Intelligent control method for induction brazing of multi-strand pure aluminum flat wire

Abstract

The present application provides a welding intelligent control method for multi-strand pure aluminum flat wire induction brazing, which respectively carries out infrared and visible light shooting on the brazing area of the multi-strand pure aluminum flat wire for completing the current brazing operation, analyzes the obtained brazing area infrared image and visible light image, generates the temperature state atlas and crack state atlas of the brazing area, thereby uniformly and accurately calibrating the brazing filler metal temperature distribution and surface crack distribution of the brazing area; the temperature state atlas and the crack state atlas are correlated to determine the relationship between the brazing filler metal temperature and the surface crack in the brazing area, to judge whether the brazing needs to be continuously carried out to eliminate the original crack, and meanwhile, the operation position for continuously carrying out the brazing is calibrated, so as to accurately fill the brazing filler metal to the crack in the subsequent process and effectively save the brazing filler metal consumption, and the brazing quality of the multi-strand pure aluminum flat wire is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding processing, and particularly relates to a welding intelligent control method for multi-strand pure aluminum flat wire induction brazing. BACKGROUND

[0002] Brazing is to use a metal with a lower melting point than the base material as a filler metal, heat and melt the filler metal, and then use the liquid filler metal to wet the base material, fill the joint gap and diffuse with the base material, so as to connect the welding parts together. When the brazing operation is completed, the liquid filler metal will gradually cool down to realize solidification connection with the base material. However, due to the influence of whether the liquid filler metal completely fills the joint gap and the cooling and solidification speed of the liquid filler metal itself, cracks will inevitably appear in the brazing area where the filler metal is located. The number and distribution of cracks will directly affect the mechanical strength of the brazing area. Generally speaking, the more cracks or the more widely distributed, the worse the mechanical strength of the brazing area, at which time the brazing area needs to be brazed again to eliminate the original crack defects. The existing technology usually judges whether to continue brazing according to the brazing experience and visual results of the operator, which not only reduces the quality of brazing and increases the workload of brazing operation, but also cannot accurately eliminate the crack defects and reduce the connection stability of brazing. SUMMARY

[0003] In view of the defects in the prior art, the present application provides a welding intelligent control method for multi-strand pure aluminum flat wire induction brazing, which respectively captures infrared and visible light images of the brazing area of the multi-strand pure aluminum flat wire after the current brazing operation is completed, analyzes the obtained brazing area infrared image and visible light image, generates a temperature state atlas and a crack state atlas of the brazing area, so as to uniformly and accurately calibrate the filler metal temperature distribution and surface crack distribution of the brazing area; correlate the temperature state atlas and the crack state atlas to determine the relationship between the filler metal temperature and the surface crack in the brazing area, judge whether to continue brazing to eliminate the original crack, and at the same time calibrate the operation position of the continued brazing to ensure accurate filler metal filling of the crack and effective saving of the filler metal amount in the subsequent operation; further analyze the operation process image of the continued brazing operation to adjust the operation state of the brazing operation, ensure the reliability of the continued brazing operation, and improve the brazing quality of the multi-strand pure aluminum flat wire.

[0004] The present application provides a welding intelligent control method for multi-strand pure aluminum flat wire induction brazing, which comprises the following steps:

[0005] Step S1, infrared images of the brazing area of the multi-strand pure aluminum flat wire after the current brazing operation is completed are collected, the brazing area infrared images are analyzed, and the temperature attribute information of the brazing area is obtained; according to the temperature attribute information, a temperature state atlas of the brazing area is generated;

[0006] Step S2, collect the visible light image of the brazing area of the plurality of pure aluminum flat wires after the current brazing operation is completed, analyze the visible light image of the brazing area to obtain the crack characteristic information of the brazing area, and generate a crack state atlas of the brazing area according to the crack characteristic information;

[0007] Step S3, perform correlation processing on the temperature state atlas and the crack state atlas to determine whether the brazing operation is allowed to continue at the current time; if so, determine the operation position for continuing the brazing operation according to the temperature state atlas and the crack state atlas.

[0008] Step S4, collect the operation process image of the brazing operation, analyze the operation process image to adjust the operation state of the brazing operation.

