Multifunctional titanium alloy welding station and welding method

Abstract

The application discloses a multifunctional titanium alloy welding workstation and a welding method, which comprises an argon cabin, a positioner, a welding robot and a gas control system. The argon cabin has at least one accommodation space which is kept closed during work to provide a stable welding environment. The positioner is arranged in the argon cabin and is used to adjust the posture of the workpiece to be welded to realize the welding of complex products. The welding robot is arranged in the argon cabin and is based on a preconfigured vision system and a control system to automatically weld the workpiece. The gas control system is used to detect the content of the predetermined gas in the argon cabin and control it within the preset range. The welding process is monitored and controlled in real time by using the vision system and the data analysis module, the deviation of the argon concentration is corrected, the image data of the welding area is obtained, and the evaluation result of the welding quality is output. The high-quality and high-efficiency welding of the titanium alloy workpiece with a complex shape is realized, and the performance and reliability of the product are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to welding technology, especially titanium alloy welding related technology. BACKGROUND

[0002] Titanium alloy is a kind of metal material with excellent mechanical properties and corrosion resistance, which is widely used in aerospace, chemical industry, medical treatment, automobile and other fields. The welding of titanium alloy is an indispensable technical means in the manufacturing and processing of titanium alloy, which plays an important role in the integrity and reliability of titanium alloy structure. However, the welding of titanium alloy also faces many technical problems, mainly in the following aspects: the chemical activity of titanium alloy is high, which is easy to be polluted by oxygen, nitrogen, hydrogen and other gases, resulting in the defects of weld embrittlement, cracking, porosity and other defects, which reduces the welding quality and performance, so it is necessary to carry out welding in strict gas protection environment to ensure the purity and stability of the atmosphere in the welding area. The thermal conductivity of titanium alloy is low, and the heat generated during welding is difficult to dissipate, which leads to the increase of the temperature in the welding area and increases the risk of welding deformation and residual stress. Therefore, reasonable preheating, postheating and stress relief treatment should be adopted to control the welding temperature and cooling rate, and reduce the welding stress and deformation. The welding process of titanium alloy is complex, which needs to consider many factors such as welding method, welding parameter, welding equipment, welding process flow and so on, and the technical level and operation experience of the welding personnel are required to be higher. Therefore, advanced welding technology and equipment should be adopted to realize the automation, intelligence and precision of welding, and improve the welding efficiency and stability.

[0003] In view of the above problems, the technical personnel provides some solutions, including argon arc welding, submerged arc welding, electron beam welding, laser welding and friction welding, but there are still many problems and defects, and there are still some problems or defects in welding speed, weld quality, welding deformation, welding equipment, welding parameter, welding environment, welding cost and applicability. SUMMARY

[0004] The present application provides a multifunctional titanium alloy welding workstation and welding method to solve the above problems existing in the prior art.

[0005] Technical scheme, a multifunctional titanium alloy welding workstation is provided, which comprises:

[0006] An argon cabin with at least one closed receiving space to provide a stable welding environment;

[0007] A positioner is arranged in the argon cabin to adjust the attitude of the workpiece to be welded, so as to realize the welding of complex products;

[0008] A welding robot is arranged in the argon cabin, which is based on a preconfigured vision system and control system to automatically weld the workpiece;

[0009] A gas control system for detecting the content of a predetermined gas in an argon tank and controlling it within a preset range.

[0010] According to an aspect of the present application, the argon tank comprises:

[0011] The body is integrally welded and provided with a reticular reinforcing rib;

[0012] The door is driven by a motor to slide open in a direction determined by a gear and rack pair, and a sealing lock and an inflatable sealing pad are arranged between the door and the body.

[0013] The transition chamber is arranged on one side of the argon tank and used for tool access to the body.

[0014] The glove port is provided with a sealing cover and a pressure balancing device to maintain the balance of the pressure inside and outside the glove when the gas in the tank is replaced by vacuum.

[0015] According to an aspect of the present application, the visual system comprises:

[0016] The first laser is used for argon concentration detection and correction.

[0017] The second laser is used for welding area quality detection and adopts a grid laser.

[0018] The coupler couples the laser emitted by the first laser and the second laser to light and emits it to the welding area through an optical window.

[0019] The reflected light guide receives the coupled laser signal reflected from the welding area.

[0020] The light splitter divides the coupled laser signal into two laser beams.

[0021] The photodetector receives the optical signals of the light splitter respectively and converts them into electrical signals.

[0022] The data analysis module calculates the argon concentration and obtains the image data of the welding area based on the received electrical signals.

[0023] According to an aspect of the present application, the data analysis module comprises:

[0024] The argon concentration calculation module obtains the absorption intensity of argon based on a preconfigured laser absorption spectrum model, establishes a mathematical model of the absorption intensity of argon and the argon concentration based on the Lambert-Beer law, and inversely calculates the concentration of argon through the emission and absorption of laser intensity of the first laser.

[0025] The concentration deviation calculation module receives the argon concentration values in at least three time periods, then calculates the mean value, compares the mean value with the pre-stored argon filling concentration, obtains the argon concentration difference value, and calculates whether the argon concentration difference value exceeds a threshold value.

