Method and system for adjusting wire feeding speed of wire feeder

Abstract

The invention discloses a method and system for adjusting the wire feeding speed of a wire feeder, and relates to the related technical field of welding machining.The method comprises the steps that a workpiece data set is read; feature extraction is conducted on workpiece material data and workpiece geometrical shape data in the workpiece data set, workpiece features are established, wire feeding speed control optimization is conducted through the workpiece features, and a wire feeding speed optimization space is established; wire feeding control of the wire feeder is conducted through the wire feeding speed optimizing space, and molten pool monitoring feedback and electric arc monitoring feedback are established; joint optimization analysis of the wire feeding speed is carried out through molten pool monitoring feedback and electric arc monitoring feedback, and optimized wire feeding speed control parameters are established; and carrying out wire feeding control on the wire feeder according to the optimized wire feeding speed control parameters. The technical problem that in the prior art, dynamic optimization control over the wire feeding speed is difficult to conduct according to workpiece materials and geometrical shapes, and consequently the machining quality is unstable is solved, and the technical effect of improving the wire feeding speed control precision and the machining quality is achieved.

Description

Technical Field

[0001] The present application relates to the technical field related to welding processing, and in particular to a method and system for adjusting the wire feeding speed of a wire feeder. Background Art

[0002] Wire feeders are widely used in welding, additive manufacturing and other industrial fields. Their core function is to feed welding or processing materials into the working area by accurately controlling the wire feeding speed, thereby achieving efficient and high-quality processing technology. The wire feeding speed control of the wire feeder plays a vital role in welding quality and efficiency. The welding process involves complex physical and chemical reactions, including arc discharge, dynamic characteristics of the molten pool and other factors. Proper adjustment of the wire feeding speed can directly affect the welding formation, penetration depth and weld quality. However, wire feeders mostly adjust the wire feeding speed in a fixed or simple feedback control manner. When faced with diverse workpiece materials and complex geometric shapes, they lack precise dynamic feedback and optimization mechanisms, making it difficult to effectively meet different process requirements. Wire feeding speed mismatch is prone to occur, and high-precision control cannot be achieved, resulting in reduced processing quality.

[0003] Therefore, in the current related technologies, there is a technical problem that it is difficult to dynamically optimize the wire feeding speed according to the workpiece material and geometry, which leads to unstable processing quality. Summary of the invention

[0004] The present application provides a method and system for adjusting the wire feeding speed of a wire feeder, thereby solving the technical problem in the prior art that it is difficult to dynamically optimize the wire feeding speed according to the workpiece material and geometric shape, which leads to unstable processing quality, and achieves the technical effect of improving the wire feeding speed control accuracy and processing quality.

[0005] The present application provides a method for adjusting the wire feeding speed of a wire feeder, the method comprising: reading a workpiece data set, the workpiece data set comprising workpiece material data and workpiece geometric shape data; performing feature extraction on the workpiece material data and the workpiece geometric shape data in the workpiece data set, establishing workpiece features, and using the workpiece features to perform wire feeding speed control optimization, and establish a wire feeding speed optimization space; performing wire feeding control of the wire feeder in the wire feeding speed optimization space, and establishing molten pool monitoring feedback and arc monitoring feedback; performing joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback, and establishing optimized wire feeding speed control parameters; and performing wire feeding control of the wire feeder according to the optimized wire feeding speed control parameters.

[0006] In a possible implementation, the establishment of molten pool monitoring feedback and arc monitoring feedback also performs the following processing: configuring an infrared temperature sensor and an industrial camera at the molten pool monitoring position; using the infrared temperature sensor to perform real-time temperature monitoring of the molten pool and establish molten pool temperature data; using the industrial camera to capture image data of the molten pool, using the image data to extract shape features of the molten pool, and establishing molten pool status data based on the shape features; integrating the molten pool temperature data and the molten pool status data as molten pool monitoring feedback output.

[0007] In a possible implementation, the shape features of the molten pool are extracted by using the image data, and the molten pool status data is established according to the shape features, and the following processing is also performed: after the image data is grayed, filtering, denoising and contrast enhancement are performed on the grayed image data to establish a standardized image; image analysis is performed on the standardized image, a pixel threshold is configured, and image segmentation of the standardized image is performed by the pixel threshold to extract the molten pool area; feature extraction based on edge detection is performed on the molten pool area, and shape symmetry analysis is performed according to the feature extraction result to establish the first molten pool status data; shape roundness analysis is performed on the feature extraction result to establish the second molten pool status data; and molten pool status data is established according to the first molten pool status data and the second molten pool status data.

[0008] In a possible implementation, the shape symmetry analysis is performed according to the feature extraction result, and the following processing is further performed: symmetry analysis is performed using a symmetry formula, as follows: ; in, Characterize the symmetry parameters, The coordinate index representing the pixel point, Representation of the image at the coordinate position The pixel intensity value at Representation image in symmetrical position The pixel intensity value at Represents the total number of pixels in the image, that is, all The number of positions.

[0009] In a possible implementation, the establishment of molten pool monitoring feedback and arc monitoring feedback also performs the following processing: using an arc sensor to monitor arc data of welding, and establishing an arc data set, wherein the arc data set includes voltage data, current data, and arc length data; and establishing arc monitoring feedback based on the arc data set.

