase the power of the laser spot or reduce the speed of the laser spot movement when the molten pool temperature is less than or equal to a first preset temperature value, thereby increasing the temperature of the weld area and keeping the temperature of the weld area within a preset temperature range to maintain the stability of the molten pool and improve weld quality. Simultaneously, the real-time wire monitoring data processor 107 is configured to control the wire fine-tuning assembly 102 to increase the wire feed speed when the molten pool defect is greater than or equal to a first preset defect value, thereby providing sufficient wire replenishment material and avoiding insufficient or weak welds. Furthermore, the real-time wire monitoring data processor 107 is configured to control the pneumatic actuator 1024 to finely adjust the wire position when the wire position is greater than or equal to a first preset offset value, thereby ensuring the stability of the welding process.

[0038] Furthermore, based on the above-mentioned adjustable ring laser welding system based on intelligent laser assisted wire filling, this application also proposes an adjustable ring laser welding method based on intelligent laser assisted wire filling, please refer to Figure 3 , Figure 3 It is a flow chart of an adjustable ring laser welding method based on intelligent laser-assisted wire filling, shown in an exemplary embodiment of the present application.

[0039] like Figure 3 As shown, in an exemplary embodiment, the adjustable ring laser welding method based on intelligent laser-assisted wire filling includes at least steps S310 to S330, which are described in detail as follows:

[0040] Step S310, obtaining molten pool status information corresponding to the weldment, the molten pool status information including molten pool temperature, molten pool morphology, and welding wire position information;

[0041] Step S320, determining the operating parameters of the laser emission module corresponding to the circumferential laser based on the molten pool temperature and the molten pool morphology, the operating parameters including the laser beam output form, the laser beam power distribution, and the laser beam focus position;

[0042] Step S330: Calculate the offset of the welding wire based on the welding wire position information, and adjust the operating parameters of the filler wire module corresponding to the welding wire based on the offset.

[0043] For example, a dual-band infrared thermal imager (medium wave 3-5μm + long wave 8-14μm) can be used in conjunction with a three-dimensional structured light scanner. The thermal imager captures the surface temperature field of the molten pool at a frame rate of 2000Hz, and eliminates the emissivity error through a two-color temperature measurement algorithm, with a temperature accuracy of ±1.5%; the structured light scanner projects a dynamic coded grating, combined with a GPU-accelerated phase unwrapping algorithm, to reconstruct the three-dimensional morphology of the molten pool with a resolution of 0.02mm, focusing on extracting the dynamic features of the weld width, weld depth, and keyhole. On the other hand, a high-speed linear array camera (100kHz line scan frequency) and a ring laser backlight system are used to track the three-dimensional coordinates of the welding wire end in real time. The angle and offset between the welding wire axis and the welding path are calculated using a sub-pixel edge detection algorithm (accuracy of ±0.05mm), and the trajectory deviation trend within the next 0.1s is predicted in combination with a Kalman filter. A nonlinear mapping relationship between the molten pool characteristics and the laser parameters is constructed based on deep learning. For example, when it is detected that the temperature gradient of the molten pool is >300℃ / mm and the keyhole oscillation frequency is >50Hz, it is determined to be a risk of keyhole instability and the laser parameters need to be adjusted. Among them, the laser mode can be switched in real time through the liquid crystal spatial light modulator (LC-SLM). When the fluidity of the molten pool is insufficient, it is switched to an annular spot (outer diameter 6mm, inner diameter 2mm) to enhance stirring; when the heat input needs to be precisely controlled, a Gaussian spot (diameter 1.5mm) is used. Using partitioned power modulation technology, the power density at the front end of the molten pool is increased to 85% to enhance penetration, and reduced to 15% at the tail to reduce overburning. Based on the feedback of the molten pool depth, the focus position is dynamically adjusted through the electric zoom lens (adjustment speed 15mm / s) to keep the focus in the range of 0.8-1.2mm below the molten pool to ensure the stability of the keyhole.

[0044] Furthermore, an LSTM neural network is used to predict the offset Δy within the next 0.2 seconds based on the wire's spatial positioning data. For example, when the wire's axial deflection angle α is detected to be greater than 1.8°, the lateral offset Δy = L·tanα (where L is the wire extension length) is calculated and the prediction error is corrected based on historical data. Based on the predicted offset Δy, a fuzzy PID controller is used to synchronously adjust the wire feed speed and oscillation parameters, including amplitude and frequency.

