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

Abstract

The invention provides an equipment current adjusting system and method based on high-efficiency chopping control, and relates to the technical field of power electronic control, the system comprises a welding feature acquisition unit, a welding control analysis unit, a welding correlation analysis unit, a chopping optimization analysis unit, a welding track fitting unit and a welding adjustment fitting unit, and a welding control adjusting unit. Through mutual calling of the unit modules, the technical problems that in the prior art, when a battery type welding machine processes a complex multi-point welding task, the welding control precision is low, the welding quality stability is insufficient, meanwhile, battery energy is wasted, and the cruising ability of equipment is reduced are solved. The technical effects that the stability of the welding quality is improved, the control precision and the battery energy utilization efficiency are improved, and the welding requirement of a complex multi-point welding task is met are achieved.

Description

Technical Field

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

[0002] Battery-powered welders are becoming a popular choice due to their portability and outdoor adaptability, but the battery voltage of such equipment is usually low and the power is limited, which puts higher requirements on the current and voltage regulation during the welding process.

[0003] In battery-powered welding machines, the choice of welding topology directly affects welding control accuracy and energy efficiency. Common topologies include full-bridge, half-bridge and chopper circuits. Although full-bridge and half-bridge circuits have high power output capabilities, they are large in size, high in cost, and not conducive to fine energy control. In contrast, chopper circuits have been widely used in the field of rechargeable welding machines due to their compact structure, high energy efficiency and superior cost performance.

[0004] As one of the core topologies of battery-powered welding machines, the chopper circuit provides more flexible and precise control for the welding process by dynamically adjusting the output voltage and current. However, the battery-powered welding machines in the prior art have the problem of low welding control accuracy when handling complex multi-spot welding tasks. During multi-spot welding, the stability of welding quality is difficult to guarantee due to the lack of fine changes in current and voltage, and the excessive consumption of battery energy significantly reduces the endurance of the equipment.

[0005] Therefore, the current technical problem is how to optimize the current and voltage control of the chopper circuit in a battery-powered welding machine, improve welding accuracy and stability, and achieve efficient use of battery energy to meet the needs of complex multi-spot welding tasks. Summary of the invention

[0006] The present application provides an equipment current regulation system and method based on high-efficiency chopping control, which is used to solve the technical problem that when a battery-type welding machine in the prior art handles complex multi-spot welding tasks, the welding control accuracy is low, which not only leads to insufficient welding quality stability, but also causes battery energy waste and reduces the endurance of the equipment.

[0007] In view of the above problems, the present application provides a device current regulation system and method based on high-efficiency chopping control.

[0008] In a first aspect of the present application, a device current regulation system based on high-efficiency chopping control is provided, the system comprising: a welding feature acquisition unit, used to perform welding site analysis on a welding design, and obtain multiple welding material feature sets of multiple welding sites, wherein the multiple welding sites have multiple welding position coordinates; a welding control analysis unit, used to perform welding control fitness analysis on the welding design based on the multiple welding material feature sets, and obtain multiple welding parameter requirements; a welding association analysis unit, used to divide the multiple welding sites into K groups of associated welding sites by performing conditionally triggered multi-way selection control analysis on the multiple welding parameter requirements; a chopping tuning analysis unit, used to perform a conditionally triggered multi-way selection control analysis on the multiple welding parameter requirements; and After combining the multiple welding parameter requirements, a chopping control stability analysis is performed to obtain K chopping control tuning sequences; a welding trajectory fitting unit is used to perform welding trajectory fitting on the K groups of associated welding sites according to the K chopping control tuning sequences, and output a target welding trajectory; a welding adjustment fitting unit is used to perform smooth fitting of the multiple welding parameter requirements according to the K chopping control tuning sequences, and output a target multi-way selection control strategy; a welding control adjustment unit is used to perform dynamic adjustment of chopping control by synchronously inputting the target multi-way selection control strategy into a PWM pulse width modulation circuit of the battery-type welding machine during the welding process of the welding entity of the welding design part by the battery-type welding machine with the target welding trajectory.

[0009] In a second aspect of the present application, a device current regulation method based on high-efficiency chopping control is provided, the method comprising: performing welding site analysis on a welding design to obtain a plurality of welding material feature sets of a plurality of welding sites, wherein the plurality of welding sites have a plurality of welding position coordinates; performing welding control fitness analysis on the welding design based on the plurality of welding material feature sets to obtain a plurality of welding parameter requirements; dividing the plurality of welding sites into K groups of associated welding sites by performing condition-triggered multi-way selection control analysis on the plurality of welding parameter requirements; combining the plurality of welding sites according to the K groups of associated welding sites After the battery-type welding machine determines the welding parameter requirements, a chopping control stability analysis is performed to obtain K chopping control tuning sequences; welding trajectory fitting is performed on the K groups of associated welding sites according to the K chopping control tuning sequences, and a target welding trajectory is output; smooth fitting of the multiple welding parameter requirements is performed according to the K chopping control tuning sequences, and a target multi-way selection control strategy is output; during the welding process of the welding entity of the welding design part performed by the battery-type welding machine with the target welding trajectory, the dynamic adjustment of the chopping control is performed by synchronously inputting the target multi-way selection control strategy into the PWM pulse width modulation circuit of the battery-type welding machine.

