Laser welding spatter test and prevention method, laser welding spatter test system

Abstract

The application belongs to the technical field of laser welding, and particularly relates to a laser welding spatter testing and prevention method and a laser welding spatter testing system. The laser welding spatter testing and prevention method comprises the following steps: a collection area is arranged around a laser welding track; the distribution of spatters falling into the collection area is counted to obtain statistical data; and the spatter degree is evaluated according to the statistical data; wherein counting the distribution of the spatters at least comprises: counting the size of the spatters, dividing the size into size grades according to the size of the spatters, and counting the number of the spatters in each size grade. The application provides a low-cost and high-efficiency laser welding spatter testing and prevention method, the spatter degree is evaluated with high accuracy according to the particle size and the number of the spatters, and effective prevention measures can be formulated according to the evaluated spatter degree to prevent in advance, so that the spatter in actual laser welding operation can be controlled within a non-serious degree.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of laser welding, in particular to a laser welding spatter testing and prevention method and a laser welding spatter testing system. BACKGROUND

[0002] In the laser welding process, spatter phenomenon exists, and spatter will affect the quality of laser welding, resulting in weak points such as blowout and porosity in the weld, and will also cause pollution to the external light path lens, which is easy to cause the failure of the laser welding system. Therefore, at present, spatter is monitored during laser welding to handle it when it is serious. The commonly used spatter monitoring method is to use a high-speed camera device to take real-time photos of the spatter during laser welding, and to judge the spatter degree by combining image processing analysis method to monitor. However, the method based on high-speed camera device combined with image processing needs to purchase high-speed camera device and needs to process a large amount of image data, which is complex in operation and high in cost; and the actual size of the spatter and other accurate spatter conditions cannot be known, which affects the accuracy and precision of the evaluation results, and also leads to the inability to effectively develop a powerful plan to reduce the spatter degree according to the monitoring results. SUMMARY

[0003] Therefore, the present application is committed to providing a low-cost and high-efficiency laser welding spatter testing and prevention method, which can statistically evaluate the spatter degree with high accuracy by counting the particle size and quantity of the actual generated spatter, so as to solve the problems of high cost and inaccurate evaluation results caused by the method of monitoring spatter by high-speed camera combined with image processing in the prior art. The present application is also committed to providing a laser welding spatter testing system.

[0004] In one aspect, the present application provides a laser welding spatter testing and prevention method, which includes the following steps: setting a collection area around the laser welding track; counting the distribution of spatter falling into the collection area to obtain statistical data; and evaluating the spatter degree according to the statistical data; wherein the counting of the distribution of spatter at least includes: counting the size of spatter, dividing the size into size grades according to the size of spatter, and counting the quantity of spatter in each size grade.

[0005] In one possible implementation, the counting of the distribution of spatter further includes: dividing the collection area into at least two direction areas along the circumferential direction, counting the quantity of spatter in each direction area; and / or dividing the distance into distance grades according to the distance between the spatter and the laser welding area, counting the quantity of spatter in each distance grade, and generating spatter intensity data.

[0006] In a possible implementation, the method further comprises simulating an actual laser welding condition, including setting welding materials, a laser welding device, laser welding quality parameters, and laser welding operation parameters, and formulating the laser welding trajectory and the laser welding area according to the laser welding quality parameters; and performing laser welding according to the laser welding trajectory; wherein the collection area surrounds the laser welding trajectory in a circumferential direction of the laser welding trajectory.

[0007] In a possible implementation, the spatter degree includes light, medium, and heavy degrees; and the testing and prevention method further comprises generating a prevention measure according to the evaluated spatter degree, the prevention measure including at least a treatment measure for controlling the spatter degree to be below the heavy degree.

[0008] In a possible implementation, if the spatter degree is light or medium, the generated prevention measure is to add an auxiliary device, the auxiliary device including at least a blowing or dust removal device; and if the spatter degree is heavy, the generated prevention measure is to change the used laser welding device according to parameters of the welding material, the parameters including material and thickness.

