Monitoring system, method and computer device for a welding process

Abstract

The application relates to a monitoring system, method and computer device of a welding process, which comprises a welding parameter acquisition device, a molten pool monitoring device, a thermal imaging acquisition device, a weld seam measuring device and a controller; the controller is connected with the welding parameter acquisition device, the molten pool monitoring device, the thermal imaging acquisition device and the weld seam measuring device respectively; the welding parameter acquisition device is used for acquiring welding parameters of a welding tool in the welding process; the molten pool monitoring device is used for acquiring arc tungsten electrode state information, molten pool state information and welding wire melting state information in the welding process; the thermal imaging acquisition device is used for acquiring temperature field information of the molten pool in the welding process; the weld seam measuring device is used for acquiring weld seam parameters of a welding object in the welding process; and the controller is used for tracking analysis of the welding process to obtain a monitoring result; through acquisition of information in all aspects, comprehensive monitoring of the welding process can be realized, and welding process quality can be comprehensively reflected.

Description

Technical Field

[0001] This application relates to the field of welding process technology, and in particular to a monitoring system, method and computer equipment for a welding process. Background Technology

[0002] In the process of developing welding technology, a large number of welding tests and simulations are usually required. If welding abnormalities occur during the welding tests, welding tests need to be repeated to find the pattern and solve the abnormality, which seriously affects the actual production efficiency. Therefore, it is very necessary to monitor the welding process.

[0003] Currently, the monitoring method for welding processes usually involves collecting image information of the welding process and then analyzing the images to monitor the welding quality.

[0004] However, the above-mentioned monitoring methods for welding processes have the problem of incomplete monitoring. Summary of the Invention

[0005] Therefore, it is necessary to provide a monitoring system, method, and computer equipment for welding processes that can achieve comprehensive detection of the welding process, addressing the aforementioned technical problems.

[0006] In a first aspect, this application provides a monitoring system for a welding process, the system comprising:

[0007] The system includes a welding parameter acquisition device, a molten pool monitoring device, a thermal imaging acquisition device, a weld measurement device, and a controller; the controller is connected to the welding parameter acquisition device, the molten pool monitoring device, the thermal imaging acquisition device, and the weld measurement device, respectively.

[0008] Welding parameter acquisition device, used to acquire welding parameters of welding tools during the welding process;

[0009] The molten pool monitoring device is used to collect information on the state of the tungsten electrode arc, the molten pool, and the melting state of the welding wire during the welding process.

[0010] Thermal imaging acquisition device is used to acquire temperature field information of the molten pool during the welding process;

[0011] A weld measurement device is used to collect weld parameters of the welded object during the welding process.

[0012] The controller is used to track and analyze the welding process based on welding parameters, tungsten electrode state information, molten pool state information, wire melting state information, temperature field information, and weld parameters, and obtain monitoring results.

[0013] In one embodiment, the welding tool includes a welding power source, a shielding gas cylinder, and a wire feeder. The welding parameter acquisition device includes a current sensor, a voltage sensor, a flow sensor, and a wire feed speed sensor. The current sensor and voltage sensor are located at the output port of the welding power source, the flow sensor is located at the outlet of the shielding gas cylinder, and the wire feed speed sensor is located at the wire outlet of the wire feeder.

[0014] In one embodiment, the molten pool monitoring device includes at least two high dynamic range cameras, each of which is positioned at a location near the wire feeder and a location away from the wire feeder.

[0015] In one embodiment, the weld measurement device includes a laser vision sensor positioned above the object being welded.

[0016] In one embodiment, the system further includes a slide rail; the slide rail is connected to a controller, welding tools, welding parameter acquisition device, molten pool monitoring device, thermal imaging acquisition device, and weld measurement device; the slide rail is used to move the welding tools, welding parameter acquisition device, molten pool monitoring device, thermal imaging acquisition device, and weld measurement device.

[0017] In one embodiment, the system further includes a support frame for supporting welding tools, welding parameter acquisition devices, molten pool monitoring devices, thermal imaging acquisition devices, and weld measurement devices.

[0018] In one embodiment, the system further includes a display; the display is connected to the controller; the display is used to show monitoring results and to display abnormal information when abnormal monitoring results are detected.

