A welding process control method and device, computer equipment and storage medium

Abstract

The present application relates to the technical field of welding, and discloses a welding process control method and device, computer equipment and a storage medium, the method comprising: acquiring a welding parameter of a welding plate and a groove cross-section image of a welding bead; selecting a welding process matched with the welding parameter of the welding plate from a preset welding process library; calculating a filled droplet area based on the welding process and the groove cross-section image of the welding bead; and calculating a working current during groove cross-section welding of the welding bead based on the filled droplet area.The working current during groove cross-section welding of the welding bead obtained by the present application is matched with the actual welding parameter of the welding plate, avoiding the situation that the initial current in the welding process is always used during welding and is inconsistent with the actual welding parameter of the welding plate, realizing automatic and dynamic adjustment of the working current during welding, and solving the problem that welding parameters cannot be dynamically adjusted according to the actual characteristics of the welding plate.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and more specifically to a welding process control method, apparatus, computer equipment, and storage medium. Background Technology

[0002] In today's rapidly developing industrialization, steel structures have become the most important material in the construction industry due to their advantages such as lightweight, high strength, stable quality, and long service life. However, the connection methods of steel structures mainly rely on welding technology, and therefore the quality of the welds plays a crucial role in the performance of the steel structure.

[0003] In the welding process, the integrated application of welding technology and weld seam tracking technology has become crucial for improving welding quality. Weld seam tracking technology, by tracking the weld seam in real time during the welding process, minimizes deviations and fully guarantees weld quality.

[0004] However, weld seam tracking technology also faces the problem of being disconnected from the welding process in practical applications. While it solves the problem of weld seam positioning and tracking, providing only the welding location, actual welding requires setting specific welding process parameters such as current, voltage, and welding speed to complete the entire weld. Furthermore, in the field of thick plate welding, multiple weld passes are often required to fill the weld bead. During the welding process, factors such as thermal deformation and inconsistent droplet formation lead to more complex weld bead conditions, making the application of weld seam tracking technology in thick plate welding even more challenging.

[0005] Current solutions have many problems. For example, welding process libraries are discrete datasets that cannot handle various changes in real-world scenarios. Furthermore, if the weld cross-section is irregular, the position determined by weld tracking technology is not precise enough. In such cases, welding combined with a welding process library lacks flexibility, cannot dynamically adjust welding parameters according to the actual characteristics of the weld plate, and cannot guarantee welding quality. Summary of the Invention

[0006] In view of this, the present invention provides a welding process control method, apparatus, computer equipment and storage medium to solve the problem of being unable to dynamically adjust welding parameters according to the actual characteristics of the welding plate.

[0007] In a first aspect, the present invention provides a welding process control method, the method comprising:

[0008] Obtain welding parameters for the weld plate and cross-sectional images of the weld bevel;

[0009] Select welding processes from the preset welding process library that match the welding parameters of the welding plate;

[0010] The area of ​​the filled molten droplet is calculated based on the welding process and the cross-sectional image of the weld bevel.

[0011] The operating current during welding of the weld bead section is calculated based on the area of ​​the filled molten droplet.

[0012] The welding process control method provided by this invention selects welding processes that match the welding parameters of the welding plate from a welding process library, calculates the area of ​​the filled molten droplets based on the welding process and the weld bevel cross-section image, and calculates the working current during welding of the weld bevel cross-section based on the area of ​​the filled molten droplets. The resulting working current during welding of the weld bevel cross-section matches the actual welding parameters of the welding plate, avoiding the situation where the initial current in the welding process is inconsistent with the actual welding parameters of the welding plate. This achieves automated dynamic adjustment of the working current during welding and solves the problem of not being able to dynamically adjust welding parameters according to the actual characteristics of the welding plate.

[0013] In one optional implementation, the welding parameters of the welding plate include the welding plate thickness, welding plate material, and welding plate bevel type. Selecting a welding process from a preset welding process library that matches the welding parameters of the welding plate includes:

[0014] Select welding processes that are the same as the weld plate thickness, weld plate material, and weld plate bevel type, or select welding processes that are the same as the weld plate material and weld plate bevel type, greater than the weld plate thickness, and adjacent to the weld plate thickness.

[0015] The welding process control method provided by this invention selects welding processes that match the welding parameters of the welding plate from a preset welding process library based on the welding plate thickness, welding plate material and welding plate bevel type, thereby improving the accuracy and speed of matching and providing a welding process basis for subsequent welding of the welding plate.

[0016] In one optional implementation, calculating the area of ​​the filled droplet based on the welding process and weld bevel cross-section data includes:

[0017] Based on the welding process, a set of cross-sectional point clouds is obtained from the weld bevel cross-section image within each preset buffer length;

[0018] Filter the coordinates of the lowest and highest points from the cross-sectional point cloud set;

[0019] Calculate the weld bevel section width based on the coordinates of the lowest and highest points;

[0020] The area of ​​the molten droplets to be filled is calculated based on the width of the weld bevel section and the preset weld bevel section melt depth.

[0021] In an alternative implementation, before processing the set of cross-sectional point clouds in the weld bevel cross-section image within each preset buffer length based on the welding process, the method further includes:

[0022] Image processing is performed on the weld bevel cross-sectional image, and geometric shape feature matching is performed on the processed weld bevel cross-sectional image; geometric features include triangular features and trapezoidal features.

[0023] The welding process control method provided by this invention performs geometric shape feature matching on the processed weld bead cross-sectional image, providing a geometric basis for calculating the area of ​​the filled molten droplet. Based on the welding process, it obtains a set of cross-sectional point clouds in the weld bead cross-sectional image within each preset buffer length, selects the coordinates of the lowest and highest points from the cross-sectional point cloud set, and then calculates the width of the weld bead cross-section. Based on the width of the weld bead cross-section and the preset weld bead cross-sectional penetration depth, it calculates the area of ​​the filled molten droplet, providing a formula basis for subsequently calculating the working current during welding of the weld plate.