[0010] One or more technical solutions provided in this application have at least the following technical effects or advantages: The system provided in the embodiment of the present application uses a welding feature acquisition unit to perform welding site analysis on a welding design part to obtain multiple welding material feature sets of multiple welding sites, wherein the multiple welding sites have multiple welding position coordinates; a welding control analysis unit to perform welding control fitness analysis on the welding design part based on the multiple welding material feature sets to obtain multiple welding parameter requirements; a welding association analysis unit to divide the multiple welding sites into K groups of associated welding sites by performing conditionally triggered multi-way selection control analysis on the multiple welding parameter requirements; a chopping tuning analysis unit to combine the multiple welding parameter requirements according to the K groups of associated welding sites After that, a chopping control stability analysis is performed to obtain K chopping control tuning sequences; a welding trajectory fitting unit is used to perform welding trajectory fitting on the K groups of associated welding sites according to the K chopping control tuning sequences, and output a target welding trajectory; a welding adjustment fitting unit is used to perform smooth fitting of the multiple welding parameter requirements according to the K chopping control tuning sequences, and output a target multi-way selection control strategy; a welding control adjustment unit is used to dynamically adjust the chopping control by synchronously inputting the target multi-way selection control strategy into the PWM pulse width modulation circuit of the battery-type welding machine during the welding process of the welding entity of the welding design part by the battery-type welding machine with the target welding trajectory. The output current and voltage are accurately adjusted, the stability of welding quality, the control accuracy and the battery energy utilization efficiency are improved, and the technical effect of meeting the welding requirements of complex multi-point welding tasks is achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 This is a schematic diagram of the structure of the device current regulation system based on high-efficiency chopper control provided in this application.

[0012] Figure 2 A schematic flow chart of a device current regulation method based on high-efficiency chopping control provided in this application.

[0013] Figure 3 A schematic diagram of a flow chart for dynamic optimization of chopping control in a device current regulation method based on high-efficiency chopping control provided in the present application.

[0014] Explanation of the reference numerals: welding feature acquisition unit 11 , welding control analysis unit 12 , welding correlation analysis unit 13 , chopping tuning analysis unit 14 , welding trajectory fitting unit 15 , welding adjustment fitting unit 16 , welding control adjustment unit 17 . DETAILED DESCRIPTION

[0015] The present application provides a device current regulation system and method based on high-efficiency chopper control, which is used to solve the technical problem that when a battery-type welder in the prior art processes complex multi-spot welding tasks, the welding control accuracy is low, which leads to insufficient welding quality stability, battery energy waste, and reduced equipment endurance. The system achieves the technical effect of accurately adjusting the output current and voltage, improving the stability of welding quality, control accuracy, and battery energy utilization efficiency, and meeting the welding requirements of complex multi-spot welding tasks.

[0016] Below, the technical solutions in the present invention will be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments of the present invention. It should be understood that the present invention is not limited to the example embodiments described herein. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. It should also be noted that, for the convenience of description, only the parts related to the present invention are shown in the accompanying drawings, rather than all of them.

[0017] Embodiment 1 like Figure 1 As shown, the present application provides a device current regulation system based on high-efficiency chopper control, the system comprising: The welding feature acquisition unit 11 is used to perform welding site analysis on the welding design part to obtain multiple welding material feature sets of multiple welding sites, wherein the multiple welding sites have multiple welding position coordinates; the welding control analysis unit 12 is used to perform welding control fitness analysis on the welding design part based on the multiple welding material feature sets to obtain multiple welding parameter requirements; the welding association analysis unit 13 is used to divide the multiple welding sites into K groups of associated welding sites by performing condition-triggered multi-way selection control analysis on the multiple welding parameter requirements; the chopping tuning analysis unit 14 is used to perform chopping after combining the multiple welding parameter requirements according to the K groups of associated welding sites. Control stability analysis to obtain K chopping control tuning sequences; a welding trajectory fitting unit 15, used to perform welding trajectory fitting on the K groups of associated welding sites according to the K chopping control tuning sequences, and output a target welding trajectory; a welding adjustment fitting unit 16, used to perform smooth fitting of the multiple welding parameter requirements according to the K chopping control tuning sequences, and output a target multi-way selection control strategy; a welding control adjustment unit 17, used to dynamically adjust the chopping control by synchronously inputting the target multi-way selection control strategy into the PWM pulse width modulation circuit of the battery-type welding machine during the welding process of the welding entity of the welding design part by the battery-type welding machine with the target welding trajectory.

[0018] In one embodiment, the welding control and adjustment unit 17 further includes the following operation steps: A chopping control monitoring window is preset; the chopping control monitoring window is used to perform cyclic sampling of the output information of the battery-type welding machine to obtain an output sampling information sequence; the target multi-way selection control strategy is aligned and framed according to the acquisition interval of the output sampling information sequence to obtain an associated control strategy; a consistency check is performed on the output sampling information sequence and the associated control strategy, and based on the check result, the chopping control of the PWM pulse width modulation circuit is dynamically optimized.

[0019] In one embodiment, the welding feature acquisition unit 11 further includes the following operation steps: Call to obtain the welding design information of the welding design part; use the welding design information to perform finite element modeling to obtain a welding assembly model; after the welding assembly model locates the welding site, collect material information of the welding-related area to obtain the multiple welding material feature sets of the multiple welding sites, wherein each welding material feature set includes a material type feature group, a material thickness feature group, a material melting point feature group and a material resistance feature group; interactively obtain welding clamping features; after using the welding clamping features to update the spatial position of the welding assembly model, collect the coordinate vectors of the multiple welding sites in the welding assembly model to obtain the multiple welding position coordinates.

