A virtual welding method, system, intelligent terminal and storage medium

Abstract

This application relates to a virtual welding method, system, intelligent terminal, and storage medium, and relates to the field of virtual teaching technology. The method includes obtaining a person's currently selected welding environment and current real-world environmental conditions; determining a current simulated welding environment based on the selected welding environment and real-world environmental conditions; after determining the simulated welding environment, obtaining the person's current operation mode of a preset virtual welding gun; determining current operation feedback based on the operation mode and the simulated welding environment; and instructing a preset feedback device to provide feedback to the person based on the operation feedback. This application improves the effectiveness of virtual welding training.

Description

Technical Field

[0001] The present application relates to the field of virtual teaching technology, and in particular to a virtual welding method, system, intelligent terminal and storage medium. Background Art

[0002] Welding, also known as fusion, is a manufacturing process and technology that joins metals or other thermoplastic materials by heating, high temperature or high pressure.

[0003] In related technologies, with the development of virtual reality technology, the welding practice process has gradually shifted from real practice to virtual welding practice. Trainees wear virtual equipment, hold a virtual welding gun and aim it at the workpiece. The system selects the welding type and identifies the operator's operation of the virtual welding gun, thereby simulating a real welding scene and allowing personnel to practice welding techniques in a virtual scene.

[0004] Regarding the above-mentioned related technologies, the inventors believe that: when personnel practice welding on a virtual welding system, the system can only simulate the welding pool and arc during the welding process based on the angle, speed and distance of the virtual welding gun used by the personnel, but cannot realize the personnel's true feeling of the actual welding process, resulting in poor results in virtual welding training and room for improvement. Summary of the Invention

[0005] In order to improve the training effect of virtual welding, the present application provides a virtual welding method, system, intelligent terminal and storage medium.

[0006] In a first aspect, the present application provides a virtual welding method, which adopts the following technical solution:

[0007] A virtual welding method, comprising:

[0008] Obtain the personnel's currently selected welding environment and current actual environmental conditions;

[0009] Determine the current simulated welding environment based on the selected welding environment and actual environmental conditions;

[0010] After determining the simulated welding environment, obtaining the personnel's current operation mode of the preset virtual welding gun;

[0011] Determine current operation feedback based on operation mode and simulated welding environment;

[0012] Feedback is provided to personnel according to the operational feedback in an instructive manner using a preset feedback device.

[0013] By adopting the above technical solution, the real environmental conditions are simulated into the selected welding environment to generate a simulated welding environment, so that the personnel can be closer to reality during virtual welding practice. The operation feedback is determined according to the personnel's operation method of the virtual welding gun. The touch and visual perception of the welding process are fed back to the practitioners through the operation feedback control feedback device, so that the practitioners can feel the real feeling of welding, thereby improving the training effect of the virtual welder.

[0014] Optionally, the feedback device includes a contraction component, and the control method for the contraction component includes:

[0015] Obtain the current moving speed of the virtual welding gun, the current welding current and the current welding rod model of the preset welding rod;

[0016] Determine the current ambient temperature and humidity values ​​according to actual environmental conditions;

[0017] Determine the current unit time consumption according to the preset unit time, moving speed and welding current;

[0018] Determine the current welding rod consumption rate based on unit time consumption, welding rod model, ambient temperature and ambient humidity;

[0019] The retraction assembly is instructed to retract the electrode according to the electrode consumption rate.

[0020] By adopting the above technical solution, the moving speed of the virtual welding gun is detected, so that the unit time consumption of the welding rod is determined according to the moving speed, the selected welding current and the unit time. Then, the welding rod model, the ambient humidity value and the ambient temperature value are simulated into the consumption of the welding rod to obtain the welding rod consumption speed, so that the shrinking component shrinks the welding rod according to the welding rod consumption speed, so that the personnel can feel the consumption of the welding rod in the actual welding process when using the virtual welding gun, thereby improving the training effect of virtual welding.

[0021] Optionally, the feedback device further includes a tightening component, and the control method for the tightening component includes:

[0022] Obtain the current electrode distance from the electrode to the preset weldment, the current weld width, the current weld pool temperature, and the current weldment type;

[0023] Compare the welding rod distance with a preset reference clamping distance to continue obtaining the welding rod distance or obtain the current dwell time of the welding rod;

[0024] Based on the obtained dwell time, the dwell time is compared with the preset adhesion time to continue to obtain the dwell time or to determine the current clamping force according to the dwell time, welding rod model, welding pool temperature, weld width and ambient temperature values;

[0025] Instruct the clamping assembly to clamp the welding rod according to the clamping force, and instruct the shrinking assembly to close;

[0026] After the clamping assembly clamps the welding rod, the current pulling force of the operator is obtained;

[0027] The pulling force is compared with the suction force to continue to obtain the pulling force or to indicate that the suction component is closed, and when the suction component is closed, the retraction component is indicated to open.

[0028] By adopting the above technical solution, the welding rod distance is detected. When the welding rod distance is less than the reference clamping distance, the dwell time of the welding rod is detected. When the dwell time exceeds the adhesion time, the clamping force is determined according to the dwell time, welding rod model, weld pool temperature, weld width and ambient temperature value, and the clamping component is controlled to clamp the welding rod with the clamping force, thereby simulating the situation where the welding rod sticks to the weldment when the arc is started during the actual welding process. When the pulling force of the personnel is greater than the clamping force, the clamping component is closed to make the welding rod leave the weldment, so that the personnel can be closer to reality during virtual welding practice, thereby improving the training effect of virtual welding.

[0029] Optionally, the method for adjusting the clamping force of the clamping assembly on the welding rod includes:

[0030] Obtain the swing trajectory and number of swings of the virtual welding gun;

[0031] Comparing the swing trajectory with a preset static trajectory to continue acquiring the swing trajectory or determining the current swing direction and swing angle according to the swing trajectory;

[0032] Determine the current tightening force correction value according to the swing direction, swing angle and swing times;

[0033] Correcting the suction force according to the suction force correction value to generate a corrected suction force;

[0034] The corrected suction force is compared with the preset release force to adjust the suction component or instruct the suction component to close according to the pulling force and the corrected suction force, and to instruct the retraction component to open when the suction component is closed.

[0035] By adopting the above technical solution, the swing trajectory and number of swings of the virtual welding gun are detected, so that when the swing direction and swing angle are consistent with the method for handling electrode adhesion in the actual welding process, the suction force correction value is determined according to the swing direction, swing angle and swing number, so that the suction force is corrected to generate a corrected suction force. When the corrected suction force is less than the release force, the suction component is controlled to close and release the welding rod, so that personnel can handle the situation of electrode adhesion in the process of virtual welding with the actual welding method, thereby improving the training effect of virtual welding.

[0036] Optionally, the feedback device further includes a light display component, and the method for controlling the light display component includes:

[0037] Get the current light receiving position of the preset virtual helmet;

[0038] Determine the current light intensity and direction based on the light receiving position and actual environmental conditions;

[0039] Comparing the electrode distance with the preset reference shading distance to determine the current shading state or the current exposure state;

[0040] Based on the determined shielding state, the current spark brightness of the welding rod is obtained;

[0041] Determine the current shading brightness according to the spark brightness, light receiving position, light intensity, light direction and preset shading intensity, and use the shading brightness to indicate the brightness of the display component;

[0042] Based on the exposure status, the current normal brightness is determined according to the light intensity, the light receiving position and the light direction, and the display brightness of the display component is indicated at the normal brightness.