[0009] In a possible implementation, the changing of the used laser welding device according to the parameters of the welding material includes:

[0010] when the welding material is aluminum and the material thickness is in a first range, it is suggested to change the laser welding device to a single-mode laser or a single-mode ring-shaped spot laser;

[0011] when the welding material is aluminum and the material thickness is in a second range, it is suggested to change the laser welding device to a ring-shaped spot laser;

[0012] when the welding material is copper and the material thickness is in a first range, it is suggested to change the laser welding device to any one of a single-mode laser, a single-mode ring-shaped spot laser, a visible light waveband laser, a single-mode visible light waveband laser, and a visible light waveband ring-shaped spot laser;

[0013] when the welding material is copper and the material thickness is in a second range, it is suggested to change the laser welding device to any one of a ring-shaped spot laser, a visible light waveband laser, and a visible light waveband ring-shaped spot laser.

[0014] In a possible implementation, the method further comprises setting a collection device in the collection area, dividing the collection area into a plurality of sub-areas by the collection device, and collecting the spatters.

[0015] In a possible implementation, a collection paper having an adhesive effect and / or a plurality of sub-areas distributed in a grid or a nested ring shape on a collection surface is used as the collection device.

[0016] Another aspect of the present application provides a laser welding spatter testing system, comprising: welding materials and a laser welding device; a collecting device for receiving spatters; a statistical device for counting spatter distribution information, generating statistical data and determining spatter degree according to the statistical data.

[0017] In a possible implementation, the statistical device comprises an information identifying device for identifying spatter size, and a controller in communication connection with the information identifying device.

[0018] In a possible implementation, the information identifying device is a camera device with camera and identification functions, a scanning device with scanning and identification functions, or an infrared imaging device with infrared sensing and identification functions.

[0019] In a possible implementation, the collecting device is a dust-sticking paper with adhesion effect, and the dust-sticking paper is arranged around the welding track to form a collecting area.

[0020] In a possible implementation, the collecting device has a plurality of sub-areas on the collecting surface, and the plurality of sub-areas are distributed in a grid shape or a nested ring shape.

[0021] According to the laser welding spatter testing and prevention and control method provided by the present application, the spatters generated in the laser welding process are collected by arranging a collecting area around the welding materials, and the actual distribution of the collected spatters is counted to evaluate the spatter degree, without using a high-speed camera device to monitor the spattering process at all times or without complex analysis and processing of image data at different times. It is a static testing method, low cost and high efficiency. In the counting of the distribution of the spatters, at least the size of the spatters is counted, and different size grades are divided, and the number of spatters in each size grade is counted, and the spatter degree is evaluated according to the statistical data, that is, the number of spatters in different size grades is used to evaluate the spatter degree, which is intuitive and accurate. Compared with evaluating whether the spatter is serious by analyzing the spatter density in the image, the method of the present application can obtain more accurate evaluation results by the size and number of the actually generated spatters, and the actual spattering situation can be clearly known, and more targeted and powerful prevention and control measures can be generated more effectively to better reduce the spatter degree. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 Fig. 1 shows a flowchart of the laser welding spatter testing and prevention and control method in some embodiments of the present application;

[0023] Figure 2 Fig. 2 shows a content diagram of counting the distribution of the spatters in some embodiments of the present application;

[0024] Figure 3The collection area and the welding area in some embodiments of the present application are shown. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not 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.

[0026] SUMMARY

[0027] At present, the spatter is monitored during the laser welding process to deal with it when the spatter is serious. The commonly used spatter monitoring method is to take real-time photos of the spatter during the laser welding process by using a high-speed camera device, and to judge the spatter degree by combining an image processing analysis method to monitor. However, the method based on the high-speed camera device combined with the image processing needs to purchase the high-speed camera device and needs to process a large amount of image data, and the operation is complex and the cost is high. Moreover, the actual size of the spatter and other accurate spatter conditions cannot be known, which affects the accuracy and precision of the evaluation results, and also leads to the inability to effectively develop a powerful scheme to reduce the spatter degree according to the monitoring results.

