Method for adjusting technological parameters in K-TIG welding process and industrial control device

Abstract

The invention provides a method for adjusting technological parameters in the K-TIG welding process and an industrial control device. The method comprises the steps that a molten pool image collected through a molten pool sensor is obtained, and the molten pool image comprises a tungsten needle part image, an electric arc contour part image and a weld bead line part image; determining a tungsten needle center line according to the tungsten needle part image, and determining a welding bead center line and an end point of the welding bead center line in the arc area according to the arc contour part image and the welding bead line part image; the vertical distance from the end point to the tungsten needle center line is obtained, and the position of the welding gun is adjusted according to the vertical distance to meet the requirement that the vertical distance from the end point to the tungsten needle center line is smaller than a preset distance. The automatic deviation correction of the welding gun can be realized without depending on welding personnel with rich experience to adjust process parameters in the welding process.

Description

Technical Field

[0001] The present application relates to the field of welding, and in particular to a method for adjusting process parameters in a K-TIG welding process, an industrial control device, a welding system and a storage medium. Background Art

[0002] K-TIG welding technology is a high-speed, one-way, full-penetration weld technology. The welding process does not require welding wire, test plate beveling, or professional technical operators, but it can efficiently weld thin and medium-thick plate materials at a speed nearly 100 times faster than ordinary tungsten inert gas arc welding technology. The welding process is stable, the corrugations are delicate and beautiful, and the microstructure and mechanical properties of the weld are better than TIG welding. It is a truly efficient, high-speed, and low-cost welding method, which has been widely used industrially at home and abroad.

[0003] Existing K-TIG welding technology is mostly based on manual welding, relying on experienced welders to adjust process parameters according to the welding process to ensure the quality of the welding weld. Summary of the invention

[0004] The main purpose of the present application is to provide a method, an industrial control device, a welding system and a storage medium for adjusting the process parameters in the K-TIG welding process, so as to at least solve the problem that the existing K-TIG welding technology needs to rely on experienced welders to adjust the process parameters according to the welding process, which has high requirements for the welders and complex operations.

[0005] In order to achieve the above-mentioned purpose, according to one aspect of the present application, a method for adjusting process parameters in a K-TIG welding process is provided, the welding system comprising a K-TIG welding subsystem, a welding robot and a molten pool sensor, the K-TIG welding subsystem is loaded in the welding robot, and the molten pool sensor is installed at the front end of the welding robot, comprising: acquiring a molten pool image acquired by the molten pool sensor, wherein the molten pool image comprises a tungsten needle partial image, an arc contour partial image and a weld bead partial image; determining a tungsten needle center line according to the tungsten needle partial image, determining a weld bead center line and an end point of the weld bead center line in an arc area according to the arc contour partial image and the weld bead partial image; acquiring a vertical distance from the end point to the tungsten needle center line, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the end point to the tungsten needle center line is less than a preset distance.

[0006] Optionally, a molten pool image acquired by the molten pool sensor is obtained, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image, and a weld line partial image, including: a first molten pool image acquired by the molten pool sensor in the welding base laying stage, the first molten pool image includes a first tungsten needle partial image, a first arc contour partial image, and a first weld line partial image; a second molten pool image acquired by the molten pool sensor in the filling stage and the multi-layer single-pass covering stage, the second molten pool image includes a second tungsten needle partial image, a second arc contour partial image, and a second weld line partial image.

[0007] Optionally, the tungsten needle center line is determined according to the tungsten needle partial image, and the weld bead center line and the endpoint of the weld bead center line in the arc area are determined according to the arc contour partial image and the weld bead line partial image, including: determining the first tungsten needle center line according to the first tungsten needle partial image in the welding base stage, determining the first arc contour according to the first arc contour partial image, extracting the bottom weld bead center line from the first weld bead line partial image, and determining the endpoint of the bottom weld bead center line in the first arc contour, and determining the endpoint as the first base point; obtaining the vertical distance from the endpoint to the tungsten needle center line, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the endpoint to the tungsten needle center line is less than a preset distance, including: obtaining the vertical distance from the first base point to the first tungsten needle center line, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the first base point to the first tungsten needle center line is less than the preset distance.

[0008] Optionally, determining the center line of the tungsten needle according to the partial image of the tungsten needle includes: obtaining a swinging center line according to multiple partial images of the second tungsten needle in the filling stage and the multi-layer single-channel covering stage; determining a relatively static line according to the swinging center line, and determining the line as the second tungsten needle center line in the filling stage and the multi-layer single-channel covering stage, wherein the swinging center line is formed by connecting multiple swinging tungsten needle center points, and the swinging center line swings up and down the relatively static line.

[0009] Optionally, the weld centerline and the endpoint of the weld centerline in the arc area are determined according to the arc contour partial image and the weld line partial image, including: in the filling stage and the multi-layer single-pass covering stage, the second arc contour is determined according to the second arc contour partial image, the outer groove weld centerline is extracted from the second weld line partial image, and the endpoint of the outer groove weld centerline in the second arc contour is determined, and the endpoint is determined as the second base point; the vertical distance from the endpoint to the center line of the tungsten needle is obtained, and the position of the welding gun is adjusted according to the vertical distance to meet the vertical distance from the endpoint to the center line of the tungsten needle is less than a preset distance, including: in the filling stage and the multi-layer single-pass covering stage, the vertical distance from the second base point to the center line of the second tungsten needle is obtained, and the position of the welding gun is adjusted according to the vertical distance to meet the vertical distance from the second base point to the center line of the second tungsten needle is less than the preset distance.

