A welding process with multiple budgets

Abstract

The present invention provides a multi-point budget welding process, comprising step S1, obtaining an image of a to-be-welded location as an image to be analyzed by a visual detector; step S2, establishing a three-dimensional coordinate system, and calculating the angle of the to-be-welded location between two workpieces as a workpiece angle value; step S3, obtaining a weld data value during welding with a welding gun and a to-be-welded depth value of the to-be-welded location, and calculating a to-be-welded layer value according to the weld data value and the to-be-welded depth value through a ratio formula; step S4, calculating the distance between the two workpieces at each welding location as a workpiece to-be-welded distance value, and then calculating the number of weld passes at each welding location as a layer weld pass value according to the weld data value and the to-be-welded distance value through a ratio formula; step S5, planning the coordinates of each point of each weld pass, connecting the coordinates of each point to obtain a weld pass trajectory of the welding gun, and performing motion welding according to the weld pass trajectory; the present invention has the advantage of being able to accurately analyze and find welding points according to the conditions of the welding location for efficient welding.

Description

Technical Field

[0001] The present invention relates to the field of welding technology, and more particularly to a multi-point budget welding process. Background Art

[0002] Welding is a manufacturing process that uses heating, high temperature or high pressure to join metals or other thermoplastic materials. Current welding methods include gas flame, arc, laser, electron beam, friction and ultrasonic, etc., and the above welding is mainly completed by manual operation. Some manufacturers also use automated equipment to complete welding, but manual welding mainly relies on work experience, which varies from person to person. The welding efficiency is low, the cost is high, and welding can cause certain harm to the human body. The linear welding or weaving welding in the existing automated welding are all achieved by structural intervention. The welding gun always moves in a certain position, and it is impossible to achieve accurate positioning of the welding or automatic identification of the welding. The welding quality is low, the welds are seriously stacked, there is too much waste of welding wire, the welds at the cut or metal joints are not firm, and so on. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the purpose of the present invention is to provide a multi-point budget welding process, which can accurately analyze the conditions of the welding point and find the welding point for efficient welding.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] A multi-point budget welding process includes the following steps:

[0006] Step S1: obtaining an image of the welded area through a visual detector as an image to be analyzed;

[0007] Step S2: establishing a three-dimensional coordinate system, and calculating the angle between the two workpieces to be welded as the workpiece angle value in the three-dimensional coordinate system using a trigonometric function formula based on the image to be analyzed;

[0008] Step S3, obtaining the weld data value during welding with the welding gun and the depth value of the weld to be welded, and calculating the value of the layer to be welded by a ratio formula based on the weld data value and the depth value of the weld to be welded;

[0009] In step S4, the distance between the two workpieces at each welding layer is calculated according to the value of the layer to be welded and the workpiece angle value according to the three-dimensional coordinate system as the workpiece welding distance value, and the number of weld passes at each welding layer is calculated according to the weld seam data value and the workpiece welding distance value by a ratio formula as the layer welding pass value;

[0010] In step S5, the coordinates of each point of each weld bead are planned in a three-dimensional coordinate system according to the hierarchical weld bead value, and a weld bead trajectory of the welding gun is obtained by connecting the coordinates of each point. The welding gun performs moving welding according to the weld bead trajectory.

[0011] Furthermore, the coordinates of each point of each weld bead include a starting point coordinate and an end point coordinate, and a line connecting the starting point coordinate and the end point coordinate constitutes a linear welding gun trajectory.

[0012] Furthermore, the S5 step also includes the S51 step. In the S51 step, the connection between the two workpieces is the initial layer, and the initial layer is sequentially superimposed and welded to form a lap weld layer. After the welding gun completes the welding of the initial layer, it moves upward to the lap weld layer for welding, and after the welding gun completes each weld track, it transfers to another weld track in an I-shape.

[0013] Furthermore, the S5 step also includes an S52 step. In the S52 step, when the hierarchical weld bead value is an integer, the welding gun performs welding according to a linear welding gun trajectory. When the hierarchical weld bead value is a decimal, the coordinates of each point of each weld bead also include a number of inflection point coordinates, and the several inflection point coordinates are located between the starting point coordinates and the end point coordinates. The starting point coordinates, the end point coordinates and the several inflection point coordinates are connected in sequence to form a broken line swing welding trajectory, and the welding gun performs motion welding according to the swing welding trajectory.

[0014] Furthermore, the distance between the coordinates of two adjacent inflection points on the same side of the weaving welding trajectory is smaller than the weld seam data value, and the coordinates of each inflection point are staggered with each other.

