Welding machine current adjusting system and method based on high-efficiency chopping control

Abstract

The invention provides a welding machine current adjusting system and method based on high-effect chopping control, and relates to the technical field of current control, and the welding machine current adjusting system comprises the steps that a welding positioning modeling module carries out modeling to obtain a welding positioning model; the welding data extraction module is used for identifying welding seam change nodes and extracting welding area data to obtain a plurality of welding material parameter sets; the chopping analysis module is used for carrying out chopping control analysis on the welding material parameter sets and outputting a plurality of chopping modulation parameters; the welding track fitting module carries out switching stability analysis and welding track fitting and outputs K welding tracks; the modulation parameter assembling module is used for assembling a plurality of chopping modulation parameters to obtain K chopping modulation sequences; the welding sequence analysis module is connected with K welding tracks to generate an optimized welding track; and the current control module performs dynamic current control. The technical problem that according to a traditional adjusting method, the welding current cannot be rapidly adjusted according to changes of welding conditions in the welding process is solved, and the welding precision and the welding quality are improved.

Description

Technical Field

[0001] The present application relates to the technical field of current control, and in particular to a welding machine current regulation system and method based on high-efficiency chopping control. Background Art

[0002] In modern welding technology, welding machine current regulation is a key link to ensure welding quality. Traditionally, the methods for adjusting welding current mainly include manual adjustment and automatic adjustment based on simple feedback mechanisms. Manual adjustment relies on the experience of the welder. Although it has certain flexibility, it is difficult to ensure the current accuracy and consistency during the welding process, especially when dealing with complex geometries or different materials, the welding quality is difficult to control. Although automatic adjustment based on simple feedback has improved the level of welding automation to a certain extent, it is difficult to adapt to the rapid changes in welding conditions due to the long feedback response time and the relatively fixed adjustment strategy. Especially in welding environments where the current demand fluctuates frequently, the welding quality may be significantly affected. In addition, traditional current adjustment methods are often accompanied by high energy loss, which reduces the energy utilization rate of welding operations. Summary of the invention

[0003] The present application provides a welding machine current regulation system and method based on high-efficiency chopper control, which solves the technical problem that the traditional welding current regulation method has a slow response speed and cannot quickly adjust the welding current according to changes in welding conditions during the welding process, resulting in limited welding flexibility and accuracy, and achieves the technical effect of improving welding accuracy and welding quality while enhancing the flexibility and adaptability of the welding machine.

[0004] In view of the above problems, on the one hand, the present application provides a welding machine current regulation system based on high-efficiency chopping control, the system comprising: a welding positioning modeling module, the welding positioning modeling module is used to interactively obtain welding assembly information of parts to be welded, and obtain a welding positioning model according to the welding assembly information modeling; a welding data extraction module, the welding data extraction module is used to identify weld change nodes based on the welding positioning model, and extract welding area data based on the identification result, to obtain multiple welding material parameter sets for multiple sub-welds; a chopping analysis module, the chopping analysis module is used to output multiple chopping modulation parameters by performing chopping control analysis on the multiple welding material parameter sets; a welding trajectory fitting module, the welding trajectory fitting module is used to extract the welding material parameter sets according to the multiple sub-welds in the welding positioning model. A chopping modulation switching stability analysis is performed on the multiple chopping modulation parameters according to the connection relationship of the bit model, and welding trajectory fitting is performed based on the analysis result to output K welding trajectories; a modulation parameter assembling module, the modulation parameter assembling module is used to assemble the multiple chopping modulation parameters according to the sub-weld composition of the K welding trajectories to obtain K chopping modulation sequences; a welding sequence analysis module, the welding sequence analysis module is used to perform welding sequence analysis on the parts to be welded according to the welding assembly information, and connect the K welding trajectories based on the analysis result to generate an optimized welding trajectory; a current control module, the current control module is used to use the optimized welding trajectory as the welding trajectory switching constraint of the welding machine, and use the K chopping modulation sequences to perform dynamic current control of the welding process of the parts to be welded by the welding machine.

[0005] On the other hand, the present application also provides a welding machine current regulation method based on high-efficiency chopping control, the method comprising: interactively obtaining welding assembly information of the parts to be welded, and modeling to obtain a welding positioning model based on the welding assembly information; identifying weld change nodes based on the welding positioning model, and extracting welding area data based on the identification results to obtain multiple welding material parameter sets of multiple sub-welds; performing chopping control analysis on the multiple welding material parameter sets to output multiple chopping modulation parameters; performing chopping modulation switching stability analysis on the multiple chopping modulation parameters based on the connection relationship of the multiple sub-welds in the welding positioning model, and performing welding trajectory fitting based on the analysis results to output K welding trajectories; assembling the multiple chopping modulation parameters according to the sub-weld composition of the K welding trajectories to obtain K chopping modulation sequences; performing welding sequence analysis on the parts to be welded based on the welding assembly information, and connecting the K welding trajectories based on the analysis results to generate an optimized welding trajectory; using the optimized welding trajectory as the welding trajectory switching constraint of the welder, and using the K chopping modulation sequences to perform dynamic current control of the welding process of the parts to be welded by the welder.

[0006] One or more technical solutions provided in this application have at least the following technical effects or advantages: The welding positioning modeling module interactively obtains the welding assembly information of the parts to be welded, and obtains the welding positioning model based on the welding assembly information, determines the spatial relationship and welding requirements of the welding parts, and thus ensures the accuracy of subsequent analysis and control. The welding data extraction module identifies the weld change nodes based on the welding positioning model, and extracts the welding area data based on the identification results, obtains multiple welding material parameter sets of multiple sub-welds, and provides data basis for subsequent chopping control. The chopping analysis module performs chopping control analysis on the multiple welding material parameter sets, outputs multiple chopping modulation parameters, and determines refined chopping control parameters for each sub-weld. The welding trajectory fitting module performs chopping modulation switching stability analysis on the multiple chopping modulation parameters according to the connection relationship of the multiple sub-welds in the welding positioning model, and performs welding trajectory fitting based on the analysis results, and outputs K welding trajectories, ensuring the smooth transition of the welding trajectory and avoiding the influence of current mutation on welding quality. The modulation parameter assembly module assembles the multiple chopping modulation parameters according to the sub-welds of K welding trajectories, obtains K chopping modulation sequences, and provides a dynamic current control strategy for the subsequent welding process. The welding sequence analysis module performs welding sequence analysis of the parts to be welded according to the welding assembly information, and connects the K welding trajectories based on the analysis results to generate an optimized welding trajectory to optimize the welding process. The current control module uses the optimized welding trajectory as a welding trajectory switching constraint of the welding machine, and uses the K chopping modulation sequences to perform dynamic current control of the welding process of the parts to be welded by the welding machine to ensure the stability of the welding process and the welding quality.

