Adaptive laser welding method and device

Abstract

The present invention provides an adaptive laser welding method and apparatus. The method includes: establishing a relational database of welding conditions and process parameters; obtaining a first welding condition of a to-be-welded object; based on the relational database, retrieving second process parameters corresponding to a second welding condition that is closest to the first welding condition; performing welding using the second process parameters as initial process parameters, and monitoring whether the welding process meets the requirements; adjusting the process parameters until the welding process meets the requirements, and storing the adjusted process parameters as first process parameters corresponding to the first welding condition into the relational database. When the change in welding conditions causes a change in the penetration depth, an adaptive adjustment of the laser welding process parameters is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of laser welding, and particularly to an adaptive laser welding method and device. Background Art

[0002] When laser welding technology uses a laser with a high energy density to melt the base material, with or without filling materials, to achieve the connection between the base materials, due to the extremely small heating area of the laser spot, relatively fast welding speed, and the difficult-to-observe melting process, when welding conditions such as the material of the workpiece to be welded, the thickness of the workpiece, the joint design, and the assembly quality change, it is easy to cause the preset parameters to fail to meet the weld quality requirements. It is necessary to carry out welding verification tests again to correct the welding parameters. However, the key parameters involved in the laser welding process include the spot diameter, laser power, welding speed, etc. The commonly used orthogonal test method consumes a large amount of materials and cannot quickly obtain the required parameters. Therefore, there is an urgent need for a laser welding method that can autonomously obtain parameters according to the weld quality. Summary of the Invention

[0003] In view of the problems existing in the prior art, the present invention provides an adaptive laser welding method and device.

[0004] An adaptive laser welding method provided by the present invention includes:

[0005] Establish a relational database of welding conditions and process parameters;

[0006] Obtain the first welding conditions of the workpiece to be welded;

[0007] Based on the relational database, retrieve the second process parameters corresponding to the second welding conditions that are closest to the first welding conditions;

[0008] Use the second process parameters as the initial process parameters for welding, and monitor whether the welding process meets the requirements;

[0009] Adjust the process parameters until the welding process meets the requirements, and store the adjusted process parameters as the first process parameters corresponding to the first welding conditions into the relational database.

[0010] According to the adaptive laser welding method provided by the present invention, establishing a relational database of welding conditions and process parameters includes:

[0011] Obtain welding test data and / or experience;

[0012] Based on the welding test data and / or experience, obtain the corresponding relationship between welding conditions and process parameters;

[0013] Wherein,

[0014] The welding conditions include basic welding conditions and detailed welding conditions.

[0015] An adaptive laser welding method provided by the present invention monitors whether the welding process meets the requirements, including:

[0016] During the welding process, obtain the keyhole depth;

[0017] Based on the keyhole depth, obtain the weld penetration situation;

[0018] Based on the penetration situation, judge whether the welding process meets the requirements.

[0019] An adaptive laser welding method provided by the present invention obtains the first welding conditions to be welded, including:

[0020] Judge whether the first welding conditions are consistent with the second welding conditions in the basic welding conditions.

[0021] According to an adaptive laser welding method provided by the present invention, if the first welding conditions are consistent with the second welding conditions in the basic welding conditions, then adjust the process parameters until the welding process meets the requirements, including:

[0022] Judge whether the welding process meets the requirements. If it meets the requirements, do not adjust the process parameters; if it does not meet the requirements, adjust the process parameters until the welding process meets the requirements.

[0023] According to an adaptive laser welding method provided by the present invention, if the first welding conditions are not consistent with the second welding conditions in the basic welding conditions, then adjust the process parameters until the welding process meets the requirements, including:

[0024] Judge whether the welding process meets the requirements. If it meets the requirements, adjust the process parameters in the direction of reducing the welding input heat per unit time until the welding process cannot meet the requirements, and take the process parameters corresponding to the situation where the welding process can meet the requirements and the input heat per unit time is the smallest as the adjusted process parameters;

[0025] If it does not meet the requirements, adjust the process parameters until the welding process meets the requirements.

[0026] According to an adaptive laser welding method provided by the present invention, adjusting the process parameters includes:

[0027] Adjust the process parameters according to a preset amplitude;

[0028] Among them, the amplitude can be modified.

[0029] An adaptive laser welding method provided by the present invention, wherein the basic welding conditions include at least one of the following sub-basic welding conditions:

[0030] The material of the workpiece to be welded, the thickness of the workpiece, and the joint design form.