[0010] In a possible implementation, the wire feeding speed is jointly optimized and analyzed through the molten pool monitoring feedback and the arc monitoring feedback to establish optimized wire feeding speed control parameters, and the following processing is also performed: based on the arc monitoring feedback, the wire feeding speed is optimized and roughly positioned to obtain a rough adjustment result of the wire feeding speed; the rough adjustment result of the wire feeding speed is used as the optimization target, and an intersection operation is performed with a pre-established wire feeding speed optimization space to determine a rough optimization range of the wire feeding speed; within the rough optimization range, the wire feeding speed accuracy is adjusted based on the molten pool monitoring feedback to establish optimized wire feeding speed control parameters.

[0011] In a possible implementation, after the wire feeding of the wire feeder is controlled according to the optimized wire feeding speed control parameters, the following processing is also performed: a hysteresis feedback interval is created based on the optimized wire feeding speed control parameters; after the hysteresis feedback interval ends, the molten pool monitoring feedback and arc monitoring feedback are re-called for optimization analysis to establish optimized feedback.

[0012] The present application also provides a wire feeding speed adjustment system for a wire feeder, comprising: a workpiece data set reading module, used to read a workpiece data set, wherein the workpiece data set includes workpiece material data and workpiece geometric shape data; a wire feeding speed optimization space establishment module, used to perform feature extraction on the workpiece material data and the workpiece geometric shape data in the workpiece data set, establish workpiece features, and use the workpiece features to perform wire feeding speed control optimization and establish a wire feeding speed optimization space; a monitoring feedback establishment module, used to perform wire feeding control of the wire feeder in the wire feeding speed optimization space, and establish molten pool monitoring feedback and arc monitoring feedback; a joint optimization analysis module, used to perform joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback, and establish optimized wire feeding speed control parameters; a wire feeding control module, used to control the wire feeding of the wire feeder according to the optimized wire feeding speed control parameters.

[0013] The wire feeding speed adjustment method and system proposed in this application are to read the workpiece data set; extract the features of the workpiece material data and the workpiece geometric shape data in the workpiece data set, establish the workpiece features, and use the workpiece features to optimize the wire feeding speed control and establish the wire feeding speed optimization space; control the wire feeding of the wire feeder in the wire feeding speed optimization space, and establish the molten pool monitoring feedback and arc monitoring feedback; perform joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback, and establish the optimized wire feeding speed control parameters; control the wire feeding of the wire feeder according to the optimized wire feeding speed control parameters. The technical problem that it is difficult to dynamically optimize the wire feeding speed according to the workpiece material and geometric shape in the prior art, which leads to unstable processing quality, is solved, and the technical effect of improving the wire feeding speed control accuracy and processing quality is achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solution of the embodiment of the present disclosure, the accompanying drawings of the embodiment of the present disclosure 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 method for adjusting the wire feeding speed of a wire feeder provided in an embodiment of the present application.

[0016] Figure 2 A schematic structural diagram of a wire feeding speed adjustment system for a wire feeder provided in an embodiment of the present application.

[0017] Explanation of the reference numerals: workpiece data set reading module 10 , wire feeding speed optimization space establishing module 20 , monitoring feedback establishing module 30 , joint optimization analysis module 40 , wire feeding control module 50 . DETAILED DESCRIPTION

[0018] 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.

[0019] 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.

[0020] 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, system, 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.

[0021] The present application provides a method for adjusting the wire feeding speed of a wire feeder. Figure 1 As shown, the method includes: Step S100 , reading a workpiece data set, wherein the workpiece data set includes workpiece material data and workpiece geometric shape data.

[0022] Preferably, data information related to the workpiece is obtained to form a workpiece data set for analyzing and optimizing the wire feeding speed of the wire feeder. The workpiece data set includes workpiece material data and workpiece geometry data. Specifically, the workpiece material data describes the material properties of the workpiece, which may include material type (such as stainless steel, aluminum alloy, carbon steel, etc.). The thermal conductivity, strength, melting point and other properties of different materials will directly affect the parameter setting during the welding process; chemical composition, the specific chemical composition of the material (such as carbon content, proportion of alloy elements, etc.) affects the welding performance of the material, such as sensitivity to welding heat input, fragility, etc.; mechanical properties (such as hardness, ductility, tensile strength, etc. of the material), which affect the strength and toughness of the welded joint during the welding process; thermal properties (such as thermal expansion coefficient, specific heat capacity, thermal conductivity, etc.), which affect the temperature distribution and cooling rate of the molten pool during the welding process; electrical conductivity, in some cases, the arc stability and heat conduction effect in the welding process are closely related to the electrical conductivity of the material. The workpiece geometry data describes the shape, size, structure and surface characteristics of the workpiece, usually including the size of the workpiece (such as the length, width, thickness, etc. of the workpiece), which directly affects the selection of welding current and wire feeding speed during welding; the geometry of the workpiece, such as whether the workpiece has complex curves, angles, and the shape of the welding joint (such as corner joints, groove joints, etc.), which affects the formation and control of the molten pool; the type of welding joint (such as butt joints, corner joints, T-joints, etc.), different joint forms have different requirements for wire feeding speed and welding current; surface roughness and state, the roughness of the workpiece surface, oxide layer and other characteristics will also affect the metal flow and joint quality during welding.