[0007] In summary, this application improves the understanding and prediction capabilities of the welding process by establishing a welding positioning model and identifying weld change nodes, thereby achieving more accurate welding control. The introduction of chopping control technology makes current regulation more flexible and efficient, and can better adapt to the needs of different welding materials and conditions. By analyzing welding assembly information and welding sequence, an optimized welding trajectory is generated, ensuring the stability and accuracy of the welding process, thereby improving welding quality.

[0008] 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. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 A schematic diagram of the structure of a welding machine current regulation system based on high-efficiency chopper control provided in an embodiment of the present application; Figure 2 A schematic diagram of a flow chart of obtaining a chopping control analysis model in a welding machine current regulation system based on high-efficiency chopping control provided in an embodiment of the present application; Figure 3 A flow chart of a welding machine current regulation method based on high-efficiency chopping control provided in an embodiment of the present application.

[0010] Explanation of the reference numerals: welding positioning modeling module 10 , welding data extraction module 20 , chopping analysis module 30 , welding trajectory fitting module 40 , modulation parameter assembly module 50 , welding sequence analysis module 60 , current control module 70 . DETAILED DESCRIPTION

[0011] The embodiments of the present application provide a welding machine current regulation system and method based on high-efficiency chopping control, thereby solving the technical problem that the traditional welding current regulation method has a slow response speed and cannot quickly adjust the welding current according to changes in welding conditions during the welding process, resulting in limited welding flexibility and accuracy. The technical effect of improving welding accuracy and welding quality while enhancing the flexibility and adaptability of the welding machine is achieved.

[0012] Embodiment 1, as Figure 1 As shown, the embodiment of the present application provides a welding machine current regulation system based on high-efficiency chopper control, the system comprising: The welding positioning modeling module 10 is used to interactively obtain welding assembly information of the parts to be welded, and to obtain a welding positioning model by modeling according to the welding assembly information.

[0013] Specifically, the welding positioning modeling module 10 collects the welding assembly information of the parts to be welded through the human-computer interaction interface or automated detection equipment, wherein the welding assembly information of the parts to be welded includes key data such as the material properties, size specifications, shape characteristics, welding positions, and welding sequences of the parts to be welded. For example, for body welding in the automotive manufacturing industry, the module will obtain data such as the material type (such as high-strength steel, aluminum alloy, etc.), thickness, size, and weld position of each part of the body. Using CAD (computer-aided design) software, such as SolidWorks, AutoCAD, or CATIA, a three-dimensional model is constructed based on the collected welding assembly information to obtain a welding positioning model, which is a virtual model used to represent the precise position and posture of the parts to be welded during the welding process to ensure the accuracy of the welding process.

[0014] The welding data extraction module 20 is used to identify weld change nodes based on the welding positioning model, and extract welding area data based on the identification results to obtain multiple welding material parameter sets of multiple sub-welds.

[0015] Specifically, the weld change node is a point in the weld path where the weld direction or attribute changes. The welding data extraction module 20 identifies all key nodes on the welding positioning model, including the start point, the end point, the intersection point, and the attribute change point, through image processing or point cloud analysis technology. For example, when welding a complex metal frame with multiple connection points, the module will accurately identify the position of each connection point. Based on the identified weld change nodes, the weld between any two adjacent key nodes is determined as a sub-weld, and each sub-weld corresponds to a welding area, and the material properties and thickness of the area tend to be consistent. Extract the necessary information such as material properties, thickness, preheating temperature, etc. of each welding area. For example, for a weld composed of different materials, it is necessary to adjust the welding parameters according to the thermal conductivity and melting point of each material to ensure the welding quality. Based on the extracted welding data, a welding material parameter set for each sub-weld is generated. Among them, the welding material parameter set is a set of specific performance parameters of the welding material corresponding to each sub-weld extracted by the welding data extraction module 20, including the thermal conductivity, melting point, thermal expansion coefficient, etc. of the welding material, which will affect the quality of the welding process.

[0016] Through the above steps, the welding data extraction module 20 can determine the welding requirements of all specific parts of the components to be welded, provide an analysis basis for subsequent chopping analysis, and ensure the accuracy of current control.

[0017] The chopping analysis module 30 is used to output a plurality of chopping modulation parameters by performing chopping control analysis on the plurality of welding material parameter sets.

[0018] Specifically, the module receives the material parameter set from the welding data extraction module 20, and uses algorithms such as PID (proportional-integral-differential) control, fuzzy logic control or neural network, combined with welding material parameters, to calculate the control parameters of the chopper circuit. Among them, the chopper modulation parameters include the switching frequency and duty cycle of the chopper circuit, which are used to control the on and off of the current to achieve precise control of the required welding current. For example, when welding stainless steel sheets, the module will determine the optimal duty cycle and switching frequency through an algorithm to ensure the welding quality. The frequency of the chopper modulation determines the repetition rate of the current pulse. A higher frequency can provide a smoother current output, which helps to improve the stability of the welding process. The duty cycle refers to the ratio of the pulse on time to the cycle time in one cycle, which directly determines the average value of the output current. By adjusting the duty cycle, precise control of the welding current can be achieved without changing the voltage.

[0019] The welding trajectory fitting module 40 is used to perform chopping modulation switching stability analysis on the multiple chopping modulation parameters according to the connection relationship between the multiple sub-welds in the welding positioning model, and perform welding trajectory fitting based on the analysis results to output K welding trajectories.