[0010] Optionally, the welding system also includes an auxiliary light source, which is installed around the molten pool sensor, and the auxiliary light source serves to illuminate the molten pool. The method also includes: in the multi-layer and multi-pass covering stage, obtaining an image of the molten pool illuminated by the auxiliary light source; extracting the previous layer of weld from the illuminated molten pool image, and determining the width of the previous layer of weld and the number of layers of welding in the previous layer; using the molten pool sensor algorithm to process the width of the previous layer of weld and the number of layers of welding in the previous layer, and determine the filling amount of the next weld based on the current center position of the welding gun swing.

[0011] Optionally, the welding system also includes a laser positioning sensor, which is installed inside the welding gun of the K-TIG welding subsystem. The method also includes: determining the relative position of the welding gun and the weld according to the position information collected by the laser positioning sensor; and calibrating the position of the welding gun according to the relative position so that the welding robot tracks along the weld through the weld line outside the groove.

[0012] According to another aspect of the present application, an industrial control device in a welding system is provided, wherein the welding system includes a K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot, and the molten pool sensor is installed at the front end of the welding robot, and includes: a first acquisition unit, used to acquire a molten pool image acquired by the molten pool sensor, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image and a weld line partial image; a first determination unit, used to determine a tungsten needle center line according to the tungsten needle partial image, and to determine a weld bead center line and an end point of the weld bead center line in an arc region according to the arc contour partial image and the weld bead partial image; an adjustment unit, used to acquire a vertical distance from the end point to the tungsten needle center line, and adjust the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the end point to the tungsten needle center line is less than a preset distance.

[0013] According to another aspect of the present application, a welding system is provided, comprising: an industrial control device for executing any one of the methods for adjusting process parameters in a K-TIG welding process; a K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot, the molten pool sensor is installed at the front end of the welding robot, and the industrial control device communicates with the K-TIG welding subsystem, the welding robot and the molten pool sensor respectively.

[0014] According to another aspect of the present application, a computer-readable storage medium is provided, wherein the computer-readable storage medium includes a stored program, wherein when the program is run, the device where the computer-readable storage medium is located is controlled to execute any one of the methods for adjusting process parameters in the K-TIG welding process.

[0015] The technical solution of the present application is applied, by acquiring a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image, and a weld line partial image; determining the tungsten needle center line according to the tungsten needle partial image, determining the weld line center line and the end point of the weld line center line in the arc area according to the arc contour partial image and the weld line partial image; obtaining the vertical distance from the end point to the tungsten needle center line, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the tungsten needle center line is less than a preset distance. Automatic correction of the welding gun is achieved. Automatic correction of the welding gun is achieved without relying on experienced welders to adjust process parameters for the welding process. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings constituting part of the present application are used to provide a further understanding of the present application. The exemplary embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0017] Figure 1 A schematic flow chart of a method for adjusting process parameters in a K-TIG welding process provided in accordance with an embodiment of the present application is shown;

[0018] Figure 2 A molten pool image at the bottoming stage provided according to an embodiment of the present application is shown;

[0019] Figure 3 A schematic diagram of obtaining a center line in a filling stage and a multi-layer single-pass covering stage according to an embodiment of the present application is shown;

[0020] Figure 4 A schematic diagram of autonomous seam finding provided according to an embodiment of the present application is shown;

[0021] Figure 5 A structural block diagram of an industrial control device provided according to an embodiment of the present application is shown. DETAILED DESCRIPTION

[0022] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0023] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present application.

[0024] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0025] As introduced in the background technology, the K-TIG welding technology in the prior art is mostly based on manual welding, relying on experienced welders to adjust process parameters for the welding process to ensure the quality of the welding weld. In order to solve the problem that the existing K-TIG welding technology needs to rely on experienced welders to adjust process parameters for the welding process, which has high requirements for welders and complex operations, the embodiments of the present application provide a method for adjusting process parameters in the K-TIG welding process, an industrial control device, a welding system and a storage medium.

[0026] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0027] In this embodiment, a method for adjusting process parameters in a K-TIG welding process is provided, which runs on a mobile terminal, a computer terminal or a similar computing device. It should be noted that the steps shown in the flowchart of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and although a logical order is shown in the flowchart, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0028] Figure 1 The present invention is a flowchart of a method for adjusting process parameters in a K-TIG welding process according to an embodiment of the present application. The method for adjusting process parameters in a K-TIG welding process is applied to an industrial control device in a welding system, wherein the welding system comprises a K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot, and the molten pool sensor is installed at the front end of the welding robot.