[0024] In one alternative implementation, the welding process includes an initial welding voltage, and the operating current for welding the weld bevel section is calculated based on the filled droplet area, including:

[0025] Calculate the droplet diameter based on the filled droplet area;

[0026] The working current for welding the weld bevel section is obtained by calculating the initial welding voltage and droplet diameter using a pre-defined welding theory.

[0027] The welding process control method provided by this invention calculates the droplet diameter based on the area of ​​the filled droplet; it uses a preset welding theory to calculate the initial welding voltage and droplet diameter to obtain the working current when welding the weld bevel section. This working current matches the actual welding parameters of the welding plate, thus achieving consistency between the welding plate and the actual welding parameters during welding, improving welding accuracy and quality, and increasing welding efficiency.

[0028] In an alternative embodiment, the welding process further includes an initial welding current, and after calculating the operating current for welding the weld bead cross-section based on the filled droplet area, the method further includes:

[0029] Calculate the current offset during welding of the weld bevel section within each preset buffer length;

[0030] Adjust the initial welding current according to the current offset.

[0031] In one optional embodiment, the welding process further includes welding speed, and adjusting the current offset during welding of the weld bevel section within each preset buffer length includes:

[0032] Track the welding position according to the initial welding voltage and welding speed;

[0033] Based on the welding position, the working current during welding of the weld bevel section is collected within each preset buffer length according to the preset step size.

[0034] Sum the operating currents corresponding to the preset step size within the preset buffer length, and calculate the average current based on the summation result;

[0035] The current offset is calculated based on the average current and the initial welding current.

[0036] The welding process control method provided by this invention adjusts the initial welding current according to the calculated current offset. The initial welding current can be adjusted within a preset buffer length, so that the welding plate works in a welding process consistent with the welding parameters during welding. It can monitor the overall condition of the weld bead on the welding plate, realize the controllable adjustment of the current during the welding process, and improve the welding quality.

[0037] In a second aspect, the present invention provides a welding process control device, the device comprising:

[0038] The acquisition module is used to acquire welding parameters of the welding plate and cross-sectional images of the weld bevel.

[0039] The filtering module is used to select welding processes that match the welding parameters of the welding plate from the preset welding process library;

[0040] The first calculation module is used to calculate the area of ​​the filled molten droplets based on the welding process and the weld bevel cross-section image;

[0041] The second calculation module is used to calculate the working current during welding of the weld bevel section based on the area of ​​the filled molten droplet.

[0042] Thirdly, the present invention provides a computer device, comprising: a memory and a processor, wherein the memory and the processor are communicatively connected to each other, the memory stores computer instructions, and the processor executes the computer instructions to perform the welding process control method of the first aspect or any corresponding embodiment described above.

[0043] Fourthly, the present invention provides a computer-readable storage medium storing computer instructions for causing a computer to execute the welding process control method of the first aspect or any corresponding embodiment thereof. Attached Figure Description

[0044] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0045] Figure 1This is a schematic flowchart of a welding process control method according to an embodiment of the present invention;

[0046] Figure 2 This is a schematic flowchart of another welding process control method according to an embodiment of the present invention;

[0047] Figure 3 This is a schematic flowchart of another welding process control method according to an embodiment of the present invention;

[0048] Figure 4 This is a schematic flowchart of another welding process control method according to an embodiment of the present invention;

[0049] Figure 5(a) is a schematic diagram of the shape of the weld bevel cross section according to an embodiment of the present invention;

[0050] Figure 5(b) is a schematic diagram of the shape of another weld bevel section according to an embodiment of the present invention;

[0051] Figure 5(c) is a schematic diagram of the shape of another weld bevel section according to an embodiment of the present invention;

[0052] Figure 6 This is a structural block diagram of a welding process control device according to an embodiment of the present invention;

[0053] Figure 7 This is a schematic diagram of the hardware structure of a computer device according to an embodiment of the present invention. Detailed Implementation

[0054] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] According to an embodiment of the present invention, a welding process control method embodiment is provided. It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowchart, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0056] This embodiment provides a welding process control method applicable to a welding system, which includes an industrial welding robot, a line laser sensor, welding equipment, and a host computer. The host computer, as the core of the system, is connected to the industrial welding robot and the line laser sensor via Ethernet cables, communicating using the TCP protocol. The welding equipment is connected to the industrial welding robot, communicating via EtherCAT protocol. Specifically, the welding equipment includes a welding machine and a welding torch. The industrial welding robot is used to install the welding machine and welding torch and to calibrate the welding torch. The industrial welding robot is also used to install the line laser sensor at a preset buffer zone of 100mm to 150mm (mm represents millimeters) in front of the welding torch and to calibrate the line laser sensor with the welding torch. Figure 1 This is a flowchart of a welding process control method according to an embodiment of the present invention, such as... Figure 1 As shown, the process includes the following steps:

[0057] Step S101: Obtain welding parameters of the welding plate and cross-sectional image of the weld bevel.

[0058] Specifically, the welding plate refers to the workpiece to be welded, which can be a steel plate. Welding parameters can be obtained from the welding plate by an industrial welding robot, including the plate thickness, material, and bevel type. Weld plate thicknesses include 30mm, 35mm, 40mm, 45mm, and 50mm. The welding plate material refers to the material grade, such as Q355. The bevel type refers to the bevel angle of the weld bead, including V-type 60°, etc. The weld bead cross-sectional image is obtained by a line laser sensor from the weld bead between two welding plates. For example, the welding parameters are shown in Table 1 below:

[0059] Table 1

[0060] Material / plate thickness 30mm 35mm 40mm 45mm 50mm Q355 30mm-Q355 35mm-Q355 40mm-Q355 45mm-Q355 50mm-Q355 Q460 30mm-Q460 35mm-Q460 40mm-Q460 45mm-Q460 50mm-Q460 Q350 30mm-Q350 35mm-Q350 40mm-Q350 45mm-Q350 50mm-Q350

[0061] Step S102: Select a welding process from the preset welding process library that matches the welding parameters of the welding plate.