[0031] An adaptive laser welding method provided by the present invention, wherein the detailed welding conditions include at least one of the following sub-detailed welding conditions:

[0032] The assembly gap and the misalignment caused by the assembly error.

[0033] An adaptive laser welding method provided by the present invention, wherein the process parameters include at least one of the following sub-process parameters:

[0034] Laser power, spot diameter, welding speed;

[0035] When the process parameters include two or more sub-process parameters, correspondingly, adjusting the process parameters until the welding process meets the requirements includes:

[0036] Adjusting the sub-process parameter with a prior adjustment order to the corresponding adjustment upper limit in a preset order. If the welding process still fails to meet the requirements, continue to adjust the sub-process parameter with a subsequent adjustment order.

[0037] The present invention also provides an adaptive laser welding device, which includes:

[0038] A relationship module for establishing a relationship database of welding conditions and process parameters;

[0039] A welding condition acquisition module for acquiring the first welding condition to be welded;

[0040] A process parameter retrieval module for retrieving the second process parameter corresponding to the second welding condition that is closest to the first welding condition based on the relationship database;

[0041] A welding monitoring module for performing welding with the second process parameter as the initial process parameter and monitoring whether the welding process meets the requirements;

[0042] An adjustment module for adjusting the process parameters until the welding process meets the requirements and storing the adjusted process parameters as the first process parameter corresponding to the first welding condition into the relationship database.

[0043] The adaptive laser welding method and device provided by the present invention can realize the adaptive adjustment of laser welding process parameters when the welding conditions change and cause the change of the penetration depth. Brief Description of the Drawings

[0044] To more clearly illustrate the technical solutions in the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0045] Figure 1 It is a schematic flow chart of an adaptive laser welding method provided by the present invention;

[0046] Figure 2 It is a schematic structural diagram of an adaptive laser welding device provided by the present invention;

[0047] Figure 3 It is a schematic physical structure diagram of an electronic device provided by the present invention. Detailed Embodiments

[0048] To make the objectives, technical solutions, and advantages of the present invention clearer, the following will clearly and completely describe the technical solutions in the present invention in conjunction with the drawings in the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

[0049] The following will, in conjunction with the drawings, provide a detailed description of the adaptive laser welding method provided by the embodiments of the present application through specific embodiments and their application scenarios.

[0050] Figure 1 It is a schematic flow chart of an adaptive laser welding method provided by the present invention. As Figure 1 shown, an adaptive laser welding method provided by the present invention may include the following steps.

[0051] It should be noted that the present invention is based on a laser automatic welding system, and the system is configured with a workpiece surface topography detection device and a laser keyhole topography detection device.

[0052] S100. Establish a relational database of welding conditions and process parameters.

[0053] Optionally, establishing a relational database of welding conditions and process parameters includes:

[0054] Obtain welding test data and / or experience;

[0055] Based on the welding test data and / or experience, obtain the corresponding relationship between welding conditions and process parameters;

[0056] Among them,

[0057] Welding conditions include basic welding conditions and detailed welding conditions.

[0058] Optionally, the basic welding conditions include at least one of the following sub - basic welding conditions:

[0059] The material of the workpiece to be welded, the thickness of the workpiece, the joint design form.

[0060] Optionally, the detailed welding conditions include at least one of the following sub - detailed welding conditions:

[0061] Assembly gap, misalignment caused by assembly error.

[0062] Optionally, the process parameters include at least one of the following sub - process parameters:

[0063] Laser power, spot diameter, welding speed.

[0064] S200, obtain the first welding condition of the workpiece to be welded.

[0065] Optionally, obtaining the first welding condition of the workpiece to be welded includes:

[0066] Judge whether the first welding condition is consistent with the second welding condition in terms of basic welding conditions.

[0067] Optionally, if the first welding condition is consistent with the second welding condition in terms of basic welding conditions, adjust the process parameters until the welding process meets the requirements, including:

[0068] Judge whether the welding process meets the requirements. If it meets the requirements, do not adjust the process parameters; if it does not meet the requirements, adjust the process parameters until the welding process meets the requirements.

[0069] Preferably, when the basic welding conditions are the same and the detailed welding conditions are different, during the welding process, by comparing with the set welding requirements, when the welding requirements are not met, gradually increase the laser power by 0 to +30%, when the requirements are still not met, reduce the spot diameter by 0 to - 0.2 mm, when the requirements are still not met, reduce the welding speed by 0 to - 0.5 m / min, and cycle this process until the requirements are met; when the welding process meets the requirements, the parameters are not adjusted.

