An automated welding system

Abstract

The present invention relates to the field of automatic welding technology, and particularly refers to an automated welding system, which includes a pretreatment module, an analysis module, a determination module, a control module, and a feedback correction module. Through detailed pretreatment and analysis, the present invention globally considers the overall situation during the welding process in advance, ensures that the welding strategy and parameters are highly accurate, constructs a three-dimensional model, precisely simulates and multi-dimensionally splits the three-dimensional model, carefully captures the complex features of the welding path, and improves the simulation accuracy; ensures that important features are not missed; and through automated simulation, analysis control, and real-time feedback correction, improves the efficiency of the welding process, reduces the manual operation time; ensures the stability and consistency of the welding quality, reduces the welding defect rate; can be flexibly adjusted according to different welding target parts and welding complexities, with strong adaptability; and realizes the intelligent management of the welding process.

Description

Technical Field

[0001] The present invention relates to the technical field of automatic welding, and particularly to an automated welding system. Background Art

[0002] In the existing welding systems, due to the inability to globally consider the overall situation during the welding process in advance, there will be situations of excessive parameter adjustment or frequent adjustment during the actual welding process, which affects the welding efficiency and quality. Moreover, relying only on real-time adjustment during the actual welding process will result in a certain delay, making the parameter adjustment not timely enough. Especially in the case of a fast welding speed or a need for quick response during the welding process, the delay will affect the welding quality and stability.

[0003] Chinese Patent Application Publication No. CN108247250A discloses an automated welding system, including a welding table for fixing welding workpieces, a positioning robot for clamping and grasping welding workpieces, a welding robot, a loading / unloading elevator, an electrical control module, a control system, a three-dimensional anatomical workpiece module, and a transportation robot. A three-dimensional vision recognition module is provided inside the positioning robot for clamping and grasping welding workpieces, which is connected to the three-dimensional anatomical workpiece module, and grabs and places a buffer device to automatically identify and select the workpieces to be welded from the loading / unloading elevator; the welding robot is provided with a welding torch, a welding torch buffer device, and a start and end position coordinate system for three-dimensional graphic welding points; the loading / unloading elevator is arranged at the end of the conveyor belt and is connected to the conveyor belt; the transportation robot is arranged at the storage of raw materials for welding workpieces on both sides of the conveyor belt.

[0004] It can be seen that the current automated welding systems cannot ensure the welding quality and stability in the case of a fast welding speed or a need for quick response during the welding process. Summary of the Invention

[0005] Therefore, the purpose of the present invention is to provide an automated welding system to overcome the problem that the current automated welding systems cannot ensure the welding quality and stability in the case of a fast welding speed or a need for quick response during the welding process.

[0006] To achieve the above purpose, the present invention provides an automated welding system, including:

[0007] A preprocessing module for performing feature recognition on the target workpiece to be welded to obtain overall feature parameters, and performing three-dimensional construction on the target workpiece to be welded to obtain a three-dimensional model to be welded, and performing feature marking on the three-dimensional model to be welded according to the overall feature parameters;

[0008] An analysis module, connected to the preprocessing module, is used to perform welding simulation on the three-dimensional model to be welded, obtain the welding simulation results, split the welding simulation results in different spatial dimensions to obtain several splitting results, perform feature analysis on each splitting result, and obtain several one-dimensional feature parameters;

[0009] A determination module, connected to the analysis module, is used to perform one-dimensional analysis and overall analysis on each one-dimensional feature parameter in sequence, evaluate the welding complexity of the welding simulation results, and determine the target welding parameters according to the welding complexity in combination with the feature marking results;

[0010] A control module, connected to the determination module, is used to integrate the target welding parameters to output a target welding strategy, and execute the target welding strategy to perform actual welding on the target part to be welded;

[0011] A feedback correction module, connected to the control module, is used to analyze the test welding results within a preset test welding time period, judge the actual welding quality of the target part to be welded during the test welding process, and adjust the target welding strategy according to the judgment result of the actual welding quality.

[0012] Further, the preprocessing module includes:

[0013] An identification unit, which is used to obtain the overall edge information and overall contour information of the target part to be welded;

[0014] A construction unit, connected to the identification unit, is used to perform three-dimensional construction on the welding area of the target part to be welded according to the overall edge information and the overall contour information to obtain the three-dimensional model to be welded;

[0015] A marking unit, connected to the construction unit, is used to mark the structural complexity level of the three-dimensional model to be welded according to the overall edge information and the overall contour information;

[0016] The overall feature parameters include the overall edge information and the overall contour information;

[0017] The overall edge information includes: surface flatness and the number of workpiece surfaces; the overall contour information includes: welding area and welding area thickness.

[0018] Further, the analysis module includes:

[0019] A simulation unit, which performs welding simulation on the three-dimensional model to be welded to obtain a simulated welding space curve;

[0020] The splitting unit is connected to the simulation unit and is used to split the simulated welding space curve according to the X-axis direction, Y-axis direction, and Z-axis direction to obtain an X-direction simulated space curve, a Y-direction simulated space curve, and a Z-direction simulated space curve;

[0021] The feature reading unit is connected to the splitting unit and is used to obtain the number of one-dimensional inflection points and several one-dimensional arc radii of each simulated space curve;

[0022] The one-dimensional feature parameters include the number of one-dimensional inflection points and one-dimensional arc radii.

[0023] Further, the determination module includes:

[0024] The single evaluation unit is used to determine the single welding complexity of each simulated space curve;

[0025] The overall evaluation unit is connected to the single evaluation unit and is used to determine the overall welding complexity of the three-dimensional model to be welded according to each single welding complexity;

[0026] The matching unit is connected to the overall evaluation unit and is used to determine the target welding difficulty of the target workpiece to be welded according to the overall welding complexity in combination with the structural complexity level;

[0027] The generation unit is connected to the matching unit and is used to determine the target welding current and target welding speed at different welding positions during the actual welding process according to the target welding difficulty in combination with each one-dimensional arc radius.