[0062] Specifically, the preset welding process library is a database that matches welding parameters in advance based on experience data from actual welding processes. The process data corresponding to the welding parameters include: welding torch offset, initial welding current, initial welding voltage, and welding speed.

[0063] At the start of welding, based on the obtained welding parameters of the welding plate, a matching welding process can be retrieved from the preset welding process library. For example, if you want to weld a welding plate with a thickness of 35mm, Q355 material, and V-shaped 60° bevel type, you can select the same welding torch offset, initial welding current, initial welding voltage, and welding speed process data from the welding process library that are the same as those for a welding plate with a thickness of 35mm, Q355 material, and V-shaped 60° bevel type.

[0064] For example, if the thickness of the welding plate is 37mm, then select the welding process with the same thickness as the plate or the welding process that is greater than the current plate thickness and adjacent. As shown in Table 1, the welding process data corresponding to the 40mm welding plate thickness is selected.

[0065] Step S103: Calculate the area of ​​the filled droplets based on the welding process and the weld bevel cross-section image.

[0066] Specifically, at the start of welding and during the welding process, a line laser sensor scans the weld bevel cross-section image in real time. The host computer tracks the weld using weld seam tracking technology to obtain the welding position. Because the line laser sensor is installed in a preset buffer zone 100mm-150mm in front of the welding torch, the welding torch starts working after the line laser sensor has scanned the weld seam within this 100mm-150mm buffer zone. This allows for sufficient reaction time for the welding torch, resulting in better welding. The weld seam tracking technology effectively extracts key features through the combined use of various filtering algorithms, feature extraction algorithms, and feature matching algorithms. These algorithms include: 1. Filtering algorithms: used to remove noise and interference from the image to better extract weld seam features. 2. Feature extraction algorithms: extracting representative features from the original image, such as edges, textures, and colors, for subsequent feature matching and tracking. 3. Feature matching algorithms: comparing the extracted features with a preset template to achieve real-time weld seam tracking. These algorithms allow the welding position to be obtained during the welding process.

[0067] During the welding process, the welding torch operates according to the initial welding voltage in the matching welding process data, and welding is performed in units of each preset buffer length. During the welding process, the weld bevel cross-section is first matched with geometric shape, and the area of ​​the geometric shape is the area of ​​the filled molten droplet.

[0068] Step S104: Calculate the working current for welding the weld bevel section based on the area of ​​the filling molten droplet. Specifically, the filling molten droplet is preset to be circular. After calculating the area of ​​the filling molten droplet, the diameter of the molten droplet can be calculated. Then, based on the diameter of the molten droplet and the initial welding voltage of the welding process, the working current for welding the weld bevel section can be calculated.

[0069] The welding process control method provided in this embodiment selects welding processes that match the welding parameters of the welding plate from the welding process library, calculates the area of ​​the filled molten droplets based on the welding process and the weld bevel cross-section image, and calculates the working current during welding of the weld bevel cross-section based on the area of ​​the filled molten droplets. The resulting working current during welding of the weld bevel cross-section matches the actual welding parameters of the welding plate, avoiding the situation where the initial current in the welding process is inconsistent with the actual welding parameters of the welding plate. This achieves automated dynamic adjustment of the working current during welding and solves the problem of not being able to dynamically adjust welding parameters according to the actual characteristics of the welding plate.

[0070] This embodiment provides a welding process control method applicable to a welding system, which includes an industrial welding robot, a line laser sensor, welding equipment, and a host computer. The host computer, as the core of the system, is connected to the industrial welding robot and the line laser sensor via Ethernet cables, communicating using the TCP protocol. The welding equipment is connected to the industrial welding robot, communicating via the EtherCAT protocol, an Ethernet control automation technology. Specifically, the welding equipment includes a welding machine and a welding torch. The industrial welding robot is used to install the welding machine and welding torch and to calibrate them. The industrial welding robot is also used to install the line laser sensor at a preset buffer zone of 100mm-150mm in front of the welding torch and to calibrate the line laser sensor with the welding torch. Figure 2 This is a flowchart of a welding process control method according to an embodiment of the present invention, such as... Figure 2 As shown, the process includes the following steps:

[0071] Step S201: Obtain the welding parameters of the welding plate and the cross-sectional image of the weld bevel. For details, please refer to [link to relevant documentation]. Figure 1 Step S101 of the illustrated embodiment will not be described again here.

[0072] Step S202: Select a welding process from the preset welding process library that matches the welding parameters of the welding plate.

[0073] Specifically, the welding parameters of the welding plate include the welding plate thickness, welding plate material, and welding plate bevel type. Welding processes with the same welding plate thickness, welding plate material, and welding plate bevel type are selected, or welding processes with the same welding plate material and welding plate bevel type, greater than the welding plate thickness, and adjacent to the welding plate thickness are selected.

[0074] Step S203: Calculate the area of ​​the filled droplets based on the welding process and the weld bevel cross-section image.

[0075] Specifically, step S203 includes:

[0076] Step S2031: Perform image processing on the weld bevel cross-section image and perform geometric shape feature matching on the processed weld bevel cross-section image; the geometric features include triangular features and trapezoidal features.