[0019] Secondly, this application also provides a method for monitoring a welding process, the method comprising:

[0020] The controller is used to acquire welding parameters of the welding tool from the welding parameter acquisition device, arc tungsten electrode state information, molten pool state information, and welding wire melting state information from the molten pool monitoring device, molten pool temperature field information from the thermal imaging acquisition device, and weld parameters of the welding object from the weld measurement device. Based on the welding parameters, arc tungsten electrode state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the controller tracks and analyzes the welding process to obtain monitoring results.

[0021] In one embodiment, the monitoring results include heat input parameters, line energy parameters, arc tungsten electrode size, molten pool size, spot temperature, line temperature, pre-weld assembly gap, pre-weld misalignment, pre-weld bevel size, post-weld weld width, post-weld reinforcement height, post-weld weld bead forming angle, and post-weld misalignment.

[0022] Thirdly, this application also provides a monitoring device for a welding process, the device comprising:

[0023] The monitoring module is used to acquire welding parameters of the welding tools from the welding parameter acquisition device, arc tungsten electrode state information, molten pool state information, and welding wire melting state information from the molten pool monitoring device, temperature field information of the molten pool from the thermal imaging acquisition device, and weld parameters of the welded object from the weld measurement device. Based on the welding parameters, arc tungsten electrode state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the module tracks and analyzes the welding process to obtain monitoring results.

[0024] Fourthly, this application also provides a computer device, which includes a memory and a processor. The memory stores a computer program, and the processor executes the computer program to perform the following steps:

[0025] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0026] Fifthly, this application also provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, performs the following steps:

[0027] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0028] Sixthly, this application also provides a computer program product, which includes a computer program that, when executed by a processor, performs the following steps:

[0029] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0030] The aforementioned welding process monitoring system, method, and computer equipment, by collecting information from various aspects of the welding process, including welding tools, welding objects, and the weld pool, can achieve comprehensive monitoring of the welding process, fully reflect the welding quality, and enable timely tracking and analysis of the welding process and its patterns. It can also detect and record various defects, deviations, and anomalies in welding tests, facilitating timely problem identification, analysis, cause identification, and improvement measures. Furthermore, the above embodiments also provide a specialized system for monitoring welding processes, applicable to various common manual or automatic welding procedures. This system is relatively simple to install, improves monitoring efficiency, and simplifies control procedures. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of a monitoring system for the welding process in one embodiment;

[0032] Figure 2 This is a schematic diagram of a monitoring system for the welding process in another embodiment;

[0033] Figure 3 This is a schematic diagram of a monitoring system for the welding process in another embodiment;

[0034] Figure 4 This is a schematic diagram of a monitoring system for the welding process in another embodiment;

[0035] Figure 5 This is a schematic diagram of a monitoring system for the welding process in another embodiment;

[0036] Figure 6 This is a schematic diagram of a monitoring system for the welding process in another embodiment;

[0037] Figure 7 This is an internal structural diagram of a computer device in one embodiment. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0040] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0041] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0042] The development of welding processes typically involves numerous welding tests and simulations. However, if welding abnormalities occur during these tests, repeated trials are necessary to identify patterns and resolve the issues, significantly impacting actual production efficiency. Therefore, monitoring the welding process is essential. Currently, welding process monitoring methods usually involve acquiring and analyzing image information of the welding process to assess welding quality. However, these methods suffer from incomplete monitoring. This application provides a welding process monitoring system and method to address the aforementioned technical problems. The following embodiments will specifically illustrate the welding process monitoring system and method described in this application.

[0043] In one embodiment, such as Figure 1 As shown, a welding process monitoring system is provided, which includes: a welding parameter acquisition device 10, a molten pool monitoring device 20, a thermal imaging acquisition device 30, a weld measurement device 40, and a controller 50; the controller 50 is connected to the welding parameter acquisition device 10, the molten pool monitoring device 20, the thermal imaging acquisition device 30, and the weld measurement device 40 respectively.

[0044] The welding parameter acquisition device 10 is used to acquire welding parameters of the welding tools during the welding process; the molten pool monitoring device 20 is used to acquire information on the state of the tungsten arc electrode, the state of the molten pool, and the melting state of the welding wire during the welding process; the thermal imaging acquisition device 30 is used to acquire temperature field information of the molten pool during the welding process; the weld measurement device 40 is used to acquire weld parameters of the welding object during the welding process; and the controller 50 is used to track and analyze the welding process based on the welding parameters, the state of the tungsten arc electrode, the state of the molten pool, the melting state of the welding wire, the temperature field information, and the weld parameters to obtain monitoring results.

