Welding machine counting and welding missing prevention monitoring system

Abstract

The invention belongs to the technical field of automatic monitoring of welding equipment, and discloses a welding machine counting and welding omission prevention monitoring system, which comprises a data acquisition module for performing multi-channel parallel acquisition on welding operation state data based on a time slice polling mechanism in a welding process, the collected welding operation state data are embedded into the parameter hash signature stream to form a tamper-proof real-time signal chain; the abnormal state judgment module is used for mapping the real-time signal chain into a state transition hypergraph, analyzing time sequence phase deviation between state nodes based on a time window sliding resonance detection algorithm, identifying a welding skipping related abnormal state and marking an abnormal topological position; the welding spot counting correction module is used for correcting the current welding spot counting value in real time when an abnormal topological position is detected, introducing a cost benefit balance factor between different nodes and outputting a corrected credible welding spot counting value; intelligent monitoring of welding and missing welding prevention are achieved, and operation safety and production efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding equipment automation monitoring, more particularly, the present application relates to a welding machine counting and anti-missing welding monitoring system. BACKGROUND

[0002] The existing welding machine counting and anti-missing welding monitoring system mainly has the following problems: The existing anti-missing welding monitoring mainly relies on single-channel current, voltage or temperature signal threshold determination, which is difficult to accurately identify missing welding in multi-channel and multi-stage welding operations, especially when the signal is disturbed or fluctuates, which is prone to misjudgment or omission. The existing detection method usually ignores the timing phase relationship between different welding states, cannot effectively analyze the dynamic correlation between nodes, and is difficult to capture the phase shift characteristics caused by missing welding. Although some methods can detect abnormalities, they cannot accurately locate the abnormal position in the welding process topology, resulting in low efficiency of subsequent correction or manual intervention. The existing system is mostly post-analysis, which cannot alarm and control in real time during the welding process.

[0003] In the welding process, the counting system may be affected by electromagnetic interference, sensor transient error or signal loss, resulting in deviation between actual welding point counting and system recording. The existing system mostly uses simple threshold or re-counting method to correct the abnormality, which cannot distinguish the severity of different abnormal nodes and their influence on the counting result, and the correction result is not accurate enough. Excessive correction may introduce misjudgment, leading to false alarm or unnecessary clamp locking; insufficient correction may cause missing welding to be missed, resulting in quality risk. The existing system usually corrects based on fixed weight or rules, and lacks the ability to dynamically adjust according to historical frequency and abnormal influence range.

[0004] In the prior art, due to sensor signal noise, transient fluctuation or occasional abnormality in the welding process, the welding point counting is prone to short-term deviation, which may cause the clamp to be unlocked or not locked in time, thereby increasing the risk of missing welding or miswelding. The existing technology usually only judges whether the welding point counting meets the requirements based on a single threshold, and cannot buffer the short-term abnormality or transient fluctuation. The system lacks dynamic monitoring and visual feedback, and when welding abnormality occurs, the operator cannot immediately determine the accuracy of the clamp state and the welding point counting, affecting the welding quality and safety.

[0005] In view of this, the present application provides a welding machine counting and anti-missing welding monitoring system to solve the above problems. SUMMARY

[0006] In order to overcome the above-mentioned defects of the prior art, in order to achieve the above-mentioned purpose, the present application provides the following technical scheme: a welding machine counting and anti-missing welding monitoring system, comprising: The data acquisition module acquires the welding operation state data in multiple channels in parallel based on a time slice polling mechanism during the welding process, and embeds the acquired welding operation state data into a parameter hash signature stream to form a tamper-proof real-time signal chain. The abnormal state determination module maps the real-time signal chain into a state transition hypergraph, analyzes the time sequence phase shift between the state nodes based on a time window sliding resonance detection algorithm, identifies the related abnormal state of the welding omission, and labels the abnormal topological position. The welding point count correction module corrects the current welding point count value in real time when the abnormal topological position is detected, introduces a cost-benefit balance factor between different nodes, and outputs the corrected reliable welding point count value. The anti-welding omission locking module is based on a double-threshold delay control mechanism. If the reliable welding point count value reaches the low threshold but does not reach the high threshold, the clamp remains in the locked state and is delayed to unlock; if the reliable welding point count value reaches the high threshold and the abnormal label is eliminated, the electromagnetic air valve is driven to unlock the clamp. The monitoring result display module receives the reliable welding point count value and the clamp locking state, dynamically generates a visual interface of the welding process state based on a graphical interface, and prompts the operator to take measures through graphical and sound prompts when an abnormality occurs.

[0007] Specifically, the method of acquiring the welding operation state data in multiple channels in parallel includes: The acquisition time axis is divided into equal time slices by a time slice polling mechanism, and the acquisition tasks of different sensing channels are triggered simultaneously in each time slice according to a preset channel priority order to obtain the welding operation state data. The welding operation state data includes electrical parameter data, thermal parameter data, position movement parameter data, process auxiliary parameter data, and environmental parameter data. Different sensing channels acquire data in parallel through a multi-channel analog-to-digital converter at the hardware layer to synchronously read different channel data, and a scheduler at the software layer controls the time sequence coordination of each channel acquisition within the time slice.