[0077] Specifically, the weld bevel cross-sectional image is sharpened and filtered to make it clearer. The processed weld bevel cross-sectional image is then subjected to geometric shape feature matching. For example, as shown in Figure 5(a), the weld bevel cross-sectional image has a triangular feature image, and as shown in Figure 5(b), it has a trapezoidal feature image. The geometric shape features can also be other approximate geometric shapes.

[0078] Step S2032: Based on the welding process, obtain the set of cross-sectional point clouds in the weld bevel cross-section image within each preset buffer length.

[0079] Specifically, the preset buffer length is set to 100mm-150mm. The host computer collects cross-sectional point cloud data from the weld bevel cross-section image, using each preset buffer length as a unit, according to the welding direction. The data can be collected using laser ranging or a 3D scanner to form a cross-sectional point cloud set. As shown in Figures 5(a) and 5(b), each point in the figure represents a cross-sectional point cloud, and all cross-sectional point clouds constitute the cross-sectional point cloud set.

[0080] Step S2033: Filter the coordinates of the lowest point and the highest point from the cross-sectional point cloud set.

[0081] For example, as shown in Figure 5(b), taking the filling surface of the trapezoidal feature weld groove section as an example, combined with the interface point cloud set, the lowest point coordinates are (10,0,20) and the highest point coordinates are (14,0,20).

[0082] Step S2034: Calculate the weld bevel section width based on the coordinates of the lowest and highest points.

[0083] For example, as shown in Figure 5(b), the difference between the coordinates of the highest point (14,0,20) and the coordinates of the lowest point (10,0,20) is the calculated weld bevel section width, which can be calculated to be 4mm.

[0084] Step S2035: Calculate the area of ​​the molten droplets to be filled based on the weld bead groove cross-section width and the preset weld bead groove cross-section penetration depth. Specifically, the preset weld bead groove cross-section penetration depth is the height or depth of the weld bead groove cross-section. The preset weld bead groove cross-section penetration depth is related to the welding process in the welding process library, and different preset values ​​can be obtained depending on the initial welding process selected.

[0085] For example, as shown in Figure 5(b), the weld penetration depth of the trapezoidal weld bead section is 4 mm. The calculated bottom width of the weld bead section is l = 4 mm. As shown in Figure 5(c), the straight line features of the weld bead section are extracted based on the collected cross-sectional point cloud data, and the angle between the waist of the trapezoidal weld bead section and the weld penetration depth is measured. The area of ​​the filling droplet can be calculated using the following formula:

[0086]

[0087] Where: S is the area of ​​the filled droplet, d is the diameter of the droplet, and θ represents the angle between the waist of the trapezoidal weld bead groove section and the weld depth.

[0088] The final calculated droplet area is S = 25.4 mm. 2 .

[0089] Step S204: Calculate the working current during welding of the weld bevel section based on the area of ​​the filled molten droplets.

[0090] Specifically, step S204 includes:

[0091] Step S2041: Calculate the droplet diameter based on the area of ​​the filled droplet. Specifically, the droplet is assumed to be circular. Therefore, based on the area of ​​the circle, i.e., the droplet area, the equation between the droplet diameter and the droplet area can be derived, as shown in the following equation:

[0092]

[0093] For example, as shown in Figure 5(b), the calculated area of ​​the filled molten droplet is S = 25.4 mm. 2 The droplet diameter can be calculated to be d = 5.68 mm.

[0094] Step S2042: The initial welding voltage and droplet diameter are calculated using a preset welding theory to obtain the working current for welding the weld bevel section.

[0095] Specifically, welding current and voltage are important factors affecting the size of weld droplets. The pre-set welding theory can be implemented using the American Society for Metals (ASM) welding arc theory. In the ASM welding arc theory, welding current determines the heat input of the arc, while welding voltage determines the electrical output of the arc. Both of them jointly affect the formation and transition process of weld droplets.

[0096] The relationship between weld droplet diameter and welding current and welding voltage can be expressed by the following formula:

[0097] d = 0.05 * k * I 2 / (2 * U2 (3)

[0098] Where: d is the droplet diameter; k is an empirical value representing the constant relating welding current and voltage; I is the welding current in amperes (A); and U is the welding voltage in volts (V).

[0099] In equation (3), there is a constant k between the welding current and the welding voltage, which is related to the relative magnitudes of the welding current and the welding voltage. When the welding current and the welding voltage increase, the diameter of the weld droplet will also increase accordingly. At the same time, the formula also considers the influence of the arc voltage, that is, the welding current is proportional to the square of the welding voltage.

[0100] In actual welding, the value of k can be estimated based on the data collected from the welding experiment; in this embodiment, the value of k is 1.325 based on the analysis of the welding experiment data. When calculating the working current in the actual welding process, the welding speed in the welding process data is kept constant, and the welding voltage is welded according to the initial welding voltage. Based on the diameter of the molten droplets that need to be filled in the weld bevel section at different times, the initial welding voltage in the welding process is substituted into the welding theoretical formula (3) to calculate the actual working current required for welding this weld bevel section.

[0101] The welding process control method provided in this embodiment performs geometric feature matching on the processed weld bead cross-section image, providing a geometric basis for calculating the filling droplet area. Based on the welding process, it acquires a set of cross-sectional point clouds in the weld bead cross-section image within each preset buffer length. It then filters the coordinates of the lowest and highest points from the cross-sectional point cloud set to calculate the weld bead cross-section width. Based on the weld bead cross-section width and the preset weld bead cross-section penetration depth, it calculates the filling droplet area, providing a formulaic basis for subsequently calculating the working current during welding. The droplet diameter is calculated based on the filling droplet area. A preset welding theory is used to calculate the initial welding voltage and droplet diameter to obtain the working current during weld bead cross-section welding. A welding arc theory is used to establish a relationship model between welding parameters and weld bead cross-section data, achieving the mutual conversion between weld filling and welding process. Furthermore, this working current matches the actual welding parameters of the weld plate, ensuring consistency between the welding parameters and the actual welding parameters during welding, improving welding accuracy, welding quality, and welding efficiency.