[0023] Step S200, extracting features of the workpiece material data and the workpiece geometric shape data in the workpiece data set, establishing workpiece features, and using the workpiece features to optimize wire feeding speed control and establish a wire feeding speed optimization space.

[0024] Preferably, feature extraction is performed on the workpiece material data and workpiece geometry data in the workpiece data set, that is, key parameters are extracted from the workpiece material data and geometry data to obtain corresponding workpiece features, which directly affect the selection of wire feeding speed in the welding process. Specifically, key parameters related to welding are extracted from the workpiece material data, such as the required heat input range, melting point temperature (used to determine the basic range of current, voltage and wire feeding speed), chemical sensitivity (for example, whether the alloy material is prone to cracks or welding deformation) derived from the thermal conductivity, specific heat capacity and thickness of the material, and the extracted data is used to optimize the wire feeding speed, wear resistance and strength characteristics. Combined with the mechanical properties of the material, special adjustments that may be required during the welding process are derived; information related to the welding path and parameter adjustment is extracted from the workpiece geometry data, for example, the joint type (such as butt joint, T-joint, etc.) affects the molten pool formation method and filling speed, geometric complexity: extract whether there are complex shapes such as arcs, bevels, steps, etc., and the wire feeding speed needs to be adjusted to match the welding path, and dimensional characteristics (such as thickness, length, weld gap, etc.) are used to calculate the welding material filling requirements, thereby optimizing the wire feeding speed.

[0025] Preferably, based on the extracted workpiece features, the wire feeding speed is optimized using an optimization algorithm to ensure welding quality and efficiency. Specifically, the optimization objectives are constructed, including weld formation quality (the wire feeding speed should ensure that the weld is uniform, free of pores, cracks or defects), welding efficiency (under the premise of ensuring quality, try to increase the welding speed and shorten the processing time) and welding stability (avoid arc instability, excessive or too small molten pool), and then the wire feeding speed is used as the core optimization variable, and the current, voltage (coupling relationship with the wire feeding speed), welding path (affected by the workpiece geometry) and molten pool state (adjusted through monitoring feedback) are combined, and then the extracted workpiece features (such as material thermal conductivity, thickness, geometry) are used as the optimization variables. The wire feeding speed is used as the input dimension, and the wire feeding speed and its impact on welding quality and efficiency are used as the output variable. The mathematical relationship between the input characteristics and the wire feeding speed optimization results is established through simulation, and then the wire feeding speed optimization space is constructed. The optimization algorithm (such as genetic algorithm, particle swarm optimization, gradient descent method, etc.) is used to find the optimal solution in the multidimensional variable space. For example, by simulating the changes in molten pool temperature, penetration depth and weld appearance under different wire feeding speeds, the wire feeding speed that meets the quality requirements and has the highest efficiency is found. Among them, the wire feeding speed optimization space refers to the multidimensional optimization space constructed based on the workpiece characteristics, which represents all possible wire feeding speeds and their corresponding welding effects, thereby realizing dynamic optimization control of the wire feeding speed.

[0026] Step S300, controlling the wire feeding of the wire feeder in the wire feeding speed optimization space, and establishing molten pool monitoring feedback and arc monitoring feedback.

[0027] Preferably, controlling the wire feeding of the wire feeder by using the wire feeding speed optimization space specifically means that during the welding process, according to the characteristics of the workpiece (such as material thermal conductivity, thickness, and geometric structure) and welding requirements, the optimal wire feeding speed parameters matching the current working conditions are extracted from the optimization space. For example, if the workpiece thickness is large, the corresponding wire feeding speed in the optimization space is faster to increase the welding heat input and ensure the penetration depth; if the workpiece has a complex geometry (such as a curved surface or a corner joint), the wire feeding speed needs to be appropriately reduced to keep the molten pool stable; the optimized wire feeding speed parameters are transmitted to the wire feeder through a control system (such as a PLC, a servo motor driver, etc.), and the wire feeder executes the control instructions to feed the welding wire according to the set optimal speed, and combines parameters such as current, voltage, and welding path to achieve accurate matching and dynamic adjustment of the wire feeding speed, thereby ensuring a stable and efficient welding process.

[0028] Preferably, during the welding process, the molten pool and arc status are the key reflections of the welding quality. The molten pool and arc status are monitored in real time and feedback is provided to further optimize the wire feeding speed control. Specifically, molten pool monitoring refers to the real-time observation and analysis of the welding molten pool status, mainly through visual monitoring, using industrial cameras or laser sensors to monitor the shape, size, temperature distribution, etc. of the molten pool in real time, or using infrared thermal imaging to monitor the molten pool temperature field to ensure that the molten pool temperature is stable and prevent overheating or insufficient cooling. The monitored molten pool image is then analyzed to extract parameters such as the molten pool width, length, and depth to determine whether the molten pool is stable. If the molten pool is abnormal (for example, the molten pool is too wide or too narrow), the control system will adjust the wire feeding speed to maintain the stability of the molten pool. For example, if the molten pool is too wide, it means that the welding heat input is too large. The wire feeding speed can be appropriately reduced, and the welding current can be reduced to control the size of the molten pool; arc monitoring refers to the real-time monitoring of the welding arc state, which mainly includes real-time measurement of welding voltage and current through sensors, judging arc stability, indirectly measuring changes in arc length through voltage fluctuations, and analyzing the stability of the arc by using the fluctuations of voltage and current signals. If arc instability is detected (such as large voltage fluctuations), it means that the wire feeding speed or welding parameters may not match, and the wire feeding speed or arc length should be adjusted in time. For example, if the voltage fluctuation is too large, it may be that the wire feeding speed is too fast, resulting in an arc that is too short. The wire feeding speed should be reduced, and the arc length should be re-matched to ensure welding stability. By real-time monitoring of the molten pool and arc state and forming a closed-loop feedback control, the dynamic optimization control of the wire feeding speed can be achieved, thereby significantly improving the welding quality and ensuring the stability of the molten pool and arc.

