Energy-saving control system of electric welding machine based on welding seam monitoring

Abstract

The invention discloses an energy-saving control system for an electric welding machine based on weld monitoring, and relates to the technical field of electric welding. The system comprises: determining an initial control scheme; taking the scheme parameter control dimension and the external intervention dimension as a benchmark, and taking the welding standard as a constraint, performing dimension joint energy-saving optimization; establishing a programmable control module, and establishing a digital controller; establishing a communication connection between the digital controller and the intelligent central control system, and performing brake control of the electric welding machine; taking the weld quality and the control energy consumption as a benchmark, performing abnormal control decision-making, and locating the pre-adjustment control point; based on the pre-adjustment control point, responding to the digital controller, performing electric welding feedback control. The system solves the technical problems that the weld monitoring results of the welding process existing in the energy-saving control of the existing electric welding machine are inaccurate, resulting in the electric welding machine adjusting the welding parameters not being timely and accurate enough, resulting in the electric welding machine having high energy consumption and low welding efficiency, and achieves the technical effect of the electric welding machine automatically adjusting the welding parameters, reducing energy consumption and improving welding efficiency.

Description

Technical Field

[0001] The present application relates to the field of electric welding technology, and in particular to an energy-saving control system for electric welding machines based on weld monitoring. Background Art

[0002] In the field of modern industrial manufacturing, welding technology plays a vital role. Its application scope covers many industries such as automobiles, aerospace, ships, and construction. With the continuous improvement of welding quality requirements, especially in large-scale and continuous welding production, the importance of weld monitoring technology has become increasingly prominent. However, the traditional energy-saving control of electric welding machines based on weld monitoring mainly achieves energy saving by setting and adjusting parameters such as welding current and voltage. In the face of environmental changes, equipment wear and other factors during the welding process, the accuracy and reliability of the weld monitoring results are difficult to guarantee, and the efficiency of manual monitoring is low, which cannot meet the needs of large-scale and high-efficiency welding production, thus affecting the welding quality and energy consumption.

[0003] Therefore, in the current energy-saving control technologies related to electric welding machines, there is a technical problem that the weld monitoring results of the welding process are inaccurate, resulting in the electric welding machine not adjusting the welding parameters in a timely and accurate manner, resulting in high energy consumption and low welding efficiency. Summary of the invention

[0004] The present application provides an energy-saving control system for electric welding machines based on weld monitoring, adopts technical means such as dimensional joint optimization and establishment of digital controllers, and solves the technical problems of inaccurate weld monitoring results in the welding process of existing energy-saving control of electric welding machines, resulting in the electric welding machine adjusting welding parameters not in a timely and accurate manner, resulting in high energy consumption and low welding efficiency of the electric welding machine, and achieves the technical effect of automatically adjusting welding parameters of the electric welding machine, reducing energy consumption and improving welding efficiency.

[0005] The present application provides an energy-saving control system for an electric welding machine based on weld monitoring, and the system includes: an initial control scheme determination module, which determines the initial control scheme based on the welding standard of the target component and the working parameters of the electric welding machine, and the initial control scheme is a periodic dynamic scheme; a dimensional joint energy-saving optimization module, which is used to perform dimensional joint energy-saving optimization based on the scheme parameter control dimension and the external intervention dimension, and the welding standard as a constraint to determine the pre-control scheme; a digital controller establishment module, which establishes a programmable control module based on the digital control function, and performs module collaborative connection and upper device coordination. , establish a digital controller, wherein the programmable control module is configured based on a functional logic program and has a built-in instruction lookup table; an electric welding machine braking control module, the electric welding machine braking control module is used to establish a communication connection between the digital controller and the intelligent central control system, and delegate the pre-control scheme to the digital controller to perform electric welding machine braking control; an abnormal control decision module, the abnormal control decision module is used to synchronously monitor electric welding, make abnormal control decisions based on weld quality and control energy consumption, and locate pre-adjustment control points; an electric welding feedback control module, the electric welding feedback control module performs electric welding feedback control based on the pre-adjustment control point and in response to the digital controller.

[0006] In a possible implementation, the dimension is combined with the energy-saving optimization module to perform the following processing: based on the welding standard, the optimization constraint space is determined; with the control parameter as the first optimization dimension, the external intervention regulation as the second optimization dimension, and low energy consumption as the goal, iterative optimization is performed based on the optimization constraint space to determine the periodic dynamic solution that meets the convergence conditions, wherein the optimization principle is iteration in the superior direction and retreat in the inferior direction.