[0070] Optionally, if the first welding condition is inconsistent with the second welding condition in terms of basic welding conditions, adjust the process parameters until the welding process meets the requirements, including:

[0071] Judge whether the welding process meets the requirements. If it meets the requirements, adjust the process parameters in the direction of reducing the welding input heat per unit time until the welding process cannot meet the requirements, and take the process parameters corresponding to the situation where the welding process can meet the requirements and the input heat per unit time is the smallest as the adjusted process parameters;

[0072] If the requirements are not met, adjust the process parameters until the welding process meets the requirements.

[0073] Preferably, when the basic welding conditions are inconsistent and the welding requirements are not met during the welding process, gradually increase the laser power by 0 to +30%. When the requirements are still not met, gradually decrease the spot diameter by 0 to -0.2 mm. When the requirements are still not met, gradually decrease the welding speed by 0 to -0.5 m / min. Repeat this process until the requirements are met. During the welding process, when the welding requirements are met, gradually decrease the laser power by 0 to -20%. When the requirements are still met, increase the spot diameter by 0 to +0.2 mm. When the requirements are still met, increase the welding speed by 0 to +0.5 m / min. Repeat this process until the requirements are not met. Eventually, the optimal process parameters that meet the requirements can be obtained.

[0074] It should be noted that for different welding condition changes, different process parameter adjustment modes are adopted for basic welding condition changes and detailed welding condition changes respectively to quickly obtain the process parameters required for welding.

[0075] Preferably, determine the basic welding conditions manually before welding, and scan the area to be welded of the workpiece through the workpiece surface topography detection device configured in front of the laser head to automatically determine the detailed assembly conditions.

[0076] S300. Based on the relational database, retrieve the second process parameters corresponding to the second welding condition that is closest to the first welding condition.

[0077] Preferably, the control computer of the welding system matches the obtained basic assembly conditions, detailed assembly conditions and the second welding conditions in the database, retrieves the second process parameters, and controls the welding system through the control computer.

[0078] S400. Weld using the second process parameters as the initial process parameters, and monitor whether the welding process meets the requirements.

[0079] Optionally, monitoring whether the welding process meets the requirements includes:

[0080] During the welding process, obtain the keyhole depth;

[0081] Based on the keyhole depth, obtain the weld penetration situation;

[0082] Based on the penetration situation, judge whether the welding process meets the requirements.

[0083] Preferably, the laser head is configured with a laser keyhole topography detection device. During the welding process, the detection laser of the laser keyhole topography detection device scans the keyhole and the workpiece surface, and the keyhole depth is obtained through spectral analysis, thereby obtaining the weld penetration situation.

[0084] Preferably, whether the welding process meets the requirements includes whether the welding penetration depth reaches a predetermined depth.

[0085] S500. Adjust the process parameters until the welding process meets the requirements, and store the adjusted process parameters as the first process parameters corresponding to the first welding condition into the relational database.

[0086] Optionally, adjusting the process parameters includes:

[0087] Adjust the process parameters according to a preset amplitude;

[0088] wherein, the amplitude can be modified.

[0089] Optionally, when the process parameters include two or more sub-process parameters, correspondingly, adjusting the process parameters until the welding process meets the requirements includes:

[0090] According to a preset order, preferentially adjust the sub-process parameter with a prior order to the corresponding adjustment upper limit. If the welding process still fails to meet the requirements, continue to adjust the sub-process parameter with a subsequent order.

[0091] It should be noted that if there are two sub-process parameters, a process parameter curve is formed. If there are three sub-process parameters, a process parameter surface is formed. The call and correction of the process parameters can be intuitively carried out through the parameter curve or the parameter surface. Further, through the above-mentioned scheme of step-by-step progressive adjustment of the sub-process parameters, the process parameters required for welding can be quickly obtained.

[0092] Preferably, a laser generator, a mirror group adjustment device, and a traveling mechanism are provided in the welding system, and the corresponding process parameters are laser power, spot diameter, and welding speed respectively.

[0093] The adaptive laser welding device provided by the present invention will be described below. The adaptive laser welding device described below can be correspondingly referred to the adaptive laser welding method described above.