[0043] By adopting the above technical solution, a comparison is made between the welding rod distance and the reference shading distance. When the welding rod distance is greater than the reference shading distance, it is determined that the person is in a situation where the shielding mask is removed during actual welding to observe the weld, thereby determining the exposure state in virtual welding, and controlling the display brightness of the light display component according to the normal brightness; when the welding rod distance is less than the reference shading distance, it is determined that the person is in a situation where the shielding mask is used to block sparks during actual welding, thereby determining the shielding state in virtual welding, and controlling the display brightness of the light display component according to the shading brightness, so that the person can experience the situation of wearing and removing the shielding mask during virtual welding practice, thereby improving the effect of virtual welding training.

[0044] Optional methods for correcting spark brightness include:

[0045] Get the current storage time, storage humidity and current welding time of the welding rod;

[0046] Determine the current smoke concentration per unit time based on storage time, storage humidity and welding rod model;

[0047] Determine the current ambient humidity and wind speed based on actual environmental conditions, and determine the actual smoke concentration based on the ambient humidity and smoke concentration per unit time;

[0048] Determine the current smoke escape range based on ambient wind speed, welding time and actual smoke concentration;

[0049] Determine the current smoke emission concentration based on the smoke emission range and actual smoke concentration;

[0050] The current brightness correction value is determined according to the smoke escape range, the smoke escape concentration and the spark brightness, and the spark brightness is corrected by the brightness correction value to generate a corrected spark brightness.

[0051] By adopting the above technical solution, the smoke concentration per unit time is determined according to the storage time, storage humidity and welding rod model, and the influence of actual environmental conditions on smoke emission is combined to simulate the smoke emission range and smoke emission concentration in virtual welding. The brightness correction value is determined according to the smoke emission range, smoke emission concentration and spark brightness, and the spark brightness is corrected by the brightness correction value to generate a corrected spark brightness, thereby simulating the reflection and refraction of the spark brightness by smoke, making the brightness displayed by the display component more accurate, thereby improving the training effect of virtual welding.

[0052] Optionally, the feedback device further includes a temperature component, and the method for controlling the temperature component includes:

[0053] Obtain the current proximity distance between the virtual helmet and the weldment and the current welding temperature;

[0054] Determine the current reference approach distance and safety distance based on the welding temperature;

[0055] Comparing the approach distance with a reference approach distance to continue acquiring the approach distance or indicating that a temperature component is turned on;

[0056] Based on the temperature component opening, the proximity distance is compared with the safe distance to indicate the preset vibration component vibration prompt or determine the current sensed temperature based on the proximity distance and welding temperature;

[0057] Based on the shielding state, the current actual temperature is determined according to the sensed temperature and the preset isolation temperature, and the temperature is emitted by the indicating temperature component according to the actual temperature;

[0058] Based on the exposure status, the temperature is emitted by the temperature indicating component according to the sensed temperature.

[0059] By adopting the above technical solution, the approach distance is compared with the benchmark approach distance. When the approach distance is less than the benchmark approach distance, it indicates that the personnel can feel the welding temperature in actual welding. Therefore, the perceived temperature is determined based on the approach distance and the welding temperature. In the shielded state, the shielding mask will isolate part of the temperature in actual welding. Therefore, the actual temperature is determined based on the perceived temperature and the isolation temperature, so that the temperature component emits temperature according to the actual temperature during virtual welding. In the exposed state, the temperature component is controlled to emit temperature according to the perceived temperature. When the approach distance is less than the safe distance, the vibration prompt of the vibration component is used to simulate the burn in actual welding, so that the personnel can feel the actual welding temperature in real time during welding, thereby improving the training effect of virtual welding.

[0060] In a second aspect, the present application provides a virtual welding system, which adopts the following technical solutions:

[0061] A virtual welding system, comprising:

[0062] The acquisition module is used to obtain the selected welding environment, actual environmental conditions, operation mode, moving speed, welding current, welding rod model, welding rod distance, weld width, welding pool temperature, weldment type, dwell time, pulling force, swing trajectory, number of swings, light receiving position, spark brightness, storage time, storage humidity, welding time, approach distance, and welding temperature;

[0063] A memory for storing a program of a virtual welding method as described above;

[0064] The program in the memory can be loaded and executed by the processor to implement any one of the above-mentioned virtual welding methods.

[0065] By adopting the above technical solution, the processor loads and executes a computer program of a virtual welding method stored in the memory, thereby controlling the acquisition module to obtain a series of data related to virtual welding and analyze and process the data, so that personnel can feel the feeling of actual welding during the virtual welding process, thereby improving the training effect of virtual welding.

[0066] In a third aspect, the present application provides a smart terminal that adopts the following technical solution:

[0067] An intelligent terminal comprises a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute any one of the above-mentioned virtual welding methods.

[0068] By adopting the above technical solution, personnel operate the intelligent terminal to issue operation instructions, so that the processor loads and executes a computer program of a virtual welding method stored in the memory according to the operation instructions, thereby responding to the operation instructions, allowing personnel to feel the feeling of actual welding in virtual welding, thereby improving the convenience of processing.

[0069] In a fourth aspect, the present application provides a computer storage medium capable of storing corresponding programs, which has the characteristics of facilitating the improvement of virtual welding training effects, and adopts the following technical solutions:

[0070] A computer-readable storage medium stores a computer program that can be loaded by a processor and execute any one of the above-mentioned virtual welding methods.

[0071] By adopting the above technical solution, a computer program of a virtual welding method is stored in the storage medium. When it is necessary to control the acquisition module to obtain data related to virtual welding and analyze and process the data, the processor loads and executes the computer program stored in the storage medium, thereby acquiring and processing the data in a timely manner, thereby improving the efficiency of responding to operations during the virtual welding process.

[0072] In summary, this application includes at least one of the following beneficial technical effects:

[0073] 1. By simulating real-world conditions into the selected welding environment to generate a simulated welding environment, the virtual welding practice is closer to reality. The operation feedback is determined according to the operator's operation of the virtual welding gun. The operation feedback control feedback device feeds back the tactile and visual experience of the welding process to the practitioner, allowing the practitioner to experience the real feeling of welding, thereby improving the training effect of the virtual welder.

[0074] 2. By detecting the movement speed of the virtual welding gun, the welding rod consumption per unit time is determined based on the movement speed, selected welding current, and unit time. The welding rod model, ambient humidity value, and ambient temperature value are then simulated into the welding rod consumption to obtain the welding rod consumption rate. The retraction component retracts the welding rod according to the welding rod consumption rate, allowing personnel to experience the actual welding rod consumption during the use of the virtual welding gun, thereby improving the training effect of virtual welding.

[0075] 3. By detecting the distance between the welding rods, when the welding rod distance is less than the reference clamping distance, the dwell time of the welding rod is detected. When the dwell time exceeds the adhesion time, the clamping force is determined according to the dwell time, welding rod model, welding pool temperature, weld width and ambient temperature. The clamping component is controlled to clamp the welding rod with the clamping force, thereby simulating the situation where the welding rod sticks to the weldment when the arc is started during the actual welding process. When the pulling force of the personnel is greater than the clamping force, the clamping component is closed to make the welding rod leave the weldment, so that the personnel can be closer to reality during virtual welding practice, thereby improving the training effect of virtual welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0076] Figure 1 This is a flow chart of a virtual welding method in an embodiment of the present application.

[0077] Figure 2 This is a flow chart of a method for controlling a contraction component in an embodiment of the present application.

[0078] Figure 3 This is a flow chart of a method for controlling a clamping assembly in an embodiment of the present application.

[0079] Figure 4This is a flow chart of a method for adjusting the clamping force of a clamping assembly on a welding rod in an embodiment of the present application.