[0007] In a possible implementation, the digital controller establishment module also performs the following processing: traverse the digital control function to determine the functional logic program, and the functional logic program is used to execute the digital control function; based on the functional logic program, configure the programmable control module, and the programmable control module corresponds one-to-one to the digital control function; based on functional synergy, establish the upper device layer, wherein functional synergy includes same-frequency synergy and sequence synergy; based on the programmable control module and the upper device layer, build the digital controller.

[0008] In a possible implementation, the digital controller establishment module also performs the following processing: the host device layer includes at least one host device; the programmable control module is connected to the host device layer through a channel to generate a programmable gate array; the programmable gate array is traversed, configuration training is performed based on an instruction lookup table, and the digital controller is generated, wherein the instruction lookup table is used to assist in instruction logic matching-logical operation processing-control signal execution.

[0009] In a possible implementation, the digital controller establishment module also performs the following processing: determining the adjustment dimension of the digital controller, including a first adjustment dimension based on changes in control requirements, a second adjustment dimension based on exceeding energy consumption trend limits, and a third adjustment dimension based on external auxiliary intervention; based on the adjustment dimensions, reconfiguring and adding management to the digital controller.

[0010] In a possible implementation, the digital controller establishes a module and also performs the following processing: setting a no-load management principle, the no-load management principle being a power outage control based on a preset no-load duration; configuring a no-load management module based on the no-load management principle; and adding the no-load management module to the digital controller.

[0011] In a possible implementation, the abnormal control decision module also performs the following processing: determining a multi-level preset step size, wherein adjacent level intervals of the multi-level preset step size are consistent; based on the multi-level preset step size, determining the random step size levels in sequence, and locating the detection welds distributed in the weld; taking the detection welds as a reference, and based on the returned welding monitoring data, performing welding quality inspection and abnormal control decisions.

[0012] In a possible implementation, the abnormal control decision module also performs the following processing: based on the electric welding monitoring data, a real-time energy consumption over-limit judgment is made to determine a first judgment result; if the first judgment result exceeds the limit, an energy consumption trend judgment is made in combination with the previous energy consumption judgment result to determine a second judgment result; if the first judgment result exceeds the limit and the second judgment result is an energy consumption increase, an abnormal control decision is made.

[0013] The energy-saving control system of the welding machine based on weld monitoring proposed in this application is proposed to determine the initial control scheme based on the welding standard of the target component and the working parameters of the welding machine; take the scheme parameter control dimension and the external intervention dimension as the benchmark, and take the welding standard as the constraint to conduct dimension joint energy-saving optimization; establish a programmable control module based on the digital control function, conduct module collaborative connection and upper device coordination, and establish a digital controller; establish a communication connection between the digital controller and the intelligent central control system, and delegate the pre-control scheme to the digital controller to perform the brake control of the welding machine; conduct welding monitoring simultaneously, and make abnormal control decisions and locate the pre-adjustment control point based on the weld quality and control energy consumption; based on the pre-adjustment control point, respond to the digital controller to perform welding feedback control. The existing energy-saving control of the welding machine solves the technical problems that the weld monitoring results of the welding process are not accurate, which leads to the welding machine adjusting the welding parameters not being real-time and accurate enough, resulting in high energy consumption and low welding efficiency of the welding machine, and achieves the technical effect of the welding machine automatically adjusting the welding parameters, reducing energy consumption and improving welding efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solution of the embodiment of the present disclosure, the accompanying drawings of the embodiment of the present disclosure will be briefly introduced below. A flow chart is used in the present application to illustrate the operations performed by the system according to the embodiment of the present application. It should be understood that the preceding or following operations are not necessarily performed accurately in order. On the contrary, various steps can be processed in reverse order or simultaneously as needed. At the same time, other operations can also be added to these processes, or one or more operations can be removed from these processes.

[0015] Figure 1 A schematic diagram of the structure of an electric welding machine energy-saving control system based on weld monitoring provided in an embodiment of the present application;

[0016] Figure 2 A schematic diagram of the execution process of a digital controller establishment module in an electric welding machine energy-saving control system based on weld monitoring provided in an embodiment of the present application.