[0045] In some embodiments of the present application, by synchronously collecting the molten pool temperature, morphology and welding wire position information, a closed-loop control system of welding heat input and material response is constructed to achieve laser-wire collaborative optimization: based on the dynamic parameters of the molten pool, the laser beam shape, power distribution and focal position are adjusted in real time to accurately control the thermal behavior of the molten pool. At the same time, the wire feeder trajectory and feed rate are adaptively corrected according to the welding wire offset, which significantly reduces the defect rate of porosity, lack of fusion, etc., and is particularly suitable for high-efficiency and high-precision welding of dissimilar metals and complex structural parts.

[0046] Further, based on the above embodiment, please refer to Figure 4 In one exemplary embodiment provided in this application, the specific implementation process of calculating the offset of the welding wire based on the welding wire position information and adjusting the operating parameters of the filler wire module corresponding to the welding wire based on the offset may further include steps S410 to S430, which are described in detail as follows:

[0047] Step S410, determining actual position information of the welding wire based on the welding wire position information;

[0048] Step S420: If the real-time position information does not match the preset position information, then calculating the offset of the welding wire position relative to the preset position information;

[0049] Step S430: determining operating parameters of the filler wire module based on the offset, the operating parameters including wire current, wire feeding trajectory, and wire feeding rate.

[0050] For example, a high-precision visual sensing system is integrated to capture the three-dimensional coordinates of the end of the welding wire in real time to determine its actual spatial position, and compare it with the ideal preset position information pre-generated based on the CAD model in the welding process database. When a deviation is detected between the real-time position and the preset position, a spatial vector analysis algorithm is used to calculate the offset of the welding wire in the three dimensions of lateral (Δy), longitudinal (Δz) and angular (θ), and then the operating parameters of the wire filling module are dynamically adjusted based on the fuzzy logic rule library. Specifically, for lateral offset, the piezoelectric ceramic micro-motion platform is used to correct the welding wire feed trajectory in real time to compensate for the spatial position error. For longitudinal offset or angular deviation, the PID control algorithm is combined to synchronously adjust the welding wire feed rate (rate adjustment range ±30%) and welding current (the current compensation amount is nonlinearly mapped to the offset and arc voltage fluctuation), and finally a closed-loop coordinated control of the welding wire position, trajectory and power is achieved to ensure that the end of the welding wire is always stably in the active area of ​​the molten pool (error ≤±0.05mm), thereby significantly improving the stability of the welding process and the quality of the joint.

[0051] In some embodiments of the present application, by real-time sensing of the welding wire position deviation and dynamically adjusting the power, trajectory and rate parameters of the filler wire module, the positioning accuracy of the welding wire is improved and the arc stability is enhanced, which effectively solves the problem of filler wire misalignment in complex weld tracking and welding of special-shaped workpieces, and significantly improves the yield and process adaptability of automated welding production.

[0052] Further, based on the above embodiment, please refer to Figure 5 In one of the exemplary embodiments provided in this application, the specific implementation process of determining the operating parameters of the laser emission module corresponding to the circumventable laser based on the molten pool temperature and the molten pool morphology may further include steps S510 and S520, which are described in detail as follows:

[0053] Step S510, determining a temperature deviation value between the molten pool temperature and a preset molten pool temperature and a morphology deviation value between the molten pool morphology and a preset molten pool morphology;

[0054] Step S520 , determining the laser beam output form, laser beam power distribution, and laser beam focus position of the laser emitting module based on the temperature deviation value and the shape deviation value.

[0055] For example, a dual-band infrared thermal imager (medium wave 3-5μm + long wave 8-14μm) can be used to capture the surface temperature distribution of the molten pool at a frame rate of 2000Hz. The emissivity error is eliminated by a two-color temperature measurement algorithm to obtain the center temperature T1 and edge temperature T2 of the molten pool. The real-time temperature data is compared with the preset molten pool temperature model (pre-calculated based on the thermophysical properties of the material and the welding speed), and the temperature deviation value ΔT is calculated. Then, the molten pool morphology is reconstructed by a structured light 3D scanner (resolution 0.02mm), and key features such as the weld width W, weld depth H, and keyhole oscillation frequency f are extracted. The real-time morphology data is matched with the preset molten pool morphology library (based on numerical simulation and experimental calibration), and the morphology deviation value ΔS is calculated using the shape context algorithm to establish a dynamic coupling relationship model between the molten pool temperature and morphology. Based on the deviations ΔT and ΔS, a liquid crystal spatial light modulator (LC-SLM) switches laser modes in real time: Gaussian spot (1.5mm diameter) for precise heat input control, suitable for applications with ΔT < -20°C; annular spot (5mm outer diameter, 2mm inner diameter) for enhanced melt pool agitation, suitable for applications with ΔS > 0.1mm and severe keyhole oscillation; and multi-focus spot, which generates dual focal points through phase modulation to improve weld penetration consistency, suitable for applications with significant ΔH deviations. Laser power density can also be dynamically adjusted based on the temperature gradient distribution.

