Optimization control system of double cavity laser welding process

Abstract

The present invention provides an optimization control system for a dual-cavity laser welding process, which relates to the technical field of welding process optimization, and includes: a laser welding equipment connection module, which is used to connect the laser welding equipment and obtain a welding process control parameter set; an air pressure control system setting module, which is used to set an air pressure control system, and the air pressure control system controls the air pressure of the inner air pressure cavity and the outer air pressure cavity by connecting to an air pressure source; an air pressure control parameter acquisition module, which is used to obtain the inner and outer air pressure control parameters according to the air pressure parameter matching module; a pressurization control module, which is used to start the air pressure control system when welding and perform pressurization control; and a feedback optimization control module, which is used to perform feedback optimization control on the welding process control parameter set. The present invention solves the technical problem that the welding process of the prior art usually relies on preset process parameters, does not consider the impact of the welding process on the mold, and leads to unstable welding quality.

Description

Technical Field

[0001] The invention relates to the technical field of welding process optimization, and in particular to an optimization control system for a dual-cavity mode laser welding process. Background Art

[0002] Laser welding is characterized by high efficiency and precision, and is particularly suitable for the processing of fine parts, complex structures or high-strength materials. However, there are still some technical limitations in the existing laser welding process, especially when dealing with complex dual-cavity mold laser welding. Specifically, during the welding process, due to the local high temperature generated by the high energy density of the laser, the material in the heated area will expand, which will lead to local deformation of the dual-cavity mold. This deformation will affect the geometric accuracy of the product in high-precision manufacturing, resulting in a decrease in the quality of the final product. In the prior art, the welding process usually relies on preset process parameters, but in this welding process, the dual-cavity mold will be deformed due to the influence of welding, which will cause the weld layer to fall off during subsequent use. Summary of the invention

[0003] The present application provides an optimized control system for a dual-cavity mold laser welding process, aiming to solve the technical problem that the welding process in the prior art usually relies on preset process parameters and does not consider the impact of the welding process on the mold, resulting in unstable welding quality.

[0004] The present application discloses an optimization control system for a dual-cavity mold laser welding process, the system comprising: a laser welding equipment connection module, the laser welding equipment connection module is used to connect the laser welding equipment and obtain the welding process control parameter set of the laser welding equipment for the dual-cavity mold; an air pressure control system setting module, the air pressure control system setting module is used to set the air pressure control system, the air pressure control system controls the air pressure of the inner air pressure cavity and the outer air pressure cavity by connecting to an air pressure source, the inner air pressure cavity is arranged inside the dual-cavity mold, and the outer air pressure cavity is arranged outside the dual-cavity mold; an air pressure control parameter acquisition module, the air pressure control parameter The acquisition module is used to input the welding process control parameter set into the air pressure parameter matching module, and obtain the internal air pressure control parameters and the external air pressure control parameters according to the air pressure parameter matching module; the pressurization control module is used to start the air pressure control system when the laser welding equipment welds the double-cavity mold, and perform pressurization control on the internal air pressure cavity and the external air pressure cavity respectively according to the internal air pressure control parameters and the external air pressure control parameters; the feedback optimization control module is used to perform feedback optimization control on the welding process control parameter set according to the pressurization control data monitored in real time.

[0005] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0006] By connecting the laser welding equipment, a complete welding process control parameter set is obtained. This parameter set includes the key variables in the welding process. These variables, combined with the structural characteristics of the dual-cavity mold, provide a basis for subsequent welding and air pressure control, ensuring that the system can adapt to complex welding needs and improve welding accuracy; by setting up an air pressure control system, independent control of the air pressure in the inner and outer air pressure cavities of the dual-cavity mold is achieved. During the welding process, since material heating will cause thermal expansion, the adjustment of the inner and outer air pressure cavities ensures the deformation control of the mold, thereby effectively controlling the deformation of the mold during welding, maintaining welding accuracy, and reducing welding defects; the welding process control parameter set is input into the air pressure parameter matching module, and the inner air pressure control parameters and The external air pressure control parameters can adapt to the stress changes in different welding stages, ensure that the internal and external air pressures are adjusted synchronously with the welding process requirements, and avoid stress concentration and uneven deformation during the welding process; during the welding process, the air pressure control system is started synchronously to adjust the pressures of the internal and external air pressure chambers in real time to cope with the constantly changing stress during the welding process. By real-time monitoring of the air pressure data and performing stability analysis, the pressurization process is optimized to ensure that the pressure adjustment of the internal and external air chambers is within the ideal range. At the same time, feedback is provided to optimize the welding process parameters. Through real-time monitoring and feedback control, the pressurization process can be dynamically adjusted to ensure the stability and efficiency of the air pressure adjustment and reduce welding defects caused by unstable air pressure. This not only improves the welding quality, but also extends the service life of the mold.