[0017] Explanation of the reference numerals: initial control scheme determination module 10, dimensional joint energy-saving optimization module 20, digital controller establishment module 30, electric welding machine braking control module 40, abnormal control decision module 50, electric welding feedback control module 60. DETAILED DESCRIPTION

[0018] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0019] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0020] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict, and the terms "first\second" involved are merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by technicians in the technical field of this application. The terms used herein are for the purpose of describing the embodiments of the present application only.

[0021] The embodiment of the present application provides an energy-saving control system for an electric welding machine based on weld monitoring, such as Figure 1 As shown, the system comprises:

[0022] The initial control scheme determining module 10 determines an initial control scheme based on the welding standard of the target component and the working parameters of the welding machine. The initial control scheme is a periodic dynamic scheme. The initial control scheme is determined based on the welding standard of the target component and the working parameters of the electric welder. The welding standard of the target component is the basic requirement for welding quality and safety, which may include the requirements of the welding quality, welding size, welding speed, etc. of the target component, as well as the differences in material type and material thickness, and other control parameter requirements to meet welding requirements, such as current, voltage, etc. The working parameters of the electric welder include welding current, voltage, welding speed, etc., which have a direct impact on welding quality. Specifically, the initial control scheme is a periodic dynamic scheme, which is a welding machine control scheme that is adjusted over time. Periodicity means that the initial control scheme will be adjusted according to a predetermined time interval or welding stage. For example, at the beginning, middle and end of each welding cycle, the working parameters of the electric welder may be adjusted as needed; dynamicity means that the control scheme is not static, but will be dynamically adjusted according to real-time feedback during the welding process. For example, the working parameters of the electric welder are adjusted according to the data of the welding quality monitoring system (such as welding temperature, welding depth, weld width, etc.), including increasing or decreasing welding current, adjusting welding speed, etc.

[0023] The dimension joint energy-saving optimization module 20 is used to perform dimension joint energy-saving optimization based on the scheme parameter control dimension and the external intervention dimension, and the welding standard as a constraint, to determine the pre-control scheme. During the welding process, based on the scheme parameter control dimension and the external intervention dimension, combined with the constraints of the welding standard, the dimension joint energy-saving optimization is performed to determine the pre-control scheme and optimize the welding process to achieve energy saving and improve efficiency. Specifically, the scheme parameter control dimension refers to the various parameters and factors that affect the welding quality and energy consumption during the welding process, which may include welding current, voltage, welding speed, welding path, preheating temperature, post-heat treatment, etc. Through the fine control of these parameters, the welding process can be optimized, unnecessary energy consumption can be reduced, and the welding quality can be guaranteed at the same time; the external intervention dimension refers to the external intervention or adjustment that may be required during the welding process. For example, according to the real-time monitored welding quality data, it may be necessary to adjust the welding parameters; or according to the changes in the welding environment (such as temperature, humidity, wind speed, etc.), it may be necessary to adjust the welding equipment working state, so that the welding process is always in the best state to achieve energy saving and improve efficiency; when conducting dimensional joint energy-saving optimization, it is necessary to ensure that all proposed pre-control schemes meet the relevant welding standards, including the quality requirements of weld size, shape, strength, sealing, etc., as well as the safe operating procedures during welding; Dimensional joint energy-saving optimization is an optimization method to find the best balance point between multiple dimensions or factors to minimize energy use or maximize efficiency. It takes the scheme parameter control dimension and external intervention dimension as the benchmark, welding standards as constraints, and minimizing energy consumption or maximizing welding efficiency as the optimization goal to comprehensively optimize the welding process, understand the interaction and influence of each dimension, as well as their influence on energy consumption and welding quality, so as to meet welding quality requirements and reduce energy consumption.