[0008] Specifically, the method of forming a tamper-proof real-time signal chain includes: The welding operation state data of each time slice is packaged with the corresponding timestamp, channel identifier, and acquisition parameter to generate an original data packet for the time slice; and a parameter hash operation is performed on the original data packet to generate a unique corresponding parameter hash signature. The parameter hash signature is concatenated with the hash signature of the previous time slice and then a hash operation is performed again to form a chain hash association between adjacent time slices; by continuously linking the parameter hash signature of the new time slice with the signature of the previous time slice, a parameter hash signature stream covering the entire welding process is formed. If the original data packet of any time slice is tampered, the hash value corresponding to the original data packet and the chain association will be inconsistent, realizing the tamper-proof protection of the welding operation state data.

[0009] Specifically, the method of mapping the real-time signal chain into a state transition hypergraph comprises: The received real-time signal chain is parsed into a state sequence in chronological order, and each state node in the state sequence corresponds to the welding operation state data of a time slice; by introducing a multi-dimensional relationship mapping in the state sequence, not only the time adjacent relationship between nodes is represented, but also the association relationship between different collection channels and different process stages is represented, and a state transition hypergraph containing different edge relationships is constructed; The vertices of the state transition hypergraph represent various state nodes in the welding process, and the hyperedges represent the associated transition relationship between different state nodes; the time interval, phase difference and physical quantity correlation between nodes are reflected by assigning edge weights to the hypergraph.

[0010] Specifically, the method of identifying a missed welding related abnormal state and labeling an abnormal topological position comprises: For any two state nodes in the state transition hypergraph, the phase difference at the time point is defined; based on the time window sliding resonance detection algorithm, a sliding time window with a length of is defined on the time axis, and the phase synchronization index of any two state nodes within the sliding time window is calculated at each time point; A preset phase synchronization threshold is set, and when the phase synchronization index of any two state nodes within the sliding time window is less than the preset phase synchronization threshold, it is determined that there is a missed welding related abnormal state between the two state nodes, and the positions of the two state nodes on the state transition hypergraph are labeled as abnormal topological positions.

[0011] Specifically, the method of outputting a corrected reliable weld point count value comprises: During the welding process, the system continuously acquires and updates the weld point count value, which represents the uncorrected weld point count value detected at the time point When an abnormal topological position is detected, the state node set corresponding to the abnormal topological position is defined as an abnormal set; Each node in the abnormal set is assigned an abnormal correction weight, which is determined according to the abnormal severity, influence range and historical occurrence frequency of the node; a cost-benefit balance factor is introduced between different nodes to adjust the balance between the correction amplitude and the system fault tolerance, a weld point reliable count correction function is constructed, and a corrected reliable weld point count value is output.

[0012] Specifically, the method of maintaining the clamp in a locked state and delaying unlocking includes: A low threshold and a high threshold are preset, and the low threshold is smaller than the high threshold. When the trusted solder point count reaches the low threshold for the first time, the time point is recorded and the dual-threshold delay control mechanism is started at the same time. If the trusted solder point count still does not reach the high threshold at this time, the system keeps the fixture locked and delays the unlocking execution.

[0013] Specifically, the method of driving the electromagnetic valve to unlock the clamp includes: If the trusted weld point count reaches the preset high threshold, it is determined that the number of weld points in the current welding operation has reached the preset safety standard, and the marked abnormal topological position has been eliminated, and the system enters the fixture unlocking preparation state; The anti-leakage welding monitoring terminal sends an unlocking command to the preset electromagnetic valve control unit. The electromagnetic valve in the electromagnetic valve control unit serves as the actuator of the fixture locking mechanism. After receiving the unlocking command, it starts the electromagnetic coil to change the position of the valve core and release the locking state of the fixture.

[0014] Specifically, the method for dynamically generating a visualization interface of the welding process status includes: Receive the trusted solder joint count value, the current identifier of the fixture locking state, and the time point when the fixture locking state changes, and transmit them to a preset graphics rendering engine. The graphics rendering engine maps the trusted solder joint count value into a dynamic line graph or bar graph based on a preset display template to reflect the growth trend of the solder joint count; The fixture locking status is mapped to a status indicator light or icon. The color and shape of the status indicator light changes dynamically with the locking or unlocking status, showing the current working status of the fixture. Based on the mapping relationship, the graphics rendering engine arranges the trusted weld point count value, the current identifier of the fixture locking status and the time point of the fixture locking status change in chronological order during the welding process, and dynamically generates a visual interface for the welding process status.

[0015] Specifically, the method of reminding the operator to take measures includes: When an abnormal state is detected during the welding process, the graphics rendering engine displays the relevant area corresponding to the abnormal state in the welding process on the visual interface based on the preset abnormal prompt template, and uses flashing animation or pop-up window to highlight the abnormal information. At the same time, the sound prompt is triggered to play the preset warning sound to remind the operator to take measures.