[0007] 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. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 A schematic diagram of the structure of an optimized control system for a dual-cavity laser welding process provided in an embodiment of the present application;

[0009] Figure 2 A schematic diagram of the execution flow of the stage control module in the optimization control system of the dual-cavity mold laser welding process provided in an embodiment of the present application.

[0010] Explanation of the reference numerals: laser welding equipment connection module 10 , air pressure control system setting module 20 , air pressure control parameter acquisition module 30 , pressurization control module 40 , feedback optimization control module 50 . DETAILED DESCRIPTION

[0011] The embodiment of the present application solves the technical problem that the welding process in the prior art usually relies on preset process parameters and does not consider the impact of the welding process on the mold, resulting in unstable welding quality, by providing an optimized control system for the dual-cavity mold laser welding process.

[0012] After introducing the basic principles of the present application, various non-limiting implementation methods of the present application will be specifically introduced below in conjunction with the accompanying drawings of the specification. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0013] Embodiment 1, as Figure 1 As shown, the embodiment of the present application provides an optimization control system for a dual-cavity laser welding process, the system comprising:

[0014] The laser welding equipment connection module 10 is used to connect the laser welding equipment and obtain the welding process control parameter set of the laser welding equipment for the double-cavity mold.

[0015] Laser welding equipment is a device that connects metal and other materials through laser beams, including light sources, transmission systems, welding heads, controllers, etc. Double-cavity molds are a special form of mold structure, with two air pressure chambers, namely the inner cavity and the outer cavity. This type of mold is usually used to manufacture complex part structures, especially workpieces that need to maintain a stable balance of internal and external pressures during the forming process.

[0016] Connect laser welding equipment. When performing welding tasks, laser welding equipment requires the coordination of multiple parameters to control the welding quality. When obtaining the welding process control parameter set, it can be read from the welding equipment controller or the configuration file entered by the operator. These parameter sets are usually set before welding begins, but may also be dynamically adjusted during the welding process based on monitoring conditions, including laser power, welding speed, welding temperature, welding depth, welding path and welding material characteristics.

[0017] An air pressure control system setting module 20 is used to set up an air pressure control system, wherein the air pressure control system controls the air pressure of an inner air pressure chamber and an outer air pressure chamber by connecting to an air pressure source, wherein the inner air pressure chamber is arranged inside the double-cavity mold, and the outer air pressure chamber is arranged outside the double-cavity mold.

[0018] An air pressure control system is set up, the purpose of which is to prevent deformation during welding and ensure the quality of welding by controlling the air pressure inside and outside the double-cavity mold. Specifically, the air pressure control system must first be connected to a stable air pressure source, which can be an air compressor or other equipment that provides stable air pressure. The air pressure source transmits air pressure to the inner and outer cavities of the double-cavity mold through a pipeline to control the air pressure in the inner and outer cavities.

[0019] Among them, the inner air pressure cavity is arranged inside the double-cavity mold, and its air pressure acts on the inner surface of the mold to generate an outward supporting force. This supporting force is similar to stretching the mold from the inside, so that the inner surface of the mold can be fully supported during welding. This design can prevent the external surface from bending or deforming during the welding process, because the high temperature during welding will cause thermal expansion and deformation of the material. The air pressure in the inner cavity stretches the inside of the mold to prevent the material from shrinking or sinking inward after heating.

[0020] The external air pressure chamber is set outside the double-cavity mold. Its air pressure acts on the outer surface of the mold to generate an inward compression force. This compression force can compress the outer surface of the mold, so that the inner surface of the mold remains stable during welding. The pressure applied by the external cavity can help the mold resist the high temperature stress generated during welding and the supporting force of the inner cavity, so that the mold will not lose structural integrity or deformation when it is subjected to welding stress inside.