[0094] Figure 2 As shown in the structural schematic diagram of an adaptive laser welding device provided by the present invention, Figure 2 as shown, an adaptive laser welding device provided by the present invention, the device includes:

[0095] A relationship module for establishing a relational database of welding conditions and process parameters;

[0096] A welding condition acquisition module for acquiring the first welding condition to be welded;

[0097] A process parameter retrieval module for retrieving the second process parameters corresponding to the second welding condition that is closest to the first welding condition based on the relational database.

[0098] A monitoring welding module is used to perform welding with the second process parameter as the initial process parameter and monitor whether the welding process meets the requirements.

[0099] An adjustment module is used to adjust the process parameter until the welding process meets the requirements, and store the adjusted process parameter as the first process parameter corresponding to the first welding condition into the relational database.

[0100] In this embodiment, when the change of welding conditions leads to the change of penetration depth, the adaptive adjustment of the laser welding process parameters is realized.

[0101] Figure 3 The following is a schematic physical structure diagram of an electronic device provided by the present invention. As Figure 3 shown, the electronic device may include: a processor 310, a communication interface 320, a memory 330, and a communication bus 340. Among them, the processor 310, the communication interface 320, and the memory 330 complete mutual communication through the communication bus 340. The processor 310 can call the logical instructions in the memory 330 to execute the adaptive laser welding method, and the method includes:

[0102] Establish a relational database of welding conditions and process parameters;

[0103] Obtain the first welding condition to be welded;

[0104] Based on the relational database, retrieve the second process parameter corresponding to the second welding condition that is closest to the first welding condition;

[0105] Perform welding with the second process parameter as the initial process parameter and monitor whether the welding process meets the requirements;

[0106] Adjust the process parameter until the welding process meets the requirements, and store the adjusted process parameter as the first process parameter corresponding to the first welding condition into the relational database.

[0107] In addition, when the logical instructions in the above-mentioned memory 330 are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on such an understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or a part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in various embodiments of the present invention. The foregoing storage medium includes: various media such as USB flash drives, mobile hard disks, read-only memories (ROM, Read-Only Memory), random access memories (RAM, Random Access Memory), magnetic disks, or optical discs that can store program codes.

[0108] On the other hand, the present invention also provides a computer program product. The computer program product includes a computer program stored on a non-transitory computer-readable storage medium. The computer program includes program instructions. When the program instructions are executed by a computer, the computer can execute the adaptive laser welding method provided by the above-mentioned various methods. The method includes:

[0109] Establish a relational database of welding conditions and process parameters;

[0110] Obtain the first welding condition to be welded;

[0111] Based on the relational database, retrieve the second process parameters corresponding to the second welding condition that is closest to the first welding condition;

[0112] Use the second process parameters as the initial process parameters for welding, and monitor whether the welding process meets the requirements;

[0113] Adjust the process parameters until the welding process meets the requirements, and store the adjusted process parameters as the first process parameters corresponding to the first welding condition into the relational database.

[0114] On yet another aspect, the present invention also provides a non-transitory computer-readable storage medium, on which a computer program is stored. When the computer program is executed by a processor, it is configured to execute the adaptive laser welding method provided by the above-mentioned various methods. The method includes:

[0115] Establish a relational database of welding conditions and process parameters;

[0116] Obtain the first welding condition to be welded;

[0117] Retrieve the second process parameters corresponding to the second welding condition that is closest to the first welding condition based on the relational database;

[0118] Perform welding using the second process parameters as the initial process parameters, and monitor whether the welding process meets the requirements;

[0119] Adjust the process parameters until the welding process meets the requirements, and store the adjusted process parameters as the first process parameters corresponding to the first welding condition into the relational database.

[0120] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment. Those of ordinary skill in the art can understand and implement it without creative effort.

[0121] Through the description of the above embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus a necessary general hardware platform, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disc, etc., and includes several instructions for causing a computer device (which can be a personal computer, server, or network device, etc.) to execute the methods described in each embodiment or some parts of the embodiments.