[0024] Below, the specific configuration of the dimensional joint energy-saving optimization module 20 will be described in detail. The dimensional joint energy-saving optimization module 20 further includes: determining the optimization constraint space based on the welding standard. The optimization constraint space may include material constraints, method constraints, process parameter constraints, quality constraints, etc. Specifically, material constraints refer to selecting suitable materials for welding according to welding standards, including base materials and filler materials (if necessary); method constraints refer to selecting welding methods that meet welding standards, such as fusion welding, pressure welding, brazing, etc. Different welding methods are suitable for different materials and working conditions; process parameter constraints refer to the need to control a series of process parameters during the welding process, such as welding current, voltage, welding speed, preheating temperature, interlayer temperature, etc. These parameters need to be adjusted according to welding standards and actual requirements to obtain the best welding effect; welding quality is an important indicator for evaluating welding effects, including the appearance quality, internal quality, mechanical properties, etc. of the weld. According to the welding standards, corresponding quality constraints need to be set. Taking control parameters as the first optimization dimension, external intervention regulation as the second optimization dimension, and low energy consumption as the goal, iterative optimization is performed based on the optimization constraint space to determine the periodic dynamic solution that meets the convergence conditions, wherein the optimization principle is good iteration and bad retreat. In the process of optimizing welding, taking control parameters as the first optimization dimension, external intervention regulation as the second optimization dimension, and low energy consumption as the goal, iterative optimization is performed in the optimization constraint space to find a periodic dynamic solution that meets the convergence conditions. Specifically, the control parameters that directly affect the welding quality, such as welding current, voltage, welding speed, and preheating temperature, are taken as the first optimization dimension, that is, different parameter combinations will be tried during the optimization process to find the best settings. Manual intervention, control of external equipment (such as wire feeders, clamps, etc.) or adjustment of environmental conditions (such as temperature, humidity, etc.) are taken as the second optimization dimension, and reducing welding energy consumption is the optimization goal. After determining a good optimization constraint, Iterative optimization is performed in the beam space, different combinations of control parameters and external access regulation are tried and the effects of the solutions are evaluated, and finally a periodic dynamic solution that meets the convergence conditions is determined. The optimization principle is good iteration and bad retreat. Specifically, good iteration means that when a better solution than the current solution is found (for example, lower energy consumption), it continues to iterate in this direction, and tries to find a better solution by gradually adjusting the control parameters and external intervention regulation. Bad retreat means that after trying a new solution, no better result is obtained (for example, energy consumption increases), and retreat to a previous better solution, and try to find a new direction from there to avoid falling into the local optimum.

[0025] A digital controller establishment module 30 is provided. The digital controller establishment module 30 establishes a programmable control module based on the digital control function, performs module cooperative connection and coordination with the host device, and establishes a digital controller, wherein the programmable control module is configured based on the functional logic program and has a built-in instruction lookup table. Based on the digital control function, a programmable control module is established, and module cooperative connection and coordination with the host device are performed, wherein module cooperative connection means that multiple control modules need to work together, communicate and exchange data to ensure that they can operate synchronously and coordinately to achieve more complex control tasks; the host device usually refers to a higher-level part in the entire control system, such as a main controller or a central processing unit, which is responsible for coordinating and coordinating the work of each module to ensure that the entire control system operates according to a predetermined program. A digital controller is established based on these components. The digital controller is the core part of the computer control system, and is usually connected to the components and devices of the feedback part of the system. The digital controller uses computer software programming to complete a specific control algorithm and has functions such as A / D conversion, D / A conversion, input and output signal conversion programs. Specifically, digital control is a process that uses numbers, characters or other symbols to control a certain work process (such as processing, measurement, assembly, etc.). ) is an automated method of programmed control, usually using a special computer. The operating instructions are expressed in digital form, and the welding machine equipment works according to a predetermined program; the programmable control module is an integrated control circuit board, which includes microcontrollers, sensors, relays and other components. It can be used to implement various Internet of Things or mechanical control solutions. It is usually highly programmable and can control various different devices or systems by writing code. Among them, the functional logic program configuration means that the function and logic of the control module are configured according to a specific program. The functional logic program defines the behavior and response of the module under different conditions. The instruction lookup table (or lookup table, LUT) is a table that stores the relationship between input and corresponding output. In the control module, the instruction lookup table may contain various possible input states and their corresponding output instructions. When the programmable control module receives an input, it will look up this table to determine which output instruction should be executed. The digital controller controls the welding machine through the interaction of input signals, control algorithms and output signals. The sensor converts the state of the equipment into electrical signals and inputs them into the digital controller. The digital controller calculates the corresponding output signal based on the input signal and control algorithm. The output signal is transmitted to the actuator through the output interface to control the welding machine to perform welding operations on the components.