[0028] To solve the above problems, please refer to the accompanying Figures 1-3 The embodiments of the present application provide a laser welding spatter test and control method, which comprises the following steps: a collection area is arranged around a laser welding track; the distribution of the spatter falling into the collection area is counted to obtain statistical data, wherein counting the distribution of the spatter at least includes: counting the size of the spatter, dividing the size grade, and counting the number of the spatter in each size grade; and the spatter degree is evaluated according to the statistical data.

[0029] The method is to set a collection area around the laser welding track to collect the spatters generated during the welding process. The collection area is set around the welding track, which can collect all solid spatters and ensure the accuracy of the statistical data. After the welding is completed and the spatters are collected, the actual distribution of the collected spatters can be counted to generate statistical data. According to the statistical data, the spatter degree can be evaluated, and a clear conclusion can be drawn about whether the spatter is serious and the specific degree. The method does not need to monitor the welding process, does not need to use a high-speed camera to monitor the spatter process at all times, and does not need to analyze and process complex image data at different times. Only the static statistics of the distribution, size and quantity of the collected actual spatters are needed, and the statistical data about the size and quantity can be obtained after the generation of the statistical data. The operation is simple, and the whole method has the advantages of low cost and high efficiency.

[0030] Meanwhile, in the step of counting the distribution of the spatters, at least the size of the spatters, such as the diameter of the spatters, is counted. Since the spatters are in a granular form, the particle diameter can accurately represent the size of the spatters, and the size can be divided into three or more size grades according to the diameter, and the number of spatters in each size grade is counted. The size and quantity of the spatters are the core factors of the spatter situation. The statistical data generated by the number distribution of the spatters in each size grade can directly reflect the real spatter situation. According to the data, the spatter degree can be evaluated, which is intuitive, clear and accurate. Compared with the evaluation of the spatter degree by analyzing the spatter density in the image, the method of the present application can obtain more accurate evaluation results by the size and quantity of the actual generated spatters, and the actual spatter situation can be clearly known, which is more conducive to generating more effective and powerful prevention and control measures according to the known information, and achieving the beneficial purpose of reducing the spatter degree.

[0031] It can be seen that the laser welding spatter test and prevention and control method provided by the present application has the advantages of low cost, high efficiency, convenience and benefit for use, and can directly and clearly obtain the actual spatter situation. The spatter degree is evaluated according to the size and quantity of the spatters, which is accurate and more conducive to generating more effective prevention and control measures to prevent the spatter from being too serious.

[0032] After introducing the basic principle of the present application, the various non-limiting embodiments of the present application will be specifically introduced with reference to the accompanying drawings.

[0033] Exemplary Methods

[0034] Figure 1 is a flowchart of the laser welding spatter test and prevention and control method provided by an embodiment of the present application. The laser welding spatter test and prevention and control method comprises the following contents:

[0035] S120, setting a collection area around the laser welding track; the collection area receives the spatters generated in the welding process.

[0036] S140, counting the distribution of the spatters falling into the collection area to obtain statistical data, wherein counting the distribution of the spatters at least includes counting the size of the spatters, dividing the size grades, and counting the number of the spatters in each size grade.

[0037] The counting of the distribution of the spatters can be implemented by a counting device, which can include a conventional camera device, a laser scanner, a thermal imager, a high-precision microscope, etc. The size of the spatters can be obtained, and the size of the spatters can be divided and counted.

[0038] It should be noted that even if a conventional camera device or a scanner device is used to count the data, and then the statistical data is generated by combining data analysis, the number of times of shooting or scanning is small, and the welding process does not need to be photographed at multiple times. Only static scanning or shooting of the spatters is needed, and the size and number of the spatters can be directly obtained after shooting or scanning. After simple operation, the statistical data can be obtained, and the amount of data operation is small. Compared with the existing technology of monitoring the welding process at all times by using a high-speed camera device and combining a large amount of image processing and analysis, the method still has the advantages of low cost and high efficiency.

[0039] S150, evaluating the spatter degree according to the statistical data; the spatter degree can be divided into mild, moderate and severe degrees according to the severity, and each degree corresponds to a range of statistical data. Therefore, after the statistical data is generated, the spatter degree under the welding condition can be directly obtained according to the corresponding relationship between the degree and the data.

