Welding mechanical arm with welding state monitoring system
By integrating the current sensing module and signal transmission unit in the robotic arm welding system, welding status monitoring is achieved without shutdown, solving the problems of production progress, high labor costs and safety caused by shutdown detection, and improving the welding process Real-time monitoring efficiency and security.
Patent Information
- Application Number
- CN202310824931.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-07-06
- Publication Date
- 2025-01-07
AI Technical Summary
The shutdown detection during mechanical arm welding has caused problems such as production progress, high labor costs, high risk, outflow of defective products and stagnation of production lines, and it is impossible to detect welding abnormalities in time.
Design an online detection welding status monitoring system. By coupling the current sensing module on the welding pliers, the current and pressure during the welding process are monitored in real time, and the data is transmitted to the outside using the signal processing unit and the signal transmission unit, so as to achieve no need Real-time monitoring of downtime.
It realizes low-cost and high-efficiency welding status monitoring, avoids losses and labor consumption from shutdown detection, timely detects welding abnormalities, and improves production efficiency and safety.
Smart Images
Figure CN119260262A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to an automatic welding device, and in particular to a welding mechanical arm with a welding state monitoring system which does not require shutdown detection. Background Art
[0002] Robotic arm welding is an automated welding technology that uses the accuracy and speed of a robot to automatically perform the welding process. Compared with traditional manual welding, robotic arm welding has higher accuracy and efficiency, and can work for a long time, while also reducing the harm of manual operation to the working environment. In the process of robotic arm welding, process factor monitoring is very important, which can usually be achieved through online detection or shutdown detection.
[0003] Online inspection refers to real-time monitoring of product quality during the manufacturing process, usually using sensors, cameras and other equipment for real-time monitoring, as well as computer vision technology to automatically analyze the equipment status. Online inspection can detect welding problems in real time and adjust welding parameters in time to ensure that welding quality meets standards.
[0004] Shutdown testing refers to the testing and maintenance performed during the downtime of manufacturing equipment. When manufacturing equipment needs to be inspected for the first and last parts, routine maintenance, or shut down due to a malfunction, the production line will stop operating, and the downtime can be used for testing and maintenance. Shutdown testing can help detect and discover potential problems with production equipment, prevent failures, and improve the reliability and stability of production equipment. Shutdown testing can include many types of inspections, such as inspections of mechanical parts, electrical systems, fluid systems, etc. Shutdown testing can also include testing the performance and function of manufacturing equipment, such as testing whether the temperature, pressure, speed and other parameters of the production equipment are normal.
[0005] At present, industrial robot arm welding adopts shutdown detection. The robot arm must stop processing, and then the on-site operator operates the detection instrument to measure the robot arm and conduct an overall assessment of the status of the robot arm equipment. The disadvantage of offline detection is that it requires time and labor costs, and it is impossible to detect and deal with welding problems in time. If problems occur, re-welding is required, which will increase costs and time. Therefore, if shutdown detection is used instead of online detection, the following troubles may occur:
[0006] 1. Impact on production progress: shutdown inspection requires the robot arm to stop production and on-site operators to conduct equipment evaluation, which seriously affects the processing and production progress.
[0007] 2. High labor cost: shutdown inspection requires removing the welded parts and inspecting them, which requires additional labor costs.
[0008] 3. High risk: The production site is a high-risk area. The welding process has high temperature and sparks often fly, and personnel are in a high-risk environment.
[0009] 4. Outflow of defective products: Poor product quality control by processing manufacturers leads to the outflow of defective products, which will cause problems such as defective product returns and fines, affecting the competitiveness of the company.
