Welding process control method for full penetration weld

Abstract

The invention discloses a welding process control method for a full penetration weld, and relates to the technical field of welding, the method comprises the following steps: performing visual acquisition and self-attention identification on a welding target, and determining weld features; mining and establishing a welding condition library according to structure conditions and width-depth ratio conditions; traversing a welding condition library, and determining welding partitions by judging welding seam characteristics; a control mechanism of the welding equipment is interacted, double-step welding simulation is carried out in combination with the welding partition step, and a welding strategy is determined; the welding strategy responds to a control center of welding equipment, and automatic full penetration welding control is conducted on a welding target. The technical problems that in the prior art, manual filling is relied on, operation is unstable, variable working conditions are difficult to accurately adjust and cope with, welding precision and stability are poor, and product quality defects are caused are solved, and the technical effect of improving welding precision, stability and product quality is achieved.

Description

Technical Field

[0001] The present application relates to the technical field related to welding, and in particular to a welding process control method for a full penetration weld. Background Art

[0002] As a widely used connection process in the manufacturing industry, welding quality directly affects the strength, durability and safety of products. In recent years, with the continuous development of automation control technology and artificial intelligence technology, the accuracy and control level of welding process have been continuously improved. Full penetration welding, as a high-precision welding method, requires that the weld must be completely melted during the welding process to ensure the strength and consistency of the weld. However, traditional welding process control methods usually rely on manual operation, the back cleaning is unstable, and there is a lack of real-time monitoring and adjustment of the welding process, which can easily lead to poor welding accuracy and unstable welding quality. Especially in complex welding joints and large-scale production, welding defects occur frequently. How to solve the unstable welding quality and frequent defects in the welding process has become a problem that needs to be solved urgently.

[0003] At present, there are technical problems in welding process control related technologies, such as reliance on manual filling, unstable operation and difficulty in precise adjustment to cope with changing working conditions, resulting in poor welding accuracy and stability, and causing product quality defects. Summary of the invention

[0004] The present application provides a welding process control method for full penetration welds, thereby solving the technical problems in the prior art of relying on manual filling, unstable operation, and difficulty in precise adjustment to cope with changing working conditions, resulting in poor welding accuracy and stability and causing product quality defects, thereby achieving the technical effect of improving welding accuracy, stability and product quality.

[0005] The present application provides a welding process control method for a full penetration weld, comprising: performing visual acquisition and self-attention recognition on a welding target to determine weld features, wherein the weld features include geometric features; mining and establishing a welding condition library based on structural conditions and width-to-depth ratio conditions, wherein the structural feature-width-to-depth ratio-defect concentration feature is a condition sequence; traversing the welding condition library, and determining a welding partitioning step by determining the weld features; a control mechanism of an interactive welding device, performing a two-step welding simulation in combination with the welding partitioning step, and determining a welding strategy, wherein the two-step welding includes a one-step base filling welding and a two-step double-wire submerged arc welding, and the welding strategy has welding accuracy compensation; the welding strategy responds to a control center of the welding device to perform automated full penetration welding control on the welding target.

[0006] In a possible implementation, the mining and establishing of the welding condition library also performs the following processing: interacting with historical welding information, integrating and determining multiple historical sequences based on weld characteristics-welding effects; traversing the multiple historical sequences, performing clustering processing based on welding effects, and determining N clustering clusters; traversing the N clustering clusters, performing condition sequence mining, obtaining N condition sequences, concentrating the N condition sequences, and generating the welding condition library.

[0007] In a possible implementation, the N clusters are traversed to perform conditional sequence mining, and the following processing is further performed: a first cluster is identified to determine M weld features under a first welding effect; X structural conditions-width-depth ratio conditions are mined with the M weld features, and a first defect concentration feature is determined based on the first welding effect, where X is a positive integer less than or equal to M; and the X structural conditions-width-depth ratio conditions and the first defect concentration feature are mapped and integrated, and added into a first conditional sequence.

[0008] In a possible implementation, the welding zoning step is determined by judging the weld features, and the following processing is also performed: for the geometric features, the weld structural features are identified and matched based on the structural conditions to determine a first determination result, wherein the first determination result is whether there is a welding defect concentration area in the structure; the weld width-to-depth ratio is identified, and matched based on the width-to-depth ratio conditions to determine a second determination result, wherein the second determination result is a distribution feature of the welding defect concentration area; based on the first determination result and the second determination result, the welding zoning step is determined.

[0009] In a possible implementation, the step of determining the welding partitions also performs the following processing: if there is a welding defect concentration area, the welding partition step is the base filling weld area-double wire submerged arc welding area-double wire submerged arc penetration weld area, wherein the double wire submerged arc penetration weld area is determined based on the distribution characteristics of the welding defect concentration area; if there is no welding defect concentration area, the welding partition step is the base filling weld area-double wire submerged arc welding area.