[0040] In this way, the actual size and number of the spatters generated in the welding process can be clearly and accurately counted. The statistical data generated according to the number distribution of the spatters in each size grade can directly reflect the real spatter situation. The spatter degree can be evaluated according to the data, which is intuitive, clear, accurate and precise. Compared with the method of evaluating the spatter degree by using a camera and image processing in the prior art, the method has higher accuracy and lower cost, and is easy to apply.

[0041] In this embodiment, the statistical data includes the size and number of the spatters, which are core factors. In addition to the core factors, other aspects of the distribution of the spatters can be counted in other embodiments to enrich the statistical data and enhance the accuracy of the evaluation.

[0042] Based on this, in one embodiment, the laser welding splash test and prevention method provided by the application, the step of counting the distribution of splashes, not only includes S201 counting the size of the splashes, dividing the size level, and counting the number of splashes in each size level; also includes: S202, dividing the collection area into at least two direction areas in the circumferential direction, and counting the number of splashes in each direction area; Here, the number of splashes can be the total number of splashes in the direction area, or the distribution number of splashes in each size level in the direction area, for example, the number of splashes of the first size level and the number of splashes of the second size level in the first direction area; the number of splashes of the first size level and the number of splashes of the second size level in the second direction area; the number of splashes in the third direction area...

[0043] In this way, the statistical data is generated according to the size, number and distribution direction of the splashes, and the splash degree is evaluated by relying on the three factors, and the result is more accurate; and according to the number of splashes in each direction area, the splash rule can be further known.

[0044] Based on this, in another embodiment, the laser welding splash test and prevention method provided by the application, the step of counting the distribution of splashes, not only includes S201 counting the size of the splashes, dividing the size level, and counting the number of splashes in each size level; also includes:

[0045] S202, dividing the distance level according to the distance between the splashes and the laser welding area, counting the number of splashes in each distance level, and generating splash intensity data; Here, the number of splashes can be the total number of splashes in the distance level, or the distribution number of splashes in each size level in the distance level, for example, the number of splashes of the first size level and the number of splashes of the second size level in the first distance level; the number of splashes of the first size level and the number of splashes of the second size level in the second distance level; the number of splashes in the third distance level...

[0046] In this way, the statistical data is generated according to the size, number and splash intensity of the splashes, and the splash degree is evaluated by relying on the three factors, and the result is more accurate; and the splash rule under the welding condition can be more clearly and comprehensively known, which is beneficial to the splash prevention and control.

[0047] In a third embodiment, as Figure 2As shown, the laser welding spatter testing and control method provided in this application includes the following steps in the statistical analysis of spatter distribution: S201, counting the size of the spatter, classifying it into size levels, and counting the number of spatter in each size level; S202, dividing the collection area into at least two directional regions along the circumference and counting the number of spatter in each directional region; and S203, classifying the spatter into distance levels based on the distance between the spatter and the laser welding area, counting the number of spatter in each distance level, and generating spatter intensity data. This setup generates statistical data based on four factors: spatter size, quantity, spatter direction, and spatter intensity (involving distance factors). The data is more comprehensive, and the determination of spatter severity is more accurate by comprehensively assessing these four factors. Furthermore, statistical analysis of spatter from all four aspects provides a clearer and more comprehensive understanding of the spatter patterns and distribution under the welding condition, which is highly beneficial for spatter control.

[0048] All statistical data are based on the distribution of the number of splashes, and the statistical and assessment results are highly accurate.

[0049] The above testing method can be implemented in welding experiments. Based on this, in one embodiment, the laser welding spatter testing and control method provided in this application further includes: S110, simulating actual laser welding conditions; S130, performing laser welding according to the laser welding trajectory. That is, in this embodiment, the laser welding spatter testing and control method specifically includes:

[0050] S110 simulates actual laser welding conditions, specifically including setting welding materials, laser welding equipment, laser welding quality parameters, and laser welding operation parameters, and formulating laser welding trajectory and laser welding area based on laser welding quality parameters.

[0051] S120, a collection area is set up around the laser welding trajectory; the collection area catches the spatter generated during the welding process, and the collection area surrounds the laser welding trajectory in the circumference.