[0080] Figure 5 This is a flow chart of a method for controlling a light display component in an embodiment of the present application.

[0081] Figure 6 This is a flow chart of a method for correcting spark brightness in an embodiment of the present application.

[0082] Figure 7 This is the process of the temperature control method of the embodiment of the present application Figure 1 .

[0083] Figure 8 This is the process of the temperature control method of the embodiment of the present application Figure 2 . DETAILED DESCRIPTION

[0084] In order to make the purpose, technical solutions and advantages of this application more clear, the following Figure 1-8 It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application.

[0085] This application simulates real-world environmental conditions into the welding environment selected by the personnel, thereby generating a simulated welding environment similar to the actual welding environment, so that the personnel can feel the impact of the environment on welding during the actual welding process during virtual welding practice. When the personnel uses a virtual welding gun to perform welding actions in the simulated welding environment, the personnel's operation method is obtained, and the operation feedback corresponding to the current operation method in actual welding is simulated based on the operation method and the simulated welding environment. The feedback device is controlled according to the operation feedback to feed back the actual welding experience to the trainee to the greatest extent, so that the trainee can feel the real feeling of actual welding during the virtual welding process, thereby improving the training effect of virtual welding.

[0086] Reference Figure 1 , the embodiment of the present application discloses a virtual welding method, comprising the following steps:

[0087] Step S100: obtaining the personnel's currently selected welding environment and current actual environmental conditions.

[0088] The selected welding environment is a pre-set welding scenario in the virtual welding system, such as a shipyard, elevated platform, field, or depot. The welding in this application is based on arc welding, selected by the operator in the virtual welding system. The computer program detects, identifies, uploads, stores, and accesses the selected welding environment. The actual environmental conditions during virtual welding, including light, wind, rain, and other environmental conditions, are obtained, uploaded, stored, and accessed by the computer program using meteorological information from a weather website. The selected welding environment and the actual environmental conditions are tested for further analysis and processing.

[0089] Step S101: determining a current simulated welding environment according to a selected welding environment and actual environmental conditions.

[0090] The simulated welding environment is a virtual scene close to the actual welding conditions generated by simulating the actual environmental conditions into the selective welding environment. It is generated using virtual reality technology. Technical personnel in this field conduct a large number of experiments based on different selective welding environments and actual environmental conditions to summarize the rules and generate a database. The database stores the selective welding environments and actual environmental conditions related to the simulated welding environment, and has multiple selective welding environments and actual environmental conditions corresponding to the simulated welding environments. According to the input selective welding environment and actual environmental conditions, the simulated welding environment is matched and output for further analysis and processing.

[0091] Step S102: After determining the simulated welding environment, obtain the current operation mode of the personnel on the preset virtual welding gun.

[0092] The virtual welding gun is a control handle for a virtual welding system that simulates an actual arc welding gun. The size, weight, and shape of the virtual welding gun are identical to those of an actual welding gun. The operator's movements with the virtual welding gun, such as approaching the workpiece, moving away from the workpiece, and moving welding over the workpiece, are detected by sensors installed on the virtual welding gun, workpiece, and virtual equipment, uploaded, and stored for later use by the computer program.

[0093] Step S103: determining the current operation feedback according to the operation mode and the simulated welding environment.

[0094] Operation feedback is the real feeling of the personnel operating the virtual welding gun in the current simulated welding environment during the actual welding process. Technical personnel in this field conduct a large number of experiments based on different operation methods and simulated welding environments to summarize the rules and generate a database. The database stores operation methods and simulated welding environments related to operation feedback, and has multiple operation methods and simulated welding environments corresponding to operation feedback. According to the input operation method and simulated welding environment, the output operation feedback is matched for further analysis and processing.

[0095] Step S104: instructing a preset feedback device to provide feedback to the personnel according to the operation feedback.

[0096] The feedback device is a device that responds to operational feedback to simulate the real welding feeling, including a shrinking component, a tightening component, a light display component, a temperature component and a vibration component. Based on the output operational feedback, the feedback device is controlled to respond according to the operational feedback, so that personnel can feel the actual welding feeling during the virtual welding process, thereby improving the training effect of virtual welding.

[0097] Reference Figure 2 The feedback device includes a contraction component, and the control method for the contraction component includes the following steps:

[0098] Step S200: obtaining the current moving speed of the virtual welding gun, the current welding current and the current welding rod model of the preset welding rod.

[0099] The movement speed is the speed at which a person moves along the length of the weld using the virtual welding gun. This speed is detected by a speed sensor, uploaded, and stored for access by the computer program. The welding current is the virtual welding current selected by the person in the virtual welding system. The current level is selected, uploaded, and stored by the person practicing the welding process. The current range is set by those skilled in the art based on actual conditions and is not detailed here. The welding rod is a pre-set virtual welding rod clamped to the virtual welding gun. The retraction assembly, which includes a motor, is mounted on the virtual welding gun. When the welding rod is consumed, the retraction assembly retracts the welding rod to simulate actual welding rod consumption. The welding rod has the same size, weight, and shape as an actual arc welding rod. The welding rod model is the corresponding welding rod model. Different models have different coatings, diameters, lengths, and cores. The welding characteristics of different welding rod models are pre-stored in the virtual welding system. The movement speed, welding current, and welding rod model of the virtual welding gun are detected for further analysis and processing.

[0100] Step S201: determining the current ambient temperature and humidity according to actual environmental conditions.

[0101] The ambient temperature and humidity values ​​are the actual temperature and humidity values ​​of the virtual environment during the welding process. A computer program retrieves, uploads, stores, and calls the actual environmental conditions based on the temperature and humidity keywords. The actual temperature and humidity values ​​are then determined for further analysis and processing.

[0102] Step S202: determining the current unit time consumption according to the preset unit time, moving speed and welding current.

[0103] The unit time is a preset time period, and the specific size is set by those skilled in the art according to actual conditions, which will not be elaborated here. The unit time consumption is the number of welding rods that should be consumed in the unit time at the current welding current and moving speed. Those skilled in the art have conducted a large number of experiments based on different unit times, moving speeds and welding currents to summarize the rules and generate a database. The database stores the unit time, moving speed and welding current related to the unit time consumption, and has multiple unit times, moving speeds and welding currents corresponding to the unit time consumption. According to the input unit time, moving speed and welding current, the output unit time consumption is matched. When the unit time and moving speed are determined, the welding current is within the current range. The larger the current, the faster the welding rod melts, and thus the faster it is consumed.

[0104] Step S203: determining the current welding rod consumption rate according to the consumption per unit time, welding rod model, ambient temperature value and ambient humidity value.

[0105] The welding rod consumption rate is the consumption rate of the current welding rod model under the conditions of unit time consumption, ambient temperature value and ambient humidity value. Technical personnel in this field have conducted a large number of experiments based on different unit time consumption, welding rod models, ambient temperature values ​​and ambient humidity values ​​to summarize the rules and generate a database. The database stores the unit time consumption, welding rod model, ambient temperature value and ambient humidity value related to the welding rod consumption rate, and has multiple unit time consumption, welding rod model, ambient temperature value and ambient humidity value corresponding to the welding rod consumption rate. According to the input unit time consumption, welding rod model, ambient temperature value and ambient humidity value, the output welding rod consumption rate is matched. When the unit time consumption and welding rod model are determined, the larger the ambient temperature value and the smaller the ambient humidity value, the greater the welding rod consumption rate, and the smaller the ambient temperature value and the larger the ambient humidity value, the smaller the welding rod consumption rate.

