An intelligent welding system and its intelligent control method

Abstract

The present invention relates to an intelligent welding system and a control method thereof. The system includes a data acquisition module, an intelligent control module, and a first power supply module. The intelligent control module includes a data operation unit, an output control unit, a data transmission unit, and a server. The output control unit includes an initialization unit, a data analysis and verification unit, a control signal limiting unit, and a control signal adjustment unit. The output control unit can set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and meet different welding requirements by setting the weight ratio. While meeting the welding requirements, it can effectively reduce the difference between the displayed data and the on-site real-time data, thus solving the problems of low data upload efficiency and slow speed in the existing welding centralized control system.

Description

Technical Field

[0001] The present invention belongs to the technical field of construction, and particularly relates to an intelligent welding system and an intelligent control method thereof. Background Art

[0002] During the repair of buildings or other equipment, arc welding generally requires a movable power supply device. In the prior art, a single DC power supply is generally used for power supply. The advantage of this power supply method for welding is flexibility and simplicity, but it will have a certain impact on the welding result and the intelligent adjustment of welding. With the development of technology, how to set up a welding structure on a mobile device to meet the stable power supply requirements for welding and make the welding result meet the requirements. With the upgrade of intelligent control, how to ensure automatic control during the welding process, improve the accuracy of the adjustment angle of the welding system, and accurately collect data during the angle adjustment and welding process. This requires better control of the rotation and angle alignment control of the welding rod, which is a difficulty and also a key point for future intelligent manufacturing. Summary of the Invention

[0003] The present invention relates to an intelligent welding system, which includes a data acquisition module, an intelligent control module, and a first power supply module. The intelligent control module includes a data operation unit, an output control unit, a data transmission unit, and a server. The data acquisition module transmits data to the data operation unit of the intelligent control module through a transmission line. After analyzing and processing the data, the data operation unit uploads the data to the server and transmits it to the output control unit through the data transmission unit respectively. The output control unit outputs a control signal to control the first power supply module to stably provide high-quality electric energy. The first power supply module includes two DC power supplies, a conversion unit corresponding to the two DC power supplies, and at least two output adjustment units.

[0004] For the intelligent welding system described above, the data acquisition module includes a camera and an ultrasonic wave. The camera is used to collect the surface image information of the welding position of the welding torch, and the ultrasonic wave is used to perform ultrasonic detection on the welding position of the welding torch to obtain an ultrasonic detection result, and both the surface image information and the ultrasonic detection result are sent to the intelligent control module.

[0005] The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and respectively analyze and process the surface image information and the ultrasonic detection result through the data operation unit. It judges whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, it then judges whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, the control signal of the current first power supply module remains unchanged; if at least one of the surface image information and the ultrasonic detection result does not meet the requirements, it collects the output current and voltage information of the first power supply module, checks whether the output current and voltage information meet the preset current and voltage requirements. If there is a deviation, it adjusts the control signal of the first power supply module. If there is no deviation, it checks the movement accuracy of the welding torch of the intelligent welding system.

[0006] For the described intelligent welding system, the first power supply module includes: a DC power supply VDC1 and a DC power supply VDC2. The DC power supply VDC1 is correspondingly connected to a first conversion unit, and the DC power supply VDC2 is correspondingly connected to a second conversion unit; both the first conversion unit and the second conversion unit have at least two outputs, each output is connected to a welding torch, and the output ends of the first conversion unit and the second conversion unit are connected in series.

[0007] The described intelligent welding system, where the positive pole of the DC power supply VDC1 is connected to the first end of the capacitor C1, the first non-controllable end of the switching transistor S1; the second end of the capacitor C1 is connected to the first end of the capacitor C2, the primary side homonymous end of the transformer T1, and the primary side heteronymous end of the transformer T2; the second end of the capacitor C2 is connected to the negative pole of the battery; the second non-controllable end of the switching transistor S1 is connected to the first end of the inductor LIK1 and the first non-controllable end of the switching transistor S3; the second non-controllable end of the switching transistor S3 is connected to the first end of the capacitor Cr; the second end of the capacitor Cr is connected to the first non-controllable end of the switching transistor S2 and the second end of the inductor LIK2; the second end of the inductor LIK1 is connected to the primary side heteronymous end of the transformer T1; the secondary side homonymous end of the transformer T1 is used as the first output terminal and is connected to the anode of the diode D1, the secondary side heteronymous end of the transformer T1 is used as the second output terminal; the primary side homonymous end of the transformer T2 is connected to the first end of the inductor LIK2; the second non-controllable end of the switching transistor S2 is connected to the negative pole of the DC power supply VDC1; the secondary side homonymous end of the transformer T2 is used as the first output terminal and is connected to the anode of the diode D2, the secondary side heteronymous end of the transformer T2 is used as the second output terminal; the cathodes of the diode D1 and the diode D2 are connected to form a parallel output; the parallel output formed by connecting the cathodes of the diode D1 and the diode D2 is connected to the anodes of the diode D3 and the diode D4, the cathode of the diode D3 is connected to the first non-controllable end of the switching transistor S4, the second non-controllable end of the switching transistor S4 is connected to the first end of the capacitor Co1 and the first end of the first welding torch; the second end of the capacitor Co1 is connected to the second output terminal of the transformer T1-T2; the cathode of the diode D4 is connected to the first non-controllable end of the switching transistor S5, the second non-controllable end of the switching transistor S5 is connected to the first end of the capacitor Co2 and the first end of the second welding torch; the second end of the capacitor Co2 is connected to the second output terminal of the transformer T1-T2; the positive pole of the DC power supply VDC2 is connected to the first non-controllable end of the switching transistor S6 and the first non-controllable end of the switching transistor S8, the second non-controllable end of the switching transistor S6 is connected to the cathode of the diode Db2, the cathode of the diode DL2, and the first end of the inductor L2, the second end of the inductor L2 is connected to the second non-controllable end of the switching transistor S7, the second output terminal of the transformer T1-T2, the first end of the capacitor Cb2, and the second end of the capacitor Co2, the first non-controllable end of the switching transistor S7 is connected to the anode of the diode DL2, the second end of the capacitor Cb2 is connected to the second end of the second welding torch; the second non-controllable end of the switching transistor S8 is connected to the cathode of the diode Db1, the cathode of the diode DL1, and the first end of the inductor L1, the second end of the inductor L1 is connected to the second non-controllable end of the switching transistor S9, the second output terminal of the transformer T1-T2, the first end of the capacitor Cb1, and the second end of the capacitor Co1, the first non-controllable end of the switching transistor S9 is connected to the anode of the diode DL1, the second end of the capacitor Cb1 is connected to the second end of the first welding torch.

[0008] The described intelligent welding system, the DC power supply VDC1 includes an energy storage battery, and the DC power supply VDC2 includes a super capacitor; the output control unit can set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and meet different welding requirements by setting the weight ratio.

[0009] The output control unit includes an initialization unit, a data analysis and verification unit, a control signal limiting unit, and a control signal adjustment unit. The initialization unit is used to analyze and calculate the corresponding first parameter of the welding requirement according to the welding requirement transmitted from the server through the data operation unit.