[0052] S130, laser welding is performed according to the laser welding trajectory.

[0053] S140, statistically analyze the distribution of splashes falling into the collection area to obtain statistical data, wherein the statistical analysis of the splash distribution includes at least: analyzing the size of the splashes, classifying them into size classes, and analyzing the number of splashes in each size class, and may also include analyzing the distribution direction and / or splash intensity of the splashes.

[0054] S150 assesses the degree of splashing based on statistical data.

[0055] With this setup, the testing and control methods provided in this application can be implemented in welding experiments. Through these experiments, the spatter situation under various welding conditions can be obtained at low cost and high efficiency, and the spatter pattern can be understood. This is very helpful in providing control direction for actual welding operations based on the spatter situation obtained from the experiments. When performing actual welding, the welding operation and spatter control can be carried out based on the obtained information, which can directly and effectively reduce the degree of spatter in the actual welding process, prevent severe spatter from affecting the welding quality, and achieve the effect of early prevention.

[0056] It can be said that, based on the laser welding spatter testing and control method provided in this application, it is possible to test the spatter situation under various welding conditions through experiments, thereby achieving the purpose and effect of reasonably controlling the degree of spatter in actual welding operations in advance.

[0057] Furthermore, in another embodiment of this application, the laser welding spatter testing and control method further includes generating control measures based on the assessed spatter level. That is, in this embodiment, the laser welding spatter testing and control method specifically includes:

[0058] S110 simulates actual laser welding conditions, specifically including setting welding materials, laser welding equipment, laser welding quality parameters, and laser welding operation parameters, and formulating laser welding trajectory and laser welding area based on laser welding quality parameters.

[0059] S120, a collection area is set up around the laser welding trajectory; the collection area catches the spatter generated during the welding process, and the collection area surrounds the laser welding trajectory in the circumference.

[0060] S130, laser welding is performed according to the laser welding trajectory.

[0061] S140, statistically analyze the distribution of splashes falling into the collection area to obtain statistical data, wherein the statistical analysis of the splash distribution includes at least: analyzing the size of the splashes, classifying them into size classes, and analyzing the number of splashes in each size class, and may also include analyzing the distribution direction and / or splash intensity of the splashes.

[0062] S150 assesses the degree of splashing based on statistical data.

[0063] S160, Based on the assessed splash level, generate prevention and control measures; the prevention and control measures shall at least include treatment measures to control the splash level to below the severe level, specifically treatment measures that correspond to and reduce the splash level.

[0064] With this setup, the laser welding spatter testing and control method provided in this application uses experiments to test spatter under various welding conditions, allowing for advance understanding of the spatter level under different welding conditions and the generation of control measures in advance. These control measures can then be directly implemented during actual welding operations, enabling reasonable and proactive control of the spatter level during actual welding. This achieves the goal of controlling the spatter level through testing, and effectively controls the spatter level during actual welding, thereby ensuring welding quality under various welding conditions and providing effective assurance for welding quality and efficiency.

[0065] Specifically, when the splash severity is categorized as mild, moderate, and severe, the control measures should at least include measures for severe splashing, or corresponding measures for each splash severity level. In some embodiments, step S160, generating control measures based on the assessed splash severity, may specifically include:

[0066] When the splashing level is light or moderate, the resulting control measures are to add auxiliary devices, which include at least air blowing or dust removal devices.

[0067] When the spatter level is severe, the resulting control measures are to change the laser welding device used according to the parameters of the welding material, including the material and thickness.

[0068] When conducting welding experiments and tests under various welding conditions, if the test results show severe spatter, it indicates that the welding equipment is unsuitable for these conditions. In this case, change the laser welding equipment used, repeat the experiment, and observe the results until the spatter is no longer severe. If the test results show mild or moderate spatter, and the spatter is not severe, there is no need to replace the welding equipment. Adding an air blowing or dust removal device can reduce spatter to a certain extent and prevent laser welding system failure. The flow rate of the air blowing or dust removal device should be selected based on the spatter level, ideally around 100 m³ / h. 3 / h-1000m 3 / h.