[0009] Further, in the step S1, the infrared image of the brazing area of the plurality of pure aluminum flat wires after the current brazing operation is completed is collected, the infrared image of the brazing area is analyzed to obtain the temperature attribute information of the brazing area, including:

[0010] When the plurality of pure aluminum flat wires completes the current brazing operation, the brazing area for infrared shooting of the plurality of pure aluminum flat wires is calibrated in the three-dimensional space based on the brazing material coverage range formed by the current brazing operation, and the brazing area is subjected to thermal infrared imaging to obtain the thermal infrared image of the brazing area.

[0011] The thermal infrared image of the brazing area is analyzed to obtain the temperature field distribution attribute information of the brazing area; wherein the temperature field distribution attribute information includes the isotherm distribution information of the surface of the brazing area.

[0012] Further, in the step S1, a temperature state atlas of the brazing area is generated according to the temperature attribute information, including:

[0013] The isotherm distribution information contained in the temperature field distribution attribute information is mapped to the plane coordinate system corresponding to the surface of the brazing area to obtain the position information of each isotherm on the surface of the brazing area, and a correlation reference atlas between the temperature value of each isotherm and the corresponding position information is constructed, which is used as the temperature state atlas of the brazing area.

[0014] Further, in the step S2, the visible light image of the brazing area of the plurality of pure aluminum flat wires after the current brazing operation is completed is collected, the visible light image of the brazing area is analyzed to obtain the crack characteristic information of the brazing area, including:

[0015] When the multiple pure aluminum flat wires complete the current brazing operation, the brazing area for visible light shooting of the multiple pure aluminum flat wires is calibrated in three-dimensional space based on the brazing filler metal coverage range formed by the current brazing operation; visible light imaging is performed on the brazing area to obtain a brazing area visible light image;

[0016] Pixel texture recognition processing is performed on the brazing area visible light image to obtain crack feature information of the brazing area; wherein the crack feature information includes crack shape and size information of the brazing surface.

[0017] Further, in the step S2, according to the crack feature information, a crack state atlas about the brazing area is generated, including:

[0018] The crack shape and size information contained in the crack feature information is mapped into the plane coordinate system corresponding to the brazing area surface to obtain the position information of all cracks on the brazing area surface, and an associated comparison atlas between the shape and size of each crack and its corresponding position information is constructed, which is used as the crack state atlas of the brazing area.

[0019] Further, in the step S3, the temperature state atlas and the crack state atlas are associated and processed to determine whether the brazing operation can continue at present, including:

[0020] The temperature state atlas and the crack state atlas are simultaneously mapped into the surface space corresponding to the brazing area to obtain the existence state information of the cracks in the region between two adjacent isotherms in the brazing area; wherein the existence state information includes the total number of cracks, the total area occupied by the cracks and the crack distribution density;

[0021] According to the existence state information, it is determined whether the brazing operation of the brazing area can continue at present.

[0022] Further, in the step S3, according to the existence state information, it is determined whether the brazing operation of the brazing area can continue at present, including:

[0023] In step S301, according to the total number of cracks and the area occupied by the cracks in the brazing area in the existence state information, the weighted average area occupied by the cracks and the maximum area occupied by the cracks of the brazing area are obtained by using the following formula (1),

[0024]

[0025] In the above formula (1), represents the weighted average area occupied by the cracks of the brazing area; S Mrepresents the maximum area occupied by the cracks; s(i) represents the area occupied by the i-th crack of the brazing area in the existence state information; L(i) represents the crack length of the i-th crack of the brazing area in the existence state information; n represents the total number of cracks of the brazing area in the existence state information; represents the maximum value obtained by bringing the value of i from 1 to n into the parentheses;

[0026] In step S302, the weighted maximum area occupied by the cracks of the brazing area is obtained according to the weighted average area occupied by the cracks of the brazing area and the maximum area occupied by the cracks by using the following formula (2),

[0027]

[0028] In the above formula (2), S0 represents the weighted maximum area occupied by the cracks of the brazing area;