[0015] Furthermore, the distance between the weld tracks on each weld surface is less than half of the weld seam data value of the welding gun.

[0016] Furthermore, step S6 is included, in which the image of each layer after the welding gun completes the welding of each layer according to the weld track is obtained through a visual detector as a comparison image, the weld depth of the layer is calculated in a three-dimensional coordinate system according to the comparison image as the actual weld depth value, the welding layer number feedback value is obtained by calculating the ratio formula according to the actual weld depth value and the depth value to be welded, and then the layer weld value and the coordinates of each point of each weld are recalculated according to the weld layer feedback value.

[0017] Furthermore, the S6 step also includes an S61 step. In the S61 step, an image of the weld after the welding gun completes each weld according to the weld trajectory is obtained through a visual detector as a comparison image, and the diameter of the weld is calculated in a three-dimensional coordinate system according to the comparison image as an actual weld diameter value. A weld number feedback value is obtained by calculating the actual weld diameter value and the distance to be welded through a ratio formula, and then the hierarchical weld value and the coordinates of each point of each weld are recalculated according to the weld number feedback value.

[0018] Furthermore, the weld data value includes a weld depth value and a weld diameter value, the weld depth value reflects the thickness of the weld during welding with a welding gun, and the weld diameter value reflects the coverage width of the weld during welding with a welding gun. The weld data value is also included in step S7, in which the weld data value table is revised according to the actual weld depth value and the actual weld diameter value.

[0019] Furthermore, the S7 step also includes an S71 step. In the S71 step, the table revision includes a main page and multiple sub-pages. The main page and the multiple sub-pages all contain voltage information, current information and speed information that correspond to each other one by one. The voltage information reflects the input voltage value of the welding gun, the current information reflects the input current value of the welding gun, and the speed information reflects the moving speed value of the welding gun during welding. The information in the sub-page is replaced according to the actual weld depth value and the actual weld diameter value, and the sub-pages with similar data are analyzed and statistics are performed to obtain the average values of each item. The average values of each item are entered into the main page as the weld data reference page of the welding gun.

[0020] The beneficial effects of the present invention are as follows: through image acquisition and the coordination of the three-dimensional coordinate system, the welding point can be mapped in the three-dimensional coordinate system, and then by comparing the requirements of the welding data and the output weld data of the welding gun, the welding trajectory and the number of weld passes can be planned quickly and accurately, which is beneficial to the welding efficiency of the welding gun and can avoid excessive waste of welding wire to the greatest extent. Specifically, by visually judging the welding surface angle between the two workpieces and the three-dimensional coordinate data, and then by the depth and width of the weld when the welding gun is output, the number of welding layers required and the number of weld passes for each layer can be calculated, and the welding trajectory of the planned welding gun can be reflected. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is a flow chart of the steps of the present invention;

[0022] Figure 2 It is the three-dimensional coordinate diagram of the workpiece welding in the present invention;

[0023] Figure 3 It is the welding point budget diagram in the present invention;

[0024] Figure 4 It is a planning diagram of the weaving welding trajectory in the present invention. DETAILED DESCRIPTION

[0025] The present invention will be described in further detail below with reference to the accompanying drawings and embodiments. Identical components are denoted by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, and the terms "bottom," "top," "inner," and "outer" refer to directions toward or away from the geometric center of a particular component, respectively.

[0026] Since welding is currently mainly done by manual operation, some manufacturers also use automated equipment to complete welding, but manual welding mainly relies on work experience, which varies from person to person, has low welding efficiency, high cost, and welding can cause certain harm to the human body. The linear welding or oscillating welding in existing automated welding are all achieved by structural intervention, and the welding gun always moves in a certain position, which cannot achieve accurate positioning of the welding or automatic identification of welding, resulting in low welding quality, serious weld stacking, excessive waste of welding wire, and weak welds at the cut or metal joints. Therefore, the present invention designs this multi-point budget welding process, such as Figure 1 As shown, the following steps are included:

[0027] Step S1: obtaining an image of the welded area through a visual detector as an image to be analyzed;

[0028] In step S2, a three-dimensional coordinate system is established, and the angle between the two workpieces to be welded is calculated in the three-dimensional coordinate system using trigonometric functions according to the image to be analyzed as the workpiece angle value;

[0029] Step S3: obtaining the weld data value during welding with the welding gun and the depth value of the weld to be welded, and calculating the value of the weld layer by using a ratio formula based on the weld data value and the depth value of the weld to be welded;

[0030] In step S4, the distance between the two workpieces at each welding layer is calculated based on the value of the layer to be welded and the workpiece angle value according to the three-dimensional coordinate system as the workpiece welding distance value, and the number of weld passes at each welding layer is calculated based on the weld seam data value and the workpiece welding distance value using a ratio formula as the layer welding pass value;

[0031] In step S5, the coordinates of each point of each weld bead are planned in a three-dimensional coordinate system according to the hierarchical weld bead value, and the weld bead trajectory of the welding gun is obtained by connecting the coordinates of each point. The welding gun performs moving welding according to the weld bead trajectory.