[0045] The aforementioned welding tools include at least one of the following: welding power source, welding torch 80, shielding gas cylinder, and wire feeder. Welding parameters include at least one of the following: welding current, arc voltage, wire feed speed, and shielding gas flow rate. Temperature field information includes molten pool temperature data. The welding object is the component or device being welded. Weld parameters include pre-weld weld parameters and post-weld weld parameters, specifically laser stripes. Monitoring results include heat input parameters, linear energy parameters, arc tungsten electrode size, molten pool size, spot temperature, linear temperature, pre-weld assembly gap, pre-weld misalignment, pre-weld bevel size, post-weld weld width, post-weld reinforcement, post-weld weld bead forming angle, and post-weld misalignment. Among them, the welding heat input parameters and line energy parameters are the monitoring results corresponding to the welding parameters; the arc tungsten electrode size and molten pool size are the monitoring results corresponding to the arc tungsten electrode state information, molten pool state information, and welding wire melting state information; the point temperature and line temperature are the monitoring results corresponding to the temperature field information; and the pre-weld assembly gap, pre-weld misalignment, pre-weld bevel size, post-weld weld width, post-weld reinforcement height, post-weld weld bead forming angle, and post-weld misalignment are the monitoring results corresponding to the weld parameters. The welding process includes laser welding, TIG welding, and MIG welding processes.

[0046] The welding parameter acquisition device 10 described above can be a sensor, a camera, a data acquisition instrument, or other acquisition device capable of acquiring welding parameters. This application embodiment does not limit the type of welding parameter acquisition device. The welding parameter acquisition device 10 can be installed on the welding tool or at a location connected to the welding tool; one or more can be installed at the same location. The molten pool monitoring device 20 described above can be a sensor, a camera, or other acquisition device capable of acquiring information on the tungsten electrode state, molten pool state, and welding wire melting state; this application embodiment does not limit this. The molten pool monitoring device 20 can be installed at any location around the molten pool, either front-to-back or side-to-side; one or more can be installed. The thermal imaging acquisition device 30 described above can be a thermal imaging camera, a thermal imager, a thermal imaging temperature gun, a thermal imaging sensor, or other acquisition device capable of acquiring thermal imaging information; this application embodiment does not limit this. The thermal imaging acquisition device 30 can be installed at any location around the molten pool; one or more can be installed. The weld measurement device 40 described above can be a laser measuring instrument, a vision measurement system, a three-dimensional measuring instrument, or other acquisition device capable of acquiring weld parameters; this application embodiment does not impose any limitations. The controller 50 described above can be, but is not limited to, various personal computers, laptops, smartphones, tablets, IoT devices, and portable wearable devices. The controller 50 is equipped with data analysis software for tracking and analyzing the welding process, such as WeldStudio Pro software, OSL Inspect software, etc. The controller 50 can be integrated with the welding parameter acquisition device 10, the molten pool monitoring device 20, the thermal imaging acquisition device 30, and the weld measurement device connection 40, or it can be set up independently.