[0069] Based on this procedure, experiments can be conducted to obtain suitable welding equipment for various welding conditions. The results can then be used to directly guide actual welding processes, effectively protect welding conditions during actual welding processes, and ensure welding quality.

[0070] In some embodiments, the laser welding apparatus used is modified according to the parameters of the welding material, including:

[0071] When the welding material is aluminum and the material thickness is within the first range, it is recommended to change the laser welding device to a single-mode laser or a single-mode ring spot laser.

[0072] When the welding material is aluminum and the material thickness is within the second range, it is recommended to change the laser welding device to a ring spot laser.

[0073] When the welding material is copper and the material thickness is within the first range, it is recommended to change the laser welding device to any one of the following: single-mode laser, single-mode ring spot laser, visible light laser, single-mode visible light laser, and visible light ring spot laser.

[0074] When the welding material is copper and the material thickness is within the second range, it is recommended to change the laser welding device to any one of the following: ring spot laser, visible light laser, or visible light ring spot laser.

[0075] Aluminum and copper are common and widely used welding materials. The laser welding spatter testing and control method provided in this application effectively determines the suitable welding equipment for aluminum and copper at different thicknesses, ensuring weak spatter and good welding quality, which has practical significance for actual laser welding production.

[0076] In some embodiments, a collection device is installed in the collection area to divide the collection area into multiple sub-areas and collect the splashes. This allows for effective and efficient collection of splashes, preventing any spillage from affecting statistics.

[0077] Specifically, in some embodiments, an adhesive paper, such as sticky paper, is used as the collection device. The sticky paper can adhere to the splashes, and when it covers the collection area, the splashes are fixed and adhered to it. This effectively collects the splashes and preserves their landing locations, providing accurate data for calculating the distribution of splashes, such as the number of splashes in each direction. In some embodiments, the collection surface of the collection device has multiple sub-regions, which are arranged in a grid pattern or in nested rings, dividing the collection area into multiple collection zones.

[0078] When setting up the collection area, the collection area is determined with reference to the laser welding trajectory or welding area. The entire area is arranged around the circumference of the welding trajectory. It can be arranged in a ring around the welding trajectory or basically around the welding trajectory. The specific shape of the collection area can be similar to or the same as the shape of the welding trajectory, or it can be different.

[0079] Specifically, it can be as follows Figure 3 As shown, a test area 101 is planned, with the central area of ​​the test area 101 being the welding area 102 and the outer periphery of the welding area 102 being the collection area 103. During the test, welding material 104 is placed inside the welding area 102.

[0080] The test area 101 can be square, with a side length of 100-1000 mm. The entire test area 101 is divided into multiple small squares. One or more small square areas in the middle form the welding area 102, and the small square areas on the outer perimeter form the collection area 103. For example, if the test area is a square with a side length of 300 mm, it is divided into 16 small squares with a side length of 75 mm. The four small square areas in the middle are the welding area, and the remaining 12 small square areas are the collection area.

[0081] When using adhesive collecting paper, such as sticky paper, as the collecting device, each small square area can be covered with a sheet of sticky paper. Alternatively, the collecting paper can have a grid, such as graph paper or similar paper, forming multiple sub-areas that can create the aforementioned multiple small squares. Alternatively, the sticky paper can be cut into small squares, each small square constituting one of the aforementioned small square areas, forming a sub-area. Multiple small squares of sticky paper can be laid together to form the aforementioned welding area 102 and collecting area 103, collectively constituting the test area 101. The entire collecting area 103, or the collecting surface, has multiple sub-areas, which are distributed in a grid pattern.

[0082] Of course, in other embodiments, the test area 101, welding area 102, and collection area 103 may also be composed of other shapes, such as circles or rings. For example, the adhesive paper has multiple sub-areas, which are arranged in nested rings.

[0083] Specific examples are provided regarding the setup of laser welding equipment, welding quality parameters, welding operation parameters, and the setting of the welding trajectory. For instance, during the testing of welding spatter between the positive electrode post and the connecting piece of a square aluminum-cased battery, a near-infrared laser with an output power of 6000W and an output core diameter of 100μm is used. A 1.5mm thick aluminum plate is welded to a 5mm thick aluminum plate at a linear velocity of 50mm / s, without shielding gas or dust removal equipment. The welding quality requirements are a lower layer penetration depth of 2.0mm and a weld width of 1.2mm. The welding trajectory is set as several concentric circles with a diameter of 10-100mm. The spacing between the concentric circles is 5-20mm, and the number of concentric circles is 5-15.