[0010] The data analysis and verification unit is used to call the image information and ultrasonic information of the welding object collected by the camera and ultrasonic wave of the acquisition module through the data operation unit, determine the material of the welding object according to the image information, and determine the state of the welding position according to the ultrasonic information. The data operation unit verifies whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit.

[0011] When the control signal limiting unit receives the first parameter, it first sets the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and generates a first threshold range of the control signal for controlling the first conversion unit and a second threshold range of the control signal for controlling the second conversion unit according to the weight ratio.

[0012] The control signal adjustment unit is used to adjust the control signal of the first conversion unit within the first threshold range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion unit within the second threshold range according to the surface image information and the ultrasonic detection result.

[0013] Optionally, the system further includes a robotic arm and a second power supply module. The robotic arm includes a first connecting rod, a second connecting rod, a steering head, and a welding installation component; the first end of the first connecting rod is fixedly connected to the welding system body through a first steering gear, the second end of the first connecting rod is fixedly connected to the first end of the second connecting rod through a second steering gear, the second end of the second connecting rod is connected to the steering head through a third steering gear, the welding installation component is installed on the steering head, the welding installation component is used to install the welding rod and the data acquisition module, a heat-insulating transparent component is arranged on the outer periphery of the data acquisition module for heat insulation of the high temperature during welding of the welding rod, the second power supply module includes two DC power supplies for supplying power to the welding rod according to the allocated weight ratio, and the second power supply module supplies standby power to the steering gears on the robotic arm.

[0014] The first steering gear is a full - circumference gear capable of full - circumference rotation. The second and third steering gears can be linked and locked. The third steering gear drives the steering head to move in a first direction, and the second steering gear drives the second connecting rod to move in a second direction. The first direction is perpendicular to the second direction. The welding and installation component includes a plurality of electrode installation holes, and through the steering of the steering head, the welding and installation component can adjust the angles of the plurality of electrode installation holes to align with the welding positions.

[0015] The second power supply module includes: DC power supply 1 (DC1) and DC power supply 2 (DC2). DC power supply 1 (DC1) is correspondingly connected to the first conversion module. The first conversion module has two output paths. The first output path of the first conversion module is connected to the motor of the robotic arm. The second output path of the first conversion module is connected to the electrode after being connected in series with the output of the second conversion module. DC power supply 2 (DC2) is correspondingly connected to the second conversion module. The second conversion module has two output paths. The first output path of the second conversion module is connected to the motor of the robotic arm. The second output path of the second conversion module is connected to the electrode after being connected in series with the output of the first conversion module. The first output path of the second conversion module and the first output path of the first conversion module form an OR circuit.

[0016] A control method for an intelligent welding system based on any one of the above, comprising the following steps: S1. According to the welding requirements transmitted from the server received by the data operation unit, analyze and calculate the corresponding first parameter of the welding requirements;

[0017] S2. The data operation unit calls the image information and ultrasonic information of the welding object collected by the camera and ultrasonic wave of the acquisition module. Determine the material of the welding object according to the image information, and determine the state of the welding position according to the ultrasonic information. The data operation unit checks whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit;

[0018] S3. When receiving the first parameter, first set the weight ratio of the outputs of DC power supply VDC1 and DC power supply VDC2, and generate a first threshold range of the control signal for controlling the first conversion unit and a second threshold range of the control signal for controlling the second conversion unit according to the weight ratio;

[0019] S4. The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and separately analyze and process the surface image information and the ultrasonic detection result through the data operation unit. It judges whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, it judges whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, the control signal of the current first power supply module remains unchanged; if at least one of the surface image information and the ultrasonic detection result does not meet the requirements, it collects the output current and voltage information of the first power supply module, checks whether the output current and voltage information meet the preset current and voltage requirements. If there is a deviation, it adjusts the control signal of the first power supply module. If there is no deviation, it checks the movement accuracy of the welding torch of the intelligent welding system; it adjusts the control signal of the first transformation unit within the first threshold range according to the surface image information and the ultrasonic detection result, and adjusts the control signal of the second transformation unit within the second threshold range according to the surface image information and the ultrasonic detection result.

[0020] An intelligent control method based on the intelligent welding system, the method includes the following steps: S1. Check the robotic arm, start DC power supply 1 DC1 and DC power supply 2 DC2, supply power to the robotic arm through DC power supply 1 DC1 and DC power supply 2 DC2, and detect whether the first steering gear, the second steering gear, and the third steering gear are all in normal rotation states. If so, judge whether the welding strip of the welding installation component is placed correctly. If the welding strip is installed correctly, turn on the data acquisition module; S2. According to the data operation unit, by receiving the welding requirements transmitted from the server, analyze and calculate the corresponding first parameter of the welding requirements.

[0021] S3. Through the data operation unit, call the image information and ultrasonic information of the welding object collected by the camera and ultrasonic wave of the acquisition module, determine the material of the welding object according to the image information, and determine the state of the welding position according to the ultrasonic information. The data operation unit checks whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, it transmits the first parameter to the output control unit.

[0022] S4. When receiving the first parameter, first set the weight ratio of the outputs of DC power supply 1 DC1 and DC power supply 2 DC2, and generate the first critical value range of the control signal for controlling the first transformation module and the second critical value range of the control signal for controlling the second transformation module according to the weight ratio.

[0023] S5. The intelligent control module controls the first steering gear of the robotic arm to rotate until the robotic arm is facing the welding position, locks the first steering gear, and then controls the second steering gear to move the robotic arm closer to the welding position so that the welding strip can touch the welding position. Then, it controls the third steering gear to rotate the welding installation component during the welding process as the welding strip is used up, replace the new welding strip and align it with the welding position until the welding is completed;

[0024] S6. The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and separately analyze and process the surface image information and the ultrasonic detection result through the data operation unit. It judges whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, it judges whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, the control signal of the current second power supply module remains unchanged; if at least one of the surface image information and the ultrasonic detection result does not meet the requirements, it collects the output current and voltage information of the second power supply module, checks whether the output current and voltage information meets the set current and voltage requirements. If there is a deviation, it adjusts the control signal of the second power supply module. If there is no deviation, it checks the movement accuracy of the robotic arm of the welding torch of the intelligent welding system; it adjusts the control signal of the first transformation module within the first critical value range according to the surface image information and the ultrasonic detection result, and adjusts the control signal of the second transformation module within the second critical value range according to the surface image information and the ultrasonic detection result.