[0029] Furthermore, step S300 also includes step S310, configuring an infrared temperature sensor and an industrial camera at the molten pool monitoring position; step S320, using the infrared temperature sensor to perform real-time temperature monitoring of the molten pool and establish molten pool temperature data; step S330, using the industrial camera to capture image data of the molten pool, using the image data to extract shape features of the molten pool, and establishing molten pool status data based on the shape features; step S340, integrating the molten pool temperature data and the molten pool status data as molten pool monitoring feedback output.

[0030] Preferably, an infrared temperature sensor and an industrial camera are configured at the molten pool monitoring position, and the temperature data and image data of the molten pool are obtained through these devices, and these data are integrated into the molten pool monitoring feedback output. Specifically, an infrared temperature sensor is used to monitor the temperature change of the molten pool in real time to generate molten pool temperature data, which can be the temperature readings of the center point, edge or multiple positions of the molten pool at each moment, which is used to determine whether the heat input during the welding process is uniform, and whether it is overheated or cooled too quickly; an industrial camera is used (using a high-definition camera to shoot the molten pool area in real time) to capture the image data of the molten pool, including capturing the shape, size, flow condition, etc. of the molten pool, and an image processing algorithm (edge The image data is used to extract the shape features of the molten pool, such as the width, depth, and shape symmetry of the molten pool. Based on the shape features of the molten pool extracted from the image data, the state data of the molten pool is established to comprehensively describe the geometric shape and stability information of the molten pool, which may include the shape features of the molten pool (such as elliptical, circular, curved, etc.), the geometric features of the molten pool (the width, depth, area, etc. of the molten pool), and the stability of the molten pool (the sudden change of shape or the irregularity of the molten pool is used to determine whether the welding process is stable). Finally, the molten pool temperature data and the molten pool state data are integrated to form a molten pool monitoring feedback output to determine whether the welding process is stable and whether the wire feeding speed needs to be adjusted. Through the real-time acquisition and analysis of the molten pool monitoring feedback data, the wire feeding speed is automatically adjusted to optimize the welding quality and ensure the stability of the welding process.

[0031] Furthermore, step S330 also includes step S331, after graying the image data, filtering, denoising and contrast enhancement are performed on the grayed image data to establish a standardized image; step S332, performing image analysis on the standardized image, configuring a pixel threshold, performing image segmentation of the standardized image through the pixel threshold, and extracting the molten pool area; step S333, performing feature extraction based on edge detection on the molten pool area, performing shape symmetry analysis based on the feature extraction result, and establishing the first molten pool state data; step S334, performing shape roundness analysis on the feature extraction result, and establishing the second molten pool state data; step S335, establishing the molten pool state data based on the first molten pool state data and the second molten pool state data.

[0032] Preferably, the image data is grayed, that is, the color information in the original image is converted into gray information, and each pixel value of the image is converted into a gray level, usually a value between 0 and 255, representing the degree from black to white, so as to simplify the image information, remove unnecessary color information, and retain only the brightness or intensity information of the image. The grayed image data is then filtered, denoised, and contrast enhanced. Filtering and denoising refers to smoothing the image using Gaussian filtering, median filtering, etc., to remove unnecessary noise signals to improve the image quality. Contrast enhancement is to adjust the brightness range of the image to make the contrast between different areas in the image more distinct, so that the target area (such as the molten pool) is more prominent, easier to segment and analyze, and the contrast between the molten pool area and the background is enhanced. The image after graying, denoising, and contrast enhancement is then established as a standardized image to unify the image quality and reduce the impact of noise on the analysis results.

[0033] Preferably, image analysis is performed on the standardized image, and a pixel threshold is configured. The pixel threshold is a set numerical value. When a pixel value in the image is greater than or less than the threshold, it will be classified into different areas. Specifically, by setting an appropriate threshold, the background and the molten pool area of ​​the image are separated. Usually, the pixel value of the molten pool area is higher, that is, the molten pool area is extracted according to the set pixel threshold, and then the molten pool area is subjected to feature extraction based on edge detection. This is a commonly used technology in image analysis, and can detect change points in the image (that is, locations where the image brightness or color changes greatly). Specifically, through edge detection (such as Canny edge detection), the contour and edge of the molten pool area are extracted, and the geometric shape of the molten pool is effectively analyzed. Shape symmetry analysis is performed based on the feature extraction result, that is, the stability of the molten pool during welding is evaluated by detecting the left-right symmetry or the top-down symmetry of the molten pool, and the first molten pool state data is obtained. For example, if the molten pool has good symmetry, it means that the molten pool is relatively stable. Otherwise, it may indicate that there is an abnormality in the welding process.

