A method and system for constructing an online monitoring digital twin model of roll welding

Abstract

The application discloses a kind of roll welding online monitoring digital twinborn model construction method and system, physical space includes: data acquisition device is collected by workshop network roll welding process data of welding equipment, workpiece and sensor, and the welding process data collected is transmitted to digital twinborn digital space;Digital twinborn digital space includes the geometric model of roll welding equipment and workpiece, welding knowledge base model, welding online monitoring model, equipment and workpiece geometric model is the three-dimensional model established according to physical equipment and product technical data;Using data acquisition device to obtain welding process data, drive virtual model, so that the equipment in digital twinborn scene presents consistent motion state, posture and position with real equipment;When abnormal event occurs, digital twinborn system can send alarm information to digital twinborn digital space and alarm device.Real-time acquisition of welding process data is carried out on-line monitoring on roll welding process, and alarm is sent when welding appears abnormal condition.

Description

Technical Field

[0001] This invention relates to the field of typical component processing technology, specifically to a method and system for constructing a digital twin model for online monitoring of roller welding. Background Technology

[0002] Welding robots are gradually replacing human welders and are increasingly widely used in industrial sectors such as shipbuilding, automotive, and machinery manufacturing due to their stable performance, high welding efficiency, high welding quality, and relatively low cost. However, like any complex mechanical equipment, welding robots are prone to various technical problems that can affect production efficiency and product quality, especially in the field of roller welding, where issues such as torch collisions, arc failures preventing arc ignition, and abnormal shielding gas supply are common. Summary of the Invention

[0003] The purpose of this invention is to address the problems encountered in current roller welding processes, such as torch collisions, arc failures preventing arc ignition, and abnormal shielding gas supply. Starting from the key factors affecting roller welding quality, this invention provides a method and system for constructing a digital twin model for online monitoring of roller welding. By acquiring welding process data in real time, the invention enables online monitoring of the roller welding process and issues alarms when abnormal welding conditions occur.

[0004] The technical solution of the present invention is as follows: A method for constructing a digital twin model for online monitoring of roller welding includes the following steps: Physical space construction: The physical space includes welding equipment, 3D welding vision sensor devices, temperature sensor devices, alarm devices, and data acquisition devices; the data acquisition devices include data acquisition programs and deployment program servers. The data acquisition devices collect roller welding process data from welding equipment, workpieces, and sensors through the workshop network, and transmit the collected welding process data to the digital twin digital space. Digital twin digital space construction: The digital twin digital space includes the geometric model of the roller welding equipment and workpiece, the welding knowledge base model, and the welding online monitoring model. The geometric model of the equipment and workpiece is a three-dimensional model established based on the physical equipment and product technical data. Virtual-real mapping: Using data acquisition devices to obtain welding process data, driving virtual models, so that the equipment in the digital twin scene presents the same motion state, posture and position as the real equipment; Anomaly Alarm: When an anomaly occurs, the digital twin system can send alarm information to the digital twin digital space and alarm devices.

[0005] Furthermore, the online welding monitoring model includes a protective gas flow field distribution monitoring unit, a welding position and distance monitoring unit, and a weld point temperature and workpiece thermal field distribution monitoring unit. The protective gas flow field distribution monitoring unit includes a threshold management module, a calculation and analysis module, and a result output module. The protective gas flow field distribution monitoring unit monitors the pressure, concentration, position, distance, and remaining gas level in the cylinder of the protective gas output during the welding process.

[0006] Furthermore, the protective gas flow field distribution monitoring unit specifically includes the following steps: Obtain the gas nozzle inner diameter, valve opening, and gas pressure, and call Fluent fluid dynamics simulation software to analyze the flow field state, pressure, concentration, and coverage area of ​​the gas after it is ejected from the nozzle; The simulation data is output to the Unity 3D engine and the particle system is used to simulate and visualize the flow of compressed gas and its range of influence. When the actual output pressure of the gas approaches or falls below the system threshold, an alarm message is sent to the digital twin digital space and alarm device. The formula for gas pressure is:

[0007] For gas pressure, For gas density, It is the acceleration due to gravity. For gas height, Atmospheric pressure.

[0008] The formula for gas flow rate is:

[0009] In the above formula, The gas flow rate is... The pressure difference between the two ends of the pipeline. For gas density, Let be the cross-sectional area of ​​the gas nozzle.

