Automobile air duct welding method and system

Abstract

The application relates to an automobile air duct welding method and system, and relates to the field of automobile part processing technology.The method comprises the following steps: obtaining a processing air pipe type; determining an air pipe welding area corresponding to the processing air pipe type, a standard demand image and a welding moving path according to a preset area matching relationship; obtaining a real-time area image at the air pipe welding area; comparing and analyzing the real-time area image and the standard demand image to determine an image similarity; judging whether the image similarity is greater than a preset demand similarity; if the image similarity is greater than the demand similarity, controlling a welding head to perform a welding operation along the welding moving path; and if the image similarity is not greater than the demand similarity, outputting a foreign matter signal and controlling the welding head to not perform an operation.The application has the effect of improving the welding quality of the automobile air pipe.

Description

Technical Field

[0001] This application relates to the field of automotive parts processing technology, and in particular to a method and system for welding automotive air ducts. Background Technology

[0002] Automotive air ducts are pipes used for airflow within a vehicle, serving to guide, distribute, and regulate airflow. During the manufacturing process of automotive air ducts, the duct components to be welded are placed on a fixed position on the welding platform of a laser welding machine. The welding head of the laser welding machine then moves according to a pre-programmed sequence to achieve welding between the air ducts.

[0003] Regarding the aforementioned technologies, the inventors believe that if there are foreign objects on the welding surface of the automotive air duct when it is placed on a welding platform for welding, the surface of the resulting molded product will have defects, resulting in poor overall welding quality, and there is still room for improvement. Summary of the Invention

[0004] To improve the welding quality of automotive air ducts, this application provides a welding method and system for automotive air ducts.

[0005] In a first aspect, this application provides a welding method for automotive air ducts, employing the following technical solution: A method for welding automotive air ducts, comprising: Obtain the type of duct to be processed; Based on the preset regional matching relationship, determine the duct welding area, standard requirement image and welding movement path corresponding to the type of duct being processed; Acquire real-time images of the duct welding area; The image similarity is determined by comparing and analyzing real-time regional images with standard required images. Determine whether the image similarity is greater than the preset required similarity. If the image similarity is greater than the required similarity, then control the welding head to perform welding operations along the welding movement path; If the image similarity is not greater than the required similarity, a foreign object signal is output and the welding head is controlled to stop working.

[0006] By adopting the above technical solution, when welding automotive air ducts, the type of automotive air duct to be welded is obtained to determine the welding area. At this time, the presence of foreign objects at the welding position can be determined by image recognition. If foreign objects are present, the work will not be carried out, thereby reducing the occurrence of defects on the surface of the welded product and improving the overall welding quality of automotive air ducts.

[0007] Alternatively, automotive air duct welding methods may also include: The external contour of the foreign object is determined by comparing and analyzing real-time regional images with standard required images. Obtain the distance between the contours of each point on the outer contour of the foreign object and the boundary lines of each area of ​​the duct welding zone; The minimum numerical distance between contours is determined according to the preset sorting rules, and the boundary line of the duct welding area corresponding to this distance is defined as the processing boundary line. The furthest endpoint on the outer contour of the foreign object that is farthest from the processing boundary line is determined based on the processing boundary line and the corresponding contour distance. The processing position and angle are determined based on the farthest endpoint, and the preset air blowing device is controlled to move to the processing position to perform air blowing operation with the processing angle and preset unit air blowing volume. After the air blowing is completed, the image is compared again, and if the foreign object signal still exists, the unit air blowing volume is updated according to the preset correction parameters to control the air blowing device to start working again until the foreign object signal disappears to control the welding head operation.

[0008] By adopting the above technical solution, when the presence of external foreign objects is confirmed, the situation of the foreign objects can be analyzed to control the air blowing equipment to process the foreign objects, thereby enabling subsequent welding operations to proceed normally.

[0009] Optionally, the steps of determining the processing location and processing angle based on the farthest endpoint include: The distance between the farthest endpoint and the processing boundary line is defined as the required movement distance; Determine the overall area of ​​the foreign object based on its external outline; The processing angle corresponding to the required moving distance, the overall area of ​​the foreign object, and the unit blowing volume is determined based on the preset angle matching relationship. Based on the processing angle, a wind action line perpendicular to the processing boundary line is generated at the farthest endpoint, and the intersection of the wind action line and the preset equipment movement plane is determined as the processing position.