[0010] In a possible implementation, a two-step welding simulation is performed in combination with the welding zoning step, and the following processing is also performed: for the base filling welding area, a one-step welding simulation is performed and compensation is performed based on the welding simulation effect to determine a one-step welding strategy; based on the one-step welding simulation effect, a two-step welding simulation is performed and compensation is performed based on the welding simulation effect to determine a two-step welding strategy, wherein the two-step welding simulation includes double-wire submerged arc welding and double-wire submerged arc penetration welding; the one-step welding strategy and the two-step welding strategy are integrated in time to determine the welding strategy.

[0011] In a possible implementation, the welding strategy has welding accuracy compensation, and also performs the following processing: obtaining the welding accuracy standard of the control mechanism; for the one-step base filling welding, dividing the first control element and the second control element, performing an outward expansion processing of the welding accuracy standard on the first control element, and performing an inward contraction processing of the welding accuracy standard on the second control element, wherein the first control element is a distribution element of base filling; for the two-step double-wire submerged arc welding, the welding accuracy standard is expanded outward.

[0012] In a possible implementation, the welding target is automatically controlled for full penetration welding, and the following processing is also performed: welding monitoring is performed synchronously with the braking of the welding equipment; control constraint management is performed based on the partition welding effect, wherein the control constraint management includes two-step welding compensation or one-step welding delay; welding management features are located and traced, and if they are non-accidental features, they are marked as welding compensation elements.

[0013] The welding process control method for full penetration weld proposed in this application is intended to perform visual acquisition and self-attention recognition on the welding target to determine the weld characteristics; mine and establish a welding condition library based on structural conditions and width-to-depth ratio conditions; traverse the welding condition library to determine the welding partitioning steps by judging the weld characteristics; the control mechanism of the interactive welding equipment is combined with the welding partitioning steps to perform two-step welding simulation to determine the welding strategy; the welding strategy responds to the control center of the welding equipment to perform automated full penetration welding control on the welding target. It solves the technical problems existing in the prior art that rely on manual filling, unstable operation, and difficulty in precise adjustment to cope with variable working conditions, resulting in poor welding accuracy and stability, and causing product quality defects, and achieves the technical effect of improving welding accuracy, stability and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0015] Figure 1 A schematic flow chart of a welding process control method for a full penetration weld provided in an embodiment of the present application;

[0016] Figure 2 A schematic diagram of a flow chart for establishing a welding condition library in a welding process control method for a full penetration weld provided in an embodiment of the present application. DETAILED DESCRIPTION

[0017] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0018] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0019] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict, and the terms "first\second" involved are merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "including" and "having" and any variations are intended to cover non-exclusive inclusions, for example, a process, method, product, or server that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by technicians in the technical field of this application. The terms used herein are for the purpose of describing the embodiments of the present application only.

[0020] The present application embodiment provides a welding process control method for a full penetration weld, such as Figure 1 As shown, the method includes:

[0021] Step S100, performing visual acquisition and self-attention recognition on the welding target to determine the weld features, wherein the weld features include geometric features.

[0022] Preferably, a visual sensor (such as a camera or a video camera) is used to monitor the welding process in real time, and the acquired image data is analyzed and processed through a self-attention mechanism to identify and extract weld features, wherein the weld features include geometric features. Specifically, the welding target is visually captured to obtain a welding image, and then the pixels of the welding image are weighted by self-attention recognition to more efficiently extract key information from the image. Self-attention recognition can focus on specific areas in the image (such as certain key parts of the weld) and ignore other irrelevant parts, thereby improving the accuracy of weld feature recognition, especially in complex welding environments, and can effectively screen and capture valuable geometric feature information. The weld features mainly include weld contours, The width and height of the weld and the geometric shape of the weld. The shape of the weld is one of the important bases for judging the welding quality. Through visual acquisition, the edge shape of the weld can be obtained, and further analyzed whether it meets the preset welding requirements, for example, whether the weld is uniform, whether it has abnormal shape (such as too large, too small or deviates from the predetermined trajectory, etc.); the width and height of the weld are important geometric parameters that affect the welding strength and quality of the weld. The real-time collection of weld width and height data can ensure that the weld size meets the design requirements; the geometric shape of the weld includes the symmetry of the weld, whether the shape is regular, etc. Judging the geometric changes of the weld at different positions can ensure the uniformity and quality of welding.

[0023] Step S200, mining and establishing a welding condition library based on structural conditions and width-to-depth ratio conditions, wherein the condition sequence is structural feature-width-to-depth ratio-defect concentration feature.

[0024] Preferably, a systematic welding condition library is established by deeply exploring and analyzing the structural characteristics of different welding targets, the geometric parameters of the weld (such as the aspect ratio), and the relationship between these parameters and welding defects. The condition sequence of structural characteristics-aspect ratio-defect concentration characteristics means that in the process of selecting welding process conditions, these factors need to be considered in sequence, so as to effectively prevent common welding defects and improve welding quality and efficiency. Specifically, the structural conditions usually refer to the characteristics of the welding joint such as the geometry, size and material type, including the type of welding joint, for example, different types of welding joints such as corner joints, butt joints, and T-joints have different requirements for welding process; the thickness of the joint, the thickness of the welding joint will affect the welding heat input, welding speed and other parameters, and thus affect the welding quality; the material of the joint, the welding of different materials (such as steel, aluminum, titanium alloy, etc.) has different requirements for the welding process, and the heat conduction, welding difficulty, molten pool behavior, etc. of the welding process will be different; the geometry and configuration of the joint, such as whether the welding position is complex, whether the angle is special, etc., the shape and configuration of the joint affect the heat input and molten pool control during welding.