[0010] 5. Derivative problems: Many additional problems are caused, including: waste of defective materials, secondary processing of defective products, production line stagnation, disruption of production plans, etc. Unable to manage the quality of all welds in the processing process: shutdown detection cannot timely detect sudden abnormal welding problems in the processing (for example: welding clamps are pressurized but not powered, insufficient current during welding, etc.), and cannot adjust welding parameters in time. Summary of the invention
[0011] In view of this, the purpose of the present invention is to provide a welding robot arm with online detection. By setting a current sensing module on the welding clamp of the welding robot arm, the current passing through the welding clamp is sensed during the process of the welding robot arm welding the plate online, and the sensing signal is processed and transmitted to the outside, thereby achieving real-time monitoring of the welding process of the welding robot arm, and the detection process does not require shutdown.
[0012] In order to achieve the above-mentioned purpose, the present invention provides a welding robot arm with a welding state monitoring system, which comprises a welding robot arm and a welding state monitoring system; the welding robot arm comprises a robot body, the robot body is coupled to a welding clamp, the welding clamp comprises two welding clamp arms and a transmission element, the two welding clamp arms are driven by the transmission element to clamp or separate, and the ends of the two welding clamp arms respectively have a welding head; the transmission element is electrically connected to a control module of an electric control system and is controlled by the electric control system, the electric control system comprises a welding power supply module, the welding power supply module is electrically connected to the two welding clamp arms, and provides power for welding when the two welding clamp arms are clamped;
[0013] The welding state monitoring system includes a current sensing module, a signal processing unit, and a signal transmission unit; the current sensing module is coupled to one of the welding clamp arms to measure a current module signal of the current size passing through the welding clamp arms when the two welding clamp arms drive the two welding heads to be clamped on two overlapping plates for welding, and the current module signal includes multiple welding parameters; the signal processing unit is electrically connected to the current sensing module and receives the current module signal from the current sensing module for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the current module signal from the signal processing unit, and transmits the current module signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
[0014] As a further improvement of the present invention, when the welding clamp is clamping the two overlapping plates, the electric control system controls the welding clamp to weld in a welding cycle; the multiple welding parameters include a welding cycle current intensity and a welding cycle time of the welding cycle.
[0015] As a further improvement of the present invention, when the welding clamp is clamping the two overlapping plates, the electronic control system controls the welding clamp to perform welding with more than two welding cycles; the multiple welding parameters include a welding cycle current intensity, a welding cycle time, and a cooling cycle time between the two welding cycles.
[0016] As a further improvement of the present invention, the welding state monitoring system has a transmission sensing module for measuring a pressure signal of the pressure magnitude of the two welding clamp arms driven by the transmission element when the two welding clamp arms drive the two welding heads to be clamped on the two stacked plates for welding; the signal processing unit is electrically connected to the transmission sensing module and receives the pressure signal for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the pressure signal, and transmits the pressure signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
[0017] As a further improvement of the present invention, the welding state monitoring system has a transmission sensing module for measuring a pressure signal of the pressure magnitude of the two welding clamp arms driven by the transmission element when the two welding clamp arms drive the two welding heads to be clamped on the two stacked plates for welding; the signal processing unit is electrically connected to the transmission sensing module and receives the pressure signal for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the pressure signal, and transmits the pressure signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
[0018] As a further improvement of the present invention, the signal processing unit fuses the current module signal with the pressure signal and draws a signal overlap graph based on time; the signal overlap graph includes multiple welding parameters, including a pressure intensity included in the pressure signal, an initial pressure time between the pressure rise time and the start time of the welding cycle, and a holding time between the pressure drop time and the end time of the welding cycle.
[0019] As a further improvement of the present invention, the welding state monitoring system has a transmission sensing module for measuring a pressure signal of the pressure magnitude of the two welding clamp arms driven by the transmission element when the two welding clamp arms drive the two welding heads to be clamped on the two stacked plates for welding; the signal processing unit is electrically connected to the transmission sensing module and receives the pressure signal for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the pressure signal, and transmits the pressure signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
[0020] As a further improvement of the present invention, the signal processing unit fuses the current module signal with the pressure signal and draws a signal overlap graph according to time; the signal overlap graph includes multiple welding parameters, including a pressure intensity included in the pressure signal, an initial pressure time between the pressure rise time and the start time of the first welding cycle, a cooling time between the two welding cycles, and a holding time between the pressure drop time and the end time of the last welding cycle.