[0028] Further, the feedback correction module includes:

[0029] The monitoring unit is used to obtain the test welding image of the target workpiece to be welded during the preset test welding time period;

[0030] The judgment unit is connected to the monitoring unit and is used to analyze the test welding image to obtain a test judgment result, and determine whether it is necessary to adjust the target welding strategy according to the test judgment result;

[0031] The compensation unit is connected to the judgment unit and is used to correct the target welding strategy according to the test judgment result.

[0032] Further, the marking unit calculates an edge evaluation value according to the surface flatness and the number of workpiece surfaces; and determines whether the overall edge information meets a single determination condition according to the absolute value of the first difference and a preset first evaluation value;

[0033] The marking unit calculates a contour evaluation value according to the area and thickness of the welding area; and determines whether the overall contour information meets the single determination condition according to the absolute value of the second difference and a preset second evaluation value;

[0034] Wherein, the absolute value of the first difference is the absolute value of the difference between the edge evaluation value and a preset edge standard value; the absolute value of the second difference is the absolute value of the difference between the contour evaluation value and a preset contour standard value.

[0035] Further, the marking unit determines the structural complexity level of the three-dimensional model to be welded according to the number of items that meet the single determination condition in the overall edge information and the overall contour information;

[0036] If the number of items that meet the single determination condition in the overall edge information and the overall contour information is 0, it is determined that the structural complexity level is level one, and the three-dimensional model to be welded is marked as a level one structural type;

[0037] If the number of items that meet the single determination condition in the overall edge information and the overall contour information is 1, it is determined that the structural complexity level is level two, and the three-dimensional model to be welded is marked as a level two structural type;

[0038] If the number of items that meet the single determination condition in the overall edge information and the overall contour information is 2, it is determined that the structural complexity level is level three, and the three-dimensional model to be welded is marked as a level three structural type.

[0039] Further, for any single-dimensional arc radius;

[0040] The single evaluation unit calculates the absolute value of the third difference according to any single-dimensional arc radius and a preset standard arc radius;

[0041] And determines the type of any single-dimensional arc radius as a normal welding type, or an easy welding type, or a difficult welding type according to the absolute value of the third difference in combination with a preset third evaluation value.

[0042] Further, the single evaluation unit integrates according to the types of each single-dimensional arc radius, and calculates the single welding complexity according to the integration situation in combination with the number of single-dimensional inflection points;

[0043] The overall evaluation unit performs an averaging process on the single welding complexities of each dimension to obtain the overall welding complexity.

[0044] Further, the monitoring unit captures the test welding image during the welding process; the test welding image represents the actual weld forming state, including: pores and cracks;

[0045] The judgment unit receives the image data from the monitoring unit,

[0046] if there are pores or cracks in the test welding image, it is determined that the target welding strategy needs to be adjusted;

[0047] if there are no pores or cracks in the test welding image, it is determined that the target welding strategy does not need to be adjusted.

[0048] Compared with the prior art, the beneficial effects of the present invention are as follows: by performing feature recognition on the target workpiece to be welded, overall feature parameters are obtained to ensure that the welding strategy can adapt to the characteristics of different target workpieces; three-dimensional modeling is performed on the target workpiece to be welded to obtain a three-dimensional model to be welded, providing a more accurate basis for welding simulation; feature marking is performed on the three-dimensional model according to the overall feature parameters, which helps the subsequent analysis module and determination module to perform precise analysis and parameter setting; by performing welding simulation on the three-dimensional model to be welded, possible problems can be predicted in advance and the welding strategy can be optimized; the welding simulation results are split in different spatial dimensions to refine and analyze the welding characteristics of each part, improving the comprehensiveness and accuracy of the analysis; feature analysis is performed on each split result to obtain several one-dimensional feature parameters, providing fine parameter input for the subsequent module; one-dimensional analysis and overall analysis are performed on each one-dimensional feature parameter to comprehensively evaluate the welding complexity; combined with the feature marking results, the target welding parameters are determined according to the welding complexity to ensure that the parameter setting in the welding process is scientific and reasonable; the target welding parameters are integrated, the target welding strategy is output, and this strategy is executed to perform actual welding on the target workpiece to be welded, ensuring the accuracy and consistency of the actual operation; the automation degree of the welding process is improved, human intervention is reduced, and the stability of the welding quality is enhanced; the test welding results within the preset test welding time period are analyzed to judge the actual welding quality and provide real-time feedback; according to the judgment result of the actual welding quality, the target welding strategy is adjusted in real time, the welding parameters are continuously optimized, and the welding quality is improved; through detailed preprocessing and analysis, it is ensured that the welding strategy and parameters are highly accurate and can adapt to the characteristics of different welding target workpieces; automated control and real-time feedback correction improve the efficiency of the welding process and reduce the human operation time; through simulation, analysis and feedback correction, the stability and consistency of the welding quality are ensured, and the welding defect rate is reduced; it can be flexibly adjusted according to different welding target workpieces and welding complexities, with strong adaptability; intelligent management of the welding process is realized.

[0049] In particular, through high-precision sensors or image processing techniques, the overall edge information and contour information of the target workpiece to be welded are obtained; ensuring reliable basic data for subsequent construction and marking units, thereby improving the accuracy and effectiveness of the entire system; using the overall edge information and contour information provided by the recognition unit to perform three-dimensional construction to obtain a three-dimensional model of the workpiece to be welded; through precise three-dimensional modeling, a detailed model of the welding area to be provided, making subsequent welding simulation and analysis more valuable and practical for reference; marking the structural complexity level of the three-dimensional model according to the overall edge information and contour information; being able to perform targeted analysis and adjustment according to different complexities to ensure the rationality and effectiveness of the welding strategy; the complete characteristic parameters cover the key characteristics of the target workpiece, ensuring comprehensive consideration and optimization of the entire welding process; the comprehensive and accurate preprocessing process reduces potential errors and uncertainties during the welding process, improving the success rate and quality of welding.