[0025] Preferably, the aspect ratio refers to the ratio of the width to the depth of the weld. The aspect ratio is directly related to the stability of the welding process and the quality of the weld, and affects the strength and stability of the weld. The aspect ratio is usually used to describe the appearance characteristics of the weld. The visual acquisition technology can be used to monitor and calculate the aspect ratio in real time to ensure that the molten pool control during the welding process meets the standards and avoid welds that are too deep or too shallow. Especially in full penetration welding, the depth and width of the weld are one of the important criteria for evaluating welding quality. A too large aspect ratio may lead to excessive heat input, resulting in cracks and deformation problems in the weld; while a too small aspect ratio may result in incomplete welding or insufficient weld strength. Defect concentration characteristics refer to the distribution patterns and characteristics of welding defects (such as pores, cracks, lack of fusion, lack of filling, weld cracks, etc.) under different welding conditions. By analyzing the types, locations and causes of defects that may occur during the welding process, it can help optimize the welding process and reduce the probability of defects. Different structural conditions (such as joint shape, material type, etc.) may have different effects on the occurrence of welding defects. For example, certain structural shapes are prone to stress concentration, which in turn causes cracks; defect concentration characteristics can help identify under which welding conditions a certain defect is more likely to occur, thereby providing guidance for optimizing the welding process. For example, under a specific width-to-depth ratio, problems such as pores may be more likely to occur.

[0026] Preferably, the welding condition library is a process database established by mining the relationship between the above-mentioned different factors, mainly including combinations of different structural conditions, aspect ratio conditions and defect concentration characteristics and corresponding optimal welding parameters. Specifically, according to the structural conditions and geometric characteristics (including aspect ratio) of the welding target, the most suitable welding parameters (such as welding current, voltage, welding speed, etc.) can be selected from the welding condition library. By combining with real-time visual acquisition and intelligent control, the appropriate welding strategy can be automatically selected from the welding condition library according to the real-time characteristics of the weld, thereby improving the accuracy and stability of the welding process. Moreover, through optimization based on the welding condition library, the welding process can be preventively adjusted for potential defects under specific structures and aspect ratio conditions, thereby effectively preventing common welding defects and improving the overall welding quality.

[0027] Further, such as Figure 2 As shown, step S200 also includes step S210, interacting with historical welding information, integrating and determining multiple historical sequences based on weld characteristics-welding effects; step S220, traversing the multiple historical sequences, performing clustering processing based on welding effects, and determining N clustering clusters; step S230, traversing the N clustering clusters, performing condition sequence mining, obtaining N condition sequences, concentrating the N condition sequences, and generating the welding condition library.

[0028] Preferably, data such as welding parameters, weld geometry, defect types, and welding effects are obtained from historical welding information and integrated into multiple historical sequences based on weld characteristics and welding effects, that is, these historical data are combined into different historical sequences according to weld characteristics and welding effects, wherein the welding effect includes quality indicators in the welding process, such as weld strength, hardness, defects (such as pores, cracks, etc.), etc.; all historical welding data (i.e., weld characteristics-welding effect sequences) are processed and analyzed one by one, and the welding effects are analyzed by clustering algorithms (such as K-means, hierarchical clustering, etc.), and sequences with similar welding effects are clustered together. The clustering standard is usually the welding effect, such as welding quality, defect type, weld shape, etc. Different welding processes are divided into several categories according to their effects. For example, if the result of a welding condition usually produces fewer defects and better weld morphology, it is classified into a cluster cluster.

[0029] Preferably, all historical welding sequences are divided into N different clusters, each cluster represents a group of process data with similar welding effects, wherein N is a positive integer, and N clusters indicate that there are N groups of welding conditions in the final result of clustering, which have similar welding effects; each cluster is further analyzed to extract effective information in each cluster, especially key conditions that can affect the welding effect. Specifically, condition sequence mining refers to mining a group of process condition sequences within each cluster, which refers to a specific set of parameters that affect the welding effect. For example, for a cluster, it may be found that a combination of welding current, voltage, and welding speed can produce a better welding effect. Finally, N condition sequences are obtained, that is, the representative welding process sequence of each cluster. The condition sequences mined from all N clusters are concentrated to generate a welding condition library, which includes a variety of different welding process conditions and their corresponding welding effects, which is helpful to select the best process conditions in different welding tasks, reduce the incidence of welding defects, and improve welding quality.

[0030] Further, step S230 also includes step S231, identifying a first cluster, and determining M weld features under a first welding effect; step S232, using the M weld features, mining X structural conditions-width-to-depth ratio conditions, and determining a first defect concentration feature based on the first welding effect, where X is a positive integer less than or equal to M; step S233, mapping and integrating the X structural conditions-width-to-depth ratio conditions and the first defect concentration feature, and adding them into a first condition sequence.