[0026] The welding image generation module receives the electrical signal of the reflected light of the second laser, pre-processes, then performs fusion analysis on the weld image under the grid laser irradiation, corrects and registers the image through the position and intensity information of the grid laser, and finally calculates the three-dimensional coordinates of the welding area through triangulation; the three-dimensional coordinate data of the weld is used to reconstruct the three-dimensional curved surface model of the welding area through interpolation and fitting, so as to obtain the width, depth, height and angle, and form the welding area vector image;

[0027] The welding quality output module outputs the welding area vector image if the argon concentration difference value does not exceed the threshold value; if the threshold value is exceeded, the welding area vector image is corrected and output.

[0028] According to one aspect of the present application, the process of correcting and outputting the welding area vector image is further:

[0029] The welding area vector image is read and corrected according to the size and direction of the argon concentration difference value, and the type of transformation and the parameters of the transformation are determined;

[0030] According to the type of transformation and the parameters, a transformation matrix is established, and the three-dimensional coordinates of the welding area are multiplied by the transformation matrix to obtain the three-dimensional coordinates of the corrected welding area;

[0031] The three-dimensional coordinates of the corrected welding area are used to reconstruct the three-dimensional curved surface model of the corrected welding area through interpolation and fitting, so as to obtain the corrected width, depth, height and angle, and form the corrected welding area vector image;

[0032] The corrected welding area vector image is output.

[0033] According to one aspect of the present application, the distance between the emitting port and the receiving port of the laser is less than a threshold value.

[0034] According to one aspect of the present application, it further comprises: gloves on both sides of the body, which realize manual welding of the body through the gloves; the gloves are composed of a glove flange, a glove sealing cover and a butyl rubber glove, and the gloves are equipped with a glove sealing cover and a glove vacuum pressure balancing device, so as to maintain the balance of the pressure inside and outside the gloves during the gas vacuum replacement of the box.

[0035] According to one aspect of the present application, it further comprises:

[0036] The transfer trolley is used to transfer the positioner and the manual platform between the inside and outside of the working cabin; when loading and unloading the workpiece, the transfer trolley moves the positioner and the manual platform to the outside of the working cabin, facilitating the loading and unloading of the workpiece;

[0037] When welding work is needed, the transfer trolley transfers the positioner and the manual platform after fixing the workpiece into the work cabin to perform the welding work.

[0038] According to an aspect of the present application, the control system comprises:

[0039] The automatic control module, the cabin pressure is controlled by the control system, the working pressure can be freely set within the specified range, and is controlled within the set range, and the system will automatically stop when the pressure set range is exceeded;

[0040] The leakage rate detection module analyzes the change of oxygen in a period of time through an oxygen analyzer, and automatically calculates the leakage rate of the argon cabin by combining with the software technology.

[0041] According to an aspect of the present application, the method comprises the following steps:

[0042] S1. Replacement and purification of gas in the argon cabin

[0043] S11. Fix the workpiece to be welded on the positioner or the manual welding platform, and transfer it from the loading area into the welding area in the argon cabin through the transfer trolley, and close the pass-through door;

[0044] S12. Perform vacuum pumping work on the argon cabin, fill argon into the argon cabin after reaching the specified pressure, and detect the oxygen and water vapor content in the argon cabin through the online detection system to determine whether the welding requirements are met;

[0045] S13. If the oxygen and water vapor content does not meet the welding requirements, open the circulating purification device to purify the atmosphere in the argon cabin, adsorb oxygen and water vapor in the atmosphere, and increase the concentration of argon in the argon cabin until the set range is reached;

[0046] S2. Automatic welding by robot

[0047] S21. Start the automatic welding of the robot, and perform welding on the workpiece to be welded. The visual driving welding technology is adopted, and the robot is guided by the offline programming software and the vision camera to realize the visual teaching programming.

[0048] S22. When the robot is automatically welding, the dust removal and purification system is started at the same time to process the welding fume during the welding process. The internal circulation structure is adopted, that is, the gas in the cabin is extracted from one side of the cabin body, passes through the dust removal filter, and then the filtered gas is sent into the cabin to realize the purification treatment of the welding fume in the cabin.

[0049] S23. After the automatic welding of the robot is completed, if manual welding is needed, the operator performs manual welding through the glove port on both sides of the argon cabin.

[0050] S3. Discharge and cleaning of gas in the argon cabin

[0051] S31. After the welding is completed, the internal circulation dust removal and purification equipment is purified and dusted for a period of time to filter the welding fume and reduce the welding fume emission amount.

[0052] S32. After the internal circulation purification is performed to the specified time, the fan for exhaust and the air inlet valve are opened, the argon gas in the cabin is exhausted to the outside of the cabin through the fan, and the air outside the cabin enters the cabin through the air inlet valve, so that the argon gas concentration in the argon gas cabin is diluted, and the danger of personnel entering the cabin after the argon gas cabin is opened is avoided.

[0053] S33. After the argon gas dilution is completed, that is, the oxygen concentration in the cabin reaches the specified concentration, the through door is opened, and the safety lock is manually closed to prevent human error from causing the through door to be closed.

[0054] S34. After the through door is opened, the transfer car moves the positioner and the manual welding platform out of the argon gas cabin, removes the welded workpiece, and completes the single workpiece welding work.

[0055] Advantages, the present application can utilize the visual system and the data analysis module to monitor and control the welding process in real time, correct the deviation of the argon gas concentration, obtain the image data of the welding area, and output the evaluation result of the welding quality; can realize high-quality and high-efficiency welding of titanium alloy workpieces with complex shapes, improve the performance and reliability of products; can effectively protect the welding area from atmospheric pollution such as oxygen, nitrogen, water vapor, etc., prevent the embrittlement and pore generation of the weld, and improve the strength and toughness of the weld. The advantages of related technologies will be described in detail in the specific embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0056] Figure 1 is a structural schematic diagram of the present application.