[0106] Step S204: instructing the shrinking assembly to shrink the welding rod according to the welding rod consumption speed.

[0107] After determining the electrode consumption rate, the retraction component is controlled to retract the electrode according to the electrode consumption rate, thereby shortening the length of the electrode clamped on the virtual welding gun, thereby simulating the electrode consumption in the actual welding process, making the personnel feel more realistic during the virtual welding process, and thus improving the training effect of virtual welding.

[0108] Reference Figure 3 The feedback device also includes a tightening component, and the control method for the tightening component includes the following steps:

[0109] Step S300: Obtain the current welding rod distance between the welding rod and the preset weldment, the current weld seam width, the current weld pool temperature and the current weldment type.

[0110] A weldment is a preset workpiece that needs to be welded. The weldment type includes, among other things, the material of the weldment. The virtual welding system stores a variety of weldment types, which can be selected, uploaded, and stored by the trainee for the computer program to call. The clamping assembly is an electromagnet assembly that clamps the welding rod to the weldment, simulating the situation in real welding where the welding rod stays on the weldment for too long during arcing, causing it to stick to the weldment. The welding rod distance is the distance between the end of the welding rod away from the virtual welding gun and the weldment, which is detected by a distance sensor, uploaded, and stored for the computer program to call. The weld seam width is the width of the weld on the weldment to be welded, which can be selected, uploaded, and stored by the trainee for the computer program to call. The weld pool temperature is the molten pool temperature of the weld under the current welding current, welding rod type, and weldment type. Technicians have conducted extensive experiments based on different welding currents, welding rod types, and weldment types to develop a database. The database stores welding currents, welding rod types, and weldment types associated with weld pool temperature. The database also contains multiple weld pool temperature-correlated values. Based on the input welding current, welding rod type, and weldment type, the output weld pool temperature is matched and uploaded and stored for later use by a computer program. Further analysis and processing is performed by testing the welding rod distance, weld seam width, weld pool temperature, and weldment type.

[0111] Step S301: Compare the welding rod distance with a preset reference clamping distance to continue obtaining the welding rod distance or obtain the current residence time of the welding rod.

[0112] The reference clamping distance is the distance at which the welding rod contacts the weldment, causing adhesion. The specific value is determined by those skilled in the art based on actual conditions and is not detailed here. The dwell time is the time the welding rod remains on the weldment, which is counted by a timer, uploaded, and stored for later use by the computer program.

[0113] By sorting and comparing the numerical values ​​corresponding to the welding rod distance and the numerical values ​​corresponding to the reference clamping distance, it is possible to determine whether the welding rod distance is greater than the reference clamping distance, thereby determining whether there is a possibility of the welding rod sticking to the weldment, for further analysis and processing.

[0114] If the welding rod distance is greater than the reference clamping distance, it means that the welding rod is far away from the weldment and is not in the arcing state. The welding rod cannot stick to the weldment, so the welding rod distance should continue to be tested to continuously monitor the possibility of welding rod sticking.

[0115] If the welding rod distance is not greater than the reference clamping distance, it means that the welding rod is in contact with the weldment, the distance is close and it is in the arc starting state, and the possibility of the welding rod sticking to the weldment is high. Therefore, the residence time is tested to further determine the possibility of the welding rod sticking to the weldment.

[0116] Step S302: Based on the obtained dwell time, the dwell time is compared with the preset adhesion time to continue to obtain the dwell time or determine the current clamping force according to the dwell time, welding rod model, welding pool temperature, weld width and ambient temperature.

[0117] The adhesion time is the minimum time that the welding rod stays at a certain position on the weldment to cause adhesion. The specific numerical value is set by technical personnel in this field according to actual conditions and will not be elaborated here. The suction force is the force used by the suction component to simulate the pulling out of the welding rod when it sticks during actual welding. Technical personnel in this field conduct a large number of experiments based on the dwell time, welding rod model, weld pool temperature, weld width and ambient temperature values ​​to summarize the rules and generate a database. The database stores the dwell time, welding rod model, weld pool temperature, weld width and ambient temperature values ​​related to the suction force, and has multiple dwell time, welding rod model, weld pool temperature, weld width and ambient temperature values ​​corresponding to the suction force. According to the input dwell time, welding rod model, weld pool temperature, weld width and ambient temperature values, the output suction force is matched. When the welding rod model, weld pool temperature, weld width and ambient temperature values ​​are determined, within the time range, the longer the dwell time, the greater the suction force.

[0118] By sorting and comparing the numerical values ​​corresponding to the dwell time and the numerical values ​​corresponding to the adhesion time, it is possible to determine whether the dwell time is greater than the adhesion time, thereby determining whether the welding rod is adhered to the weldment for further analysis and processing.

[0119] If the dwell time is less than the adhesion time, it indicates that the contact time between the welding rod and the weldment is short, and the condition for the welding rod to adhere to the weldment is not met. Therefore, the dwell time is continued to be tested to continuously monitor the dwell condition of the welding rod.

[0120] If the dwell time is not less than the adhesion time, it indicates that the contact time between the welding rod and the weldment is long, which meets the conditions for the welding rod to adhere to the weldment. Therefore, the clamping force of the clamping assembly on the welding rod is determined according to the dwell time, welding rod model, weld pool temperature, weld width and ambient temperature values ​​for further analysis and processing.

[0121] Step S303: instructing the clamping assembly to clamp the welding rod according to the clamping force, and instructing the retracting assembly to close.

[0122] After determining the clamping force, the clamping component is controlled to clamp the welding rod to the weldment according to the clamping force, thereby simulating the situation where the welding rod sticks to the weldment during the actual welding process, and the shrinking component is controlled to close, so as to avoid the shrinking component and the clamping component applying opposite forces to the welding rod at the same time, so that the personnel can feel the real feeling of actual welding in the virtual welding, thereby improving the training effect of virtual welding.

[0123] Step S304: After the clamping assembly clamps the welding rod, the current pulling force of the operator is obtained.

[0124] The pull force is the force applied by the operator to the virtual welding gun when the welding rod adheres to the workpiece. This force is detected by the force sensor, uploaded, and stored for later use by the computer program. After the clamping assembly secures the welding rod to the workpiece, the operator's pull force is detected for further analysis and processing.

[0125] Step S305: Compare the pulling force with the sucking force to continue to obtain the pulling force or instruct the sucking component to close, and instruct the retracting component to open when the sucking component is closed.

[0126] By comparing and analyzing the numerical magnitude and direction corresponding to the pulling force with the numerical magnitude and direction corresponding to the suction force, it is possible to determine whether the magnitude of the pulling force is greater than the magnitude of the suction force under the correct force application direction, thereby determining whether personnel can remove the welding rod from the weldment for further analysis and processing.

[0127] If the pulling force is not greater than the suction force in the correct direction of force application or the direction of the pulling force is inconsistent with the correct direction of force application, it indicates that the personnel cannot currently remove the welding rod from the weldment. Therefore, the pulling force is continued to be tested to continuously monitor the situation of the personnel pulling out the welding rod.

[0128] If the pulling force is greater than the suction force in the correct direction of force application, it means that the personnel's current force can remove the welding rod from the weldment, thereby closing the suction component to make the welding rod leave the weldment, simulating the situation in which the personnel remove the welding rod from the weldment in actual welding, and opening the retraction component to continue to retract the welding rod according to the consumption of the welding rod, so that the personnel can feel the real feeling of actual welding in virtual welding, thereby improving the training effect of virtual welding.

[0129] Reference Figure 4 The method for adjusting the clamping force of the clamping assembly on the welding rod includes the following steps:

[0130] Step S400: Obtain the swing trajectory and number of swings of the virtual welding gun.

