A Welding Process Control Method for Full Penetration Welds

Abstract

The present invention discloses a welding process control method for full penetration welds, which relates to the field of welding technology. The method includes: visually collecting and self-attention identifying a welding target to determine weld features; mining and establishing a welding condition library based on structural conditions and width-depth ratio conditions; traversing the welding condition library, determining welding partition steps by judging weld features; interacting with the control mechanism of welding equipment, and performing two-step welding simulation in combination with the welding partition steps to determine a welding strategy; the welding strategy responds to the control center of the welding equipment to perform automatic full penetration welding control on the welding target. It solves the technical problems existing in the prior art, such as relying on manual filling, unstable operation and difficult to precisely adjust to cope with variable working conditions, resulting in poor welding accuracy and stability and causing product quality defects, and achieves the technical effects of improving welding accuracy, stability and product quality.

Description

Technical Field

[0001] This application relates to the technical field of welding, and in particular, to a welding process control method for full penetration welds. Background Art

[0002] Welding, as a widely used joining process in manufacturing, its 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 processes have been continuously improved. As a high-precision welding method, full penetration welding 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, with unstable back gouging, lack of real-time monitoring and adjustment during the welding process, which easily leads to poor welding accuracy and unstable welding quality. Especially in complex welding joints and large-scale production, the occurrence frequency of welding defects is relatively high. How to solve the problems of unstable welding quality and frequent defects in welding processes has become an urgent problem to be solved.

[0003] In the current related technologies of welding process control, there are technical problems such as relying on manual filling, unstable operation, and difficulty in precisely adjusting to cope with variable working conditions, resulting in poor welding accuracy and stability, and causing product quality defects. Summary of the Invention

[0004] This application provides a welding process control method for full penetration welds, which solves the technical problems in the prior art, such as relying on manual filling, unstable operation, and difficulty in precisely adjusting to cope with variable working conditions, resulting in poor welding accuracy and stability, and causing product quality defects, and achieves the technical effects of improving welding accuracy, stability, and product quality.

[0005] This application provides a welding process control method for full penetration welds, including: visually collecting and self-attention identifying a welding target to determine weld features, where the weld features include geometric features; mining and establishing a welding condition library based on structural conditions and width-depth ratio conditions, where the condition sequence is structural feature - width-depth ratio - defect concentration feature; traversing the welding condition library, determining welding partition steps by judging the weld features; interacting with the control mechanism of the welding equipment, and performing two-step welding simulation in combination with the welding partition steps to determine a welding strategy, where two-step welding includes one-step backing filling welding and two-step twin-wire submerged arc welding, and there is a welding accuracy compensation in the welding strategy; the welding strategy responds to the control center of the welding equipment to perform automatic full penetration welding control on the welding target.

[0006] In a possible implementation manner, when mining and establishing the welding condition library, the following processing is further performed: interacting with historical welding information, integrating and determining multiple historical sequences based on weld seam features - 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 conditional sequence mining, obtaining N conditional sequences, aggregating the N conditional sequences, and generating the welding condition library.

[0007] In a possible implementation manner, when traversing the N clustering clusters and performing conditional sequence mining, the following processing is further performed: identifying the first clustering cluster, and determining M weld seam features under the first welding effect; using the M weld seam features to mine X structural condition - width - depth ratio conditions, and based on the first welding effect, determining the first defect concentration feature, where X is a positive integer less than or equal to M; mapping and integrating the X structural condition - width - depth ratio conditions and the first defect concentration feature, and adding them to the first conditional sequence.

[0008] In a possible implementation manner, when determining the welding partition step by judging the weld seam features, the following processing is further performed: for the geometric features, identifying the weld seam structural features and performing matching based on the structural conditions to determine the first judgment result, where the first judgment result is whether there is a welding defect concentration area in the structure; identifying the weld seam width - depth ratio, and performing matching based on the width - depth ratio conditions to determine the second judgment result, where the second judgment result is the distribution feature of the welding defect concentration area; based on the first judgment result and the second judgment result, determining the welding partition step.