[0057] Figure 2 is a flowchart of the present application. DETAILED DESCRIPTION

[0058] As Figure 1 shown, a multifunctional titanium alloy welding workstation is provided, comprising:

[0059] an argon gas cabin having at least one accommodation space that is kept closed during work to provide a stable welding environment;

[0060] a positioner arranged in the argon gas cabin and used to adjust the posture of the workpiece to be welded to realize welding of complex products;

[0061] a welding robot arranged in the argon gas cabin and based on a preconfigured visual system and control system to automatically weld the workpiece;

[0062] A gas control system for detecting the content of a predetermined gas in an argon cabin and controlling it within a preset range.

[0063] In the present application, in order to solve the above problems existing in the prior art, a closed working space is constructed to control the welding environment and ensure the stability of the welding environment, thereby overcoming the welding quality problems caused by the instability of the welding environment existing in the prior art. At the same time, through the automatic welding process, the problem of high requirement for welding technology and operation experience is solved, and through the machine vision and automatic control system, autonomous welding is realized.

[0064] In a specific embodiment, it comprises:

[0065] Argon cabin: used to ensure the requirements and stability of the welding environment during titanium alloy welding; the system includes an argon cabin body, a passing door, a transition cabin, a glove port, an observation window, a camera monitoring system, and a detection feedback and early warning system.

[0066] Argon cabin body: the cabin body is integrally welded, and the outside of the cabin body is reinforced with a mesh to ensure the rigidity and strength of the entire cabin during vacuumizing.

[0067] Passing door: a passing door is arranged on the cabin body for the passing of a positioner; the passing door is horizontally divided into two parts, and is driven by a motor and slid open through a gear and rack transmission; the sealing lock between the passing door and the cabin body is forced by a cylinder, and the sealing is achieved by using an inflatable sealing pad; the passing door has both automatic and manual closing and opening functions; an infrared anti-pinch sensor is arranged on the door; after the door is opened, an audible and visual indication is given to prompt the manual locking of a door closing mechanical lock to avoid the closing of the door when there is a person in the cabin; when the door is closed, the position of the mechanical lock is first detected, and the door can be closed only after the mechanical lock is opened.

[0068] Transition cabin: a transition cabin is arranged on one side of the argon cabin, and small items and tools can be transferred in and out of the argon cabin through the transition cabin to avoid damaging the environment of the entire argon cabin due to the transfer of small items.

[0069] Glove port: glove ports are arranged on both sides of the cabin body to realize manual welding in the cabin; the glove port is composed of a glove port flange, a glove port sealing cover, and a butyl rubber glove (butyl rubber material is standard), and the glove port is equipped with a glove port sealing cover and a glove port vacuum pressure balancing device to facilitate the balance of the pressure inside and outside the glove during the gas vacuum replacement of the box.

[0070] Observation window: an observation window is arranged on the cabin body, and the observation window adopts a double-sealing structure; one layer is a transparent protective glass to ensure the rigidity and strength of the observation window under extreme vacuum, and the other layer is an anti-arc radiation glass to prevent light pollution during welding.

[0071] Camera: The cabin is provided with a monitoring camera. The display device of the camera can display the conditions of the internal equipment of the cabin (such as the positioner, robot, and welded workpiece) and the welding working condition, so as to facilitate manual troubleshooting and processing.

[0072] Detection feedback warning function: The cabin is provided with sensors such as a vacuum gauge, a water content detector, an oxygen content detector, and a pressure detector, which can realize vacuum measurement, water content detection, oxygen content detection, and pressure measurement.

[0073] Industrial robot: The welding gun of the welding system is fixedly installed on the six-axis robot. The robot is used as an automatic welding execution mechanism to realize automatic welding of the robot.

[0074] Positioner: The control system of the positioner is integrated into the robot controller, and uses the same driving technology and programming software as the robot. The positioner can be operated by a teach pendant outside the cabin. The positioner can realize welding of more complex products.

[0075] Transfer trolley: The positioner and the manual welding platform are fixedly installed on the transfer trolley. The transfer trolley is responsible for transferring the positioner and the manual platform between the inside and outside of the working cabin. When loading and unloading the workpiece, the transfer trolley moves the positioner and the manual platform to the outside of the working cabin to facilitate loading and unloading of the workpiece. When welding is needed, the transfer trolley moves the positioner and the manual platform with the workpiece to the inside of the working cabin for welding.

[0076] Manual platform: The manual platform is arranged on both sides of the positioner mechanism. The arrangement of the manual platform does not affect the operation of the positioner and can meet the needs of automatic and manual welding. In order to consider the ergonomics and facilitate manual welding, the workbench has a lifting function. The lifting is driven by electricity, and personnel outside the cabin can realize the lifting action of the workbench.

[0077] Vacuum pump equipment: The vacuum pump is used for vacuumizing the argon cabin to realize the function of replacing the gas in the cabin. The vacuum pump adopts a dual-pole pump to ensure the vacuum degree of the argon cabin. The primary pump adopts a rotary vane pump, and the secondary pump adopts a Roots vacuum pump.