[0102] This embodiment provides a welding process control method applicable to a welding system, which includes an industrial welding robot, a line laser sensor, welding equipment, and a host computer. The host computer, as the core of the system, is connected to the industrial welding robot and the line laser sensor via Ethernet cables, communicating using the TCP protocol. The welding equipment is connected to the industrial welding robot, communicating via EtherCAT protocol. Specifically, the welding equipment includes a welding machine and a welding torch. The industrial welding robot is used to install the welding machine and welding torch and to calibrate the welding torch. The industrial welding robot is also used to install the line laser sensor at a preset buffer zone of 100mm-150mm in front of the welding torch and to calibrate the line laser sensor with the welding torch. Figure 3 This is a flowchart of a welding process control method according to an embodiment of the present invention, such as... Figure 3 As shown, the process includes the following steps:

[0103] Step S301: Obtain the welding parameters of the welding plate and the cross-sectional image of the weld bevel. For details, please refer to [link to relevant documentation]. Figure 2 Step S201 of the illustrated embodiment will not be described again here.

[0104] Step S302: Select a welding process from the preset welding process library that matches the welding parameters of the welding plate. For details, please refer to [link to relevant documentation]. Figure 2 Step S202 of the illustrated embodiment will not be described again here.

[0105] Step S303: Calculate the area of ​​the filled molten droplet based on the welding process and the weld bevel cross-section image. For details, please refer to [link to relevant documentation]. Figure 2 Step S203 of the illustrated embodiment will not be described again here.

[0106] Step S304: Calculate the operating current for welding the weld bead section based on the area of ​​the filled molten droplets. For details, please refer to [link to relevant documentation]. Figure 2 Step S204 of the illustrated embodiment will not be described again here.

[0107] Step S305: Calculate the current offset during welding of the weld bevel section within each preset buffer length.

[0108] Specifically, step S305 includes:

[0109] Step S3051: Track the welding position according to the initial welding voltage and welding speed.

[0110] Specifically, during the welding process, the welding process is adjusted by controlling variables. Therefore, the welding speed and initial welding voltage matched in the welding process library are kept constant, and weld seam tracking technology is used to track the weld seam and obtain the welding position.

[0111] Step S3052: Based on the welding position, collect the working current of the weld bevel section during welding within each preset buffer length according to the preset step size.

[0112] Specifically, the preset buffer length is set to 100mm-150mm. The preset step size is set to 1mm. Within each preset buffer length of 100mm-150mm, the working current of the weld bevel section is collected every 1mm along the welding advance direction until the preset buffer length is completed, thus obtaining the working current of multiple weld bevel sections.

[0113] Step S3053: Sum the operating currents corresponding to the preset step length within the preset buffer length, and calculate the average current based on the summation result.

[0114] Specifically, the working currents collected in step S3052 during welding of multiple weld bevel sections are summed, and the average current value is calculated based on the summation result, which is used as the actual working current value of the welding gun during welding within the preset buffer length.

[0115] Step S3054: Calculate the current offset based on the average current and the initial welding current. Specifically, the difference between the average current and the initial welding current is calculated to obtain the current offset.

[0116] Step S306: Adjust the initial welding current based on the current offset. Specifically, under the control of the host computer, the line laser sensor calculates the current offset within each preset buffer length. The line laser sensor adjusts the initial welding current based on the current offset, and the adjusted initial welding current is used as the actual working current of the welding torch during the welding process. This operation allows for monitoring the overall weld bead condition throughout the entire welding process. For example, if the plate thickness is 37mm, a welding process with the same plate thickness or a welding process greater than the current plate thickness and adjacent to it is selected. As shown in Table 1, the welding process data corresponding to a 40mm plate thickness is selected. However, since the actual plate thickness is 37mm, selecting the welding process data corresponding to a 40mm plate thickness will still produce errors during welding. But after adjusting the initial welding current based on the current offset, the working current in the welding process corresponding to the actual plate thickness of 37mm can be obtained, and the working current in the welding process corresponding to the plate thickness of 37mm is added to the welding process database.

[0117] The welding process control method provided in this embodiment adjusts the initial welding current according to the calculated current offset. The initial welding current can be adjusted within a preset buffer length, so that the welding plate works in a welding process consistent with the welding parameters during welding. It can monitor the overall condition of the weld bead on the welding plate, realize the controllable adjustment of the current during the welding process, and improve the welding quality.

[0118] As one or more specific application embodiments of the present invention, such as Figure 4 As shown, the welding process control method can be implemented using the following process:

[0119] Step S401: The industrial welding robot is used to install the welding machine and welding torch, and to complete the calibration work with the welding torch.

[0120] In step S402, the industrial welding robot is also used to install a line laser sensor at a position of 100mm to 150mm (mm represents millimeters) in front of the welding torch, and to complete the calibration of the line laser sensor and the welding torch.

[0121] Step S403: When welding begins, input the obtained welding plate thickness, welding plate material and bevel type on the host computer.

[0122] Step S404: Based on the thickness, material, and bevel type of the welding plate to be welded, select a welding process that matches the welding parameters of the welding plate from the preset welding process library.

[0123] Step S405: Welding begins and during the welding process. A line laser sensor is used to scan the weld bevel cross-section image in real time. The host computer tracks the weld seam using weld seam tracking technology to obtain the welding position. The line laser sensor is installed 100mm-150mm in front of the welding torch. After the line laser sensor has scanned the 100mm-150mm length of the weld seam, the welding torch starts working.

[0124] Step S406: Perform image processing on the weld bevel cross-section image and perform geometric shape feature matching on the processed weld bevel cross-section image; geometric features include triangular features, trapezoidal features, or other approximate geometric shapes.