[0034] Preferably, the feature extraction result is subjected to shape roundness analysis, that is, the regularity of the molten pool shape is further evaluated by calculating the roundness of the molten pool area, and then the second molten pool state data is obtained, and the shape stability and welding quality of the molten pool are further analyzed. Among them, the molten pool shape with higher roundness usually means that the stability of the molten pool is better and the welding process is relatively stable. If the roundness of the molten pool is lower, it may indicate that the molten pool is irregular and there are unstable factors in the welding process. The shape roundness analysis calculation formula is as follows: , where A is the molten pool area and P is the circumference of the molten pool; finally, the first molten pool state data (shape symmetry analysis) and the second molten pool state data (shape roundness analysis) are combined to establish a comprehensive molten pool state data set, which contains information on multiple dimensions such as the temperature, shape, symmetry, and roundness of the molten pool, and can comprehensively reflect the morphological characteristics, stability, and regularity of the molten pool, thereby optimizing the wire feeding speed and other welding parameters and improving the welding quality and stability.

[0035] Furthermore, step S333 also includes performing symmetry analysis using a symmetry formula, as follows: ; in, Characterize the symmetry parameters, The coordinate index representing the pixel point, Representation of the image at the coordinate position The pixel intensity value at Representation image in symmetrical position The pixel intensity value at Represents the total number of pixels in the image, that is, all The number of positions.

[0036] Furthermore, step S300 also includes step S350, using an arc sensor to monitor arc data of welding and establish an arc data set, wherein the arc data set includes voltage data, current data, and arc length data; step S360, establishing arc monitoring feedback based on the arc data set.

[0037] Preferably, an arc sensor is used to monitor the voltage data, current data, and arc length data during the welding process, and an arc data set is established for analyzing the arc stability and performance during the welding process. Specifically, the voltage data refers to the potential difference between the two ends of the arc, which is usually measured in real time by an arc sensor (such as a voltage probe). The arc voltage reflects the energy and stability of the arc during the welding process. If the voltage fluctuates greatly, it may indicate that the arc is unstable or the wire feeding speed is not suitable for the current working conditions. The current data is the welding current measured by the arc sensor, which directly affects the welding heat input, the depth and width of the molten pool, etc. Too high a current may lead to excessive heat input, while too low a current may lead to incomplete welding. The arc length data refers to the length of the arc. An arc length that is too long or too short will affect the electric Arc stability and welding quality, arc length stability are important control parameters of the welding process; then, arc monitoring feedback is established based on the arc data set, that is, based on the analysis results of the arc data set, it is used to provide real-time feedback on the arc state during the welding process and guide the adjustment of the welding process, including arc stability analysis (by real-time analysis of voltage, current and arc length fluctuations, it is possible to determine whether the arc is stable), welding quality prediction (based on the voltage, current and arc length data in the arc data set, the quality of welding is predicted), and then the dynamic adjustment of welding parameters is realized. For example, if the current is too large, the current is automatically reduced, and the wire feeding speed and voltage are adjusted to prevent overheating or uneven welding. Arc monitoring feedback forms a closed-loop control in the welding system, thereby improving welding quality, stability and efficiency.

[0038] Step S400: performing a joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback to establish an optimized wire feeding speed control parameter.

[0039] Preferably, during the welding process, the wire feeding speed is optimized through joint optimization analysis in combination with real-time feedback data from the molten pool and the arc to ensure the optimal balance between welding quality and efficiency. The coupling relationship between the molten pool and the arc is very close, because the heat input of the arc directly affects the formation of the molten pool, and conversely, the stability of the molten pool also affects the performance of the arc, that is, by simultaneously considering the changes in the molten pool state and the arc state, the optimal wire feeding speed is found. Specifically, the goals of the joint optimization analysis include maintaining the stability of the molten pool. The temperature and shape of the molten pool must be within an appropriate range to ensure the depth of penetration, weld quality and connection strength of the workpiece; maintaining arc stability. Arc instability will lead to fluctuations in welding quality, and problems such as arc flutter and porosity may occur; by precisely controlling the wire feeding speed, the heat input (i.e., arc energy and molten pool heat) is adjusted to avoid overheating or too rapid cooling to ensure welding quality; by optimizing the wire feeding speed, not only In order to ensure the welding quality, it is also necessary to increase the welding speed as much as possible without affecting the welding quality, so as to improve the production efficiency; and then establish the optimized wire feeding speed control parameters, specifically including integrating the temperature data and morphological data (such as width, depth, shape symmetry) of the molten pool with the voltage, current, and arc length data of the arc, and extracting the key features affecting the welding quality, such as the stability of the molten pool, the fluctuation range of the arc length, the change trend of the current, etc. Based on the integrated data, mathematical modeling, machine learning or optimization algorithms (such as genetic algorithms, particle swarm optimization, fuzzy control, etc.) are used to establish an optimization model for the wire feeding speed. During the welding process, the feedback data of the molten pool and the arc are monitored in real time, and the wire feeding speed is continuously adjusted. The optimized wire feeding speed control parameters are finally generated through the optimization model and real-time feedback. The wire feeding speed can be automatically adjusted to cope with different welding conditions, ensuring the stability and efficiency of the welding quality while improving production efficiency.