[0056] In some embodiments of the present application, by real-time quantification of the dual deviations of molten pool temperature and morphology and dynamic optimization of laser beam parameters (shape, power distribution and focal position), precise matching of welding heat input and molten pool evolution is achieved, thereby improving the consistency of penetration and reducing the keyhole instability defect rate, significantly enhancing the process stability and quality controllability of welding high-reflectivity metals and dissimilar materials.

[0057] Optionally, in some feasible embodiments, a laser emitting assembly in the welding system can emit an adjustable ring-shaped light source toward the surface of the workpiece to be welded. This light source can be precisely focused on the workpiece surface, forming a ring-shaped laser spot. As the welding wire is fed into the system, a monitoring device detects the distance between the welding wire and the adjustable ring-shaped laser spot. A control system adjusts the position and shape of the laser spot to ensure a predetermined spacing between the welding wire and the adjustable ring-shaped laser spot. The welding wire and the adjustable ring-shaped laser spot are moved along a trajectory relative to the workpiece to be welded, initiating the welding process. The welding wire and the adjustable ring-shaped laser spot move synchronously along the predetermined trajectory. Using a welding robot or automated welding equipment, the relative position of the welding wire and the laser spot is strictly controlled to ensure they maintain the predetermined relative position. Once the welding equipment is activated, the laser light source and the welding wire act together on the surface of the workpiece to be welded, initiating the molten pool formation process. During this process, the welding system precisely controls the speed and direction of the laser light source and the welding wire to ensure the stability of the molten pool and the uniform melting of the weld metal. The monitoring component monitors weld parameters such as wire position deviation and the weld pool's surface topography. The welding process monitoring component acquires the wire position and weld pool's surface topography in real time, ensuring the wire remains on the predetermined trajectory and promptly detecting even the slightest deviation from the track. Simultaneously, the weld pool's surface topography is monitored in real time by a high-precision infrared thermometer and a high-speed camera to analyze the weld pool's depth, width, and flow during welding. Changes in the weld pool's topography provide real-time feedback to the control system, ensuring weld uniformity and quality. Based on the feedback system, the control component controls the process parameters of the adjustable ring laser spot and wire position according to the weld parameters. These parameters primarily include power, movement parameters along the trajectory, and wire offset. The feedback system provides real-time control of the welding process. The control system dynamically adjusts the power of the adjustable ring laser spot, wire feed speed, and wire offset based on weld parameters such as wire position deviation, weld pool depth, and welding temperature. During welding, if the control system detects that the welding wire has deviated from the set position, it can automatically adjust the wire feed speed or welding path to bring the wire to the correct position. If the molten pool morphology is detected to not meet the set requirements, the system will adjust the laser power or welding speed in real time to optimize the weld quality. This precise feedback adjustment ensures the stability of the welding process, effectively reduces defects, and improves welding efficiency.

[0058] The welding process of the welding device and method is described below by taking the welding of 6063 aluminum alloy plates by adjustable ring laser welding based on intelligent laser-assisted filler wire as an example.

[0059] (1) Use sandpaper to remove the oxide film on the surface of the welded 6063 aluminum alloy plate until the surface reveals the metallic luster, wipe the butt edge and the surface to be welded to remove the surface oil;

[0060] (2) Fix the 6063 aluminum alloy plate on the welding platform, adjust the position of the adjustable ring laser source 103 and the distance to the 6063 aluminum alloy plate, so that the beam of the adjustable ring laser is focused on the surface of the 6063 aluminum alloy plate;

[0061] (3) Set the laser defocus to 0 mm; the welding power to 1.5 kW; the welding speed to 3 m / min; the laser incident angle to 90°; the filament spacing to 1 mm; the wire feeding speed to 0.02 mm / s; and use a copper shielding gas nozzle to protect the welding process. The shielding gas is argon with a purity of 99.99% and a flow rate of 20 L / min.