[0025] The present invention provides an intelligent welding system, which can determine whether the welding process meets the requirements through image acquisition and analysis, and in cooperation with ultrasonic detection and analysis. If the requirements are not met, the power supply accuracy or rotation accuracy is adjusted to meet the welding requirements of the welding machine, improving the accuracy and stability of the welding machine. One of the improvement points of the present invention is to set two DC power supplies that can match the welding machine, enabling adaptive adjustment and matching according to the welding machine's requirements for different types of power supplies, and being able to adjust the output accuracy and accuracy of the DC power supply by adjusting the output signal. Another improvement of the present invention is that it can judge the welding result through dual signals of images and ultrasonic waves, and supply power to the welding machine according to the judgment result, improving the intelligence of the welding system and also enabling timely verification of the welding result. Another improvement point of the present invention is to adjust the output of the first power supply module in two key steps. The first key step is to set the weight ratio of the two DC power supplies according to the welding requirements and the characteristics of different DC power supplies. The second key step is to adjust the control signals of the conversion units of each power supply within the threshold range that satisfies the weight ratio of the two DC power supplies according to the results of camera and ultrasonic detection, so that the conversion unit can meet the requirements for adjusting the welding machine after the acquisition module collects signals. One of the improvement points of the present invention is to set two DC power supplies that can match the welding machine, enabling adaptive adjustment and matching according to the welding machine's requirements for different types of power supplies, and being able to adjust the output accuracy and accuracy of the DC power supply by adjusting the output signal. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the intelligent welding system according to an embodiment of the present invention.

[0027] Figure 2 It is a schematic diagram of the first power supply module according to an embodiment of the present invention.

[0028] Figure 3 It is a schematic diagram of the control method of the intelligent welding system according to an embodiment of the present invention.

[0029] Figure 4 It is a schematic diagram of the intelligent welding system according to another embodiment of the present invention.

[0030] Figure 5 It is a schematic diagram of the function of the robotic arm according to another embodiment of the present invention.

[0031] Figure 6 It is a schematic diagram of the second power supply module according to another embodiment of the present invention.

[0032] Figure 7 It is a schematic diagram of the intelligent control method of the intelligent welding system according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0033] The present application will be further described in detail below with reference to the accompanying drawings. It is necessary to point out here that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the protection scope of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0034] Embodiment 1: As Figure 1 shown, it is a schematic diagram of the intelligent welding system according to Embodiment 1 of the present invention. The system includes a data acquisition module, an intelligent control module, and a first power supply module. The intelligent control module includes a data operation unit, an output control unit, a data transmission unit, and a server. The data acquisition module transmits data to the data operation unit of the intelligent control module through a transmission line. After analyzing and processing the data, the data operation unit uploads the data to the server and transmits it to the output control unit through the data transmission unit respectively. The output control unit outputs a control signal to control the first power supply module to stably provide high-quality electric energy. The first power supply module includes two DC power supplies, a conversion unit corresponding to the two DC power supplies, and at least two output adjustment units.

[0035] For the intelligent welding system, the data acquisition module includes a camera and an ultrasonic wave. The camera is used to collect the surface image information of the welding position of the welding torch, and the ultrasonic wave is used to perform ultrasonic detection on the welding position of the welding torch to obtain the ultrasonic detection result, and send both the surface image information and the ultrasonic detection result to the intelligent control module.

[0036] For the intelligent welding system, the intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and respectively analyze and process the surface image information and the ultrasonic detection result through the data operation unit. It judges whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, it judges whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, the control signal of the current first power supply module remains unchanged. If at least one of the surface image information and the ultrasonic detection result does not meet the requirements, it collects the output current and voltage information of the first power supply module, checks whether the output current and voltage information meet the preset current and voltage requirements. If there is a deviation, it adjusts the control signal of the first power supply module. If there is no deviation, it checks the moving position of the welding torch of the intelligent welding system.

[0037] As Figure 2As shown in the figure, it is a schematic diagram of the first power supply module according to an embodiment of the present invention. The first power supply module includes: a DC power supply VDC1 and a DC power supply VDC2. The DC power supply VDC1 is correspondingly connected to a first conversion unit, and the DC power supply VDC2 is correspondingly connected to a second conversion unit. Both the first conversion unit and the second conversion unit have at least two outputs, and each output is connected to a welding torch. The output ends of the first conversion unit and the second conversion unit are connected in series.

[0038] For the described intelligent welding system, the positive pole of the DC power supply VDC1 is connected to the first end of the capacitor C1 and the first non-controllable end of the switching transistor S1. The second end of the capacitor C1 is connected to the first end of the capacitor C2, the primary side's same-named end of the transformer T1, and the primary side's different-named end of the transformer T2. The second end of the capacitor C2 is connected to the negative pole of the battery. The second non-controllable end of the switching transistor S1 is connected to the first end of the inductor LIK1 and the first non-controllable end of the switching transistor S3. The second non-controllable end of the switching transistor S3 is connected to the first end of the capacitor Cr. The second end of the capacitor Cr is connected to the first non-controllable end of the switching transistor S2 and the second end of the inductor LIK2. The second end of the inductor LIK1 is connected to the primary side's different-named end of the transformer T1. The secondary side's same-named end of the transformer T1 serves as the first output terminal and is connected to the anode of the diode D1. The secondary side's different-named end of the transformer T1 serves as the second output terminal. The primary side's same-named end of the transformer T2 is connected to the first end of the inductor LIK2. The second non-controllable end of the switching transistor S2 is connected to the negative pole of the DC power supply VDC1. The secondary side's same-named end of the transformer T2 serves as the first output terminal and is connected to the anode of the diode D2. The secondary side's different-named end of the transformer T2 serves as the second output terminal. The cathodes of the diode D1 and the diode D2 are connected to form a parallel output. The parallel output formed by connecting the cathodes of the diode D1 and the diode D2 is connected to the anodes of the diode D3 and the diode D4. The cathode of the diode D3 is connected to the first non-controllable end of the switching transistor S4. The second non-controllable end of the switching transistor S4 is connected to the first end of the capacitor Co1 and the first end of the first welding torch. The second end of the capacitor Co1 is connected to the second output terminal of the transformer T1-T2. The cathode of the diode D4 is connected to the first non-controllable end of the switching transistor S5. The second non-controllable end of the switching transistor S5 is connected to the first end of the capacitor Co2 and the first end of the second welding torch. The second end of the capacitor Co2 is connected to the second output terminal of the transformer T1-T2. The positive pole of the DC power supply VDC2 is connected to the first non-controllable end of the switching transistor S6 and the first non-controllable end of the switching transistor S8. The second non-controllable end of the switching transistor S6 is connected to the cathode of the diode Db2, the cathode of the diode DL2, and the first end of the inductor L2. The second end of the inductor L2 is connected to the second non-controllable end of the switching transistor S7, the second output terminal of the transformer T1-T2, the first end of the capacitor Cb2, and the second end of the capacitor Co2. The first non-controllable end of the switching transistor S7 is connected to the anode of the diode DL2. The second end of the capacitor Cb2 is connected to the second end of the second welding torch. The second non-controllable end of the switching transistor S8 is connected to the cathode of the diode Db1, the cathode of the diode DL1, and the first end of the inductor L1. The second end of the inductor L1 is connected to the second non-controllable end of the switching transistor S9, the second output terminal of the transformer T1-T2, the first end of the capacitor Cb1, and the second end of the capacitor Co1. The first non-controllable end of the switching transistor S9 is connected to the anode of the diode DL1. The second end of the capacitor Cb1 is connected to the second end of the first welding torch.