[0131] The swing trajectory is the movement path of the virtual welding gun as the operator twists it. This is captured and uploaded by a camera, and a computer program uses image recognition to generate a path, upload, store, and access it. The number of swings is the number of times the operator twists the virtual welding gun. This is counted by a counter, uploaded, and stored for future access by the computer program. The swing trajectory and number of swings are detected for further analysis and processing.

[0132] Step S401: Compare the swing trajectory with a preset static trajectory to continue to obtain the swing trajectory or determine the current swing direction and swing angle according to the swing trajectory.

[0133] The stationary trajectory is the trajectory of the virtual welding gun when it is stationary relative to the workpiece. The specific position is determined by those skilled in the art based on actual circumstances and is not detailed here. The swing direction is the direction of movement of the swing trajectory relative to the stationary trajectory. The swing angle is the angle between the line connecting the virtual welding gun at the stationary trajectory and the weld point on the workpiece and the line connecting the virtual welding gun at the end point of the swing trajectory and the weld point on the workpiece. The swing trajectory is identified, uploaded, stored, and retrieved by a computer program.

[0134] By comparing and analyzing the swing trajectory with the static trajectory, it is determined whether the swing trajectory is consistent with the static trajectory, so as to determine whether the person twists the virtual welding gun to remove the welding rod from the weldment for further analysis and processing.

[0135] If the swing trajectory is consistent with the stationary trajectory, it indicates that the current virtual welding gun is in a relatively stationary state with respect to the weldment, and the personnel has not twisted the virtual welding gun to remove the welding rod from the weldment. Therefore, the swing trajectory is continued to be detected to continuously monitor the situation in which the personnel twists the virtual welding gun.

[0136] If the swing trajectory is inconsistent with the static trajectory, it indicates that the current virtual welding gun is in a state of relative motion with the weldment, and the person is twisting the virtual welding gun to remove the welding rod from the weldment. Therefore, the swing direction and swing angle are determined according to the swing trajectory for further analysis and processing.

[0137] Step S402: determining a current clamping force correction value according to the swing direction, swing angle, and swing times.

[0138] The clamping force correction value is a correction value for the clamping force in a virtual welding system that simulates the situation of twisting to remove the welding rod during actual welding. Technical personnel in this field conduct a large number of experiments and summarize the rules based on different swing directions, swing angles and swing times to generate a database. The database stores the swing directions, swing angles and swing times related to the clamping force correction value, and has multiple swing directions, swing angles and swing times corresponding to the clamping force correction value. According to the input swing direction, swing angle and swing number, the output clamping force correction value is matched. When the swing direction and swing angle are determined, the more the swing times, the greater the clamping force correction value. When the swing direction and swing number are determined, the greater the swing angle, the greater the clamping force correction value.

[0139] Step S403: Correcting the suction force according to the suction force correction value to generate a corrected suction force.

[0140] The corrected clamping force is the force applied by the clamping assembly to the welding rod after the clamping force is corrected using the clamping force correction value. This is obtained by subtracting the clamping force from the clamping force correction value, which is then uploaded, stored, and retrieved by a computer program. The clamping force is corrected using the clamping force correction value to generate the corrected clamping force for further analysis and processing.

[0141] Step S404: Compare the corrected suction force with the preset release force to adjust the suction component or instruct the suction component to close according to the pulling force and the corrected suction force, and instruct the retracting component to open when the suction component is closed.

[0142] The release force is the minimum holding force required when the clamping assembly closes and releases the welding rod. The specific value is determined by those skilled in the art based on actual conditions and is not detailed here. By sorting and comparing the values ​​corresponding to the corrected holding force and the release force, it is determined whether the corrected holding force is less than the release force. This allows for further analysis and processing to determine whether the operator's twisting of the virtual welding gun has removed the welding rod from the workpiece.

[0143] If the corrected clamping force is greater than the release force, it indicates that the twisting of the virtual welding gun by the operator is not sufficient to remove the welding rod from the weldment during actual welding, and can only loosen the welding rod from the weldment. Therefore, whether the welding rod can be removed is determined by comparing the pulling force and the corrected clamping force.

[0144] If the corrected clamping force is less than the release force, it indicates that the twisting of the virtual welding gun by the person is sufficient to remove the welding rod from the weldment during actual welding. Therefore, the clamping assembly is controlled to close to remove the welding rod from the weldment, and the shrinking assembly is controlled to open when the clamping assembly is closed, so that the shrinking assembly continues to shrink the welding rod according to the consumption of the welding rod.

[0145] Reference Figure 5 The feedback device also includes a light display component, and the control method for the light display component includes the following steps:

[0146] Step S500: obtaining the current light receiving position of the preset virtual helmet.

[0147] The display assembly is a pre-set device that controls the display brightness of the virtual helmet. It includes a screen and an adjustment panel for adjusting the screen brightness. A computer program controls the adjustment panel to adjust the screen brightness according to different conditions. The virtual helmet simulates the shielding helmet used in actual welding. The size, weight, and shape of the virtual helmet are identical. The virtual helmet uses virtual reality technology to generate a virtual reality environment corresponding to the simulated welding environment. The light receiving position is the position of the goggles on the virtual helmet in the environment. This position is detected by a camera, uploaded, and stored for subsequent access by the computer program. The light receiving position of the virtual helmet is detected for further analysis and processing.

[0148] Step S501: determining the current light intensity and light direction according to the light receiving position and actual environmental conditions.

[0149] The illumination intensity is the intensity of the light on the illuminated position in the actual environmental conditions. A large number of experiments are conducted by technicians in this field based on different illuminated positions and actual environmental conditions to summarize the rules and generate a database. The database stores the illuminated positions and actual environmental conditions related to the illumination intensity, and has multiple illuminated positions and actual environmental conditions corresponding to the illumination intensity. The output illumination intensity is matched according to the input illuminated position and the actual environmental conditions. The illumination direction is the direction of the light on the illuminated position in the actual environmental conditions. A large number of experiments are conducted by technicians in this field based on different illuminated positions and actual environmental conditions to summarize the rules and generate a database. The database stores the illuminated positions and actual environmental conditions related to the illumination direction, and has multiple illuminated positions and actual environmental conditions corresponding to the illumination direction. The output illumination direction is matched according to the input illuminated position and the actual environmental conditions. The illumination intensity and illumination direction are determined according to the illuminated position and the actual environmental conditions for further analysis and processing.

[0150] Step S502: Compare the welding rod distance with a preset reference shading distance to determine the current shading state or the current exposure state.

[0151] The baseline light shielding distance is the maximum distance between the electrode and the workpiece when the virtual welding helmet simulates the actual welding process using a shielding mask to block strong light. The specific value is set by those skilled in the art based on actual conditions and is not detailed here. The shielded state simulates the virtual helmet using the shielding mask to block strong light during actual welding, while the exposed state simulates the virtual helmet removing the shielding mask to observe the weld during actual welding.

[0152] By sorting and comparing the numerical values ​​corresponding to the welding rod distance and the numerical values ​​corresponding to the reference shading distance, it is possible to determine whether the welding rod distance is greater than the reference shading distance, thereby determining whether the virtual helmet is in a blocked state or an exposed state for further analysis and processing.

[0153] If the electrode distance is greater than the reference shading distance, it indicates that the distance between the electrode and the weldment is far, and the personnel is in a situation where they remove the shielding mask to observe the weld in actual welding. Therefore, it is determined that the personnel is in an exposed state in virtual welding.