[0031] Preferably, a first cluster is identified from the clustering results, and information related to weld characteristics is further extracted according to the welding effects contained in the cluster, that is, M weld characteristics under the first welding effect are determined, such as weld width, depth, penetration, weld pool shape and other geometric or morphological characteristics of the weld.

[0032] Wherein, M is a positive integer; according to the M weld features in the first cluster, a set of combinations of structural conditions and width-to-depth ratio conditions are further analyzed and mined, that is, from the M weld features, combined with the structural characteristics and width-to-depth ratio of the welding target, a series of process conditions (such as specific welding current, welding speed, heat input, etc.) are obtained, X represents the number of mined structural conditions and width-to-depth ratio conditions, and X≤M means that the number of mined conditions is at most M.

[0033] Preferably, based on the analysis results of the welding effect in the first cluster, a feature set that may cause welding defects is determined, namely, a first defect concentration feature, wherein the welding defects may include cracks, pores, slag inclusions, lack of fusion, etc. The first defect concentration feature refers to a specific defect type that may occur and is related to the welding effect in the first cluster. Then, the mined X-item structural conditions and width-to-depth ratio conditions are associated with the first defect concentration feature to form a new comprehensive condition set. Specifically, the relationship between welding conditions and welding defects is mapped out so as to avoid or reduce the occurrence of defects in actual welding. For example, certain specific structural conditions (such as welding angle, weld joint form) and width-to-depth ratio conditions (such as welding current, voltage, etc.) may have a strong correlation with certain specific types of defects (such as pores and cracks). Through these mapping relationships, more accurate welding process conditions can be formed. Finally, the integrated welding conditions and defect feature information are added to the first condition sequence. The first condition sequence is a condition set optimized for the first welding effect and welding defects to ensure high-quality welding.

[0034] Step S300, traversing the welding condition library, and determining the welding partitioning step by determining the weld characteristics.

[0035] Preferably, in welding process control, the established welding condition library is used to judge and determine the appropriate welding zoning scheme according to the weld characteristics (such as geometric characteristics, defect distribution, etc.) obtained in real time, that is, the weld characteristics (such as weld geometry, defect information, etc.) are matched with the contents in the welding condition library, and the appropriate zoning strategy is selected to reasonably divide the welding area into different welding zones, and the corresponding welding process is applied in each zone to ensure welding quality and efficiency. Specifically, according to the geometric characteristics of the weld, defect information, etc., suitable welding conditions are selected from the welding condition library, which may include welding current, voltage, welding speed, heat input, etc. According to the characteristics of different areas of the welding target, the welding strategy for different areas is determined. For example, more heat input may be required in some areas (such as the weld root), while less heat input is required in other areas (such as the weld surface or the outside of the joint). In addition to determining the zoning, it is also necessary to consider the welding sequence and the two-step welding strategy (such as first performing bottom layer welding and then performing surface layer welding), etc. These steps can help reduce welding stress, deformation and welding defects.

[0036] Preferably, through real-time determination of weld characteristics, important information about the welding process status can be obtained, and appropriate process parameters and welding zoning steps can be selected accordingly. The welding zoning step refers to dividing the welding area into several parts according to different characteristics and needs, and each part (i.e., partition) adopts a different welding process or strategy. For example, some areas may require higher heat input, and other areas may require lower heat input to avoid deformation. The welding zoning step helps to accurately control heat input, welding sequence and welding strategy in a complex welding environment to ensure the final welding quality. By reasonably dividing the welding area and taking targeted welding steps, not only can the welding quality be ensured, but also the welding efficiency can be improved and common welding defects can be avoided.

[0037] Furthermore, step S300 also includes step S310, identifying the weld structural features for the geometric features and matching them based on the structural conditions to determine a first judgment result, wherein the first judgment result is whether there is a welding defect concentration area in the structure; step S320, identifying the weld width-to-depth ratio, and matching them based on the width-to-depth ratio conditions to determine a second judgment result, wherein the second judgment result is a distribution characteristic of the welding defect concentration area; and step S330, determining a welding zoning step based on the first judgment result and the second judgment result.

[0038] Preferably, the welding partition is optimized and controlled according to the geometric characteristics, structural conditions, width-to-depth ratio and defect characteristics of the weld during the welding process. Specifically, the structural characteristics of the weld are identified according to the determined geometric characteristics of the weld, such as the transition zone of the weld, the shape change of the weld, the hierarchical distribution of the weld, etc., and the geometric characteristics of the weld (such as the width, depth, shape, etc. of the weld) are analyzed and matched with the pre-set structural conditions (such as the type of welding joint, angle, joint size, etc.). The result after matching is to determine whether there is a defect concentration area in the welding structure, which is the first judgment result. For example, the weld is deep, and the structure is a triangular structure, an irregular structure, etc., and there is a welding blind area, that is, some positions cannot be covered. In the covering stage, the penetration depth is compensated; if the weld is shallow, or the bottom is a square, arc-shaped or other structure, there will be no welding blind area, and this step can be omitted. The defect concentration area refers to an area where defects are prone to occur in the welding process due to improper welding conditions or structural problems. For example, some parts of the weld may have too many defects such as pores and cracks due to complex structure and uneven heat input.