[0016] Compared with the prior art, the present invention has the following beneficial effects: The present application improves the robustness of the missed welding identification by mapping the welding operation state data into a state transition hypergraph, comprehensively considering the time adjacency, inter-channel correlation and process stage relationship. By defining the phase difference between any two state nodes and calculating the phase synchronization index within the sliding time window, the phase consistency change between nodes can be detected in real time, and the phase mismatch caused by missed welding can be accurately captured. In the state transition hypergraph, the abnormal topology position is directly labeled to realize the spatial positioning and visual display of the abnormality, which facilitates the operator to quickly judge and handle; the detection process uses a sliding window to update in real time, and the abnormal result can be output without waiting for the entire welding operation to end, which can be linked with the anti-missed welding locking module of the system to trigger the clamp locking or alarm in the first time to prevent unqualified workpieces from flowing into the subsequent link.

[0017] By mapping the detected abnormal topology position into an abnormal node set and assigning each node a correction weight based on severity, impact range and historical frequency, differentiated and accurate correction can be achieved. By introducing a cost-benefit balance factor, a balance between missed welding risk and misjudgment risk can be achieved, so that the correction result can effectively compensate for the error caused by the abnormality, while avoiding false alarms caused by excessive correction. The abnormal correction weight can be dynamically adjusted according to the production environment, equipment aging degree and historical data statistics to ensure that the system can maintain high-precision counting correction ability in long-term operation. The corrected reliable count value directly affects the subsequent clamp unlocking and alarm logic, which can effectively reduce the missed welding unreported phenomenon caused by counting error, thereby improving the overall welding quality control level; the abnormal state is fed back in real time to improve the response speed and processing efficiency of the operator.

[0018] By presetting low and high threshold values and keeping the clamp locked when the low threshold is reached but the high threshold is not met, the risk of missed welding is significantly reduced. The control mechanism of double thresholds combined with delay time enables the system to buffer short-term abnormalities or errors in weld point counting, improving the fault tolerance and stability of the welding process. By keeping the clamp locked until the high threshold condition is met, the reliability of the weld point count value is ensured, providing an accurate data basis for weld point count correction and real-time visual monitoring, which facilitates the operator to take timely measures; the system automatically controls the clamp state without human intervention, while the delay mechanism avoids misoperation, achieving high reliability and high efficiency management of the welding process. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 A welding machine counting and missed welding prevention monitoring system structure schematic diagram of the present application; Figure 2 A method flowchart for dynamically generating a visual interface of a welding process provided by the present application; Figure 3A flowchart of a welding machine counting and missed welding monitoring method of the present application is shown. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0021] Embodiment One

[0022] Please refer to Figure 1 and Figure 2 Embodiment One further describes a welding machine counting and missed welding monitoring system proposed by the present application, which includes: The existing welding machine counting and missed welding monitoring system mainly relies on single-channel current, voltage or temperature signals to identify missed welding by threshold determination. However, in multi-channel and multi-stage welding operations, this method is difficult to accurately detect missed welding, especially when the signal is disturbed or fluctuated, which is easy to produce misjudgment or missed judgment. In addition, the existing technology usually ignores the timing phase relationship between different welding states, and cannot effectively analyze the dynamic correlation between state nodes, so it is difficult to capture the phase shift characteristics caused by missed welding. Although some methods can detect abnormalities, they cannot accurately locate the abnormal position in the topology structure of the welding process, resulting in low efficiency of subsequent correction or manual intervention. At the same time, most systems are mainly based on post-analysis, lacking the ability of immediate alarm and protection control during the welding process.

[0023] During the welding counting process, the system is easily affected by electromagnetic interference, sensor transient error or signal loss, resulting in deviation between the actual welding point count and the system record. The existing system mostly uses simple threshold or recounting method to correct the abnormality, but cannot distinguish the severity of different abnormal nodes and their influence on the counting result, and the correction accuracy is insufficient. Excessive correction may introduce misjudgment, leading to false alarm or unnecessary clamp locking; insufficient correction may cause missed welding to be undetected, which poses a quality risk. In addition, the existing system mostly corrects based on fixed weight or rules, lacking the ability to dynamically adjust according to the historical occurrence frequency and abnormal influence range.

[0024] The prior art also has the problem that the welding point count fluctuation cannot be effectively buffered. During the welding process, due to sensor signal noise, transient fluctuation or occasional abnormality, the welding point count is prone to short-term deviation, which may cause the fixture to be unlocked in advance or fail to be locked in time, thereby increasing the risk of missed welding or miswelding. The existing system usually only relies on a single threshold to determine whether the welding point count meets the standard, lacking a processing mechanism for short-term abnormalities or transient fluctuations. In addition, the system lacks dynamic monitoring and visual feedback, and when welding abnormalities occur, it is difficult for the operator to obtain accurate information about the fixture state and welding point count in a timely manner, affecting the welding quality and operational safety.