[0154] If the electrode distance is not greater than the reference shading distance, it indicates that the distance between the electrode and the weldment is close, and the personnel is in a situation where the mask blocks the strong light in actual welding. Therefore, it is determined that the personnel is in a shielded state in virtual welding.

[0155] Step S5021: Based on the determined shielding state, obtain the current spark brightness of the welding rod.

[0156] Spark brightness is the brightness of sparks produced when welding with a welding rod. A computer program simulates sparks under realistic conditions based on the weldment type, welding rod model, and welding current. This data is then uploaded, stored, and retrieved. If the welding rod is blocked, the spark brightness is tested for further analysis and processing.

[0157] Step S503: Determine the current shading brightness according to the spark brightness, the light receiving position, the light intensity, the light direction and the preset shading intensity, and use the shading brightness to indicate the display brightness of the display component.

[0158] The shading intensity is the light blocking intensity of the virtual helmet simulating the goggles. The specific numerical value is set by the technicians in this field according to the actual situation and will not be elaborated here. The shading brightness is the brightness felt by the personnel when the virtual helmet is in the blocking state. The technicians in this field have conducted a large number of experiments based on different spark brightness, light receiving position, light intensity, light direction and shading intensity to summarize the rules and generate a database. The database stores the spark brightness, light receiving position, light intensity, light direction and shading intensity related to the shading brightness, and has multiple spark brightness, light receiving position, light intensity, light direction and shading intensity corresponding to the shading brightness. According to the input spark brightness, light receiving position, light intensity, light direction and shading intensity, the output shading brightness is matched, and the display brightness of the display component is controlled according to the shading brightness, so that the personnel in the virtual welding can feel the visual feeling of the mask blocking the strong light in the actual welding.

[0159] Step S5022: Based on the exposure state, determine the current normal brightness according to the light intensity, the light receiving position and the light direction, and indicate the display brightness of the light display component with the normal brightness.

[0160] Normal brightness is the light-sensitive brightness when the virtual welding simulation personnel removes the shielding mask to observe the weld in actual welding. Technical personnel in this field have conducted a large number of experiments based on different light intensities, light receiving positions and light directions to summarize the rules and generate a database. The database stores the light intensity, light receiving position and light direction related to normal brightness, and has multiple light intensities, light receiving positions and light directions corresponding to normal brightness. According to the input light intensity, light receiving position and light direction, the output normal brightness is matched, and the display component is controlled to display the brightness according to the normal brightness, so that personnel in virtual welding can feel the visual feeling of removing the shielding mask to observe the weld in actual welding.

[0161] Reference Figure 6 , the method for correcting the spark brightness includes the following steps:

[0162] Step S600: Obtain the current storage time, storage humidity and current welding time of the welding rod.

[0163] The retention time simulates the time a person selects to hold the welding rod in the virtual welding system. This is detected, uploaded, stored, and recalled by a computer program. The retention humidity simulates the time a person selects to hold the welding rod in the virtual welding system. This is detected, uploaded, stored, and recalled by a computer program. The welding time is the time it takes a person to weld the workpiece using the welding rod. This is measured by a timer, uploaded, stored, and recalled. The retention time, retention humidity, and welding time are monitored for further analysis and processing.

[0164] Step S601: Determine the current smoke concentration per unit time according to the storage time, storage humidity and welding rod model.

[0165] The smoke concentration per unit time is the smoke concentration that can be generated by the welding rod selected by the personnel per unit time. Technical personnel in this field conduct a large number of experiments based on different storage times, storage humidity and welding rod models to summarize the rules and generate a database. The database stores the storage time, storage humidity and welding rod model related to the smoke concentration per unit time, and has multiple storage times, storage humidity and welding rod models corresponding to the smoke concentration per unit time. According to the input storage time, storage humidity and welding rod model, the output smoke concentration per unit time is matched for further analysis and processing.

[0166] Step S602: determining the current environmental humidity value and the current environmental wind speed value according to the actual environmental conditions, and determining the actual smoke concentration according to the environmental humidity value and the smoke concentration per unit time.

[0167] The ambient humidity value is the humidity value in the actual environmental conditions, which is detected, uploaded, stored and called by the computer program. The ambient wind speed value is the wind speed value in the actual environmental conditions, which is detected, uploaded, stored and called by the computer program. The real smoke concentration is the smoke concentration generated by the welding rod under the ambient humidity value. The technical personnel in this field conduct a large number of experiments based on different ambient humidity values ​​and smoke concentrations per unit time to summarize the rules and generate a database. The database stores ambient humidity values ​​and smoke concentrations per unit time related to the real smoke concentration, and has multiple ambient humidity values ​​and smoke concentrations per unit time corresponding to the real smoke concentration. According to the input ambient humidity value and smoke concentration per unit time, the real smoke concentration is matched and output for further analysis and processing.

[0168] Step S603: Determine the current smoke dissipation range according to the ambient wind speed value, welding time and actual smoke concentration.

[0169] The smoke dissipation range is the range of actual smoke concentration under the influence of welding time and ambient wind speed. Personnel skilled in the art have conducted a large number of experiments based on different ambient wind speed values, welding times, and actual smoke concentrations to summarize the patterns and generate a database. The database stores ambient wind speed values, welding times, and actual smoke concentrations related to the smoke dissipation range. The database also contains multiple ambient wind speed values, welding times, and actual smoke concentrations corresponding to the smoke dissipation range. Based on the input ambient wind speed value, welding time, and actual smoke concentration, the smoke dissipation range is matched and output for further analysis and processing.

[0170] Step S604: determining the current smoke emission concentration according to the smoke emission range and the actual smoke concentration.

[0171] The smoke escape concentration is the concentration of smoke that escapes from the actual smoke concentration to the smoke escape range. Technical personnel in this field conduct a large number of experiments based on different smoke escape ranges and actual smoke concentrations to summarize the rules and generate a database. The database stores smoke escape ranges and actual smoke concentrations related to the smoke escape concentration, and has multiple smoke escape ranges and actual smoke concentrations corresponding to the smoke escape concentration. According to the input smoke escape range and actual smoke concentration, the output smoke escape concentration is matched for further analysis and processing.

[0172] Step S605: determining a current brightness correction value according to the smoke escape range, smoke escape concentration, and spark brightness, and correcting the spark brightness with the brightness correction value to generate a corrected spark brightness.

[0173] The brightness correction value is the brightness reduction of the spark during actual welding due to refraction and reflection of smoke. Technicians in this field have conducted extensive experiments based on different smoke emission ranges, smoke emission concentrations, and spark brightnesses to develop a database. The database stores smoke emission ranges, smoke emission concentrations, and spark brightnesses associated with the brightness correction value. The database also contains multiple smoke emission ranges, smoke emission concentrations, and spark brightnesses corresponding to the brightness correction value. Based on the input smoke emission ranges, smoke emission concentrations, and spark brightness, the output brightness correction value is matched. The corrected spark brightness is the spark brightness corrected by the brightness correction value. A computer program calculates the difference between the spark brightness and the brightness correction value to obtain the corrected spark brightness, which is then uploaded, stored, and retrieved. The spark brightness is corrected by the brightness correction value to generate the corrected spark brightness, thereby simulating the refraction and reflection of smoke on the spark brightness during actual welding in virtual welding.

[0174] Reference Figure 7 The feedback device further includes a temperature component, and the method for controlling the temperature component includes the following steps:

[0175] Step S700: Acquire the current proximity distance between the virtual helmet and the weldment and the current welding temperature.