[0039] Preferably, the aspect ratio is matched according to the aspect ratio characteristics of the weld in combination with the process conditions (such as welding current, speed, etc.), that is, by analyzing the aspect ratio of the weld, it is determined whether it meets the optimal welding conditions. Too large or too small aspect ratio may lead to welding defects. By matching the aspect ratio conditions, the distribution characteristics of the welding defect concentration area are determined, that is, the second judgment result is determined, wherein the second judgment result is to determine the distribution of welding defects in the weld through the analysis of the aspect ratio. For example, an area with too large aspect ratio may lead to uneven cooling of the molten pool, and then cracks are generated in the welding part; while an area with too small aspect ratio may lead to insufficient joint strength; the first judgment result is combined with the second judgment result. , determine the welding zoning steps. The occurrence of welding defects is closely related to the temperature distribution in the welding area, the shape of the weld, and the welding process parameters (such as current, voltage, welding speed, etc.). By judging whether there is a defect concentration area in the structure (the first judgment result) and the distribution characteristics of the defects (the second judgment result), the entire welding area can be divided into different welding zones, and different welding strategies can be formulated according to these zones. For example, some areas may require more heat input, while some areas need to control the cooling rate. Based on this information, it can be decided to adopt different welding processes (such as different welding currents, welding speeds, etc.) in the defect concentration area for compensation, thereby optimizing the welding effect and reducing defects.

[0040] Further, step S300 also includes step S340, if there is a welding defect concentration area, the welding zoning step is the bottom filling weld area-double wire submerged arc welding area-double wire submerged arc penetration weld area, wherein the double wire submerged arc penetration weld area is determined based on the distribution characteristics of the welding defect concentration area; step S350, if there is no welding defect concentration area, the welding zoning step is the bottom filling weld area-double wire submerged arc welding area.

[0041] Preferably, different welding zoning steps are determined according to the presence or absence of welding defect concentration areas, so as to optimize the welding process and quality. If there are defect concentration areas during the welding process, the welding zoning steps are base filling welding area-double-wire submerged arc welding area-double-wire submerged arc deep penetration welding area. The base filling welding area is the first stage in the welding process, which uses a lower welding current to fill part of the weld area to ensure the basic structural stability of the weld joint; double-wire submerged arc welding is the second stage, which uses two welding wires to work simultaneously and performs welding with higher heat input in the main welding area to ensure the overall strength of the weld; double-wire submerged arc deep penetration welding area It is to further strengthen the welding defect concentration area, that is, to optimize the welding effect by increasing the penetration depth. It is usually used to repair or avoid problems caused by insufficient heat input in the welding defect concentration area. By increasing the penetration depth, it ensures good welding of the weld and reduces local defects. Among them, the double-wire submerged arc penetration welding area is determined based on the distribution characteristics of the welding defect concentration area. Specifically, the distribution characteristics of the welding defect concentration area may affect the heat input of the welding, the stability of the molten pool, etc. By analyzing the distribution of the welding defect area, the area where the penetration depth needs to be strengthened is determined to avoid local defects such as cracks and pores due to low heat input.

[0042] Preferably, if no defect concentration area is detected during the welding process, that is, there is no obvious quality problem or unstable area during the welding process, the welding process is simplified, and the welding zoning steps are the base filling welding area-double wire submerged arc welding area, that is, the base filling welding is still the first step of the welding process, providing a basis for the next welding layer, and ensuring the stability and quality of the joint under reasonable heat input, and then entering the double wire submerged arc welding stage, the double wire submerged arc welding technology is used for the main welding area. Through this zoning strategy, the welding process can be accurately adjusted according to the defect situation of the welding area, the welding quality and efficiency can be improved, and the occurrence of defects can be reduced.

[0043] Step S400, the control mechanism of the interactive welding equipment performs a double-step welding simulation in combination with the welding partitioning step to determine the welding strategy, wherein the double-step welding includes a one-step base filling welding and a two-step double-wire submerged arc welding, and the welding strategy has welding accuracy compensation.

[0044] Preferably, the welding process is optimized through the intelligent control mechanism of the welding equipment according to the welding zoning strategy and through the double-step welding simulation, especially in complex structures or large-size welding tasks, thereby improving the welding quality and efficiency. Specifically, the welding equipment can interact with the control system in real time, and automatically adjust its working parameters according to the data feedback in the welding process (such as weld characteristics, temperature distribution, welding current, voltage, etc.) to achieve precise welding operation. The interactive control mechanism usually includes a combination of visual systems, sensors and computer algorithms, which can monitor various factors in the welding process (such as welding pool state, weld morphology, etc.) in real time, and adjust the operation of the equipment according to these data, for example, welding current, welding speed and welding sequence, etc., and can also adjust the welding strategy based on the real-time characteristics of the target weldment (such as weld geometry, defect monitoring, etc.) through combination with the welding condition library, to ensure the accuracy and quality of the welding process and significantly improve the stability of the welding process.