[0050] In particular, by accurately obtaining the surface flatness, the number of workpiece surfaces, the welding area, and the welding area thickness of the target workpiece to be welded, the comprehensiveness and accuracy of the data are ensured; ensuring the accuracy of the overall edge information and overall contour information, providing reliable basic data for subsequent processing; the meticulous construction of the three-dimensional model helps to better reflect the actual situation in welding simulation, thereby enhancing the credibility and reference value of the simulation results; being able to mark the structural complexity level of the three-dimensional model of the workpiece to be welded, which helps to perform targeted analysis and adjustment according to the complexity in subsequent steps; being able to formulate corresponding welding strategies for models with different complexities; through high-precision recognition and detailed marking, potential errors during the welding process are reduced, and the welding success rate and product quality are improved; providing a solid foundation for subsequent welding simulation and actual welding, helping to improve the overall quality and efficiency of the welding process.

[0051] In particular, through precise simulation and multi-dimensional splitting of the three-dimensional model, the analysis module can meticulously capture the complex characteristics of the welding path, improving the simulation accuracy; the extraction of single-dimensional characteristic parameters makes the analysis process more meticulous, ensuring that important characteristics are not missed; detailed characteristic parameters help to optimize the welding path planning, avoiding discontinuous points and abnormal bends in the path, and improving the welding quality; through the precise simulation of the simulation unit, potential welding problems are identified in advance, enhancing the system's prediction and response capabilities; through the provided multi-dimensional data support, a rich information basis is provided for further optimization of the welding strategy and quality control; through precise simulation and feature extraction, the trial-and-error links in the actual welding process are reduced, improving the welding efficiency and the quality of the final product; achieving high-precision simulation and optimization of the welding process, helping to improve the overall quality and efficiency of the welding operation.

[0052] In particular, by independently evaluating the simulation curves in each direction, the meticulousness and accuracy of the welding complexity evaluation are ensured; subtle changes in the welding path can be captured, providing high-precision data for the overall evaluation; the overall welding complexity of the three-dimensional model to be welded is determined based on each individual welding complexity, integrating the evaluation results in multiple directions to ensure the comprehensiveness of the overall evaluation; by comprehensively analyzing the welding complexities in different directions, the overall evaluation unit provides a global perspective, facilitating a comprehensive understanding of the welding challenges of the target workpiece to be welded; the target welding difficulty of the target workpiece to be welded is determined based on the overall welding complexity in combination with the structural complexity level, achieving an accurate match of the welding difficulty; the overall welding complexity and the structural complexity level are comprehensively considered to ensure the scientificity and rationality of the evaluation results; based on the target welding difficulty in combination with the single-dimensional arc radii, the target welding current and target welding speed at different welding positions during the actual welding process are determined, realizing the optimization of welding parameters; enabling the welding process to achieve precise control, improving the welding quality and efficiency; being able to adjust the welding parameters according to the actual welding situation, ensuring the flexibility and adaptability of the welding process, reducing welding defects and mistakes; enhancing the reliability and stability of the welding process.

[0053] In particular, by accurately obtaining the key characteristic parameters of the simulated space curve, every detail in the welding path is captured, providing an accurate data basis for subsequent evaluation and optimization; re-numbering and integrating the single-dimensional arc radii of the easily weldable type and the difficult-to-weld type helps to optimize and process the welding path more pertinently; through the difference calculation and classification of the single-dimensional arc radii, different types in the welding path can be accurately distinguished, improving the accuracy of the evaluation; by accurately evaluating the welding complexity, a reliable basis for subsequent welding parameter optimization is provided, ensuring the efficiency and quality during the actual welding process; being able to adapt to welding paths with different complexities, having high flexibility and adaptability, and being applicable to various welding scenarios; providing strong support for the efficient execution and quality improvement of the welding process.

[0054] In particular, through mean processing, the influence of the complexity in each direction can be balanced, avoiding deviations in the overall evaluation result caused by overly high or low complexity in a single direction; being able to be flexibly adjusted according to the actual welding process indicators, improving the flexibility and adaptability of the evaluation and matching; making fine adjustments to the welding types corresponding to the single-dimensional arc radii at different positions to ensure the integrity of the weld seam; by accurately matching and optimizing the welding parameters, the efficiency and productivity of the welding process can be improved, reducing the production cost.

[0055] In particular, by obtaining the test welding images of the target workpiece to be welded in real time during the preset test welding time period, every detail during the welding process is accurately recorded; high-precision image acquisition technology is used to ensure that the captured welding images are clear and accurate, providing reliable data for subsequent analysis; through the analysis of the test welding images, the welding results are intelligently judged to ensure the scientificity and accuracy of the judgment; according to the test judgment results, it is dynamically determined whether it is necessary to adjust the target welding strategy to ensure the flexibility and adaptability during the welding process; according to the test judgment results, the target welding strategy is accurately corrected to ensure that the welding parameters are always in the best state, improving the welding quality; an effective feedback mechanism is established, and by continuously correcting the welding strategy, the welding process is optimized to ensure the reliability and stability of the final welding effect; through monitoring, judgment and compensation, a closed-loop control system is formed to dynamically optimize the welding process to ensure the continuous improvement of the welding quality; real-time monitoring and dynamic adjustment reduce the occurrence of welding defects, improve production efficiency, and reduce the rework rate and production cost; through accurate image acquisition and intelligent analysis, it is ensured that every step during the welding process is under high-precision control, improving the welding quality; it can be flexibly adjusted according to different welding situations, has strong adaptability, and can meet various welding requirements.

[0056] In particular, through the monitoring in the initial time period, potential problems during the welding process can be discovered in time, preventing the problems from expanding and reducing the rework rate; devices such as high-resolution cameras and infrared cameras are used to obtain the test welding images to ensure that the details during the welding process are accurately captured, which helps to accurately analyze the weld forming state; according to whether there are pores or cracks in the test welding images, it is decided whether to adjust the target welding strategy to ensure the accuracy and timeliness of the judgment results; it can receive the image data of the monitoring unit in real time and perform rapid analysis and judgment to ensure the real-time adjustment and optimization of the welding process; welding problems are discovered and corrected in advance, reducing rework and production interruptions, and improving the overall production efficiency and quality control level; the effective monitoring and adjustment mechanism reduces welding defects and rework costs, improving the economic benefits of the production process; ensuring the integrity and quality of the weld forming, improving the qualified rate of products; being able to react quickly during the welding process and adjust the welding parameters in time to ensure the continuity and stability of the welding quality; being able to comprehensively monitor every detail during the welding process to ensure that no potential problems are missed; enabling the welding process to be optimized and adjusted according to the actual situation, improving the intelligent level of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Figure 1 It is a schematic structural diagram of the automated welding system according to an embodiment of the present invention;