[0047] The working principle of the welding process monitoring system described in this application embodiment is as follows: the welding parameter acquisition device 10 sends the acquired welding parameters to the controller 50; the molten pool monitoring device 20 sends the acquired arc tungsten electrode state information, molten pool state information, and welding wire melting state information to the controller 50; the thermal imaging acquisition device 30 sends the acquired temperature field information to the controller 50; and the weld measurement device 40 sends the acquired weld parameters to the controller 50. After receiving the welding parameters, arc tungsten electrode state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the controller 50 can track and analyze the welding parameters, arc tungsten electrode state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters respectively to obtain the monitoring results. Specifically, the process of controller 50 tracking and analyzing welding parameters is as follows: After receiving the welding parameters, controller 50 can input the welding parameters into a preset function or preset algorithm to calculate parameters such as heat input and line energy, and further compare the heat input and line energy parameters with corresponding thresholds. An alarm is issued when the parameters exceed the threshold, or when gas interruption or arc interruption occurs. The process of controller 50 tracking and analyzing welding parameters is as follows: Controller 50 can receive video, images, or other formats of information corresponding to the arc tungsten electrode status, molten pool status, and welding wire melting status. After receiving the arc tungsten electrode status, molten pool status, and welding wire melting status information, controller 50 can input these information into data analysis software for analysis. For example, it can input them into WeldStudio Pro software to analyze and obtain the arc tungsten electrode size and molten pool size. The process of controller 50 tracking and analyzing temperature field information is as follows: After receiving temperature field information, controller 50 can input the temperature field information into data analysis software for analysis. For example, the molten pool temperature data, which can represent temperature field information, can be input into WeldStudio Pro software to measure the temperature field of the welding process in real time and display and analyze it as a color contour image. It can also display a three-dimensional image of the weld in real time. The process of controller 50 tracking and analyzing temperature field information is as follows: After receiving weld parameters, controller 50 can input the weld parameters into data analysis software for analysis. For example, the laser stripes that can represent weld parameters can be input into OSL Inspect software for display, recording, and analysis. During welding, information such as pre-weld assembly gap, misalignment, and bevel size can be measured. After welding, weld width, reinforcement height, weld bead forming angle, post-weld misalignment, and other weld formation quality data can be measured.After tracking and analyzing the information of each parameter to obtain the monitoring results corresponding to each parameter, the controller 50 can further determine the weight based on the influence of each parameter, or calculate the weighted average of the detection results corresponding to each parameter based on the preset weight, and compare the calculation result with the preset threshold. Then, it can determine whether there is a defect in the quality of the welding process based on the comparison result. If the comparison result indicates that the calculation result is greater than the preset threshold, then there is a defect in the quality of the welding process. If the comparison result indicates that the calculation result is not greater than the preset threshold, then there is no defect in the quality of the welding process.

[0048] The welding process monitoring system provided in this application can comprehensively monitor the welding process by collecting information from various aspects such as welding tools, welding objects, and the weld pool during the welding process. This allows for a complete reflection of the welding process quality and enables timely tracking and analysis of the welding process and its patterns. It can also detect and record various defects, deviations, and other anomalies in welding tests, facilitating timely problem identification, analysis, cause identification, and improvement measures. Furthermore, the above embodiments also provide a specialized system for monitoring welding processes, applicable to various common manual or automatic welding procedures. This system is relatively simple to install, improves monitoring efficiency, and simplifies control procedures.

[0049] In one embodiment, in Figure 1 Based on the welding process monitoring system described in the embodiment, the welding tools include a welding power source, a shielding gas cylinder, and a wire feeder. The welding parameter acquisition device includes a current sensor, a voltage sensor, a flow sensor, and a wire feed speed sensor. The current sensor and voltage sensor are located at the output port of the welding power source, the flow sensor is located at the outlet of the shielding gas cylinder, and the wire feed speed sensor is located at the wire outlet of the wire feeder.

[0050] Among them, the current sensor acquisition accuracy and the voltage sensor acquisition accuracy are 1%, and the flow sensor acquisition accuracy is 0.1L / min.

[0051] In the embodiments of this application, such as Figure 2 As shown, the welding parameter acquisition device 10 (see the data acquisition card in the figure) can acquire welding current through a current sensor, arc voltage through a voltage sensor, shielding gas flow rate through a flow sensor, and wire feeding speed through a wire feeding speed sensor. Then, it sends the welding current, arc voltage, wire feeding speed, and shielding gas flow rate to the controller 50 (see the industrial computer in the figure), and then the data analysis software installed on the controller 50 (see the welding parameter software in the figure) analyzes the data.

[0052] In one embodiment, in Figure 1Based on the welding process monitoring system described in the embodiment, the molten pool monitoring device 20 includes at least two high dynamic range cameras, each of which is respectively located near the wire feed and away from the wire feed in the molten pool.

[0053] The high dynamic range camera can be the XVC-1000e or other types of cameras. The camera resolution is 1280×1024, with remote electric focus function, dynamic range greater than 140dB, and built-in LED lighting that can automatically turn off and on according to the arc starting and ending. Specifically, the LED can be automatically turned off and on according to the brightness of the image corresponding to the arc starting and ending.

[0054] In the embodiments of this application, such as Figure 3 As shown, the molten pool monitoring device 20 can simultaneously acquire videos corresponding to the state information of the tungsten electrode arc, the state information of the molten pool, and the state information of the welding wire from both in front of and behind the molten pool using two high dynamic range cameras (see XVC-1000e in the figure). These videos are then sent to the controller 50 (see industrial computer in the figure), where the data analysis software (see WeldStudio Pro software in the figure) installed on the controller 50 performs the analysis. Through real-time acquisition and playback, the device can perform dimensional analysis of the tungsten electrode arc and its dimensions.