[0025] To effectively solve the above problems, the present application proposes a welding machine counting and missed welding prevention monitoring system, comprising: A data acquisition module, which performs multi-channel parallel acquisition of welding operation state data based on a time slice polling mechanism during the welding process, and embeds the acquired welding operation state data into a parameter hash signature stream to form a tamper-proof real-time signal chain; An abnormal state determination module, which maps the real-time signal chain into a state transition hypergraph, and analyzes the timing phase shift between state nodes based on a time window sliding resonance detection algorithm to identify missed welding related abnormal states and label the abnormal topological positions; A welding point count correction module, which corrects the current welding point count value in real time when an abnormal topological position is detected, introduces a cost-benefit balance factor between different nodes, and outputs a corrected credible welding point count value; A missed welding prevention locking module, which is based on a double threshold delay control mechanism. If the credible welding point count value reaches the low threshold but not the high threshold, the fixture remains in the locked state and delays unlocking execution. If the credible welding point count value reaches the high threshold and the abnormal label is eliminated, the electromagnetic air valve is driven to unlock the fixture; A monitoring result display module, which receives the credible welding point count value and the fixture locking state, dynamically generates a visual interface of the welding process state based on a graphical interface, and prompts the operator to take measures through graphical and sound prompts when an abnormality occurs.

[0026] The method for multi-channel parallel acquisition of welding operation state data comprises: The acquisition time axis is divided into equal length time slices by a time slice polling mechanism, and the acquisition tasks of different sensing channels are triggered simultaneously in each time slice according to the preset channel priority order to obtain welding operation state data; The welding operation state data includes electrical parameter data, thermal parameter data, position movement parameter data, process auxiliary parameter data and environmental parameter data; different sensing channels are parallelly acquired by a multi-channel analog-to-digital converter at the hardware layer to synchronously read different channel data, and the scheduler at the software layer controls the timing coordination of each channel acquisition within the time slice.

[0027] The method for forming the tamper-proof real-time signal chain comprises: packaging the collected welding operation state data of each time slice with the corresponding timestamp, channel identifier and acquisition parameter to generate an original data packet of the time slice; performing a parameter hash operation on the original data packet to generate a unique corresponding parameter hash signature; concatenating the parameter hash signature with the hash signature of the previous time slice and then performing a hash operation again to form a chain hash association between adjacent time slices; by continuously linking the parameter hash signature of the new time slice with the signature of the previous time slice, a parameter hash signature stream covering the entire welding process is formed; If the original data packet of any time slice is tampered with, the hash value corresponding to the original data packet and the chain association will be inconsistent, realizing tamper-proof protection of the welding operation state data.

[0028] The method for mapping the real-time signal chain into a state transition hypergraph comprises: parsing the received real-time signal chain into a state sequence in chronological order, each state node in the state sequence corresponding to the welding operation state data of a time slice; by introducing a multi-dimensional relationship mapping in the state sequence, not only the time adjacent relationship between nodes is represented, but also the association relationship between different acquisition channels and different process stages is represented, a state transition hypergraph containing different edge relationships is constructed; The vertices of the state transition hypergraph represent the state nodes in the welding process, and the hyperedges represent the association transition relationship between different state nodes; the edge weight of the hypergraph is valued to reflect the time interval, phase difference and physical quantity correlation between nodes.

[0029] The time interval is decayed according to the time difference between nodes to ensure that the nodes with similar time are more strongly associated; the phase difference measures the degree of synchronization between nodes by calculating the cosine value of the phase difference of the node signal; the physical quantity correlation reflects the consistency of the physical characteristics between nodes by calculating the correlation coefficient or similarity between the feature vectors.

[0030] The method for identifying the related abnormal state of the missed welding and marking the abnormal topological position comprises: For any two state nodes in the state transition hypergraph, define the phase difference at time point The phase difference of any two state nodes at time point is: ; wherein, represents the phase difference of node and node at time point ; and represent any two state nodes in the state transition hypergraph. an index representing a time point; a node representing a time point a phase value at a time point, the phase information can be obtained by corresponding welding operation state data extraction; a node representing a time point a phase value at a time point; Based on the time window sliding resonance detection algorithm, a sliding time window with a length of is defined on the time axis, and the phase synchronization index of any two state nodes in the sliding time window is calculated at each time point; The phase synchronization index is: ; wherein, a node representing a time point a node representing a time point a phase synchronization index (resonance coefficient) at a time point ; represents a sampling time point in the sliding time window, the value range is ; represents the cosine value of the phase difference at a time point , indicating the degree of phase consistency; the value of 1 indicates complete synchronization, and the value of -1 indicates complete opposition; A preset phase synchronization threshold value, when the phase synchronization index of any two state nodes in the sliding time window is less than the preset phase synchronization threshold value, it is determined that there is a related abnormal state between the two state nodes. The position of the two state nodes on the state transition hypergraph is marked as an abnormal topological position.