[0020] Specifically, the sub-weld connection relationship refers to the relative position and connection method of multiple sub-welds in space. The module first identifies the relative position and connection point of each sub-weld in space and determines a reasonable welding sequence. Based on the determined welding sequence, the switching of the chopping modulation parameters between different sub-welds is analyzed to ensure a smooth transition of the current. According to the stability analysis results of the chopping modulation parameters, the welding path is divided into K welding trajectories, and the chopping modulation parameters of each welding trajectory tend to be consistent. Through the intelligent analysis and optimization of the welding trajectory fitting module 40, the welding trajectory fitting module 40 can realize the precise planning of the welding path and ensure the continuity and stability of the welding process.

[0021] The modulation parameter assembly module 50 is used to assemble the multiple chopping modulation parameters according to the sub-welds of K welding tracks to obtain K chopping modulation sequences.

[0022] Specifically, the chopping modulation sequence is a set of a series of chopping modulation parameters, and each set of parameters in the set corresponds to a sub-weld of the welding trajectory. The modulation parameter assembly module 50 first receives K welding trajectories generated by the welding trajectory fitting module 40. Each welding trajectory is composed of a plurality of sub-welds, and each sub-weld has its corresponding chopping modulation parameters. Then, the module assembles the corresponding chopping modulation parameters according to the composition of these sub-welds, generates a chopping modulation sequence for each welding trajectory, and obtains K chopping modulation sequences to ensure that each chopping modulation sequence can adapt to its corresponding welding trajectory.

[0023] The welding sequence analysis module 60 is used to perform welding sequence analysis of the components to be welded according to the welding assembly information, and connect the K welding trajectories based on the analysis results to generate an optimized welding trajectory.

[0024] Specifically, the welding sequence analysis module 60 first receives the welding assembly information from the welding positioning modeling module 10, including the structure, material properties, connection points, etc. of the components, and parses out the welding priority and constraints of each subcomponent. Then, the welding sequence is analyzed to determine the welding sequence of each subcomponent. For example, the module may consider factors such as the structural stability of the components, welding deformation, and thermal effects to determine the optimal welding sequence. According to the determined welding sequence, the module will connect K welding trajectories in this order, generate an optimized welding trajectory, and determine the optimal current control strategy for the welding process.

[0025] The current control module 70 is used to use the optimized welding trajectory as a welding trajectory switching constraint of the welding machine, and use the K chopping modulation sequences to perform dynamic current control of the welding process of the welding machine on the parts to be welded.

[0026] Specifically, the current control module 70 receives the optimized welding trajectory and uses the trajectory as the welding path switching constraint of the welder to ensure that the welder welds according to the preset path, such as starting from the bottom of the structural member and gradually welding upwards. According to the sub-weld sequence on the optimized trajectory, the module reads the chopping modulation sequence, generates a control signal, and adjusts the welder to output a current suitable for welding the material. As the welding process progresses, the current control module 70 dynamically adjusts the current according to the chopping modulation sequence. Whenever the welder transitions from one weld to another, it automatically adjusts to the corresponding switch device duty cycle and switching frequency according to the material combination type, thereby controlling the output voltage, thereby adjusting the current to a suitable welding level, achieving efficient welding process control, and ensuring the continuity and welding quality of the welding process.

[0027] Furthermore, the execution steps of the welding positioning modeling module 10 in the embodiment of the present application also include: Based on the welding assembly information, M welding component information of M welding components is obtained, wherein the M welding component information includes M component geometric parameters and M component attribute information; after constructing and obtaining M component structural models with the M component geometric parameters as modeling constraints, the M component attribute information is fitted to the M component structural models to obtain M welding component models; the assembly relationship information extracted from the welding assembly information is used as an assembly constraint to assemble the M welding component models to obtain the welding positioning model.

[0028] Specifically, the M welding component information is detailed information of the M components contained in the part to be welded, including geometric parameters and attribute information, wherein the component geometric parameters are parameters including size, shape, etc. that describe the physical structure of the component; the component attribute information is information that affects the setting of welding process parameters including material type and welding requirements; M is a positive integer, representing the total number of components in the part to be welded.

[0029] The welding positioning modeling module 10 first extracts detailed information of M welding components from the welding assembly information, including component geometric parameters and component attribute information. Then, based on the geometric parameters of these components, M component structure models are constructed using 3D modeling software (such as SolidWorks or AutoCAD). Next, the module fits the attribute information of these components to the corresponding component structure models to form M welding component models to ensure that the models can accurately reflect the physical and chemical properties of the components. Using the assembly relationship information extracted from the welding assembly information as an assembly constraint, these welding component models are assembled to form a complete welding positioning model. This model not only shows the structure and attribute information of each welding component, but also shows the assembly and connection relationship between components, providing an accurate reference for welding trajectory planning and welding process control.

[0030] Furthermore, the execution steps of the welding data extraction module 20 in the embodiment of the present application also include: Based on the weld change nodes, the weld path extraction is performed on the welding positioning model to obtain H weld paths; the welding associated dimensions are preset, and the welding associated dimensions and the H weld paths are used as welding area collection constraints, and the welding area data is extracted on the welding positioning model to obtain H area geometric parameters and H area attribute information; the consistency judgment is performed on the H area geometric parameters and the H area attribute information, and the weld path is split based on the judgment result to obtain the multiple sub-welds; the multiple welding material parameter sets of the multiple sub-welds are extracted from the H area geometric parameters and the H area attribute information, wherein each of the multiple welding material parameter sets includes a first component welding attribute-thickness information and a second component welding attribute-thickness information.

[0031] Specifically, based on the weld change nodes in the welding positioning model, H weld paths, i.e., the basic framework of the welding path, are extracted. H is a positive integer, indicating the specific number of weld paths generated. A welding associated dimension is preset, which is a preset dimension used to define the size of the welding area, and determines the extraction range of the welding area data. With the welding associated dimension and the H weld paths as constraints, the welding area data is extracted in the welding positioning model to obtain the geometric parameters and attribute information of the H areas. The geometric parameters and attribute information of the extracted H areas are judged for consistency. If significant changes are found in the material properties or thickness, the weld path is split to form multiple sub-welds. The welding material parameter set of the sub-weld is extracted from the regional geometric parameters and attribute information. Each parameter set contains the material attribute information and welding thickness information of the components at both ends of the weld, i.e., the welding attribute-thickness information of the first component and the welding attribute-thickness information of the second component.