[0020] In one embodiment, the welding control and analysis unit 12 further includes the following operating steps: Interactively obtain multiple sample material feature sets and multiple sample welding parameter sets; call N random operators to construct N welding control analysis channels, and after using the multiple sample material feature sets and multiple sample welding parameter sets to adjust the model parameters of the N welding control analysis channels, connect the N welding control analysis channels in parallel to obtain a welding control analysis model; synchronize the first welding material feature set to the welding control analysis model to obtain N alternative welding parameters, wherein each of the N alternative welding parameters includes an alternative welding current, an alternative welding voltage and an alternative welding speed; call the first weld length of the first welding position in the welding assembly model, and calculate the energy consumption of the N alternative welding parameters based on the first weld length to obtain N alternative welding energy consumptions; obtain a first welding parameter requirement from the N alternative welding parameters according to the serialization results of the N alternative welding energy consumptions; and so on, perform welding control fitness analysis on the welding design based on the multiple welding material feature sets to obtain the multiple welding parameter requirements.

[0021] In one embodiment, the welding control and adjustment unit 17 further includes the following operation steps: Interactively obtain multiple sample wire feeding speed settings of the multiple sample welding parameter sets; obtain multiple sample thickness feature groups from the multiple sample material feature sets; use the multiple sample welding parameter sets, multiple sample thickness feature groups and multiple sample wire feeding speed settings to perform multivariate function fitting to obtain a wire feeding speed calculation function; obtain multiple material thickness feature groups from the multiple welding material feature sets, and synchronize the multiple material thickness feature groups and multiple welding parameter requirements to the wire feeding speed calculation function to calculate and obtain multiple wire feeding speed settings; perform data fusion on the multiple wire feeding speed settings according to the target welding trajectory to obtain a wire feeding speed change sequence; during the welding process of the welding entity of the welding design part performed by the battery-type welding machine with the target welding trajectory, perform synchronous control of the wire feeding motor in the battery-type welding machine with the wire feeding speed change sequence as a constraint.

[0022] In one embodiment, the welding correlation analysis unit 13 further includes the following operation steps: Interactively obtain K working intervals of K chopping branches in a parallel chopping circuit group, wherein the parallel chopping circuit group is embedded in the battery-type welding machine; divide the multiple welding parameter requirement groups based on the K working intervals as constraints, and divide the multiple welding sites into K groups of associated welding sites based on the mapping of the division results.

[0023] In one embodiment, the welding control and adjustment unit 17 further includes the following operation steps: The target welding trajectory and the target multi-path selection control strategy are data aligned with the constraints of the multiple welding sites; the PWM pulse width modulation circuit receives and generates a modulation signal based on the target multi-path selection control strategy to obtain a dynamic PWM modulation signal; the chopper drive circuit receives and dynamically adjusts the chopping control of the K chopping branches in the parallel chopper circuit group based on the dynamic PWM modulation signal.

[0024] Embodiment 2 Based on the same inventive concept as the device current regulation system based on high-efficiency chopping control in the aforementioned embodiment, Figure 2 As shown, the present application provides a device current regulation method based on high-efficiency chopping control, wherein the method comprises: A100: Perform welding site analysis on the welding design part to obtain multiple welding material feature sets of multiple welding sites, wherein the multiple welding sites have multiple welding position coordinates.

[0025] In one embodiment, a welding site analysis is performed on a welding design part to obtain a plurality of welding material feature sets of a plurality of welding sites, wherein the plurality of welding sites have a plurality of welding position coordinates. The method step A100 provided in the present application includes: A110: Call to obtain the welding design information of the welding design part.

[0026] A120: The welding design information is used to perform finite element modeling to obtain a welding assembly model.

[0027] A130: After locating the welding site in the welding assembly model, material information of the welding-related area is collected to obtain the multiple welding material feature sets of the multiple welding sites, wherein each welding material feature set includes a material type feature group, a material thickness feature group, a material melting point feature group and a material resistance feature group.

[0028] A140: Interactively obtain welding clamp features.

[0029] A150: After the welding clamping feature is used to update the spatial position of the welding component model, the coordinate vectors of the multiple welding sites are collected in the welding component model to obtain the multiple welding position coordinates.

[0030] Specifically, it should be understood that the welding design part is an abstract welding part that has not yet been produced and is in the conceptual design stage. This embodiment calls to obtain the welding design information of the welding design part. The welding design information specifically includes information such as the geometric shape, structural characteristics, and material type of the welding structure. The welding design information provides comprehensive parameter support for the subsequent analysis of welding sites.

[0031] After obtaining the welding design information, finite element modeling is performed on the welding design part based on the information to generate a welding component model that simulates the material physical properties of the actual welding component. The welding component model provides a reference for the planning and parameter setting of the welding path.

[0032] After the finite element modeling generates the welding component model, the next step is to locate each welding site in the model to obtain multiple welding sites, and then collect material property information of the surrounding welding-related areas of the multiple welding sites to generate multiple welding material feature sets.

[0033] Each welding material feature set includes a set of material type features, a set of material thickness features, a set of material melting point features and a set of material resistance features around the welding site of two welding sub-parts to be welded.

[0034] Multiple welding material feature sets will provide an important basis for the subsequent setting of welding parameters, ensuring that the current and voltage of the welding process are adapted to the requirements of different materials.

[0035] After obtaining the material properties, the clamping features in the welding process are further obtained interactively. The welding clamping features include the position of the clamping device, the direction and size of the clamping force, etc., to ensure the stability of the design during the welding process. The clamping features are crucial in the conceptual design stage and can better support welding path planning and precise fixation of welded parts.