[0021] The effect of the present invention is that, by coupling the current sensing module to the welding clamp arm, the welding state monitoring system can obtain the amount of current passing through the welding clamp during the welding process, thereby obtaining the current module signal and analyzing the welding parameters contained in the current module signal, and can monitor in real time whether the welding process is abnormal (no power, insufficient power). In addition, since the welding state monitoring system monitors the welding robot arm during welding, the welding robot arm does not need to be shut down, and the on-site personnel do not need to disassemble the plate for inspection, which can avoid the loss of shutdown, the consumption of manpower, and the danger that may arise from personnel approaching the welding robot arm. It is an online detection technology with low detection cost, high detection efficiency, short time consumption and low cost. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 It is a schematic diagram of a first preferred embodiment of the present invention.
[0023] Figure 2 This is a schematic diagram of two welding clamp arms used for welding plates according to the first preferred embodiment of the present invention.
[0024] Figure 3 FIG. 4 is a block diagram of a first preferred embodiment of the present invention.
[0025] Figure 4A The current and time rectangular coordinate diagram for analyzing the current module signal of a welding cycle.
[0026] Figure 4B The current and time rectangular coordinate diagram for analyzing the current module signal of two welding cycles.
[0027] Figure 5 FIG. 4 is a schematic diagram of a second preferred embodiment of the present invention.
[0028] Figure 6 This is a schematic diagram of two welding clamp arms used for welding plates according to a second preferred embodiment of the present invention.
[0029] Figure 7 FIG. 4 is a block diagram of a second preferred embodiment of the present invention.
[0030] Fig. 8A A dual-axis diagram for analyzing the current and pressure changes over time of a welding cycle current module signal.
[0031] Figure 8B A dual-axis diagram for analyzing the current and pressure changes over time of the current module signal of two welding cycles.
[0032] Explanation of symbols:
[0033] 100: Welding robot with welding status monitoring system
[0034] 10: Welding robot arm
[0035] 12: Robot body
[0036] 14: Welding tongs
[0037] 141: welding clamp arm
[0038] 142: Transmission element
[0039] 143: Welding head
[0040] 16:Electronic control system
[0041] 161: Control Module
[0042] 162: Welding power module
[0043] 20: Welding status monitoring system
[0044] 22: Current sensing module
[0045] 24: Signal processing unit
[0046] 26: Signal transmission unit
[0047] 28: Transmission sensing module
[0048] 30: Wireless Router
[0049] 40:Computer operation module
[0050] 200: Signal Overlapping Graphics
[0051] A: Panel
[0052] A1: Current module signal
[0053] A2: Pressure signal
[0054] C1: Cooling cycle time
[0055] P1: Pressure strength
[0056] P2: Initial pressure time
[0057] P3: Keep Time
[0058] S1: First welding cycle
[0059] S11: Current intensity of the first welding cycle
[0060] S12: First welding cycle time
[0061] S2: Second welding cycle
[0062] S21: Second welding cycle current intensity
[0063] S22: Second welding cycle time DETAILED DESCRIPTION
[0064] In order to more clearly illustrate the present invention, a preferred embodiment is given and described in detail with reference to the drawings. Figures 1 to 3 FIG. 1 shows a welding robot arm 100 with a welding state monitoring system according to a first preferred embodiment of the present invention, comprising a welding robot arm 10 and a welding state monitoring system 20 disposed on the welding robot arm 10. In the first preferred embodiment, the welding state monitoring system 20 is a system for measuring the current size of the welding robot arm 10 during welding using a current sensing module 22, and is a welding state monitoring system 20 with a single sensing module, wherein:
[0065] The welding robot arm 10 has a robot body 12; specifically, the robot body 12 is a multi-joint, programmable mechanical device, usually composed of a base, an arm, a transmission mechanism of multiple joints and a control system, each joint can move and rotate within a certain range, so as to realize the flexible operation of the robot arm. The control system of the robot body 12 is composed of computer software, which can accurately control the movement, position, speed and force of the robot arm. Usually, the robot body 12 will be equipped with an end effector combined with the end of the robot body 12. Common end effectors include grippers, welding guns, paint spray guns, polishing wheels, etc. Combining different end effectors at the end of the robot body 12 can enable the welding robot arm 10 to be used in different industrial automation applications, such as loading and unloading, welding, polishing, grinding, painting, deburring, etc.