[0055] In one embodiment, in Figure 1 Based on the welding process monitoring system described in the embodiment, the thermal imaging acquisition device 30 includes a high dynamic range infrared thermal imaging welding camera, which is positioned in the molten pool away from the wire feed.

[0056] The high dynamic infrared thermal imaging welding camera can be an XIR-1800 camera or other types of cameras. The camera resolution is 640H×512V (15 square micrometers), and the temperature measurement range is 300-1800℃.

[0057] In the embodiments of this application, such as Figure 4 As shown, the thermal imaging acquisition device 30 can clearly record the molten pool temperature data under strong interference conditions of electric arc light using a high dynamic infrared thermal imaging welding camera (see XIR-1800 in the figure). The molten pool temperature data is then sent to the controller 50 (see industrial computer in the figure), and then analyzed by the data analysis software installed on the controller 50 (see WeldStudio Pro software in the figure). Through real-time measurement and playback of the temperature field, point temperature and line temperature measurement can be achieved.

[0058] In one embodiment, in Figure 1Based on the welding process monitoring system described in the embodiment, the weld measurement device 40 includes a laser vision sensor, which is positioned above the welding object.

[0059] The laser vision sensor can be the OSL-50A structured light sensor, or other types of vision sensors. The laser vision sensor emits a single laser stripe with a resolution of 0.03H × 0.1V (mm), and its field of view depth is 85mm. When assembled at a nominal height of 150mm, its stripe width is nominally 50mm.

[0060] In the embodiments of this application, such as Figure 5 As shown, the weld measurement device 40 can emit and collect laser stripes through a laser vision sensor (see OSL-50A in the figure), and then send the laser stripe information to the controller 50 (see the industrial computer in the figure). The data analysis software installed on the controller 50 (see OSL Inspect software in the figure) analyzes the data, and through three-dimensional reconstruction of the weld bead, it can measure information such as assembly gap, misalignment, and bevel size before welding, and weld bead width, reinforcement height, weld bead forming angle, and post-weld misalignment, etc., to obtain weld formation quality data. The working process of the laser vision sensor is as follows: before welding, the sensor is turned on to scan along the bevel to obtain assembly gap, misalignment, bevel size, etc., and then the sensor is turned off to start welding; after welding, the sensor is turned on again to scan along the weld to obtain weld formation data, and then the sensor is turned off to complete one measurement. This process can be repeated multiple times.

[0061] In one embodiment, in Figure 1 Based on the welding process monitoring system described in the embodiment, the system further includes a slide rail 60; the slide rail 60 is connected to the controller 50, welding tools, welding parameter acquisition device 10, molten pool monitoring device 20, thermal imaging acquisition device 30, and weld measurement device 40; the slide rail 60 is used to move the welding tools, welding parameter acquisition device 10, molten pool monitoring device 20, thermal imaging acquisition device 30, and weld measurement device 40.

[0062] The slide rail can be made of steel or plastic.

[0063] In the embodiments of this application, such as Figure 1 As shown, during the monitoring of the welding process, the controller can send movement control commands to the slide rail to control the slide rail to move, so as to ensure that each device in the monitoring system can monitor the welding process.

[0064] In one embodiment, in Figure 1Based on the welding process monitoring system described in the embodiment, the system also includes a support frame 70; the support frame 70 is used to support welding tools, welding parameter acquisition device 10, molten pool monitoring device 20, thermal imaging acquisition device 30, and weld measurement device 40.

[0065] The support frame can be made of metal or plastic.

[0066] In the embodiments of this application, such as Figure 1 As shown, welding tools, welding parameter acquisition device 10, molten pool monitoring device 20, thermal imaging acquisition device 30, weld seam measuring device 40, etc. can be set on the support frame 70 to form an integrated monitoring system, which is easy to move.

[0067] In one embodiment, in Figure 1 Based on the welding process monitoring system described in the embodiment, the system also includes a display; the display 80 is connected to the controller 40; the display 80 is used to display the monitoring results, and displays abnormal information when the monitoring results are abnormal.