[0078] Argon circulation purification equipment: the equipment in a cyclic manner to achieve the water and oxygen removal from the argon cabin gas; through the cycle of water and oxygen removal to achieve the maintenance function of the cabin atmosphere, ensure the content of water and oxygen in the cabin; the equipment uses physical adsorption to remove water in the atmosphere, and uses chemical catalytic method to remove oxygen; water and oxygen removal agent can be activated by regeneration method for repeated use; oxygen removal agent regeneration is reduced by heating and reducing gas, CuO+H2 heated to 200°C Cu+H2O, the reducing gas of oxygen removal agent is argon-hydrogen mixed gas, the hydrogen content is 5-10%, the rest is argon, the water removal agent is regenerated by heating and vacuumizing to realize physical desorption activation and repeated use.

[0079] Internal circulation dust removal purification equipment: through the equipment, the welding fume generated in the argon welding process is filtered to reduce the harm of welding fume to the environment and operators; through the circulation dust removal fan, the gas in the cabin is extracted and filtered through the dust removal tank, and the dust removal gas is transported to the cabin to complete the welding fume circulation dust removal work.

[0080] Welding equipment: mainly used for welding work of welding products, the welding equipment includes automatic welding equipment and manual welding equipment.

[0081] Operation control system: the system is used for action program control, detection of the whole set of equipment and as a carrier of visual driving welding technology software; it has interlock protection, emergency stop protection, alarm function, cabin pressure automatic control function, self-detection leakage rate and other functions.

[0082] Interlock protection function: each system and device has safety interlock protection function, that is, when the system or device action changes, the specified conditions must be met to execute the related action change; through the interlock function of the control system, the safety of the operator and the equipment is ensured.

[0083] Emergency protection function: the control cabinet and control panel are provided with emergency stop button, which stops the protection of the equipment action in emergency state.

[0084] Alarm function: when an abnormality occurs, an alarm will be given to remind the abnormal state on the operation screen.

[0085] Cabin pressure automatic control function: the cabin pressure is controlled by the control system, the working pressure can be freely set within the specified range, and controlled within the set range, and the system will automatically stop protection when the pressure exceeds the set range.

[0086] Self-detection leakage rate function: the oxygen analyzer analyzes the change of oxygen in a period of time, and the calculation software automatically calculates the leakage rate of the argon cabin.

[0087] Visual system: the system is mainly used for obtaining the information of the weld of the product to be welded; the visual camera of the system is fixedly installed on the sixth axis flange of the robot, and the robot is used as an executing mechanism to realize the robot teaching-free operation by cooperating with the visual driving welding technology software.

[0088] According to an aspect of the present application, the argon cabin comprises:

[0089] The body is integrally welded and is provided with mesh reinforcing ribs;

[0090] The door is provided with a sealing lock and an inflatable sealing pad between the door and the body.

[0091] The transition cabin is arranged on one side of the argon cabin and is used for the tool to enter and exit the body.

[0092] The glove port is provided with a sealing cover and a pressure balancing device to keep the pressure balance inside and outside the glove when the gas in the box is replaced in vacuum.

[0093] The body is integrally welded and is provided with mesh reinforcing ribs, which can enhance the rigidity and strength of the cabin body and prevent deformation or cracking due to pressure change; the door is provided with a motor-driven gear and rack pair transmission and sliding open structure, which can realize fast, stable and safe opening and closing, save time and space, and avoid leakage of argon and pollution from the outside; the door and the body are provided with a sealing lock and an inflatable sealing pad, which can further improve the sealing performance of the argon cabin, ensure the purity and stability of argon, and improve the welding quality; the transition cabin is arranged on one side of the argon cabin and is used for the tool to enter and exit the body, which can conveniently replace or adjust the welding tool, reduce the consumption and waste of argon, and reduce the cost; the glove port is provided with a sealing cover and a pressure balancing device to keep the pressure balance inside and outside the glove when the gas in the box is replaced in vacuum, which can prevent the glove from being damaged or falling off, protect the safety of the operator, and also realize the flexibility and adaptability of manual welding.

[0094] According to an aspect of the present application, the visual system comprises:

[0095] The first laser is used for argon concentration detection and correction.

[0096] The second laser is used for welding area quality detection and adopts a grid laser.

[0097] The coupler couples the laser emitted by the first laser and the second laser to light and emits to the welding area through an optical window.

[0098] The reflected light guide receives the coupled laser signal reflected from the welding area.

[0099] The light splitter divides the coupled laser signal into two beams of laser.

[0100] A photodetector receives the optical signal from the optical splitter and converts it into an electrical signal.

[0101] A data analysis module calculates the argon concentration based on the received electrical signal and obtains image data of the welding area.

[0102] The laser emitted by the first laser can monitor the argon concentration in the argon tank in real time, and automatically adjust the welding parameters according to the change of the argon concentration, to ensure the welding quality and efficiency. The grid laser emitted by the second laser can scan the welding area with high precision, obtain the image data of the welding area, and detect and evaluate the surface topography, defects, cracks, etc. of the welding area through the data analysis module, to discover and handle welding problems in time. The laser emitted by the two lasers is coupled together through the coupler and emitted through the same optical window, reducing the complexity and cost of the optical system and improving the stability and reliability of the optical system. At the same time, the coupled laser signal reflected from the welding area is received and transmitted to the optical splitter through the reflective light guide, realizing the separation and conversion of the photoelectric signal and improving the signal-to-noise ratio and sensitivity of the signal.