[0058] Figure 2 It is a schematic structural diagram of the preprocessing module in the automated welding system according to an embodiment of the present invention;

[0059] Figure 3 Schematic diagram of the analysis module in the automated welding system according to an embodiment of the present invention;

[0060] Figure 4 Schematic diagram of the determination module in the automated welding system according to an embodiment of the present invention;

[0061] Figure 5 Schematic diagram of the feedback correction module in the automated welding system according to an embodiment of the present invention;

[0062] The figure includes: a preprocessing module 1, an analysis module 2, a determination module 3, a control module 4, and a feedback correction module 5. Detailed implementation manners

[0063] In order to make the objectives and advantages of the present invention more clear and understandable, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0064] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0065] It should be noted that in the description of the present invention, the terms indicating directions or positional relationships such as "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings. This is only for convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0066] Please refer to Figure 1 As shown, an embodiment of the present invention provides an automated welding system, which includes:

[0067] A preprocessing module 1, used to perform feature recognition on the target workpiece to be welded to obtain overall feature parameters, perform three-dimensional construction on the target workpiece to be welded to obtain a three-dimensional model to be welded, and perform feature marking on the three-dimensional model to be welded according to the overall feature parameters;

[0068] An analysis module 2, connected to the preprocessing module 1, used to perform welding simulation on the three-dimensional model to be welded, obtain the welding simulation result, split the welding simulation result in different spatial dimensions to obtain several split results, perform feature analysis on each split result, and obtain several single-dimensional feature parameters;

[0069] A determination module 3, connected to the analysis module 2, is configured to perform one-dimensional analysis and overall analysis on each one-dimensional feature parameter in sequence, evaluate the welding complexity of the welding simulation result, and determine target welding parameters according to the welding complexity in combination with the feature marking result;

[0070] A control module 4, connected to the determination module 3, is configured to integrate the target welding parameters to output a target welding strategy, and execute the target welding strategy to perform actual welding on the target workpiece to be welded;

[0071] A feedback correction module 5, connected to the control module 4, is configured to analyze the test welding result within a preset test welding time period, judge the actual welding quality of the target workpiece to be welded during the test welding process, and adjust the target welding strategy according to the judgment result of the actual welding quality.

[0072] Specifically, in the embodiment of the present invention, by performing feature recognition on the target workpiece to be welded, overall feature parameters are obtained to ensure that the welding strategy can adapt to the characteristics of different target workpieces; three-dimensional modeling is performed on the target workpiece to be welded to obtain a three-dimensional model to be welded, providing a more accurate basis for welding simulation; feature marking is performed on the three-dimensional model according to the overall feature parameters, which helps the subsequent analysis module and determination module to perform precise analysis and parameter setting; by performing welding simulation on the three-dimensional model to be welded, potential problems can be predicted in advance to optimize the welding strategy; the welding simulation result is split into different spatial dimensions to refine and analyze the welding characteristics of each part, improving the comprehensiveness and accuracy of the analysis; feature analysis is performed on each split result to obtain a number of one-dimensional feature parameters, providing fine parameter input for the subsequent modules; one-dimensional analysis and overall analysis are performed on each one-dimensional feature parameter to comprehensively evaluate the welding complexity; in combination with the feature marking result, target welding parameters are determined according to the welding complexity to ensure that the parameter setting in the welding process is scientific and reasonable; the target welding parameters are integrated to output a target welding strategy, and this strategy is executed to perform actual welding on the target workpiece to be welded, ensuring the accuracy and consistency of the actual operation; the automation degree of the welding process is improved, human intervention is reduced, and the stability of the welding quality is enhanced; the test welding result within a preset test welding time period is analyzed to judge the actual welding quality and provide real-time feedback; according to the judgment result of the actual welding quality, the target welding strategy is adjusted in real time to continuously optimize the welding parameters and improve the welding quality; through detailed preprocessing and analysis, it is ensured that the welding strategy and parameters are highly accurate and can adapt to the characteristics of different welding target workpieces; automated control and real-time feedback correction improve the efficiency of the welding process and reduce the human operation time; through simulation, analysis and feedback correction, the stability and consistency of the welding quality are ensured, and the welding defect rate is reduced; it can be flexibly adjusted according to different welding target workpieces and welding complexities, with strong adaptability; intelligent management of the welding process is realized.

[0073] Specifically, please refer to Figure 2 As shown, the preprocessing module 1 includes:

[0074] An identification unit for obtaining the overall edge information and overall contour information of the target part to be welded;

[0075] A construction unit connected to the identification unit for three-dimensionally constructing the welding area of the target part to be welded according to the overall edge information and the overall contour information to obtain the three-dimensional welding model;

[0076] A marking unit connected to the construction unit for marking the structural complexity level of the three-dimensional welding model according to the overall edge information and the overall contour information;

[0077] The overall feature parameters include the overall edge information and the overall contour information.

[0078] Specifically, in the embodiment of the present invention, the overall edge information and contour information of the target part to be welded are obtained through a high-precision sensor or image processing technology; ensuring reliable basic data for the subsequent construction and marking units, thereby improving the accuracy and effectiveness of the entire system; using the overall edge information and contour information provided by the identification unit for three-dimensional construction to obtain a three-dimensional welding model; through precise three-dimensional modeling, providing a detailed model of the welding area, making subsequent welding simulation and analysis more valuable and practical for reference; marking the structural complexity level of the three-dimensional model according to the overall edge information and contour information; being able to perform targeted analysis and adjustment according to different complexities, ensuring the rationality and effectiveness of the welding strategy; the complete feature parameters cover the key characteristics of the target part, ensuring comprehensive consideration and optimization of the entire welding process; the comprehensive and accurate preprocessing process reduces potential errors and uncertainties during the welding process, improving the success rate and quality of welding.