[0068] The display 80 can be integrated with the controller 40, or it can be set up independently.

[0069] In this embodiment, the controller 40 tracks and analyzes the welding parameters collected by the welding parameter acquisition device 10, the arc tungsten electrode state information, molten pool state information, and welding wire melting state information collected by the molten pool monitoring device 20, the temperature field information collected by the thermal imaging acquisition device 30, and the weld parameters collected by the weld measurement device 40. After obtaining the monitoring results, the monitoring results can be displayed on the display 80 for the user to view in a timely manner. Optionally, if the monitoring results indicate an anomaly, the display 80 can display the anomaly information and the corresponding solution to resolve the problem promptly.

[0070] In addition to the welding process monitoring systems described in all the above embodiments, this application also provides a welding process monitoring system, such as... Figure 1 As shown, the monitoring system includes: a welding parameter acquisition device, a molten pool monitoring device, a thermal imaging acquisition device, a weld measurement device, a controller, a slide rail, a support frame, and a display.

[0071] The welding parameter acquisition device is used to collect welding parameters of the welding tools during the welding process. It includes current sensors, voltage sensors, flow sensors, and wire feed speed sensors. The welding tools include a welding power source, a shielding gas cylinder, and a wire feeder. The current and voltage sensors are located at the output port of the welding power source, the flow sensor is located at the outlet of the shielding gas cylinder, and the wire feed speed sensor is located at the wire feed outlet of the wire feeder. The molten pool monitoring device is used to collect information on the state of the tungsten electrode arc, the molten pool, and the melting state of the welding wire during the welding process. It includes at least two high-dynamic cameras, one positioned near the wire feeder and the other away from it. The weld measurement device is used to collect weld parameters of the welded object during the welding process. It includes a laser vision sensor positioned above the welded object. The thermal imaging acquisition device is used to collect temperature field information of the molten pool during the welding process and can be a high-dynamic infrared thermal imaging welding camera. The controller is used to track and analyze the welding process based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters to obtain monitoring results. The slide rail connects to the controller, welding tools, welding parameter acquisition device, molten pool monitoring device, thermal imaging acquisition device, and weld measurement device. The slide rail is used to move these devices. The support frame supports the welding tools, welding parameter acquisition device, molten pool monitoring device, thermal imaging acquisition device, and weld measurement device. The display connects to the controller to show the monitoring results and to display abnormal information when abnormalities occur.

[0072] In the embodiments of this application, such as Figure 6As shown, the welding parameter acquisition device 10 (see welding process parameter acquisition module) can acquire welding current through a current sensor, arc voltage through a voltage sensor, shielding gas flow rate through a flow sensor, and wire feed speed through a wire feed speed sensor. It then sends the welding current, arc voltage, wire feed speed, and shielding gas flow rate to the controller 50 (see the central control unit module in the figure), where the data analysis software installed on the controller 50 performs the analysis. The molten pool monitoring device 20 (see the high-dynamic arc molten pool video monitoring module in the figure) can simultaneously acquire welding area images containing video information corresponding to the arc tungsten electrode state, molten pool state, and wire melting state from both in front of and behind the molten pool using two high-dynamic cameras. These images are then sent to the controller 50 (see the central control unit module in the figure), where the data analysis software installed on the controller 50 performs the analysis. Through real-time acquisition and playback, the dimensional analysis of the arc tungsten electrode and its dimensions is achieved. The thermal imaging acquisition device 30 (see the high dynamic infrared thermal imaging welding camera module in the figure) can clearly acquire temperature field information of the welding area under the strong interference of arc light through the high dynamic infrared thermal imaging welding camera. Then, the acquired temperature field information of the welding area is sent to the controller 50 (see the central control unit module in the figure). The data analysis software installed on the controller 50 then analyzes the information and realizes point temperature and line temperature measurement through real-time temperature field measurement and playback. The weld measurement device 40 (see the weld vision measurement module in the figure) can emit and acquire laser stripes through a laser vision sensor. The laser stripe information is then sent to the controller 50 (see the central control unit module in the figure). The data analysis software installed on the controller 50 then analyzes the information. Through three-dimensional reconstruction of the weld bead, forming quality data can be obtained. During welding, information such as pre-weld assembly gap, misalignment, and bevel size can be measured. After welding, weld bead width, reinforcement height, weld bead forming angle, post-weld misalignment, and other weld forming quality data can be measured. The laser vision sensor operates as follows: before welding, it turns on the light, scans along the bevel to obtain assembly gaps, misalignments, bevel dimensions, etc., and then turns off the light; welding begins; after welding is completed, it turns on the light again, scans along the weld to obtain weld formation data, turns off the light, and completes one measurement, which can be repeated multiple times.