[0066] In the preferred embodiment, the welding robot arm 10 uses a welding clamp 14 as an end effector, and the welding clamp 14 is coupled to the end of the robot body 12. The welding clamp 14 includes two welding clamp arms 141 and a transmission element 142. The two welding clamp arms 141 are driven by the transmission element 142 to clamp or separate. The ends of the two welding clamp arms 141 are respectively provided with a welding head 143; the transmission element 142 provides clamping power to the two welding clamp arms 141 for clamping. The transmission element 142 is usually an electric element, a pneumatic element or a hydraulic element.
[0067] The above-mentioned electric components are driven by electricity, such as electric cylinders, electric motors, servo motors, stepper motors, and linear motors. Pneumatic components are driven by air pressure, such as pneumatic cylinders and air pressure switches. Hydraulic components are driven by liquid, such as hydraulic cylinders, oil pipes, oil pumps, etc. The transmission element 142 is electrically connected to a control module 161 of an electric control system 16 and is controlled by the electric control system 16. The robot body 12 has its own controller, which is used to control the robot body 12 to move the welding clamp 14 at its end to the correct position so that the welding clamp 14 can perform clamping and welding. In other preferred embodiments, the control module 161 can also be integrated into the controller of the robot body 12, as long as the control module 161 can be used to control the clamping operation of the welding clamp 14, regardless of whether it is an independent controller.
[0068] The electric control system 16 further includes a welding power module 162, which is electrically connected to the two welding clamp arms 141 to provide power for welding when the two welding clamp arms 141 are clamped. The two welding clamp arms 141 and their welding heads 143 are usually made of conductive metal materials, such as copper, steel, aluminum, etc. Before the welding robot arm 10 performs welding, the two welding clamp arms 141 of the welding clamp 14 will first be moved to the correct position for operation by the robot body 12, and then the transmission element 142 drives the two welding clamp arms 141 to clamp the two overlapping plates A and start to apply pressure. At the same time, the two welding clamp arms 141 are used as two energized electrodes, and the transformer and inverter included in the welding power module 162 supply current to the two welding clamp arms 141, so that the two welding clamp arms 141 and their welding heads 143 pass thousands to tens of thousands of amperes of current between the two plates A to generate resistance heat, melt the welding material between the two plates A to form a joint welding point.
[0069] The welding state monitoring system 20 includes the above-mentioned current sensing module 22, a signal processing unit 24, and a signal transmission unit 26. The current sensing module 22 is coupled to one of the welding clamp arms 141, and is a device for measuring the current size, which can convert the current into a voltage signal proportional to the current, so as to facilitate measurement and control by a microcontroller or other electronic device. Specifically, the current sensing module 22 includes a coupled Rogowski coil and an integrator, wherein the Rogowski coil is wound as a hollow ring coil. When a certain current passes through the coil, an induced magnetic field is generated and a voltage differential signal of the time rate of change of the magnetic field is output. The output signal of the Rogowski coil is then transmitted to the integrator, and the integrator integrates the input signal. Finally, the amplitude change rate of the signal output by the current sensing module 22 is proportional to the magnetic field.