[0045] Preferably, two-step welding simulation is to simulate the effects of the two-step welding process by simulation technology before actual welding, verify the rationality of welding parameters, predict welding quality, and further optimize process parameters. The heat distribution, stress changes, molten pool dynamics, etc. in the welding process can be simulated by computer to ensure that no unnecessary defects will occur in the actual welding process. Among them, two-step welding means that the welding process is divided into two steps, and the welding method and purpose of each step are different. It is usually suitable for scenes with high requirements on welding accuracy or complex welding target structures, including one-step base filling welding and two-step double-wire submerged arc welding. One-step base filling welding usually refers to using a lower welding temperature first in the welding process. The welding heat input is used for preliminary welding filling. The purpose of base filling welding is to form a preliminary weld foundation at the joint first. Usually a lower heat input is required to avoid deformation or cracks caused by excessive heat. Base welding usually uses a single welding wire and generally has a higher welding speed; two-step double-wire submerged arc welding usually adopts higher heat input and double-wire welding technology (that is, two welding wires are used for welding at the same time). This process improves welding quality and depth by increasing heat input. It is especially suitable for large-area or deep-melting welding tasks. The heat input of double-wire submerged arc welding is more uniform, which can increase the welding speed while maintaining good welding quality and reducing defects that may occur during the welding process.

[0046] Preferably, after simulating the two-step welding, the welding strategy is determined according to the simulation results, which usually includes optimizing the heat input of each welding partition by region according to the welding partition steps. The heat input of different regions will affect the welding penetration, molten pool morphology, weld geometry and the occurrence of welding defects; the best welding sequence and process parameters (such as current, voltage, welding speed, etc.) are determined through the simulation results, especially to ensure that after the first step of base filling welding is completed, the second step of double-wire submerged arc welding can be carried out smoothly to avoid defects such as lack of fusion, cracks or pores; in the two-step welding process, the thermal cycle during the welding process may cause deformation or internal stress of the welded parts. The welding strategy needs to consider how to reduce welding deformation by adjusting the welding sequence, heat input and welding parameters, or Appropriate stress compensation is performed during the welding process; and welding accuracy compensation, wherein welding accuracy compensation refers to adjusting the welding process according to the real-time feedback information from the equipment during the welding process to ensure the welding quality and the accuracy of the target size, including real-time adjustment of welding current, voltage, welding speed and other parameters to compensate for errors caused by insufficient or excessive heat input to ensure that the welding quality meets the requirements; according to the real-time monitoring data during the welding process, the welding sequence, speed and other parameters are adjusted to minimize or correct deformations such as warping and shrinkage; according to the characteristics of the welding partition, the welding parameters are adjusted in time to ensure that the final weld shape (such as width, depth, appearance, etc.) meets the design requirements, significantly improve the welding quality, reduce welding defects, and improve the stability of the welding process.

[0047] Furthermore, step S400 also includes step S410, performing a one-step welding simulation on the base filling welding area and compensating based on the welding simulation effect to determine a one-step welding strategy; step S420, taking the one-step welding simulation effect as a benchmark, performing a two-step welding simulation and compensating based on the welding simulation effect to determine a two-step welding strategy, wherein the two-step welding simulation includes double-wire submerged arc welding and double-wire submerged arc penetration welding; step S430, time-sequentially integrating the one-step welding strategy and the two-step welding strategy to determine the welding strategy.

[0048] Preferably, a one-step welding simulation is performed on the base filling welding area to predict various parameters and their possible influences in the base filling welding process, such as the temperature distribution of the molten pool, the cooling rate, the weld shape, etc., and the welding process is optimized. The possible errors in the welding process (such as temperature unevenness, deformation, weld size, etc.) are analyzed through the simulation results, that is, these errors are corrected by adjusting the welding parameters (such as current, welding speed, wire feed speed, etc.), and the one-step welding strategy is determined according to the simulation results and their compensation adjustments; after completing the base filling welding, a two-step welding simulation is performed to evaluate the effects of depth of penetration, heat input, etc. during the welding process, and the simulation results are used to perform Compensation adjustment may include adjusting parameters such as current, welding speed, and wire feed speed to ensure that the welding effect meets the expected quality standards. According to the two-step welding simulation and compensation results, the two-step welding strategy is determined to ensure that double-wire submerged arc welding and double-wire submerged arc penetration welding can effectively reduce defects and ensure welding quality in actual operation; the one-step welding strategy and the two-step welding strategy are integrated in time to ensure their sequence and coordination in the actual welding process, to ensure that the transition between each step is smooth, to avoid problems such as temperature stress and weld deformation, and finally to determine the welding strategy to make the entire welding process more efficient and precise, and ultimately achieve ideal welding quality.

[0049] Furthermore, step S400 also includes step S440, obtaining the welding accuracy standard of the control mechanism; step S450, dividing the first control element and the second control element for the one-step base filling welding, performing an outward expansion processing on the first control element and performing an inward contraction processing on the second control element, wherein the first control element is a distribution element of base filling; step S460, performing an outward expansion processing on the welding accuracy standard for the two-step double-wire submerged arc welding.