[0039] Preferably, the controllable terminals of the switching tubes S1-S9 can all be adjusted by outputting a control signal through the output control unit of the intelligent control module, and the control signal is preferably a PWM signal.

[0040] For the intelligent welding system described above, the DC power supply VDC1 includes a storage battery, and the DC power supply VDC2 includes a super capacitor; the output control unit can set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and meet different welding requirements by setting the weight ratio.

[0041] The output control unit includes an initialization unit, a data analysis and verification unit, a control signal limiting unit, and a control signal adjustment unit. The initialization unit is used to analyze and calculate the first parameter of the corresponding welding requirement according to the welding requirement transmitted from the server through the data operation unit.

[0042] The data analysis and verification unit is used to call the image information and ultrasonic information of the welding object collected by the camera and ultrasonic wave of the acquisition module through the data operation unit, determine the material of the welding object according to the image information, and determine the state of the welding position according to the ultrasonic information. The data operation unit verifies whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit.

[0043] When the control signal limiting unit receives the first parameter, it first sets the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and generates a first threshold range of the control signal for controlling the first conversion unit and a second threshold range of the control signal for controlling the second conversion unit according to the weight ratio.

[0044] The control signal adjustment unit is used to adjust the control signal of the first conversion unit within the first threshold range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion unit within the second threshold range according to the surface image information and the ultrasonic detection result.

[0045] As Figure 3 shown, it is a schematic diagram of the intelligent control method based on the embodiment of the intelligent welding system of the present invention. The intelligent control method includes the following steps: S1. Analyze and calculate the first parameter of the corresponding welding requirement according to the welding requirement transmitted from the server through the data operation unit.

[0046] S2. The data operation unit calls the image information and ultrasonic information of the welding object collected by the camera and ultrasonic wave of the collection module, determines the material of the welding object according to the image information, and determines the state of the welding position according to the ultrasonic information. The data operation unit checks whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit.

[0047] S3. When receiving the first parameter, first set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and generate a first threshold range of the control signal for controlling the first conversion unit and a second threshold range of the control signal for controlling the second conversion unit according to the weight ratio.

[0048] S4. The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data collection module, and respectively analyze and process the surface image information and the ultrasonic detection result through the data operation unit, and judge whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, then judge whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, keep the control signal of the current first power supply module unchanged; if at least one of the surface image information and the ultrasonic detection result does not meet the requirements, collect the output current and voltage information of the first power supply module, check whether the output current and voltage information meet the preset current and voltage requirements. If there is a deviation, adjust the control signal of the first power supply module. If there is no deviation, check the moving position of the welding torch of the intelligent welding system; adjust the control signal of the first conversion unit within the first threshold range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion unit within the second threshold range according to the surface image information and the ultrasonic detection result.

[0049] An intelligent welding system shown in this embodiment can determine whether the welding process meets the requirements through image acquisition and analysis, combined with ultrasonic detection and analysis. If it does not meet the requirements, it adjusts the power supply accuracy and rotation accuracy to meet the welding requirements of the welding machine, improving the accuracy and stability of the welding machine. One of the improvement points of this embodiment is to set two DC power supplies that can be matched with the welding machine, enabling adaptive adjustment and matching according to the welding machine's requirements for different types of power supplies, and being able to adjust the output accuracy and accuracy of the DC power supply by adjusting the output signal. Another improvement of this embodiment is that it can judge the welding result through dual signals of images and ultrasonic waves, and adjust the power supply and moving position accuracy of the welding machine according to the judgment result, improving the intelligence of the welding system and also being able to improve the timely verification of the welding result. Another improvement point of this embodiment is to adjust the output of the first power supply module in two key steps. The first key step is to set the weight ratio of the two DC power supplies according to the welding requirements and the characteristics of different DC power supplies. The second key step is to adjust the control signals of the conversion units of each power supply within the threshold range that satisfies the weight ratio of the two DC power supplies according to the results of camera and ultrasonic detection, so that the conversion unit can meet the welding torch power supply requirements of the welding machine after the acquisition module collects signals.

[0050] In this embodiment, it is also possible to add content such as Figures 4 - 7 shown for controlling the robotic arm. Optionally, in the aforementioned intelligent control system, it may further include a robotic arm and a second power supply module. The robotic arm includes a first connecting rod, a second connecting rod, a steering head, and a welding mounting component. The first end of the first connecting rod is fixedly connected to the welding system body through a first steering gear. The second end of the first connecting rod is fixedly connected to the first end of the second connecting rod through a second steering gear. The second end of the second connecting rod is connected to the steering head through a third steering gear. The welding mounting component is mounted on the steering head. The welding mounting component is used to mount the welding strip and the data acquisition module. An insulating transparent component is arranged on the outer periphery of the data acquisition module for insulating the high temperature during the welding of the welding strip. The second power supply module includes two DC power supplies for supplying power to the welding strip according to the allocated weight ratio, and the second power supply module supplies standby power to the steering gears on the robotic arm.

[0051] Furthermore, the insulating transparent component can be selected as heat-resistant glass.

[0052] The described intelligent welding system, wherein the first steering gear is a full - circumference gear capable of full - circumference rotation, the second steering gear and the third steering gear can be linked and locked, the third steering gear drives the steering head to move in the first direction, the second steering gear drives the second connecting rod to move in the second direction, and the first direction is perpendicular to the second direction; the welding installation component includes a plurality of electrode installation holes, and the welding installation component can adjust the angles of the plurality of electrode installation holes to align with the welding position through the steering of the steering head.

[0053] The same as the foregoing content, the intelligent control module in this intelligent welding system includes a data operation unit, an output control unit, a data transmission unit, and a server; the data acquisition module includes a camera and an ultrasonic wave. The camera is used to collect the surface image information of the welding position of the welding torch, and the ultrasonic wave is used to perform ultrasonic detection on the welding position of the welding torch to obtain an ultrasonic detection result, and both the surface image information and the ultrasonic detection result are sent to the intelligent control module. In this embodiment, the output control unit can also output a control signal to control the second power supply module.

[0054] Preferably, the heat - insulating transparent component can be set as a high - temperature - resistant glass that can be opened and closed. During the welding process, the heat - insulating transparent component is closed to protect the data acquisition module. After the welding is completed, when it is detected that the temperature at the welding position has dropped to an acceptable range, the heat - insulating transparent component can be automatically opened so that the camera and the ultrasonic wave can collect the data of the welding position more accurately.

[0055] As Figure 6 shown, it is a schematic diagram of the second power supply module of the present invention. The second power supply module includes: DC power supply 1 (DC1) and DC power supply 2 (DC2). DC power supply 1 (DC1) is correspondingly connected to the first conversion module. The first conversion module has two outputs. The first output of the first conversion module is connected to the motor of the robotic arm, and the second output of the first conversion module is connected in series with the output of the second conversion module and then connected to the electrode. DC power supply 2 (DC2) is correspondingly connected to the second conversion module. The second conversion module has two outputs. The first output of the second conversion module is connected to the motor of the robotic arm, and the second output of the second conversion module is connected in series with the output of the first conversion module and then connected to the electrode. The first output of the second conversion module and the first output of the first conversion module form an OR circuit.