[0036] After determining the welding clamping features, these clamping features are applied to the welding assembly model to update the spatial positioning information of the welding design. Subsequently, the coordinate vectors of the welding sites are collected in the updated model to obtain the multiple welding position coordinates that characterize the precise position coordinates of the multiple welding sites. The multiple welding position coordinates provide accurate data support for welding path planning, which helps to achieve precise control of the welding trajectory in subsequent welding production.

[0037] This embodiment lays a foundation for subsequent welding parameter setting and welding path planning through in-depth analysis and modeling of welding design parts in the conceptual design stage.

[0038] A200: Perform welding control fitness analysis on the welding design component based on the multiple welding material feature sets to obtain multiple welding parameter requirements.

[0039] In one embodiment, a welding control fitness analysis is performed on the welding design component based on the multiple welding material feature sets to obtain multiple welding parameter requirements. The method step A200 provided in the present application includes: A210: Interactively obtain multiple sample material feature sets and multiple sample welding parameter sets.

[0040] A220: Call N random operators to construct N welding control analysis channels, and after using the multiple sample material feature sets and the multiple sample welding parameter sets to adjust the model parameters of the N welding control analysis channels, connect the N welding control analysis channels in parallel to obtain a welding control analysis model.

[0041] A230: Synchronize the first welding material feature set to the welding control analysis model to obtain N alternative welding parameters, wherein each of the N alternative welding parameters includes an alternative welding current, an alternative welding voltage and an alternative welding speed.

[0042] A240: Invoking the first weld length of the first welding position in the welding assembly model, and performing energy consumption calculation of the N alternative welding parameters based on the first weld length to obtain N alternative welding energy consumptions.

[0043] A250: Obtain a first welding parameter requirement from the N candidate welding parameters according to the serialization results of the N candidate welding energy consumptions.

[0044] A260: Similarly, based on the multiple welding material feature sets, welding control adaptability analysis is performed on the welding design component to obtain the multiple welding parameter requirements.

[0045] Specifically, in this embodiment, a welding control analysis model for welding parameter prediction needs to be pre-built, and the specific construction process of the welding control analysis model is as follows: First, multiple sample material feature sets and multiple sample welding parameter sets with corresponding relationships are obtained interactively. These sample data come from welding experimental records of different materials. Each sample material feature set contains two sample materials welded together, two sets of material types, thicknesses, melting points, and resistance characteristics at the welding position. Each sample welding parameter set includes welding current, voltage, and speed parameters under corresponding welding conditions (sample material feature sets). By collecting these sample data, a standardized reference database is formed to provide data support for subsequent welding control analysis models.

[0046] The random operators of the random operator library include but are not limited to back-propagation neural networks and recurrent neural networks. N random operators are called from the random operator library to construct N welding control analysis channels. The input information of any welding control analysis channel is two sets of material types, thicknesses, melting points, and resistance characteristics of two welding sub-components at the welding site. The output result is a set of welding current, voltage, and speed parameters for achieving reliable welding at the welding site.

[0047] A conventional model training method of the N random operators is adopted, and the multiple sample material feature sets and multiple sample welding parameter sets are used as training data to perform model parameter optimization of the N welding control analysis channels, so as to obtain N welding control analysis channels that can accurately output welding process based on material properties.

[0048] The construction of the welding control analysis model is completed by connecting the N welding control analysis channels in parallel and connecting the data input layer at the channel input end. The advantage of the welding control analysis model is that different reliable outputs (N groups of welding current, voltage, and speed parameters for reliable welding at the welding site) are given based on the same input, providing a wider range of options for setting the welding control parameters.

[0049] The specific implementation method of this embodiment using the welding control analysis model to analyze and obtain the multiple welding parameter requirements is as follows: The first welding material feature set is synchronized to the welding control analysis model to obtain N alternative welding parameters, wherein each of the N alternative welding parameters includes an alternative welding current, an alternative welding voltage and an alternative welding speed.

[0050] The welding component model calls the first weld length of the first welding position, and calculates the welding time based on the first weld length and N alternative welding speeds among the N alternative welding parameters to obtain N welding time consumptions, and then calculates the energy consumption based on the N welding time consumptions, N alternative welding currents and N alternative welding voltages to obtain N alternative welding energy consumptions.

[0051] According to the serialization results of the N candidate welding energy consumptions, the first welding parameter requirement with the lowest energy consumption and suitable for welding requirements is obtained from the N candidate welding parameters, including the optimal current, voltage and welding speed.

[0052] Repeat the above process and use the same method to analyze the welding control fitness of other welding locations of the welded design one by one to obtain the specific welding parameter requirements of each welding location. Finally, a set of optimized welding parameter configurations is completed for the specific material characteristics of multiple welding locations to ensure the balance of welding effect and energy efficiency under different materials and weld conditions.

[0053] This embodiment achieves the technical effect of realizing precise welding control of different materials under different welding conditions by optimizing the parameter requirements of each welding site, while also achieving energy consumption optimization and improving the welding endurance of the battery-powered welding machine.

[0054] A300: Divide the multiple welding sites into K groups of associated welding sites by performing condition-triggered multi-way selection control analysis on the multiple welding parameter requirements.

[0055] In one embodiment, by performing condition-triggered multi-way selection control analysis on the multiple welding parameter requirements, the multiple welding sites are divided into K groups of associated welding sites. The method step A300 provided in the present application includes: A310: Interactively obtain K working intervals of K chopping branches in a parallel chopping circuit group, wherein the parallel chopping circuit group is embedded in the battery-type welding machine.