[0029] In step S303, whether the brazing operation of the brazing area can be continued at present is judged according to the weighted area occupied by the cracks of the brazing area and the crack distribution density of the brazing area by using the following formula (3),

[0030]

[0031] In the above formula (3), E represents the control value of whether the brazing operation of the brazing area can be continued at present; s z represents a preset threshold area value; p z represents a preset threshold density value; p0 represents the crack distribution density of the brazing area; F() represents a judgment function, the function value of the judgment function is 1 if the formula in the parentheses is true, and the function value of the judgment function is 0 if the formula in the parentheses is not true;

[0032] If E=1, it is controlled that the brazing operation of the brazing area can be continued at present;

[0033] If E=0, it is controlled that the brazing operation of the brazing area cannot be continued at present.

[0034] Further, in the step S3, the operation position for continuing the brazing operation is determined according to the temperature state map and the crack state map, including:

[0035] If the brazing operation of the brazing area can be continued at present, the crack existence position of the area between two adjacent isotherms in the brazing area and the temperature value of the area between the two adjacent isotherms are extracted from the existence state information, and the filler metal filling position and the filler metal heating temperature for continuing the brazing operation are determined.

[0036] Further, in the step S4, operation process images of the operation of continuing the brazing operation are collected, and the operation process images are analyzed to adjust the operation state of the brazing operation, including:

[0037] Operation process binocular images of the operation of continuing the brazing operation are collected, and operation process three-dimensional images are generated according to the operation process binocular images;

[0038] The relative position relationship between a heating device for heating the brazing filler metal and the operation position is identified from the operation process three-dimensional images, so as to adjust the relative distance of the heating device relative to the operation position.

[0039] Compared with the prior art, the welding intelligent control method for the induction brazing of the multi-strand pure aluminum flat wire can respectively perform infrared and visible light shooting on the brazing area of the multi-strand pure aluminum flat wire for completing the current brazing operation, analyze the obtained brazing area infrared image and visible light image, generate a temperature state atlas and a crack state atlas about the brazing area, and uniformly and accurately calibrate the brazing filler metal temperature distribution and the surface crack distribution of the brazing area; the temperature state atlas and the crack state atlas are associated to determine the relationship between the brazing filler metal temperature and the surface crack in the brazing area, to judge whether the brazing needs to be continued to eliminate the original crack, and to simultaneously calibrate the operation position of continuing the brazing, to ensure that the crack is accurately filled with the brazing filler metal in the subsequent operation and the brazing filler metal consumption is effectively saved; the operation process images of the operation of continuing the brazing operation are analyzed to adjust the operation state of the brazing operation, to ensure the reliability of the operation of continuing the brazing, and to improve the brazing quality of the multi-strand pure aluminum flat wire.

[0040] Additional features and advantages of the application will be set forth in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following or can be learned by practice of the application. The objectives and other advantages of the application can be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

[0041] The technical solutions of the present application will be further described in detail below with the help of the accompanying drawings and examples. BRIEF DESCRIPTION OF DRAWINGS

[0042] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the accompanying drawings needed to be used in the embodiments or the prior art description will be briefly introduced. Obviously, the accompanying drawings in the following description are only some embodiments of the present application, and other accompanying drawings can be obtained by those skilled in the art without any creative effort on the basis of these accompanying drawings.

[0043] Figure 1The application provides a flowchart of a welding intelligent control method for multi-strand pure aluminum flat wire induction brazing. DETAILED DESCRIPTION

[0044] The technical solutions in the embodiments of the application will be clearly and completely described with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the application.

[0045] Reference Figure 1 The application provides a flowchart of a welding intelligent control method for multi-strand pure aluminum flat wire induction brazing. The welding intelligent control method for multi-strand pure aluminum flat wire induction brazing comprises the following steps:

[0046] In step S1, infrared images of brazing areas of multi-strand pure aluminum flat wires after completion of current brazing operation are collected, the infrared images of the brazing areas are analyzed, temperature attribute information of the brazing areas is obtained, and a temperature state atlas of the brazing areas is generated according to the temperature attribute information.