[0032] For example: Figure 2As shown, the image of the connection between the two workpieces is taken by the camera as the image to be analyzed, and a three-dimensional coordinate system is established in the image to be analyzed, and several points on the panels of the two workpieces are projected in the three-dimensional coordinate system. The angle between the two workpieces can be calculated through the two corresponding coordinate points on the two workpieces. The depth and width of the weld when the welding gun is welded and the overall depth of the weld required by the user are obtained in the early stage, and the number of layers that the welding gun needs to weld can be calculated. Then, according to the angle between the two workpieces, the width of each welding layer can be calculated, and the number of welds required for each welding layer can be calculated. Finally, according to the determined number of welding passes, the coordinates of each point of each welding pass can be planned, and finally the welding trajectory of the welding gun is obtained by connecting the lines. Specifically, for example: the coordinates of point w on the first workpiece in the image to be analyzed and the coordinates of point w' on the second workpiece are obtained, where the coordinates of point w are (X1, 0, Z1), the coordinates of point w' are (X2, 0, Z2), and the angle between the first workpiece and the vertical plane is The angle between the second workpiece and the horizontal plane is The angle between the first workpiece and the second workpiece is θ=θ1+(90-θ2). The weld depth obtained in the previous welding process is h1, and the width is r1. The overall welding depth required by the user is H1, and the number of layers required to be welded is H1 / h1. Assuming that Figure 2 As shown in Figure 3 (Q1, Q2 and Q3), the first layer does not need to calculate the number of welding passes of the welding gun, because the first layer is the intersection of the first workpiece and the second workpiece, which is a straight line. Therefore, the first layer only needs to weld the welding gun along the straight line of the intersection. When the first layer is welded to the second layer, the width of the second layer needs to be calculated as R1 based on the angle between the two workpieces. The number of welding passes of the second layer welding gun can be calculated as R1 / r1. Finally, according to the number of welding passes, the points where the welding gun moves can be accurately estimated and the welding trajectory of the welding gun can be obtained by connecting them. The beneficial effects are: through image acquisition and three-dimensional coordinate system The welding point can be mapped in a three-dimensional coordinate system by means of the cooperation, and then the welding data requirements and the output weld data of the welding gun are compared. Compared with the existing manual welding and automatic welding, the automatic welding method of the present invention can quickly and accurately plan the welding trajectory and the number of weld passes, which is beneficial to the welding efficiency of the welding gun and can avoid excessive waste of welding wire to the greatest extent. Specifically, the welding surface angle between the two workpieces and the three-dimensional coordinate data are visually judged, and the depth and width of the weld when the welding gun is output can be used to calculate the number of welding layers and the number of passes for each layer, and can also reflect the planning of the welding trajectory of the welding gun.

[0033] The coordinates of each point of each weld bead include the coordinates of the starting point and the coordinates of the end point, and the line connecting the coordinates of the starting point and the coordinates of the end point constitutes a straight welding gun track; step S5 also includes step S51, in which the connection between the two workpieces is the initial layer, and the initial layer is welded in sequence as a lap welding layer. After the welding gun completes the welding of the initial layer, it moves upward to the lap welding layer for welding, and after completing each weld track, the welding gun is transferred to another weld track in an I-shape. Specifically, Figure 3 As shown in the figure, the starting point of the first layer of weld is point a, and the end point is point b. The line connecting point a and point b is the straight welding track of the welding gun welding the first layer. When the first layer is welded, the welding gun moves upward to point c of the second layer. Point c is the starting point of the first pass of the second layer, and point d is the end point of the second pass of the second layer. The line connecting point c and point d is the welding of the second pass of the welding gun. The welding gun moves from the first layer welding to the second layer first pass welding. The weld track is an "I" shape attached to the first workpiece surface. When the second layer is welded, the welding gun moves upward to point c of the second layer. After the first pass is completed, the welding gun moves to one side to point e, and point e is the starting point of the second pass of the second layer. Point f is found, and point f is the end point of the second pass of the second layer. The line connecting point e and point f is the third pass of the welding gun. The welding gun moves from the first pass of the second layer to the second pass of the second layer. The weld trajectory is an "I" shape sticking to the second layer. The welding gun forms an "I" shape when changing lanes. This is mainly to avoid the welding gun from swinging back to one side after completing one weld and then welding to the other side, thereby reducing the time spent on welding.