[0062] (4) Turn on the laser welding protective gas, start welding, and the adjustable ring laser head emits laser;

[0063] (5) During the welding process, an infrared thermometer is used to monitor the molten pool temperature in real time, a high-speed camera is used to monitor the molten pool morphology in real time, and a wire position monitoring device is used to monitor the wire position in real time. The molten pool real-time monitoring data is transmitted in real time through the acquisition system to the real-time monitoring data processor, and the difference between the current molten pool temperature and the set temperature is calculated. At this time, the temperature is higher than the preset range, the active feedback system is started, and the laser power is automatically adjusted to 1.4KW. The temperature is continued to be monitored. At this time, the temperature is within the preset range; at this time, the left offset of the wire position is higher than the preset range, the pneumatic actuator has more air intake on the left and less on the right, and the pressure on the left increases, causing the wire to shift to the right, completing the fine-tuning of the wire position. At this time, the wire offset is within the preset range, the active feedback system is turned off, and the welding is completed at the end position.

[0064] It should be noted that the adjustable ring laser welding device based on intelligent laser-assisted wire filling provided in the above embodiment and the adjustable ring laser welding method based on intelligent laser-assisted wire filling provided in the above embodiment are based on the same concept, wherein the specific manner in which each module and unit performs the operation has been described in detail in the method embodiment and will not be repeated here. In actual application, the adjustable ring laser welding device based on intelligent laser-assisted wire filling provided in the above embodiment can allocate the above functions to different functional modules as needed, that is, divide the internal structure of the device into different functional modules to complete all or part of the functions described above, and this is not limited here.

[0065] An embodiment of the present application also provides an electronic device, comprising: one or more processors; a storage device for storing one or more programs, wherein when the one or more programs are executed by the one or more processors, the electronic device implements the adjustable ring laser welding method based on intelligent laser-assisted wire filling provided in the above-mentioned embodiments.

[0066] Figure 6 The following is a schematic diagram showing the structure of a computer system suitable for implementing an electronic device according to an embodiment of the present application. Figure 6 The computer system 600 of the electronic device shown is only an example and should not bring any limitation to the functions and scope of use of the embodiments of the present application.

[0067] like Figure 6 As shown, the computer system 1200 includes a central processing unit (CPU) 1201, which can perform various appropriate actions and processes according to the program stored in the read-only memory (ROM) 1202 or the program loaded from the storage part 1208 to the random access memory (RAM) 1203, such as executing the method described in the above embodiment. Various programs and data required for system operation are also stored in the RAM 1203. The CPU 1201, ROM 1202 and RAM 1203 are connected to each other via a bus 1204. An input / output (I / O) interface 1205 is also connected to the bus 1204.

[0068] The following components are connected to the I / O interface 1205: an input section 1206 including a keyboard, a mouse, and the like; an output section 1207 including devices such as a cathode ray tube (CRT), a liquid crystal display (LCD), and speakers; a storage section 1208 including a hard disk; and a communication section 1209 including a network interface card such as a LAN (Local Area Network) card or a modem. The communication section 1209 performs communication processing via a network such as the Internet. A drive 1210 is also connected to the I / O interface 1205 as needed. Removable media 1211, such as a magnetic disk, an optical disk, a magneto-optical disk, or a semiconductor memory, is installed in the drive 1210 as needed, so that computer programs read from the removable media can be installed in the storage section 1208 as needed.

[0069] In particular, according to an embodiment of the present application, the process described above with reference to the flowchart can be implemented as a computer software program. For example, an embodiment of the present application includes a computer program product, which includes a computer program carried on a computer-readable medium, and the computer program includes a computer program for executing the method shown in the flowchart. In such an embodiment, the computer program can be downloaded and installed from a network via the communication section 1209, and / or installed from a removable medium 1211. When the computer program is executed by the central processing unit (CPU) 1201, the various functions defined in the system of the present application are executed.

[0070] It should be noted that the computer-readable medium shown in the embodiments of the present application can be a computer-readable signal medium or a computer-readable storage medium or any combination of the above two. The computer-readable storage medium can be, for example, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, device or device, or any combination of the above. More specific examples of computer-readable storage media can include, but are not limited to: an electrical connection with one or more wires, a portable computer disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM), a flash memory, an optical fiber, a portable compact disk read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the above. In the present application, a computer-readable signal medium can include a data signal propagated in baseband or as part of a carrier wave, which carries a computer-readable computer program. This propagated data signal can take a variety of forms, including but not limited to an electromagnetic signal, an optical signal, or any suitable combination of the above. A computer-readable signal medium may also be any computer-readable medium other than a computer-readable storage medium that can transmit, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device. A computer program embodied on a computer-readable medium may be transmitted using any suitable medium, including but not limited to wireless, wired, or any suitable combination thereof.