[0047] In step S2, visible light images of the brazing areas of the multi-strand pure aluminum flat wires after completion of the current brazing operation are collected, the visible light images of the brazing areas are analyzed, crack feature information of the brazing areas is obtained, and a crack state atlas of the brazing areas is generated according to the crack feature information.

[0048] In step S3, the temperature state atlas and the crack state atlas are associated, whether the brazing areas are allowed to continue brazing operation currently is judged, if yes, an operation position for continuing brazing operation is determined according to the temperature state atlas and the crack state atlas.

[0049] In step S4, operation process images of the brazing operation are collected, the operation process images are analyzed, and the operation state of the brazing operation is adjusted.

[0050] The beneficial effects of the above technical solution are: the welding intelligent control method for the multi-strand pure aluminum flat wire induction brazing respectively carries out infrared and visible light shooting on the brazing area of the multi-strand pure aluminum flat wire which completes the current brazing operation, analyzes the obtained brazing area infrared image and visible light image, generates the temperature state atlas and the crack state atlas of the brazing area, and accurately calibrates the brazing filler metal temperature distribution and the surface crack distribution of the brazing area; the temperature state atlas and the crack state atlas are associated to determine the relationship between the brazing filler metal temperature and the surface crack in the brazing area, to judge whether the brazing needs to be continued to eliminate the original crack, and to calibrate the operation position of the continued brazing operation to ensure that the subsequent brazing filler metal filling and effective brazing filler metal saving are accurate; the operation process image of the continued brazing operation is also analyzed to adjust the operation state of the brazing operation to ensure the reliability of the continued brazing operation and improve the brazing quality of the multi-strand pure aluminum flat wire.

[0051] Preferably, in the step S1, the brazing area infrared image of the multi-strand pure aluminum flat wire which completes the current brazing operation is collected, and the brazing area infrared image is analyzed to obtain the temperature attribute information of the brazing area, including:

[0052] When the multi-strand pure aluminum flat wire completes the current brazing operation, the brazing area for infrared shooting of the multi-strand pure aluminum flat wire is calibrated in the three-dimensional space based on the brazing filler metal coverage range formed by the current brazing operation; the brazing area is thermally imaged to obtain the brazing area thermal infrared image;

[0053] The brazing area thermal infrared image is analyzed to obtain the temperature field distribution attribute information of the brazing area; wherein the temperature field distribution attribute information includes the isotherm distribution information of the surface of the brazing area.

[0054] The beneficial effects of the above technical solution are: since the brazing filler metal used for brazing is completely different from the material of the pure aluminum flat wire, when the multi-strand pure aluminum flat wire completes the brazing operation, there is a clear visual difference (such as color difference, etc.) between the brazing filler metal covered on the surface of the pure aluminum flat wire and the surface of the pure aluminum flat wire. According to the visual difference, the brazing filler metal coverage range formed by the current brazing operation can be accurately determined, and the brazing area for infrared shooting of the multi-strand pure aluminum flat wire is calibrated in the three-dimensional space based on the boundary of the brazing filler metal coverage range, which is convenient for subsequent alignment shooting of the brazing area by the thermal infrared camera to ensure the comprehensiveness of the brazing area thermal infrared image. The temperature of the brazing area thermal infrared image is identified to determine the isotherm distribution information of the surface where the brazing area is located. The isotherm distribution information refers to the isotherm distribution of the surface where the brazing area is located corresponding to different temperature values.

[0055] Preferably, in the step S1, according to the temperature attribute information, the temperature state atlas of the brazing area is generated, including:

[0056] mapping the isotherm distribution information contained in the temperature field distribution attribute information into a plane coordinate system corresponding to the surface of the brazing area, obtaining position information of all isotherms on the surface of the brazing area, and constructing a correlation map between the temperature value of each isotherm and the corresponding position information thereof, thereby taking the correlation map as a temperature state map of the brazing area.

[0057] The above technical solution has the beneficial effects that: the isotherm distribution information is mapped into a plane coordinate system corresponding to the surface of the brazing area, so that the extension and distribution position of each isotherm on the surface of the brazing area are also determined accordingly. At this time, the correlation map between the temperature value of each isotherm and the corresponding position information thereof is constructed, which can ensure that the temperature value to which the different positions on the surface of the brazing area belong can be accurately determined from the correlation map, and the temperature change of the brazing filler metal of the brazing area can be accurately calibrated.