[0010] Furthermore, the welding position and distance monitoring unit monitors the roller pressing process and the welding process, specifically monitoring the position and angle of the shaft head pressed onto both ends of the cylinder body, the gap between the shaft head and the cylinder body, the positioning accuracy and attitude accuracy of the welding torch, and the welding position accuracy; the welding position and distance monitoring unit specifically includes the following steps: By configuring 3D welding vision sensors, the motion trajectory and position of the press-fitting and welding equipment and workpieces can be obtained in real time. Using a pre-calibrated transformation matrix, the position and orientation data of the object in the camera are transformed into the digital twin digital space coordinate system. The 3D model of the corresponding object in the digital twin digital space is set to the transformed position and orientation. Rigid body components are added to the relevant virtual object model to detect the collision behavior that the virtual model may have in the data-driven motion. The actual processing parameters are compared with the theoretical process parameters to analyze the deviations. When the deviation exceeds a threshold, an alarm message is issued, and the abnormal equipment or workpiece is rendered in the digital twin digital space with special effects. Different spatial coordinates are converted to:

[0011] Represents the transformed coordinates. Represents the coordinates before the transformation. It is a rotation matrix. It is a translation vector, a scaling factor. It is the ratio of corresponding side lengths of two rigid bodies, and the translation vector. Need to rotate the matrix Only after confirmation can confirmation be made. It is a 3x3 matrix.

[0012] Furthermore, the weld point temperature and workpiece thermal field distribution monitoring unit monitors the total welding heat and workpiece thermal field distribution, specifically including the following steps: By acquiring the current and voltage values ​​of the welding equipment, the total heat output during welding is calculated and compared with a threshold. Temperature sensors are used to acquire the thermal field distribution of the workpiece and the temperature changes during welding. Extreme values ​​are extracted and compared with threshold values ​​to analyze the deviation. When the welding temperature exceeds the threshold, an alarm message is issued. The formula for welding heat transfer is:

[0013] Where Q is the amount of welding heat transfer, k is the conductivity coefficient (taken as 0.8), U is the voltage, I is the current, and v is the welding speed.

[0014] Furthermore, the 3D welding vision sensor is installed in front of the welding equipment frame and can capture images of the welding equipment and the position of the roller to be welded; the alarm device is installed at the welding site to receive alarm information issued by the digital twin system.

[0015] This invention also includes a digital twin system for online monitoring of roller welding, which employs a method for constructing a digital twin model for online monitoring of roller welding for control, including: The data acquisition device connects to welding equipment and smart terminal devices via wired and wireless networks in the workshop. The 3D welding vision sensor device adopts an ultrafast laser encoding full-field projection mode, which can directly output three-dimensional point cloud data and connect to the workshop network through a wireless communication device. The temperature sensor device is an infrared temperature sensor, which is connected to the workshop network via a wireless communication device. The alarm device is an audible and visual alarm that connects to the workshop network via a wireless communication device. The online monitoring model for roller welding includes a protective gas flow field distribution monitoring unit, a welding position and distance monitoring unit, and a weld point temperature and workpiece thermal field distribution monitoring unit.

[0016] Furthermore, the protective gas flow field distribution monitoring unit includes a threshold management module, a calculation and analysis module, and a result output module. The protective gas flow field distribution monitoring unit monitors the pressure, concentration, location, distance, and remaining gas level in the cylinder of the protective gas output during the welding process.

[0017] Furthermore, the welding position and distance monitoring unit monitors the roller pressing process and the welding process, specifically monitoring the position and angle of the shaft head pressing onto both ends of the cylinder body, the gap between the shaft head and the cylinder body, the positioning accuracy and posture accuracy of the welding torch, and the welding position accuracy.

[0018] Furthermore, the weld point temperature and workpiece thermal field distribution monitoring unit monitors the total welding heat and workpiece thermal field distribution.

[0019] Compared with existing technologies, the advantages of this invention are: A method and system for constructing a digital twin model for online monitoring of roller welding is disclosed. This system acquires welding process data in real time, monitors the roller welding process online, and issues alarms when abnormal conditions occur during welding. Attached Figure Description

[0020] Figure 1 This is a flowchart illustrating a method and system for constructing a digital twin model for online monitoring of roller welding.

[0021] Figure 2 This is a schematic diagram of the online welding monitoring model structure of a method and system for constructing a digital twin model for online monitoring of roller welding.

[0022] Figure 3 This is a schematic diagram illustrating a method for constructing a digital twin model for online monitoring of roller welding and a method for constructing a protective gas flow field distribution monitoring unit.