[0031] The following problems existing in the prior art are solved: The existing anti-welding leakage monitoring mainly relies on the threshold value determination of single-channel current, voltage or temperature signal, and it is difficult to accurately identify welding leakage in multi-channel and multi-stage welding operation, especially when the signal is disturbed or fluctuated, false judgment or missed judgment is easy to occur. The existing detection method usually ignores the timing phase relationship between different welding states, cannot effectively analyze the dynamic correlation between nodes, and is difficult to capture the phase shift characteristics caused by welding leakage. Although some methods can detect abnormalities, they cannot accurately locate the abnormal position in the welding process topology, resulting in low efficiency of subsequent correction or manual intervention. The existing system is mainly for post-analysis, and cannot alarm and control in real time during the welding process.

[0032] The beneficial effects of the prior art are: mapping the welding operation state data into a state transition hypergraph, comprehensively considering the time adjacency, inter-channel correlation and process stage relationship, and improving the robustness of the missed welding identification. By defining the phase difference between any two state nodes and calculating the phase synchronization index in the sliding time window, the phase consistency change between nodes can be detected in real time, and the phase mismatch caused by missed welding can be accurately captured. In the state transition hypergraph, the abnormal topology position is directly labeled, realizing the spatial positioning and visual display of the abnormality, which is convenient for operators to quickly judge and handle; the detection process uses a sliding window to update in real time, and the abnormal result can be output without waiting for the entire welding operation to end, which can be linked with the anti-missed welding locking module of the system to trigger the clamp locking or alarm in the first time to prevent unqualified workpieces from flowing into the subsequent link.

[0033] The method of outputting the corrected reliable weld count value comprises: During the welding process, the system continuously acquires and updates the weld count value, which represents the number of completed welds at a time point The detected uncorrected weld count value; when an abnormal topology position is detected, the state node set corresponding to the abnormal topology position is defined as an abnormal set, which contains all node indexes that may cause weld count errors; An abnormal correction weight is assigned to each node in the abnormal set, which is determined according to the abnormal severity, influence range and historical occurrence frequency of the node; a cost-benefit balance factor is introduced between different nodes to adjust the balance between the correction amplitude and the system fault tolerance, a weld reliable count correction function is constructed, and a corrected reliable weld count value is output.

[0034] The weld reliable count correction function is: ; wherein, represents the reliable weld count value at time point ; represents the detected uncorrected weld count value at time point ; represents the cost-benefit balance factor, which is used to adjust the weight of the abnormal correction amount in the final count, balancing the risk of false judgment and the risk of missed welding; represents the detected abnormal set at time point ; represents the abnormal correction weight, which can be calculated based on the importance of the node, the detection confidence, the process stage and other parameters; represents the index of an abnormal node in the abnormal set; The problems existing in the prior art are solved: in the welding process, the counting system may be affected by electromagnetic interference, sensor instantaneous error or signal loss, resulting in deviation between actual weld point count and system record. The existing system usually uses simple threshold or recounting method to correct the anomaly, which cannot distinguish the severity of different abnormal nodes and their influence on the counting result, and the correction result is not accurate enough. Excessive correction may introduce false judgment, leading to false alarm or unnecessary clamp locking; insufficient correction may cause missed welding, resulting in quality risk. The existing system usually corrects based on fixed weight or rules, lacking dynamic adjustment according to historical frequency and abnormal influence range.

[0035] The beneficial effects of the prior art are: by mapping the detected abnormal topology position to an abnormal node set and assigning each node a correction weight based on severity, influence range and historical frequency, differentiated and accurate correction can be achieved; by introducing a cost-benefit balance factor, a balance between missed welding risk and false judgment risk can be achieved, so that the correction result can effectively compensate for the error caused by the anomaly, and avoid false alarm caused by excessive correction. The abnormal correction weight can be dynamically adjusted according to the production environment, equipment aging degree and historical data statistics, ensuring that the system can maintain high-precision counting correction ability in long-term operation. The corrected reliable count value directly affects the subsequent clamp unlocking and alarm logic, which can effectively reduce the phenomenon of missed welding caused by counting error, thereby improving the overall welding quality control level; realizing instant feedback of abnormal state, improving the response speed and processing efficiency of operators.

[0036] The method for keeping the clamp in a locked state and delaying unlocking execution comprises: A low threshold value and a high threshold value are preset, and the low threshold value is less than the high threshold value; when the reliable weld point count value reaches the low threshold value for the first time, the time point is recorded, and a double-threshold delay control mechanism is started; if the reliable weld point count value has not reached the high threshold value at this time, the system keeps the clamp in a locked state and delays unlocking execution.

[0037] The double-threshold delay control mechanism is: ; wherein, represents the preset low threshold value; represents the preset high threshold value; represents the time point when the reliable weld point count value reaches the low threshold value for the first time; represents the preset delay time; Solve the following problems existing in the prior art: In the prior art, due to sensor signal noise, transient fluctuations or occasional abnormalities during the welding process, the weld point count is prone to short-term deviation, which may cause the fixture to be unlocked prematurely or fail to lock in time, thereby increasing the risk of missed welding or miswelding. The prior art usually only determines whether the weld point count meets the requirements based on a single threshold, and cannot buffer short-term abnormalities or transient fluctuations. The system lacks dynamic monitoring and visual feedback, and when welding abnormalities occur, the operator cannot immediately determine the accuracy of the fixture state and weld point count, affecting the welding quality and safety.