[0073] Based on the above-mentioned welding process monitoring system, this application also provides a welding process monitoring method, which can be applied to... Figure 1 Taking controller 40 as an example, the following steps are included:

[0074] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0075] The monitoring results include heat input parameters, line energy parameters, arc tungsten electrode dimensions, molten pool dimensions, spot temperature, line temperature, pre-weld assembly gap, pre-weld misalignment, pre-weld bevel dimensions, post-weld weld width, post-weld reinforcement height, post-weld weld bead forming angle, and post-weld misalignment. Each of these steps has been described in the preceding text; please refer to the foregoing descriptions for details, which will not be repeated here.

[0076] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0077] Based on the same inventive concept, this application also provides a welding process monitoring device for implementing the welding process monitoring method described above. The solution provided by this device is similar to the solution described in the above method; therefore, the specific limitations of one or more welding process monitoring device embodiments provided below can be found in the limitations of the welding process monitoring method described above, and will not be repeated here.

[0078] In one embodiment, a monitoring device for a welding process is provided, comprising:

[0079] The monitoring module is used to acquire welding parameters of the welding tools from the welding parameter acquisition device, arc tungsten electrode state information, molten pool state information, and welding wire melting state information from the molten pool monitoring device, molten pool temperature field information from the thermal imaging acquisition device, and weld parameters of the welded object from the weld measurement device. Based on the welding parameters, arc tungsten electrode state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the module tracks and analyzes the welding process to obtain monitoring results.

[0080] Each module in the aforementioned welding process monitoring device can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in or independent of the processor in a computer device, or stored in the computer device's memory as software, so that the processor can call and execute the corresponding operations of each module.

[0081] In one embodiment, a computer device is provided, which may be a terminal or a server, and its internal structure diagram may be as follows. Figure 7 As shown, the computer device includes a processor, memory, input / output interface, communication interface, display unit, and input device. The processor, memory, and input / output interface are connected via a system bus, and the communication interface, display unit, and input device are also connected to the system bus via the input / output interface. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage media. The input / output interface is used for exchanging information between the processor and external devices. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, mobile cellular networks, NFC (Near Field Communication), or other technologies. When the computer program is executed by the processor, it implements a method for monitoring a welding process. The display unit is used to form a visually visible image and can be a display screen, projection device, or virtual reality imaging device. The display screen can be an LCD screen or an e-ink screen. The input device of the computer device can be a touch layer covering the display screen, or buttons, trackballs, or touchpads set on the casing of the computer device, or external keyboards, touchpads, or mice, etc.

[0082] Those skilled in the art will understand that Figure 7The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer device to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0083] In one embodiment, a computer device is provided, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to perform the following steps:

[0084] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0085] The computer device provided in the above embodiments has a similar implementation principle and technical effect to the above method embodiments, and will not be described again here.

[0086] In one embodiment, a computer-readable storage medium is provided having a computer program stored thereon, the computer program performing the following steps when executed by a processor:

[0087] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0088] The computer-readable storage medium provided in the above embodiments has a similar implementation principle and technical effect to the above method embodiments, and will not be described again here.

[0089] In one embodiment, a computer program product is provided, including a computer program that, when executed by a processor, performs the following steps:

[0090] Welding parameters of the welding tools are acquired from the welding parameter acquisition device; information on the state of the tungsten electrode arc, the state of the molten pool, and the melting state of the welding wire are acquired from the molten pool monitoring device; temperature field information of the molten pool is acquired from the thermal imaging acquisition device; and weld parameters of the welded object are acquired from the weld measurement device. Based on the welding parameters, tungsten electrode arc state information, molten pool state information, welding wire melting state information, temperature field information, and weld parameters, the welding process is tracked and analyzed to obtain monitoring results.

[0091] The computer program product provided in the above embodiments has a similar implementation principle and technical effect to the above method embodiments, and will not be described again here.