[0010] By adopting the above technical solution, a more reasonable treatment angle and treatment position can be determined according to the foreign object situation, thereby making the air blowing equipment work better.

[0011] Optionally, after the overall area of ​​the foreign object is determined, the automotive air duct welding method may also include: Determine whether the outer contour of the foreign object intersects the processing boundary line at two points; If the outer contour of the foreign object does not intersect with the processing boundary line at two points, the determined overall area of ​​the foreign object is maintained. If the outer contour of the foreign object intersects the processing boundary line at two points, the distance between the two points is determined based on the two points. The control processing boundary line moves vertically a preset unit distance along the direction of the foreign object's outer contour and obtains the virtual distance of the intersection point; The difference between the intersection points is calculated based on the distance between the points and the virtual distance between the intersection points to determine the intersection point difference distance, and the trend of change is determined based on the intersection point difference distance. The compensation area corresponding to the change trend, unit distance, intersection difference distance, and intersection distance is determined based on the preset compensation matching relationship, and the overall area of ​​the foreign object is updated based on the compensation area.

[0012] By adopting the above technical solution, the overall area of ​​the foreign object can be determined more accurately according to its specific circumstances, which facilitates subsequent processing.

[0013] Optionally, the step of controlling a preset blowing device to move to the treatment position includes: Obtain the standby operating position of the air blowing equipment; Determine if there are at least two external outlines of foreign objects; If there are no at least two external outlines of foreign objects, the moving operation path is determined based on the standby operation position and the processing position, and the blowing equipment is controlled to move along the moving operation path. If there are at least two foreign object outlines, then different combination processing sequences are determined based on all processing locations; The required movement distance is determined based on the processing position in the combined processing sequence and the standby operation position. The minimum required movement distance is determined according to the sorting rules, and the combination processing sequence corresponding to the required movement distance is defined as the operation movement sequence. The movement operation path is determined according to the operation movement sequence and the corresponding processing position to control the movement of the air blowing equipment.

[0014] By adopting the above technical solution, when there are multiple foreign objects that need to be processed, the movement sequence can be defined so that the air blowing equipment can operate efficiently and improve the overall operation efficiency.

[0015] Optionally, after the combination processing sequence is determined, the automotive air duct welding method may further include: Define a variable virtual position in the processing position of the combined processing order, and define the processing position that is adjacent to and precedes the virtual position in the combined processing order as the earlier position; Determine the straight-line distance to the location based on the virtual location and the foreground location; When the straight-line distance to the position is less than the preset influence distance, the angle of the processing direction is determined based on the processing angle of the virtual position and the processing angle of the forward position. Determine whether the angle of the processing direction is less than the preset influence angle; If the angle between the processing directions is not less than the angle of influence, then the original processing order of the combination is maintained; If the angle of the processing direction is smaller than the angle of influence, the corresponding virtual position will be removed in the combined processing sequence.

[0016] By adopting the above technical solution, we analyze the situation where the air blowing equipment affects another foreign object when operating at the relative position of one foreign object, so as to improve the rationality of determining the operation movement sequence.

[0017] Optionally, after the required travel distance is determined, the automotive air duct welding method may also include: Calculate the included angles of all processing directions based on the determined combined processing sequence to determine the required adjustment angles; The waiting time corresponding to the straight-line distance to the location and the angle of the processing direction is determined based on the preset waiting matching relationship; The first selection parameter corresponding to the waiting time is determined based on the preset duration matching relationship, and the second selection parameter corresponding to the required adjustment angle is determined based on the preset rotation matching relationship. The adjustment parameters are determined based on the first and second selection parameters, and the required movement distance is updated based on the adjustment parameters.

[0018] By adopting the above technical solution, and combining the angle that the air blowing equipment needs to be adjusted with the distance that needs to be waited for, the required moving distance is updated so as to determine a more suitable operation sequence in the future.

[0019] Secondly, this application provides an automotive air duct welding system, which adopts the following technical solution: An automotive air duct welding system, comprising: The acquisition module is used to obtain the type of duct being processed; The processing module, connected to the acquisition and judgment modules, is used for information storage and processing; The judgment module, connected to the acquisition and processing modules, is used for judging information. The processing module determines the welding area, standard requirement image, and welding movement path of the duct corresponding to the type of duct being processed based on the preset area matching relationship. The acquisition module obtains real-time images of the area where the duct is welded. The processing module compares and analyzes real-time regional images with standard required images to determine image similarity. The judgment module determines whether the image similarity is greater than the preset required similarity. If the judgment module determines that the image similarity is greater than the required similarity, the processing module controls the welding head to perform welding operations along the welding movement path; If the judgment module determines that the image similarity is not greater than the required similarity, the processing module outputs a foreign object signal and controls the welding head to stop working.