[0058] Preferably, in the step S2, visible light images of the brazing area of the plurality of pure aluminum flat wires after the completion of the current brazing operation are collected, and the visible light images of the brazing area are analyzed to obtain crack feature information of the brazing area, including:

[0059] When the plurality of pure aluminum flat wires completes the current brazing operation, the brazing area of the plurality of pure aluminum flat wires for visible light shooting is calibrated in the three-dimensional space based on the brazing filler metal coverage range formed by the current brazing operation; the visible light imaging of the brazing area is performed to obtain the visible light image of the brazing area.

[0060] The pixel texture recognition processing is performed on the visible light image of the brazing area to obtain the crack feature information of the brazing area; wherein the crack feature information includes the crack shape and size information of the brazing surface.

[0061] The above technical solution has the beneficial effects that: since the brazing filler metal used for brazing is completely different from the material of the pure aluminum flat wire, there is an obvious visual difference (such as color difference, etc.) between the brazing filler metal covering the surface of the pure aluminum flat wire and the surface of the pure aluminum flat wire after the completion of the brazing operation on the plurality of pure aluminum flat wires. According to the visual difference, the brazing filler metal coverage range formed by the current brazing operation can be accurately determined, and the boundary of the brazing filler metal coverage range is taken as the reference to calibrate the brazing area of the plurality of pure aluminum flat wires for visible light shooting in the three-dimensional space, which facilitates the subsequent alignment shooting of the brazing area by the thermal infrared camera, and ensures the comprehensiveness of the visible light image of the brazing area. When there is a crack on the surface of the brazing area, the pixel texture at the position of the crack will be different from the pixel texture at other positions without cracks, and the shape and size (such as length and width, etc.) of the crack will also affect the corresponding pixel texture pattern. The pixel texture recognition processing performed on the visible light image of the brazing area can accurately extract the crack feature information of the surface of the brazing area, and quantitatively represent the existence state of the crack.

[0062] Preferably, in the step S2, according to the crack feature information, a crack state atlas of the brazing area is generated, including:

[0063] The crack shape and size information contained in the crack feature information is mapped into the plane coordinate system corresponding to the surface of the brazing area to obtain the position information of each crack on the surface of the brazing area, and a correlation atlas between the shape and size of each crack and the corresponding position information is constructed, which is taken as the crack state atlas of the brazing area.

[0064] The beneficial effects of the above technical solution are: the crack shape and size information contained in the crack feature information is mapped into the plane coordinate system corresponding to the surface of the brazing area, the existing position and occupied range (such as length and width) of each crack on the surface of the brazing area are also determined, and at this time, the correlation atlas between the shape and size of each crack and the corresponding position information is constructed, which can ensure that the number of crack distribution, distribution density and crack occupied area of the brazing surface area can be accurately determined from the correlation atlas, and the crack distribution of the brazing area is accurately calibrated.

[0065] Preferably, in the step S3, the temperature state atlas and the crack state atlas are associated and processed to determine whether the brazing operation of the brazing area is currently allowed to continue, including:

[0066] The temperature state atlas and the crack state atlas are simultaneously mapped into the surface space corresponding to the brazing area to obtain the existence state information of the cracks in the region between two adjacent isotherms in the brazing area; wherein the existence state information includes the total number of cracks, the total area occupied by the cracks and the crack distribution density;

[0067] According to the existence state information, it is determined whether the brazing operation of the brazing area is currently allowed to continue.

[0068] The beneficial effects of the above technical solution are: the temperature state atlas and the crack state atlas are uniformly mapped into the surface space corresponding to the brazing area, so that the temperature distribution and the crack distribution of the brazing area can be determined at the same time in the same surface space, so as to further obtain the existence state information of the cracks in the region between two adjacent isotherms in the brazing area. And when the total number of cracks in the existence state information is greater than a preset number threshold, or the total area occupied by the cracks is greater than a preset area threshold, or the crack distribution density is greater than a preset density threshold, it indicates that there are many cracks on the surface of the brazing area, and secondary brazing is needed to fill and flatten the cracks. At this time, it is determined that the brazing operation of the brazing area is currently allowed to continue; otherwise, it is determined that the brazing operation of the brazing area is currently not allowed to continue.