[0056] Further, the positive electrode of the DC power supply 1DC1 is connected to the cathode of the diode 1D2, the first non-controllable terminal of the switching transistor 1S1, the first terminal of the capacitor 1C1, the cathode of the diode 1D5, and the homonymous terminal of the second primary side of the transformer 1T1. The second terminal of the capacitor 1C1 is connected to the anode of the diode 1D3 and the cathode of the diode 1D4. The cathode of the diode 1D3 is connected to the anode of the diode 1D2, the second non-controllable terminal of the switching transistor 1S1, the homonymous terminal of the secondary side of the transformer 1T1, the first terminal of the inductor 1L3, and the cathode of the diode 1D1. The anode of the diode 1D1 is connected to the negative electrode of the DC power supply 1DC1. The anode of the diode 1D4 is connected to the homonymous terminal of the first primary side of the transformer 1T1. The non-homonymous terminal of the first primary side of the transformer 1T1 is connected to the first terminal of the inductor 1L5. The second terminal of the inductor 1L5 is connected to the negative electrode of the DC power supply 1DC1. The non-homonymous terminal of the second primary side of the transformer 1T1 is connected to the first terminal of the inductor 1L6. The second terminal of the inductor 1L6 is connected to the cathode of the diode 1D6. The anode of the diode 1D6 is connected to the cathode of the diode 1D7 and the first terminal of the capacitor 1C2. The second terminal of the capacitor 1C2 is connected to the negative electrode of the DC power supply 1DC1. The anode of the diode 1D5 is connected to the non-homonymous terminal of the secondary side of the transformer 1T1, the anode of the diode 1D7, the first non-controllable terminal of the switching transistor 1S2, the non-homonymous terminal of the primary side of the transformer 1T2, and the cathode of the diode 1D8. The second non-controllable terminal of the switching transistor 1S2 is connected to the anode of the diode 1D8 and the negative electrode of the DC power supply 1DC1. The second terminal of the inductor 1L3 is connected to the homonymous terminal of the primary side of the transformer 1T2. The non-homonymous terminal of the secondary side of the transformer 1T2 is connected to the first terminal of the inductor 1L4. The second terminal of the inductor 1L4 is connected to the anode of the diode 1D9. The cathode of the diode 1D9 is connected to the anode of the diode 1D12 and the anodes of the diodes 1D10 - 1D11. The cathode of the diode 1D12 is connected to the motor of the robotic arm. The homonymous terminal of the secondary side of the transformer 1T2 is used as the second output terminal and is connected to the second terminals of the capacitors 1Co1 - 1Co2.

[0057] Further, the cathode of diode 1D10 is connected to the first non-controllable end of switch 1S4, the second non-controllable end of switch 1S4 is connected to the first end of capacitor 1Co1 and the first end of the first welding torch; the second end of capacitor 1Co1 is connected to the second output end of transformer 1T2; the cathode of diode 1D11 is connected to the first non-controllable end of switch 1S5, the second non-controllable end of switch 1S5 is connected to the first end of capacitor 1Co2 and the first end of the second welding torch; the second end of capacitor 1Co2 is connected to the second output end of transformer 1T1-1T2; the positive pole of DC power supply 2DC2 is connected to the anode of diode 1D13, the first non-controllable end of switch 1S6 and the first non-controllable end of switch 1S8, the cathode of diode 1D13 is connected to the motor of the robotic arm, diodes 1D12 and 1D13 form an OR circuit to supply power to the motor of the robotic arm as a backup to each other, the second non-controllable end of switch 1S6 is connected to the cathode of diode 1Db2, the cathode of diode 1DL2 and the first end of inductor 1L2, the second end of inductor 1L2 is connected to the second non-controllable end of switch 1S7, the second output end of transformer 1T2, the first end of capacitor 1Cb2 and the second end of capacitor 1Co2, the first non-controllable end of switch 1S7 is connected to the anode of diode 1DL2, the second end of capacitor 1Cb2 is connected to the second end of the second welding torch; the second non-controllable end of switch 1S8 is connected to the cathode of diode 1Db1, the cathode of diode 1DL1 and the first end of inductor 1L1, the second end of inductor 1L1 is connected to the second non-controllable end of switch 1S3, the second output end of transformer 1T2, the first end of capacitor 1Cb1 and the second end of capacitor 1Co1, the first non-controllable end of switch 1S3 is connected to the anode of diode 1DL1, the second end of capacitor 1Cb1 is connected to the second end of the first welding torch.

[0058] Further, the DC power supply 1DC1 includes an energy storage battery pack formed by connecting multiple energy storage batteries in series and parallel. The energy storage battery packs are actively balanced through a balancing circuit, and a bypass switch is provided. When a fault occurs in the energy storage battery, it can be bypassed through the bypass switch to achieve the function of eliminating the fault; the DC power supply 2DC2 includes a super capacitor.

[0059] As Figure 7 shown, it is a schematic diagram of an intelligent control method based on the foregoing intelligent welding system embodiment including a robotic arm. This method can be executed independently of Figure 3 the method shown. The intelligent control method includes the following steps: S1. Check the robotic arm, start the DC power supply 1DC1 and the DC power supply 2DC2, supply power to the robotic arm through the DC power supply 1DC1 and the DC power supply 2DC2, and detect whether the first steering gear, the second steering gear, and the third steering gear are all in a normal rotating state. If so, judge whether the welding strip of the welding installation component is placed correctly. If the welding strip is installed correctly, then turn on the data acquisition module;

[0060] S2. According to the welding requirements transmitted from the receiving server by the data operation unit, analyze and calculate the first parameter corresponding to the welding requirements;

[0061] S3. The data operation unit calls the camera of the acquisition module and the ultrasonic wave to acquire the image information and ultrasonic wave information of the welding object. Determine the material of the welding object according to the image information, and determine the state of the welding position according to the ultrasonic wave information. The data operation unit checks whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit;

[0062] S4. When receiving the first parameter, first set the weight ratio of the outputs of the DC power supply 1 DC1 and the DC power supply 2 DC2, and generate the first critical value range of the control signal for controlling the first conversion module and the second critical value range of the control signal for controlling the second conversion module according to the weight ratio;

[0063] S5. The intelligent control module controls the first steering gear of the robotic arm to rotate until the robotic arm is facing the welding position, locks the first steering gear, and then controls the second steering gear to make the robotic arm approach the welding position so that the welding rod can touch the welding position. Then control the third steering gear so that during the welding process, as the welding rod is used up, rotate the welding installation component to replace the new welding rod and align it with the welding position until the welding is completed;

[0064] S6. The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and respectively analyze and process the surface image information and the ultrasonic detection result through the data operation unit. Judge whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, then judge whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, keep the control signal of the current second power supply module unchanged; If at least one of the surface image information and the ultrasonic detection result does not meet the requirements, collect the output current and voltage information of the second power supply module, and check whether the output current and voltage information meet the set current and voltage requirements. If there is a deviation, adjust the control signal of the second power supply module. If there is no deviation, check the movement accuracy of the robotic arm of the welding torch of the intelligent welding system; Adjust the control signal of the first conversion module within the first critical value range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion module within the second critical value range according to the surface image information and the ultrasonic detection result. The set current and voltage requirements in this embodiment can be the pre-set current and voltage requirements.