[0092] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments described above. Any references to memory, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM can take many forms, such as Static Random Access Memory (SRAM) or Dynamic Random Access Memory (DRAM). The databases involved in the embodiments provided in this application may include at least one type of relational database and non-relational database. Non-relational databases may include, but are not limited to, blockchain-based distributed databases. The processors involved in the embodiments provided in this application may be general-purpose processors, central processing units, graphics processing units, digital signal processors, programmable logic devices, quantum computing-based data processing logic devices, etc., and are not limited to these.

[0093] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0094] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A monitoring system for a welding process, characterized by, The system comprises a welding parameter acquisition device, a molten pool monitoring device, a thermal imaging acquisition device, a weld seam measurement device and a controller; the controller is connected with the welding parameter acquisition device, the molten pool monitoring device, the thermal imaging acquisition device and the weld seam measurement device respectively; The welding parameter acquisition device is used for acquiring welding parameters of a welding tool in a welding process. The molten pool monitoring device comprises at least two high-dynamic cameras, each of which is arranged at a position close to or far from a welding wire feeding position of the molten pool, and is used for acquiring arc tungsten electrode state information, molten pool state information and welding wire melting state information in the welding process. The thermal imaging acquisition device is used for acquiring temperature field information of a welding area under strong interference of arc light by a high-dynamic infrared thermal imaging welding camera. The weld seam measurement device is used for acquiring weld seam parameters of a welding object in the welding process; the welding process comprises the following steps: pre-welding light opening, scanning along a groove, obtaining assembly gap, misalignment and groove size, light closing; starting welding; after welding, light opening, scanning along a weld seam, obtaining weld seam forming data, and light closing. The controller is used for tracking and analyzing the welding process according to the welding parameters, the arc tungsten electrode state information, the molten pool state information, the welding wire melting state information, the temperature field information and the weld seam parameters, so as to obtain monitoring results; the monitoring results comprise welding heat input parameters, linear energy parameters, arc tungsten electrode size, molten pool size, point temperature, linear temperature, pre-welding assembly gap, pre-welding misalignment, pre-welding groove size, post-welding weld width, post-welding reinforcement, post-welding weld forming angle and post-welding misalignment.

2. The system of claim 1, wherein, The welding tool comprises a welding power source, a protective gas cylinder and a welding wire feeder; the welding parameter acquisition device comprises a current sensor, a voltage sensor, a flow sensor and a welding wire feeding speed sensor; the current sensor and the voltage sensor are arranged at an output port position of the welding power source, the flow sensor is arranged at an air outlet position of the protective gas cylinder, and the welding wire feeding speed sensor is arranged at a wire outlet position of the welding wire feeder.

3. The system of claim 1, wherein, The weld seam measurement device comprises a laser vision sensor, which is arranged above the welding object.

4. The system of claim 1, wherein, The system further comprises a slide rail; the slide rail is connected with the controller, the welding tool, the welding parameter acquisition device, the molten pool monitoring device, the thermal imaging acquisition device and the weld seam measurement device; the slide rail is used for moving the welding tool, the welding parameter acquisition device, the molten pool monitoring device, the thermal imaging acquisition device and the weld seam measurement device.

5. The system of claim 1, wherein, The system further comprises a support frame; the support frame is used for supporting the welding tool, the welding parameter acquisition device, the molten pool monitoring device, the thermal imaging acquisition device and the weld seam measurement device.

6. The system of claim 1, wherein, The system further comprises a display; the display is connected with the controller; the display is used for displaying the monitoring results and abnormal information when the monitoring results are abnormal.

7. A method of monitoring a welding process, characterized by, The method is applied to a controller in a monitoring system of a welding process as claimed in any one of claims 1-6, and the method comprises: The controller is configured to acquire welding parameters of a welding tool from a welding parameter acquisition device, acquire arc tungsten electrode state information, molten pool state information, and welding wire melting state information from a molten pool monitoring device, acquire temperature field information of the molten pool from a thermal imaging acquisition device, acquire weld seam parameters of a welding object from a weld seam measurement device, and perform tracking analysis on the welding process according to the welding parameters, the arc tungsten electrode state information, the molten pool state information, the welding wire melting state information, the temperature field information, and the weld seam parameters to obtain a monitoring result. 8.A computer device, comprising a memory and a processor, wherein the memory stores a computer program, and the computer device is configured to perform the method according to any one of claims 1-7. The processor implements the steps of the method of claim 7 when executing the computer program.

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