[0020] By adopting the above technical solution, when welding automotive air ducts, the acquisition module acquires the type of automotive air duct to be welded so that the processing module can determine the welding area. At this time, the processing module can use image recognition to enable the judgment module to determine whether there are external foreign objects at the welding position. When the judgment module determines that there are external foreign objects, the operation will not be performed, thereby reducing the occurrence of defects on the surface of the welded product and improving the overall welding quality of automotive air ducts.

[0021] In summary, this application includes at least one of the following beneficial technical effects: When welding automotive air ducts, foreign matter analysis can be performed on the welding location of the air duct to reduce the occurrence of welding operations with foreign matter present, thereby improving the overall welding quality of automotive air ducts. When there are foreign objects at the welding position, they can be removed by blowing air, so that the automotive air duct can be welded normally. When controlling the air blowing equipment to remove foreign objects, the air blowing equipment can be effectively controlled according to the specific situation of the foreign objects, so that the foreign objects can be effectively processed while the overall operation efficiency is high. Attached Figure Description

[0022] Figure 1 This is a flowchart of the automotive air duct welding method.

[0023] Figure 2 This is a flowchart of the external foreign object handling control method.

[0024] Figure 3 This is a flowchart illustrating the method for determining the position and angle of the air blowing device.

[0025] Figure 4 This is a flowchart of the method for updating the overall area of ​​a foreign object.

[0026] Figure 5 This is a flowchart of the method for determining the order of job movements.

[0027] Figure 6 This is a flowchart of the method for adjusting the sequence of combined operations.

[0028] Figure 7 This is a flowchart of the method for updating the required movement distance.

[0029] Figure 8 This is a flowchart of the module process for welding automotive air ducts. Detailed Implementation

[0030] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figure 1-8 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0031] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0032] This application discloses a method for welding automotive air ducts. Before welding the automotive air duct, the welding area of ​​the automotive air duct can be determined and foreign objects can be identified. When there are external foreign objects, the air blowing equipment can be controlled to operate on them according to the specific situation of the foreign objects. After the foreign objects are processed, the subsequent welding work can be carried out, so that the overall quality of the welded product is better.

[0033] Reference Figure 1 The welding process for automotive air ducts includes the following steps: Step S100: Obtain the type of duct to be processed.

[0034] The type of duct to be processed refers to the type of duct that needs to be welded and placed on the processing platform of the laser welding machine. The model of the automotive duct is manually entered by the staff through a touch screen. When different models are entered, the fixing points of the automotive duct will be different, that is, the positions where the automotive duct is placed on the processing platform will be different. The corresponding positions are determined by the staff in advance.

[0035] Step S101: Determine the duct welding area, standard requirement image, and welding movement path corresponding to the type of duct to be processed based on the preset area matching relationship.

[0036] The duct welding area is the area where two automotive ducts are welded when they are welded on the processing platform. The standard requirement image is the image that the duct welding area should present when there are no foreign objects at the weld of the duct of the processing type. The welding movement path is the path that the welding head needs to move when welding the duct. Different types of ducts have different duct welding areas, standard requirement images and welding movement paths. The area matching relationship between the four is determined by the staff in advance.

[0037] Step S102: Obtain a real-time image of the area where the duct is welded.

[0038] The real-time regional image is an image of the duct welding area of ​​the automotive duct that needs to be welded. It can be acquired by a camera installed on the laser welding machine facing the duct welding area. The position of the camera can be adjusted according to the determination of the duct welding area to ensure that only the real-time regional image of the duct welding area is acquired.

[0039] Step S103: Compare and analyze the real-time regional images with the standard required images to determine the image similarity.

[0040] Image similarity is the degree of similarity between two images when comparing a real-time image of a region with a standard required image. When an external foreign object appears on a car duct, the two images of the corresponding region will be inconsistent, and their similarity value will decrease.

[0041] Step S104: Determine whether the image similarity is greater than the preset required similarity.

[0042] The requirement similarity is the minimum image similarity set by the staff to determine that there are no foreign objects in the duct welding area. Generally, this value is 99.5%. The purpose of the judgment is to determine whether there are foreign objects in the duct welding area.