[0103] Some prior art can refer to patents or published papers of the applicant, related persons or peers. For the technology that the applicant has applied but not yet disclosed, please refer to patents such as CN2023230916454 and CN2023226983390. In order to avoid repetition of patent content, it will not be described in detail here. In fact, the working environment such as argon concentration in the optical path is detected by one laser, and the image recognition and processing effect of another laser is corrected, so as to improve the recognition accuracy of the welding surface.

[0104] In further embodiments, the accuracy of subsequent laser image imaging is verified by the argon detection concentration and laser image recognition concentration of several areas that have been welded, to continuously improve the quality of subsequent welding.

[0105] In further embodiments, the laser wavelength for argon concentration detection needs to match the absorption peak of argon, such as selecting near-infrared laser around 1.5 μm. The laser wavelength for welding quality detection needs to be able to effectively penetrate plasma and metal vapor, such as selecting visible light or near-infrared laser between 0.8~1.1 μm. The laser power for argon concentration detection does not need to be very high, as long as it can produce enough absorption signal, for example between several tens of milliwatts to several hundred milliwatts. The laser power for welding quality detection needs to be high to achieve deep penetration welding effect, for example between several thousand watts to several ten thousand watts.

[0106] In further embodiments, parallel laser light paths can be provided instead of coupling two lasers into one light path. If a welding laser is also provided, it can be coupled with one of the laser light paths, such as the laser light path for argon concentration detection, which needs to be separated from the welding laser light path to avoid interference, generally using a beam splitter or fiber coupling to irradiate the welding area from the same direction. The laser light path for welding quality detection needs to coincide with the welding laser light path to ensure the alignment of the weld, generally using a mirror or lens to focus the laser on the welding area from different directions.

[0107] According to an aspect of the present application, the data analysis module comprises:

[0108] An argon concentration calculation module, based on a pre-configured laser absorption spectrum model, obtains the absorption intensity of argon, and establishes a mathematical model of the absorption intensity of argon and the argon concentration combined with the Lambert-Beer law, and inversely deduces the concentration of argon through the emission and absorption of laser intensity of the first laser;

[0109] A concentration deviation calculation module receives the argon concentration values in at least three time periods, then calculates the mean value, and compares the mean value with the pre-stored argon filling concentration to obtain the argon concentration difference, and calculates whether the argon concentration difference exceeds the threshold value;

[0110] A welding image generation module receives the electrical signal of the reflected light of the second laser, pre-processes, then performs fusion analysis on the weld image under the grid laser irradiation, corrects and registers the image through the position and intensity information of the grid laser, and finally calculates the three-dimensional coordinates of the welding area through triangulation method; using the three-dimensional coordinate data of the weld, through interpolation and fitting, the three-dimensional curved surface model of the welding area is reconstructed, so as to obtain the width, depth, height and angle, and form the welding area vector image;

[0111] A welding quality output module, if the argon concentration difference does not exceed the threshold value, the welding area vector image is output; if it exceeds the threshold value, the welding area vector image is corrected and output.

[0112] The laser absorption spectrum technology is used to quickly and accurately measure the argon concentration in the argon tank, avoid using traditional gas analyzers, save time and cost, and improve the measurement efficiency and accuracy. The change trend of the argon concentration can be monitored in real time, abnormal fluctuations in the argon concentration can be found in time, and it can be judged whether the set threshold is exceeded, thereby providing a basis and guidance for the control of the welding quality. The grid laser technology can be used to scan the welding area at high resolution, obtain image data of the welding area, calculate the three-dimensional coordinates of the welding area through triangulation, and reconstruct a three-dimensional curved surface model of the welding area, so as to obtain the width, depth, height and angle of the welding area, and provide detailed information for the evaluation of the welding quality. According to the size and direction of the argon concentration difference, the type and parameters of the transformation of the three-dimensional coordinates of the welding area are determined, the welding area vector image is corrected, the influence of the argon concentration is eliminated, and more accurate welding quality results are output.

[0113] According to one aspect of the present application, the process of outputting the corrected welding area vector image is further:

[0114] read and determine the type and parameters of the transformation of the three-dimensional coordinates of the welding area according to the size and direction of the argon concentration difference;

[0115] According to the transformation type and parameters, a transformation matrix is established, the three-dimensional coordinates of the welding area are multiplied by the transformation matrix to obtain the corrected three-dimensional coordinates of the welding area;

[0116] Using the corrected three-dimensional coordinates of the welding area, the corrected three-dimensional curved surface model of the welding area is reconstructed through interpolation and fitting, so as to obtain the corrected width, depth, height and angle, and form the corrected welding area vector image;

[0117] output the corrected welding area vector image.

[0118] According to one aspect of the present application, the distance between the emitting port and the receiving port of the laser is less than a threshold value, by reducing the moving distance of the laser in the non-light guide, the influence of the concentration change on the reflected laser is reduced, thereby improving the accuracy and precision of the detection.