[0038] The beneficial effects of the prior art are: by presetting low and high threshold values, and keeping the fixture locked when the low threshold is reached but the high threshold is not met, the risk of missed welding is significantly reduced due to premature unlocking of the fixture caused by transient fluctuations. The control mechanism of the double threshold combined with the delay time enables the system to buffer short-term abnormalities or errors in weld point counting, improving the fault tolerance and stability of the welding process. By keeping the fixture locked until the high threshold condition is met, the reliability of the weld point count value is ensured, providing accurate data basis for weld point count correction and real-time visual monitoring, facilitating the operator to take timely measures; the system automatically controls the fixture state without manual intervention, and avoids misoperation by combining the delay mechanism, achieving high reliability and high efficiency management of the welding process.

[0039] The method for driving the electromagnetic air valve to unlock the fixture comprises: If the reliable weld point count value reaches the preset high threshold value, it is determined that the number of weld points of the current welding operation meets the preset safety standard, and the abnormal topology position marked has been eliminated, and the system enters the fixture unlocking preparation state; The anti-missed welding monitoring terminal sends an unlocking instruction to the preset electromagnetic air valve control unit, and the electromagnetic air valve in the electromagnetic air valve control unit serves as an execution element of the fixture locking mechanism. After receiving the unlocking instruction, the electromagnetic coil is started to act, the position of the air valve core is changed, and the locking state of the fixture is released.

[0040] The method for dynamically generating a visual interface of the welding process state comprises: The reliable weld point count value, the current identification of the fixture locking state (such as "locked" or "unlocked"), and the fixture locking state change time point are received and transmitted to a preset graphics rendering engine. The graphics rendering engine maps the reliable weld point count value to a dynamic line chart or a column chart according to a preset display template, reflecting the growth trend of the weld point count; the preset display template includes interface layout structure, graphic element style, data mapping rule, refresh frequency and abnormality prompt design; The clamp locking state is mapped to a state indicator light or icon, the color and form of the state indicator light dynamically changes with the locking or unlocking state, and the current working state of the clamp is displayed; the graphical rendering engine arranges the trusted welding point count value in the welding process, the current identifier of the clamp locking state and the change time point of the clamp locking state in time sequence according to the mapping relationship, and dynamically generates a visual interface of the welding process state.

[0041] The method for reminding the operator to take measures comprises: When an abnormal state in the welding process is detected, the graphical rendering engine displays the related area corresponding to the abnormal state in the welding process on the visual interface based on a preset abnormal prompt template, highlights the abnormal information in the form of a flashing animation or a pop-up window, and triggers the sound prompt to play a preset warning sound, reminding the operator to take measures.

[0042] The preset low threshold is set by the worker based on the historical data analysis result, and the historical analysis process comprises that the system collects a plurality of thresholds and calculates the average value as a reference to obtain the preset low threshold; similarly, the preset high threshold and the preset phase synchronization threshold are also set by the worker according to the system historical running data and the specific application scene requirement.

[0043] In the embodiment, the welding operation state data is mapped to a state transition hypergraph, the time adjacency, the inter-channel correlation and the process stage relationship are comprehensively considered, and the robustness of the missed welding identification is improved. The phase difference between any two state nodes is defined, and the phase synchronization index in the sliding time window is calculated, which can detect the phase consistency change between nodes in real time and accurately capture the phase mismatch caused by missed welding. The abnormal topological position is directly marked in the state transition hypergraph, the spatial positioning and visual display of the abnormality are realized, and the operator can quickly judge and handle; the detection process adopts a sliding window for real-time updating, and the abnormal result can be output without waiting for the whole welding operation to end, which can be linked with the anti-missed welding locking module of the system to trigger the clamp locking or alarm in the first time and prevent unqualified workpieces from flowing into the subsequent link.

[0044] By mapping the detected abnormal topology position to an abnormal node set and assigning each node a correction weight based on severity, impact range, and historical frequency, differentiated and accurate correction can be achieved. By introducing a cost-benefit balance factor, a balance between missed welding risk and false judgment risk can be achieved, so that the correction result can effectively compensate for the error caused by the abnormality, and avoid false alarms caused by excessive correction. The abnormal correction weight can be dynamically adjusted according to the production environment, equipment aging degree, and historical data statistics, ensuring that the system can maintain high-precision count correction capability in long-term operation. The corrected reliable count value directly affects the subsequent clamp unlocking and alarm logic, which can effectively reduce the missed welding phenomenon caused by count error, thereby improving the overall welding quality control level; and realizing instant feedback of abnormal state, improving the response speed and processing efficiency of the operator.