[0043] Step S1041: If the image similarity is greater than the required similarity, then control the welding head to perform welding operations along the welding movement path.

[0044] When the image similarity is greater than the required similarity, it indicates that there are no external foreign objects. At this time, the welding head can be controlled to move along the welding path.

[0045] Step S1042: If the image similarity is not greater than the required similarity, output the foreign object signal and control the welding head to stop working.

[0046] When the image similarity is not greater than the required similarity, it indicates the presence of an external foreign object. At this time, a foreign object signal is output to identify the situation, which facilitates subsequent processing steps. At the same time, the welding head is controlled to not operate to reduce the possibility of defects in the product after duct welding and improve the overall welding quality.

[0047] Reference Figure 2 After the foreign object signal is output, the automotive air duct welding method also includes: Step S200: Compare and analyze the real-time regional image with the standard required image to determine the external contour of the foreign object.

[0048] The external contour of the foreign object is the defined external contour line of the foreign object.

[0049] Step S201: Obtain the contour distance between each point on the outer contour of the foreign object and each boundary line of the duct welding area.

[0050] The distance between contours is the vertical distance between each point on the outer contour of the foreign object and the boundary line of the duct welding area.

[0051] Step S202: Determine the minimum profile spacing distance according to the preset sorting rules, and define the boundary line of the duct welding area corresponding to the profile spacing distance as the processing boundary line.

[0052] The sorting rules are methods set by staff to sort numerical values, such as bubble sort. The sorting rules can determine the boundary line closest to the foreign object. At this point, the processing boundary line is defined to distinguish between different boundary lines, which facilitates subsequent analysis steps.

[0053] Step S203: Determine the farthest endpoint on the outer contour of the foreign object that is farthest from the processing boundary line based on the processing boundary line and the corresponding contour distance.

[0054] The farthest endpoint is the point on the outer contour of the foreign object that is furthest from the processing boundary line.

[0055] Step S204: Determine the processing position and processing angle based on the farthest endpoint, and control the preset air blowing device to move to the processing position to perform air blowing operation with the processing angle and preset unit air blowing volume. After the air blowing is completed, perform image comparison again, and if the foreign object signal still exists, update the unit air blowing volume according to the preset correction parameters to control the air blowing device to start working again until the foreign object signal disappears to control the welding head operation.

[0056] The air blowing device is a device that can blow air onto objects, such as an air pump. This device is also equipped with a moving module, allowing it to move along a parallel plane corresponding to the placement platform. The processing position is the location of the air blowing head, and the processing angle is the angle of the gas blown from the head relative to the placement platform. The processing position and angle will be explained below and will not be repeated here. The unit air volume is the amount of gas set by the operator to process foreign objects. This value is fixed. By moving the air blowing device to the processing position and operating at the processing angle, foreign objects can be processed. After blowing is completed, an image comparison is used to determine if the foreign object has been processed. If the foreign object has not been processed, the unit air volume is increased by adding correction parameters, allowing the air blowing device to process the foreign object with greater air force until it is removed from the welding area, ensuring subsequent welding operations can proceed normally.

[0057] Reference Figure 3 The steps for determining the processing location and processing angle based on the farthest endpoint include: Step S300: Define the distance between the farthest endpoint and the processing boundary line as the required movement distance.

[0058] Define the required movement distance to distinguish the distance between different contours, which facilitates subsequent analysis. This required movement distance is the minimum distance that the foreign object needs to move when it is removed.

[0059] Step S301: Determine the overall area of ​​the foreign object based on its external outline.

[0060] The total area of ​​a foreign object is the area of ​​the object enclosed by its outer contour lines.

[0061] Step S302: Determine the processing angle corresponding to the required moving distance, the overall area of ​​the foreign object, and the unit blowing volume based on the preset angle matching relationship.

[0062] Different overall areas of foreign objects indicate different sizes of foreign objects, and different required movement distances indicate different distances that foreign objects need to be moved. At this time, under the same unit air volume, different blowing effects can be achieved by using different angles to process foreign objects. The angle matching relationship between the four factors is determined by the staff in advance through multiple experiments.

[0063] Step S303: Generate a wind action line perpendicular to the processing boundary line at the farthest endpoint based on the processing angle, and determine the intersection of the wind action line and the preset equipment movement plane as the processing position.