[0032] Exemplarily, in the welding positioning model of the oil tank, the weld change nodes include the connection between the bottom plate and the side plate, the connection between the side plates, and the connection between the side plate and the top cover. By identifying the weld change nodes, H weld paths are extracted. For this oil tank, H=3, representing the bottom plate-side plate connection path, the side plate-side plate connection path, and the side plate-top cover connection path, respectively. The preset welding association size is 10mm, and within the 10mm range of each weld path, geometric parameters (such as thickness change) and attribute information (such as material type) are extracted. On the bottom plate-side plate connection path, thickness information of 3mm (bottom plate) and 5mm (side plate) is collected. Check whether the thickness information of the welding area is consistent. At the bottom plate-side plate connection, it is found that the thickness changes from 3mm to 5mm, so the bottom plate-side plate connection path is split into two sub-welds at the bottom plate end and the side plate end. Extract welding material parameter sets for each sub-weld. The bottom plate end parameter set contains the first component welding attribute-thickness information (3mm) and the second component welding attribute-thickness information (5mm). Similarly, extract the parameter set for the side panel end.

[0033] Through the precise operation of the welding data extraction module 20, detailed welding material parameters can be provided for each weld, ensuring the accuracy and efficiency of the welding process.

[0034] Furthermore, the execution steps of the welding data extraction module 20 in the embodiment of the present application also include: The weld path is extracted based on the welding positioning model to obtain the weld path topology; the weld change nodes are identified on the weld path topology to obtain multiple weld intersections; the weld path topology is disassembled based on the multiple weld intersections to obtain H weld paths.

[0035] Specifically, based on the welding positioning model, a topology analysis tool (such as OpenCASCADE or CGAL) is used to extract the overall structure of the weld path to form a weld path topology. The weld path topology is an abstract representation of the overall structure of the weld path, including the connection method of the welds and the path direction. The weld path topology is analyzed to identify the weld change nodes, especially the weld intersection points, that is, the points where multiple weld paths intersect. These points are important turning points of the weld path.

[0036] Starting from the weld intersection, define a weld path segment along any direction of the weld path until the next weld intersection or the end point of the weld path is encountered. Treat each defined weld path segment as an independent welding unit to ensure that each weld path segment is topologically complete. For example, in the welding of an oil storage tank, the intersection point of the bottom plate and the side plate is A, and the intersection point of the side plate and the top plate is B. Starting from point A, follow the bottom plate weld path until the end point of the bottom plate welding, which is defined as weld path segment 1. Starting from point A, follow the side plate weld path until the intersection point B, which is defined as weld path segment 2.

[0037] For each independent weld path segment, its geometric information (such as length, width, thickness) and position information, as well as the connection relationship with the weld intersection point are recorded in detail. The detailed information of all independent weld path segments is integrated to form H specific weld path information sets, each of which corresponds to an independent weld path segment, providing detailed path information for the subsequent welding process planning.

[0038] Further, such as Figure 2 As shown, the chopping analysis module 30 of the embodiment of the present application performs chopping control analysis on the multiple welding material parameter sets and outputs multiple chopping modulation parameters. Before that, the execution steps also include: Interactively obtain multiple sample material parameter sets and multiple sample chopping modulation parameters; aggregate the multiple sample material parameter sets and multiple sample chopping modulation parameters based on material properties to obtain K groups of sample material thickness parameters and K groups of sample chopping modulation parameters of K heterogeneous property combinations; perform regression analysis on the K groups of sample material thickness parameters and the K groups of sample chopping modulation parameters, and construct K chopping control analysis branches based on the analysis results; connect the K chopping control analysis branches in parallel to obtain a chopping control analysis model.

[0039] Specifically, multiple sample material parameter sets and corresponding sample chopping modulation parameters are interactively collected from historical welding data or experimental data, wherein the sample material parameter set is a set of material property data collected from the actual welding process, including parameters such as thickness and type of different materials. The sample chopping modulation parameters are a set of chopping control parameters corresponding to the sample material parameter set, including chopping frequency and duty cycle. The collected sample data are classified based on material properties, and K heterogeneous property combinations are identified, each combination representing a set of sample data sets for a specific material property and thickness. Linear regression or multivariate regression is used to perform statistical regression analysis on K groups of sample material thickness parameters and corresponding chopping modulation parameters, a relationship model between material parameters and chopping modulation parameters is established, and K chopping control analysis branches are constructed, each branch corresponding to a welding situation of a heterogeneous property combination. The specific construction process includes: Collect multiple sample data sets including material type, thickness, frequency and duty cycle. Based on the material combination type on both sides of the weld, aggregate multiple sample material parameter sets and multiple sample chopping modulation parameters to obtain K heterogeneous attribute combinations. Each combination contains multiple sample material parameter sets and multiple sample chopping modulation parameters of the same material combination type but different thicknesses, such as 1.2mm copper-2mm stainless steel, 1.5mm copper-2mm stainless steel, etc. For each set of heterogeneous material combination data, select a suitable regression model to construct a regression model of chopping modulation parameters and material thickness. For frequency and duty cycle, linear regression or nonlinear regression models can be used respectively. For example, ; . Estimate model parameters using least squares or Bayesian methods. For new material combination types, collect data and build and optimize the model according to the above steps.

[0040] K chopping control analysis branches are connected in parallel to form a comprehensive chopping control analysis model. The chopping control analysis model can output corresponding optimized chopping modulation parameters according to the input material parameter set to adapt to the welding requirements of different materials and improve the adaptability of the welding machine to different welding conditions.