[0009] In a possible implementation manner, when determining the welding partition step, the following processing is further performed: if there is a welding defect concentration area, the welding partition step is the backing filling welding area - twin - wire submerged arc welding area - twin - wire submerged arc penetration welding area, where the twin - wire submerged arc penetration welding area is determined based on the distribution feature of the welding defect concentration area; if there is no welding defect concentration area, the welding partition step is the backing filling welding area - twin - wire submerged arc welding area.

[0010] In a possible implementation manner, when performing two - step welding simulation in combination with the welding partition step, the following processing is further performed: for the backing filling welding area, performing one - step welding simulation and compensating based on the welding simulation effect to determine the one - step welding strategy; taking the one - step welding simulation effect as a benchmark, performing two - step welding simulation and compensating based on the welding simulation effect to determine the two - step welding strategy, where the two - step welding simulation includes twin - wire submerged arc welding and twin - wire submerged arc penetration welding; integrating the one - step welding strategy and the two - step welding strategy in time sequence to determine the welding strategy.

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

[0012] In a possible implementation manner, for the automated full penetration welding control of the welding target, the following processing is also performed: synchronously performing welding monitoring as the welding equipment brakes; performing control constraint management based on the welding effect of each zone, where the control constraint management includes two-step welding compensation or one-step welding time delay; positioning the welding management feature and tracing its origin, and if it is a non-accidental feature, marking it as a welding compensation element.

[0013] A welding process control method for a full penetration weld proposed by this application is intended to perform visual acquisition and self-attention recognition on the welding target to determine the weld features; excavate and establish a welding condition library based on the structural conditions and the width-depth ratio conditions; traverse the welding condition library, determine the welding zone steps by judging the weld features; interact with the control mechanism of the welding equipment, and perform two-step welding simulation in combination with the welding zone steps 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. This solves the technical problems in the prior art, such as relying on manual filling, unstable operation, and difficulty in precisely adjusting to cope with variable working conditions, resulting in poor welding precision and stability and causing product quality defects, and achieves the technical effects of improving welding precision, stability, and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments of the present invention will be briefly introduced below. Flowcharts are used in this application to illustrate the operations performed by the systems according to the embodiments of the application. It should be understood that the operations before or below do not necessarily need to be executed precisely in sequence. On the contrary, according to the need, they can be executed in reverse order or simultaneously. At the same time, other operations can also be added to these processes, or one or several operations can be removed from these processes.

[0015] Figure 1 It is a schematic flowchart of a welding process control method for a full penetration weld provided by an embodiment of this application;

[0016] Figure 2 It is a schematic flowchart of establishing a welding condition library in a welding process control method for a full penetration weld provided by an embodiment of this 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 purpose, technical solutions and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings. The described embodiments should not be regarded as limiting this application. All other embodiments obtained by ordinary technicians in this 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 describes a subset of all possible embodiments, but it will be 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 the 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 commonly understood by those skilled in the art to which this application belongs. The terms used herein are for the purpose of describing the embodiments of this application only.

[0020] The embodiment of the present application 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 a welding target to determine weld features, wherein the weld features include geometric features.

[0022] Preferably, a visual sensor (such as a camera) is used to monitor the welding process in real time, and the obtained image data is analyzed and processed through the Self-Attention Mechanism to identify and extract the weld features. Among them, the weld features include geometric features. Specifically, visual acquisition of the welding target is carried out to obtain a welding image, and then weight distribution is performed on the pixels of the welding image through self-attention recognition to more efficiently extract key information in the image. Among them, self-attention recognition can focus on specific areas in the image (such as some key parts of the weld) and ignore other irrelevant parts, thereby improving the accuracy of weld feature recognition. Especially in a complex welding environment, it can effectively screen and capture valuable geometric feature information. The weld features mainly include the weld profile, weld width and height, 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 analysis can be carried out to determine whether it meets the preset welding requirements. For example, whether the weld is uniform and whether there are abnormal shapes (such as being too large, too small, or deviating from the predetermined trajectory, etc.); the width and height of the weld are important geometric parameters that affect the welding strength and weld quality. The real-time acquired 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 and whether the shape is regular, etc. Judging the geometric changes of the weld at different positions can ensure the welding uniformity and welding quality.