[0045] By presetting low and high threshold values and keeping the clamp locked when the low threshold is reached but the high threshold is not met, the risk of missed welding caused by transient fluctuations is significantly reduced. The double-threshold control mechanism combined with a delay time enables the system to buffer short-term abnormalities or errors in weld point counting, improving fault tolerance and stability in the welding process. By keeping the clamp locked until the high threshold condition is met, the reliability of the weld point count value is ensured, providing an accurate data basis for weld point count correction and real-time visual monitoring, facilitating the operator to take timely measures; the system automatically controls the clamp state without human intervention, and combines the delay mechanism to avoid false actions, achieving high reliability and high efficiency management in the welding process.

[0046] Embodiment Two

[0047] Please refer to Figure 3 The embodiment does not describe some parts in detail, see the description of embodiment 1. A welding machine counting and missed welding prevention monitoring method is provided, which includes: S1. In the welding process, based on a time slice polling mechanism, multi-channel parallel acquisition of welding operation state data is performed, and the acquired welding operation state data is embedded in a parameter hash signature stream to form a tamper-proof real-time signal chain; S2. Map the real-time signal chain to a state transition hypergraph, and based on a time window sliding resonance detection algorithm, analyze the timing phase offset between state nodes, identify missed welding related abnormal states, and label the abnormal topology position; S3. When the abnormal topology position is detected, the current weld point count value is corrected in real time, a cost-benefit balance factor is introduced between different nodes, and the corrected reliable weld point count value is output; S4, based on the double threshold delay control mechanism, if the trusted solder joint count value reaches the low threshold value but does not reach the high threshold value, the clamp remains in the locked state and the unlocking is delayed; if the trusted solder joint count value reaches the high threshold value and the abnormal label is eliminated, the electromagnetic air valve is driven to unlock the clamp; S5, receiving the trusted solder joint count value and the clamp locking state, based on the graphical interface, dynamically generating the visual interface of the welding process state, and through the graphical and sound prompts, reminding the operator to take measures when the abnormality occurs.

[0048] The above formulas are dimensionless values, and the formulas are obtained by collecting a large amount of data to simulate the most recent real situation, and the preset parameters and threshold values in the formula are set by the person skilled in the art according to the actual situation.

[0049] The above only describes the preferred embodiments of the present application, and the protection scope of the present application is not limited to the above-mentioned embodiments, and any technical solution belonging to the idea of the present application shall belong to the protection scope of the present application. It should be noted that for ordinary technical users in the technical field, some improvements and decorations without departing from the principles of the present application shall also be considered as the protection scope of the present application.

Claims

1. A welding machine counting and leak prevention monitoring system, characterized in that: include: The data acquisition module collects welding status data in parallel through multiple channels based on a time-slice polling mechanism during the welding process. The collected welding status data is then embedded into the parameter hash signature stream to form a tamper-proof real-time signal chain. The abnormal state determination module maps the real-time signal chain into a state transition hypergraph and analyzes the timing phase offset between state nodes based on the time window sliding resonance detection algorithm to identify abnormal states related to weld leaks and mark the abnormal topological locations. The solder joint count correction module corrects the current solder joint count value in real time when an abnormal topological position is detected, introduces a cost-benefit balance factor between different nodes, and outputs a corrected and reliable solder joint count value; The anti-missing weld locking module is based on a dual-threshold delay control mechanism. If the trusted weld count reaches the low threshold but does not reach the high threshold, the fixture remains locked and unlocking is delayed. If the trusted weld count reaches the high threshold and the abnormality mark is removed, the electromagnetic valve is driven to unlock the fixture. The monitoring result display module receives the trusted weld point count value and fixture locking status, and dynamically generates a visual interface of the welding process status based on a graphical interface. When an abnormality occurs, it reminds the operator to take measures through graphical and sound prompts.

2. A welding machine counting and leak prevention monitoring system according to claim 1, characterized in that: The method for performing multi-channel parallel acquisition of welding operation status data includes: The acquisition time axis is divided into time slices of equal length through the time slice polling mechanism. Within each time slice, the acquisition tasks of different sensor channels are triggered simultaneously according to the preset channel priority order to obtain the welding operation status data; The welding operation status data includes electrical parameter data, thermal parameter data, position motion parameter data, process auxiliary parameter data and environmental parameter data; the parallel acquisition of different sensor channels is carried out through the multi-channel analog-to-digital converter of the hardware layer to synchronously read the data of different channels, and the scheduler of the software layer controls the timing coordination of the acquisition of each channel within the time slice.

3. A welding machine counting and leak prevention monitoring system according to claim 2, characterized in that: The method of forming a tamper-resistant real-time signal chain includes: The collected welding operation status data of each time slice is packaged with the corresponding timestamp, channel identifier and acquisition parameters to generate the original data packet of the time slice; a parameter hash operation is performed on the original data packet to generate a unique corresponding parameter hash signature; The parameter hash signature is concatenated with the hash signature of the previous time slice and the hash operation is performed again to form a chain hash association between adjacent time slices. By continuously linking the parameter hash signature of the new time slice with the signature of the previous time slice, a parameter hash signature stream covering the entire welding process is formed. If the original data packet of any time slice is tampered with, the hash value corresponding to the original data packet will be inconsistent with the chain association, thereby realizing tamper-proof protection of the welding operation status data.