[0065] Example 2: As Figure 4 shown, it is a schematic diagram of another embodiment of the intelligent welding system of the present invention. As Figure 5 shown, it is a schematic diagram of the functions of the robotic arm in this embodiment. This embodiment is another embodiment that can be independent of Embodiment 1. The intelligent welding system shown in this embodiment includes a robotic arm, a data acquisition module, an intelligent control module, and a second power supply module. The robotic arm includes a first connecting rod, a second connecting rod, a steering head, and a welding installation component. The first end of the first connecting rod is fixedly connected to the welding system body through a first steering gear. The second end of the first connecting rod is fixedly connected to the first end of the second connecting rod through a second steering gear. The second end of the second connecting rod is connected to the steering head through a third steering gear. The welding installation component is installed on the steering head. The welding installation component is used to install a welding rod and a data acquisition module. An insulating transparent component is arranged on the outer periphery of the data acquisition module to insulate the high temperature during the welding of the welding rod. The second power supply module includes two DC power supplies, which are used to supply power to the welding rod according to the weighted proportion. The second power supply module supplies standby power to the steering gears on the robotic arm.

[0066] Preferably, the insulating transparent component can be selected as heat-resistant glass.

[0067] For the intelligent welding system described above, the first steering gear is a full-circle gear that can perform full-circle rotation. The second steering gear and the third steering gear can be linked and locked. The third steering gear drives the steering head to move in a first direction, and the second steering gear drives the second connecting rod to move in a second direction. The first direction and the second direction are perpendicular to each other. The welding installation component includes a plurality of welding rod installation holes. The welding installation component can adjust the angles of the plurality of welding rod installation holes to align with the welding position through the steering of the steering head.

[0068] For the intelligent welding system described above, the intelligent control module includes a data operation unit, an output control unit, a data transmission unit, and a server. The data acquisition module includes a camera and an ultrasonic wave. The camera is used to collect the surface image information of the welding position of the welding torch. The ultrasonic wave is used to perform ultrasonic detection on the welding position of the welding torch to obtain an ultrasonic detection result, and both the surface image information and the ultrasonic detection result are sent to the intelligent control module.

[0069] Preferably, the insulating transparent component can be set as heat-resistant glass that can be opened and closed. During the welding process, the insulating transparent component is closed to protect the data acquisition module. After the welding is completed, when it is detected that the temperature of the welding position has dropped to an acceptable range, the insulating transparent component can be automatically opened so that the camera and the ultrasonic wave can collect the data of the welding position more precisely.

[0070] As Figure 6 shown, it is a schematic diagram of the second power supply module in the second embodiment of the present invention. The second power supply module includes: a DC power supply 1 DC1 and a DC power supply 2 DC2. The DC power supply 1 DC1 is correspondingly connected to a first conversion module. The first conversion module outputs in two paths. The first path output of the first conversion module is connected to the motor of the robotic arm. The second path output of the first conversion module is connected in series with the output of the second conversion module and then connected to the welding electrode. The DC power supply 2 DC2 is correspondingly connected to the second conversion module. The second conversion module outputs in two paths. The first path output of the second conversion module is connected to the motor of the robotic arm. The second path output of the second conversion module is connected in series with the output of the first conversion module and then connected to the welding electrode. The first path output of the second conversion module and the first path output of the first conversion module form an OR circuit.

[0071] Optionally, the positive electrode of the DC power supply 1DC1 is connected to the cathode of the diode 1D2, the first non-controllable end of the switching tube 1S1, the first end of the capacitor 1C1, the cathode of the diode 1D5, and the homonymous end of the second primary side of the transformer 1T1. The second end of the capacitor 1C1 is connected to the anode of the diode 1D3 and the cathode of the diode 1D4. The cathode of the diode 1D3 is connected to the anode of the diode 1D2, the second non-controllable end of the switching tube 1S1, the homonymous end of the secondary side of the transformer 1T1, the first end of the inductor 1L3, and the cathode of the diode 1D1. The anode of the diode 1D1 is connected to the negative electrode of the DC power supply 1DC1. The anode of the diode 1D4 is connected to the homonymous end of the first primary side of the transformer 1T1. The non-homonymous end of the first primary side of the transformer 1T1 is connected to the first end of the inductor 1L5. The second end of the inductor 1L5 is connected to the negative electrode of the DC power supply 1DC1. The non-homonymous end of the second primary side of the transformer 1T1 is connected to the first end of the inductor 1L6. The second end of the inductor 1L6 is connected to the cathode of the diode 1D6. The anode of the diode 1D6 is connected to the cathode of the diode 1D7 and the first end of the capacitor 1C2. The second end of the capacitor 1C2 is connected to the negative electrode of the DC power supply 1DC1. The anode of the diode 1D5 is connected to the non-homonymous end of the secondary side of the transformer 1T1, the anode of the diode 1D7, the first non-controllable end of the switching tube 1S2, the non-homonymous end of the primary side of the transformer 1T2, and the cathode of the diode 1D8. The second non-controllable end of the switching tube 1S2 is connected to the anode of the diode 1D8 and the negative electrode of the DC power supply 1DC1. The second end of the inductor 1L3 is connected to the homonymous end of the primary side of the transformer 1T2. The non-homonymous end of the secondary side of the transformer 1T2 is connected to the first end of the inductor 1L4. The second end of the inductor 1L4 is connected to the anode of the diode 1D9. The cathode of the diode 1D9 is connected to the anode of the diode 1D12 and the anodes of the diodes 1D10 - 1D11. The cathode of the diode 1D12 is connected to the motor of the robotic arm. The homonymous end of the secondary side of the transformer 1T2 is used as the second output terminal and is connected to the second ends of the capacitors 1Co1 - 1Co2. The cathode of the diode 1D10 is connected to the first non-controllable end of the switching tube 1S4. The second non-controllable end of the switching tube 1S4 is connected to the first end of the capacitor 1Co1 and the first end of the first welding torch. The second end of the capacitor 1Co1 is connected to the second output terminal of the transformer 1T2. The cathode of the diode 1D11 is connected to the first non-controllable end of the switching tube 1S5. The second non-controllable end of the switching tube 1S5 is connected to the first end of the capacitor 1Co2 and the first end of the second welding torch. The second end of the capacitor 1Co2 is connected to the second output terminals of the transformers 1T1 - 1T2.The positive electrode of the DC power supply 2DC2 is connected to the anode of the diode 1D13, the first non-controllable terminal of the switching transistor 1S6, and the first non-controllable terminal of the switching transistor 1S8. The cathode of the diode 1D13 is connected to the motor of the robotic arm. The diodes 1D12 and 1D13 form an OR circuit to supply power to the motor of the robotic arm as a backup for each other. The second non-controllable terminal of the switching transistor 1S6 is connected to the cathode of the diode 1Db2, the cathode of the diode 1DL2, and the first end of the inductor 1L2. The second end of the inductor 1L2 is connected to the second non-controllable terminal of the switching transistor 1S7, the second output terminal of the transformer 1T2, the first end of the capacitor 1Cb2, and the second end of the capacitor 1Co2. The first non-controllable terminal of the switching transistor 1S7 is connected to the anode of the diode 1DL2. The second end of the capacitor 1Cb2 is connected to the second end of the second welding torch. The second non-controllable terminal of the switching transistor 1S8 is connected to the cathode of the diode 1Db1, the cathode of the diode 1DL1, and the first end of the inductor 1L1. The second end of the inductor 1L1 is connected to the second non-controllable terminal of the switching transistor 1S3, the second output terminal of the transformer 1T2, the first end of the capacitor 1Cb1, and the second end of the capacitor 1Co1. The first non-controllable terminal of the switching transistor 1S3 is connected to the anode of the diode 1DL1. The second end of the capacitor 1Cb1 is connected to the second end of the first welding torch.;