[0122] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An adaptive laser welding method, characterized in that, The method includes: Establishing a relational database of welding conditions and process parameters, where the welding conditions include basic welding conditions and detailed welding conditions. The basic welding conditions include at least one of the following sub-basic welding conditions: the material of the workpiece to be welded, the thickness of the workpiece, and the joint design form. The detailed welding conditions include at least one of the following sub-detailed welding conditions: the assembly gap and the misalignment caused by assembly errors; Obtaining the first welding condition of the workpiece to be welded; Based on the relational database, retrieving the second process parameters corresponding to the second welding condition that is closest to the first welding condition; Using the second process parameters as the initial process parameters for welding and monitoring whether the welding process meets the requirements; Adjusting the process parameters until the welding process meets the requirements, and storing the adjusted process parameters as the first process parameters corresponding to the first welding condition into the relational database; Obtaining the first welding condition of the workpiece to be welded includes: Judging whether the first welding condition is the same as the second welding condition in terms of the basic welding conditions; If the first welding condition is the same as the second welding condition in terms of the basic welding conditions, then the adjusting the process parameters until the welding process meets the requirements includes: Judging whether the welding process meets the requirements. If it meets the requirements, the process parameters are not adjusted; if it does not meet the requirements, the process parameters are adjusted until the welding process meets the requirements; If the first welding condition is not the same as the second welding condition in terms of the basic welding conditions, then the adjusting the process parameters until the welding process meets the requirements includes: Judging whether the welding process meets the requirements. If it meets the requirements, the process parameters are adjusted in the direction of reducing the welding input heat per unit time until the welding process cannot meet the requirements, and the process parameters corresponding to the situation where the welding process can meet the requirements and the input heat per unit time is the smallest are used as the adjusted process parameters; If it does not meet the requirements, the process parameters are adjusted until the welding process meets the requirements.

2. The adaptive laser welding method according to claim 1, characterized in that, Establishing a relational database of welding conditions and process parameters includes: Obtaining welding test data and / or experience; Based on the welding test data and / or experience, obtaining the corresponding relationship between the welding conditions and the process parameters.

3. The adaptive laser welding method according to claim 2, wherein Monitoring whether the welding process meets the requirements includes: During the welding process, obtaining the keyhole depth; Based on the keyhole depth, obtaining the weld penetration situation; Based on the weld penetration situation, judging whether the welding process meets the requirements.

4. The adaptive laser welding method according to claim 2 or 3, characterized in that, The process parameters include at least one of the following sub-process parameters: Laser power, spot diameter, welding speed; When the process parameters include two or more sub-process parameters, correspondingly, the adjusting the process parameters until the welding process meets the requirements includes: According to a preset order, preferentially adjusting the sub-process parameter with a prior order to the corresponding adjustment upper limit. If the welding process still fails to meet the requirements, continue to adjust the sub-process parameter with a subsequent order.

5. An adaptive laser welding device, characterized in that, The welding device includes: A relationship module, used to establish a relational database of welding conditions and process parameters. The welding conditions include basic welding conditions and detailed welding conditions. The basic welding conditions include at least one of the following sub-basic welding conditions: the material of the workpiece to be welded, the thickness of the workpiece, and the joint design form. The detailed welding conditions include at least one of the following sub-detailed welding conditions: the assembly gap and the misalignment caused by the assembly error; A welding condition acquisition module, used to acquire the first welding condition of the workpiece to be welded; A process parameter retrieval module, used to retrieve the second process parameter corresponding to the second welding condition that is closest to the first welding condition based on the relational database; A welding monitoring module, used to perform welding with the second process parameter as the initial process parameter and monitor whether the welding process meets the requirements; An adjustment module, used to adjust the process parameters until the welding process meets the requirements, and store the adjusted process parameters as the first process parameter corresponding to the first welding condition into the relational database; Acquiring the first welding condition of the workpiece to be welded includes: Judging whether the first welding condition is consistent with the second welding condition in the basic welding conditions; If the first welding condition is consistent with the second welding condition in the basic welding conditions, then adjusting the process parameters until the welding process meets the requirements includes: Judging whether the welding process meets the requirements. If it meets the requirements, the process parameters are not adjusted; if it does not meet the requirements, the process parameters are adjusted until the welding process meets the requirements; If the first welding condition is not consistent with the second welding condition in the basic welding conditions, then adjusting the process parameters until the welding process meets the requirements includes: Judging whether the welding process meets the requirements. If it meets the requirements, the process parameters are adjusted in the direction of reducing the welding input heat per unit time until the welding process cannot meet the requirements, and the process parameters corresponding to the situation where the welding process can meet the requirements and the input heat per unit time is the smallest are used as the adjusted process parameters; If it does not meet the requirements, the process parameters are adjusted until the welding process meets the requirements.

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