[0026] Next, the specific configuration of the digital controller building module 30 will be described in detail. Figure 2As shown, the digital controller establishment module 30 further includes: traversing the digital control function, determining the functional logic program, and the functional logic program is used to execute the digital control function. All relevant digital control functions in the system are checked or analyzed one by one, including checking the system documents, code base, user interface, etc., to understand the input, output, execution conditions, dependencies, etc. of each function. Based on the analysis of each digital control function, a logic program for executing the function is written or identified. The functional logic program is used to execute the digital control function, which is a set of instructions or algorithms that define when, how, and based on what conditions the function is executed. These instructions may include conditional judgment, loop, variable assignment, function call, etc. Based on the functional logic program, the programmable control module is configured, and the programmable control module corresponds to the digital control function one by one. The written functional logic program is matched and set with the programmable control module (such as PLC, PAC, CNC, etc.) to ensure that each digital control function can be correctly executed by the corresponding control module. Based on functional synergy, an upper layer is established, wherein functional synergy includes frequency synergy and sequence synergy. Based on functional synergy, for example, functional synergy can be achieved by formulating a unified communication protocol, adopting a unified data format and interface standard, designing a reasonable task scheduling and process control mechanism, etc., and establishing a host layer to ensure that the various functions in the system can work together efficiently and orderly. Functional synergy includes co-frequency synergy and sequential synergy. Specifically, co-frequency synergy refers to multiple functions or modules working together at the same time or frequency to achieve a common goal, and sequential synergy refers to multiple functions or modules working together in a certain order or process to complete a task. Based on the programmable control module and the host layer, the digital controller is built. The programmable control module (such as PLC, PAC, etc.) is integrated and configured with the host layer (a computer or a higher-level control system composed of multiple host devices) to build a complete digital control system, namely a digital controller.

[0027] The specific configuration of the digital controller establishment module 30 will be described in detail below. The digital controller establishment module 30 further includes: the upper device layer includes at least one upper device. The programmable control module is connected to the upper device layer through a channel to generate a programmable gate array. A communication connection is established between the programmable control module and the upper device layer so that they can exchange data and control instructions with each other. After the channel is connected, the upper device layer can send control instructions to the programmable control module to control the operation of the field equipment; at the same time, the programmable control module can also feed back the status data of the field equipment to the upper device layer for monitoring and decision-making. The circuit logic is written in a hardware description language to generate a programmable gate array. The programmable gate array is a programmable digital logic device that allows users to implement customized digital circuits at the hardware level. The programmable gate array is traversed, and configuration training is performed based on the instruction lookup table to generate the digital controller. The instruction lookup table is used to assist in the execution of instruction logic matching-logical operation processing-control signals. Traverse the programmable gate array, use the pre-calculated results or instructions stored in the instruction lookup table to configure the logic blocks of the programmable gate array according to specific needs or instructions, configure and program the logic blocks and resources of the programmable gate array, and generate a digital controller, specifically, a programmable control module, including complete program logic to complete the corresponding function control, based on the instruction lookup table, match the corresponding parts and perform logical operation processing, determine the control signal corresponding to the instruction, and respond to the control of the welding machine.

[0028] The specific configuration of the digital controller establishment module 30 will be described in detail below. The digital controller establishment module 30 further includes: determining the adjustment dimension of the digital controller, including a first adjustment dimension based on the change of control demand, a second adjustment dimension based on the excessive energy consumption trend, and a third adjustment dimension based on external auxiliary intervention. The first adjustment dimension focuses on the change of demand of the control system itself. With the change of production process, product quality requirements, operation mode, etc., the control demand will also change accordingly. For example, on a certain production line, when the product type is changed, the controller parameters may need to be adjusted to adapt to the new production speed, temperature control range, etc.; the second adjustment dimension focuses on the energy consumption of the system. According to the energy consumption data of the system, the reason for the excessive energy consumption is found, and the control strategy, optimization algorithm, etc. of the controller are adjusted accordingly to reduce the overall energy consumption of the system. For example, if the energy consumption in the predetermined time zone is higher than expected, the control configuration is traced and adjusted; the third adjustment dimension considers the influence of external factors (such as no-load management, etc.) or auxiliary systems on the control system, such as environmental changes, equipment failures, manual operations, etc., to coordinate and ensure effective control under the lowest energy consumption. Based on the adjustment dimension, the digital controller is reconfigured and newly added. According to the changes in control requirements, energy consumption trends, external auxiliary intervention and other factors, the configuration of the digital controller is dynamically adjusted or new functions are added. Specifically, the configuration of the digital controller is modified, which may include modifying the control algorithm, adjusting parameter settings, changing the communication protocol, etc. New management refers to adding new functions or modules on the basis of the digital controller to expand its control capabilities and application scope.