[0029] Specifically, the welding robot is a trackless all-position crawling welding robot;

[0030] Among them, the molten pool sensor is installed at the front end of the welding robot at a preset angle;

[0031] like Figure 1 As shown, the method comprises the following steps:

[0032] Step S101, obtaining a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image;

[0033] Among them, the molten pool image is the image taken during the K-TIG welding process;

[0034] Among them, the molten pool sensor uses a visual sensor;

[0035] Specifically, from left to right in the molten pool image are the tungsten needle part image, the arc profile part image and the weld line part image;

[0036] Step S102, determining the center line of the tungsten needle according to the partial image of the tungsten needle, and determining the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line;

[0037] The end point of the weld center line in the arc region is the end point on the left side of the weld center line;

[0038] Step S103, obtaining the vertical distance from the end point to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

[0039] Among them, when the vertical distance between the end point of the weld centerline in the arc area and the center line of the tungsten needle is zero, the weld centerline and the tungsten needle centerline are deemed to coincide with each other. When the vertical distance between the end point of the weld centerline in the arc area and the center line of the tungsten needle is less than the preset distance, real-time deviation correction of the welding gun can be achieved.

[0040] The method of adjusting the process parameters in the K-TIG welding process of the present application is to obtain a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image, and a weld line partial image; determine the tungsten needle center line according to the tungsten needle partial image, determine the weld line center line and the end point of the weld line center line in the arc area according to the arc contour partial image and the weld line partial image; obtain the vertical distance from the end point to the tungsten needle center line, and adjust the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the tungsten needle center line is less than a preset distance. Automatic correction of the welding gun is achieved. Automatic correction of the welding gun is achieved without relying on experienced welders to adjust the process parameters for the welding process.

[0041] In an embodiment of the present application, a molten pool image acquired by the molten pool sensor is obtained, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image, including:

[0042] In the welding base stage, a first molten pool image acquired by the molten pool sensor is obtained, wherein the first molten pool image includes a first tungsten needle partial image, a first arc contour partial image and a first weld line partial image; specifically, Figure 2 shown.

[0043] The second molten pool image collected by the molten pool sensor during the filling stage and the multi-layer single-pass capping stage includes a second tungsten needle partial image, a second arc contour partial image, and a second weld line partial image. Figure 3 shown.

[0044] Specifically, the method comprises: determining the center line of the tungsten needle according to the partial image of the tungsten needle, determining the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line, including: determining the center line of the first tungsten needle (i.e., the center line of the weld bead) according to the partial image of the first tungsten needle in the welding primer stage; Figure 2 The first arc profile is determined according to the first arc profile partial image ( Figure 2 The arc contour part in the middle), the bottom weld center line is extracted from the first weld line part image (see Figure 2 The bottom weld centerline in the first arc profile is determined, and the endpoint of the bottom weld centerline in the first arc profile is determined as the first base point (i.e. Figure 2 (the basis point in );

[0045] Obtaining a vertical distance from the end point to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance, including: obtaining the first base point ( Figure 2 The left end point of the bottom weld centerline in the weld) to the centerline of the first tungsten needle (i.e. Figure 2 and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the first base point to the center line of the first tungsten needle is less than the preset distance.

[0046] Specifically, since the welding gun does not swing during the base laying stage, in order to reduce human intervention and improve the degree of automation during the welding process, the center line of the tungsten needle is identified and ensured to coincide with the center line of the bottom weld bead (or within a certain threshold range so as not to affect the welding forming quality). This can ensure that the welding does not deviate and the welding quality is guaranteed.

[0047] In the actual test process, the coincidence measurement of the two center lines is difficult due to the influence of the target surface size of the molten pool sensor and the accuracy of the test plate group. In addition, the gap at the bottom of the groove will change all the time during the welding process, and the accuracy is prone to fluctuations. In order to improve the tracking accuracy, the left endpoint of the bottom weld center line is selected as the tracking base point, and the vertical distance from the base point to the center line of the tungsten needle is measured to provide real-time feedback on the welding gun position. The welding gun is adjusted to be less than the judgment threshold at present, so as to realize real-time deviation correction of the welding gun.

[0048] Specifically, the tungsten needle is identified and tracked through two intersecting contour lines, and the bottom weld line is extracted through deep learning (lightweight HED network). Considering the real-time adjustment of the welding process, the base point on the left side of the bottom weld line is taken as the standard for weld line identification.

[0049] According to the two contour lines of the tungsten needle, the equation of the central straight line corresponding to the angle bisector is extracted: ax+by+c=0. The base point may be set as P(x0, y0). Then the calculation formula for judging the deviation threshold is the vertical distance from the base point P to the straight line L:

[0050]

[0051] Assume the threshold is δ, then:

[0052]

[0053] The adjustment margin of the tungsten needle (welding gun) is as follows: take the intersection of the straight line L and the y-axis, and use the ordinate of the intersection on the axis and the ordinate on the base point P to determine whether the center line of the tungsten needle is on the upper or lower side of the base point. The θ obtained on the upper side will have θ≤0. At this time, the tungsten needle adjusts the margin β in the downward direction (if adjustment is required). Otherwise, adjust upward. The calculation process is as follows:

[0054] ax+by+c=0

[0055] by+C=0

[0056]

[0057] The above process controls the adjustment and alignment of the tungsten needle (welding gun) during welding, ensuring that the welding gun is always in the center of the weld.