[0079] Specifically, in this embodiment, the overall edge information includes: surface flatness and the number of workpiece surfaces;

[0080] The overall contour information includes: welding area area and welding area thickness;

[0081] In this embodiment, the identification unit can scan the target part to be welded through a laser scanner to obtain the surface flatness, the number of workpiece surfaces, the welding area area and the welding area thickness. Of course, other scanning instruments can also be used, such as: a profiler or a coordinate measuring machine, which is not specifically limited in this embodiment;

[0082] The marking unit calculates an edge evaluation value K1 based on the surface flatness A1 and the number of workpiece surfaces A2, where K1 = (1 - A1) × (A2 / 10);

[0083] And calculates an absolute value of the first difference S1 based on the edge evaluation value K1 and a preset edge standard value K10;

[0084] S1 = |K1 - K10|;

[0085] If S1 ≤ S10, the marking unit determines that the overall edge information does not meet the single determination condition;

[0086] If S1 > S10 and K1 < K10, the marking unit determines that the overall edge information does not meet the single determination condition;

[0087] If S1 > S10 and K1 > K10, the marking unit determines that the overall edge information meets the single determination condition;

[0088] Wherein, S10 is a preset first evaluation value;

[0089] The marking unit calculates a contour evaluation value K2 based on the welding area B1 and the welding area thickness B2, where K1 = B1 × B2; wherein, the welding area B1 is: welding area / the total surface area of the target workpiece to be welded × 100%; the welding area thickness B2 is: welding area thickness / the thickness of the target workpiece to be welded × 100%;

[0090] And calculates an absolute value of the second difference S2 based on the contour evaluation value K2 and a preset contour standard value K20;

[0091] S2 = |K2 - K20|;

[0092] If S2 ≤ S20, the marking unit determines that the overall contour information does not meet the single determination condition;

[0093] If S2 > S20 and K2 < K20, the marking unit determines that the overall contour information does not meet the single determination condition;

[0094] If S2 > S20 and K2 > K20, the marking unit determines that the overall contour information meets the single determination condition;

[0095] Wherein, S20 is a preset second evaluation value;

[0096] In this embodiment, the edge standard value K10 is set to 8%; the profile standard value K20 is set to 13%; the first evaluation value S10 is set to 3%; the second evaluation value S20 is set to 5%; the specific setting is also affected by the actual welding process indicators. In this embodiment, the actual welding process indicator is that the number of welded finished parts with qualified welding quality within one welding cycle needs to reach more than 90% of the total target parts to be welded. The actual welding process indicator is set according to the running time and equipment aging degree of the welding equipment. For example, when the welding equipment has been continuously working for more than 50h and the equipment service life is four years, the actual welding process indicator at this time is 83%; then the setting parameters should also be adjusted accordingly;

[0097] The marking unit determines the structural complexity level of the three-dimensional model to be welded according to the number of items that meet the single determination condition in the overall edge information and the overall profile information;

[0098] If the number of items that meet the single determination condition in the overall edge information and the overall profile information is 0, the marking unit determines that the structural complexity level is the first level and marks the three-dimensional model to be welded as the first-level structural type;

[0099] If the number of items that meet the single determination condition in the overall edge information and the overall profile information is 1, the marking unit determines that the structural complexity level is the second level and marks the three-dimensional model to be welded as the second-level structural type;

[0100] If the number of items that meet the single determination condition in the overall edge information and the overall profile information is 2, the marking unit determines that the structural complexity level is the third level and marks the three-dimensional model to be welded as the third-level structural type.

[0101] Specifically, the embodiment of the present invention accurately obtains the surface flatness, the number of workpiece surfaces, the welding area, and the welding area thickness of the target part to be welded, ensuring the comprehensiveness and accuracy of the data; ensuring the accuracy of the overall edge information and the overall profile information, providing reliable basic data for subsequent processing; the detailed construction of the three-dimensional model helps to better reflect the actual situation in the welding simulation, thereby improving the credibility and reference value of the simulation results; being able to mark the structural complexity level of the three-dimensional model to be welded helps to conduct targeted analysis and adjustment according to the complexity in subsequent steps; being able to formulate corresponding welding strategies for models with different complexities; through high-precision recognition and detailed marking, potential errors in the welding process are reduced, the welding success rate and product quality are improved; providing a solid foundation for subsequent welding simulation and actual welding, helping to improve the overall quality and efficiency of the welding process.

[0102] Specifically, please refer toFigure 3 As shown, the analysis module 2 includes:

[0103] A simulation unit, which performs welding simulation on the three-dimensional model to be welded to obtain a simulated welding space curve;

[0104] A splitting unit, connected to the simulation unit, for splitting the simulated welding space curve according to the X-axis direction, Y-axis direction, and Z-axis direction to obtain an X-direction simulated space curve, a Y-direction simulated space curve, and a Z-direction simulated space curve;

[0105] A feature reading unit, connected to the splitting unit, for obtaining the number of one-dimensional inflection points and several one-dimensional arc radii of each simulated space curve in each direction;

[0106] The one-dimensional feature parameters include the number of one-dimensional inflection points and one-dimensional arc radii.

[0107] Specifically, in the embodiment of the present invention, through the accurate simulation and multi-dimensional splitting of the three-dimensional model, the analysis module can carefully capture the complex features of the welding path, improving the simulation accuracy; the extraction of one-dimensional feature parameters makes the analysis process more detailed, ensuring that important features are not missed; the detailed feature parameters help to optimize the welding path planning, avoid discontinuous points and abnormal bends in the path, and improve the welding quality; through the accurate simulation of the simulation unit, potential welding problems can be identified in advance, enhancing the system's prediction and response capabilities; through the provided multi-dimensional data support, it provides a rich information basis for further optimization of welding strategies and quality control; through accurate simulation and feature extraction, the trial-and-error links in the actual welding process are reduced, improving the welding efficiency and the quality of the final product; achieving high-precision simulation and optimization of the welding process, which helps to improve the overall quality and efficiency of welding operations.

[0108] Specifically, please refer to Figure 4 As shown, the determination module 3 includes:

[0109] A single evaluation unit, which is used to determine the single welding complexity of each simulated space curve in each direction;

[0110] An overall evaluation unit, connected to the single evaluation unit, for determining the overall welding complexity of the three-dimensional model to be welded according to each single welding complexity;

[0111] A matching unit, connected to the overall evaluation unit, for determining the target welding difficulty of the target workpiece to be welded according to the overall welding complexity in combination with the structural complexity level;

[0112] A generation unit, connected to the matching unit, for determining the target welding current and target welding speed at different welding positions in the actual welding process according to the target welding difficulty in combination with each one-dimensional arc radius.