[0023] Figure 4 This is a schematic diagram illustrating a method for constructing a digital twin model for online monitoring of roller welding and a method for constructing a monitoring unit for welding position and distance.

[0024] Figure 5 This is a schematic diagram illustrating a method for constructing a digital twin model for online monitoring of roller welding and a method for constructing a monitoring unit for weld point temperature and workpiece thermal field distribution.

[0025] Figure 6 This is a schematic diagram illustrating the functional interaction relationships of a method and system for constructing a digital twin model for online monitoring of roller welding.

[0026] Figure 7 This is a schematic diagram of the data flow for a method and system for constructing a digital twin model for online monitoring of roller welding.

[0027] Figure 8 This is a schematic diagram of the electronic equipment structure of a method and system for constructing a digital twin model for online monitoring of roller welding. Detailed Implementation

[0028] It should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0029] The features and performance of the present invention will be further described in detail below with reference to embodiments.

[0030] Please see Figure 1-8 A method for constructing a digital twin model for online monitoring of roller welding includes the following steps: Physical space construction: The physical space includes welding equipment, 3D welding vision sensor devices, temperature sensor devices, alarm devices, and data acquisition devices; the data acquisition devices include data acquisition programs and deployment program servers. The data acquisition devices collect roller welding process data from welding equipment, workpieces, and sensors through the workshop network, and transmit the collected welding process data to the digital twin digital space. Digital twin digital space construction: The digital twin digital space includes a geometric model of the roller welding equipment, a welding knowledge base model, and a welding online monitoring model. The three-dimensional geometric model of the equipment is a three-dimensional model established based on the physical welding equipment, while the geometric models of the equipment and the workpiece are three-dimensional models established based on the physical equipment and product technical data. Virtual-real mapping: Using data acquisition devices to obtain welding process data, driving virtual models, so that the equipment in the digital twin scene presents the same motion state, posture and position as the real equipment; Anomaly Alarm: When an anomaly occurs, the digital twin system can send alarm information to the digital twin digital space and alarm devices.

[0031] The online welding monitoring model includes a protective gas flow field distribution monitoring unit, a welding position and distance monitoring unit, and a weld point temperature and workpiece thermal field distribution monitoring unit. The protective gas flow field distribution monitoring unit includes a threshold management module, a calculation and analysis module, and a result output module. The protective gas flow field distribution monitoring unit monitors the pressure, concentration, position, distance, and remaining gas level in the cylinder of the protective gas output during the welding process.

[0032] The protective gas flow field distribution monitoring unit specifically includes the following steps: Obtain the gas nozzle inner diameter, valve opening, and gas pressure, and call Fluent fluid dynamics simulation software to analyze the flow field state, pressure, concentration, and coverage area of ​​the gas after it is ejected from the nozzle; The simulation data is output to the Unity 3D engine and the particle system is used to simulate and visualize the flow of compressed gas and its range of influence. When the actual output pressure of the gas approaches or falls below the system threshold, an alarm message is sent to the digital twin digital space and alarm device. The formula for gas pressure is:

[0033] For gas pressure, For gas density, It is the acceleration due to gravity. For gas height, Atmospheric pressure.

[0034] The formula for gas flow rate is:

[0035] In the above formula, The gas flow rate is... The pressure difference between the two ends of the pipeline. For gas density, Let be the cross-sectional area of ​​the gas nozzle.

[0036] The welding position and distance monitoring unit monitors the roller pressing process and the welding process. Specifically, it monitors the position and angle of the shaft head pressing onto both ends of the cylinder body, the gap between the shaft head and the cylinder body, the positioning accuracy and attitude accuracy of the welding torch, and the welding position accuracy. The welding position and distance monitoring unit specifically includes the following steps: By configuring 3D welding vision sensors, the motion trajectory and position of the press-fitting and welding equipment and workpieces can be obtained in real time. Using a pre-calibrated transformation matrix, the position and orientation data of the object in the camera are transformed into the digital twin digital space coordinate system. The 3D model of the corresponding object in the digital twin digital space is set to the transformed position and orientation. Rigid body components are added to the relevant virtual object model to detect the collision behavior that the virtual model may have in the data-driven motion. The actual processing parameters are compared with the theoretical process parameters to analyze the deviations. When the deviation exceeds a threshold, an alarm message is issued, and the abnormal equipment or workpiece is rendered in the digital twin digital space with special effects. Different spatial coordinates are converted to:

[0037] Represents the transformed coordinates. Represents the coordinates before the transformation. It is a rotation matrix. It is a translation vector, a scaling factor. It is the ratio of corresponding side lengths of two rigid bodies, and the translation vector. Need to rotate the matrix Only after confirmation can confirmation be made. It is a 3x3 matrix.