[0064] The straight line of wind action is a straight line that passes through the farthest endpoint and extends along the direction of the processing angle. The equipment moving plane is a platform parallel to the processing platform that allows the air blowing equipment to move. By using the intersection point to determine the processing position, the specific position of the air blowing equipment during operation can be determined, so that the subsequent air blowing equipment can perform its operation better.

[0065] Reference Figure 4 After determining the overall area of ​​the foreign object, the welding method for automotive air ducts also includes: Step S400: Determine whether the outer contour of the foreign object intersects with the processing boundary line at two points.

[0066] The purpose of the assessment is to determine whether any external foreign object extends beyond the designated duct welding area, so as to accurately determine the specific size of the foreign object.

[0067] Step S4001: If the outer contour of the foreign object does not have two intersections with the processing boundary line, then maintain the determined overall area of ​​the foreign object.

[0068] When the outer contour of the foreign object does not intersect with the processing boundary line at two points, it means that the foreign object does not exceed the welding area of ​​the duct. In other words, the size of the foreign object currently determined is the actual size of the foreign object. At this time, the overall area of ​​the foreign object can be maintained.

[0069] Step S4002: If there are two intersection points between the outer contour of the foreign object and the processing boundary line, then determine the distance between the two intersection points based on the two intersection points.

[0070] When there are two intersections between the outer contour of the foreign object and the processing boundary line, it indicates that the foreign object exceeds the welding area of ​​the duct, that is, the size of the foreign object currently determined is not the actual size of the foreign object, and further analysis is required; the distance between the intersections is the distance between the two intersections on the processing boundary line.

[0071] Step S401: Control the processing boundary line to move vertically along the direction of the foreign object's outer contour by a preset unit distance and obtain the virtual distance of the intersection point.

[0072] The unit distance is a fixed distance set by the staff, and the virtual intersection distance is the distance between the two intersection points with the largest interval between the boundary line and the outer contour of the foreign object after the boundary line is moved.

[0073] Step S402: Calculate the difference between the intersection points based on the distance between the intersection points and the virtual distance between the intersection points to determine the difference distance between the intersection points, and determine the trend of change based on the difference distance between the intersection points.

[0074] The intersection difference distance is the difference between the distance between the intersection points and the virtual distance between the intersection points. It is determined by subtracting the distance between the intersection points from the virtual distance. The trend of change is the trend of the portion of the foreign object that exceeds the area. When the intersection difference distance is positive, it means that the portion of the foreign object that exceeds the area is gradually decreasing, and the trend of change is decreasing. When the intersection difference distance is negative, it means that the portion of the foreign object that exceeds the area is gradually increasing, and the trend of change is increasing.

[0075] Step S403: Determine the compensation area corresponding to the change trend, unit distance, intersection difference distance, and intersection distance according to the preset compensation matching relationship, and update the overall area of ​​the foreign object according to the compensation area.

[0076] Different intersection point differences per unit distance indicate different overall trends. The larger the absolute value of the intersection point difference, the greater the trend. The compensation area is the virtual area of ​​the part of the foreign object that exceeds the area. This area is only a set approximate guess value and not the actual value. The corresponding compensation matching relationship is determined by the staff in advance through multiple experiments, which will not be elaborated here.

[0077] Reference Figure 5 The steps of controlling the preset air blowing device to move to the treatment position include: Step S500: Obtain the standby operating position of the air blowing device.

[0078] The standby operating position is the position of the air blowing equipment before it is moved.

[0079] Step S501: Determine whether there are at least two external contours of foreign objects.

[0080] The purpose of the assessment is to determine whether there are multiple external foreign objects that need to be dealt with.

[0081] Step S5011: If there are no at least two foreign object outlines, determine the moving operation path based on the standby operation position and the processing position, and control the air blowing device to move along the moving operation path.

[0082] When there are no at least two foreign object outlines, it means that there is only one foreign object that needs to be processed. In this case, the movement path is determined by taking the standby position as the starting point and the processing position as the ending point, and the air blowing equipment is controlled to move along the movement path to process the foreign object.

[0083] Step S5012: If there are at least two foreign object outlines, determine different combination processing sequences based on all processing positions.

[0084] When there are at least two foreign object outlines, it indicates that different foreign objects need to be processed. At this time, the order of processing needs to be determined. The combined processing order is the order in which the air blowing device moves to the processing position. Different numbers of processing positions correspond to different numbers of combined processing orders. For example, if there are processing positions A, B, and C, the corresponding combined processing orders include ABC, ACB, BAC, BCA, CAB, and CBA, respectively.