[0070] Therefore, the above-mentioned current sensing module 22 is used to measure the current size of the welding clamp arm 141 when the two welding clamp arms 141 drive the two welding heads 143 to clamp the two overlapping plates A for welding, and generate a current module signal A1. The current module signal A1 includes multiple current magnitude values with time stamps. Multiple welding parameters can be analyzed through the current module signal A1. The welding parameters obtained by the current module signal A1 of the welding status monitoring system 20 can determine whether the welding operation status of the welding robot arm 10 is abnormal. The signal processing unit 24 is electrically connected to the current sensing module 22 and receives the current module signal A1 from the current sensing module 22 for analog-to-digital conversion; specifically, the signal processing unit 24 is an electronic component composed of a processor, a storage medium, and an input / output interface, which can perform tasks such as analog / digital signal conversion, packet format conversion, filtering, and zooming in and out. In addition, the signal processing unit 24 can also perform signal fusion analysis when necessary.
[0071] The signal transmission unit 26 is electrically connected to the signal processing unit 24 and receives the current module signal A1 converted into a digital format by the signal processing unit 24. The signal transmission unit 26 is used to transmit the current module signal A1 to the outside of the welding robot arm 10 and the welding state monitoring system 20 in a wired or wireless manner. Specifically, the signal transmission unit 26 is a component for transmitting digital signals, and its main function is to transmit signals from one device to another. The transmission method can be wired transmission or wireless transmission. The wired transmission method is to transmit the current module signal A1 to the external computer computing module 40 through the signal transmission line, and the transmission interface includes Ethernet, fiber optic, serial serial port RS-485 / RS-232, USB and other methods; the wireless transmission method is to transmit the current module signal A1 to the external computer computing module 40 through a wireless router 30 in the middle, and the transmission means can be WiFi, Zigbee, Bluetooth, 4G / 5G mobile network and other methods.
[0072] In this preferred embodiment, the signal transmission unit 26 transmits the current module signal A1 to the outside of the welding robot arm 10 and the welding status monitoring system 20 to a wireless router 30 by wireless transmission, and then wirelessly transmits the current module signal A1 to a computer calculation module 40 connected to the wireless router 30 signal. The computer calculation module 40 is a computer calculator with a central processing unit (CPU) and a data storage medium. It can complete various tasks according to software programs and is responsible for information display, data storage, data calculation, network communication and other tasks.
[0073] When using the first preferred embodiment, please refer to Figures 2 to 4B As shown, when the welding clamp arm 141 is clamping two overlapping plates A, the welding power module 162 of the electric control system 16 controls the welding clamp 14 to perform welding in one welding cycle or more than two welding cycles. Figure 4A , Figure 4B As shown, the current module signal A1 is plotted as a rectangular coordinate graph with the horizontal axis being time and the vertical axis being current. When there is only one welding cycle, the welding cycle is called the first welding cycle S1. The multiple welding parameters include the first welding cycle current intensity S11 of the first welding cycle S1 and the first welding cycle time S12 of the first welding cycle.
[0074] like Figure 4BAs shown, when there are more than two welding cycles, the first welding cycle in time sequence is called the first welding cycle S1, the second welding cycle is called the second welding cycle S2, and so on. Taking the first welding cycle S1 and the second welding cycle S2 as an example, the plurality of welding parameters include a first welding cycle current intensity S11 of the first welding cycle S1, a first welding cycle time S12 of the first welding cycle S1, a second welding cycle current intensity S21 of the second welding cycle S2, a second welding cycle time S22 of the second welding cycle S2, and a cooling cycle time C1 between the first welding cycle S1 and the second welding cycle S2.
[0075] Specifically, the first welding cycle current intensity S11 is the average current value between the first rising edge and the first falling edge of the current module signal A1. The first welding cycle time S12 is the time between the first rising edge and the first falling edge of the current module signal A1. The second welding cycle current intensity S21 is the average current value between the second rising edge and the second falling edge of the current module signal A1. The second welding cycle time S22 is the time between the second rising edge and the second falling edge of the current module signal A1. The cooling cycle time is the time between the first falling edge and the second rising edge of the current module signal A1. In other preferred embodiments, the current intensity sampling method is not limited to the average current value. For example, the first welding cycle current intensity S11 can also be the maximum or minimum value of the current value between the first rising edge and the first falling edge of the current module signal A1; the second welding cycle current intensity S21 can also be the maximum or minimum value of the current value between the second rising edge and the second falling edge of the current module signal A1.