[0029] The specific configuration of the digital controller establishment module 30 will be described in detail below. The digital controller establishment module 30 further includes: setting a no-load management principle, which is a power outage control based on a preset no-load duration. Power outage control is performed based on the preset no-load duration, and the no-load management principle is set. Specifically, the no-load duration refers to the time period when the electric welder is running without load or with only a very small load. The preset no-load duration refers to a no-load duration threshold set according to historical data. When the no-load duration of the device or system reaches or exceeds the preset threshold, power outage control is triggered, such as automatically shutting down the electric welder to reduce energy consumption. Based on the no-load management principle, a no-load management module is configured. Based on the no-load management principle, a module, namely a no-load management module, is configured in the electric welder energy-saving control system, which is responsible for monitoring the operating status of the equipment, especially the no-load status, and triggering corresponding power outage control measures according to the preset no-load duration threshold. The no-load management module is installed on the digital controller.

[0030] The electric welding machine braking control module 40 is used to establish a communication connection between the digital controller and the intelligent central control system, and to delegate the pre-control scheme to the digital controller to perform braking control of the electric welding machine. In the energy-saving control system of the automated welding machine, a communication connection is established between the digital controller and the intelligent central control system, and the pre-control scheme is delegated to the digital controller for the braking control of the welding machine. The intelligent central control system is a central management platform responsible for monitoring, controlling and managing multiple devices and systems. In the welding scene, it may include a user interface for displaying the welding status, setting parameters and receiving alarms. It has powerful data processing and communication capabilities and can interact with other devices and systems. Specifically, establishing a communication connection between the digital controller and the intelligent central control system through wired or wireless communication protocols (such as Ethernet, Wi-Fi, Bluetooth, CAN bus, etc.) is the key to achieving remote control and data transmission. The communication connection ensures real-time data exchange between the two, so that the intelligent central control system can send control instructions to the digital controller and receive status feedback from the digital controller. Then the control scheme is loaded into the digital controller so that it can perform the braking control of the welding machine according to the control scheme. That is, the digital controller adjusts the parameters of the welding equipment (such as current, voltage, speed, etc.) to accurately adjust the parameters of the welding equipment and control the quality, efficiency and stability of the welding process.

[0031] The abnormal control decision module 50 is used to synchronously monitor the electric welding, make abnormal control decisions based on the weld quality and the control energy consumption, and locate the pre-adjustment control point. Various sensors and monitoring equipment are used to monitor welding synchronously, and data from the welding process, such as welding current, voltage, speed, temperature, etc., are collected in real time. Abnormal control decisions are made based on weld quality and controlled energy consumption. Specifically, weld quality is one of the most important indicators in the welding process, which is directly related to the strength, sealing and durability of welded parts. Controlling energy consumption involves energy utilization efficiency in the welding process, which is a key factor in reducing production costs and improving production efficiency. In the monitoring process, weld quality and controlled energy consumption are used as benchmarks, which means that these two factors are used as the main evaluation criteria when analyzing and processing monitoring data. When the monitoring data is abnormal or does not meet the preset standards, abnormal control decisions are made, which may include adjusting welding parameters, suspending welding, performing emergency braking and other operations to prevent welding quality from deteriorating or energy consumption from being too high. Finally, the pre-adjustment control point is located, that is, the control point of the key welding control area is found, which may include the starting point, end point, key structural parts of the weld, etc. At these points or areas, higher-precision sensors and monitoring equipment can be used to obtain more detailed and accurate welding data.