[0056] A320: Divide the plurality of welding parameter requirements into groups based on the K working intervals as constraints, and divide the plurality of welding sites into K groups of associated welding sites based on the mapping of the division results.

[0057] Specifically, in this embodiment, in order to optimize the welding operation, the system needs to divide these welding sites into multiple associated groups according to the welding parameter requirements of different welding sites. By performing condition-triggered multi-way selection control analysis on these welding parameter requirements, it is possible to determine which welding sites have similar or compatible parameter requirements, so that these sites can share the chopping control strategy and improve welding efficiency.

[0058] In this embodiment, the parallel chopper circuit group is the core circuit module of the battery-type welding machine. Through voltage regulation, load distribution and PWM control, it ensures that the welding machine can efficiently and stably provide appropriate power support for various welding tasks and achieve stable welding effects.

[0059] In the subsequent explanation, the connection relationship between the parallel chopper circuit group and the PWM pulse width modulation circuit and other circuit elements will be elaborated in detail to realize the technical implementation of the welding machine current and voltage regulation.

[0060] This embodiment obtains the working intervals of K chopping branches of the parallel chopping circuit group in the battery welding machine by means of interactive design information of the battery welding machine. The working interval of each chopping branch defines the current and voltage output range that the branch can effectively provide, ensuring that the branch can meet the parameter requirements of a specific welding site. The information of each working interval is the basis for subsequent grouping operations.

[0061] After obtaining the working ranges of K chopping branches, they are used as constraints to group the welding parameter requirements. This process matches the parameter requirements of each welding site with the working range of the chopping circuit. Through multi-way selection control strategy analysis, sites with similar welding current and voltage requirements are classified into the same associated group. The result of this division is that multiple welding sites are mapped into K groups of associated welding sites, ensuring that each group of associated sites can share the same chopping branch, simplifying the control logic and improving the overall efficiency of the welding process.

[0062] After analyzing the welding parameter requirements of each welding site, this embodiment divides the welding sites with similar requirements into the same associated group and allocates them to chopping branches that are adapted to their current and voltage requirements, thereby ensuring that the welding sites in each associated group can share the working range of the same chopping branch, significantly improving the continuity and stability of the welding process, avoiding delays and instability factors caused by frequent switching of chopping branches, optimizing welding efficiency and battery energy consumption, and providing stable support for multi-point and high-frequency welding requirements. Technical effect.

[0063] A400: After combining the multiple welding parameter requirements according to the K groups of associated welding sites, perform a chopping control stability analysis to obtain K chopping control tuning sequences.

[0064] A500: Perform welding trajectory fitting for the K groups of associated welding locations according to the K chopping control tuning sequences, and output a target welding trajectory.

[0065] Specifically, in this embodiment, firstly, according to the combination of the K groups of associated welding locations, the welding parameter requirements in each group are aggregated to form K groups of welding parameter requirements.

[0066] Furthermore, the data within the group are sorted based on the data change amount of each group of welding parameter requirements. The specific sorting method is to use the Euclidean distance to find adjacent points with smaller changes between the welding parameter requirements, and use this as a basis to sort several welding parameter requirements within the group, and obtain K chopping control tuning sequences that achieve smaller single change amplitudes of the chopping branch current and voltage.

[0067] Then, according to the generated K chopper control tuning sequences, the welding order of K groups of associated welding sites is optimized and sorted, and the shortest distance connection fitting of the welding trajectory is performed on each group of associated welding sites according to the optimized order to form K initial welding trajectories. Finally, according to the step-by-step progressive relationship of the working intervals of the K chopper branches, the K initial welding trajectories are spliced ​​to obtain the overall target welding trajectory, which can achieve smooth connection of the welding path and stable transition of current and voltage, thereby improving the continuity and accuracy of the welding process and further optimizing the welding efficiency and energy utilization.

[0068] A600: Perform smooth fitting of the multiple welding parameter requirements according to K chopping control tuning sequences, and output a target multi-path selection control strategy.

[0069] Specifically, it should be understood that since there are jumps between different welding sites in the K initial welding trajectories, a smooth transition of current and voltage is very critical in the process of switching from one welding site to the next, so as to avoid welding instability or thermal shock caused by instantaneous large changes.

[0070] Therefore, in this embodiment, in such a discontinuous welding trajectory with jumps, the current and voltage are adjusted by smooth transition during the jump process to effectively alleviate the impact of site switching on welding stability. Specifically, a short "transition interval" is set between two adjacent welding sites, and within this interval, a set of continuous and gradually changing parameter values ​​are generated between the two adjacent welding sites through a smooth fitting algorithm (such as curve fitting or interpolation method), so as to adjust the sudden changes in current and voltage to gradual changes. By analogy, a smooth transition of current and voltage is performed between all adjacent welding sites of the K initial welding trajectories to obtain a K-path selection control strategy of K chopping branches.

[0071] A smooth transition is performed between the K-way selection control strategies according to the target welding trajectory to obtain the target multi-way selection control strategy.

[0072] A700: During the welding process of the battery-type welding machine performing the welding process of the welding design part with the target welding trajectory, the dynamic adjustment of the chopping control is performed by synchronously inputting the target multi-way selection control strategy into the PWM pulse width modulation circuit of the battery-type welding machine.