[0084] After welding is completed according to the welding trajectory, the size and quantity of spatter particles are counted. Spatter size can be classified as follows: Level 1: spatter particles with a diameter less than 100μm; Level 2: spatter particles with a diameter of 100-600μm; Level 3: spatter particles with a diameter greater than 600μm. The collection area is then divided directionally, specifically according to the welding trajectory. If the welding trajectory is circular, square, or a regular polygon, the directional area can be divided into two or four parts with the central axis as the boundary. If the welding trajectory is arc-shaped or an irregular strip, the directional area can be divided into two parts along the width of the strip or arc. The distance between the spatter and the welding area is also classified: distances within 0-100 are classified as Level 1, and distances outside this range are classified as Level 2.

[0085] When generating statistical data and assessing the degree of splashing based on the size and quantity of splashes, the following criteria can be set: when the number of particles with a diameter greater than 600 μm (i.e., tertiary splashes) is not less than the first value, the degree of splashing is severe; when the number of particles with tertiary splashes is less than the first value and the number of particles with tertiary splashes is not less than the second value, the degree of splashing is moderate; and when the number of particles with tertiary splashes is less than the first value, the number of particles with tertiary splashes is less than the second value, and the number of particles with tertiary splashes is not less than the third value, the degree of splashing is mild.

[0086] When assessing the degree of spatter based on three factors—size, quantity, and direction—it is necessary to consider the correlation between the spatter direction and the welding trajectory. If the welding trajectory is symmetrical, the correlation between the spatter direction and the welding trajectory is generally weak; if the welding trajectory is asymmetrical, the correlation is stronger. Therefore, the degree of spatter can be comprehensively assessed based on the size and quantity of spatter, its distribution in a directional area, and the correlation between direction and trajectory.

[0087] When assessing the degree of splashing based on the size, quantity, and intensity of the splashes, it is necessary to comprehensively evaluate the degree of splashing based on the data of the size and distance levels of the splashes.

[0088] When assessing the severity of splashing based on four factors—size, quantity, direction, and intensity—it is necessary to comprehensively evaluate the splashing severity by considering multiple data points, including the size class and quantity of splashes, their distribution in directional areas, the correlation between direction and trajectory, and the number of distance classes.

[0089] Furthermore, by statistically analyzing the distribution of splashes across directional regions, the directionality of the splashes can be evaluated, and the intensity of the splashes can be assessed by analyzing their quantity distribution across distance levels. These evaluation results contribute to a clearer understanding of the specific circumstances and patterns of the splashes. All evaluation data is based on the quantity distribution of splashes, ensuring high accuracy.

[0090] Exemplary Devices

[0091] One embodiment provides a laser welding spatter testing system, which includes welding material as the welding object, a laser welding device for performing laser welding operations, and a statistical device for counting the distribution of spatter. The statistical device counts the distribution information of the spatter, generates statistical data, and can also generate an evaluation result that assesses the degree of spatter.

[0092] In one embodiment, the collecting device is an adhesive paper with an adhesive effect. The adhesive paper is arranged around the welding trajectory to form a collecting area. The adhesive paper has an adhesive effect, which sticks to the splashes when they fall, preventing them from bouncing. It can also retain the landing position of the splashes, providing an effective and accurate guarantee for the statistical analysis of the actual situation of the splashes.

[0093] In one embodiment, the collection surface of the collecting device has multiple sub-regions, which divide the collection area into multiple collection zones. The multiple sub-regions are distributed in a grid pattern or nested rings. In another embodiment, the collecting device is an adhesive paper, which has a grid or multiple nested rings. In other words, multiple adhesive papers are distributed in a grid pattern or nested rings to divide the collection area into multiple sub-regions, facilitating zoned statistics.