[0032] The specific configuration of the abnormal control decision module 50 will be described in detail below. The abnormal control decision module 50 further includes: determining a multi-level preset step length, and the adjacent level intervals of the multi-level preset step length are consistent. In the electric welding machine energy-saving control system, multiple preset step lengths of different levels are determined, and the difference (i.e., interval) of the multiple preset step lengths is equal. Based on the multi-level preset step lengths, the random step length level is determined in sequence to locate the detection welding points distributed in the weld. According to the determined multi-level preset step lengths, a random step length level is determined in sequence, that is, the multi-level preset step length is used as a constraint, and on the basis of ensuring randomness, the detection welding points are avoided from agglomerating, the global detection accuracy under limited detection points is guaranteed, and the randomness and coverage of the detection are increased. Through the determination of the random step length level, the detection probe or device can move along a certain path on the weld, thereby locating and detecting the welding points distributed in the weld. Based on the detection welding points as a reference, the welding quality detection and abnormal control decision are carried out based on the returned welding monitoring data. The collected monitoring data is matched with the preset inspection welds, and the welding quality at each weld is analyzed. Based on the analysis results, the welding quality of the entire weld is evaluated, including determining whether the weld has defects such as cracks, pores, slag inclusions, and evaluating whether the weld's geometric dimensions, strength and other performance indicators meet the requirements. If problems or abnormalities are found in the welding quality, corresponding control decisions are taken, including adjusting welding parameters (such as current, voltage, speed, etc.), replacing welding materials, adjusting welding processes, etc., to improve welding quality.

[0033] The specific configuration of the abnormal control decision module 50 will be described in detail below. The abnormal control decision module 50 further includes: based on the electric welding monitoring data, performing real-time energy consumption over-limit judgment and determining the first judgment result. According to the electric welding monitoring data, it is judged whether the real-time energy consumption exceeds the limit (whether the energy consumption of the electric welding machine is greater than the preset energy consumption threshold of the electric welding machine), and the first judgment result is determined. If the first judgment result exceeds the limit, the energy consumption trend is judged in combination with the energy consumption judgment result of the previous step, and the second judgment result is determined. If the energy consumption of the electric welding machine exceeds the limit, the energy consumption trend is judged. Specifically, after obtaining the energy consumption data of multiple time points, the trend analysis of these electric welding machine energy consumption data is performed to determine whether the energy consumption shows continuous growth, fluctuation, decline, etc. For example, if the energy consumption exceeds the limit, but the energy consumption trend is declining, it is judged to be normal, and the judgment result is used as the second judgment result. If the first judgment result exceeds the limit, and the second judgment result is that the energy consumption is increasing, an abnormal control decision is made. The monitored energy consumption data exceeds the preset threshold or standard (i.e., the first judgment result exceeds the limit), and from the trend point of view, the energy consumption is still increasing (i.e., the second judgment result is that the energy consumption is increasing), and abnormal control decisions are made, for example, adjusting the control parameters of related equipment (ambient temperature, process parameters, etc.), optimizing the welding process, reducing the operating power of the electric welder, etc., to reduce the energy consumption of the welding process of the electric welder.

[0034] The welding feedback control module 60 performs welding feedback control based on the preset control point and in response to the digital controller. In the electric welding process, the pre-set key control points (i.e., pre-adjustment control points) are used as references, and the feedback information from these control points is received in real time through the digital controller, and the electric welding process is adjusted and controlled accordingly according to the feedback information. Specifically, the sensors on the pre-adjustment control points will monitor the welding parameters (such as current, voltage, temperature, etc.) and other factors that may affect the welding quality in real time, and feed back to the digital controller. After receiving the feedback information from the pre-adjustment control points, the digital controller performs data processing and analysis, compares the actual welding parameters with the preset parameters (or expected parameters), and calculates the deviation or error. According to these deviations or errors, the digital controller will determine whether the welding process is in a normal state, and then determine whether the welding parameters of the electric welder need to be adjusted. Specifically, according to the results of data processing and analysis, the digital controller will make a control decision to realize electric welding feedback control. For example, if the welding process is in a normal state, the current parameters may continue to be maintained; if an abnormality is detected or the deviation exceeds the preset range, the welding parameters need to be adjusted. The electric welding machine control system continuously adjusts and optimizes the welding parameters according to the real-time feedback information to ensure that the welding process is always in the best state, thereby realizing electric welding feedback control.

[0035] Although the present application makes various references to certain modules in the system according to the embodiments of the present application, any number of different modules may be used and run on the user terminal and / or server, and the various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of the functional units are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention.

[0036] The above specific implementations do not constitute a limitation on the protection scope of this application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of this application should be included in the protection scope of this application.