4. A welding machine counting and leak prevention monitoring system according to claim 3, characterized in that: The method of mapping a real-time signal chain into a state transition hypergraph includes: The received real-time signal chain is parsed into a state sequence in chronological order. Each state node in the state sequence corresponds to the welding operation state data of a time slice. By introducing a multidimensional relationship mapping in the state sequence, the nodes are not only represented by the temporal proximity relationship, but also the association relationship between different acquisition channels and different process stages, thus constructing a state transition hypergraph containing different edge relationships. The vertices of the state transition hypergraph represent the various state nodes in the welding process, and the hyperedges represent the associated transfer relationships between different state nodes. The time interval, phase difference and physical quantity correlation between nodes are reflected by assigning edge weights to the hypergraph.

5. A welding machine counting and leak prevention monitoring system according to claim 4, characterized in that: The method for identifying abnormal conditions related to welding leaks and marking abnormal topological locations includes: For any two state nodes in the state transition hypergraph, defined at time point Based on the time window sliding resonance detection algorithm, the length is defined on the time axis as The sliding time window is used, and the phase synchronization index of any two state nodes in the sliding time window is calculated at each time point; A phase synchronization threshold is preset. When the phase synchronization index of any two state nodes in the sliding time window is less than the preset phase synchronization threshold, it is determined that there is a leakage-related abnormal state between the two state nodes, and the positions of the two state nodes are moved to the same position on the state transition hypergraph. Marked as abnormal topological locations.

6. A welding machine counting and leak prevention monitoring system according to claim 5, characterized in that: The method for outputting a corrected reliable solder joint count value comprises: During the welding process, the system continuously obtains and updates the welding point count value, which represents the welding point count value at the time point. The detected uncorrected solder joint count value; when an abnormal topological position is detected, the state node set corresponding to the abnormal topological position is defined as an abnormal set; Anomaly correction weights are assigned to each node in the anomaly set, and the anomaly correction weights are determined according to the severity of the anomaly, the scope of impact, and the historical frequency of occurrence of the node. A cost-benefit balance factor is introduced between different nodes to adjust the balance between the correction amplitude and the system fault tolerance, and a solder joint trusted count correction function is constructed to output the corrected trusted solder joint count value.

7. A welding machine counting and leak prevention monitoring system according to claim 6, characterized in that: The method of maintaining the clamp in a locked state and delaying unlocking includes: A low threshold and a high threshold are preset, and the low threshold is smaller than the high threshold. When the trusted solder point count reaches the low threshold for the first time, the time point is recorded and the dual-threshold delay control mechanism is started at the same time. If the trusted solder point count still does not reach the high threshold at this time, the system keeps the fixture locked and delays the unlocking execution.

8. A welding machine counting and leak prevention monitoring system according to claim 7, characterized in that: The method of driving the electromagnetic valve to unlock the fixture includes: If the trusted weld point count reaches the preset high threshold, it is determined that the number of weld points in the current welding operation has reached the preset safety standard, and the marked abnormal topological position has been eliminated, and the system enters the fixture unlocking preparation state; The anti-leakage welding monitoring terminal sends an unlocking command to the preset electromagnetic valve control unit. The electromagnetic valve in the electromagnetic valve control unit serves as the actuator of the fixture locking mechanism. After receiving the unlocking command, it starts the electromagnetic coil to change the position of the valve core and release the locking state of the fixture.

9. A welding machine counting and leak prevention monitoring system according to claim 8, characterized in that: The method for dynamically generating a visual interface of the welding process status includes: Receive the trusted solder joint count value, the current identifier of the fixture locking state, and the time point when the fixture locking state changes, and transmit them to a preset graphics rendering engine. The graphics rendering engine maps the trusted solder joint count value into a dynamic line graph or bar graph based on a preset display template to reflect the growth trend of the solder joint count; The fixture locking status is mapped to a status indicator light or icon. The color and shape of the status indicator light changes dynamically with the locking or unlocking status, showing the current working status of the fixture. Based on the mapping relationship, the graphics rendering engine arranges the trusted weld point count value, the current identifier of the fixture locking status and the time point of the fixture locking status change in chronological order during the welding process, and dynamically generates a visual interface for the welding process status.

10. A welding machine counting and leak prevention monitoring system according to claim 9, characterized in that: The method of reminding the operator to take measures includes: When an abnormal state is detected during the welding process, the graphics rendering engine displays the relevant area corresponding to the abnormal state in the welding process on the visual interface based on the preset abnormal prompt template, and uses flashing animation or pop-up window to highlight the abnormal information. At the same time, the sound prompt is triggered to play the preset warning sound to remind the operator to take measures.

Images