[0085] Step S502: Determine the required movement distance based on the processing position in the combined processing sequence and the standby operation position.

[0086] The required movement distance is the total distance that the blowing equipment needs to move when processing according to the combined processing sequence.

[0087] Step S503: Determine the minimum required moving distance according to the sorting rules, define the combined processing sequence corresponding to the required moving distance as the operation moving sequence, and determine the moving operation path according to the operation moving sequence and the corresponding processing position to control the air blowing equipment to move.

[0088] By sorting and combining, the minimum required moving distance can be determined. The corresponding processing order will then be the order that minimizes the moving distance of the air blowing equipment. At this point, the operation moving order is defined to distinguish between different processing orders, so that the air blowing equipment can determine the moving operation path according to the processing position corresponding to the operation moving order, so that the air blowing equipment can perform better operation.

[0089] Reference Figure 6 After the assembly process sequence is determined, the automotive air duct welding method also includes: Step S600: Define a variable virtual position in the processing position of the combined processing order, and define the processing position that is adjacent to and precedes the virtual position in the combined processing order as the earlier position.

[0090] When the air blowing equipment is performing processing operations, there may be situations where other foreign objects are removed simultaneously, which requires further analysis; defining virtual positions and forward positions can distinguish different processing positions, which will facilitate subsequent analysis steps.

[0091] Step S601: Determine the straight-line distance to the location based on the virtual location and the forward location.

[0092] The linear distance is the straight-line distance between the virtual position and the position in front.

[0093] Step S602: When the straight-line distance between the positions is less than the preset influence distance, determine the included angle of the processing direction based on the processing angle of the virtual position and the processing angle of the forward position.

[0094] The influence distance is the maximum straight-line distance set by the staff when they believe that two foreign objects are close enough to be processed simultaneously; the processing direction angle is the angle between the direction corresponding to the processing angle when the air blowing device is operating at the virtual position and the direction corresponding to the processing angle at the forward position.

[0095] Step S603: Determine whether the angle of the processing direction is less than the preset influence angle.

[0096] The influence angle is the maximum processing direction angle set by the staff to determine the range that the blowing equipment will simultaneously affect during operation. The purpose of the judgment is to know whether the blowing equipment can handle the foreign object at the virtual position when it is handling foreign objects at the forward position, that is, whether it is necessary to continue to move to the virtual position to handle foreign objects.

[0097] Step S6031: If the angle between the processing directions is not less than the angle of influence, then maintain the original processing order.

[0098] When the angle of the processing direction is not less than the angle of influence, it means that there is no situation where the foreign object at the virtual position can be processed when the foreign object at the front position is processed. In this case, the determined combination processing order can be maintained.

[0099] Step S6032: If the angle of the processing direction is smaller than the angle of influence, the corresponding virtual position is removed in the combined processing sequence.

[0100] When the angle of the processing direction is less than the angle of influence, it means that when processing the foreign object corresponding to the front position, the foreign object corresponding to the virtual position can be processed simultaneously. That is, the air blowing equipment is likely not to need to move to the virtual position. At this time, the corresponding virtual position in the combined processing sequence is eliminated, so as to facilitate the determination of a more accurate operation movement sequence. After the virtual position is eliminated, the combined processing sequence is updated, that is, the relationship between the corresponding front position and the virtual position is also updated. The virtual position elimination operation is repeated until all virtual positions cannot be eliminated. The combined processing sequence determined at this time is the sequence that needs to be judged.

[0101] Reference Figure 7 Once the required moving distance is determined, the welding methods for automotive air ducts also include: Step S700: Calculate the included angles of all processing directions according to the determined combined processing sequence to determine the required adjustment angles.

[0102] The required adjustment angle is the overall angle that the corresponding air blowing head needs to rotate when the air blowing equipment operates according to the determined combined processing sequence. It is obtained by adding the included angles of all processing directions.

[0103] Step S701: Determine the waiting time corresponding to the straight-line distance of the position and the angle of the processing direction according to the preset waiting matching relationship.

[0104] The waiting time is the time required for the air blowing device to move to the corresponding processing position and for the air blowing head to rotate. This can be calculated and analyzed by determining the moving speed of the air blowing device and the rotation speed of the air blowing head, thereby determining the corresponding waiting matching relationship.

[0105] Step S702: Determine the first selection parameter corresponding to the waiting time according to the preset duration matching relationship, and determine the second selection parameter corresponding to the required adjustment angle according to the preset rotation matching relationship.