[0058] Specifically, determining the center line of the tungsten needle according to the partial image of the tungsten needle includes: obtaining a swing center line according to multiple partial images of the second tungsten needle in the filling stage and the multi-layer single-pass covering stage; determining a relatively static line according to the swing center line, and determining the line as the second tungsten needle center line in the filling stage and the multi-layer single-pass covering stage, wherein the swing center line is formed by connecting multiple swing tungsten needle center points, and the swing center line swings up and down the relatively static line. Figure 3 As shown, the swing center line swings above and below the relatively static line.

[0059] Specifically, determining the weld centerline and the endpoint of the weld centerline in the arc area according to the arc contour partial image and the weld line partial image includes: in the filling stage and the multi-layer single-pass capping stage, determining the second arc contour according to the second arc contour partial image, extracting the outer groove weld centerline from the second weld line partial image, and determining the endpoint of the outer groove weld centerline in the second arc contour, and determining the endpoint as the second base point;

[0060] Obtaining the vertical distance from the endpoint to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the endpoint to the center line of the tungsten needle is less than a preset distance, including: in the filling stage and the multi-layer single-pass covering stage, obtaining the vertical distance from the second base point to the center line of the second tungsten needle, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the second base point to the center line of the second tungsten needle is less than the preset distance.

[0061] The filling and covering stage is different from the priming stage. Considering the different angles on both sides of the groove (such as the groove angle of one test plate is 15°, and the angle of the groove on the other side is 25°), the bottom weld line is covered after the priming stage is completed. At this time, it can be effectively identified by the center line of the outer groove weld line. The center line of the outer weld groove is the terminal point on the left side of the arc area. The tungsten needle is in a swinging state in the filling and covering stage. The swinging center line is used as a reference. The adjustment method of the tungsten needle (welding gun) is the same as that in the priming stage.

[0062] In an embodiment of the present application, the welding system further includes an auxiliary light source, which is installed around the molten pool sensor and serves to illuminate the molten pool. The method further includes:

[0063] In the multi-layer and multi-pass covering stage, an image of the molten pool illuminated by the auxiliary light source is obtained;

[0064] Extracting a previous weld bead from the irradiated molten pool image, and determining a width of the previous weld bead and the number of welds in the previous layer;

[0065] The molten pool sensor algorithm is used to process the width of the previous weld and the number of welds in the previous layer, and determine the filling amount of the next weld based on the current welding gun swing center position.

[0066] That is, in the multi-layer and multi-pass covering stage, the auxiliary light source is used to obtain the width of the previous weld and the number of layers welded in the previous layer, and then the filling amount of the next weld is determined.

[0067] In the multi-layer and multi-pass covering stage, if the filling amount and slope of the previous layer are basically the same, the shape of the welding groove cannot be effectively segmented and identified. At this time, with the help of the auxiliary light source of the molten pool sensor, the number of layers welded in the previous layer can be effectively identified through the weld texture, and the width of the previous weld can be extracted and synchronized to the molten pool sensor algorithm. In this way, the influence of the current welding gun swing center position on the filling amount of the next weld can be extracted in real time, realizing accurate tracking and gun correction of multiple layers and multiple passes.

[0068] In the embodiment of the present application, the welding system further includes a laser positioning sensor, and the laser positioning sensor is installed inside the welding gun of the K-TIG welding subsystem. The method further includes:

[0069] Determining the relative position of the welding gun and the weld according to the position information collected by the laser positioning sensor;

[0070] The position of the welding gun is calibrated according to the relative position so that the welding robot tracks the weld line outside the groove along the weld.

[0071] Figure 4 The schematic diagram shows that the center position of the crawler body always coincides with the center line of the current weld bead, and the welding gun is at the geometric center of the crawler body. Since K-TIG welding will produce dazzling arc light during the welding process, the arc light will show the surrounding groove information. The crawler tracks the weld bead line outside the groove along the weld seam, and the center position of the crawler body always coincides with the center line of the current weld bead, realizing the function of welding along the seam.

[0072] The welding system also includes an arc voltage tracking sensor, which mainly realizes adaptive adjustment of the welding gun on the groove depth according to process parameters such as the current and voltage of the arc column during welding;

[0073] It also includes: the laser positioning sensor is mainly used to record the position of the welding gun relative to the weld pool, transmit the depth information to the weld pool sensor, and combine it with the two-dimensional information of the weld pool sensor observation screen to achieve three-dimensional morphology reconstruction of the weld pool area. Specifically, the laser positioning sensor is a point laser, which is fixedly connected to the welding gun (relatively static), and is used to provide real-time feedback on the relative position of the welding gun relative to the weld. The three-dimensional coordinate position of the welding gun is effectively fed back through the electric shaft, forming a corresponding position relationship with the weld pool sensor installed on the front side. Through the calibration algorithm, the depth information missing from the monocular camera is effectively integrated, and the morphology of the weld pool area is reconstructed in three dimensions. The defects that may occur during the welding process are judged by the changes in the morphology, and intelligent welding is achieved.