[0034] like Figure 4 As shown, step S5 also includes step S52. In step S52, when the level weld bead value is an integer, the welding gun welds according to a linear welding gun trajectory. When the level weld bead value is a decimal, the coordinates of each point of each weld bead also include a number of inflection point coordinates, and the several inflection point coordinates are located between the starting point coordinates and the end point coordinates. The starting point coordinates, the end point coordinates and the several inflection point coordinates are sequentially connected to form a broken line swing welding trajectory. The welding gun performs motion welding according to the swing welding trajectory. The distance between the two adjacent inflection point coordinates on the same side of the swing welding trajectory is less than the weld data value, and each inflection point coordinate is staggered. The distance between the weld bead tracks on each layer of the weld bead surface is less than half of the weld data value of the welding gun. For example, the width of the third layer is R3, and the width of the welding gun weld is r1. In order to make the welding more firm, more than 50% of the two adjacent welds need to overlap each other. Therefore, the number of welds required for the third layer is 2(R1-r1) / r1. If the calculated value is an integer, according to Figure 3 For straight line welding, if the calculated number is a decimal, then Figure 4 As shown in A, there is a distance β in the middle that is smaller than the adjacent α. Therefore, in order to avoid welding waste, it is necessary to change to swing welding. The third layer is directly planned into several evenly distributed passes (T). The swing point of the welding gun is found on each weld pass, as shown in Figure 4In B, find a' as the starting point, b' as the first swing point, and c' as the second swing point. The welding gun welds according to the sequence of the points to obtain an arc or broken line welding trajectory, and completes automated and efficient welding.

[0035] The step S6 also includes a step S6, in which a visual detector is used to obtain an image of each layer after the welding gun completes the welding of each layer according to the weld track as a comparison image, and the weld depth of the layer is calculated in a three-dimensional coordinate system according to the comparison image as the actual weld depth value, and a welding layer number feedback value is obtained by calculating the ratio formula according to the actual weld depth value and the depth value to be welded, and then the layer weld value and the coordinates of each point of each weld are recalculated according to the weld layer feedback value; further, the step S6 also includes a step S61, and the step S61 is used to obtain an image of the weld after the welding gun completes the welding of each layer according to the weld track as a comparison image, and the diameter of the weld is calculated in a three-dimensional coordinate system according to the comparison image as the actual weld diameter value, and the actual weld diameter is calculated according to the actual weld diameter. The value and the distance to be welded are calculated through the ratio formula to obtain the weld pass number feedback value, and then the layer weld pass value and the coordinates of each point of each weld pass are recalculated according to the weld pass number feedback value. Due to the large number of factors of welding gun input, the width and depth of the weld welded by the welding gun in different scenarios will have certain deviations. Before welding, the system can estimate the number of welding layers and the number of weld passes of each layer in the three-dimensional coordinate system according to the image. However, if the weld size deviates from the weld size preset in the system, feedback is required. When the welding gun welds each pass, it is necessary to take a picture with the camera to calculate the actual width and depth of the weld to compare with the preset data, and then re-correct the number of welding layers and weld passes to complete precise welding.

[0036] The weld data value includes a weld depth value and a weld diameter value. The weld depth value reflects the thickness of the weld when the welding gun is welding, and the weld diameter value reflects the coverage width of the weld when the welding gun is welding. The step S7 is also included. In the step S7, the weld data value is revised in a table according to the actual weld depth value and the actual weld diameter value. The step S7 also includes a step S71. In the step S71, the table revision includes a main page and multiple sub-pages. The main page and the multiple sub-pages each contain voltage information, current information and speed information that correspond to each other one by one. The voltage information reflects the input voltage value of the welding gun, the current information reflects the input current value of the welding gun, and the speed information reflects the moving speed value of the welding gun when welding. According to the actual weld depth value and the actual weld diameter value, the information in the sub-page is replaced with data. The sub-pages with similar data are analyzed and statistics are performed to obtain the average values of each item. The average values of each item are input into the main page as the weld data reference page of the welding gun. The purpose is to more accurately correspond to the input and output of the welding gun in the system to achieve more accurate data when the welding gun is welding. The optimization of the main page can achieve accurate and efficient welding of the welding gun.

[0037] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions based on the principles of the present invention are within the scope of protection of the present invention. It should be noted that improvements and modifications that do not depart from the principles of the present invention are within the scope of protection of the present invention.