[0076] Please see Figures 1 to 3 As shown, the analysis of the welding parameters contained in the current module signal A1 is performed in the signal processing unit 24 in the preferred embodiment, and then the current module signal A1 and the welding parameter signal contained therein are transmitted to the computer calculation module 40 for display, storage and use. In other preferred embodiments, the signal processing unit 24 may only perform digital-to-analog conversion on the current module signal A1, and when the current module signal A1 is transmitted to the computer calculation module 40, the computer calculation module 40 further analyzes the welding parameters contained in the current module signal A1.
[0077] Please see Figures 5 to 7, a welding robot arm 100 with a welding state monitoring system according to a second preferred embodiment of the present invention is shown, which also includes a welding robot arm 10 and a welding state monitoring system 20 disposed on the welding robot arm 10. In the second preferred embodiment, the structure, possible changes in the structure, and the operation mode of the structure of the welding robot arm 10 are the same as those of the welding robot arm 10 described in the first preferred embodiment. The difference between the second preferred embodiment and the first preferred embodiment is that the sensing module is added to the welding state monitoring system 20.
[0078] In the second preferred embodiment, the welding state monitoring system 20 not only uses a current sensing module 22 to measure the current size of the welding robot arm 10 during welding, but also adds a transmission sensing module 28 to measure the pressure size of the two welding clamp arms 141 driven by the transmission element 142 when the two welding clamp arms 141 drive the two welding heads 143 to clamp the two overlapping plates A for welding, so that the welding state monitoring system 20 can obtain the current module signal A1 through 22 sensing, and further obtain a pressure signal A2 through the sensing function of the transmission sensing module 28. Compared with the welding state monitoring system 20 in the first embodiment, the welding state monitoring system 20 in the second preferred embodiment is a welding state monitoring system with dual sensing modules.
[0079] The welding state monitoring system 20 in the second preferred embodiment also has a signal processing unit 24 and a signal transmission unit 26. The signal processing unit 24 is electrically connected to the current sensing module 22 and the transmission sensing module 28 respectively, and the signal processing unit 24 is electrically connected to the signal transmission unit 26. In the second preferred embodiment, the function of the signal processing unit 24 to process the current module signal A1, and the function of the signal transmission unit 26 to receive and transmit the current module signal A1 to the outside of the welding robot arm 10 and the welding state monitoring system 20 are also the same as the signal processing unit 24 and the signal transmission unit 26 in the first preferred embodiment.
[0080] In the second preferred embodiment of the present invention, the welding state monitoring system 20 further has a transmission sensing module 28 disposed on the welding clamp 14, for measuring the pressure of the transmission element 142 driving the two welding clamp arms 141 to generate a pressure signal A2. The signal processing unit 24 receives the pressure signal A2 from the transmission sensing module 28 for analog-to-digital conversion, and the signal processing unit 24 transmits the digitized pressure signal A2 to the signal transmission unit 26, so that the signal transmission unit 26 receives the pressure signal A2 from the signal processing unit 24, and transmits the pressure signal A2 to the outside of the welding robot arm 10 and the welding state monitoring system 20 in a wired or wireless manner.
[0081] In the second preferred embodiment, the signal transmission unit 26 transmits the current module signal A1 and the pressure signal A2 to the outside of the welding robot arm 10 and the welding state monitoring system 20 to a wireless router 30 by wireless transmission, and then wirelessly transmits the current module signal A1 to a computer computing module 40 connected to the wireless router 30. And just like the current module signal A1 includes multiple current magnitude values with time stamps, the pressure signal A2 also includes multiple pressure magnitude values with time stamps. Please refer to Figures 7 to 8B As shown, by fusing the pressure signal A2 and the current module signal A1, a signal overlap graph 200 is drawn according to time to analyze multiple welding parameters. The welding parameters obtained by the current module signal A1 and the pressure signal A2 of the welding state monitoring system 20 can be used to determine whether the welding operation of the welding robot arm 10 is abnormal. The above-mentioned signal fusion is performed in the signal processing unit 24 in the preferred embodiment; in other preferred embodiments, the signal fusion can also be performed in Figure 1 The computer calculation module 40 shown in the figure is used to analyze the welding parameters contained in the fusion of the current module signal A1 and the pressure signal A2.