[0021] The internal and external air pressure chambers do not operate in isolation, but cooperate with each other to maintain the stress balance of the mold. The internal and external stresses generated during welding will affect the deformation of the material. Reasonable internal and external air pressure control can effectively offset these stresses, reduce dimensional deviations caused by thermal expansion or contraction during welding, and ensure welding quality.

[0022] The air pressure control parameter acquisition module 30 is used to input the welding process control parameter set into the air pressure parameter matching module, and obtain the internal air pressure control parameters and the external air pressure control parameters according to the air pressure parameter matching module.

[0023] The obtained welding process control parameter set is input into the air pressure parameter matching module. The function of the air pressure parameter matching module is to calculate the appropriate internal and external air pressure control parameters based on the input welding process parameters and the actual stress analysis of the double-cavity mold. Specifically, the air pressure parameter matching module determines the stress areas that may appear in the double-cavity mold during the welding process by performing stress analysis. The high temperature, welding path and material properties in the welding process will cause different degrees of stress on the surface and inside of the mold. Especially in the double-cavity mold, due to the different forces of the inner and outer cavities, there may be areas of uneven stress on the surface of the mold, that is, areas where large deformation or stress concentration may occur during the welding process. The surface stress of these areas is quantified to form a surface stress index. According to the surface stress index, the appropriate internal and external air pressure control parameters are matched. These parameters are the air pressure setting values ​​of the inner and outer air pressure cavities. The purpose is to balance the stress inside and outside the mold by adjusting the air pressure and reduce deformation and defects during the welding process.

[0024] The pressurization control module 40 is used to start the air pressure control system when the laser welding equipment is welding the double-cavity mold, and to perform pressurization control on the inner air pressure cavity and the outer air pressure cavity according to the inner air pressure control parameters and the outer air pressure control parameters respectively.

[0025] When the laser welding equipment starts welding, the air pressure control system is also started synchronously. The air pressure control system adjusts the pressure of the air pressure chamber in real time according to the set internal air pressure control parameters and external air pressure control parameters to ensure that the pressure is always within the set value range. During the entire welding process, the pressures of the internal and external air pressure chambers keep working together. The air pressure control of the internal air pressure chamber provides support for the interior of the mold to prevent the external surface of the mold from bending or deformation due to high temperature during the welding process. Through appropriate internal air pressure, the internal structure of the mold is supported to prevent the collapse or uneven deformation of the material under high temperature; the air pressure control of the external air pressure chamber provides compression force for the external surface of the mold to enhance the stability of the external structure of the mold. This inward pressure can help offset the thermal stress during welding and prevent the mold from expanding or deforming excessively due to high temperature or the support pressure of the inner cavity during welding.

[0026] The feedback optimization control module 50 is used to perform feedback optimization control on the welding process control parameter set according to the pressurization control data monitored in real time.

[0027] During the laser welding and air pressure control process, the pressure sensor installed in the inner and outer air pressure chambers monitors the pressure changes in the air pressure chamber in real time, obtains the pressure values ​​of the inner and outer air pressure chambers as the pressurization control data, and performs feedback optimization control based on the obtained pressurization control data. Specifically, the actual pressures of the inner and outer air chambers are compared with the preset targets. If a deviation is found, the pressurization control module is automatically adjusted to adjust the pressures of the inner and outer air chambers. For example, if the inner air pressure is too high and causes the outer surface of the mold to deform, the pressure of the inner chamber is reduced according to the pressurization control data; similarly, when the outer chamber pressure is too low, the air pressure of the outer chamber is increased. Through feedback optimization, the pressures of the inner and outer air pressure chambers can be automatically corrected to ensure that the welding process is always in the best state.

[0028] Furthermore, if Figure 2 As shown, the air pressure control system includes a stage control module, and the stage control module includes:

[0029] The welding process control parameter set is divided into stages, and multi-stage welding process control parameters are output; the multi-stage welding process control parameter set is input into the air pressure parameter matching module for multi-stage matching, and multi-stage internal air pressure control parameters and multi-stage external air pressure control parameters are obtained; when the laser welding equipment welds the double-cavity mold, the air pressure control system is started in stages, and the inner air pressure cavity and the outer air pressure cavity are respectively pressurized in stages according to the multi-stage internal air pressure control parameters and the multi-stage external air pressure control parameters.