[0119] By determining the transformation type and parameters of the three-dimensional coordinates of the welding area according to the size and direction of the argon concentration difference, automatic adjustment of the three-dimensional coordinates of the welding area can be realized, thereby eliminating the influence of argon concentration on welding quality and improving welding precision and stability. By establishing a transformation matrix and performing matrix multiplication between the three-dimensional coordinates of the welding area and the transformation matrix, the transformation calculation of the three-dimensional coordinates of the welding area can be simplified, the calculation amount and time can be reduced, and the calculation efficiency and speed can be improved. By using the corrected three-dimensional coordinates of the welding area, the three-dimensional surface model of the corrected welding area can be reconstructed through interpolation and fitting, and parameters such as the width, depth, height, and angle of the corrected welding area can be obtained, providing detailed information for the evaluation of welding quality. By outputting the corrected welding area vector image, more accurate welding quality results can be obtained, providing basis and guidance for the control and optimization of the welding process. According to the real-time changes of argon concentration, the three-dimensional coordinates of the welding area can be automatically adjusted to eliminate the influence of argon concentration on welding quality and improve welding precision and stability. The transformation matrix can be used to simplify the transformation calculation of the three-dimensional coordinates of the welding area, reduce the calculation amount and time, and improve the calculation efficiency and speed.

[0120] In some example embodiments, according to the preprocessed data, the information on how the size and direction of the argon concentration difference affect the three-dimensional coordinates of the welding area is obtained. Generally, the size of the argon concentration difference reflects the size change of the welding area, and the direction of the argon concentration difference reflects the position change of the welding area. For example, if the argon concentration difference is positive and along the length direction of the welding area, it indicates that the length of the welding area increases, and scaling transformation is needed; if the argon concentration difference is negative and along the width direction of the welding area, it indicates that the width of the welding area decreases, and scaling transformation is also needed; if the argon concentration difference is positive and along the height direction of the welding area, it indicates that the height of the welding area increases, and translation transformation is needed; if the argon concentration difference is negative and along the depth direction of the welding area, it indicates that the depth of the welding area decreases, and translation transformation is also needed; if the argon concentration difference is positive and along the diagonal direction of the welding area, it indicates that the angle of the welding area increases, and rotation transformation is needed; if the argon concentration difference is negative and along the diagonal direction of the welding area, it indicates that the angle of the welding area decreases, and rotation transformation is also needed.

[0121] Secondly, the transformation type and parameters need to be calculated according to the size and direction of the argon concentration difference. The transformation type can be determined according to the above rules, and the transformation parameters can be calculated according to the proportional relationship between the argon concentration difference and the size of the welding area. For example, if the argon concentration difference is positive and along the length direction of the welding area, the transformation type is scaling transformation, and the scaling ratio can be calculated according to the following formula:

[0122] Scaling ratio = (length of the welding area + argon concentration difference) / length of the welding area;

[0123] If the argon concentration difference is negative and along the width direction of the welding area, the transformation type is scaling transformation, and the transformation parameter is scaling ratio, which can be calculated according to the following formula: scaling ratio = (width of the welding area - argon concentration difference) / width of the welding area.

[0124] If the argon concentration difference is positive and along the height direction of the welding area, the transformation type is translation transformation, and the transformation parameter is translation distance, which can be calculated according to the following formula: translation distance = argon concentration difference. If the argon concentration difference is negative and along the depth direction of the welding area, the transformation type is translation transformation, and the transformation parameter is translation distance, which can be calculated according to the following formula: translation distance = - argon concentration difference.

[0125] If the argon concentration difference is positive and along the diagonal direction of the welding area, the transformation type is rotation transformation, and the transformation parameter is rotation angle, which can be calculated according to the following formula: rotation angle = arctan (argon concentration difference / diagonal length of the welding area). If the argon concentration difference is negative and along the diagonal direction of the welding area, the transformation type is rotation transformation, and the transformation parameter is rotation angle, which can be calculated according to the following formula: rotation angle = - arctan (argon concentration difference / diagonal length of the welding area). It should be noted that in actual cases, it is relatively complex, and the transformation is also relatively complex.

[0126] According to an aspect of the present application, the glove port is provided on both sides of the body, and manual welding of the body is realized through the glove port; the glove port is composed of a glove port flange, a glove port sealing cover and a butyl rubber glove, and the glove port is provided with a glove port sealing cover and a glove port vacuum pressure balancing device to facilitate the balance of the pressure inside and outside the glove during the vacuum replacement of the gas in the box.

[0127] According to an aspect of the present application, the glove port is provided on both sides of the body, and manual welding of the body is realized through the glove port; the glove port is composed of a glove port flange, a glove port sealing cover and a butyl rubber glove, and the glove port is provided with a glove port sealing cover and a glove port vacuum pressure balancing device to facilitate the balance of the pressure inside and outside the glove during the vacuum replacement of the gas in the box.

[0128] The transfer trolley is used to transfer the positioner and the manual platform between the inside and outside of the working cabin; when loading and unloading the workpiece, the transfer trolley moves the positioner and the manual platform to the outside of the working cabin to facilitate loading and unloading of the workpiece.

[0129] When welding is needed, the transfer trolley moves the positioner and the manual platform after fixing the workpiece to the inside of the working cabin for welding work.

[0130] According to an aspect of the present application, the control system comprises:

[0131] The automatic control module controls the cabin pressure through the control system, the working pressure can be freely set within the specified range, and the system will automatically stop when the pressure exceeds the set range;

[0132] The leakage rate detection module analyzes the change of oxygen in a period of time through an oxygen analyzer, and automatically calculates the leakage rate of the argon cabin by combining with the software technology.