[0069] Preferably, in this step S3, according to the existence state information, it is judged whether the brazing operation can be continued in the current brazing area or not, including:

[0070] In step S301, according to the total number of cracks in the brazing area, the crack area in the existence state information, the weighted average crack area and the maximum crack area in the brazing area are obtained by using the following formula (1),

[0071]

[0072] In the above formula (1), S0 represents the weighted average crack area in the brazing area; Smax represents the maximum crack area; s(i) represents the crack area of the i-th crack in the brazing area in the existence state information; L(i) represents the crack length of the i-th crack in the brazing area in the existence state information; n represents the total number of cracks in the brazing area in the existence state information; M Smax represents the maximum crack area; s(i) represents the crack area of the i-th crack in the brazing area in the existence state information; L(i) represents the crack length of the i-th crack in the brazing area in the existence state information; n represents the total number of cracks in the brazing area in the existence state information;

[0073] In step S302, according to the weighted average crack area and the maximum crack area in the brazing area, the maximum weighted crack area in the brazing area is obtained by using the following formula (2),

[0074]

[0075] In the above formula (2), S0 represents the maximum weighted crack area in the brazing area;

[0076] In step S303, according to the maximum weighted crack area in the brazing area and the crack distribution density in the brazing area, it is judged whether the brazing operation can be continued in the current brazing area or not by using the following formula (3),

[0077]

[0078] In the above formula (3), E represents the control value of whether the brazing operation can be continued in the current brazing area or not; s z Smax represents the preset threshold area value; p z p0 represents the crack distribution density in the brazing area; F() represents a judgment function, if the formula in the parentheses is true, the function value of the judgment function is 1, if the formula in the parentheses is not true, the function value of the judgment function is 0;

[0079] If E=1, it is controlled that the brazing operation can be continued in the current brazing area; ​​

[0080] If E=0, the control of the brazing area indicates that the brazing operation is not allowed to continue at present.

[0081] The above technical solution has the following beneficial effects: according to the total number of cracks and the area occupied by the cracks in the existing state information of the brazing area, the weighted average area occupied by the cracks and the maximum area occupied by the cracks of the brazing area are obtained by using the above formula (1), and then two values reflecting the crack area state are calculated, which lays a foundation for subsequent control and judgment; according to the weighted average area occupied by the cracks and the maximum area occupied by the cracks of the brazing area, the maximum area occupied by the cracks with the largest weight of the brazing area is obtained by using the above formula (2), and then the subsequent judgment is made through the comprehensive maximum area occupied by the weight, which increases the reliability of the judgment and avoids the continuous development of the cracks to cause greater impact; finally, according to the weight area occupied by the cracks of the brazing area and the crack distribution density of the brazing area, it is judged whether the brazing operation is allowed to continue at present, thereby realizing the automatic judgment and control, which embodies the intelligent and automatic characteristics of the system.

[0082] Preferably, in the step S3, according to the temperature state atlas and the crack state atlas, the operation position for continuing the brazing operation is determined, including:

[0083] If the brazing operation is allowed to continue at present, the crack existence position of the area between the adjacent two isotherms in the brazing area and the temperature value of the area between the adjacent two isotherms are extracted from the existing state information, and the filler metal filling position and the filler metal heating temperature for continuing the brazing operation are determined.

[0084] The above technical solution has the following beneficial effects: when the brazing operation is allowed to continue at present, the crack existence position of the area between the adjacent two isotherms in the brazing area and the temperature value of the area between the adjacent two isotherms are extracted from the existing state information as the basis to determine the filler metal filling position and the filler metal heating temperature for continuing the brazing operation, which can ensure that the filler metal is filled into the corresponding position and the filler metal is heated at a suitable temperature when the brazing operation continues, thereby improving the reliability of the brazing operation.