[0023] Step S200: Based on the structural conditions and the width-depth ratio conditions, excavate and establish a welding condition library, where the condition sequence is structural feature - width-depth ratio - defect concentration feature.

[0024] Preferably, by deeply excavating and analyzing the structural features of different welding targets, the geometric parameters of the weld (such as the width-depth ratio), and the relationship between these parameters and welding defects, a systematic welding condition library is established. Among them, the condition sequence of structural feature - width-depth ratio - defect concentration feature means that these factors need to be considered in turn during the selection of welding process conditions, thereby effectively preventing common welding defects and improving the welding quality and efficiency. Specifically, the structural conditions usually refer to the geometric shape, size, and material type of the welding joint, etc., including the type of welding joint. For example, different types of welding joints such as corner joints, butt joints, and T-joint welds have different requirements for the welding process; the thickness of the joint, the thickness of the welding joint will affect parameters such as the welding heat input and welding speed, thereby affecting the welding quality; the material of the joint, welding of different materials (such as steel, aluminum, titanium alloy, etc.) has different requirements for the welding process, and there will be differences in heat conduction during the welding process, welding difficulty, molten pool behavior, etc.; the geometric shape and configuration of the joint, such as whether the welding position is complex and whether the angle is special, etc., the joint shape and configuration affect the heat input and molten pool control during the welding process.

[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 external characteristics of the weld. Through visual acquisition technology, the aspect ratio can be monitored and calculated 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, causing 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, width-to-depth ratio conditions and defect concentration characteristics and corresponding optimal welding parameters. Specifically, according to the structural conditions and geometric characteristics (including the width-to-depth 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 structural and width-to-depth 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 and welding effects; step S220, traversing the multiple historical sequences, performing clustering based on welding effects, and determining N clusters; step S230, traversing the N clusters, performing condition sequence mining, obtaining N condition sequences, concentrating the N condition sequences, and generating the welding condition library.

[0028] Preferably, welding parameters, weld geometry features, defect types, welding effects and other data are obtained from historical welding information and integrated into multiple historical sequences based on weld features - welding effects, that is, these historical data are combined into different historical sequences according to weld features and welding effects. Among them, the welding effect includes quality indicators during the welding process, such as the strength, hardness, defects (such as pores, cracks, etc.) of the weld; all historical welding data (i.e., the sequences of weld features - welding effects) are processed and analyzed one by one. The welding effect is analyzed through clustering algorithms (such as K-means, hierarchical clustering, etc.), and the sequences with similar welding effects are clustered together. The clustering criteria are usually welding effects, such as welding quality, defect types, weld shape, etc. Different welding processes are classified 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 clustering cluster.

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

[0030] Further, step S230 further includes step S231, identifying the first clustering cluster and determining M weld features under the first welding effect; step S232, mining X structural condition - aspect ratio conditions based on the M weld features, and determining the first defect set features 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 condition - aspect ratio conditions and the first defect set features and adding them into the first conditional sequence.

[0031] Preferably, the first clustering cluster is identified from the clustering result, and according to the welding effects included in this clustering cluster, information related to the weld features is further extracted, that is, M weld features under the first welding effect are determined, such as geometric or morphological features of the weld, such as weld width, depth, penetration depth, molten pool shape, etc.

[0032] Where M is a positive integer. Based on the M weld features in the first cluster, a set 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. X ≤ M means that the number of mined conditions is at most M.

[0033] Preferably, based on the analysis results of the welding effects 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 structural conditions and width-to-depth ratio conditions are associated with the first defect concentration feature to form a new comprehensive condition set. Specifically, by mapping the relationship between welding conditions and welding defects, the occurrence of defects can be avoided or reduced 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 judging the weld characteristics.