[0133] According to one aspect of the present application, comprising the following steps:

[0134] S1. Replace and purify the gas in the argon cabin

[0135] S11. Fix the workpiece to be welded on the positioner or manual welding platform, move it from the loading area to the welding area in the argon cabin through the transfer trolley, and close the access door;

[0136] S12. Perform vacuum pumping on the argon cabin, fill argon into the argon cabin after reaching the specified pressure, and detect the oxygen and water vapor content in the argon cabin through the online detection system to determine whether it meets the welding requirements;

[0137] S13. If the oxygen and water vapor content does not meet the welding requirements, open the circulating purification device to purify the atmosphere in the argon cabin, adsorb oxygen and water vapor in the atmosphere, and increase the concentration of argon in the argon cabin until the set range is reached;

[0138] S2. Automatic welding by robot

[0139] S21. Start the automatic welding of the robot, weld the workpiece to be welded, use visual driving welding technology, and realize robot teaching-free programming through offline programming software and visual camera guidance;

[0140] S22. When the robot automatically welds, start the dust removal and purification system at the same time to process the welding fume during welding. The structure adopts an internal circulation form, i.e. the gas in the cabin is extracted from one side of the cabin body, passes through the dust removal filter, and then the filtered gas is sent into the cabin to realize the purification treatment of the welding fume in the cabin;

[0141] S23. After the automatic welding of the robot is completed, if manual welding is required, the operator can perform manual welding through the glove port on both sides of the argon cabin;

[0142] S3. Discharge and clean the gas in the argon cabin

[0143] S31. After welding is completed, the internal circulation dust removal and purification device is purified and dusted for a period of time to filter the welding fume in the argon cabin, reducing the amount of welding fume emission;

[0144] S32. After the internal circulation purification to the specified time, open the fan for exhaust and the intake valve, discharge the argon in the cabin to the outside of the cabin through the fan, and the air outside the cabin enters the cabin through the intake valve, thereby diluting the argon concentration in the argon cabin, avoiding the danger of personnel entering the argon cabin after the door is opened;

[0145] S33. After the argon dilution is completed, that is, the oxygen concentration in the cabin reaches the specified concentration, the through door is opened, and the safety lock is manually closed to prevent human error from causing the through door to be closed;

[0146] S34. After the through door is opened, the transfer car moves the positioner and the manual welding platform out of the argon cabin, removes the welded workpiece, and completes the single workpiece welding work.

[0147] The visual driving welding technology process includes:

[0148] 1) Import the 3D model (stl format) of the product to be welded into the welding software;

[0149] 2) Place the product to be welded at the specified welding position;

[0150] 3) Configure the welding process parameters, so that the camera scans the weld information, and automatically matches the welding parameters through the characteristics of the weld;

[0151] 4) Import the welded product into the welding software, and the software scans the path through the pre-set and configured parameters and rules, and under the assistance of manual operation;

[0152] 5) When the product to be welded starts to be welded, first take a photo of the product through the camera to determine the position characteristics and other information of the product to be welded;

[0153] 6) According to the obtained product characteristic information, automatically modify the deviation of the production robot scanning path;

[0154] 7) Scan the weld of the product to be welded through the visual camera (the scanning path is automatically generated in the previous step), and obtain the weld characteristic information of the product to be welded;

[0155] 8) The software automatically generates the welding path of the robot through the obtained weld information of the product to be welded;

[0156] 9) Weld the generated weld; complete the single-pass weld of the product;

[0157] 10) Repeat steps 7-9 above to complete the welding of all welds of the product to be welded; complete the welding process of a single product.

[0158] The preferred embodiments of the present application are described in detail above, but the present application is not limited to the specific details of the above-described embodiments, and various equivalent transformations of the technical solutions of the present application can be made within the technical concept of the present application, and these equivalent transformations all belong to the protection scope of the present application.

Claims

1. A multi-functional titanium alloy welding workstation, characterized in that, include: An argon chamber, having at least one containment space that remains closed during operation to provide a stable welding environment; A positioner, installed in an argon chamber, is used to adjust the posture of the workpiece to be welded, enabling the welding of complex products. The welding robot, set up in an argon chamber, automatically performs welding operations on workpieces based on a pre-configured vision and control system; The gas control system is used to detect the content of a predetermined gas in the argon chamber and control it within a preset range. The vision system includes: The first laser is used for argon concentration detection and calibration. The second laser, used for quality inspection of the welding area, employs a grid laser. A coupler couples the laser beams emitted by the first and second lasers to the light beams, which then exit through an optical window and are projected onto the welding area. A reflective light guide receives coupled laser signals reflected from the welding area; A beam splitter splits the coupled laser signal into two laser beams. The photodetector receives the optical signal from the beam splitter and converts it into an electrical signal. The data analysis module calculates the argon concentration and acquires image data of the welding area based on the received electrical signal. The data analysis module includes: The argon concentration calculation module obtains the absorption intensity of argon based on a pre-configured laser absorption spectrum model. It establishes a mathematical module that relates the absorption intensity of argon to its concentration by combining the Lambert-Beer law. The concentration of argon is then deduced by using the laser intensity emitted and absorbed by the first laser. The concentration deviation calculation module receives argon concentration values ​​over at least three time periods, calculates the average, compares the average with the pre-stored argon filling concentration, obtains the argon concentration difference, and calculates whether the argon concentration difference exceeds the threshold. The welding image generation module receives the electrical signal of the reflected light from the second laser, preprocesses it, and then performs fusion analysis on the weld image under the grid laser illumination. Through the position and intensity information of the grid laser, the image is corrected and registered. Finally, the three-dimensional coordinates of the welding area are calculated by triangulation. Using the three-dimensional coordinate data of the weld, the three-dimensional surface model of the welding area is reconstructed through interpolation and fitting, thereby obtaining the width, depth, height and angle, forming a vector image of the welding area. The welding quality output module outputs a vector image of the welding area if the argon concentration difference does not exceed the threshold; otherwise, it corrects the vector image of the welding area before outputting it.