[0072] Optionally, the DC power supply 1DC1 includes an energy storage battery pack formed by connecting multiple energy storage batteries in series and parallel. Active balancing is performed between the energy storage battery packs through a balancing circuit, and a bypass switch is provided. When a fault occurs in the energy storage battery, it can be bypassed through the bypass switch to achieve the function of eliminating the fault. The DC power supply 2DC2 includes a super capacitor.

[0073] As Figure 7 shown, it is a schematic diagram of the intelligent control method of the intelligent welding system based on Embodiment 2. The intelligent control method includes the following steps: S1. Check the robotic arm, start the DC power supply 1DC1 and the DC power supply 2DC2, supply power to the robotic arm through the DC power supply 1DC1 and the DC power supply 2DC2, and detect whether the first steering gear, the second steering gear, and the third steering gear are all in a normal rotating state. If so, judge whether the welding strip of the welding and installation component is placed correctly. If the welding strip is installed correctly, then turn on the data acquisition module;

[0074] S2. According to the welding requirements transmitted from the server received by the data operation unit, analyze and calculate the corresponding first parameter of the welding requirements;

[0075] S3. The data operation unit calls the image information and ultrasonic information of the welding object collected by the camera and ultrasonic wave of the acquisition module, determines the material of the welding object according to the image information, and determines the state of the welding position according to the ultrasonic information. The data operation unit checks whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit;

[0076] S4. When receiving the first parameter, first set the weight ratio of the outputs of DC power supply 1 DC1 and DC power supply 2 DC2, and generate a first critical value range of the control signal for controlling the first conversion module and a second critical value range of the control signal for controlling the second conversion module according to the weight ratio;

[0077] S5. The intelligent control module controls the first steering gear of the robotic arm to rotate until the robotic arm is facing the welding position, locks the first steering gear, then controls the second steering gear to make the robotic arm approach the welding position so that the welding rod can touch the welding position, and then controls the third steering gear to rotate the welding installation component during welding as the welding rod is used up, replace the new welding rod and align it with the welding position until the welding is completed;

[0078] S6. The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and respectively analyze and process the surface image information and the ultrasonic detection result through the data operation unit. Judge whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, judge whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, keep the control signal of the current second power supply module unchanged; If at least one of the surface image information and the ultrasonic detection result does not meet the requirements, collect the output current and voltage information of the second power supply module, check whether the output current and voltage information meet the set current and voltage requirements. If there is a deviation, adjust the control signal of the second power supply module. If there is no deviation, check the movement accuracy of the robotic arm of the welding torch of the intelligent welding system; Adjust the control signal of the first conversion module within the first critical value range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion module within the second critical value range according to the surface image information and the ultrasonic detection result.

[0079] The intelligent welding system shown in this embodiment can determine whether the welding process meets the requirements through image acquisition and analysis, combined with ultrasonic detection and analysis. It is equipped with a robotic arm for welding, which can accurately control the precision during the welding process. Through two DC power supplies, it can supply power to different types of welding objects and at the same time meet the power supply requirements for the robotic arm to be used as a backup for each other. One of the improvement points of this embodiment is that through three steering gears with different directions and types, the precision of the rotation direction of the robotic arm is satisfied. In cooperation with the first connecting rod, the second connecting rod, and the rotatable welding installation component, the welding strip can be flexibly switched, and it is ensured that the data acquisition module can accurately and timely collect the required data. Two DC power supplies that can be matched with the welding machine are set, so that it can be adaptively adjusted and matched according to the requirements of the welding machine for different types of power supplies, and the power supply requirements of the robotic arm are met. Another improvement of this embodiment is that it can judge the welding result through dual signals of images and ultrasonic waves, and adjust the power supply of the welding machine and the precision of the moving position according to the judgment result, improving the intelligence of the welding system and at the same time enabling timely verification of the welding result. Another improvement point of this embodiment is that two different types of power supplies are set, and they respectively correspond to two different types of conversion units, which can meet the stability of the output of different types of DC power supplies. The output of the second power supply module is adjusted in two key steps. The first key step is to set the weight ratio of the two DC power supplies according to the welding requirements and the characteristics of different DC power supplies. The second key step is to adjust and control the control signals of the conversion units of each power supply within the threshold range of the weight ratio of the two DC power supplies according to the results of camera and ultrasonic detection, so that the conversion unit can meet the requirements for adjusting the welding machine after the acquisition module collects the signals. One of the improvement points of this embodiment is that two DC power supplies that can be matched with the welding machine are set, so that it can be adaptively adjusted and matched according to the requirements of the welding machine for different types of power supplies, and the output precision and accuracy of the DC power supply can be adjusted by adjusting the output signal.