[0073] In one embodiment, during the welding process of the welding entity of the welding design part by the battery-type welding machine with the target welding trajectory, the target multi-way selection control strategy is synchronously input into the PWM pulse width modulation circuit of the battery-type welding machine for dynamic adjustment of chopping control. The method step A700 provided in the present application includes: A700-1: Perform data alignment of the target welding trajectory and the target multi-way selection control strategy with the multiple welding sites as constraints.

[0074] A700-2: The PWM pulse width modulation circuit receives and generates a modulation signal based on the target multi-path selection control strategy to obtain a dynamic PWM modulation signal.

[0075] A700-3: The chopper drive circuit receives and dynamically adjusts the chopping control of the K chopping branches in the parallel chopper circuit group based on the dynamic PWM modulation signal.

[0076] Specifically, it should be understood that in a battery-type welding machine, the PWM pulse width modulation circuit controls the chopper drive circuit by generating and adjusting a square wave signal, thereby accurately adjusting the on and off time of the K chopper branches in the parallel chopper circuit group to dynamically adjust the output voltage and current during the welding process. Through the synergistic effect of the PWM pulse width modulation circuit and the chopper drive circuit, the parallel chopper circuit group can adapt to the different current and voltage requirements of the welding machine, achieve accurate current and voltage regulation, and ensure the stability of the output during the welding process and the reliability of the welding quality.

[0077] Based on this, in this step, firstly, the target welding trajectory and the target multi-path selection control strategy are data aligned based on the spatial positions and welding parameter requirements of multiple welding sites. This data alignment is to accurately match the specific requirements of the welding site (such as current, voltage, etc.) with the welding trajectory of each site to ensure that during the welding process, the welding parameters can correspond to the path changes of the site. The purpose is to ensure a smooth transition between different sites during the welding process, so that the welding current and voltage can adapt to the requirements of each site, and improve the accuracy and quality of welding.

[0078] After the target welding trajectory and the target multi-channel selection control strategy are aligned, the PWM pulse width modulation circuit receives the adjusted and aligned target multi-channel selection control strategy and generates a dynamic PWM modulation signal that matches the current welding site requirements. This signal not only includes the duty cycle adjustment based on the specific current and voltage requirements of each welding site, but also includes the selection of specific chopping branches to achieve flexible adjustment of welding parameters. By controlling the selection of appropriate chopping branches, the dynamic PWM modulation signal ensures that the battery-type welder can flexibly adjust the output according to real-time needs to adapt to the requirements of different welding sites.

[0079] During the welding process of the battery-type welding machine performing the welding of the welding design with the target welding trajectory, the chopper drive circuit receives the dynamic PWM modulation signal generated by the PWM circuit, and accurately controls the K chopper branches in the parallel chopper circuit group based on the signal. The dynamic PWM signal not only controls the on and off time of each chopper branch, but also indicates the specific selected chopper branch, thereby ensuring a fast response to the welding current and voltage requirements of the welding site.

[0080] This embodiment ensures a smooth transition of current and voltage between different welding sites, effectively avoiding instability or thermal shock caused by sudden changes in welding parameters. At the same time, the chopping branch selection and duty cycle adjustment included in the dynamic PWM signal enable the battery-type welder to accurately adapt to the current and voltage requirements of each welding site, thereby improving the stability and quality reliability of the welding process. In addition, the dynamic adjustment of the multi-channel selection control strategy optimizes energy utilization efficiency, makes the welding process more efficient, and extends the endurance performance of the welder.

[0081] This embodiment uses a dynamic adjustment mechanism of chopping control to accurately adjust the output current and voltage, thereby achieving the technical effect of improving the stability of welding quality, control accuracy and battery energy utilization efficiency, and meeting the welding requirements of complex multi-spot welding tasks.

[0082] In one embodiment, Figure 3 As shown, the method steps provided by this application include: A710: Preset chopping control monitoring window.

[0083] A720: The chopping control monitoring window is used to perform cyclic sampling of the output information of the battery welding machine to obtain an output sampling information sequence.

[0084] A730: Align and frame the target multi-path selection control strategy according to the acquisition interval of the output sampling information sequence to obtain an associated control strategy.

[0085] A740: Perform consistency check on the output sampling information sequence and the associated control strategy, and dynamically optimize the chopping control of the PWM pulse width modulation circuit based on the check result.

[0086] Specifically, in the battery-type welding machine, the current and voltage sampling circuit is directly connected to the output terminal of the battery-type welding machine to collect the real-time current and voltage data of the welding machine during the welding process. The current and voltage sampling circuit is usually composed of a current sensor and a voltage sensor, which can convert the current and voltage signals output by the welding machine into analog or digital signals for subsequent processing and analysis.

[0087] The current and voltage sampling circuit is connected to the control system input of the PWM pulse width modulation circuit to provide feedback data to adjust the PWM signal. The specific PWM signal adjustment is implemented as follows: Before welding operation, a chopping control monitoring window is pre-set to monitor the dynamic changes of the output current and voltage of the battery welding machine. The chopping control monitoring window will serve as the operation cycle of the sampling circuit and provide a time benchmark for subsequent cyclic sampling and control strategy optimization.

[0088] In the chopping control monitoring window, the current and voltage sampling circuit is connected to the output end of the welding machine to perform cyclic sampling of the current and voltage to generate an output sampling information sequence.

[0089] The control system aligns and frames the target multi-way selection control strategy by analyzing the acquisition interval of the output sampling information sequence (i.e., the current and voltage changes within each monitoring window) to match the sampled actual current and voltage data with the target control strategy to obtain an associated control strategy that is consistent with the current sampling sequence mapping.