[0176] The temperature component simulates the welding temperature experienced by a user during the virtual welding process. The proximity sensor measures the distance between the virtual helmet and the workpiece, which is then uploaded, stored, and retrieved. The welding temperature is the temperature the virtual welding system would experience when simulating actual welding using the current electrode type, workpiece type, and welding current. A computer program determines the electrode type, workpiece type, and welding current and outputs a matching welding temperature. The proximity sensor measures the welding temperature for further analysis and processing.

[0177] Step S701: determining the current reference approach distance and safety distance according to the welding temperature.

[0178] The reference approach distance is the maximum distance at which a person experiences a sharp sensation during actual welding at the current welding temperature. This database, created by those skilled in the art through extensive testing at different welding temperatures, contains welding temperatures associated with the reference approach distance. The database also contains multiple welding temperatures corresponding to the reference approach distance. The reference approach distance is then matched and output based on the input welding temperature. The safety distance is the maximum distance at which a person experiences a stinging sensation during actual welding at the current welding temperature. This database, created by those skilled in the art through extensive testing at different welding temperatures, contains multiple welding temperatures associated with the safety distance. The safety distance is then matched and output based on the input welding temperature. The welding temperature is used to determine the reference approach distance and safety distance for further analysis and processing.

[0179] Step S702: Compare the approach distance with the reference approach distance to continue acquiring the approach distance or indicate that the temperature component is turned on.

[0180] By sorting and comparing the numerical values ​​corresponding to the approach distance with the numerical values ​​corresponding to the benchmark approach distance, it is determined whether the approach distance is greater than the benchmark approach distance, so as to determine whether the personnel can feel the welding temperature in actual welding, which is subject to further analysis and processing.

[0181] If the approach distance is greater than the reference approach distance, it indicates that the current person is far away from the weldment and cannot feel the welding temperature during actual welding. Therefore, the approach distance is continued to be tested to continuously monitor whether the person can feel the temperature.

[0182] If the approach distance is not greater than the reference approach distance, it indicates that the current person is close to the weldment and can feel the welding temperature during actual welding. Therefore, the temperature control component is turned on for further analysis and processing.

[0183] Step S703: Based on the temperature component being turned on, the approach distance is compared with the safety distance to indicate a preset vibration component vibration prompt or to determine the current sensed temperature based on the approach distance and the welding temperature.

[0184] The vibration component is a vibration motor installed in the virtual helmet, used to warn users when they are too close. The perceived temperature is the temperature of the welding temperature at the current approach distance. Technicians have conducted extensive experiments based on different approach distances and welding temperatures, summarizing patterns and generating a database that stores approach distances and welding temperatures associated with perceived temperatures. The database contains multiple approach distances and welding temperatures corresponding to perceived temperatures. The perceived temperature is then matched to the input approach distance and welding temperature.

[0185] By sorting and comparing the numerical values ​​corresponding to the approach distance and the numerical values ​​corresponding to the safety distance, it is possible to determine whether the approach distance is greater than the safety distance, so as to determine whether personnel can feel stinging during actual welding, which is subject to further analysis and processing.

[0186] If the approach distance is not greater than the safe distance, it indicates that the distance between the person and the weldment is too close and the person may be injured during the actual welding process. Therefore, the vibration of the vibration component is controlled to replace the stinging pain felt by the person during actual welding.

[0187] If the approach distance is greater than the safe distance, it means that the distance between the person and the weldment has not reached the distance that causes harm. Therefore, the current sensed temperature is determined based on the approach distance and welding temperature for further analysis and processing.

[0188] Step S7031: Based on the shielding state, the current actual temperature is determined according to the sensed temperature and the preset isolation temperature, and the temperature is emitted by the indicating temperature component according to the actual temperature.

[0189] The isolation temperature is the temperature at which the virtual helmet simulates the actual temperature of the mask during welding. The specific value is determined by those skilled in the art based on actual conditions and is not detailed here. The actual temperature is the temperature felt by the operator in the shielded state. This is determined by the difference between the perceived temperature and the isolation temperature, which is then uploaded, stored, and retrieved by the computer program. When the operator is shielded, the temperature control component generates a temperature corresponding to the actual temperature, allowing the operator to experience the actual temperature during welding when the mask is blocked.

[0190] Step S7032: Based on the exposure state, the temperature indicating component emits a temperature according to the sensed temperature.

[0191] If the personnel is in an exposed state, the temperature component is controlled to sense the temperature and emit the temperature, so that the personnel can feel the temperature they would feel in the actual welding process without the shielding of the mask.

[0192] Reference Figure 8 , the method for controlling the temperature component further includes the following steps:

[0193] Step S800: obtaining the current close distance distribution between the virtual welding gun and the weldment and the current hand-held position of the operator.

[0194] The proximity distance distribution is the distance distribution between the virtual welding gun and the workpiece along its length. This is detected by a distance sensor, uploaded, and stored for later use by the computer program. The hand position is the position of the operator's hand on the virtual welding gun. This is detected by a position sensor, uploaded, and stored for later use by the computer program. By detecting the proximity distance distribution and hand position, further analysis and processing can be performed.

[0195] Step S801: determining the current welding gun temperature distribution according to the welding temperature and the proximity distance distribution.

[0196] The welding gun temperature distribution is the welding temperature felt at different positions on the virtual welding gun. Technical personnel in this field conduct a large number of experiments based on different welding temperatures and proximity distance distributions to summarize the rules and generate a database. The database stores welding temperatures and proximity distance distributions related to the welding gun temperature distribution, and has multiple welding temperatures and proximity distance distributions corresponding to the welding gun temperature distribution. According to the input welding temperature and proximity distance distribution, the output welding gun temperature distribution is matched for further analysis and processing.

[0197] Step S802: determining the current hand-held position temperature according to the hand-held position and the welding gun temperature distribution.

[0198] The handheld temperature is the temperature felt by the operator holding the virtual welding gun. A computer program uses the handheld position and the welding gun temperature distribution to map the handheld position to the welding gun temperature distribution. This program then obtains the handheld temperature, uploads it, and stores it for later retrieval. The handheld temperature is then determined based on the handheld position and the welding gun temperature distribution for further analysis and processing.

[0199] Step S803: Determine the current hand-feeling temperature based on the hand-holding position temperature and the preset glove insulation temperature.

[0200] The glove insulation temperature is the insulation temperature of the gloves during the virtual welding system's simulation of actual welding. The specific value is determined by those skilled in the art based on actual conditions and is not detailed here. The hand-feel temperature is the temperature the virtual welding system simulates a person feeling while wearing gloves. This is determined by a computer program by subtracting the hand-held position temperature from the glove insulation temperature, uploading, storing, and accessing it. The hand-feel temperature is determined based on the hand-held position temperature and the glove insulation temperature for further analysis and processing.

[0201] Step S804: Compare the hand-felt temperature with the preset safety temperature to instruct the temperature component to emit a temperature according to the hand-felt temperature or instruct the vibration component to vibrate.

[0202] The safety temperature is the minimum temperature that will not cause burns to personnel. The specific value is determined by those skilled in the art based on actual conditions and is not detailed here. By sorting and comparing the values ​​corresponding to the hand-felt temperature and the values ​​corresponding to the safety temperature, it is determined whether the hand-felt temperature is greater than the safety temperature, thereby determining whether the hand-felt temperature will cause harm to personnel, and further analysis and processing are required.

[0203] If the hand-felt temperature is greater than the safe temperature, it indicates that the hand-felt temperature is too high and may cause harm to personnel, so the vibration component is controlled to vibrate to prompt instead of the personnel feeling the temperature.