Claims

1. An intelligent welding system, characterized in that, the system includes a data acquisition module, an intelligent control module and a first power supply module. The intelligent control module includes a data operation unit, an output control unit, a data transmission unit and a server; the data acquisition module transmits data to the data operation unit of the intelligent control module through a transmission line. After analyzing and processing the data, the data operation unit uploads the data to the server and transmits it to the output control unit through the data transmission unit respectively. The output control unit outputs a control signal to control the first power supply module to stably supply electric energy. The first power supply module includes two DC power supplies, conversion units corresponding to the two DC power supplies, and at least two output adjustment units; the output control unit includes an initialization unit, a data analysis and verification unit, a control signal limiting unit and a control signal adjustment unit. The initialization unit is used to analyze and calculate the first parameter of the corresponding welding requirement according to the welding requirement transmitted from the server through the data operation unit; the data analysis and verification unit is used to call the surface image information of the welding object collected by the camera and ultrasonic wave of the acquisition module and the ultrasonic detection result through the data operation unit, determine the material of the welding object according to the surface image information, and determine the state of the welding position according to the ultrasonic detection result. The data operation unit verifies whether the first parameter meets the welding machine requirements according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit; the control signal limiting unit is used to set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2 when receiving the first parameter, and generate a first threshold range of the control signal for controlling the first conversion unit and a second threshold range of the control signal for controlling the second conversion unit according to the weight ratio; the control signal adjustment unit is used to adjust the control signal of the first conversion unit within the first threshold range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion unit within the second threshold range according to the surface image information and the ultrasonic detection result; the output control unit can set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and meet different welding requirements by setting the weight ratio; the first power supply module includes: a DC power supply VDC1 and a DC power supply VDC2. The DC power supply VDC1 is correspondingly connected to a first conversion unit, and the DC power supply VDC2 is correspondingly connected to a second conversion unit; both the first conversion unit and the second conversion unit have at least two outputs, each output is connected to a welding torch, and the output ends of the first conversion unit and the second conversion unit are connected in series; The positive electrode of the DC power supply VDC1 is connected to the first end of the capacitor C1 and the first non-controllable end of the switching transistor S1. The second end of the capacitor C1 is connected to the first end of the capacitor C2, the primary side homonymous end of the transformer T1, and the primary side heteronymous end of the transformer T2. The second end of the capacitor C2 is connected to the negative electrode of the battery. The second non-controllable end of the switching transistor S1 is connected to the first end of the inductor LIK1 and the first non-controllable end of the switching transistor S3. The second non-controllable end of the switching transistor S3 is connected to the first end of the capacitor Cr. The second end of the capacitor Cr is connected to the first non-controllable end of the switching transistor S2 and the second end of the inductor LIK2. The second end of the inductor LIK1 is connected to the primary side heteronymous end of the transformer T1. The secondary side homonymous end of the transformer T1 is used as the first output terminal and is connected to the anode of the diode D1. The secondary side heteronymous end of the transformer T1 is used as the second output terminal. The primary side homonymous end of the transformer T2 is connected to the first end of the inductor LIK2. The second non-controllable end of the switching transistor S2 is connected to the negative electrode of the DC power supply VDC1. The secondary side homonymous end of the transformer T2 is used as the first output terminal and is connected to the anode of the diode D2. The secondary side heteronymous end of the transformer T2 is used as the second output terminal. The cathodes of the diode D1 and the diode D2 are connected to form a parallel output; the parallel output formed by connecting the cathodes of the diode D1 and the diode D2 is connected to the anodes of the diode D3 and the diode D4. The cathode of the diode D3 is connected to the first non-controllable end of the switching transistor S4. The second non-controllable end of the switching transistor S4 is connected to the first end of the capacitor Co1 and the first end of the first welding torch. The second end of the capacitor Co1 is connected to the second output terminal of the transformer T1-T2. The cathode of the diode D4 is connected to the first non-controllable end of the switching transistor S5. The second non-controllable end of the switching transistor S5 is connected to the first end of the capacitor Co2 and the first end of the second welding torch. The second end of the capacitor Co2 is connected to the second output terminal of the transformer T1-T2. The positive electrode of the DC power supply VDC2 is connected to the first non-controllable end of the switching transistor S6 and the first non-controllable end of the switching transistor S8. The second non-controllable end of the switching transistor S6 is connected to the cathode of the diode Db2, the cathode of the diode DL2, and the first end of the inductor L2. The second end of the inductor L2 is connected to the second non-controllable end of the switching transistor S7, the second output terminal of the transformer T1-T2, the first end of the capacitor Cb2, and the second end of the capacitor Co2. The first non-controllable end of the switching transistor S7 is connected to the anode of the diode DL2. The second end of the capacitor Cb2 is connected to the second end of the second welding torch;The second non-controllable terminal of switch tube S8 is connected to the cathode of diode Db1, the cathode of diode DL1, and the first end of inductor L1. The second end of inductor L1 is connected to the second non-controllable terminal of switch tube S9, the second output terminal of transformer T1-T2, the first end of capacitor Cb1, and the second end of capacitor Co1. The first non-controllable terminal of switch tube S9 is connected to the anode of diode DL1. The second end of capacitor Cb1 is connected to the second end of the first welding torch.; 2. The intelligent welding system according to claim 1, characterized in that, The data acquisition module includes a camera and ultrasonic waves. The camera is used to collect surface image information of the welding position of the welding torch, and the ultrasonic waves are used to perform ultrasonic detection on the welding position of the welding torch to obtain ultrasonic detection results, and both the surface image information and the ultrasonic detection results are sent to the intelligent control module.

3. The intelligent welding system according to claim 2, wherein, the intelligent control module is configured to receive the surface image information of the welding position and the ultrasonic detection results collected by the data acquisition module, and respectively analyze and process the surface image information and the ultrasonic detection results through the data operation unit, and determine whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, then determine whether the ultrasonic detection results meet the requirements. If the ultrasonic detection results also meet the requirements, the control signal of the current first power supply module remains unchanged; if at least one of the surface image information and the ultrasonic detection results does not meet the requirements, collect the output current and voltage information of the first power supply module, check whether the output current and voltage information meet the preset current and voltage requirements. If there is a deviation, adjust the control signal of the first power supply module. If there is no deviation, check the movement accuracy of the welding torch of the intelligent welding system.

4. The intelligent welding system according to claim 3, wherein, the DC power supply VDC1 includes an energy storage battery, and the DC power supply VDC2 includes a super capacitor.

5. An intelligent control method based on the intelligent welding system according to claim 4, wherein, The method includes the following steps: S1. According to the welding requirements transmitted from the server by the data operation unit, analyze and calculate the first parameter corresponding to the welding requirements; S2. Call the surface image information and ultrasonic detection results of the welding object collected by the camera and ultrasonic wave of the acquisition module through the data operation unit, determine the material of the welding object according to the surface image information, and determine the state of the welding position according to the ultrasonic detection result. The data operation unit checks whether the first parameter meets the requirements of the welding machine according to the material of the welding object and the state of the welding position. If it meets the requirements, the first parameter is transmitted to the output control unit; S3. When receiving the first parameter, first set the weight ratio of the outputs of the DC power supply VDC1 and the DC power supply VDC2, and generate a first threshold range of the control signal for controlling the first conversion unit and a second threshold range of the control signal for controlling the second conversion unit according to the weight ratio; S4. The intelligent control module is used to receive the surface image information of the welding position and the ultrasonic detection result collected by the data acquisition module, and respectively analyze and process the surface image information and the ultrasonic detection result through the data operation unit, and judge whether the surface image information of the welding position meets the welding requirements. If the surface image information meets the requirements, judge whether the ultrasonic detection result meets the requirements. If the ultrasonic detection result also meets the requirements, keep the control signal of the current first power supply module unchanged; If at least one of the surface image information and the ultrasonic detection result does not meet the requirements, collect the output current and voltage information of the first power supply module, check whether the output current and voltage information meet the preset current and voltage requirements. If there is a deviation, adjust the control signal of the first power supply module. If there is no deviation, check the moving position of the welding torch of the intelligent welding system; adjust the control signal of the first conversion unit within the first threshold range according to the surface image information and the ultrasonic detection result, and adjust the control signal of the second conversion unit within the second threshold range according to the surface image information and the ultrasonic detection result.

Images