[0113] Specifically, in the embodiments of the present invention, by independently evaluating the simulation curves in each direction, the meticulousness and accuracy of the welding complexity evaluation are ensured; the subtle changes in the welding path can be captured, providing high-precision data for the overall evaluation; according to the single welding complexities, the overall welding complexity of the three-dimensional model to be welded is determined, integrating the evaluation results in multiple directions and ensuring the comprehensiveness of the overall evaluation; by comprehensively analyzing the welding complexities in different directions, the overall evaluation unit provides a global perspective, facilitating a comprehensive understanding of the welding challenges of the target workpiece to be welded; according to the overall welding complexity and combined with the structural complexity level, the target welding difficulty of the target workpiece to be welded is determined, achieving an accurate matching of the welding difficulty; comprehensively considering the overall welding complexity and the structural complexity level, the scientificity and rationality of the evaluation results are ensured; according to the target welding difficulty and combined with the single-dimensional arc radii, the target welding current and target welding speed at different welding positions during the actual welding process are determined, realizing the optimization of welding parameters; enabling the welding process to achieve precise control, improving the welding quality and efficiency; being able to adjust the welding parameters according to the actual welding situation, ensuring the flexibility and adaptability of the welding process, reducing welding defects and mistakes; and enhancing the reliability and stability of the welding process.

[0114] Specifically, in this embodiment, for the simulated space curve corresponding to any dimension, the feature reading unit can obtain the number of single-dimensional inflection points and several single-dimensional arc radii of the simulated space curve;

[0115] The several single-dimensional arc radii include: the first single-dimensional arc radius R1, the second single-dimensional arc radius R2,..., the nth single-dimensional arc radius Rn;

[0116] For any single-dimensional arc radius Ri, i = 1, 2,..., n;

[0117] The single evaluation unit calculates the absolute value of the third difference S3 according to the ith single-dimensional arc radius Ri and the preset standard arc radius R0; S3 = |Ri - R0|;

[0118] If S3 ≤ S30, the single evaluation unit determines that the ith single-dimensional arc radius Ri is of a normal welding type;

[0119] If S3 > S30 and Ri > R0, the single evaluation unit determines that the ith single-dimensional arc radius Ri is of an easy welding type;

[0120] If S3 > S30 and Ri < R0, the single evaluation unit determines that the ith single-dimensional arc radius Ri is of a difficult welding type;

[0121] Wherein, S30 is a preset third evaluation value;

[0122] In this embodiment, the standard arc radius R0 is set to 50 cm; the third evaluation value S30 is set to 10; the specific setting is also affected by the actual welding process index; in this embodiment, the actual welding process index is that the welded finished parts with qualified welding quality in a welding cycle need to reach more than 90% of the total target parts to be welded. The actual welding process index is set according to the running time and equipment aging degree of the welding equipment. For example, when the welding equipment has been continuously working for more than 50 h and the equipment service life is four years, the actual welding process index at this time is 83%; then the setting parameters should also be adjusted accordingly;

[0123] The single evaluation unit integrates each single-dimensional arc radius, including;

[0124] 1) Renumber each single-dimensional arc radius of the easy-welding type, denoted as the first easy-welding point, the second easy-welding point,..., the p-th easy-welding point,

[0125] 2) Renumber each single-dimensional arc radius of the difficult-welding type, denoted as the first difficult-welding point, the second difficult-welding point,..., the q-th difficult-welding point,

[0126] The single evaluation unit calculates the single welding complexity Lj according to the integration situation in combination with the number G of single-dimensional inflection points; where j = 1, 2, 3;

[0127] ;

[0128] Among them, is the single-dimensional arc radius of the q-th difficult-welding point, is the first calculation compensation parameter of the single-dimensional arc radius of the q-th difficult-welding point for the single welding complexity Lj; is the single-dimensional arc radius of the p-th easy-welding point, E2 is the second calculation compensation parameter of the single-dimensional arc radius of the p-th easy-welding point for the single welding complexity Lj, and E3 is the third calculation compensation parameter of the number G of single-dimensional inflection points for the single welding complexity Lj;

[0129] In this embodiment, the first calculated compensation parameter E1 is set to 0.7; the second calculated compensation parameter E2 is set to 0.5; the third calculated compensation parameter E3 is set to 0.7; the specific setting is also affected by the actual welding process index; in this embodiment, the actual welding process index is that the number of qualified welded finished parts within a welding cycle needs to reach more than 90% of the total parts to be welded. The actual welding process index is set according to the running time and aging degree of the welding equipment. For example, when the welding equipment has been continuously working for more than 50h and the service life of the equipment is four years, the actual welding process index at this time is 83%; then the calculated compensation parameters should also be adjusted accordingly.

[0130] Specifically, in the embodiment of the present invention, by accurately obtaining the key feature parameters of the simulated space curve and capturing every detail in the welding path, an accurate data basis is provided for subsequent evaluation and optimization; re-numbering and integrating the single-dimensional arc radii of easy-to-weld types and difficult-to-weld types helps to optimize and process the welding path more pertinently; through the difference calculation and classification of the single-dimensional arc radii, different types in the welding path can be accurately distinguished, improving the accuracy of evaluation; by accurately evaluating the welding complexity, a reliable basis is provided for the optimization of subsequent welding parameters, ensuring the efficiency and quality in the actual welding process; it can adapt to welding paths of different complexities, has high flexibility and adaptability, and is applicable to various welding scenarios; it provides strong support for the efficient execution and quality improvement of the welding process.