[0035] Preferably, in the welding process control, by using the established welding condition library, the appropriate welding partition scheme is judged and determined 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 content in the welding condition library, and the appropriate partition strategy is selected, and the welding area is reasonably divided into different welding partitions, and the corresponding welding process is applied in each partition to ensure the welding quality and efficiency. Specifically, according to the geometric characteristics, defect information, etc. of the weld, the 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 regions of the welding target, the welding strategies for different regions are determined. For example, in some regions, more heat input may be required (such as the welding root), while in other regions, less heat input may be required (such as the weld surface or the outside of the joint). In addition to determining the partition, the welding sequence and the two-step welding strategy (such as performing the bottom layer welding first and then the surface layer welding) also need to be considered. These steps can help reduce welding stress, reduce deformation and welding defects.

[0036] Preferably, through the real-time determination of the weld characteristics, important information about the welding process state can be obtained, and based on this, the suitable process parameters and welding partition steps are selected. The welding partition steps refer to dividing the welding area into several parts according to different characteristics and needs, and different welding processes or strategies are adopted for each part (i.e., partition). For example, some regions may require a higher heat input, while other regions may require a lower heat input to avoid deformation. The welding partition steps help to precisely control the heat input, welding sequence and welding strategy in a complex welding environment, ensuring 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] Further, step S300 further includes step S310, for the geometric characteristics, identifying the weld structure characteristics and performing matching based on the structure conditions to determine the first determination result, where the first determination result is whether there is a welding defect concentration area in the structure; step S320, identifying the weld width-depth ratio and performing matching based on the width-depth ratio conditions to determine the second determination result, and the second determination result is the distribution characteristics of the welding defect concentration area; step S330, based on the first determination result and the second determination result, determining the welding partition steps.

[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 layer 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, angle, and size of the weld joint). The result after matching is to determine whether there is a defect concentration area in the weld structure, which is the first judgment result. For example, if the weld is deep and the structure is a triangular structure or an irregular structure, there is a welding blind area, that is, some positions cannot be covered, and the penetration is compensated in the covering stage; if the weld is shallow, or the bottom is a square or arc-shaped 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 excessive pores, cracks and other defects 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 judged 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 judge the distribution of welding defects in the weld by analyzing 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 of 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] Furthermore, 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 bottom filling welding area-double-wire submerged arc welding area-double-wire submerged arc penetration welding area. The bottom 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; the double-wire submerged arc penetration welding area It is aimed at further strengthening the welding defect concentration area, that is, optimizing 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 twin-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 too low heat input.

[0042] Preferably, if no defect concentration area is detected during the welding process, that is, there are no obvious quality problems or unstable areas during the welding process, the welding process is simplified, and the welding zoning steps are bottom filler welding area-double wire submerged arc welding area. That is, bottom filler welding is still the first step of the welding process, providing a foundation for the next welding layer and ensuring the stability and quality of the joint under reasonable heat input. Then enter the double wire submerged arc welding stage, and use double wire submerged arc welding technology to weld the main welding area. Through this zoning strategy, the welding process can be accurately adjusted according to the defect situation of the welding area, improving welding quality and efficiency, and reducing the occurrence of defects.

[0043] In step S400, the control mechanism of the interactive welding equipment performs a two-step welding simulation in combination with the welding partitioning step to determine a welding strategy, wherein the two-step welding includes a one-step backfill welding and a two-step double-wire submerged arc welding, and the welding strategy includes 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 double-step welding simulation, especially in complex structures or large-scale 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 during the welding process (such as weld characteristics, temperature distribution, welding current, voltage, etc.) to achieve precise welding operations. 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 status, weld morphology, etc.) in real time and adjust the operation of the equipment according to these data, such as welding current, welding speed and welding sequence, etc. It can also adjust the welding strategy based on the real-time characteristics of the target weldment (such as weld geometry, defect monitoring, etc.) by combining 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 welding accuracy requirements 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 the use of a lower pass 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 twin-wire submerged arc welding usually adopts higher heat input and twin-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, and is especially suitable for large-area or deep-penetration welding tasks. The heat input of twin-wire submerged arc welding is more uniform, which can increase welding speed while maintaining good welding quality and reducing defects that may occur during the welding process.