[0040] Furthermore, step S400 also includes step S410, performing rough optimization positioning of the wire feeding speed based on the arc monitoring feedback to obtain a rough adjustment result of the wire feeding speed; step S420, taking the rough adjustment result of the wire feeding speed as the optimization target, performing an intersection operation with a pre-established wire feeding speed optimization space, and determining a rough optimization range of the wire feeding speed; step S430, performing precision adjustment of the wire feeding speed based on the molten pool monitoring feedback within the rough optimization range, and establishing optimized wire feeding speed control parameters.

[0041] Preferably, the voltage and current data of the arc are analyzed, and the wire feeding speed is roughly positioned to be optimized to obtain the rough adjustment result of the wire feeding speed, that is, a preliminary rough positioning is performed to obtain an approximate wire feeding speed range. Usually, the optimal state of welding quality cannot be achieved, but it can ensure that welding starts within the approximate range. The rough adjustment result obtained from the arc monitoring feedback is used as the optimization target, and an intersection operation is performed with the wire feeding speed optimization space established in advance, that is, the wire feeding speed range obtained from the rough adjustment result is combined with the preset optimal wire feeding speed range for the workpiece characteristics to find a rough optimization range, and a candidate wire feeding speed interval within the range is provided. Then, wire feeding is performed within the rough optimization range based on the molten pool monitoring feedback. Speed ​​accuracy adjustment, that is, within the rough optimization range, according to the data fed back by the molten pool (temperature, shape and other parameters of the molten pool), the wire feeding speed is adjusted more accurately. For example, if the molten pool temperature is too high, it may be overheating caused by too fast wire feeding speed. The heat input can be reduced by adjusting the wire feeding speed to the low end value of the rough optimization range. If the molten pool shape is asymmetrical or too small, the wire feeding speed may need to be increased to ensure the welding quality. By continuously analyzing the real-time status of the molten pool and adjusting the wire feeding speed, it is ensured that the heat input and molten pool shape during welding are kept within the optimal range, and finally the optimized wire feeding speed control parameters are formed for the wire feeding speed control in the subsequent welding process to ensure the efficiency and stability of the welding process.

[0042] Step S500, controlling the wire feeding of the wire feeder according to the optimized wire feeding speed control parameters.

[0043] Preferably, the optimal wire feeding speed control parameters obtained through the optimization process are used to adjust and control the wire feeder in the actual welding process to ensure that the wire feeding speed during the welding process is always kept within the optimal range, thereby optimizing the welding quality and improving the welding efficiency. Specifically, the optimized wire feeding speed control parameters are transmitted to the control system of the wire feeder, and the wire feeding speed is adjusted in real time so that the wire feeder can perform precise wire feeding operations according to actual welding requirements. The wire feeder is usually regulated by an integrated control system (such as a PLC, a servo control system, etc.), and the optimized control parameters are fed back to the motor or driver of the wire feeder through the control system. As the welding conditions change (such as arc state, changes in molten pool temperature, etc.), the wire feeding speed is adjusted in real time to ensure that the heat input during welding remains stable and the molten pool is stable. By automatically adjusting the wire feeding speed, the wire feeder can optimize the welding heat input, improve the welding efficiency, and avoid welding defects according to real-time molten pool and arc feedback, thereby achieving efficient, stable, and high-quality welding.

[0044] Furthermore, step S500 also includes step S510, creating a hysteresis feedback interval based on the optimized wire feeding speed control parameters; step S520, after the hysteresis feedback interval ends, re-calling the molten pool monitoring feedback and arc monitoring feedback for optimization analysis to establish optimized feedback.

[0045] Preferably, a hysteresis feedback interval is created based on the optimized wire feeding speed control parameters, wherein the hysteresis feedback interval refers to the system maintaining the existing wire feeding speed control parameters unchanged for a period of time, and not updating the monitoring feedback of the molten pool and the arc in real time. Within the hysteresis feedback interval, slight fluctuations in the feedback are temporarily ignored to prevent frequent and ineffective adjustments due to overly sensitive feedback, avoid over-adjustment or oscillation, and thus improve the stability and continuity of the welding process. During the welding process, the molten pool and arc states will be affected by instantaneous disturbances (such as welding current fluctuations, small irregularities on the workpiece surface, etc.), which may cause frequent changes in the feedback signal. If the system adjusts the wire feeding speed in real time according to these short-term fluctuations, it may cause instability in the welding process.

[0046] Preferably, according to the optimized wire feeding speed control parameters, an allowable feedback fluctuation range (such as temperature variation range, upper and lower limits of arc voltage or current, etc.) and a time threshold are set. If the optimized wire feeding speed is 4.5m / min, an adjustment hysteresis range of ±0.2m / min can be set; within the molten pool temperature fluctuation of ±30°C and within the hysteresis feedback interval (for example, 5 seconds or before a certain section of the welding path is completed), the wire feeding speed is not adjusted immediately, and the continuity and stability of the welding process are maintained as much as possible. After the hysteresis feedback interval ends, the molten pool monitoring feedback and arc monitoring feedback are combined again to perform a new optimization analysis on the state of the welding process. If both show that the state is normal, the existing wire feeding speed can be maintained; if the feedback of any party shows abnormality (such as molten pool overheating, arc instability, etc.), the wire feeding speed needs to be further adjusted; and then the optimization feedback is established according to the new optimization analysis results, and the new wire feeding speed control is executed, thereby improving the stability, efficiency and quality of the welding process.