[0030] According to the process of welding technology, the welding process is divided into different stages. The environment and conditions of each stage are different. For example, according to the welding temperature and time curve, it is divided into preheating stage, welding stage, and cooling stage. In the preheating stage, before welding, the material needs to be preheated to prevent excessive thermal stress caused by temperature difference in the early stage of welding; the welding stage is the actual welding process, the laser welding equipment starts to perform the welding task, the material is subjected to high temperature, and melts and fuses; the cooling stage is after the welding is completed, the material cools and solidifies, and the internal and external air pressures still need to be controlled to avoid deformation caused by stress during cooling. Each stage requires different welding process parameters, such as different laser power, welding speed, welding temperature, etc. According to the needs of each stage, these parameters are divided into stages to generate a multi-stage welding process control parameter set.

[0031] The above-mentioned multi-stage welding process control parameter set is input into the air pressure parameter matching module. The air pressure parameter matching module calculates the corresponding multi-stage internal air pressure control parameters and multi-stage external air pressure control parameters according to the welding requirements of each stage. The specific working process of the air pressure parameter matching module has been described in detail in the previous steps and will not be repeated here.

[0032] At the beginning of each welding stage, the air pressure control system is started accordingly, and the inner and outer air cavities are pressurized and controlled according to the internal and external air pressure control parameters of the current stage. This process is staged, that is, the air pressure values ​​in different stages are different. For example, in the preheating stage, a lower pressure is applied to the inner air pressure cavity to prevent stress concentration in the material at the initial stage of heating, while ensuring that the outer cavity provides the necessary compression force to stabilize the external structure of the mold; in the welding stage, during the welding process, the material is in a molten state, and the air pressure cavity needs to be dynamically adjusted according to the expansion characteristics of the material. At this time, the supporting force of the inner air cavity and the compression force of the outer air cavity will be strengthened to prevent the material from deforming at high temperature; in the cooling stage, as the welding is completed, the air pressure cavity needs to be gradually depressurized to adapt to the contraction process of the material during cooling, while avoiding deformation caused by the difference in air pressure between the inner and outer cavities.

[0033] Furthermore, the air pressure control system includes a synchronous control module, which is used to connect the laser welding equipment and the air pressure control system; when the laser welding equipment is performing welding, the air pressure control system is started synchronously, and the inner air pressure chamber and the outer air pressure chamber are synchronously pressurized and controlled according to the internal air pressure control parameters and the external air pressure control parameters.

[0034] The pneumatic control system includes a synchronous control module, which is responsible for connecting the laser welding equipment with the pneumatic control system. It can be implemented through an industrial communication protocol so that the two systems can communicate in real time. The module can receive the start signal from the laser welding equipment, confirm the start of welding, and at the same time feed back the status of the pneumatic control system to the welding equipment to ensure that the pneumatic control system can be started synchronously when the laser welding equipment is started.

[0035] When the laser welding equipment starts the welding operation, the air pressure control system is automatically started through the synchronous control module. The synchronous start ensures that the air pressure adjustment of the inner and outer air pressure chambers also starts working at the same time as the welding starts. That is, according to the preset inner air pressure control parameters, the air pressure control system controls the pressure of the inner air pressure chamber of the double-cavity mold, and according to the preset outer air pressure control parameters, controls the pressure of the outer air pressure chamber of the double-cavity mold. During the laser welding process, the pressure adjustment of the inner and outer air pressure chambers is coordinated with the welding operation to ensure that the pressure changes of the inner and outer chambers match the stress changes during the welding process.

[0036] Furthermore, setting the air pressure control system includes:

[0037] Determine whether the first inner air pressure cavity and the second inner air pressure cavity of the double-cavity mold are connected spaces; if the first inner air pressure cavity and the second inner air pressure cavity are connected spaces, set an inner air pressure regulator, and adjust the air pressure of the first inner air pressure cavity and the second inner air pressure cavity according to the inner air pressure regulator.

[0038] The double-cavity mold contains multiple internal air pressure chambers, wherein the first internal air pressure chamber and the second internal air pressure chamber refer to any two independent chambers inside the double-cavity mold, which can be independent of each other or interconnected. The air cavity structure of the double-cavity mold is detected through internal design or detection procedures. For example, a flow sensor or an air pressure sensor is used to check the gas flow between the first internal air pressure chamber and the second internal air pressure chamber to determine whether they are connected. When the two air cavities are connected, changing the air pressure of one air cavity will affect the air pressure of the other air cavity. A connected space means that there is a fluid channel between the two air pressure chambers, and the gas can flow freely, so that the air pressure of the two is consistent. A non-connected space means that the two air pressure chambers are independent of each other, cannot directly exchange gas, and each maintains an independent air pressure state.