[0125] Specifically, the weld bevel cross-sectional image is sharpened and filtered to make it clearer. The processed weld bevel cross-sectional image is then subjected to geometric shape feature matching. For example, as shown in Figure 5(a), the weld bevel cross-sectional image is a triangular feature image, and as shown in Figure 5(b), the weld bevel cross-sectional image is a trapezoidal feature image.

[0126] Step S407: Based on the welding process, obtain the set of cross-sectional point clouds in the weld bevel cross-section image within each preset buffer length.

[0127] Specifically, the preset buffer length is set to 100mm-150mm. The host computer collects cross-sectional point cloud data from the weld bevel cross-section image, using each preset buffer length as a unit, according to the welding direction. The data can be collected using laser ranging or a 3D scanner to form a cross-sectional point cloud set. As shown in Figures 5(a) and 5(b), each point in the figure represents a cross-sectional point cloud, and all cross-sectional point clouds constitute the cross-sectional point cloud set.

[0128] Step S408: Filter the coordinates of the lowest point and the highest point from the cross-sectional point cloud set.

[0129] For example, as shown in Figure 5(b), taking the filling surface of the trapezoidal feature weld groove section as an example, combined with the interface point cloud set, the lowest point coordinates are (10,0,20) and the highest point coordinates are (14,0,20).

[0130] Step S409: Calculate the weld bevel section width based on the coordinates of the lowest and highest points.

[0131] For example, as shown in Figure 5(b), the difference between the coordinates of the highest point (14,0,20) and the coordinates of the lowest point (10,0,20) is the calculated weld bevel section width, which can be calculated to be 4mm.

[0132] Step S410: Calculate the area of ​​the molten droplets to be filled based on the weld bead groove cross-section width and the preset weld bead groove cross-section penetration depth. Specifically, the preset weld bead groove cross-section penetration depth is the height or depth of the weld bead groove cross-section. The preset weld bead groove cross-section penetration depth is related to the welding process in the welding process library, and can have different preset values ​​depending on the initial welding process selected.

[0133] For example, as shown in Figure 5(b), the weld penetration depth of the trapezoidal weld bead section is 4 mm. The calculated bottom width of the weld bead section is l = 4 mm. As shown in Figure 5(c), the straight line features of the weld bead section are extracted based on the collected cross-sectional point cloud data, and the angle between the waist of the trapezoidal weld bead section and the weld penetration depth is measured. The area of ​​the filling droplet can be calculated using the following formula:

[0134]

[0135] Where: S is the area of ​​the filled droplet, d is the diameter of the droplet, and θ represents the angle between the waist of the trapezoidal weld bead groove section and the weld depth.

[0136] The final calculated droplet area is S = 25.4 mm. 2 .

[0137] Step S411: Calculate the droplet diameter based on the area of ​​the filled droplet. Specifically, the droplet is assumed to be circular. Therefore, based on the area of ​​the circle, i.e., the droplet area, the equation between the droplet diameter and the droplet area can be derived, as shown in the following equation:

[0138]

[0139] For example, as shown in Figure 5(b), the calculated area of ​​the filled molten droplet is S = 25.4 mm. 2 The droplet diameter can be calculated to be d = 5.68 mm.

[0140] Step S412: The initial welding voltage and droplet diameter are calculated using a preset welding theory to obtain the working current for welding the weld bevel section.

[0141] Specifically, the relationship between the weld droplet diameter and the welding current and welding voltage can be expressed by the following formula:

[0142] d = 0.05 * k * I 2 / (2 * U 2 (3)

[0143] Where: d is the droplet diameter; k is an empirical value representing the constant relating welding current and voltage; I is the welding current in amperes (A); and U is the welding voltage in volts (V).

[0144] In equation (3), there is a constant k between the welding current and the welding voltage, which is related to the relative magnitudes of the welding current and the welding voltage. When the welding current and the welding voltage increase, the diameter of the weld droplet will also increase accordingly. At the same time, the formula also considers the influence of the arc voltage, that is, the welding current is proportional to the square of the welding voltage.

[0145] In actual welding, the value of k can be estimated based on the data collected from the welding experiment; in this embodiment, the value of k is 1.325 based on the analysis of the welding experiment data. When calculating the working current in the actual welding process, the welding speed in the welding process data is kept constant, and the welding voltage is welded according to the initial welding voltage. Based on the diameter of the molten droplets that need to be filled in the weld bevel section at different times, the initial welding voltage in the welding process is substituted into the welding theoretical formula (3) to calculate the actual working current required for welding this weld bevel section.

[0146] Step S413: Track the welding position according to the initial welding voltage and welding speed.

[0147] Specifically, during the welding process, the welding process is adjusted by controlling variables. Therefore, the welding speed and initial welding voltage matched in the welding process library are kept constant, and weld seam tracking technology is used to track the weld seam and obtain the welding position.

[0148] Step S414: Based on the welding position, collect the working current of the weld bevel section during welding within each preset buffer length according to the preset step size.

[0149] Specifically, the preset buffer length is set to 100mm-150mm. The preset step size is set to 1mm. Within each preset buffer length of 100mm-150mm, the working current of the weld bevel section is collected every 1mm along the welding advance direction until the preset buffer length is completed, thus obtaining the working current of multiple weld bevel sections.

[0150] Step S415: Sum the operating currents corresponding to the preset step size within the preset buffer length, and calculate the average current based on the summation result.

[0151] Specifically, the working currents collected in step S3052 during welding of multiple weld bevel sections are summed, and the average current value is calculated based on the summation result, which is used as the actual working current value of the welding gun during welding within the preset buffer length.

[0152] Step S416: Calculate the current offset based on the average current and the initial welding current.