2. The multifunctional titanium alloy welding workstation as described in claim 1, characterized in that, The argon chamber includes: The main body is welded as a whole and is equipped with a mesh-like reinforcing rib. The door is slid open by a motor-driven rack and pinion transmission, and a sealing lock and an inflatable sealing gasket are installed between the door and the main body. The transition chamber, located on one side of the argon chamber, is used for tools to enter and exit the main body; The glove opening is equipped with a sealing cap and a pressure balancing device to maintain pressure balance inside and outside the glove during vacuum replacement of the chamber.

3. The multifunctional titanium alloy welding workstation as described in claim 1, characterized in that, The process of correcting the vector image of the welding area and then outputting it is as follows: Read and determine the type of transformation and parameters of the three-dimensional coordinates of the welding area based on the magnitude and direction of the argon concentration difference; Based on the transformation type and parameters, a transformation matrix is ​​established. The three-dimensional coordinates of the welding area are then multiplied with the transformation matrix to obtain the corrected three-dimensional coordinates of the welding area. Using the corrected three-dimensional coordinates of the welding area, the three-dimensional surface model of the corrected welding area is reconstructed through interpolation and fitting, thereby obtaining the corrected width, depth, height and angle, and forming a corrected vector image of the welding area. Output the corrected vector image of the weld area.

4. The multifunctional titanium alloy welding workstation as described in claim 1, characterized in that, The distance between the laser's emission port and receiving port is less than a threshold value.

5. The multifunctional titanium alloy welding workstation as described in claim 1, characterized in that, Also includes: The main body has glove openings on both sides, which enable manual welding of the main body. The glove opening consists of a glove opening flange, a glove opening sealing cap, and a butyl rubber glove. The glove opening is equipped with a glove opening sealing cap and a glove opening vacuum pressure balancing device to facilitate maintaining the pressure balance inside and outside the glove during gas vacuum replacement of the chamber.

6. The multifunctional titanium alloy welding workstation as described in claim 1, characterized in that, Also includes: The transfer trolley is used to move the positioner and manual platform between the inside and outside of the work compartment; During loading and unloading, the transfer trolley moves the positioner and manual platform to the outside of the work chamber to facilitate loading and unloading of workpieces; When welding is required, the transfer trolley moves the positioner and manual platform, which have been fixed to the workpiece, into the work chamber for welding.

7. The multifunctional titanium alloy welding workstation as described in claim 1, characterized in that, The control system includes: The automatic control module controls the cabin pressure through the control system. The working pressure can be freely set within a specified range and controlled within the set range. If the pressure exceeds the set range, the system will automatically stop for protection. The leakage rate detection module analyzes changes in oxygen levels over a period of time using an oxygen analyzer and automatically calculates the leakage rate of the argon chamber using calculation software.

8. The welding method using the multifunctional titanium alloy welding workstation as described in claim 7, characterized in that, Includes the following steps: S1. Gas replacement and purification in the argon chamber S11. Fix the workpiece to be welded on the positioner or manual welding platform, and move it from the loading area into the welding area in the argon chamber using a transfer trolley, then close the passage door; S12. Evacuate the argon chamber to reach the specified pressure, then fill the argon chamber with argon gas. After reaching the specified pressure, use an online detection system to check whether the oxygen and water vapor content in the argon chamber meets the welding requirements. S13. If the oxygen and water vapor content does not meet the welding requirements, turn on the circulation purification equipment to purify the atmosphere in the argon chamber, adsorb the oxygen and water vapor in the atmosphere, and increase the concentration of argon in the argon chamber until it reaches the set range. S2. Robotic Automated Welding S21. Start the robot's automatic welding and weld the workpiece to be welded. Use vision-driven welding technology and achieve robot programming without teaching by offline programming software and vision camera guidance. S22. When the robot is automatically welding, the dust removal and purification system is activated at the same time to treat the welding fumes during the welding process. It adopts an internal circulation structure, that is, the gas inside the chamber is drawn from one side of the chamber, passes through the dust removal filter, and then the filtered gas is sent back into the chamber to achieve purification of the welding fumes inside the chamber. S23. After the robot completes the automatic welding, if manual welding is required, the operator shall perform manual welding through the glove openings on both sides of the argon chamber; S3. Argon chamber gas venting and cleaning S31. After welding is completed, the internal circulation dust removal and purification equipment will purify and remove dust for a period of time, and filter the gas in the argon chamber for welding fume dust removal to reduce the amount of welding fume emissions. S32. After the internal circulation purification reaches the specified time, open the exhaust fan and the air inlet valve. The fan will discharge the argon gas in the chamber to the outside, and the outside air will enter the chamber through the air inlet valve. In this way, the concentration of argon gas in the argon chamber will be diluted to prevent personnel from entering the argon chamber after the door is opened, which could lead to danger to personnel. S33. After the argon gas dilution is completed, that is, after the oxygen concentration in the chamber reaches the specified concentration, open the passage door and manually close the safety lock to prevent human error from causing the passage door to close. S34. After the door is opened, the transfer trolley moves the positioner and manual welding platform out of the argon chamber, removes the welded workpiece, and completes the single workpiece welding operation.

Images