[0106] The first selection parameter reflects whether the waiting time is appropriate. The larger the first selection parameter, the more appropriate it is. The longer the waiting time, the less appropriate it is. The matching relationship between the two is determined in advance by the staff. The second selection parameter reflects whether the required adjustment angle is appropriate. Under normal circumstances, the smaller the required adjustment angle, the better. That is, the smaller the required adjustment angle, the larger the corresponding second selection parameter. The matching relationship between the two is determined in advance by the staff.

[0107] Step S703: Calculate and determine the adjustment parameters based on the first selection parameters and the second selection parameters, and update the required movement distance based on the adjustment parameters.

[0108] The adjustment parameters are determined by adding the first selection parameter to the second selection parameter. The required movement distance is updated by subtracting the adjustment parameters from the required movement distance. This ensures that when selecting the order of operation movement in the future, the solution with the shortest waiting time and the smallest required adjustment angle is selected as much as possible, thereby improving the overall operation efficiency while reducing the energy required for adjustment.

[0109] Reference Figure 8 Based on the same inventive concept, embodiments of the present invention provide an automotive air duct welding system, comprising: The acquisition module is used to obtain the type of duct being processed; The processing module, connected to the acquisition and judgment modules, is used for information storage and processing; The judgment module, connected to the acquisition and processing modules, is used for judging information. The processing module determines the welding area, standard requirement image, and welding movement path of the duct corresponding to the type of duct being processed based on the preset area matching relationship. The acquisition module obtains real-time images of the area where the duct is welded. The processing module compares and analyzes real-time regional images with standard required images to determine image similarity. The judgment module determines whether the image similarity is greater than the preset required similarity. If the judgment module determines that the image similarity is greater than the required similarity, the processing module controls the welding head to perform welding operations along the welding movement path; If the judgment module determines that the image similarity is not greater than the required similarity, the processing module outputs a foreign object signal and controls the welding head to stop working; The foreign object handling control module controls the air blowing device to handle the foreign object according to its condition. The position and angle determination module is used to determine the processing position and angle when the air blowing device handles foreign objects. The foreign object area update module updates the overall area of ​​the foreign object in cases where foreign object recognition is incomplete. The operation sequence determination module determines the operation sequence of the air blowing equipment when multiple foreign objects are present. The combination order adjustment module is used to adjust the order of combination processing. The demand distance update module updates the demand movement distance based on the rotation of the air blowing head of the air blowing device and the waiting status.

[0110] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

Claims

1. A method for welding automotive air ducts, characterized in that, include: Obtain the type of duct to be processed; Based on the preset regional matching relationship, determine the duct welding area, standard requirement image and welding movement path corresponding to the type of duct being processed; Acquire real-time images of the duct welding area; The image similarity is determined by comparing and analyzing real-time regional images with standard required images. Determine whether the image similarity is greater than the preset required similarity. If the image similarity is greater than the required similarity, then control the welding head to perform welding operations along the welding movement path; If the image similarity is not greater than the required similarity, output a foreign object signal and control the welding head to stop working; After the foreign object signal is output, the automotive air duct welding method also includes: The external contour of the foreign object is determined by comparing and analyzing real-time regional images with standard required images. Obtain the distance between the contours of each point on the outer contour of the foreign object and the boundary lines of each area of ​​the duct welding zone; The minimum numerical distance between contours is determined according to the preset sorting rules, and the boundary line of the duct welding area corresponding to this distance is defined as the processing boundary line. The furthest endpoint on the outer contour of the foreign object that is farthest from the processing boundary line is determined based on the processing boundary line and the corresponding contour distance. The processing position and angle are determined based on the farthest endpoint, and the preset air blowing device is controlled to move to the processing position to perform air blowing operation with the processing angle and preset unit air blowing volume. After the air blowing is completed, the image is compared again, and if the foreign object signal still exists, the unit air blowing volume is updated according to the preset correction parameters to control the air blowing device to start working again until the foreign object signal disappears to control the welding head operation.

2. The automotive air duct welding method according to claim 1, characterized in that, The steps for determining the processing location and processing angle based on the farthest endpoint include: The distance between the farthest endpoint and the processing boundary line is defined as the required movement distance. Determine the overall area of ​​the foreign object based on its external outline; Based on the preset angle matching relationship, determine the processing angle corresponding to the required moving distance, the overall area of ​​the foreign object, and the unit blowing volume; Based on the processing angle, a wind action line perpendicular to the processing boundary line is generated at the farthest endpoint, and the intersection of the wind action line and the preset equipment movement plane is determined as the processing position.