[0204] If the hand-felt temperature is not greater than the safe temperature, it indicates that the hand-felt temperature has not reached the temperature range that may cause harm to personnel. Therefore, the temperature control component emits temperature according to the hand-felt temperature, so that personnel can feel the temperature during the actual welding process during the virtual welding process, thereby improving the training effect of virtual welding.

[0205] Based on the same inventive concept, an embodiment of the present invention provides a virtual welding system, comprising:

[0206] The acquisition module is used to obtain the selected welding environment, actual environmental conditions, operation mode, moving speed, welding current, welding rod model, welding rod distance, weld width, welding pool temperature, weldment type, dwell time, pulling force, swing trajectory, number of swings, light receiving position, spark brightness, storage time, storage humidity, welding time, approach distance, and welding temperature;

[0207] Memory, used to store Figure 1-8 A procedure for a virtual welding method according to any one of the preceding claims;

[0208] Processor, the program in the memory can be loaded and executed by the processor and realize the following Figure 1-8 A virtual welding method according to any one of the preceding claims.

[0209] Those skilled in the art will clearly understand that for the sake of convenience and brevity, the division of the above-mentioned functional modules is only used as an example for illustration. In actual applications, the above-mentioned functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working processes of the above-mentioned systems, devices, and units can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0210] An embodiment of the present invention provides a computer-readable storage medium storing a computer program capable of being loaded by a processor and executing a virtual welding method.

[0211] Computer storage media include, for example, various media that can store program codes, such as USB flash drives, mobile hard disks, read-only memories (ROMs), random access memories (RAMs), magnetic disks, or optical disks.

[0212] Based on the same inventive concept, an embodiment of the present invention provides an intelligent terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute a virtual welding method.

[0213] Those skilled in the art will clearly understand that for the sake of convenience and brevity, the division of the above-mentioned functional modules is only used as an example for illustration. In actual applications, the above-mentioned functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working processes of the above-mentioned systems, devices, and units can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0214] The above are all preferred embodiments of the present application and are not intended to limit the scope of protection of this application. Unless otherwise specified, any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features. In other words, unless otherwise specified, each feature is merely an example of a series of equivalent or similar features.

Claims

1. A virtual welding method, characterized in that: include: Obtain the personnel's currently selected welding environment and current actual environmental conditions; Determine the current simulated welding environment based on the selected welding environment and actual environmental conditions; After determining the simulated welding environment, obtaining the personnel's current operation mode of the preset virtual welding gun; Determine current operation feedback based on operation mode and simulated welding environment; Provide feedback to personnel based on operational feedback using a preset feedback device; The feedback device includes a contraction component, and the control method for the contraction component includes: Obtain the current moving speed of the virtual welding gun, the current welding current and the current welding rod model of the preset welding rod; Determine the current ambient temperature and humidity values ​​according to actual environmental conditions; Determine the current unit time consumption according to the preset unit time, moving speed and welding current; Determine the current welding rod consumption rate based on unit time consumption, welding rod model, ambient temperature and ambient humidity; The retraction assembly is instructed to retract the electrode based on the electrode consumption rate.

2. A virtual welding method according to claim 1, characterized in that: The feedback device also includes a tightening component, and the control method for the tightening component includes: Obtain the current electrode distance from the electrode to the preset weldment, the current weld width, the current weld pool temperature, and the current weldment type; Compare the welding rod distance with a preset reference clamping distance to continue obtaining the welding rod distance or obtain the current dwell time of the welding rod; Based on the obtained dwell time, the dwell time is compared with the preset adhesion time to continue to obtain the dwell time or to determine the current clamping force according to the dwell time, welding rod model, welding pool temperature, weld width and ambient temperature values; Instruct the clamping assembly to clamp the welding rod according to the clamping force, and instruct the retraction assembly to close; After the clamping assembly clamps the welding rod, the current pulling force of the operator is obtained; The pulling force is compared with the suction force to continue to obtain the pulling force or to indicate that the suction component is closed, and when the suction component is closed, the retraction component is indicated to be opened.

3. A virtual welding method according to claim 2, characterized in that: The method for adjusting the clamping force of the clamping assembly on the welding rod includes: Obtain the swing trajectory and number of swings of the virtual welding gun; Comparing the swing trajectory with a preset static trajectory to continue acquiring the swing trajectory or determining the current swing direction and swing angle according to the swing trajectory; Determine the current tightening force correction value according to the swing direction, swing angle and swing times; Correcting the suction force according to the suction force correction value to generate a corrected suction force; The corrected suction force is compared with the preset release force to adjust the suction component or instruct the suction component to close according to the pulling force and the corrected suction force, and to instruct the retraction component to open when the suction component is closed.

4. A virtual welding method according to claim 1, characterized in that: The feedback device also includes a light display component, and the control method for the light display component includes: Get the current light receiving position of the preset virtual helmet; Determine the current light intensity and direction based on the light receiving position and actual environmental conditions; Comparing the electrode distance with the preset reference shading distance to determine the current shading state or the current exposure state; Based on the determined shielding state, the current spark brightness of the welding rod is obtained; Determine the current shading brightness according to the spark brightness, light receiving position, light intensity, light direction and preset shading intensity, and use the shading brightness to indicate the brightness of the display component; Based on the exposure status, the current normal brightness is determined according to the light intensity, the light receiving position and the light direction, and the display brightness of the display component is indicated at the normal brightness.

5. A virtual welding method according to claim 4, characterized in that: Correction methods for spark brightness include: Get the current storage time, storage humidity and current welding time of the welding rod; Determine the current smoke concentration per unit time based on storage time, storage humidity and welding rod model; Determine the current ambient humidity and wind speed based on actual environmental conditions, and determine the actual smoke concentration based on the ambient humidity and smoke concentration per unit time; Determine the current smoke escape range based on ambient wind speed, welding time and actual smoke concentration; Determine the current smoke emission concentration based on the smoke emission range and actual smoke concentration; The current brightness correction value is determined according to the smoke escape range, the smoke escape concentration and the spark brightness, and the spark brightness is corrected by the brightness correction value to generate a corrected spark brightness.

6. A virtual welding method according to claim 4, characterized in that: The feedback device also includes a temperature component, and the control method for the temperature component includes: Obtain the current proximity distance between the virtual helmet and the weldment and the current welding temperature; Determine the current reference approach distance and safety distance based on the welding temperature; Comparing the approach distance with a reference approach distance to continue acquiring the approach distance or indicating that a temperature component is turned on; Based on the temperature component opening, the proximity distance is compared with the safe distance to indicate the preset vibration component vibration prompt or determine the current sensed temperature based on the proximity distance and welding temperature; Based on the shielding state, the current actual temperature is determined according to the sensed temperature and the preset isolation temperature, and the temperature is emitted by the indicating temperature component according to the actual temperature; Based on the exposure status, the temperature is emitted by the temperature indicating component according to the sensed temperature.

7. A virtual welding system, characterized in that: include: The acquisition module is used to obtain the selected welding environment, actual environmental conditions, operation mode, moving speed, welding current, welding rod model, welding rod distance, weld width, welding pool temperature, weldment type, dwell time, pulling force, swing trajectory, number of swings, light receiving position, spark brightness, storage time, storage humidity, welding time, approach distance, and welding temperature; A memory for storing a program of a virtual welding method according to any one of claims 1 to 6; The program in the memory can be loaded and executed by the processor to implement a virtual welding method according to any one of claims 1 to 6.

8. An intelligent terminal, characterized in that: The method comprises a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute the virtual welding method according to any one of claims 1 to 6.

9. A computer-readable storage medium, characterized in that A computer program is stored which can be loaded by a processor and execute the virtual welding method according to any one of claims 1 to 6.

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