[0038] The weld point temperature and workpiece thermal field distribution monitoring unit monitors the total welding heat and workpiece thermal field distribution, specifically including the following steps: By acquiring the current and voltage values ​​of the welding equipment, the total heat output during welding is calculated and compared with a threshold. Temperature sensors are used to acquire the thermal field distribution of the workpiece and the temperature changes during welding. Extreme values ​​are extracted and compared with threshold values ​​to analyze the deviation. When the welding temperature exceeds the threshold, an alarm message is issued. The formula for welding heat transfer is:

[0039] Where Q is the amount of welding heat transfer, k is the conductivity coefficient (taken as 0.8), U is the voltage, I is the current, and v is the welding speed.

[0040] The 3D welding vision sensor is installed in front of the welding equipment frame and can capture images of the welding equipment and the position of the roller to be welded; the alarm device is installed at the welding site to receive alarm information issued by the digital twin system.

[0041] This invention also includes a digital twin system for online monitoring of roller welding, which employs a method for constructing a digital twin model for online monitoring of roller welding for control, including: The data acquisition device connects to the welding equipment and smart terminal devices via wired and wireless networks in the workshop. The 3D welding vision sensor device adopts an ultrafast laser encoding full-field projection mode, which can directly output three-dimensional point cloud data and connect to the workshop network through a wireless communication device. The temperature sensor device is an infrared temperature sensor, which is connected to the workshop network via a wireless communication device. The alarm device is an audible and visual alarm that connects to the workshop network via a wireless communication device. The online monitoring model for roller welding includes a protective gas flow field distribution monitoring unit, a welding position and distance monitoring unit, and a weld point temperature and workpiece thermal field distribution monitoring unit.

[0042] The protective gas flow field distribution monitoring unit includes a threshold management module, a calculation and analysis module, and a result output module. The protective gas flow field distribution monitoring unit monitors the pressure, concentration, location, distance, and remaining gas level in the cylinder of the protective gas output during the welding process.

[0043] The welding position and distance monitoring unit monitors the roller pressing process and the welding process, specifically monitoring the position and angle of the shaft head pressing onto both ends of the cylinder body, the gap between the shaft head and the cylinder body, the positioning accuracy and posture accuracy of the welding torch, and the welding position accuracy.

[0044] The welding point temperature and workpiece thermal field distribution monitoring unit monitors the total welding heat and workpiece thermal field distribution.

[0045] The embodiments described above merely illustrate specific implementation methods of this application, and while the descriptions are detailed and specific, they should not be construed as limiting the scope of protection of this application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the technical solution of this application, and these modifications and improvements all fall within the scope of protection of this application.

Claims

1. A method for constructing a digital twin model for online monitoring of roller welding, characterized in that, Includes the following steps: Physical space construction: The physical space includes roller welding equipment and workpieces, 3D welding vision sensor devices, temperature sensor devices, alarm devices, and data acquisition devices; The data acquisition device includes a data acquisition program and a server for the deployment program. The data acquisition device collects roller welding process data from welding equipment, workpieces and sensors through the workshop network, and transmits the collected welding process data to the digital twin digital space. Digital twin digital space construction: The digital twin digital space includes the geometric model of the roller welding equipment and workpiece, the welding knowledge base model, and the welding online monitoring model. The geometric model of the equipment and workpiece is a three-dimensional model established based on the physical equipment and product technical data. Virtual-real mapping: Using data acquisition devices to obtain welding process data, driving virtual models, so that the equipment in the digital twin scene presents the same motion state, posture and position as the real equipment; Anomaly Alarm: When an anomaly occurs, the digital twin system can send alarm information to the digital twin digital space and alarm devices; The welding online monitoring model includes a shielding gas flow field distribution monitoring unit, a welding position and distance monitoring unit, and a weld point temperature and workpiece thermal field distribution monitoring unit. The shielding gas flow field distribution monitoring unit includes a threshold management module, a calculation and analysis module, and a result output module. The shielding gas flow field distribution monitoring unit monitors the pressure, concentration, position, distance, and remaining gas level in the cylinder of the shielding gas output during the welding process. The welding position and distance monitoring unit monitors the roller pressing process and the welding process. Specifically, it monitors the position and angle of the shaft head pressing onto both ends of the cylinder body, the gap between the shaft head and the cylinder body, the positioning accuracy and attitude accuracy of the welding torch, and the welding position accuracy. The welding position and distance monitoring unit specifically includes the following steps: By configuring 3D welding vision sensors, the motion trajectory and position of the press-fitting and welding equipment and workpieces can be obtained in real time. Using a pre-calibrated transformation matrix, the position and orientation data of the object in the camera are transformed into the digital twin digital space coordinate system. The 3D model of the corresponding object in the digital twin digital space is set to the transformed position and orientation. Rigid body components are added to the relevant virtual object model to detect the collision behavior that the virtual model may have in the data-driven motion. The actual processing parameters are compared with the theoretical process parameters to analyze the deviations. When the deviation exceeds a threshold, an alarm message is issued, and the abnormal equipment or workpiece is rendered in the digital twin digital space with special effects. Different spatial coordinates are converted to: Represents the transformed coordinates. Represents the coordinates before the transformation. It is a rotation matrix. It is a translation vector, a scaling factor. It is the ratio of corresponding side lengths of two rigid bodies, and the translation vector. Need to rotate the matrix Only after confirmation can confirmation be made. It is a 3x3 matrix.