[0039] If it is determined that the first inner air pressure chamber and the second inner air pressure chamber are connected spaces, it means that the pressures between the two air pressure chambers can affect each other, and it is usually necessary to uniformly control the air pressure through an air pressure regulator. Therefore, an inner air pressure regulator is set. The inner air pressure regulator is a device for controlling and adjusting the pressure of the inner air chamber. It is connected to an air pressure source and controls the air flow by adjusting a valve, thereby adjusting the air pressure of the first inner air pressure chamber and the second inner air pressure chamber.

[0040] Furthermore, if the first internal air pressure chamber and the second internal air pressure chamber are non-connected spaces, a first internal air pressure regulator and a second internal air pressure regulator are provided; the air pressure of the first internal air pressure chamber is adjusted according to the first internal air pressure regulator, and the air pressure of the second internal air pressure chamber is adjusted according to the second internal air pressure regulator; wherein the first internal air pressure regulator and the second internal air pressure regulator are controlled by the air pressure control system.

[0041] If it is determined that the first inner air pressure chamber and the second inner air pressure chamber are non-connected spaces, it means that the first inner air pressure chamber and the second inner air pressure chamber are independent of each other, and there is no gas flow channel between them. Therefore, each air chamber needs to independently control its air pressure, and a first inner air pressure regulator and a second inner air pressure regulator are set. The first inner air pressure regulator is responsible for adjusting the air pressure of the first inner air pressure chamber, and the second inner air pressure regulator is responsible for adjusting the air pressure of the second inner air pressure chamber. Each regulator is connected to an independent air source and control system to ensure that each air chamber can be independently adjusted according to different needs.

[0042] The first internal air pressure regulator independently adjusts the first internal air pressure chamber according to the air pressure value set in the welding process parameter set; similarly, the second internal air pressure regulator independently adjusts the second internal air pressure chamber according to the air pressure value set in the welding process parameter set. Since the physical positions and force conditions of the two air cavities may be different, their air pressure adjustment targets may also be different. The first and second internal air pressure regulators adjust the air pressures separately according to the real-time pressure conditions of their respective air cavities to ensure that various parts of the mold are properly supported during the welding process.

[0043] Among them, although the two internal air pressure regulators control two independent internal air pressure chambers respectively, they are both controlled by the same air pressure control system. The air pressure control system automatically adjusts the corresponding air pressure regulator according to the difference between the monitoring data and the set value to ensure that the air pressure of the two air chambers is maintained within the ideal range.

[0044] Furthermore, the air pressure parameter matching module includes:

[0045] The welding process control parameter set is input into the gas pressure parameter matching module, wherein the welding process control parameter set includes laser power, welding speed, welding temperature, welding depth, welding path and welding material characteristics; stress analysis is performed according to the gas pressure parameter matching module to obtain a marked stress area, wherein the marked stress area is an area where stress on the outer surface of the double-cavity mold is uneven; a surface stress index of the marked stress area is determined; matching is performed according to the surface stress index to obtain internal gas pressure control parameters and external gas pressure control parameters.

[0046] The obtained welding process control parameter set is input into the gas pressure parameter matching module, where the laser power is the output energy intensity of the laser beam during the laser welding process. The size of the laser power will directly affect the melting depth of the material and the welding effect. The higher the power, the greater the melting depth; the welding speed is the speed at which the laser beam moves on the welding path. The welding speed and power jointly determine the heat input of the welding. A higher welding speed may lead to insufficient heat input and affect the welding quality, while a too low welding speed may lead to excessive heat input and increase the risk of material deformation; the welding temperature is the temperature of the surface and inside of the material during the welding process. The welding temperature depends on the laser power and the welding speed. Too high a temperature will cause the material to soften or melt; the welding depth is the depth of penetration of the laser beam in the material, also known as the melting depth, which determines the strength and quality of the weld; the welding path is the movement trajectory of the laser beam on the workpiece, which determines the overall structure of the weld; the welding material properties are the physical properties of the welding material, such as thermal conductivity, expansion coefficient, melting point, etc. Different materials have different responses to gas pressure and temperature.