[0131] Specifically, in this embodiment, the overall evaluation unit performs a mean processing on the single welding complexities of each dimension to obtain the overall welding complexity L';

[0132] L'=(L1 + L2 + L3) / 3;

[0133] Wherein, L1 is the single welding complexity of the simulated space curve in the X direction;

[0134] L2 is the single welding complexity of the simulated space curve in the Y direction;

[0135] L3 is the single welding complexity of the simulated space curve in the Z direction;

[0136] The matching unit determines the target welding difficulty U according to the overall welding complexity L' and the structural complexity level;

[0137]

[0138] Among them, o1 is the preset first-level compensation value when the structural complexity level is the first level; o2 is the preset second-level compensation value when the structural complexity level is the second level; o3 is the preset third-level compensation value when the structural complexity level is the third level;

[0139] In this embodiment, the first-level compensation value o1 is set to 0.3; the second-level compensation value o2 is set to 0.5; the third-level compensation value o3 is set to 0.7; the specific setting is also affected by the actual welding process indicators;

[0140] The generating unit determines the allowable fluctuation range of the welding current and welding speed when welding the target workpiece to be welded according to the target welding difficulty, and selects the target welding current and the target welding speed at different welding positions within the allowable fluctuation range according to the welding types corresponding to the single-dimensional arc radii on the multi-dimensional simulation space curves in different dimensions;

[0141] For the target workpiece to be welded with a relatively high target welding difficulty, it means that more precise control of the welding current and speed is required. At this time, the upper limit value of the allowable fluctuation range should be selected to be smaller; to avoid burn-through or weld deformation; and for different positions corresponding to the single-dimensional arc radius, different target welding currents and target welding speeds should be selected; for example, when the welding type corresponding to the single-dimensional arc radius is the difficult welding type, a slightly slower target welding speed and a smaller target welding current are required to ensure the integrity of the weld.

[0142] Specifically, the embodiment of the present invention can balance the influence of the complexity in each direction through mean processing, avoiding the deviation of the overall evaluation result caused by too high or too low complexity in a single direction; it can be flexibly adjusted according to the actual welding process indicators, improving the flexibility and adaptability of evaluation and matching; fine adjustment is performed for the welding types corresponding to the single-dimensional arc radii at different positions to ensure the integrity of the weld; by accurately matching and optimizing the welding parameters, the efficiency and productivity of the welding process can be improved, and the production cost can be reduced.

[0143] Specifically, please refer to Figure 5 As shown, the feedback correction module 5 includes:

[0144] A monitoring unit, which is used to obtain the test welding image of the target workpiece to be welded during the preset test welding time period;

[0145] A judgment unit, connected to the monitoring unit, which is used to analyze the test welding image to obtain a test judgment result, and determine whether it is necessary to adjust the target welding strategy according to the test judgment result;

[0146] A compensation unit, connected to the judgment unit, is used to correct the target welding strategy according to the test determination result.

[0147] Specifically, in the embodiment of the present invention, during a preset test welding time period, the test welding image of the target part to be welded is obtained in real time to ensure that every detail during the welding process is accurately recorded; high-precision image acquisition technology is used to ensure that the captured welding image is clear and accurate, providing reliable data for subsequent analysis; through the analysis of the test welding image, the welding result is intelligently judged to ensure the scientificity and accuracy of the judgment; according to the test determination result, it is dynamically determined whether the target welding strategy needs to be adjusted to ensure flexibility and adaptability during the welding process; according to the test determination result, the target welding strategy is accurately corrected to ensure that the welding parameters are always in the best state, improving the welding quality; an effective feedback mechanism is established, and by continuously correcting the welding strategy, the welding process is optimized to ensure the reliability and stability of the final welding effect; through monitoring, judgment and compensation, a closed-loop control system is formed to dynamically optimize the welding process to ensure continuous improvement of the welding quality; real-time monitoring and dynamic adjustment reduce the occurrence of welding defects, improve production efficiency, and reduce the rework rate and production cost; through accurate image acquisition and intelligent analysis, it is ensured that every step during the welding process is under high-precision control, improving the welding quality; it can be flexibly adjusted according to different welding situations, has strong adaptability, and can meet various welding requirements.

[0148] Specifically, in this embodiment, the preset test welding time period is set to one-third of the overall welding duration;

[0149] In this embodiment, the monitoring unit is an image acquisition device for monitoring the welding process, and a high-resolution camera, an infrared camera, etc. can be used; no specific limitation is made in this embodiment;

[0150] During the preset test welding time period, the monitoring unit is started and captures the test welding image of the welding process; the test welding image represents the actual weld formation state, including: pores and cracks;

[0151] The judgment unit receives the image data from the monitoring unit,

[0152] If there are pores or cracks in the test welding image, it is judged that the target welding strategy needs to be adjusted;

[0153] If there are no pores or cracks in the test welding image, it is judged that the target welding strategy does not need to be adjusted;

[0154] The compensation unit corrects the target welding strategy according to the test determination result provided by the judgment unit;

[0155] If pores and cracks exist in the test welding images, the target welding current is decreased;

[0156] If either pores or cracks exist in the test welding images, the target welding speed is decreased.

[0157] Specifically, through the monitoring in the initial time period, the embodiments of the present invention can timely detect potential problems in the welding process, prevent the problems from expanding, and reduce the rework rate; high-resolution cameras, infrared cameras and other devices are used to obtain test welding images to ensure that the details in the welding process are accurately captured, which helps to accurately analyze the weld forming state; whether to adjust the target welding strategy is determined according to whether pores or cracks exist in the test welding images to ensure the accuracy and timeliness of the judgment results; the image data of the monitoring unit can be received in real time and quickly analyzed and judged to ensure the real-time adjustment and optimization of the welding process; welding problems can be discovered and corrected in advance, rework and production interruption are reduced, and the overall production efficiency and quality control level are improved; the effective monitoring and adjustment mechanism reduces the welding defects and rework costs and improves the economic benefits of the production process; the integrity and quality of the weld forming are ensured, and the qualified rate of the product is improved; it can quickly respond during the welding process and timely adjust the welding parameters to ensure the continuity and stability of the welding quality; it can comprehensively monitor each detail in the welding process to ensure that no potential problem is missed; the welding process can be optimized and adjusted according to the actual situation to improve the intelligent level of the production line.

[0158] In the present invention, the functions of calculating the compensation parameters and the adjustment parameters are twofold. One is to balance the dimensions on both sides of the formula, and the other is to adjust the numerical results. No specific assignment is made in this embodiment. Moreover, the calculation formulas in this embodiment are used to intuitively reflect the adjustment relationships between various values, such as positive correlation and negative correlation. Without special instructions, the parameter values of the parameters without specific numerical limitations are all taken as positive.