[0046] Preferably, after simulating two-step welding, the welding strategy is determined according to the simulation results, which usually includes optimizing the heat input of each welding zone according to the welding zone steps. The heat input of different zones will affect the welding penetration, molten pool shape, 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 welding 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, among which 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 parameters such as welding current, voltage, and welding speed, so as to compensate for errors caused by insufficient or excessive heat input, and 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, based on the one-step welding simulation effect, 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, perform a one-step welding simulation on the backing filling weld zone to predict various parameters and their possible impacts during the backing filling welding process, such as the temperature distribution of the molten pool, cooling rate, weld shape, etc., optimize the welding process, and analyze possible errors (such as uneven temperature, deformation, weld size, etc.) during the welding process through the simulation results, that is, correct these errors by adjusting welding parameters (such as current, welding speed, wire feeding speed, etc.), and determine the one-step welding strategy based on the simulation results and their compensation adjustments; after completing the backing filling welding, perform a two-step welding simulation, evaluate the effects in terms of penetration depth, heat input, etc. during the welding process, and perform compensation adjustments according to the simulation results, which may include adjusting parameters such as current, welding speed, and wire feeding speed, to ensure that the welding effect meets the expected quality standards, and determine the two-step welding strategy based on the two-step welding simulation and compensation results to ensure that double-wire submerged arc welding and double-wire submerged arc penetration welding can effectively reduce defects and ensure welding quality during actual operation; integrate the one-step welding strategy and the two-step welding strategy in time sequence to ensure their sequence and coordination during the actual welding process, ensure that the transition between each step is smooth, avoid problems such as temperature stress and weld deformation, and finally determine the welding strategy to make the entire welding process more efficient and precise and ultimately achieve the ideal welding quality.

[0049] Further, step S400 further includes step S440 of obtaining the welding precision standard of the control mechanism; step S450 of dividing the first control element and the second control element for the one-step backing filling welding, performing an outward expansion process on the welding precision standard for the first control element, and performing an inward contraction process on the welding precision standard for the second control element, wherein the first control element is the distribution element of the backing filling; step S460 of performing an outward expansion process on the welding precision standard for the two-step double-wire submerged arc welding.

[0050] Preferably, obtain the welding precision standard of the control mechanism, that is, determine the acceptable welding quality range, including the shape requirements of the welded joint (such as weld width, thickness), and the defect tolerance during the welding process (such as pores, cracks, etc.). Among them, the welding precision standard refers to the quality control standard set during the welding process, such as the size of the weld, the strength of the welded joint, the control of penetration depth, the appearance of the weld, etc. Then, for the one-step backing filling welding, divide the first control element and the second control element. Among them, the first control element refers to the distribution element of the backing filling, that is, the distribution of the welding molten pool and the shape of the weld during the welding process, and the second control element refers to the weld quality element of the backing filling, such as the flatness and depth of the weld.

[0051] Preferably, an external expansion treatment is performed on the welding precision standard of the first control element, that is, on the basis of ensuring the welding precision, the requirements for the first control element are relaxed so that it can vary within a certain range to adapt to the uncertainties in the welding process. Double-wire submerged arc welding is carried out on the basis of the welding results of backing and filling, and to a certain extent, it can compensate for filling defects, such as the surface state of the filling, etc. These actually do not need to be considered, and only the distribution of the welding filling area needs to be ensured. For example, during the backing and filling stage, the distribution of the welding molten pool and the shape of the weld seam may fluctuate, and the external expansion treatment leaves a certain tolerance range for these fluctuations to avoid unnecessary frequent adjustments caused by strict requirements; an internal contraction treatment is performed on the welding precision standard of the second control element, tightening the requirements for certain control elements, that is, restricting the change range of these elements to ensure more precise welding quality. For double-wire submerged arc welding, higher requirements are imposed on the connection state between the welded part and the original component, surface welding, etc. For example, it is required that the depth or width of the weld seam cannot exceed a specific range because too deep or too wide weld seams will affect the strength and appearance of the welded joint.