2. The method for constructing a digital twin model for online monitoring of roller welding according to claim 1, characterized in that, The protective gas flow field distribution monitoring unit specifically includes the following steps: Obtain the gas nozzle inner diameter, valve opening, and gas pressure, and call Fluent fluid dynamics simulation software to analyze the flow field state, pressure, concentration, and coverage area of ​​the gas after it is ejected from the nozzle; The simulation data is output to the Unity 3D engine and the particle system is used to simulate and visualize the flow of compressed gas and its range of influence. When the actual output pressure of the gas is close to or less than the system threshold, an alarm message is sent to the digital twin digital space and alarm device.

3. The method for constructing a digital twin model for online monitoring of roller welding according to claim 1, characterized in that, The weld point temperature and workpiece thermal field distribution monitoring unit monitors the total welding heat and workpiece thermal field distribution, specifically including the following steps: By acquiring the current and voltage values ​​of the welding equipment, the total heat output during welding is calculated and compared with a threshold. Temperature sensors are used to acquire the thermal field distribution of the workpiece and the temperature changes during welding. Extreme values ​​are extracted and compared with threshold values ​​to analyze the deviation. When the welding temperature exceeds the threshold, an alarm message is issued. The formula for welding heat transfer is: Where Q is the amount of welding heat transfer, k is the conductivity coefficient (taken as 0.8), U is the voltage, I is the current, and v is the welding speed.

4. The method for constructing a digital twin model for online monitoring of roller welding according to claim 1, characterized in that, The 3D welding vision sensor is installed in front of the welding equipment frame and can capture images of the welding equipment and the position of the roller to be welded; the alarm device is installed at the welding site to receive alarm information issued by the digital twin system.

5. A digital twin system for online monitoring of roller welding, characterized in that, Control is achieved using a digital twin model construction method for online monitoring of roller welding according to any one of claims 1-4, comprising: The data acquisition device connects to welding equipment and smart terminal devices via wired and wireless networks in the workshop. The 3D welding vision sensor device adopts an ultrafast laser encoding full-field projection mode, which can directly output three-dimensional point cloud data and connect to the workshop network through a wireless communication device. The temperature sensor device is an infrared temperature sensor, which is connected to the workshop network via a wireless communication device. The alarm device is an audible and visual alarm that connects to the workshop network via a wireless communication device. The online monitoring model for roller welding includes a protective gas flow field distribution monitoring unit, a welding position and distance monitoring unit, and a weld point temperature and workpiece thermal field distribution monitoring unit. The protective gas flow field distribution monitoring unit includes a threshold management module, a calculation and analysis module, and a result output module. The protective gas flow field distribution monitoring unit monitors the pressure, concentration, location, distance, and remaining gas level in the cylinder of the protective gas output during the welding process. The welding position and distance monitoring unit monitors the roller pressing process and the welding process, specifically monitoring the position and angle of the shaft head pressing onto both ends of the cylinder body, the gap between the shaft head and the cylinder body, the positioning accuracy and posture accuracy of the welding torch, and the welding position accuracy.

6. The digital twin system for online monitoring of roller welding according to claim 5, characterized in that, The welding point temperature and workpiece thermal field distribution monitoring unit monitors the total welding heat and workpiece thermal field distribution.

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