[0159] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the protection scope of the present invention.

[0160] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An automated welding system, characterized in that, Including: A preprocessing module for performing feature recognition on the target workpiece to be welded to obtain overall feature parameters, and performing three-dimensional construction on the target workpiece to be welded to obtain a three-dimensional model to be welded, and performing feature marking on the three-dimensional model to be welded according to the overall feature parameters; An analysis module, connected to the preprocessing module, for performing welding simulation on the three-dimensional model to be welded, obtaining welding simulation results, splitting the welding simulation results in different spatial dimensions to obtain several split results, performing feature analysis on each split result, and obtaining several one-dimensional feature parameters; A determination module, connected to the analysis module, for sequentially performing one-dimensional analysis and overall analysis on each one-dimensional feature parameter, evaluating the welding complexity of the welding simulation results, and determining target welding parameters according to the welding complexity in combination with the feature marking results; A control module, connected to the determination module, for integrating the target welding parameters to output a target welding strategy, and executing the target welding strategy to perform actual welding on the target workpiece to be welded; A feedback correction module, connected to the control module, for analyzing the test welding results within a preset test welding time period, judging the actual welding quality of the target workpiece to be welded during the test welding process, and adjusting the target welding strategy according to the judgment result of the actual welding quality; The preprocessing module includes: An identification unit for obtaining the overall edge information and overall contour information of the target workpiece to be welded; A construction unit, connected to the identification unit, for performing three-dimensional construction on the welding area of the target workpiece to be welded according to the overall edge information and the overall contour information to obtain the three-dimensional model to be welded; A marking unit, connected to the construction unit, for marking the structural complexity level of the three-dimensional model to be welded according to the overall edge information and the overall contour information; The overall feature parameters include the overall edge information and the overall contour information; The overall edge information includes: surface flatness and the number of workpiece surfaces; the overall contour information includes: welding area and welding area thickness; The analysis module includes: A simulation unit for performing welding simulation on the three-dimensional model to be welded to obtain a simulated welding space curve; A splitting unit, connected to the simulation unit, for splitting the simulated welding space curve in the X-axis direction, Y-axis direction, and Z-axis direction to obtain an X-direction simulated space curve, a Y-direction simulated space curve, and a Z-direction simulated space curve; A feature reading unit, connected to the splitting unit, for obtaining the number of one-dimensional inflection points and several one-dimensional arc radii of each direction simulated space curve; The one-dimensional feature parameters include the number of one-dimensional inflection points and one-dimensional arc radii; The determination module includes: A single evaluation unit for determining the single welding complexity of each direction simulated space curve; An overall evaluation unit, connected to the single evaluation unit, for determining the overall welding complexity of the three-dimensional model to be welded according to each single welding complexity; A matching unit, connected to the overall evaluation unit, is used to determine the target welding difficulty of the target workpiece to be welded according to the overall welding complexity and the structural complexity level. A generating unit, connected to the matching unit, is used to determine the target welding current and the target welding speed at different welding positions during the actual welding process according to the target welding difficulty and each single-dimensional arc radius.

2. The automated welding system according to claim 1, wherein, The feedback correction module includes: A monitoring unit, which is used to obtain the test welding image of the target workpiece to be welded during the preset test welding time period. A judging unit, connected to the monitoring unit, is used to analyze the test welding image to obtain a test judgment result, and determine whether it is necessary to adjust the target welding strategy according to the test judgment result. A compensation unit, connected to the judging unit, is used to correct the target welding strategy according to the test judgment result.

3. The automated welding system according to claim 2, wherein The marking unit calculates an edge evaluation value according to the surface flatness and the number of workpiece surfaces; and determines whether the overall edge information meets a single judgment condition according to the absolute value of the first difference and a preset first evaluation value. The marking unit calculates a contour evaluation value according to the welding area and the welding area thickness. And determines whether the overall contour information meets the single judgment condition according to the absolute value of the second difference and a preset second evaluation value. Wherein, the absolute value of the first difference is the absolute value of the difference between the edge evaluation value and a preset edge standard value; the absolute value of the second difference is the absolute value of the difference between the contour evaluation value and a preset contour standard value.

4. The automated welding system according to claim 3, wherein, The marking unit determines the structural complexity level of the three-dimensional workpiece to be welded according to the number of items that meet the single judgment condition in the overall edge information and the overall contour information. If the number of items that meet the single judgment condition in the overall edge information and the overall contour information is 0, it is determined that the structural complexity level is the first level, and the three-dimensional workpiece to be welded is marked as the first-level structure type. If the number of items that meet the single judgment condition in the overall edge information and the overall contour information is 1, it is determined that the structural complexity level is the second level, and the three-dimensional workpiece to be welded is marked as the second-level structure type. If the number of items that meet the single judgment condition in the overall edge information and the overall contour information is 2, it is determined that the structural complexity level is the third level, and the three-dimensional workpiece to be welded is marked as the third-level structure type.

5. The automated welding system according to claim 4, characterized in that For any single-dimensional arc radius; The single evaluation unit calculates the absolute value of the third difference according to any single-dimensional arc radius and a preset standard arc radius. And determines the type of any single-dimensional arc radius as: normal welding type, or easy welding type, or difficult welding type according to the absolute value of the third difference and a preset third evaluation value.

6. The automated welding system according to claim 5, wherein, The single evaluation unit integrates according to the types of each single-dimensional arc radius, and calculates the single welding complexity according to the integration situation and the number of single-dimensional inflection points. The overall evaluation unit performs an average process on the single welding complexities of each dimension to obtain the overall welding complexity.

7. The automated welding system according to claim 6, wherein The monitoring unit captures the test welding image during the welding process; The test welding image represents the actual weld formation state, including: pores and cracks; The judgment unit receives the image data from the monitoring unit, If there are pores or cracks in the test welding image, it is judged that the target welding strategy needs to be adjusted; If there are no pores or cracks in the test welding image, it is judged that the target welding strategy does not need to be adjusted.

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