[0153] Step S417: Adjust the initial welding current based on the current offset. Specifically, under the control of the host computer, the line laser sensor calculates the current offset within each preset buffer length. The line laser sensor adjusts the initial welding current based on the current offset, and the adjusted initial welding current is used as the actual working current of the welding torch during the welding process. This operation allows for monitoring the overall weld bead condition throughout the entire welding process. For example, if the plate thickness is 37mm, a welding process with the same plate thickness or a welding process greater than the current plate thickness and adjacent to it is selected. As shown in Table 1, the welding process data corresponding to a 40mm plate thickness is selected. However, since the actual plate thickness is 37mm, selecting the welding process data corresponding to a 40mm plate thickness will still produce errors during welding. But after adjusting the initial welding current based on the current offset, the working current in the welding process corresponding to the actual plate thickness of 37mm can be obtained, and the working current in the welding process corresponding to the plate thickness of 37mm is added to the welding process database.

[0154] The welding process control method provided in this embodiment introduces the Arc Welding Theory (ASM) to establish a relationship model between welding parameters and weld bead cross-sectional geometric parameters, achieving the mutual conversion between weld filling and welding processes. Combined with weld seam tracking technology, which involves scanning before welding and using a preset buffer path with a pre-defined buffer length, the numerical offset of the working current during welding is adjusted within the buffer path, achieving controllable current adjustment during the welding process and improving welding quality.

[0155] This embodiment also provides a welding process control device for implementing the above embodiments and preferred embodiments; details already described will not be repeated. As used below, the term "module" can refer to a combination of software and / or hardware that performs a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0156] This embodiment provides a welding process control device, such as... Figure 6 As shown, it includes:

[0157] The acquisition module 601 is used to acquire welding parameters of the welding plate and cross-sectional images of the weld bevel.

[0158] The filtering module 602 is used to filter welding processes that match the welding parameters of the welding plate from the preset welding process library.

[0159] The first calculation module 603 is used to calculate the area of ​​the filled droplets based on the welding process and the weld bevel cross-section image.

[0160] The second calculation module 604 is used to calculate the working current during welding of the weld bevel section based on the area of ​​the filled molten droplets.

[0161] In some alternative implementations, the filtering module 602 includes:

[0162] The first screening unit is used to screen welding processes that are the same as the welding plate thickness, welding plate material, and welding plate groove type, or to screen welding processes that are the same as the welding plate material and welding plate groove type, are greater than the welding plate thickness, and are adjacent to the welding plate thickness.

[0163] In some alternative implementations, the first computing module 603 includes:

[0164] The processing and matching unit is used to perform image processing on the weld bevel cross-section image and to perform geometric shape feature matching on the processed weld bevel cross-section image; the geometric features include triangular features and trapezoidal features.

[0165] The acquisition unit is used to acquire a set of cross-sectional point clouds in the weld bevel cross-section image within each preset buffer length based on the welding process.

[0166] The second filtering unit is used to filter the coordinates of the lowest point and the highest point from the cross-sectional point cloud set.

[0167] The first calculation unit is used to calculate the weld bevel section width based on the coordinates of the lowest and highest points.

[0168] The second calculation unit is used to calculate the area of ​​the filled droplets based on the weld bead groove cross-section width and the preset weld bead groove cross-section melt depth.

[0169] In some alternative implementations, the second computing module 604 includes:

[0170] The third calculation unit is used to calculate the droplet diameter based on the filled droplet area.

[0171] The fourth calculation unit is used to calculate the initial welding voltage and droplet diameter using a preset welding theory, and to obtain the working current when welding the weld bevel section.

[0172] The welding process control device also includes:

[0173] The third calculation module is used to calculate the current offset during welding of the weld bevel section within each preset buffer length.

[0174] The adjustment module is used to adjust the initial welding current based on the current offset.

[0175] In some alternative implementations, the third computing module includes:

[0176] The tracking unit is used to track the welding position according to the initial welding voltage and welding speed.

[0177] The acquisition unit is used to acquire the working current of the weld bevel section during welding based on the welding position within each preset buffer length and according to a preset step size.

[0178] The fifth calculation unit is used to sum the operating current corresponding to the preset step size within the preset buffer length, and calculate the average current based on the summation result;

[0179] The sixth calculation unit is used to calculate the current offset based on the average current and the initial welding current.

[0180] Further functional descriptions of the above modules and units are the same as those in the corresponding embodiments described above, and will not be repeated here.

[0181] In this embodiment, the welding process control device is presented in the form of a functional unit. Here, a unit refers to an ASIC (Application Specific Integrated Circuit) circuit, a processor and memory that execute one or more software or fixed programs, and / or other devices that can provide the above functions.

[0182] This invention also provides a computer device having the above-described features. Figure 6 The welding process control device shown.

[0183] Please see Figure 7 , Figure 7 This is a schematic diagram of the structure of a computer device provided in an optional embodiment of the present invention, such as... Figure 7 As shown, the computer device includes one or more processors 10, memory 20, and interfaces for connecting the components, including high-speed interfaces and low-speed interfaces. The components communicate with each other via different buses and can be mounted on a common motherboard or otherwise installed as needed. The processors can process instructions executed within the computer device, including instructions stored in or on memory to display graphical information of a GUI on external input / output devices (such as display devices coupled to the interfaces). In some alternative implementations, multiple processors and / or multiple buses can be used with multiple memories and multiple memory modules, if desired. Similarly, multiple computer devices can be connected, each providing some of the necessary operations (e.g., as a server array, a group of blade servers, or a multiprocessor system). Figure 7 Take a processor 10 as an example.

[0184] Processor 10 may be a central processing unit, a network processor, or a combination thereof. Processor 10 may further include a hardware chip. The hardware chip may be an application-specific integrated circuit (ASIC), a programmable logic device (PLD), or a combination thereof. The programmable logic device may be a complex programmable logic device (CAMP), a field-programmable gate array (FPGA), a general-purpose array logic (GDA), or any combination thereof.