[0047] The air pressure parameter matching module uses stress analysis to identify the uneven stress areas that may occur in the double-cavity mold during the welding process. Stress analysis is specifically done by using mathematical models, such as finite element analysis, to simulate the thermal expansion, contraction and stress distribution of materials during welding by meshing and mechanical calculation of materials, thereby identifying and marking the uneven stress areas on the outer surface of the double-cavity mold. Uneven stress areas refer to the parts of the double-cavity mold surface that are subjected to uneven stress during the welding process. Due to different heat inputs during welding, these areas are prone to deformation, resulting in the detachment of the coating on the outer surface or material fatigue. Therefore, marking these areas is crucial to preventing welding defects.

[0048] The surface stress index is a parameter used to quantify the stress intensity and distribution of the identified stress area. It reflects the magnitude and direction of the stress these areas are subjected to during the welding process. The air pressure parameter matching module calculates the stress intensity, direction and duration of the identified stress area based on the stress analysis results and the mechanical properties of the material, and converts these data into a surface stress index to evaluate whether the double-cavity mold surface can withstand the stress generated during the welding process.

[0049] According to the surface stress index, the air pressure parameter matching module calculates the pressure values ​​of the inner and outer air cavities that need to be applied, where the inner air pressure needs to provide sufficient support for the marked stress area, while the outer air pressure needs to resist the external thermal stress through compression force. The inner and outer air pressure control parameters are obtained through calculation. These control parameters are used to adjust the inner and outer air pressure cavities of the double-cavity mold to ensure that during the welding process, the pressures of the inner and outer air cavities can alleviate or offset the stress concentration in the marked stress area.

[0050] Furthermore, the air pressure parameter matching module also includes:

[0051] The inner surface coating information and the outer surface coating information of the dual-cavity mold are obtained; the inner pressure index and the outer pressure index are determined based on the inner surface coating information and the outer surface coating information; and the output result of the air pressure parameter matching module is constrained based on the inner pressure index and the outer pressure index as constraint conditions.

[0052] The inner and outer surfaces of double-cavity molds have different types of coatings, which can enhance the corrosion resistance, wear resistance or improve the surface finish of the material. Get the inner and outer surface coating information of the double-cavity mold, including coating thickness, material properties, coating adhesion, etc., which can be directly obtained from the design data of the mold.

[0053] According to the coating information, the pressure-bearing index of the inner and outer surfaces of the double-cavity mold is calculated. The pressure-bearing index is a numerical value that reflects the maximum pressure that the coating can withstand during the welding process. It is used to limit the pressure adjustment of the inner and outer air cavities to prevent the coating from cracking or falling off when the pressure is too high. Among them, the pressure-bearing capacity of the inner surface coating is mainly affected by the air pressure of the inner air cavity. The thickness, material properties and adhesion of the coating jointly determine the size of the inner pressure-bearing index; the pressure-bearing capacity of the outer surface coating is mainly affected by the air pressure of the outer air cavity. Similar to the internal pressure-bearing index, the external pressure-bearing index also depends on the thickness of the coating, material properties and external forces during welding.

[0054] Illustratively, a theoretical calculation method is used to calculate the maximum pressure-bearing capacity of the coating under different pressures through mechanical formulas based on the material properties of the coating, such as Young's modulus, yield strength, etc., and the thickness of the coating. The theoretical calculation results can be verified through actual welding and air pressure tests. In the experiment, the air pressure is gradually increased, the state of the coating is observed, and the limit of its pressure-bearing capacity is determined.

[0055] The internal and external pressure indicators are used as constraints to limit the output results of the air pressure parameter matching module to ensure that the pressure of the internal and external pressure chambers does not exceed the pressure bearing capacity of the coating, thus avoiding damage to the coating due to excessive air pressure during the welding process.

[0056] Furthermore, feedback optimization control of the welding process control parameter set is performed according to the real-time monitored pressurization control data, including:

[0057] Performing stability analysis on the real-time monitored pressurization control data to obtain a pressurization stability coefficient; optimizing the pressurization control data with minimizing the difference between the pressurization stability coefficient and a preset stability coefficient as a feedback target, and outputting optimized pressurization control data; optimizing the welding process control parameter set according to the optimized pressurization control data.