Claims

1. The energy-saving control system of electric welding machine based on weld monitoring is characterized in that: The system comprises: An initial control scheme determination module, wherein the initial control scheme determination module determines an initial control scheme based on a welding standard of a target component and an operating parameter of an electric welder, wherein the initial control scheme is a periodic dynamic scheme; A dimension joint energy-saving optimization module, which is used to perform dimension joint energy-saving optimization based on the scheme parameter control dimension and the external intervention dimension, and the welding standard as a constraint, to determine the pre-control scheme, wherein the scheme parameter control dimension refers to the parameters and factors that affect the welding quality and energy consumption during the welding process, and the external intervention dimension refers to the influencing factors that require external intervention or adjustment during the welding process; A digital controller establishment module, wherein the digital controller establishment module establishes a programmable control module based on a digital control function, performs module cooperative connection and upper device coordination, and establishes a digital controller, wherein the programmable control module is configured based on a functional logic program and has a built-in instruction lookup table, the module cooperative connection refers to multiple programmable control modules working together, communicating and exchanging data, and the upper device coordination refers to the coordination and coordination of the multiple programmable control modules through the upper controller; An electric welding machine braking control module, the electric welding machine braking control module is used to establish a communication connection between the digital controller and the intelligent central control system, and delegate the pre-control scheme to the digital controller to perform electric welding machine braking control; An abnormal control decision module, which is used to synchronously monitor electric welding, make abnormal control decisions based on weld quality and control energy consumption, and locate pre-adjustment control points; A welding feedback control module, which performs welding feedback control based on the preset control point and in response to the digital controller; The digital controller establishes a module, and the steps performed include: Traversing the digital control function to determine a functional logic program, wherein the functional logic program is used to execute the digital control function; Based on the functional logic program, the programmable control module is configured, and the programmable control module corresponds to the digital control function one by one; Based on functional synergy, the upper device layer is established, where functional synergy includes frequency synergy and sequence synergy; The digital controller is constructed based on the programmable control module and the upper device layer.

2. The energy-saving control system for electric welding machine based on weld monitoring as claimed in claim 1, characterized in that: The steps performed by the dimension joint energy-saving optimization module include: Based on the welding standard, determining the optimization constraint space; Taking control parameters as the first optimization dimension, external intervention regulation as the second optimization dimension, and low energy consumption as the goal, iterative optimization is performed based on the optimization constraint space to determine the periodic dynamic scheme that meets the convergence conditions, wherein the optimization principle is iteration in the superior direction and retreat in the inferior direction.

3. The energy-saving control system for electric welding machine based on weld monitoring as claimed in claim 1, characterized in that: The digital controller establishes a module, and the steps performed include: The upper device layer includes at least one upper device; Connecting the programmable control module to the upper device layer through a channel to generate a programmable gate array; The programmable gate array is traversed, configuration training is performed based on an instruction lookup table, and the digital controller is generated. The instruction lookup table is used to assist in the execution of instruction logic matching-logic operation processing-control signal.

4. The energy-saving control system for electric welding machine based on weld monitoring as claimed in claim 3, characterized in that: After the digital controller establishes the module, the steps performed include: Determining adjustment dimensions of the digital controller, including a first adjustment dimension based on a change in control demand, a second adjustment dimension based on an energy consumption trend exceeding a limit, and a third adjustment dimension based on external auxiliary intervention; Based on the adjustment dimension, reconfiguration management and additional management are performed on the digital controller.

5. The energy-saving control system for electric welding machine based on weld monitoring as claimed in claim 1, characterized in that: The steps performed by the system also include: Setting a no-load management principle, wherein the no-load management principle is a power outage control based on a preset no-load duration; Based on the no-load management principle, configure the no-load management module; The no-load management module is added to the digital controller.

6. The energy-saving control system for electric welding machine based on weld monitoring as claimed in claim 1, characterized in that: The abnormal control decision module performs the following steps: Determine a plurality of preset step sizes, wherein the intervals between adjacent levels of the plurality of preset step sizes are consistent; Based on the multi-level preset step lengths, the random step length levels are determined sequentially to locate the detection welding points distributed on the weld; Based on the detected welding points and the returned welding monitoring data, welding quality detection and abnormal control decisions are performed.

7. The energy-saving control system for electric welding machine based on weld monitoring as claimed in claim 1, characterized in that: The abnormal control decision module performs the following steps: Based on the electric welding monitoring data, a real-time energy consumption over-limit judgment is performed to determine a first judgment result; If the first determination result exceeds the limit, combine the energy consumption determination result of the previous step to determine the energy consumption trend and determine the second determination result; If the first determination result exceeds the limit and the second determination result is that energy consumption is increasing, an abnormal control decision is made.

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