Claims

1. A multi-point budget welding process, characterized by: The following steps are involved: Step S1: obtaining an image of the welded area through a visual detector as an image to be analyzed; Step S2: establishing a three-dimensional coordinate system, and calculating the angle between the two workpieces to be welded as the workpiece angle value in the three-dimensional coordinate system using a trigonometric function formula based on the image to be analyzed; Step S3: obtaining weld data values during welding with a welding gun and obtaining a depth value of the weld to be welded, and calculating a value of the layer to be welded based on the weld data values and the depth value of the weld to be welded by a ratio formula, wherein the weld data values include a weld depth value and a weld diameter value, wherein the weld depth value reflects the thickness of the weld during welding with a welding gun, and the weld diameter value reflects the coverage width of the weld during welding with a welding gun; In step S4, the distance between the two workpieces at each welding layer is calculated according to the value of the layer to be welded and the workpiece angle value according to the three-dimensional coordinate system as the workpiece welding distance value, and the number of weld passes at each welding layer is calculated according to the weld seam data value and the workpiece welding distance value by a ratio formula as the layer welding pass value; In step S5, coordinates of each point of each weld bead are planned in a three-dimensional coordinate system according to the hierarchical weld bead values, a weld bead trajectory of a welding gun is obtained by connecting the coordinates of each point, and the welding gun performs moving welding according to the weld bead trajectory; The step S5 further includes a step S51, in which the connection between the two workpieces is an initial layer, the initial layer is sequentially superimposed and welded to form a stitching layer, the welding gun moves upward to the stitching layer after completing the welding of the initial layer, and the welding gun moves in an I-shape to another welding track after completing each weld track; The S5 step also includes an S52 step. In the S52 step, when the hierarchical weld bead value is an integer, the welding gun performs welding according to a linear welding gun trajectory. When the hierarchical weld bead value is a decimal, the coordinates of each point of each weld bead also include a plurality of inflection point coordinates, and the plurality of inflection point coordinates are located between the starting point coordinates and the end point coordinates. The starting point coordinates, the end point coordinates and the plurality of inflection point coordinates are sequentially connected to form a zigzag oscillating welding trajectory, and the welding gun performs motion welding according to the oscillating welding trajectory.

2. A multi-point budget welding process according to claim 1, characterized in that: The coordinates of each point of each weld bead include a starting point coordinate and an end point coordinate, and a line connecting the starting point coordinate and the end point coordinate constitutes a linear welding gun trajectory.

3. The multi-point budget welding process according to claim 1, characterized in that: The distance between the coordinates of two adjacent inflection points on the same side of the weaving welding track is smaller than the weld seam data value, and the coordinates of each inflection point are staggered with each other.

4. A multi-point budget welding process according to claim 1 or 2, characterized in that: The distance between the weld tracks on each weld surface is less than half of the weld data value of the welding gun.

5. The multi-point budget welding process according to claim 1, characterized in that: It also includes step S6, in which the image of each layer after the welding gun completes the welding of the layer according to the weld track is obtained through a visual detector as a comparison image, the weld depth of the layer is calculated in a three-dimensional coordinate system according to the comparison image as the actual weld depth value, the welding layer number feedback value is obtained by calculating the ratio formula according to the actual weld depth value and the depth value to be welded, and then the layer weld value and the coordinates of each point of each weld are recalculated according to the weld layer feedback value.

6. The multi-point budget welding process according to claim 5, characterized in that: The step S6 also includes a step S61. In the step S61, an image of the weld after the welding gun completes each weld according to the weld trajectory is obtained through a visual detector as a comparison image, and the diameter of the weld is calculated in a three-dimensional coordinate system according to the comparison image as an actual weld diameter value. A weld number feedback value is obtained by calculating the actual weld diameter value and the distance to be welded through a ratio formula, and then the hierarchical weld value and the coordinates of each point of each weld are recalculated according to the weld number feedback value.

7. The multi-point budget welding process according to claim 6, characterized in that: The method further includes step S7, in which the table of weld data values is revised according to the actual weld depth value and the actual weld diameter value.

8. The multi-point budget welding process according to claim 7, characterized in that: The step S7 also includes a step S71. In the step S71, the table revision includes a main page and multiple sub-pages. The main page and the multiple sub-pages all contain voltage information, current information and speed information that correspond to each other. The voltage information reflects the input voltage value of the welding gun, the current information reflects the input current value of the welding gun, and the speed information reflects the moving speed value of the welding gun during welding. The information in the sub-page is replaced according to the actual weld depth value and the actual weld diameter value. The sub-pages with similar data are analyzed and statistics are performed to obtain the average values of each item. The average values of each item are input into the main page as the weld data reference page of the welding gun.

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