[0085] Preferably, in the step S4, the operation process image for continuing the brazing operation is collected, and the operation process image is analyzed to adjust the operation state of the brazing operation, including:

[0086] The operation process binocular image for continuing the brazing operation is collected, and the operation process three-dimensional image is generated according to the operation process binocular image;

[0087] The relative position relationship between the heating device for heating the filler metal and the operation position is identified from the operation process three-dimensional image, so as to adjust the relative distance of the heating device relative to the operation position.

[0088] The above technical solution has the beneficial effects that: during the continuous brazing operation, the operation process binocular image of the brazing operation is collected to generate the operation process three-dimensional image, so that the relative position between the heating device and the filler metal during the brazing process can be accurately calibrated, and the heating device can be ensured to be within the appropriate distance range from the operation position, so that the filler metal at the operation position can be heated in time and efficiently, and the filler metal can completely fill the original cracks.

[0089] From the above embodiment, it can be seen that the welding intelligent control method for multi-strand pure aluminum flat wire induction brazing respectively performs infrared and visible light shooting on the brazing area of the multi-strand pure aluminum flat wire for completing the current brazing operation, analyzes the obtained brazing area infrared image and visible light image, generates the temperature state atlas and crack state atlas of the brazing area, and accurately calibrates the filler metal temperature distribution and surface crack distribution of the brazing area; the temperature state atlas and the crack state atlas are associated to determine the relationship between the filler metal temperature and the surface crack in the brazing area, to judge whether the original crack needs to be eliminated by continuing brazing, and to also calibrate the operation position for continuing brazing, to ensure that the crack is accurately filled with filler metal and the filler metal consumption is effectively saved; the operation process image of the continued brazing operation is also analyzed to adjust the operation state of the brazing operation, to ensure the reliability of the continued brazing operation and improve the brazing quality of the multi-strand pure aluminum flat wire.

[0090] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalent technologies, the present application also intends to include these modifications and variations.

Claims

1. A welding intelligent control method for induction brazing of multi-strand pure aluminum flat wires, characterized in that, Includes the following steps: Step S1: Acquire infrared images of the brazing area of ​​the multi-strand pure aluminum flat wire after the current brazing operation is completed; analyze the infrared images of the brazing area to obtain temperature attribute information of the brazing area; generate a temperature state map of the brazing area based on the temperature attribute information. Step S2: Acquire visible light images of the brazing area of ​​the multi-strand pure aluminum flat wire after the current brazing operation is completed, analyze the visible light images of the brazing area, and obtain crack feature information of the brazing area; A crack state map of the brazing region is generated based on the crack feature information. Step S3: Simultaneously map the temperature state map and the crack state map onto the surface space corresponding to the brazing area to obtain the existence state information of cracks in the area between two adjacent isotherms in the brazing area; wherein, the existence state information includes the total number of cracks, the total area occupied by cracks, and the crack distribution density; based on the existence state information, determine whether the brazing operation can continue in the brazing area; if so, determine the operation position to continue the brazing operation based on the temperature state map and the crack state map; Step S4: Acquire images of the brazing process and analyze them to adjust the brazing operation status. The step of determining whether brazing operation is currently permitted to continue in the brazing area based on the existence status information includes: obtaining the weighted average area and the maximum area occupied by cracks in the brazing area based on the total number of cracks and the area occupied by cracks in the brazing area from the existence status information; obtaining the maximum area occupied by cracks with weighted weights in the brazing area based on the weighted average area occupied by cracks and the maximum area occupied by cracks in the brazing area; and determining whether brazing operation is currently permitted to continue in the brazing area based on the crack area occupied by cracks with weighted weights and the crack distribution density in the brazing area.

2. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 1, characterized in that: In step S1, an infrared image of the brazing area of ​​the multi-strand pure aluminum flat wire after the current brazing operation is completed is acquired. The infrared image of the brazing area is analyzed to obtain the temperature attribute information of the brazing area, including: After the current brazing operation of the multi-strand pure aluminum flat wire is completed, the brazing area of ​​the multi-strand pure aluminum flat wire is marked in three-dimensional space based on the brazing filler metal coverage area formed by the current brazing operation; thermal infrared imaging is performed on the brazing area to obtain thermal infrared image of the brazing area. The thermal infrared image of the brazing area is analyzed to obtain the temperature field distribution attribute information of the brazing area; wherein, the temperature field distribution attribute information includes the isotherm distribution information of the surface of the brazing area.

3. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 2, characterized in that: In step S1, a temperature state map of the brazing area is generated based on the temperature attribute information, including: The isotherm distribution information contained in the temperature field distribution attribute information is mapped to the plane coordinate system corresponding to the surface of the brazing area to obtain the position information of each isotherm on the surface of the brazing area, and a correlation comparison map between the temperature value of each isotherm and its corresponding position information is constructed, which serves as the temperature state map of the brazing area.

4. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 1, characterized in that: In step S2, a visible light image of the brazing area of ​​the multi-strand pure aluminum flat wire after the current brazing operation is completed is acquired. The visible light image of the brazing area is analyzed to obtain crack feature information of the brazing area, including: After the current brazing operation of the multi-strand pure aluminum flat wire is completed, the brazing area of ​​the multi-strand pure aluminum flat wire is marked in three-dimensional space based on the brazing filler metal coverage area formed by the current brazing operation; the brazing area is imaged with visible light to obtain a visible light image of the brazing area. The visible light image of the brazing area is subjected to pixel texture recognition processing to obtain crack feature information of the brazing area; wherein, the crack feature information includes the crack shape and size information of the surface of the brazing area.

5. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 4, characterized in that: In step S2, a crack state map of the brazed region is generated based on the crack feature information, including: The crack shape and size information contained in the crack feature information are mapped to the plane coordinate system corresponding to the surface of the brazing area to obtain the position information of each crack on the surface of the brazing area, and a correlation map between the shape and size of each crack and its corresponding position information is constructed, which serves as the crack state map of the brazing area.

6. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 1, characterized in that: Using the formula (1) below, based on the total number of cracks and the area occupied by cracks in the brazed region in the existence status information, the weighted average area occupied by cracks and the maximum area occupied by cracks in the brazed region are obtained. （1） In the above formula (1), This represents the weighted average area occupied by cracks in the brazing region; This indicates the maximum area occupied by the crack. The first brazing region in the existence status information indicates The area occupied by each crack; The first brazing region in the existence status information indicates The length of each crack; This indicates the total number of cracks in the brazing area within the existing state information; Indicates will The value ranges from 1 to Substituting it into the parentheses gives the maximum value within the parentheses; Using the formula (2) below, the weighted maximum area of ​​cracks in the brazed region is obtained based on the weighted average area of ​​cracks and the maximum area of ​​cracks in the brazed region. （2） In the above formula (2), The area with the largest weight for cracks in the brazing region; Using the formula (3) below, based on the area occupied by the crack weight in the brazing region and the crack distribution density in the brazing region, it is determined whether the brazing operation can continue in the brazing region. （3） In the above formula (3), A control value indicating whether brazing operation is currently permitted to continue in the brazing area; This represents the preset threshold area value; This indicates the preset threshold density value; This indicates the crack distribution density in the brazing area; This represents a judgment function. If the expression within the parentheses is true, the function value is 1; if the expression within the parentheses is false, the function value is 0. like If so, then the brazing area is currently allowed to continue brazing operations; like If so, brazing operations are not allowed to continue in the brazing area at this time.

7. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 6, characterized in that: In step S3, the operating position for continuing the brazing operation is determined based on the temperature state spectrum and the crack state spectrum, including: If the brazing area is currently allowed to continue brazing, the location of the crack and the temperature value of the area between two adjacent isotherms in the brazing area are extracted from the existence status information to determine the filler metal filling position and filler metal heating temperature for continuing the brazing operation.

8. The intelligent control method for induction brazing of multi-strand pure aluminum flat wire as described in claim 1, characterized in that: In step S4, images of the brazing process are acquired, and the images are analyzed to adjust the brazing operation status, including: Acquire binocular images of the brazing process and generate a three-dimensional image of the process based on the binocular images. The relative positional relationship between the heating device for heating the brazing filler metal and the operating position is identified from the three-dimensional image of the operation process, and the relative distance between the heating device and the operating position is adjusted accordingly.

Images