3. The automotive air duct welding method according to claim 2, characterized in that, After determining the overall area of ​​the foreign object, the welding method for automotive air ducts also includes: Determine whether the outer contour of the foreign object intersects the processing boundary line at two points; If the outer contour of the foreign object does not intersect with the processing boundary line at two points, the determined overall area of ​​the foreign object is maintained. If the outer contour of the foreign object intersects the processing boundary line at two points, the distance between the two points is determined based on the two points. The control processing boundary line moves vertically a preset unit distance along the direction of the foreign object's outer contour and obtains the virtual distance of the intersection point; The difference between the intersection points is calculated based on the distance between the points and the virtual distance between the intersection points to determine the intersection point difference distance, and the trend of change is determined based on the intersection point difference distance. The compensation area corresponding to the change trend, unit distance, intersection difference distance, and intersection distance is determined based on the preset compensation matching relationship, and the overall area of ​​the foreign object is updated based on the compensation area.

4. The automotive air duct welding method according to claim 1, characterized in that, The steps for controlling the preset air blowing device to move to the treatment position include: Obtain the standby operating position of the air blowing equipment; Determine if there are at least two external outlines of foreign objects; If there are no at least two external outlines of foreign objects, the moving operation path is determined based on the standby operation position and the processing position, and the blowing equipment is controlled to move along the moving operation path. If there are at least two foreign object outlines, then different combination processing sequences are determined based on all processing locations; The required movement distance two is determined based on the processing position in the combined processing sequence and the standby operation position. The required movement distance two is the total distance value that the air blowing device needs to move when processing according to the combined processing sequence. The minimum required movement distance 2 is determined according to the sorting rules, and the combination processing sequence corresponding to the required movement distance 2 is defined as the operation movement sequence. The movement operation path is determined according to the operation movement sequence and the corresponding processing position to control the movement of the air blowing equipment.

5. The automotive air duct welding method according to claim 4, characterized in that, After the assembly process sequence is determined, the automotive air duct welding method also includes: Define a variable virtual position in the processing position of the combined processing order, and define the processing position that is adjacent to and precedes the virtual position in the combined processing order as the earlier position; Determine the straight-line distance to the location based on the virtual location and the foreground location; When the straight-line distance to the position is less than the preset influence distance, the angle of the processing direction is determined based on the processing angle of the virtual position and the processing angle of the forward position. Determine whether the angle of the processing direction is less than the preset influence angle; If the angle between the processing directions is not less than the angle of influence, then the original processing order of the combination is maintained; If the angle of the processing direction is smaller than the angle of influence, the corresponding virtual position will be removed in the combined processing sequence.

6. The automotive air duct welding method according to claim 5, characterized in that, Once the required travel distance is determined, the automotive air duct welding method also includes: Calculate the included angles of all processing directions based on the determined combined processing sequence to determine the required adjustment angles; The waiting time corresponding to the straight-line distance to the location and the angle of the processing direction is determined based on the preset waiting matching relationship; The first selection parameter corresponding to the waiting time is determined based on the preset duration matching relationship, and the second selection parameter corresponding to the required adjustment angle is determined based on the preset rotation matching relationship. The adjustment parameters are determined by calculation based on the first and second selection parameters, and the required movement distance is updated based on the adjustment parameters.

7. An automotive air duct welding system for implementing the automotive air duct welding method as described in any one of claims 1-6, characterized in that, include: The acquisition module is used to obtain the type of duct being processed; The processing module, connected to the acquisition and judgment modules, is used for information storage and processing; The judgment module, connected to the acquisition and processing modules, is used for judging information. The processing module determines the welding area, standard requirement image, and welding movement path of the duct corresponding to the type of duct being processed based on the preset area matching relationship. The acquisition module obtains real-time images of the area where the duct is welded. The processing module compares and analyzes real-time regional images with standard required images to determine image similarity. The judgment module determines whether the image similarity is greater than the preset required similarity. If the judgment module determines that the image similarity is greater than the required similarity, the processing module controls the welding head to perform welding operations along the welding movement path; If the judgment module determines that the image similarity is not greater than the required similarity, the processing module outputs a foreign object signal and controls the welding head to stop working.

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