[0047] In the above, refer to Figure 1 A method for adjusting the wire feeding speed of a wire feeder according to an embodiment of the present invention is described in detail. Figure 2 A wire feeding speed adjustment system for a wire feeder according to an embodiment of the present invention is described.

[0048] A wire feeding speed adjustment system for a wire feeder according to an embodiment of the present invention is used to solve the technical problem in the prior art that it is difficult to dynamically optimize the wire feeding speed according to the material and geometric shape of the workpiece, which leads to unstable processing quality, and achieves the technical effect of improving the control accuracy of the wire feeding speed and the processing quality. A wire feeding speed adjustment system for a wire feeder includes: a workpiece data set reading module 10, a wire feeding speed optimization space establishment module 20, a monitoring feedback establishment module 30, a joint optimization analysis module 40, and a wire feeding control module 50.

[0049] A workpiece data set reading module 10 is used to read a workpiece data set, wherein the workpiece data set includes workpiece material data and workpiece geometry data; a wire feeding speed optimization space establishment module 20 is used to perform feature extraction on the workpiece material data and the workpiece geometry data in the workpiece data set, establish workpiece features, and use the workpiece features to perform wire feeding speed control optimization and establish a wire feeding speed optimization space; a monitoring feedback establishment module 30 is used to perform wire feeding control of a wire feeder in the wire feeding speed optimization space and establish molten pool monitoring feedback and arc monitoring feedback; a joint optimization analysis module 40 is used to perform joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback and establish optimized wire feeding speed control parameters; a wire feeding control module 50 is used to control the wire feeding of a wire feeder according to the optimized wire feeding speed control parameters.

[0050] The specific configuration of the monitoring feedback establishment module 30 will be described in detail below. The monitoring feedback establishment module 30 further includes: configuring an infrared temperature sensor and an industrial camera at the molten pool monitoring position point; using the infrared temperature sensor to perform real-time temperature monitoring of the molten pool and establish molten pool temperature data; using the industrial camera to capture image data of the molten pool, using the image data to extract the shape features of the molten pool, and establishing molten pool state data based on the shape features; integrating the molten pool temperature data and the molten pool state data as molten pool monitoring feedback output.

[0051] The specific configuration of the monitoring feedback establishment module 30 will be described in detail below. The monitoring feedback establishment module 30 further includes: after graying the image data, filtering, denoising and contrast enhancement are performed on the grayed image data to establish a standardized image; performing image analysis on the standardized image, configuring a pixel threshold, performing image segmentation of the standardized image by the pixel threshold, and extracting the molten pool area; performing feature extraction based on edge detection on the molten pool area, performing shape symmetry analysis based on the feature extraction result, and establishing the first molten pool state data; performing shape roundness analysis on the feature extraction result, and establishing the second molten pool state data; and establishing the molten pool state data based on the first molten pool state data and the second molten pool state data.

[0052] The specific configuration of the monitoring feedback establishment module 30 will be described in detail below. The monitoring feedback establishment module 30 further includes: performing symmetry analysis using a symmetry formula, as follows: ; in, Characterize the symmetry parameters, The coordinate index representing the pixel point, Representation of the image at the coordinate position The pixel intensity value at Representation image in symmetrical position The pixel intensity value at Represents the total number of pixels in the image, that is, all The number of positions.

[0053] The specific configuration of the monitoring feedback establishment module 30 will be described in detail below. The monitoring feedback establishment module 30 further includes: using an arc sensor to monitor arc data of welding, establishing an arc data set, the arc data set including voltage data, current data, and arc length data; and establishing arc monitoring feedback according to the arc data set.

[0054] The specific configuration of the joint optimization analysis module 40 will be described in detail below. The joint optimization analysis module 40 further includes: performing optimization rough positioning of the wire feeding speed based on the arc monitoring feedback to obtain a rough adjustment result of the wire feeding speed; taking the rough adjustment result of the wire feeding speed as the optimization target, performing an intersection operation with the pre-established wire feeding speed optimization space to determine a rough optimization range of the wire feeding speed; adjusting the wire feeding speed precision within the rough optimization range based on the molten pool monitoring feedback to establish an optimized wire feeding speed control parameter.

[0055] The specific configuration of the wire feeding control module 50 will be described in detail below. The wire feeding control module 50 further includes: creating a hysteresis feedback interval based on the optimized wire feeding speed control parameter; after the hysteresis feedback interval ends, re-calling the molten pool monitoring feedback and the arc monitoring feedback for optimization analysis to establish optimization feedback.

[0056] A wire feeding speed adjustment system for a wire feeder provided in an embodiment of the present invention can execute a wire feeding speed adjustment method for a wire feeder provided in any embodiment of the present invention, and has functional modules and beneficial effects corresponding to the execution method.