[0074] The embodiment of the present application also provides an industrial control device. It should be noted that the industrial control device of the embodiment of the present application can be used to execute the method for adjusting the process parameters in the K-TIG welding process provided by the embodiment of the present application. The device is used to implement the above-mentioned embodiments and preferred implementation modes, and the descriptions that have been made will not be repeated. As used below, the term "module" can implement a combination of software and / or hardware for a predetermined function. Although the devices described in the following embodiments are preferably implemented in software, the implementation of hardware, or a combination of software and hardware, is also possible and conceivable.

[0075] The following is an introduction to the industrial control device provided in the embodiments of the present application.

[0076] Figure 5 Schematic diagram of an industrial control device according to an embodiment of the present application. The welding system includes a K-TIG welding subsystem, a welding robot and a molten pool sensor. The K-TIG welding subsystem is loaded in the welding robot, and the molten pool sensor is installed at the front end of the welding robot. Figure 5 As shown, the device comprises:

[0077] A first acquisition unit 51 is used to acquire a molten pool image acquired by the molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image and a weld line portion image;

[0078] A first determining unit 52 is used to determine the tungsten needle center line according to the tungsten needle partial image, and determine the weld bead center line and an end point of the weld bead center line in the arc area according to the arc contour partial image and the weld bead line partial image;

[0079] The adjustment unit 53 is used to obtain the vertical distance from the end point to the center line of the tungsten needle, and adjust the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

[0080] The industrial control device of the present application obtains the molten pool image acquired by the molten pool sensor through the first acquisition unit, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image and a weld line partial image; the first determination unit determines the tungsten needle center line according to the tungsten needle partial image, and determines the weld center line and the end point of the weld center line in the arc area according to the arc contour partial image and the weld line partial image; the adjustment unit obtains the vertical distance from the end point to the tungsten needle center line, and adjusts the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the tungsten needle center line is less than a preset distance. Automatic correction of the welding gun is achieved automatically. Automatic correction of the welding gun is achieved without relying on experienced welders to adjust process parameters for the welding process.

[0081] In an embodiment of the present application, the first acquisition unit includes a first acquisition module and a second acquisition module. The first acquisition module is used to acquire a first molten pool image obtained by the molten pool sensor in the welding base stage, and the first molten pool image includes a first tungsten needle partial image, a first arc contour partial image and a first weld line partial image; the second acquisition module is used to acquire a second molten pool image obtained by the molten pool sensor in the filling stage and the multi-layer single-pass covering stage, and the second molten pool image includes a second tungsten needle partial image, a second arc contour partial image and a second weld line partial image.

[0082] In an embodiment of the present application, the first determination unit includes a first determination module and a second determination module, the first determination module is used to determine the first tungsten needle center line according to the first tungsten needle partial image in the welding base stage; the second determination module is used to determine the first arc profile according to the first arc profile partial image, extract the bottom weld center line from the first weld line partial image, and determine the end point of the bottom weld center line in the first arc profile, and determine the end point as the first base point;

[0083] The adjustment unit includes a third acquisition module and a first adjustment module, the third acquisition module is used to obtain the vertical distance from the first base point to the center line of the first tungsten needle; the first adjustment module is used to adjust the position of the welding gun according to the vertical distance to ensure that the vertical distance from the first base point to the center line of the first tungsten needle is less than the preset distance.

[0084] In an embodiment of the present application, the first determination unit includes a fourth acquisition module and a third determination module, the fourth acquisition module is used to obtain the swinging center line according to multiple partial images of the second tungsten needle in the filling stage and the multi-layer single-channel covering stage; the third determination module is used to determine a relatively static connecting line according to the swinging center line, and determine the connecting line as the second tungsten needle center line in the filling stage and the multi-layer single-channel covering stage, wherein the swinging center line is formed by connecting multiple swinging tungsten needle center points, and the swinging center line swings up and down the relatively static connecting line.

[0085] In an embodiment of the present application, the first determination unit further includes a fourth determination module and a fifth determination module, the fourth determination module being used to determine the second arc profile according to the second arc profile partial image in the filling stage and the multi-layer single-pass capping stage, and the fifth determination module being used to extract the outer groove weld center line from the second weld line partial image, and determine the endpoint of the outer groove weld center line in the second arc profile, and determine the endpoint as the second base point;

[0086] The adjustment unit includes a fifth acquisition module and a second adjustment module. The fifth acquisition module is used to obtain the vertical distance from the second base point to the center line of the second tungsten needle in the filling stage and the multi-layer single-pass covering stage; the second adjustment module is used to adjust the position of the welding gun according to the vertical distance to ensure that the vertical distance from the second base point to the center line of the second tungsten needle is less than the preset distance.

[0087] Furthermore, the welding system also includes an auxiliary light source, which is installed around the molten pool sensor. The auxiliary light source serves to illuminate the molten pool. The industrial control device also includes a second acquisition unit, an extraction and determination unit, and a filling unit. The second acquisition unit is used to obtain the irradiated molten pool image under the irradiation of the auxiliary light source in the multi-layer and multi-pass covering stage; the extraction and determination unit is used to extract the previous layer of weld from the irradiated molten pool image, and determine the width of the previous layer of weld and the number of layers of welding in the previous layer; the filling unit is used to process the width of the previous layer of weld and the number of layers of welding in the previous layer using the molten pool sensor algorithm, and determine the filling amount of the next weld based on the current center position of the welding gun swing.