[0052] Preferably, for two-step double-wire submerged arc welding, an external expansion treatment is performed on the welding precision standard. Specifically, there are certain control errors in actual control, such as position errors caused by vibration, etc., which are different from the ideal effect in the simulation. The external expansion treatment means appropriately relaxing the welding precision standard so that some 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, ensuring that even if there are certain errors in actual operation, the welding effect still meets the standards, avoiding difficulties in process adjustment caused by strict standards, and thus improving the stability of the welding process.

[0053] Step S500, the welding strategy responds to the control center of the welding equipment to perform automated 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 (such as current, voltage, welding speed, etc.) in the welding process 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 requirements of welding quality. Specifically, the control system of the welding equipment (usually including a computer, sensors, actuators, etc.) can receive real-time data feedback during the welding process, automatically adjust the welding process according to the preset welding strategy, and perform automatic full penetration welding control on the welding target. Among them, 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 to ensure the strength and structural integrity of the welded joint; automatic full penetration welding control means that the control system of the welding equipment does not rely on manual intervention and intelligently adjusts various parameters in the welding process in a highly automated manner according to the characteristics of the welding target, weld characteristics, and real-time feedback data to ensure that the welded joint achieves full penetration welding.

[0055] Further, step S500 further includes step S510, during which welding monitoring is synchronously performed as the welding equipment brakes; step S520, control constraint management is performed based on the welding effect of each zone, where the control constraint management includes two-step welding compensation or one-step welding time delay; step S530, the welding management characteristics are located and traced, and if they are non-accidental characteristics, they are marked as welding compensation elements.

[0056] Preferably, the braking of the welding equipment refers to the pauses, decelerations, and adjustments during the welding or welding control process. For example, when abnormalities occur during the welding process (such as too high temperature, excessive cooling, etc.), the equipment may decelerate or pause to adjust the welding parameters and perform synchronous welding detection on the welding process, which usually includes temperature monitoring, penetration depth detection, weld formation analysis, etc. Control constraint management is performed based on the welding effect of each zone (the actual effect after each zone is welded, including parameters such as the size, quality, and penetration depth of the weld), that is, the management strategy for welding parameters and the process during the welding process to ensure that the welding quality meets the predetermined standards. Among them, the control constraint management includes two-step welding compensation or one-step welding time delay. For example, if the effect does not meet the expectation after one step, compensation can be performed in two steps, or the time of one step can be extended to make it meet the standard; specifically, two-step welding compensation is to adjust the welding speed, temperature, or current, etc. to ensure welding quality, and one-step welding time delay is to appropriately delay or adjust the welding time, that is, by adjusting the time, the cooling speed of the molten pool can be affected, thereby improving the welding quality.

[0057] Preferably, at the same time, trace back to the elements that lead to its existence for making decisions on subsequent other weldings, that is, locate specific welding management characteristics (such as welding defects, uneven penetration, etc.) during the welding process, and trace back to the reasons for these characteristics, which may be caused by factors such as welding process, equipment problems, improper operation, etc. Some characteristics (such as local defects, overheating or uneven cooling of the weld seam, etc.) may be caused by accidental factors, while those characteristics that appear repeatedly and regularly are called non-accidental characteristics, and they are marked as welding compensation elements, that is, factors that need to take measures for compensation. For example, if the depth of the molten pool is too shallow due to equipment error, the welding parameters need to be adjusted according to this compensation element, which may include adjusting the welding current, welding speed, etc., to ensure that the welding quality always remains within the qualified range and avoid quality degradation caused by repeatedly occurring problems.

[0058] The above specific implementation manners do not constitute a limitation on the protection scope of the present application. Those skilled in the art should understand 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 principle of the present application shall be included within the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be executed in a different order from that in the embodiments and still achieve the desired results. Additionally, the processes depicted in the drawings do not necessarily require the specific order or continuous order shown to achieve the desired results. In certain embodiments, multi-tasking and parallel processing are also possible or may be advantageous.