[0090] The consistency of the sampled information sequence and the associated control strategy is verified to evaluate the deviation between the actual output and the expected strategy. If the deviation exceeds the allowable range, the output parameters of the PWM pulse width modulation circuit are adjusted to improve the current and voltage control in subsequent batch welding by optimizing the duty cycle of the PWM signal.

[0091] Specifically, the PWM pulse width modulation circuit will control the on and off time of each chopping branch in the parallel chopping circuit group during this process to achieve more precise current and voltage output, thereby improving stability and consistency in subsequent batch welding and effectively ensuring welding quality.

[0092] In one embodiment, the method steps provided by the present application further include: A750: Interactively obtain multiple sample wire feed speed settings of the multiple sample welding parameter sets.

[0093] A760: Obtain multiple sample thickness feature groups from the multiple sample material feature sets.

[0094] A770: Use the multiple sample welding parameter sets, multiple sample thickness feature groups and multiple sample wire feeding speed settings to perform multivariate function fitting to obtain a wire feeding speed calculation function.

[0095] A780: Calling and obtaining multiple material thickness feature groups from the multiple welding material feature sets, and synchronizing the multiple material thickness feature groups and multiple welding parameter requirements to the wire feeding speed calculation function to calculate and obtain multiple wire feeding speed settings.

[0096] A790: Perform data fusion on the multiple wire feeding speed settings according to the target welding trajectory to obtain a wire feeding speed change sequence.

[0097] A7100: During the welding process of the battery-type welding machine performing the welding process of the welding design part with the target welding trajectory, the synchronous control of the wire feeding motor in the battery-type welding machine is performed with the wire feeding speed change sequence as a constraint.

[0098] Specifically, in this embodiment, multiple welding parameter sets are obtained from a known welding process sample library, and corresponding wire feeding speed settings are extracted. These sample data contain the optimal wire feeding speeds under different welding materials and welding conditions, providing reference data for subsequent calculation and fitting.

[0099] It should be understood that the welding material thickness at the welding site is a key factor affecting the wire feeding speed. Collecting thickness data in the sample helps to accurately fit the changing pattern of the wire feeding speed. Based on this, material thickness information is extracted from the sample material feature set to form multiple sample thickness feature groups.

[0100] Based on the sample welding parameter set, thickness feature group and wire feeding speed setting, a wire feeding speed calculation function is generated through multivariate function fitting. The wire feeding speed calculation function can dynamically predict the appropriate wire feeding speed according to the thickness characteristics and welding parameter requirements during actual welding to ensure welding stability.

[0101] The thickness information in the actual welding material feature set is called, and it is input into the wire feeding speed calculation function together with the welding parameter requirements to obtain the wire feeding speed setting corresponding to each welding position.

[0102] According to the target welding trajectory, the wire feeding speed settings of multiple welding locations are merged to generate a wire feeding speed change sequence. This sequence is used to ensure that the point-by-point change of the wire feeding speed during welding is consistent with the progress of the welding trajectory, avoiding sudden changes in speed that affect the welding quality.

[0103] During the actual welding process, the system controls the wire feeding motor in the battery welding machine in real time based on the wire feeding speed change sequence, so as to achieve a smooth transition of the wire feeding speed between different positions of the welding trajectory, effectively coordinate the changes in welding current and voltage, and ensure the continuity and stability of the welding quality.

[0104] Any of the methods or steps described above may be stored as computer instructions or programs in various types of computer memories, and the computer instructions or programs may be recognized by various types of computer processors to implement any of the methods or steps described above.

[0105] Based on the above specific embodiments of the present invention, any improvements and modifications made to the present invention by those skilled in the art without departing from the principles of the present invention shall fall within the patent protection scope of the present invention.

Claims

1. A device current regulation system based on high-efficiency chopper control, characterized in that: include: A welding feature acquisition unit, used to perform welding site analysis on a welding design part to obtain a plurality of welding material feature sets of a plurality of welding sites, wherein the plurality of welding sites have a plurality of welding position coordinates; A welding control analysis unit, configured to perform welding control fitness analysis on the welding design component based on the multiple welding material feature sets to obtain multiple welding parameter requirements; A welding correlation analysis unit, configured to divide the plurality of welding sites into K groups of correlated welding sites by performing condition-triggered multi-way selection control analysis on the plurality of welding parameter requirements; A chopping tuning analysis unit, configured to perform a chopping control stability analysis after combining the multiple welding parameter requirements according to the K groups of associated welding sites, and obtain K chopping control tuning sequences; A welding trajectory fitting unit, used for performing welding trajectory fitting on the K groups of associated welding locations according to the K chopping control tuning sequences, and outputting a target welding trajectory; A welding adjustment fitting unit, used for performing smooth fitting of the multiple welding parameter requirements according to the K chopping control tuning sequences, and outputting a target multi-path selection control strategy; The welding control and adjustment unit is used to dynamically adjust the chopping control by synchronously inputting the target multi-way selection control strategy into the PWM pulse width modulation circuit of the battery-type welding machine during the welding process of the welding entity of the welding design part with the target welding trajectory.

2. The device current regulation system based on high-efficiency chopper control as claimed in claim 1, characterized in that: The welding control and adjustment unit also includes the following operating steps: Preset chopping control monitoring window; The chopping control monitoring window is used to perform cyclic sampling of the output information of the battery-type welding machine to obtain an output sampling information sequence; Aligning and framing the target multi-path selection control strategy according to the collection interval of the output sampling information sequence to obtain an associated control strategy; A consistency check is performed on the output sampling information sequence and the associated control strategy, and based on the check result, the chopping control of the PWM pulse width modulation circuit is dynamically optimized.