[0057] Although the present application makes various references to certain modules in the system according to the embodiments of the present application, any number of different modules may be used and run on the user terminal and / or server, and the various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of the functional units are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention.

[0058] The above specific implementations do not constitute a limitation on the protection scope of this 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 this application should be included in the protection scope of this application.

Claims

1. A method for adjusting the wire feeding speed of a wire feeder, characterized in that: The method comprises: Reading a workpiece data set, wherein the workpiece data set includes workpiece material data and workpiece geometric shape data; Extracting features of the workpiece material data and the workpiece geometric shape data in the workpiece data set to establish workpiece features, and using the workpiece features to optimize wire feeding speed control to establish a wire feeding speed optimization space; The wire feeding speed optimization space is used to control the wire feeding of the wire feeder, and a molten pool monitoring feedback and an arc monitoring feedback are established; Performing a joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback to establish an optimized wire feeding speed control parameter; The wire feeding of the wire feeder is controlled according to the optimized wire feeding speed control parameters.

2. A method for adjusting the wire feeding speed of a wire feeder according to claim 1, characterized in that: The establishing of molten pool monitoring feedback and arc monitoring feedback comprises: Configure infrared temperature sensors and industrial cameras at the molten pool monitoring locations; Using the infrared temperature sensor to monitor the real-time temperature of the molten pool and establish molten pool temperature data; Using the industrial camera to capture image data of the molten pool, using the image data to extract shape features of the molten pool, and establishing molten pool state data according to the shape features; The molten pool temperature data and the molten pool status data are integrated and output as molten pool monitoring feedback.

3. A method for adjusting the wire feeding speed of a wire feeder according to claim 2, characterized in that: The step of extracting shape features of the molten pool using the image data and establishing molten pool state data according to the shape features comprises: After graying the image data, filtering, denoising and contrast enhancement are performed on the grayed image data to establish a standardized image; Performing image analysis on the standardized image, configuring a pixel threshold, performing image segmentation on the standardized image by using the pixel threshold, and extracting a molten pool area; Performing feature extraction based on edge detection on the molten pool area, performing shape symmetry analysis according to the feature extraction result, and establishing first molten pool state data; Perform shape and roundness analysis on the feature extraction results to establish the second molten pool state data; The molten pool state data is established according to the first molten pool state data and the second molten pool state data.

4. A method for adjusting the wire feeding speed of a wire feeder according to claim 3, characterized in that: The shape symmetry analysis is performed according to the feature extraction result, including: Symmetry analysis is performed using the symmetry formula as follows: ； in, Characterize the symmetry parameters, The coordinate index representing the pixel point, Representation of the image at the coordinate position The pixel intensity value at Representation image in symmetrical position The pixel intensity value at Represents the total number of pixels in the image, that is, all The number of positions.

5. A method for adjusting the wire feeding speed of a wire feeder according to claim 2, characterized in that: The establishment of molten pool monitoring feedback and arc monitoring feedback also includes: Using an arc sensor to monitor arc data of welding and establish an arc data set, wherein the arc data set includes voltage data, current data, and arc length data; An arc monitoring feedback is established based on the arc data set.

6. A method for adjusting the wire feeding speed of a wire feeder according to claim 1, characterized in that: The method of performing a joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback to establish an optimized wire feeding speed control parameter includes: Based on the arc monitoring feedback, the wire feeding speed is optimized and roughly positioned to obtain a wire feeding speed coarse adjustment result; Taking the rough adjustment result of the wire feeding speed as the optimization target, performing an intersection operation with the pre-established wire feeding speed optimization space to determine the rough optimization range of the wire feeding speed; The wire feeding speed precision is adjusted within the coarse optimization range based on the molten pool monitoring feedback to establish optimized wire feeding speed control parameters.

7. A method for adjusting the wire feeding speed of a wire feeder according to claim 1, characterized in that: After the wire feeding control of the wire feeder is performed according to the optimized wire feeding speed control parameter, the method further includes: Creating a hysteresis feedback interval based on the optimized wire feeding speed control parameters; After the hysteresis feedback interval ends, the molten pool monitoring feedback and arc monitoring feedback are re-called for optimization analysis to establish optimization feedback.

8. A wire feeding speed adjustment system for a wire feeder, characterized in that: The system is used to implement a method for adjusting the wire feeding speed of a wire feeder according to any one of claims 1 to 7, and the system comprises: A workpiece data set reading module, used for reading a workpiece data set, wherein the workpiece data set includes workpiece material data and workpiece geometric shape data; A wire feeding speed optimization space establishment module is used to extract features of the workpiece material data and the workpiece geometry data in the workpiece data set, establish workpiece features, and use the workpiece features to optimize wire feeding speed control and establish a wire feeding speed optimization space; A monitoring feedback establishment module is used to control the wire feeding of the wire feeder by searching the optimal space of the wire feeding speed, and to establish molten pool monitoring feedback and arc monitoring feedback; A joint optimization analysis module, used for performing a joint optimization analysis of the wire feeding speed through the molten pool monitoring feedback and the arc monitoring feedback, and establishing an optimized wire feeding speed control parameter; The wire feeding control module is used to control the wire feeding of the wire feeding machine according to the optimized wire feeding speed control parameters.

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