[0041] Furthermore, the execution steps of the chopping analysis module 30 in the embodiment of the present application also include: A first welding material parameter set is extracted from the multiple welding material parameter sets, and a first heterogeneous attribute combination is obtained by performing welding attribute extraction on the first component welding attribute-thickness information and the second component welding attribute-thickness information in the first welding material parameter set; welding thickness extraction is performed on the first component welding attribute-thickness information and the second component welding attribute-thickness information in the first welding material parameter set to obtain a first welding thickness combination; after locating and activating the first chopping control analysis branch in the chopping control analysis model according to the first heterogeneous attribute combination, the first welding thickness combination is synchronized to the first chopping control analysis branch to obtain a first chopping modulation parameter through analysis; and so on, chopping control analysis is performed on the multiple welding material parameter sets to output the multiple chopping modulation parameters.

[0042] Specifically, a parameter set is selected from a plurality of welding material parameter sets as a first welding material parameter set, and welding property-thickness information of the first component and welding property-thickness information of the second component are extracted therefrom to form a first heterogeneous property combination. Specific thickness values ​​of the first component and the second component are further extracted from the first welding material parameter set to form a first welding thickness combination. According to the first heterogeneous property combination, a first chopping control analysis branch matching it is located and activated in a pre-built chopping control analysis model. The first welding thickness combination is input into the first chopping control analysis branch, which outputs a first chopping modulation parameter through analysis. Repeat the above steps, perform chopping control analysis on multiple welding material parameter sets, and output multiple chopping modulation parameters.

[0043] Exemplarily, a composite structural part is welded, including an aluminum plate with a thickness of 2 mm, a stainless steel plate with a thickness of 3 mm, and a copper plate with a thickness of 5 mm. A parameter set consisting of a 2 mm aluminum plate and a 3 mm stainless steel plate is selected to form a first heterogeneous property combination. Thickness information of 2 mm and 3 mm is extracted from the parameter set. In the chopping control analysis model, the analysis path corresponding to aluminum and stainless steel is located and activated. Through the analysis path, the optimized chopping modulation parameters for the thickness of 2 mm and 3 mm are output. The above process is repeated for all material parameter sets to obtain the optimized chopping modulation parameters for each heterogeneous property combination.

[0044] Through the above steps, the chopping analysis module 30 can intelligently output the optimal chopping modulation parameters according to the welding requirements of different materials and thicknesses, thereby significantly improving the welding accuracy and welding quality.

[0045] Furthermore, the execution steps of the welding trajectory fitting module 40 in the embodiment of the present application also include: Predefine a chopping modulation switching threshold; after fitting the multiple sub-welds to the weld path topology, locate the first sub-weld in the weld path topology; predefine a first connection direction, use the first connection direction as a constraint, and call the first associated weld information in the weld path topology based on the connection relationship; if the first associated weld information is a single associated weld, obtain a single associated parameter mapped to the single associated weld from the multiple chopping modulation parameters; if the deviation between the single associated parameter and the first chopping modulation parameter meets the chopping modulation switching threshold, connect the single associated parameter and the first group of associated welds to generate a first updated welding trajectory; if the deviation between the single associated parameter and the first chopping modulation parameter does not meet the chopping modulation switching threshold, use the first sub-weld as the first welding trajectory; use the chopping modulation switching threshold and the weld path topology as welding trajectory extension constraints, extend the single associated weld, and generate a second welding trajectory; and so on, traverse the multiple sub-welds to produce the K welding trajectories.

[0046] Specifically, before starting to fit the welding trajectory, a reasonable switching threshold is set to determine the necessity of switching the chopping modulation parameters between different welds, that is, the chopping modulation switching threshold. Multiple sub-welds are fitted into the weld path topology, and the first sub-weld is located, which is the weld to be welded first. Next, a first connection direction is predefined, and the connection direction refers to the connection direction of the welds in the welding trajectory, which is used to guide the generation of the welding trajectory. Based on the first connection direction, the first associated weld information is called according to the connection relationship between the welds. The first associated weld information is the subsequent weld information associated with the current sub-weld.

[0047] If the first associated weld information is a single associated weld, that is, the current sub-weld is only connected to one subsequent weld, then check the corresponding single associated parameter, which is the chopping modulation parameter corresponding to the single associated weld. Calculate the difference between the single associated parameter and the first chopping modulation parameter. If the deviation between the single associated parameter and the first chopping modulation parameter meets the chopping modulation switching threshold, connect the two to generate the first updated welding trajectory; otherwise, treat the first sub-weld as an independent first welding trajectory. Obtain the associated weld information of the first updated welding trajectory according to the weld path topology, perform the switching threshold judgment according to the associated weld information, extend the single associated weld, and generate subsequent welding trajectories. Repeat the above process, traverse all sub-welds, and finally generate K welding trajectories.

[0048] For example, a weld path including three sub-welds is welded: A, B and C, where A is connected to B, B is connected to C, and the weld path topology is ABC. The chopping modulation switching threshold is set to 5%. Sub-weld A is located, and the weld information of B associated with A is called based on the connection direction. The chopping modulation parameters of A are 200 Hz frequency and 50% duty cycle, while the single associated parameters of B are 205 Hz frequency and 52% duty cycle.

[0049] Since the changes in frequency and duty cycle do not exceed 5%, A and B are connected to generate an updated welding trajectory. The relationship between B and C is continued to be checked. If the parameter change exceeds the switching threshold, A and B form a welding trajectory; otherwise, B is connected to C. All welds are traversed to finally generate a welding trajectory set that meets the requirements.

[0050] Furthermore, the execution steps of the welding trajectory fitting module 40 in the embodiment of the present application also include: If the first associated weld information includes multiple first associated welds, then multiple first associated parameters mapped to the multiple first associated welds are obtained from the multiple chopping modulation parameters; the first chopping modulation parameter mapped to the first sub-weld is obtained from the multiple chopping modulation parameters; based on the multiple first associated parameters and the first chopping modulation parameters, the first associated weld that meets the chopping modulation switching threshold and has the smallest Euclidean distance is obtained as a welding trajectory to extend and connect the first sub-weld, so as to generate the first updated welding trajectory.

[0051] Specifically, if the first associated weld information includes multiple first associated welds, multiple first associated parameters corresponding to these welds and the first chopping modulation parameter corresponding to the first sub-weld are obtained. The differences between the multiple first associated parameters and the first chopping modulation parameter are calculated respectively, and compared with the chopping modulation switching threshold, and the associated welds that meet the chopping modulation switching threshold are screened out. Among the welds that meet the conditions, the Euclidean distance between the first associated parameters corresponding to these welds that meet the conditions and the first chopping modulation parameter is further calculated, and the first associated weld with the smallest Euclidean distance in the multidimensional space is selected. The screened first associated weld is connected with the first sub-weld to generate a first updated welding trajectory. This selection process ensures the rationality of the switching and the smooth transition of the welding process.