3. The device current regulation system based on high-efficiency chopper control as claimed in claim 1, characterized in that: The welding feature acquisition unit also includes the following operating steps: Calling and obtaining welding design information of the welding design part; Using the welding design information to perform finite element modeling to obtain a welding assembly model; After the welding assembly model locates the welding site, material information of the welding associated area is collected to obtain the multiple welding material feature sets of the multiple welding sites, wherein each welding material feature set includes a material type feature group, a material thickness feature group, a material melting point feature group and a material resistance feature group; Interactively obtain welding clamping features; After the welding assembly model is updated in space by using the welding clamping feature, the coordinate vectors of the multiple welding sites are collected in the welding assembly model to obtain the multiple welding position coordinates.

4. The device current regulation system based on high-efficiency chopper control as claimed in claim 3, characterized in that: The welding control and analysis unit further comprises the following operating steps: interactively obtaining multiple sample material feature sets and multiple sample welding parameter sets; Calling N random operators to construct N welding control analysis channels, and after adjusting the model parameters of the N welding control analysis channels using the multiple sample material feature sets and the multiple sample welding parameter sets, connecting the N welding control analysis channels in parallel to obtain a welding control analysis model; Synchronizing the first welding material feature set to the welding control analysis model to obtain N candidate welding parameters, wherein each of the N candidate welding parameters includes an alternative welding current, an alternative welding voltage, and an alternative welding speed; Invoking a first weld length of a first welding position in the welding assembly model, and performing energy consumption calculation of the N candidate welding parameters based on the first weld length to obtain N candidate welding energy consumptions; Obtaining a first welding parameter requirement by calling the N candidate welding parameters according to the serialization results of the N candidate welding energy consumptions; By analogy, welding control adaptability analysis is performed on the welding design component based on the multiple welding material feature sets to obtain the multiple welding parameter requirements.

5. The device current regulation system based on high-efficiency chopper control as claimed in claim 4, characterized in that: The welding control and adjustment unit also includes the following operating steps: interactively obtaining a plurality of sample wire feed speed settings for the plurality of sample welding parameter sets; Obtaining a plurality of sample thickness feature groups from the plurality of sample material feature sets; Using the multiple sample welding parameter sets, the multiple sample thickness feature groups and the multiple sample wire feeding speed settings to perform multivariate function fitting to obtain a wire feeding speed calculation function; Obtain multiple material thickness feature groups from the multiple welding material feature sets, and synchronize the multiple material thickness feature groups and multiple welding parameter requirements to the wire feeding speed calculation function to calculate and obtain multiple wire feeding speed settings; Performing data fusion on the multiple wire feeding speed settings according to the target welding trajectory to obtain a wire feeding speed change sequence; During the welding process of the battery-type welding machine performing the welding of the welding entity of the welding design part with the target welding trajectory, the synchronous control of the wire feeding motor in the battery-type welding machine is performed with the wire feeding speed variation sequence as a constraint.

6. The device current regulation system based on high-efficiency chopper control according to claim 1, characterized in that: The welding correlation analysis unit also includes the following operating steps: Interactively obtaining K working intervals of K chopping branches in a parallel chopping circuit group, wherein the parallel chopping circuit group is embedded in the battery-type welding machine; The plurality of welding parameter requirements are divided into groups based on the K working intervals as constraints, and the plurality of welding sites are divided into K groups of associated welding sites based on the mapping of the division results.

7. The device current regulation system based on high-efficiency chopper control as claimed in claim 6, characterized in that: The welding control and adjustment unit also includes the following operating steps: Performing data alignment of the target welding trajectory and the target multi-path selection control strategy with the multiple welding sites as constraints; The PWM pulse width modulation circuit receives and generates a modulation signal based on the target multi-path selection control strategy to obtain a dynamic PWM modulation signal; The chopper drive circuit receives and dynamically adjusts the chopper control of the K chopper branches in the parallel chopper circuit group based on the dynamic PWM modulation signal.

8. A device current regulation method based on high-efficiency chopper control, characterized in that: Based on the implementation of the device current regulation system based on high-efficiency chopper control according to any one of claims 1 to 7, the method comprises: Performing welding site analysis on the welding design part to obtain a plurality of welding material feature sets of the plurality of welding sites, wherein the plurality of welding sites have a plurality of welding position coordinates; Performing welding control fitness analysis on the welding design part based on the multiple welding material feature sets to obtain multiple welding parameter requirements; By performing condition-triggered multi-way selection control analysis on the multiple welding parameter requirements, the multiple welding sites are divided into K groups of associated welding sites; After combining the multiple welding parameter requirements according to the K groups of associated welding sites, performing a chopping control stability analysis to obtain K chopping control tuning sequences; Perform welding trajectory fitting on the K groups of associated welding locations according to the K chopping control tuning sequences, and output a target welding trajectory; Perform smooth fitting of the multiple welding parameter requirements according to K chopping control tuning sequences, and output a target multi-path selection control strategy; During the welding process of the battery-type welding machine performing the welding process of the welding entity of the welding design part with the target welding trajectory, the dynamic adjustment of the chopping control is performed by synchronously inputting the target multi-way selection control strategy into the PWM pulse width modulation circuit of the battery-type welding machine.

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