Claims

1. A welding process control method for full penetration welds, characterized in that, The method includes: Performing visual acquisition and self-attention recognition on the welding target to determine the weld seam features, where the weld seam features include geometric features; Digging and establishing a welding condition library based on structural conditions and width-depth ratio conditions, where the condition sequence is structural feature - width-depth ratio - defect concentration feature; Traversing the welding condition library and determining the welding partition step by judging the weld seam features; Interacting with the control mechanism of the welding equipment, and performing two-step welding simulation in combination with the welding partition step to determine the welding strategy, where the two-step welding includes one-step backing filling welding and two-step twin-wire submerged arc welding, and there is a welding precision compensation in the welding strategy; The welding strategy responds to the control center of the welding equipment to perform automatic full penetration welding control on the welding target; Among them, the digging and establishing of the welding condition library includes: Interacting with historical welding information and integrating to determine multiple historical sequences based on weld seam features - welding effects; Traversing the multiple historical sequences, performing clustering processing based on welding effects to determine 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; Among them, determining the welding partition step by judging the weld seam features includes: For the geometric features, identifying the weld seam structural features and matching them based on the structural conditions to determine the first judgment result, where the first judgment result is whether there is a welding defect concentration area in the structure; Identifying the width-depth ratio of the weld seam and matching it based on the width-depth ratio condition to determine the second judgment result, and the second judgment result is the distribution feature of the welding defect concentration area; Based on the first judgment result and the second judgment result, determining the welding partition step; Among them, the determining of the welding partition step includes: If there is a welding defect concentration area, the welding partition step is backing filling welding area - twin-wire submerged arc welding area - twin-wire submerged arc penetration welding area, where the twin-wire submerged arc penetration welding area is determined based on the distribution feature of the welding defect concentration area; If there is no welding defect concentration area, the welding partition step is backing filling welding area - twin-wire submerged arc welding area.

2. The welding process control method for a full penetration weld as described in claim 1, characterized in that, Traversing the N clustering clusters and performing condition sequence mining includes: Identifying the first clustering cluster and determining M weld seam features under the first welding effect; Using the M weld seam features to dig X structural condition - width-depth ratio conditions, and based on the first welding effect, determining the first defect concentration feature, where X is a positive integer less than or equal to M; Mapping and integrating the X structural condition - width-depth ratio conditions and the first defect concentration feature, and adding them to the first condition sequence.

3. The welding process control method for a full penetration weld as described in claim 1, characterized in that, Combining the welding partition step to perform two-step welding simulation includes: For the backing filling welding area, performing one-step welding simulation and compensating based on the welding simulation effect to determine the one-step welding strategy; Taking the one-step welding simulation effect as a benchmark, performing two-step welding simulation and compensating based on the welding simulation effect to determine the two-step welding strategy, where the two-step welding simulation includes twin-wire submerged arc welding and twin-wire submerged arc penetration welding; Integrating the one-step welding strategy and the two-step welding strategy in time sequence to determine the welding strategy.

4. The welding process control method for a full penetration weld as described in claim 1, characterized in that, The welding strategy has welding precision compensation, including: Obtaining the welding precision standard of the control mechanism; For the one-step backing filling welding, dividing the first control element and the second control element, performing an outward expansion process of the welding precision standard on the first control element, and performing an inward contraction process of the welding precision standard on the second control element, wherein the first control element is the distribution element of the backing filling; For the two-step double-wire submerged arc welding, performing an outward expansion process on the welding precision standard.

5. The welding process control method for a full penetration weld as claimed in claim 1, wherein Performing automatic full penetration welding control on the welding target, including: Synchronously performing welding monitoring as the welding equipment brakes; Based on the welding effect of each zone, performing control constraint management, wherein the control constraint management includes two-step welding compensation or one-step welding time delay; Locating the welding management features and tracing their sources, and if they are non-accidental features, marking them as welding compensation elements.

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