[0050] Preferably, the welding accuracy standard of the control mechanism is obtained, that is, the acceptable welding quality range is determined, including the appearance requirements of the welding joint (such as weld width and thickness), and the defect tolerance during the welding process (such as pores, cracks, etc.), wherein the welding accuracy standard refers to the quality control standard set during the welding process, such as the size of the weld, the strength of the weld joint, the control of the penetration depth, the appearance of the weld, etc., and then for the one-step base filling welding, the first control factor and the second control factor are divided, wherein the first control factor refers to the distribution factor of the base filling, that is, the distribution of the welding molten pool during the welding process, the shape of the weld, etc., and the second control factor refers to the weld quality factor of the base filling, such as the flatness and depth of the weld.

[0051] Preferably, the first control element is subjected to an external expansion process of the welding accuracy standard, that is, on the basis of ensuring the welding accuracy, the requirements for the first control element are relaxed so that it can be changed within a certain range to adapt to the uncertainty in the welding process. The double-wire submerged arc is performed on the welding result of the base filling, which can compensate for the filling defects to a certain extent, such as the surface state of the filling, etc. These do not need to be considered. It is only necessary to ensure the distribution of the filling area of ​​the welding. For example, in the base filling stage, the distribution of the welding molten pool and the shape of the weld may fluctuate. The external expansion process leaves a certain tolerance range for these fluctuations to avoid unnecessary frequent adjustments due to strict requirements; the second control element is subjected to an internal contraction process of the welding accuracy standard, tightening the requirements for certain control elements, that is, limiting the range of variation of these elements to ensure more accurate welding quality. For the double-wire submerged arc, the requirements for the connection state of the welding part with the original component, surface welding, etc. are relatively high. For example, the depth or width of the weld is required not to exceed a specific range, because a weld that is too deep or too wide will affect the strength and appearance of the welded joint.

[0052] Preferably, for two-step twin-wire submerged arc welding, the welding accuracy standard is expanded. Specifically, there are certain control errors in actual control, such as position errors caused by vibration, which are different from the ideal effect in the simulation. The expansion process refers to appropriately relaxing the welding accuracy standard so that certain elements in the welding process (such as heat input, molten pool depth, etc.) can vary within a certain range to adapt to the actual situation in the welding process, so as to ensure that even if there are certain errors in actual operation, the welding effect still meets the standard, avoid the difficulty of process adjustment due to strict standards, and thus improve the stability of the welding process.

[0053] Step S500: the welding strategy responds to the control center of the welding equipment to perform automatic full penetration welding control on the welding target.

[0054] Preferably, during the welding process, the control system of the welding equipment will automatically adjust various parameters in the welding process (such as current, voltage, welding speed, etc.) according to the preset welding strategy and real-time feedback to ensure full penetration welding, and maintain high precision and high stability throughout the process, and finally meet the welding quality requirements. Specifically, the control system of the welding equipment (usually including computers, sensors, actuators, etc.) can receive data feedback in real time during the welding process, and automatically adjust the welding process according to the preset welding strategy, and perform automatic full penetration welding control on the welding target, wherein full penetration welding (Full Penetration Welding) means that during the welding process, the weld completely penetrates the thickness of the welded material to form a firm welded joint. Full penetration welding is usually used in occasions with high welding requirements, requiring the depth of the molten pool to completely penetrate the thickness of the workpiece, thereby ensuring the strength and structural integrity of the welded joint; automatic full penetration welding control means that the welding equipment control system does not rely on manual intervention, and in a highly automated manner, according to the characteristics of the welding target, the weld characteristics and the real-time feedback data, intelligently adjusts various parameters in the welding process to ensure that the welded joint achieves full penetration welding.

[0055] Furthermore, step S500 also includes step S510, synchronously performing welding monitoring as the welding equipment is braked; step S520, performing control constraint management based on the partition welding effect, wherein the control constraint management includes two-step welding compensation or one-step welding delay; step S530, locating the welding management feature and tracing it, and if it is a non-accidental feature, it is marked as a welding compensation factor.

[0056] Preferably, the braking of the welding equipment refers to the pause, deceleration and adjustment during the welding or welding control process. For example, when an abnormality occurs in the welding process (such as excessive temperature, overcooling, etc.), the equipment may slow down or pause in order to adjust the welding parameters and perform synchronous welding detection on the welding process, which usually includes temperature monitoring, penetration detection, weld formation analysis, etc., and control constraint management is performed based on the partition welding effect (the actual effect after welding in each area, including parameters such as weld size, quality, penetration, etc.) as a benchmark, that is, the management strategy of welding parameters and processes during the welding process to ensure that the welding quality meets the predetermined standards, wherein the control constraint management includes two-step welding compensation or one-step welding delay. For example, after one step is completed, the effect does not meet the expectations, which can be compensated by two steps, or the time of one step can be extended to meet the standards; specifically, the two-step welding compensation is to adjust the welding speed, temperature or current, etc. to ensure the welding quality, and the one-step welding delay is to appropriately delay or adjust the welding time, that is, by adjusting the time, the cooling rate of the molten pool can be affected, thereby improving the welding quality.