[0088] Furthermore, the welding system also includes a laser positioning sensor, which is installed inside the welding gun of the K-TIG welding subsystem. The industrial control device also includes a second determination unit and a tracking unit. The second determination unit is used to determine the relative position of the welding gun and the weld according to the position information collected by the laser positioning sensor; the tracking unit is used to calibrate the position of the welding gun according to the relative position so that the welding robot tracks along the weld through the weld line outside the groove.

[0089] The industrial control device includes a processor and a memory, and the acquisition unit, the first determination unit, the adjustment unit, etc. are all stored in the memory as program units, and the processor executes the program units stored in the memory to implement corresponding functions. The modules are all located in the same processor; or, the modules are located in different processors in any combination.

[0090] The processor includes a kernel, which retrieves the corresponding program unit from the memory. One or more kernels can be set, and the automatic deviation correction of the welding gun can be achieved by adjusting the kernel parameters.

[0091] The memory may include non-permanent memory in a computer-readable medium, random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM, and the memory includes at least one memory chip.

[0092] An embodiment of the present invention provides a welding system, comprising:

[0093] An industrial control device for executing any of the methods for adjusting process parameters in a K-TIG welding process;

[0094] A K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot, the molten pool sensor is installed at the front end of the welding robot, and the industrial control device communicates with the K-TIG welding subsystem, the welding robot and the molten pool sensor respectively.

[0095] An embodiment of the present invention provides a computer-readable storage medium, which includes a stored program, wherein when the program is executed, the device where the computer-readable storage medium is located is controlled to execute the method for adjusting the process parameters in the K-TIG welding process.

[0096] Specifically, the method for adjusting the process parameters during K-TIG welding includes:

[0097] Step S101, obtaining a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image;

[0098] Step S102, determining the center line of the tungsten needle according to the partial image of the tungsten needle, and determining the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line;

[0099] Step S103, obtaining the vertical distance from the end point to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

[0100] Optionally, a molten pool image acquired by the molten pool sensor is obtained, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image, and a weld line partial image, including: a first molten pool image acquired by the molten pool sensor in the welding base laying stage, the first molten pool image includes a first tungsten needle partial image, a first arc contour partial image, and a first weld line partial image; a second molten pool image acquired by the molten pool sensor in the filling stage and the multi-layer single-pass covering stage, the second molten pool image includes a second tungsten needle partial image, a second arc contour partial image, and a second weld line partial image.

[0101] Optionally, the tungsten needle center line is determined according to the tungsten needle partial image, and the weld bead center line and the endpoint of the weld bead center line in the arc area are determined according to the arc contour partial image and the weld bead line partial image, including: determining the first tungsten needle center line according to the first tungsten needle partial image in the welding base stage, determining the first arc contour according to the first arc contour partial image, extracting the bottom weld bead center line from the first weld bead line partial image, and determining the endpoint of the bottom weld bead center line in the first arc contour, and determining the endpoint as the first base point; obtaining the vertical distance from the endpoint to the tungsten needle center line, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the endpoint to the tungsten needle center line is less than a preset distance, including: obtaining the vertical distance from the first base point to the first tungsten needle center line, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the first base point to the first tungsten needle center line is less than the preset distance.

[0102] Optionally, determining the center line of the tungsten needle according to the partial image of the tungsten needle includes: obtaining a swinging center line according to multiple partial images of the second tungsten needle in the filling stage and the multi-layer single-channel covering stage; determining a relatively static line according to the swinging center line, and determining the line as the second tungsten needle center line in the filling stage and the multi-layer single-channel covering stage, wherein the swinging center line is formed by connecting multiple swinging tungsten needle center points, and the swinging center line swings up and down the relatively static line.

[0103] Optionally, the weld centerline and the endpoint of the weld centerline in the arc area are determined according to the arc contour partial image and the weld line partial image, including: in the filling stage and the multi-layer single-pass covering stage, the second arc contour is determined according to the second arc contour partial image, the outer groove weld centerline is extracted from the second weld line partial image, and the endpoint of the outer groove weld centerline in the second arc contour is determined, and the endpoint is determined as the second base point; the vertical distance from the endpoint to the center line of the tungsten needle is obtained, and the position of the welding gun is adjusted according to the vertical distance to meet the vertical distance from the endpoint to the center line of the tungsten needle is less than a preset distance, including: in the filling stage and the multi-layer single-pass covering stage, the vertical distance from the second base point to the center line of the second tungsten needle is obtained, and the position of the welding gun is adjusted according to the vertical distance to meet the vertical distance from the second base point to the center line of the second tungsten needle is less than the preset distance.

[0104] Optionally, the welding system also includes an auxiliary light source, which is installed around the molten pool sensor, and the auxiliary light source serves to illuminate the molten pool. The method also includes: in the multi-layer and multi-pass covering stage, obtaining an image of the molten pool illuminated by the auxiliary light source; extracting the previous layer of weld from the illuminated molten pool image, and determining the width of the previous layer of weld and the number of layers of welding in the previous layer; using the molten pool sensor algorithm to process the width of the previous layer of weld and the number of layers of welding in the previous layer, and determine the filling amount of the next weld based on the current center position of the welding gun swing.