[0071] The flowcharts and block diagrams in the accompanying drawings illustrate the possible implementation architecture, functions and operations of the systems, methods and computer program products according to various embodiments of the present application. Among them, each box in the flowchart or block diagram can represent a module, program segment, or part of the code, and the above-mentioned module, program segment, or part of the code contains one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in an order different from that marked in the accompanying drawings. For example, two boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram or flowchart, and the combination of boxes in the block diagram or flowchart, can be implemented with a dedicated hardware-based system that performs the specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0072] The units involved in the embodiments described in this application may be implemented by software or hardware, and the units described may also be set in a processor. In some cases, the names of these units do not constitute limitations on the units themselves.

[0073] Another aspect of the present application provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the aforementioned adjustable ring laser welding method based on intelligent laser-assisted wire filling. The computer-readable storage medium may be included in the electronic device described in the above embodiments, or may exist independently and not be incorporated into the electronic device.

[0074] Another aspect of the present application provides a computer program product or computer program, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the adjustable ring laser welding method based on intelligent laser-assisted wire filling provided in each of the above embodiments.

[0075] The above content is only a preferred exemplary embodiment of the present application and is not intended to limit the implementation scheme of the present application. Ordinary technicians in this field can easily make corresponding changes or modifications based on the main ideas and spirit of the present application. Therefore, the scope of protection of the present application shall be based on the scope of protection required by the claims.

Claims

1. An adjustable ring laser welding system based on intelligent laser-assisted wire filling, characterized in that: The device comprises: A laser emitting module, configured to emit a corresponding laser beam toward the surface of the weldment, wherein the shape of the laser beam is an adjustable ring; A wire feeding module, used for feeding welding wire to the welding part; The feedback module is used to obtain the temperature and morphology of the molten pool corresponding to the welded part during the welding process to generate corresponding real-time monitoring data, and determine the feedback signal of the laser emission module and the feedback signal of the wire filling module based on the real-time monitoring data.

2. The system according to claim 1, wherein The feedback module includes: A monitoring unit, configured to monitor real-time observation data of the molten pool during welding, wherein the real-time observation data includes the temperature of the molten pool and the position information of the welding wire; A feedback unit is used to generate feedback adjustment signals corresponding to the filler wire module and the laser module based on the temperature and position information of the welding wire.

3. The system according to claim 2, wherein: The laser emission module also includes: a laser source, configured to emit a corresponding annular laser beam toward the surface of the weldment; The laser adjustment module is used to adjust the operating parameters of the laser based on the feedback signal, wherein the operating parameters include the laser beam output form, the laser beam power distribution and the laser beam focus position.

4. The system according to claim 2, wherein: The wire filling module also includes: A welding wire fine-tuning unit is used to adjust the operating parameters of the welding wire based on the feedback signal, wherein the operating parameters include welding wire current, welding wire feed trajectory and welding wire feed rate.

5. The system according to claim 4, wherein: The wire filling module also includes: a servo motor, a pneumatic actuator, and a wire adjustment chamber; The servo motor is used to control the internal air pressure of the pneumatic actuator under the guidance of the operating parameters of the welding wire, thereby achieving fine adjustment of the feeding speed and position of the welding wire in the welding wire adjustment chamber.

6. An adjustable ring laser welding method based on intelligent laser-assisted wire filling, characterized in that: Applied to an adjustable ring laser welding system based on intelligent laser-assisted wire filling, the method includes: Obtaining molten pool status information corresponding to the weldment, wherein the molten pool status information includes molten pool temperature, molten pool morphology, and welding wire position information; Determine the operating parameters of the laser emission module corresponding to the circumferential laser based on the molten pool temperature and the molten pool morphology, wherein the operating parameters include the laser beam output form, the laser beam power distribution and the laser beam focus position; The offset of the welding wire is calculated based on the welding wire position information, and the operating parameters of the filler wire module corresponding to the welding wire are adjusted based on the offset.

7. The method according to claim 6, wherein The calculating the offset of the welding wire based on the welding wire position information, and adjusting the operating parameters of the filler wire module corresponding to the welding wire based on the offset, includes: determining actual position information of the welding wire based on the welding wire position information; If the real-time position information does not match the preset position information, calculating the offset of the welding wire position relative to the preset position information; The operating parameters of the filler wire module are determined based on the offset, wherein the operating parameters include wire current, wire feed trajectory, and wire feed rate.

8. The method according to claim 6, wherein The determining of the operating parameters of the laser emission module corresponding to the circumventable laser based on the molten pool temperature and the molten pool morphology includes: Determining a temperature deviation between the molten pool temperature and a preset molten pool temperature and a morphology deviation between the molten pool morphology and a preset molten pool morphology; The laser beam output form, laser beam power distribution and laser beam focus position of the laser emitting module are determined based on the temperature deviation value and the shape deviation value.

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