[0052] For example, there is a main weld A in the welding path, which needs to be connected with one of the subsequent welds B, C, and D. The chopping modulation parameters of weld A are frequency 200Hz and duty cycle 50%. Get the first associated parameters: B (frequency 203Hz, duty cycle 51%); C (frequency 205Hz, duty cycle 49%); D (frequency 190Hz, duty cycle 51%). The switching threshold is set as: the frequency change does not exceed 3Hz, and the duty cycle change does not exceed 2%. After judgment, welds B and C both meet the switching threshold, and the Euclidean distance of the chopping modulation parameters of welds B, welds C and welds A is calculated respectively: The distance between A and B is ; The distance between A and C is .

[0053] Since the parameter changes of B and C both meet the switching threshold, but the Euclidean distance between B and A is smaller, B is selected as the weld connecting with A.

[0054] Through the above specific steps, the welding trajectory fitting module 40 can intelligently adjust the welding trajectory and chopping modulation parameters according to the weld path topology and the preset switching threshold, optimize the connection between welds, and ensure the efficiency and smoothness of the welding process.

[0055] In summary, the welding machine current regulation system based on high-efficiency chopper control provided by the embodiment of the present application has the following technical effects: The welding positioning modeling module 10 interactively obtains M welding component information of the parts to be welded, constructs M welding component models respectively, and assembles M welding component models according to the assembly relationship information to obtain a welding positioning model, determine the spatial relationship and welding requirements of the welding parts, thereby ensuring the accuracy of subsequent analysis and control. The welding data extraction module 20 identifies the weld change nodes based on the welding positioning model, obtains H weld paths based on the identification results, extracts welding area data, obtains multiple welding material parameter sets of multiple sub-welds, and provides data basis for subsequent chopping control. The chopping analysis module 30 constructs a chopping control analysis model through regression analysis, performs chopping control analysis on the multiple welding material parameter sets, outputs multiple chopping modulation parameters, optimizes welding parameters for different materials and thicknesses, and determines refined chopping control parameters for each sub-weld to improve welding quality. The welding trajectory fitting module 40 performs a chopping modulation switching stability analysis on the multiple chopping modulation parameters according to the connection relationship of the multiple sub-welds in the welding positioning model, obtains the associated weld information and compares it with the chopping modulation switching threshold, and performs welding trajectory fitting based on the comparison analysis results, outputs K welding trajectories, ensures the smooth transition of the welding trajectory, and avoids the influence of current mutation on welding quality. The modulation parameter assembly module 50 assembles the multiple chopping modulation parameters according to the sub-welds of the K welding trajectories, obtains K chopping modulation sequences, and provides a dynamic current control strategy for the subsequent welding process. The welding sequence analysis module 60 performs a welding sequence analysis of the parts to be welded according to the welding assembly information, and connects the K welding trajectories based on the analysis results to generate an optimized welding trajectory, ensure the efficiency and continuity of the welding process, and reduce welding interruption and adjustment time. The current control module 70 uses the optimized welding trajectory as the welding trajectory switching constraint of the welding machine, and uses the K chopping modulation sequences to perform dynamic current control of the welding process of the welding machine on the parts to be welded, ensuring the stability of the welding process and the welding quality.

[0056] In general, the embodiments of the present application improve the understanding and prediction capabilities of the welding process by establishing a welding positioning model and identifying weld change nodes, thereby achieving more accurate welding control. The introduction of chopping control technology makes current regulation more flexible and efficient, and can better meet the needs of different welding materials and conditions. By analyzing welding assembly information and welding sequence, an optimized welding trajectory is generated, ensuring the stability and accuracy of the welding process, thereby improving welding quality.

[0057] Embodiment 2, as Figure 3 As shown, the embodiment of the present application provides a welding machine current regulation method based on high-efficiency chopping control, the method comprising: The welding assembly information of the parts to be welded is interactively obtained, and a welding positioning model is obtained by modeling according to the welding assembly information.

[0058] Weld seam change nodes are identified based on the welding positioning model, and welding area data is extracted based on the identification result to obtain multiple welding material parameter sets of multiple sub-weld seams.

[0059] A plurality of chopping modulation parameters are outputted by performing chopping control analysis on the plurality of welding material parameter sets.

[0060] According to the connection relationship between the multiple sub-welds in the welding positioning model, the multiple chopping modulation parameters are subjected to chopping modulation switching stability analysis, and welding trajectory fitting is performed based on the analysis result to output K welding trajectories.

[0061] The plurality of chopping modulation parameters are assembled according to the sub-weld seams of the K welding tracks to obtain K chopping modulation sequences.

[0062] The welding sequence of the components to be welded is analyzed according to the welding assembly information, and the K welding trajectories are connected based on the analysis result to generate an optimized welding trajectory.

[0063] The optimized welding trajectory is used as a welding trajectory switching constraint of a welding machine, and the K chopping modulation sequences are used to perform dynamic current control of the welding process of the welding machine on the parts to be welded.

[0064] Furthermore, the embodiment of the present application interactively obtains welding assembly information of the parts to be welded, and models the welding positioning model according to the welding assembly information, and further includes: Based on the welding assembly information, M welding component information of M welding components is obtained, wherein the M welding component information includes M component geometric parameters and M component attribute information; after constructing and obtaining M component structural models with the M component geometric parameters as modeling constraints, the M component attribute information is fitted to the M component structural models to obtain M welding component models; the assembly relationship information extracted from the welding assembly information is used as an assembly constraint to assemble the M welding component models to obtain the welding positioning model.