[0105] Optionally, the welding system also includes a laser positioning sensor, which is installed inside the welding gun of the K-TIG welding subsystem. The method also includes: determining the relative position of the welding gun and the weld according to the position information collected by the laser positioning sensor; and calibrating the position of the welding gun according to the relative position so that the welding robot tracks along the weld through the weld line outside the groove.

[0106] An embodiment of the present invention provides a processor, which is used to run a program, wherein the method for adjusting process parameters in a K-TIG welding process is executed when the program is run.

[0107] Specifically, the method for adjusting the process parameters during K-TIG welding includes:

[0108] Step S101, obtaining a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image;

[0109] Step S102, determining the center line of the tungsten needle according to the partial image of the tungsten needle, and determining the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line;

[0110] Step S103, obtaining the vertical distance from the end point to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

[0111] An embodiment of the present invention provides a device, the device including a processor, a memory, and a program stored in the memory and executable on the processor, and when the processor executes the program, at least the following steps are implemented:

[0112] Step S101, obtaining a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image;

[0113] Step S102, determining the center line of the tungsten needle according to the partial image of the tungsten needle, and determining the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line;

[0114] Step S103, obtaining the vertical distance from the end point to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

[0115] The devices in this article can be servers, PCs, PADs, mobile phones, etc.

[0116] The present application also provides a computer program product, which, when executed on a data processing device, is suitable for executing a program for initializing at least the following method steps:

[0117] Step S101, obtaining a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image;

[0118] Step S102, determining the center line of the tungsten needle according to the partial image of the tungsten needle, and determining the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line;

[0119] Step S103, obtaining the vertical distance from the end point to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

[0120] Obviously, those skilled in the art should understand that the above modules or steps of the present invention can be implemented by a general computing device, they can be concentrated on a single computing device, or distributed on a network composed of multiple computing devices, they can be implemented by a program code executable by a computing device, so that they can be stored in a storage device and executed by the computing device, and in some cases, the steps shown or described can be executed in a different order than here, or they can be made into individual integrated circuit modules, or multiple modules or steps therein can be made into a single integrated circuit module for implementation. Thus, the present invention is not limited to any specific combination of hardware and software.

[0121] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment in combination with software and hardware. Moreover, the present application may adopt the form of a computer program product implemented in one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) that include computer-usable program code.

[0122] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0123] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0124] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process in the computer or other programmable device. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0125] In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0126] The memory may include non-permanent memory in a computer-readable medium, random access memory (RAM) and / or non-volatile memory in the form of read-only memory (ROM) or flash RAM. The memory is an example of a computer-readable medium.

[0127] Computer readable media include permanent and non-permanent, removable and non-removable media that can be implemented by any method or technology to store information. Information can be computer readable instructions, data structures, program modules or other data. Examples of computer storage media include, but are not limited to, phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disk read-only memory (CD-ROM), digital versatile disk (DVD) or other optical storage, magnetic cassettes, magnetic tape disk storage or other magnetic storage devices or any other non-transmission media that can be used to store information that can be accessed by a computing device. As defined herein, computer readable media does not include temporary computer readable media (transitory media), such as modulated data signals and carrier waves.

[0128] It should also be noted that the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, commodity or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, commodity or device. In the absence of more restrictions, the elements defined by the sentence "comprises a ..." do not exclude the existence of other identical elements in the process, method, commodity or device including the elements.

[0129] From the above description, it can be seen that the above embodiments of the present application achieve the following technical effects:

[0130] 1) The method of adjusting the process parameters in the K-TIG welding process of the present application is to obtain a molten pool image acquired by a molten pool sensor, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image and a weld line partial image; determine the tungsten needle center line according to the tungsten needle partial image, determine the weld line center line and the end point of the weld line center line in the arc area according to the arc contour partial image and the weld line partial image; obtain the vertical distance from the end point to the tungsten needle center line, and adjust the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the tungsten needle center line is less than a preset distance. Automatically realize automatic deviation correction of the welding gun. Automatic deviation correction of the welding gun is realized without relying on experienced welders to adjust the process parameters for the welding process.

[0131] 2) The industrial control device of the present application obtains the molten pool image acquired by the molten pool sensor through the first acquisition unit, wherein the molten pool image includes a tungsten needle partial image, an arc contour partial image and a weld line partial image; the first determination unit determines the tungsten needle center line according to the tungsten needle partial image, and determines the weld center line and the end point of the weld center line in the arc area according to the arc contour partial image and the weld line partial image; the adjustment unit obtains the vertical distance from the end point to the tungsten needle center line, and adjusts the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the tungsten needle center line is less than a preset distance. Automatic correction of the welding gun is achieved automatically. Automatic correction of the welding gun is achieved without relying on experienced welders to adjust process parameters for the welding process.