[0082] When using the second preferred embodiment, please refer to Figure 6 , Figure 7 As shown, when the welding clamp arm 141 is clamping two overlapping plates A, the welding power module 162 of the electric control system 16 controls the welding clamp 14 to perform welding in one welding cycle or more than two welding cycles. Fig. 8A , Figure 8B As shown, the current module signal A1 and the pressure signal A2 are combined and plotted into a signal overlap graph 200. The signal overlap graph 200 is a rectangular coordinate graph with the horizontal axis being time and the vertical axis being current or pressure. Fig. 8A As shown, when there is only one welding cycle, the welding cycle is called the first welding cycle S1, and the plurality of welding parameters include the first welding cycle current intensity S11 of the first welding cycle S1, and the first welding cycle time S12 of the first welding cycle. The plurality of welding parameters also include a pressure intensity P1, an initial pressure time P2 between the pressure rise time and the start time of the first welding cycle S1, and a holding time P3 between the pressure drop time and the end time of the first welding cycle S1.
[0083] like Figure 8BAs shown, when there are more than two welding cycles, the first welding cycle in time sequence is called the first welding cycle S1, the second welding cycle is called the second welding cycle S2, and so on. Taking the first welding cycle S1 and the second welding cycle S2 as examples, the plurality of welding parameters include the first welding cycle current intensity S11 of the first welding cycle S1, the first welding cycle time S12 of the first welding cycle S1, the second welding cycle current intensity S21 of the second welding cycle S2, the second welding cycle time S22 of the second welding cycle S2, and a cooling cycle time C1 between the first welding cycle S1 and the second welding cycle S2. The plurality of welding parameters also include a pressure intensity P1, an initial pressure time P2 between the pressure rise time and the start time of the first welding cycle S1, and a holding time P3 between the pressure drop time and the end time of the second welding cycle S2.
[0084] Specifically, the first welding cycle current intensity S11 is the average current value between the first rising edge and the first falling edge of the current module signal A1. The first welding cycle time S12 is the time between the first rising edge and the first falling edge of the current module signal A1. The second welding cycle current intensity S21 is the average current value between the second rising edge and the second falling edge of the current module signal A1. The second welding cycle time S22 is the time between the second rising edge and the second falling edge of the current module signal A1. The cooling cycle time is the time between the first falling edge and the second rising edge of the current module signal A1. The pressure intensity P1 is the average pressure value between the rising edge and the falling edge of the pressure signal A2, the initial pressure time P2 is the time between the rising edge of the pressure signal A2 and the first rising edge of the current module signal A1, and the holding time P3 is the time between the falling edge of the pressure signal A2 and the second falling edge of the current module signal A1.
[0085] In other preferred embodiments, the current intensity sampling method is not limited to the average current value. For example, the current intensity S11 of the first welding cycle can also be the maximum or minimum current value between the first rising edge and the first falling edge of the current module signal A1; the current intensity S21 of the second welding cycle can also be the maximum or minimum current value between the second rising edge and the second falling edge of the current module signal A1; the pressure intensity P1 can also be the maximum or minimum pressure value between the rising edge and the falling edge of the pressure signal A2.
[0086] The above description is only a preferred embodiment of the present invention. Any equivalent changes made by applying the present invention specification and the scope of patent application should be included in the patent scope of the present invention.