[0057] Preferably, at the same time, the factors that cause its existence are traced to make decisions for other subsequent welding, that is, specific welding management features (such as welding defects, uneven penetration, etc.) in the positioning welding process are traced back to the causes of these features, which may be caused by welding process, equipment problems, improper operation and other factors. Some features (such as local defects in welds, overheating or uneven cooling, etc.) may be caused by accidental factors, and those recurring and regular features are called non-accidental features, which are marked as welding compensation factors, that is, factors that need to be compensated. For example, if the depth of the molten pool is too shallow due to equipment errors, it is necessary to adjust the welding parameters according to this compensation factor, which may include adjusting the welding current, welding speed, etc., to ensure that the welding quality is always kept within the qualified range and avoid quality degradation due to recurring problems.

[0058] The above specific implementation manner does not constitute a limitation to the protection scope of the present application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be performed in an order different from that in the embodiment and can still achieve the desired results. In addition, the process depicted in the accompanying drawings does not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. A welding process control method for a full penetration weld, characterized in that: The method comprises: Performing visual acquisition and self-attention recognition on the welding target to determine the weld features, wherein the weld features include geometric features; Based on the structural conditions and width-to-depth ratio conditions, the welding condition library is mined and established, in which the structural characteristics-width-to-depth ratio-defect concentration characteristics are used as the condition sequence; Traversing the welding condition library, and determining the welding partitioning steps by determining the weld characteristics; The control mechanism of the interactive welding equipment is combined with the welding partitioning steps to perform double-step welding simulation and determine the welding strategy, wherein the double-step welding includes a one-step backfill welding and a two-step double-wire submerged arc welding, and the welding strategy has welding accuracy compensation; The welding strategy is responsive to a control center of the welding equipment to perform automated full penetration welding control on the welding target.

2. A welding process control method for a full penetration weld as claimed in claim 1, characterized in that: The mining and establishment of welding condition library includes: Interactive historical welding information, integrating and determining multiple historical sequences based on weld characteristics and welding effects; Traversing the multiple historical sequences, performing clustering processing based on welding effects, and determining N clusters; The N clusters are traversed to perform condition sequence mining to obtain N condition sequences, and the N condition sequences are concentrated to generate the welding condition library.

3. A welding process control method for a full penetration weld as claimed in claim 2, characterized in that: Traversing the N clusters, and performing conditional sequence mining, including: Identify a first cluster and determine M weld features under a first welding effect; Using the M weld features, mining X structural conditions - width-to-depth ratio conditions, and determining a first defect concentration feature based on the first welding effect, where X is a positive integer less than or equal to M; The X-item structural condition - the aspect ratio condition and the first defect concentration feature are mapped and integrated, and added into a first condition sequence.

4. A welding process control method for a full penetration weld as claimed in claim 1, characterized in that: The step of determining the welding zone by determining the weld characteristics comprises: According to the geometric features, the weld structure features are identified and matched based on the structural conditions to determine a first determination result, wherein the first determination result is whether there is a welding defect concentration area in the structure; Identify the width-to-depth ratio of the weld, and match based on the width-to-depth ratio condition to determine a second determination result, wherein the second determination result is a distribution feature of a welding defect concentration area; Based on the first determination result and the second determination result, a welding partitioning step is determined.

5. The welding process control method for a full penetration weld according to claim 1, characterized in that: The step of determining the welding partition comprises: If there is a welding defect concentration area, the welding zoning step is the bottom filling welding area-double wire submerged arc welding area-double wire submerged arc penetration welding area, wherein the double wire submerged arc penetration welding area is determined based on the distribution characteristics of the welding defect concentration area; If there is no concentrated area of ​​welding defects, the welding zoning step is base filling welding area-double wire submerged arc welding area.

6. A welding process control method for a full penetration weld as claimed in claim 5, characterized in that: Combining the welding partitioning steps, a double-step welding simulation is performed, including: For the base filling welding area, one-step welding simulation is performed and compensation is performed based on the welding simulation effect to determine a one-step welding strategy; Based on the one-step welding simulation effect, a two-step welding simulation is performed and compensation is performed based on the welding simulation effect to determine a two-step welding strategy, wherein the two-step welding simulation includes double-wire submerged arc welding and double-wire submerged arc penetration welding; The one-step welding strategy and the two-step welding strategy are sequentially integrated to determine the welding strategy.

7. A welding process control method for a full penetration weld as claimed in claim 1, characterized in that: The welding strategy includes welding accuracy compensation, including: obtaining a welding accuracy standard of the control mechanism; For the one-step base filling welding, a first control element and a second control element are divided, the first control element is subjected to an outward expansion process of the welding precision standard, and the second control element is subjected to an inward contraction process of the welding precision standard, wherein the first control element is a distribution element of the base filling; For the two-step twin-wire submerged arc welding, the welding accuracy standard is expanded.

8. A welding process control method for a full penetration weld as claimed in claim 1, characterized in that: Automated full penetration welding control is performed on the welding target, including: With the braking of the welding equipment, welding monitoring is performed synchronously; Based on the zoned welding effect, control constraint management is performed, wherein the control constraint management includes two-step welding compensation or one-step welding delay; Locate welding management features and trace them back to their source. If they are non-accidental features, mark them as welding compensation elements.

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