[0132] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method for adjusting process parameters in a K-TIG welding process, characterized in that: The welding system includes a K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot and the molten pool sensor is installed at the front end of the welding robot, including: Acquire a molten pool image acquired by the molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image; Determine the center line of the tungsten needle according to the partial image of the tungsten needle, determine the center line of the weld bead and the end point of the center line of the weld bead in the arc area according to the partial image of the arc contour and the partial image of the weld bead line; The vertical distance from the end point to the center line of the tungsten needle is obtained, and the position of the welding gun is adjusted according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

2. The method according to claim 1, characterized in that The molten pool image acquired by the molten pool sensor is obtained, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image, and a weld line portion image, including: Acquire a first molten pool image acquired by the molten pool sensor during the welding base laying stage, wherein the first molten pool image includes a first tungsten needle partial image, a first arc contour partial image, and a first weld bead line partial image; The second molten pool image is acquired by the molten pool sensor during the filling stage and the multi-layer single-pass covering stage, and the second molten pool image includes a second tungsten needle partial image, a second arc contour partial image, and a second weld line partial image.

3. The method according to claim 2, characterized in that Determining the tungsten needle center line according to the tungsten needle partial image, and determining the weld bead center line and the end point of the weld bead center line in the arc area according to the arc contour partial image and the weld bead line partial image, including: In the welding base-making stage, a first tungsten needle center line is determined according to the first tungsten needle partial image, a first arc profile is determined according to the first arc profile partial image, a bottom weld bead center line is extracted from the first weld bead line partial image, and an endpoint of the bottom weld bead center line in the first arc profile is determined, and the endpoint is determined as a first base point; Obtaining a vertical distance from the endpoint to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the endpoint to the center line of the tungsten needle is less than a preset distance, including: obtaining a vertical distance from the first base point to the center line of the first tungsten needle, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the first base point to the center line of the first tungsten needle is less than the preset distance.

4. The method according to claim 2, characterized in that: Determining the center line of the tungsten needle according to the partial image of the tungsten needle includes: Acquiring a swing center line according to a plurality of images of the second tungsten needle portion in a filling stage and a multi-layer single-pass capping stage; A relatively static line is determined based on the swinging center line, and the line is determined as the second tungsten needle center line in the filling stage and the multi-layer single-channel covering stage, wherein the swinging center line is formed by connecting multiple swinging tungsten needle center points, and the swinging center line swings up and down the relatively static line.

5. The method according to claim 4, characterized in that Determining a weld bead center line and an endpoint of the weld bead center line in an arc region according to the arc contour partial image and the weld bead line partial image, comprising: in the filling stage and the multi-layer single-pass capping stage, determining a second arc contour according to the second arc contour partial image, extracting an outer groove weld bead center line from the second weld bead line partial image, and determining an endpoint of the outer groove weld bead center line in the second arc contour, and determining the endpoint as a second base point; Obtaining the vertical distance from the endpoint to the center line of the tungsten needle, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the endpoint to the center line of the tungsten needle is less than a preset distance, including: in the filling stage and the multi-layer single-pass covering stage, obtaining the vertical distance from the second base point to the center line of the second tungsten needle, and adjusting the position of the welding gun according to the vertical distance to satisfy that the vertical distance from the second base point to the center line of the second tungsten needle is less than the preset distance.

6. The method according to claim 1, characterized in that The welding system further includes an auxiliary light source, which is installed around the molten pool sensor and serves to illuminate the molten pool. The method further includes: In the multi-layer and multi-pass covering stage, an image of the molten pool illuminated by the auxiliary light source is obtained; Extracting a previous weld bead from the irradiated molten pool image, and determining a width of the previous weld bead and the number of welds in the previous layer; The molten pool sensor algorithm is used to process the width of the previous weld and the number of welds in the previous layer, and determine the filling amount of the next weld based on the current welding gun swing center position.

7. The method according to claim 1, characterized in that The welding system further includes a laser positioning sensor, which is installed inside a welding gun of the K-TIG welding subsystem. The method further includes: Determining the relative position of the welding gun and the weld according to the position information collected by the laser positioning sensor; The position of the welding gun is calibrated according to the relative position so that the welding robot tracks the weld line outside the groove along the weld.

8. An industrial control device in a welding system, characterized in that: The welding system includes a K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot and the molten pool sensor is installed at the front end of the welding robot, including: A first acquisition unit is used to acquire a molten pool image acquired by the molten pool sensor, wherein the molten pool image includes a tungsten needle portion image, an arc contour portion image and a weld line portion image; A first determining unit is used to determine the tungsten needle center line according to the tungsten needle partial image, and determine the weld bead center line and an end point of the weld bead center line in the arc area according to the arc contour partial image and the weld bead line partial image; The adjustment unit is used to obtain the vertical distance from the end point to the center line of the tungsten needle, and adjust the position of the welding gun according to the vertical distance to ensure that the vertical distance from the end point to the center line of the tungsten needle is less than a preset distance.

9. A welding system, characterized in that: include: An industrial control device for executing the method for adjusting process parameters in a K-TIG welding process as claimed in any one of claims 1 to 7; A K-TIG welding subsystem, a welding robot and a molten pool sensor, wherein the K-TIG welding subsystem is loaded in the welding robot, the molten pool sensor is installed at the front end of the welding robot, and the industrial control device communicates with the K-TIG welding subsystem, the welding robot and the molten pool sensor respectively.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium includes a stored program, wherein when the program is executed, the device where the computer-readable storage medium is located is controlled to execute the method for adjusting process parameters in the K-TIG welding process according to any one of claims 1 to 7.

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