[0058] During the welding process, real-time pressure data of the internal and external air pressure chambers are continuously collected to obtain pressurization control data. Stability analysis is performed on the obtained pressurization control data to evaluate the stability of the pressurization process. The goal of the stability analysis is to determine whether the air pressure regulation can quickly reach the set value and remain stable, or whether there will be excessive fluctuations or lags when pressure is applied. The air pressure fluctuations are analyzed, and the time and fluctuation amplitude required for the air pressure to reach the set value are calculated. These data are converted into a pressurization stability coefficient. The pressurization stability coefficient is a stability parameter used to quantify the pressurization process. It reflects the stability of the system when the set pressure is reached. The smaller the stability coefficient, the smoother the air pressure regulation process; the larger the stability coefficient, the greater the fluctuation or instability of the system.

[0059] The preset stability coefficient is a pre-set target stability value, which reflects the stable state that the air pressure regulation should achieve under ideal conditions. The difference between the pressurization stability coefficient and the preset stability coefficient is used to measure the deviation between the actual pressurization control process and the ideal situation. The larger the difference, the worse the stability of the system, and the smaller the difference, the closer the air pressure regulation is to the ideal state. With the goal of minimizing the difference, the pressurization control data is adjusted to make the actual pressurization stability coefficient as close to the preset stability coefficient as possible. Through continuous iteration and adjustment, the optimized pressurization control data is output to ensure that the pressure regulation process of the inner and outer air cavities is smoother, the fluctuation is reduced, and it is close to the ideal stable state.

[0060] After the pressurization control data is optimized, the optimized data is fed back to the welding process control parameter set. This means that not only the gas pressure adjustment itself, but also the parameters of the entire welding process, such as laser power, welding speed, etc., can be adjusted according to the optimization results of the pressurization data to ensure the coordinated optimization of parameters such as gas pressure, temperature, and speed during the welding process. By adjusting the welding process control parameters, the welding equipment can better adapt to the needs of real-time gas pressure adjustment and reduce welding defects caused by the mismatch between welding parameters and gas pressure control, such as material deformation and uneven welding.

[0061] In summary, the optimization control system of the dual-cavity laser welding process provided by the embodiment of the present application has the following technical effects:

[0062] By connecting the laser welding equipment, a complete welding process control parameter set is obtained. This parameter set includes the key variables in the welding process. These variables, combined with the structural characteristics of the dual-cavity mold, provide a basis for subsequent welding and air pressure control, ensuring that the system can adapt to complex welding needs and improve welding accuracy; by setting up an air pressure control system, independent control of the air pressure in the inner and outer air pressure cavities of the dual-cavity mold is achieved. During the welding process, since material heating will cause thermal expansion, the adjustment of the inner and outer air pressure cavities ensures the deformation control of the mold, thereby effectively controlling the deformation of the mold during welding, maintaining welding accuracy, and reducing welding defects; the welding process control parameter set is input into the air pressure parameter matching module, and the inner air pressure control parameters and The external air pressure control parameters can adapt to the stress changes in different welding stages, ensure that the internal and external air pressures are adjusted synchronously with the welding process requirements, and avoid stress concentration and uneven deformation during the welding process; during the welding process, the air pressure control system is started synchronously to adjust the pressures of the internal and external air pressure chambers in real time to cope with the constantly changing stress during the welding process. By real-time monitoring of the air pressure data and performing stability analysis, the pressurization process is optimized to ensure that the pressure adjustment of the internal and external air chambers is within the ideal range. At the same time, feedback is provided to optimize the welding process parameters. Through real-time monitoring and feedback control, the pressurization process can be dynamically adjusted to ensure the stability and efficiency of the air pressure adjustment and reduce welding defects caused by unstable air pressure. This not only improves the welding quality, but also extends the service life of the mold.