Claims
1. A welding robot arm with a welding status monitoring system, characterized in that: Its structure includes: A welding robot arm comprises a robot body, the robot body is coupled to a welding clamp, the welding clamp comprises two welding clamp arms and a transmission element, the two welding clamp arms are driven by the transmission element to clamp or separate, and the ends of the two welding clamp arms are respectively provided with a welding head; the transmission element is electrically connected to a control module of an electric control system and is controlled by the electric control system, the electric control system comprises a welding power supply module, the welding power supply module is electrically connected to the two welding clamp arms, and provides power for welding when the two welding clamp arms are clamped; and A welding state monitoring system includes a current sensing module, a signal processing unit, and a signal transmission unit; the current sensing module is coupled to one of the welding clamp arms to measure a current module signal of the current size passing through the welding clamp arms when the two welding clamp arms drive the two welding heads to be clamped on two stacked plates for welding, and the current module signal includes multiple welding parameters; the signal processing unit is electrically connected to the current sensing module and receives the current module signal from the current sensing module for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the current module signal from the signal processing unit, and transmits the current module signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
2. The welding robot arm with a welding status monitoring system according to claim 1, characterized in that: When the welding clamp clamps the two overlapping plates, the electric control system controls the welding clamp to perform welding in a welding cycle; the multiple welding parameters include a welding cycle current intensity and a welding cycle time of the welding cycle.
3. The welding robot arm with a welding status monitoring system according to claim 1, characterized in that: When the welding clamp clamps the two overlapping plates, the electronic control system controls the welding clamp to perform welding in more than two welding cycles; multiple welding parameters include a welding cycle current intensity, a welding cycle time, and a cooling cycle time between the two welding cycles.
4. The welding robot arm with a welding status monitoring system according to claim 1, characterized in that: The welding state monitoring system has a transmission sensing module for measuring a pressure signal of the pressure magnitude of the two welding clamp arms driven by the transmission element when the two welding clamp arms drive the two welding heads to be clamped on the two stacked plates for welding; the signal processing unit is electrically connected to the transmission sensing module and receives the pressure signal for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the pressure signal, and transmits the pressure signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
5. The welding robot arm with a welding status monitoring system as claimed in claim 2, characterized in that: The welding state monitoring system has a transmission sensing module for measuring a pressure signal of the pressure magnitude of the two welding clamp arms driven by the transmission element when the two welding clamp arms drive the two welding heads to be clamped on the two stacked plates for welding; the signal processing unit is electrically connected to the transmission sensing module and receives the pressure signal for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the pressure signal, and transmits the pressure signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
6. The welding robot arm with a welding status monitoring system as claimed in claim 5, characterized in that: The signal processing unit fuses the current module signal with the pressure signal and draws a signal overlap graph according to time; the signal overlap graph includes multiple welding parameters, including a pressure intensity included in the pressure signal, an initial pressure time between the pressure rise time and the start time of the welding cycle, and a holding time between the pressure drop time and the end time of the welding cycle.
7. The welding robot arm with a welding status monitoring system as claimed in claim 3, characterized in that: The welding state monitoring system has a transmission sensing module for measuring a pressure signal of the pressure magnitude of the two welding clamp arms driven by the transmission element when the two welding clamp arms drive the two welding heads to be clamped on the two stacked plates for welding; the signal processing unit is electrically connected to the transmission sensing module and receives the pressure signal for analog-to-digital conversion; the signal transmission unit is electrically connected to the signal processing unit and receives the pressure signal, and transmits the pressure signal to the welding robot arm and the outside of the monitoring system in a wired or wireless manner.
8. The welding robot arm with a welding status monitoring system as claimed in claim 7, characterized in that: The signal processing unit fuses the current module signal with the pressure signal and draws a signal overlap graph according to time; the signal overlap graph includes multiple welding parameters, including a pressure intensity included in the pressure signal, an initial pressure time between the pressure rise time and the start time of the first welding cycle, a cooling time between the two welding cycles, and a holding time between the pressure drop time and the end time of the last welding cycle.