[0094] In other embodiments, the collection device may be a cushioning pad that catches splashes, reduces the impact of the splashes when they land, and prevents the splashes from bouncing out of the collection area.

[0095] In one embodiment, the statistical device includes an information identification device for recognizing the size of splashes and a controller communicatively connected to the information identification device. The information identification device identifies splashes and their sizes by photographing or scanning a collection area, and then counts the number of splashes at different size levels. The controller acquires the identification information and generates statistical data based on it, and then generates an evaluation result based on the statistical data. This configuration of the statistical device results in high efficiency and high accuracy.

[0096] Specifically, the information identification device can be a camera with imaging and recognition functions, such as a conventional camera or a 3D camera; it can also be a scanning device with scanning and recognition functions, such as a laser scanner; or it can be a thermal imaging device with infrared sensing and recognition functions, such as an infrared imager. After welding is completed, the spatter adheres to the adhesive paper or is distributed within the collection area. The information identification device identifies the distribution of the spatter, that is, it identifies where the spatter is located and its size. The controller generates statistical data based on the identification information.

[0097] The basic principles of this application have been described above with reference to specific embodiments. However, it should be noted that the advantages, benefits, and effects mentioned in this application are merely examples and not limitations, and should not be considered as essential features of each embodiment of this application. Furthermore, the specific details disclosed above are for illustrative and facilitative purposes only, and are not limitations. These details do not limit the application to the necessity of employing the aforementioned specific details for implementation.

[0098] The components and devices described in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the accompanying drawings. As those skilled in the art will recognize, these components and devices can be connected, arranged, and configured in any manner. Words such as “comprising,” “including,” “having,” etc., are open-ended terms meaning “including but not limited to,” and are used interchangeably with them. The terms “or” and “and” as used herein refer to the words “and / or,” and are used interchangeably with them unless the context clearly indicates otherwise. The term “such as” as used herein refers to the phrase “such as but not limited to,” and is used interchangeably with it.

[0099] It should also be noted that in the apparatus and method of this application, the components or steps can be disassembled and / or recombined. These disassemblies and / or recombinations should be considered as equivalent solutions of this application.

[0100] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use this application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other aspects without departing from the scope of this application. Therefore, this application is not intended to be limited to the aspects shown herein, but rather to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0101] The above description has been given for purposes of illustration and description. Furthermore, this description is not intended to limit the embodiments of this application to the forms disclosed herein. Although numerous exemplary aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, alterations, additions, and sub-combinations thereof.

[0102] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications or equivalent substitutions made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method of laser welding spatter testing and prevention, characterized by, The method comprises the following steps: S01, setting a collection area around a laser welding track, the collection area being circumferentially arranged around the laser welding track; S02, setting a collection device in the collection area, using a collection paper with adhesion and a plurality of sub-areas distributed in a grid shape on a collection surface as the collection device, and collecting spatters through the collection device; S03, counting the distribution of spatters falling into the collection area through a statistical device and generating statistical data; wherein counting the distribution of spatters at least includes: counting the size of spatters, dividing the size into size grades according to the size of spatters, and counting the number of spatters in each size grade; dividing the distance into distance grades according to the distance between spatters and the laser welding area, counting the number of spatters in each distance grade, and generating spatter intensity data; S04, evaluating the spatter degree according to the spatter intensity data, the spatter degree including mild, moderate and severe; S05, generating control measures according to the evaluated spatter degree: if the spatter degree is mild or moderate, the generated control measures are to increase auxiliary devices, the auxiliary devices at least including blowing or dust removal devices; if the spatter degree is severe, the generated control measures are to change the used laser welding device according to the parameters of the welding material, wherein the parameters include material and thickness.

2. The laser welding spatter testing and mitigation method of claim 1, wherein, dividing the collection area into at least two direction areas in the circumferential direction, and counting the number of spatters in each direction area.

3. The laser welding spatter testing and mitigation method of claim 1, wherein, Further comprising, simulating actual laser welding conditions, including setting welding materials, laser welding devices, laser welding quality parameters and laser welding operation parameters, and formulating the laser welding track and laser welding area according to the laser welding quality parameters; carrying out laser welding according to the laser welding track.

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