[0063] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. The optimization control system of the dual-cavity laser welding process is characterized by: The system comprises: A laser welding equipment connection module, wherein the laser welding equipment connection module is used to connect to a laser welding equipment and obtain a welding process control parameter set of the laser welding equipment for a double-cavity mold; An air pressure control system setting module, the air pressure control system setting module is used to set an air pressure control system, the air pressure control system controls the air pressure of the inner air pressure cavity and the outer air pressure cavity by connecting to an air pressure source, the inner air pressure cavity is arranged inside the double-cavity mold, and the outer air pressure cavity is arranged outside the double-cavity mold; An air pressure control parameter acquisition module, the air pressure control parameter acquisition module is used to input the welding process control parameter set into the air pressure parameter matching module, and obtain the internal air pressure control parameters and the external air pressure control parameters according to the air pressure parameter matching module; A pressurization control module, which is used to start the air pressure control system when the laser welding equipment is welding the double-cavity mold, and to perform pressurization control on the inner air pressure cavity and the outer air pressure cavity respectively according to the inner air pressure control parameter and the outer air pressure control parameter; A feedback optimization control module, the feedback optimization control module is used to perform feedback optimization control on the welding process control parameter set according to the pressurization control data monitored in real time; Wherein, the air pressure control parameter acquisition module includes: Inputting the welding process control parameter set into the gas pressure parameter matching module, wherein the welding process control parameter set includes laser power, welding speed, welding temperature, welding depth, welding path and welding material characteristics; Performing stress analysis according to the air pressure parameter matching module to obtain a marked stress area, wherein the marked stress area is an area with uneven stress on the outer surface of the double-cavity mold; Determining a surface stress index of the identified stress region; Matching is performed according to the surface stress index to obtain internal air pressure control parameters and external air pressure control parameters.

2. The optimization control system for the dual-cavity laser welding process according to claim 1, characterized in that: The air pressure control system includes a stage control module, and the stage control module includes: Dividing the welding process control parameter set into stages and outputting multi-stage welding process control parameters; Inputting the multi-stage welding process control parameter set into the gas pressure parameter matching module for multi-stage matching to obtain multi-stage internal gas pressure control parameters and multi-stage external gas pressure control parameters; When the laser welding equipment is welding the double-cavity mold, the air pressure control system is started in stages, and the inner air pressure cavity and the outer air pressure cavity are pressurized in stages according to the multi-stage inner air pressure control parameters and the multi-stage outer air pressure control parameters.

3. The optimization control system for the dual-cavity laser welding process according to claim 2, characterized in that: The air pressure control system includes a synchronous control module, and the synchronous control module is used to connect the laser welding equipment and the air pressure control system; When the laser welding equipment is performing welding, the air pressure control system is started synchronously, and the inner air pressure chamber and the outer air pressure chamber are pressurized synchronously and controlled respectively according to the inner air pressure control parameters and the outer air pressure control parameters.

4. The optimization control system for the dual-cavity laser welding process according to claim 1, characterized in that: Setting the air pressure control system includes: Determine whether the first inner air pressure cavity and the second inner air pressure cavity of the double cavity mold are connected spaces; If the first internal air pressure chamber and the second internal air pressure chamber are connected spaces, an internal air pressure regulator is provided, and the air pressures of the first internal air pressure chamber and the second internal air pressure chamber are adjusted by the internal air pressure regulator.

5. The optimization control system for the dual-cavity laser welding process as claimed in claim 4, characterized in that: If the first internal air pressure chamber and the second internal air pressure chamber are non-connected spaces, a first internal air pressure regulator and a second internal air pressure regulator are provided; adjusting the air pressure of the first internal air pressure chamber according to the first internal air pressure regulator, and adjusting the air pressure of the second internal air pressure chamber according to the second internal air pressure regulator; Wherein, the first internal air pressure regulator and the second internal air pressure regulator are controlled by the air pressure control system.

6. The optimization control system for the dual-cavity laser welding process according to claim 1, characterized in that: The air pressure parameter matching module also includes: Obtaining inner surface coating information and outer surface coating information of the dual-cavity mold; Determine an inner pressure index and an outer pressure index based on the inner surface coating information and the outer surface coating information; The output result of the air pressure parameter matching module is constrained based on the internal pressure index and the external pressure index as constraint conditions.

7. The optimization control system for the dual-cavity laser welding process according to claim 1, characterized in that: Feedback optimization control is performed on the welding process control parameter set according to the real-time monitored pressurization control data, including: Performing stability analysis on the pressurization control data monitored in real time to obtain a pressurization stability coefficient; Taking minimizing the difference between the pressurization stability coefficient and the preset stability coefficient as a feedback target, optimizing the pressurization control data, and outputting the optimized pressurization control data; The welding process control parameter set is optimized according to the optimized pressurization control data.

Images