[0065] Furthermore, the embodiment of the present application identifies weld change nodes based on the welding positioning model, extracts welding area data based on the identification results, and obtains multiple welding material parameter sets of multiple sub-welds, and also includes: Based on the weld change nodes, the weld path extraction is performed on the welding positioning model to obtain H weld paths; the welding associated dimensions are preset, and the welding associated dimensions and the H weld paths are used as welding area collection constraints, and the welding area data is extracted on the welding positioning model to obtain H area geometric parameters and H area attribute information; the consistency judgment is performed on the H area geometric parameters and the H area attribute information, and the weld path is split based on the judgment result to obtain the multiple sub-welds; the multiple welding material parameter sets of the multiple sub-welds are extracted from the H area geometric parameters and the H area attribute information, wherein each of the multiple welding material parameter sets includes a first component welding attribute-thickness information and a second component welding attribute-thickness information.

[0066] Furthermore, the embodiment of the present application extracts weld paths from the welding positioning model based on weld change nodes to obtain H weld paths, and further includes: The weld path is extracted based on the welding positioning model to obtain the weld path topology; the weld change nodes are identified on the weld path topology to obtain multiple weld intersections; the weld path topology is disassembled based on the multiple weld intersections to obtain H weld paths.

[0067] Furthermore, the embodiment of the present application performs chopping control analysis on the multiple welding material parameter sets and outputs multiple chopping modulation parameters, and before that, it also includes: Interactively obtain multiple sample material parameter sets and multiple sample chopping modulation parameters; aggregate the multiple sample material parameter sets and multiple sample chopping modulation parameters based on material properties to obtain K groups of sample material thickness parameters and K groups of sample chopping modulation parameters of K heterogeneous property combinations; perform regression analysis on the K groups of sample material thickness parameters and the K groups of sample chopping modulation parameters, and construct K chopping control analysis branches based on the analysis results; connect the K chopping control analysis branches in parallel to obtain a chopping control analysis model.

[0068] Furthermore, the embodiment of the present application performs chopping control analysis on the multiple welding material parameter sets and outputs multiple chopping modulation parameters, and also includes: A first welding material parameter set is extracted from the multiple welding material parameter sets, and a first heterogeneous attribute combination is obtained by performing welding attribute extraction on the first component welding attribute-thickness information and the second component welding attribute-thickness information in the first welding material parameter set; welding thickness extraction is performed on the first component welding attribute-thickness information and the second component welding attribute-thickness information in the first welding material parameter set to obtain a first welding thickness combination; after locating and activating the first chopping control analysis branch in the chopping control analysis model according to the first heterogeneous attribute combination, the first welding thickness combination is synchronized to the first chopping control analysis branch to obtain a first chopping modulation parameter through analysis; and so on, chopping control analysis is performed on the multiple welding material parameter sets to output the multiple chopping modulation parameters.

[0069] Further, the embodiment of the present application performs chopping modulation switching stability analysis on the multiple chopping modulation parameters according to the connection relationship of the multiple sub-welds in the welding positioning model, and performs welding trajectory fitting based on the analysis results to output K welding trajectories, and also includes: Predefine a chopping modulation switching threshold; after fitting the multiple sub-welds to the weld path topology, locate the first sub-weld in the weld path topology; predefine a first connection direction, use the first connection direction as a constraint, and call the first associated weld information in the weld path topology based on the connection relationship; if the first associated weld information is a single associated weld, obtain a single associated parameter mapped to the single associated weld from the multiple chopping modulation parameters; if the deviation between the single associated parameter and the first chopping modulation parameter meets the chopping modulation switching threshold, connect the single associated parameter and the first group of associated welds to generate a first updated welding trajectory; if the deviation between the single associated parameter and the first chopping modulation parameter does not meet the chopping modulation switching threshold, use the first sub-weld as the first welding trajectory; use the chopping modulation switching threshold and the weld path topology as welding trajectory extension constraints, extend the single associated weld, and generate a second welding trajectory; and so on, traverse the multiple sub-welds to produce the K welding trajectories.

[0070] Furthermore, the method described in the embodiment of the present application also includes: If the first associated weld information includes multiple first associated welds, then multiple first associated parameters mapped to the multiple first associated welds are obtained from the multiple chopping modulation parameters; the first chopping modulation parameter mapped to the first sub-weld is obtained from the multiple chopping modulation parameters; based on the multiple first associated parameters and the first chopping modulation parameters, the first associated weld that meets the chopping modulation switching threshold and has the smallest Euclidean distance is obtained as a welding trajectory to extend and connect the first sub-weld, so as to generate the first updated welding trajectory.

[0071] Through the above detailed description of the welding machine current regulation system based on high-efficiency chopping control in this specification, those skilled in the art can clearly understand the welding machine current regulation method based on high-efficiency chopping control in this embodiment. For the method disclosed in Example 2, since it corresponds to the system disclosed in Example 1 and has corresponding execution steps and beneficial effects, the relevant parts can be referred to the system part description.

[0072] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A welding machine current regulation system based on high-efficiency chopper control, characterized in that: The system comprises: A welding positioning modeling module, wherein the welding positioning modeling module is used to interactively obtain welding assembly information of the parts to be welded, and to obtain a welding positioning model by modeling according to the welding assembly information; A welding data extraction module, the welding data extraction module is used to identify weld change nodes based on the welding positioning model, and extract welding area data based on the identification result to obtain multiple welding material parameter sets of multiple sub-welds; A chopping analysis module, the chopping analysis module is used to output a plurality of chopping modulation parameters by performing chopping control analysis on the plurality of welding material parameter sets; A welding trajectory fitting module, wherein the welding trajectory fitting module is used to perform a chopping modulation switching stability analysis on the multiple chopping modulation parameters according to the connection relationship between the multiple sub-welds in the welding positioning model, and perform welding trajectory fitting based on the analysis result to output K welding trajectories; A modulation parameter assembly module, the modulation parameter assembly module is used to assemble the multiple chopping modulation parameters according to the sub-weld seams of K welding tracks to obtain K chopping modulation sequences; A welding sequence analysis module, the welding sequence analysis module is used to perform welding sequence analysis of the components to be welded according to the welding assembly information, and connect the K welding trajectories based on the analysis results to generate an optimized welding trajectory; A current control module is used to use the optimized welding trajectory as a welding trajectory switching constraint of the welding machine, and adopt the K chopping modulation sequences to perform dynamic current control of the welding process of the welding machine on the parts to be welded.

2. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 1, characterized in that: The execution steps of the welding positioning modeling module also include: Extracting and obtaining M welding component information of the M welding components based on the welding assembly information, wherein the M welding component information includes M component geometric parameters and M component attribute information; After constructing and obtaining M component structural models by taking the M component geometric parameters as modeling constraints, the M component attribute information is fitted to the M component structural models to obtain M welding component models; The assembly relationship information extracted from the welding assembly information is used as assembly constraints to assemble the M welding component models to obtain the welding positioning model.

3. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 2, characterized in that: The execution steps of the welding data extraction module also include: Extracting weld paths from the welding positioning model based on weld change nodes to obtain H weld paths; Preset welding associated dimensions, and use the welding associated dimensions and H weld paths as welding area acquisition constraints, perform welding area data extraction on the welding positioning model, and obtain H area geometric parameters and H area attribute information; Performing consistency judgment on the H regional geometric parameters and the H regional attribute information, and splitting the weld path based on the judgment result to obtain the multiple sub-welds; The multiple welding material parameter sets of the multiple sub-welds are extracted from the H regional geometric parameters and the H regional attribute information, wherein each of the multiple welding material parameter sets includes a first component welding attribute-thickness information and a second component welding attribute-thickness information.

4. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 3, characterized in that: The execution steps of the welding data extraction module also include: Extracting weld paths based on the welding positioning model to obtain weld path topology; Performing weld change node identification on the weld path topology to obtain multiple weld intersection points; The weld path topology is decomposed based on the multiple weld intersection points to obtain H weld paths.

5. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 3, characterized in that: The chopping analysis module performs chopping control analysis on the multiple welding material parameter sets and outputs multiple chopping modulation parameters. Before that, the execution step also includes: interactively obtaining a plurality of sample material parameter sets and a plurality of sample chopping modulation parameters; Aggregating the plurality of sample material parameter sets and the plurality of sample chopping modulation parameters based on material properties to obtain K groups of sample material thickness parameters and K groups of sample chopping modulation parameters of K heterogeneous property combinations; Performing regression analysis on the K groups of sample material thickness parameters and the K groups of sample chopping modulation parameters, and constructing K chopping control analysis branches based on the analysis results; The K chopping control analysis branches are connected in parallel to obtain a chopping control analysis model.

6. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 5, characterized in that: The execution steps of the chopping analysis module also include: Extracting a first welding material parameter set from the plurality of welding material parameter sets, and obtaining a first heterogeneous attribute combination by performing welding attribute extraction on first component welding attribute-thickness information and second component welding attribute-thickness information in the first welding material parameter set; Extract welding thickness from the first component welding property-thickness information and the second component welding property-thickness information in the first welding material parameter set to obtain a first welding thickness combination; After locating and activating a first chopping control analysis branch in the chopping control analysis model according to the first heterogeneous attribute combination, synchronizing the first welding thickness combination to the first chopping control analysis branch, and analyzing to obtain a first chopping modulation parameter; By analogy, the chopping control analysis is performed on the multiple welding material parameter sets, and the multiple chopping modulation parameters are output.

7. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 4, characterized in that: The execution steps of the welding trajectory fitting module also include: Predefined chopping modulation switching thresholds; After fitting the plurality of sub-welds to the weld path topology, positioning a first sub-weld in the weld path topology; Predefine a first connection direction, use the first connection direction as a constraint, and call first associated weld information in the weld path topology based on the connection relationship; If the first associated weld information is a single associated weld, a single associated parameter mapped to the single associated weld is obtained by calling from the multiple chopping modulation parameters; If the deviation between the single associated parameter and the first chopping modulation parameter satisfies the chopping modulation switching threshold, connecting the single associated parameter and the first group of associated welds to generate a first updated welding trajectory; If the deviation between the single associated parameter and the first chopping modulation parameter does not satisfy the chopping modulation switching threshold, taking the first sub-weld as the first welding trajectory; Using the chopping modulation switching threshold and the weld path topology as welding trajectory extension constraints, extending the single associated weld to generate a second welding trajectory; In this way, the multiple sub-welds are traversed to produce the K welding tracks.

8. The welding machine current regulation system based on high-efficiency chopper control as claimed in claim 7, characterized in that: The execution steps of the welding trajectory fitting module also include: If the first associated weld information includes a plurality of first associated welds, a plurality of first associated parameters mapped to the plurality of first associated welds are obtained by calling from the plurality of chopping modulation parameters; Obtaining a first chopping modulation parameter mapped to the first sub-weld seam from the plurality of chopping modulation parameters; Based on the multiple first associated parameters and the first chopping modulation parameter screening, a first associated weld that meets the chopping modulation switching threshold and has the smallest Euclidean distance is obtained as a welding trajectory to extend and connect the first sub-weld, thereby generating the first updated welding trajectory.

9. A welding machine current regulation method based on high-efficiency chopping control, characterized in that: The method is performed by the welding machine current regulation system based on high-efficiency chopper control according to any one of claims 1 to 8, and the method comprises: Interactively obtain welding assembly information of the parts to be welded, and obtain a welding positioning model by modeling according to the welding assembly information; Identify weld change nodes based on the welding positioning model, and extract welding area data based on the identification result to obtain multiple welding material parameter sets of multiple sub-welds; Outputting a plurality of chopping modulation parameters by performing chopping control analysis on the plurality of welding material parameter sets; According to the connection relationship of the multiple sub-welds in the welding positioning model, the multiple chopping modulation parameters are subjected to chopping modulation switching stability analysis, and welding trajectory fitting is performed based on the analysis result to output K welding trajectories; Assembling the plurality of chopping modulation parameters according to the sub-weld seams of the K welding tracks to obtain K chopping modulation sequences; Performing a welding sequence analysis of the components to be welded according to the welding assembly information, and connecting the K welding trajectories based on the analysis results to generate an optimized welding trajectory; The optimized welding trajectory is used as a welding trajectory switching constraint of a welding machine, and the K chopping modulation sequences are used to perform dynamic current control of the welding process of the welding machine on the parts to be welded.

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