[0185] The memory 20 stores instructions executable by at least one processor 10 to cause the at least one processor 10 to perform the method shown in the above embodiments.

[0186] The memory 20 may include a program storage area and a data storage area. The program storage area may store the operating system and applications required for at least one function; the data storage area may store data created based on the use of the computer device. Furthermore, the memory 20 may include high-speed random access memory and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some alternative embodiments, the memory 20 may optionally include memory remotely located relative to the processor 10, and these remote memories may be connected to the computer device via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0187] The memory 20 may include volatile memory, such as random access memory; the memory may also include non-volatile memory, such as flash memory, hard disk or solid-state drive; the memory 20 may also include a combination of the above types of memory.

[0188] The computer device also includes an input device 30 and an output device 40. The processor 10, memory 20, input device 30, and output device 40 can be connected via a bus or other means. Figure 7 Taking the example of a connection between China and Israel via a bus.

[0189] Input device 30 can receive input numerical or character information, and generate key signal inputs related to user settings and function control of the computer device, such as a touchscreen, keypad, mouse, trackpad, touchpad, joystick, one or more mouse buttons, trackball, joystick, etc. Output device 40 may include display devices, auxiliary lighting devices (e.g., LEDs), and haptic feedback devices (e.g., vibration motors). The aforementioned display devices include, but are not limited to, liquid crystal displays, light-emitting diodes, displays, and plasma displays. In some alternative embodiments, the display device may be a touchscreen.

[0190] This invention also provides a computer-readable storage medium. The methods described above according to embodiments of the invention can be implemented in hardware or firmware, or implemented as computer code that can be recorded on a storage medium, or implemented as computer code downloaded via a network and originally stored on a remote storage medium or a non-transitory machine-readable storage medium and then stored on a local storage medium. Thus, the methods described herein can be processed by software stored on a storage medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware. The storage medium can be a magnetic disk, optical disk, read-only memory, random access memory, flash memory, hard disk, or solid-state drive, etc.; further, the storage medium can also include combinations of the above types of memory. It is understood that computers, processors, microprocessor controllers, or programmable hardware include storage components capable of storing or receiving software or computer code, which, when accessed and executed by the computer, processor, or hardware, implements the methods shown in the above embodiments.

[0191] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A welding process control method, characterized in that, The method includes: Obtain welding parameters for the weld plate and cross-sectional images of the weld bevel; Select welding processes from the preset welding process library that match the welding parameters of the welding plate; The area of ​​the filled molten droplet is calculated based on the welding process and weld bevel cross-sectional image; the calculation of the area of ​​the filled molten droplet based on the welding process and weld bevel cross-sectional data includes: Based on the welding process, a set of cross-sectional point clouds is obtained from the weld bevel cross-sectional image within each preset buffer length; Filter the coordinates of the lowest point and the highest point from the set of cross-sectional point clouds; Calculate the weld bevel section width based on the coordinates of the lowest and highest points; The area of ​​the filled droplets is calculated based on the width of the weld bevel section and the preset weld bevel section melt depth. The working current during welding of the weld bead section is calculated based on the area of ​​the filled molten droplets. The welding process includes an initial welding voltage, and the working current for welding the weld bevel section is calculated based on the filled droplet area, including: The droplet diameter is calculated based on the filled droplet area; The working current for welding the weld bevel section was obtained by calculating the initial welding voltage and droplet diameter using a pre-defined welding theory. The welding process further includes an initial welding current. After calculating the working current for welding the weld bevel section based on the filled droplet area, the method further includes: Calculate the current offset during welding of the weld bevel section within each preset buffer length; The initial welding current is adjusted according to the current offset; The welding process also includes welding speed, and the current offset during welding of the weld bevel section within each preset buffer length includes: Track the welding position according to the initial welding voltage and welding speed; Based on the welding position, the working current during welding of the weld bevel section is collected within each preset buffer length according to a preset step size. The operating current corresponding to the preset step size within the preset buffer length is summed, and the average current value is calculated based on the summation result. The current offset is calculated based on the average current and the initial welding current.

2. The method according to claim 1, characterized in that, The welding parameters of the welding plate include the welding plate thickness, welding plate material, and welding plate bevel type. The step of selecting a welding process from a preset welding process library that matches the welding parameters of the welding plate includes: Select welding processes that are the same as the welding plate thickness, welding plate material, and welding plate bevel type, or select welding processes that are the same as the welding plate material and welding plate bevel type, are greater than the welding plate thickness, and are adjacent to the welding plate thickness.

3. The method according to claim 1, characterized in that, Before processing the cross-sectional point cloud set in the weld bevel cross-section image within each preset buffer length based on the welding process, the method further includes: The weld bevel cross-sectional image is processed, and geometric shape features are matched on the processed weld bevel cross-sectional image; the geometric shape features include triangular features and trapezoidal features.

4. A welding process control device, characterized in that, The apparatus for implementing the welding process control method as described in any one of claims 1 to 3 includes: The acquisition module is used to acquire welding parameters of the welding plate and cross-sectional images of the weld bevel. The filtering module is used to select welding processes that match the welding parameters of the welding plate from the preset welding process library; The first calculation module is used to calculate the area of ​​the filled molten droplets based on the welding process and the weld bevel cross-section image; The second calculation module is used to calculate the working current during welding of the weld bevel section based on the area of ​​the filled molten droplets.

5. A computer device, characterized in that, include: A memory and a processor are interconnected, the memory storing computer instructions, and the processor executing the computer instructions to perform the welding process control method according to any one of claims 1 to 3.

6. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions for causing the computer to execute the welding process control method according to any one of claims 1 to 3.

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