Frame welding high-precision control method

Abstract

The invention discloses a vehicle frame welding high-precision control method, and relates to the technical field of welding control, and the method comprises the following steps: obtaining a welding position set of a first vehicle frame; stress analysis is conducted on the first frame, and a key welding position set is obtained; a frame welding device is connected, welding control is conducted on all the positions in the welding position set according to the welding head, and a second frame is obtained; identifying a welding data set and welding material information; according to the welding data set and the welding material information, repair welding control parameters are configured, and the configured repair welding control parameters are output; and the welding head carries out repair welding control on the key welding position of the second frame according to the configured repair welding control parameters, and a third frame is output. The technical problem that in the prior art, in the frame welding process, key welding positions are difficult to control accurately, repair welding parameter configuration lacks pertinence, and consequently the frame welding quality is unstable is solved, and the technical effect of improving the overall frame welding quality is achieved.

Description

Technical Field

[0001] The present application relates to the technical field related to welding control, and in particular to a high-precision control method for frame welding. Background Art

[0002] As an important tool for urban cleaning and garbage disposal, the frame structure of sanitation vehicles needs to have high strength and stability to bear the use requirements under complex working conditions. As the core load-bearing component of sanitation vehicles, the welding quality is a key factor affecting the performance, safety and service life of the frame during the frame manufacturing process. However, the frame usually has a more complex geometric structure and a diverse combination of materials. Currently, most welding is processed in one welding process, and it is difficult to perform high-precision control of the repair welding. For example, different welding parts of the frame have different stress characteristics, among which key stress parts (such as load-bearing beams, connection nodes, etc.) require particularly high welding quality. The existing welding control lacks stress analysis for key parts and refined welding parameter configuration, which may cause insufficient local strength of the weld or cracks, thereby affecting the quality stability and life of the entire frame.

[0003] In the current related technologies, there are technical problems that the key welding positions in the frame welding process are difficult to accurately control and the repair welding parameter configuration lacks specificity, which leads to unstable frame welding quality. Summary of the invention

[0004] The present application provides a high-precision control method for frame welding, thereby solving the technical problems in the prior art that key welding positions in the frame welding process are difficult to accurately control and the repair welding parameter configuration lacks specificity, thereby leading to unstable frame welding quality, thereby achieving the technical effect of improving the overall welding quality of the frame.

[0005] The present application provides a high-precision control method for frame welding, comprising: obtaining a welding position set of a first frame, wherein the first frame is a target frame that has not been welded; performing a force analysis on the first frame to obtain a key welding position set in the welding position set; connecting a frame welding device, performing welding control on each position in the welding position set according to a welding head of the frame welding device, and obtaining a second frame, wherein the second frame is a target frame after welding; identifying a welding data set and welding material information of the key welding positions; configuring a repair welding control parameter according to the welding data set and the welding material information, and outputting the configured repair welding control parameter; the welding head of the frame welding device performs repair welding control on each position in the key welding position set of the second frame according to the configured repair welding control parameter, and outputs a third frame, wherein the third frame is the target frame after repair welding.

[0006] In a possible implementation, a force analysis is performed on the first frame to obtain key welding positions in the welding position set, and the following processing is performed: the first frame is set in a first state, and a first force distribution data set of the first frame in the first state is collected, wherein the first state is a non-load state; a force analysis is performed on each welding position in the welding position set according to the force distribution data set, and welding positions whose force intensity in the first state is greater than a first preset threshold are identified as key welding positions.

[0007] In a possible implementation, the high-precision control method for frame welding further performs the following processing: setting the first frame in a second state, collecting a second force distribution data set of the first frame in the second state, wherein the second state is a load state; performing force analysis on each welding position in the welding position set according to the second force distribution data set, and identifying a welding position whose force intensity in the second state is greater than a second preset threshold as a key welding position, wherein the second preset threshold is greater than the first preset threshold.

[0008] In a possible implementation, the high-precision control method for vehicle frame welding further performs the following processing: performing an overlap analysis on the key welding positions in the first state and the key welding positions in the second state, and if there are no overlapping welding positions, outputting a set of key welding positions; if there are overlapping welding positions, they are covered and retained, and outputting a set of key welding positions.

[0009] In a possible implementation, repair welding control parameters are configured according to the welding data set and the welding material information, and the configured repair welding control parameters are output, and the following processing is also performed: repair welding related features are extracted from the welding data set and the welding material information, including geometric features of the defect area and thermal sensitivity features of the material; repair welding analysis is performed according to the geometric features of the defect area and the thermal sensitivity features of the material, and repair welding control parameters that meet the preset repair welding quality are output, wherein the repair welding control parameters include welding speed, welding current and welding voltage.

[0010] In a possible implementation, the high-precision control method for frame welding also performs the following processing: analyzing the geometric features of the defect area to determine whether the defect depth in the geometric features of the defect area is greater than or equal to a preset defect depth; if the defect depth in the geometric features of the defect area is greater than or equal to the preset defect depth, updating the repair welding control parameters with a filling amount index as a new control parameter item.

[0011] In a possible implementation, the welding head of the frame welding device controls the repair welding of each position in the key welding position set of the second frame according to the configured repair welding control parameters, and also performs the following processing: performing defect identification on each position in the key welding position set and outputting defect three-dimensional data; performing defect modeling according to the defect three-dimensional data and outputting a defect three-dimensional model; performing repair welding path planning for each position according to the defect three-dimensional model, and the welding head controls the repair welding according to the planned repair welding path.

[0012] In a possible implementation, the high-precision control method for frame welding further performs the following processing: the welding head of the frame welding device is a detachable component, including a first welding head and a second welding head, and the welding granularity of the first welding head is greater than the granularity of the second welding head; wherein, when the welding head of the frame welding device performs welding control on each position in the welding position set, the first welding head is switched, and when the welding head of the frame welding device performs repair welding control on each position in the key welding position set, the second welding head is switched.

[0013] Through the high-precision control method for frame welding proposed in this application, a set of welding positions of the first frame is obtained; a force analysis is performed on the first frame to obtain a set of key welding positions; the frame welding device is connected, and welding control is performed on each position in the welding position set according to the welding head to obtain the second frame; the welding data set and welding material information are identified; the repair welding control parameters are configured according to the welding data set and welding material information, and the configured repair welding control parameters are output; the welding head controls the repair welding of the key welding positions of the second frame according to the configured repair welding control parameters, and outputs the third frame. The technical problem that the key welding positions in the frame welding process are difficult to accurately control and the repair welding parameter configuration lacks pertinence in the prior art, which leads to unstable frame welding quality, is solved, and the technical effect of improving the overall welding quality of the frame is achieved. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0015] Figure 1 A schematic flow chart of a high-precision control method for frame welding provided in an embodiment of the present application.

[0016] Figure 2A schematic diagram of a flow chart for obtaining key welding positions in a high-precision control method for vehicle frame welding provided in an embodiment of the present application. DETAILED DESCRIPTION

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

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

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

[0020] The present application embodiment provides a high-precision control method for frame welding, such as Figure 1 As shown, the method includes: Step S100, obtaining a welding position set of a first frame, where the first frame is an unwelded target frame.

[0021] Preferably, before the welding operation begins, all parts of the frame that need to be welded are determined based on the structural characteristics and welding requirements of the target frame of the sanitation vehicle, and the spatial position information, geometric characteristics and welding requirements of these parts are collected and recorded to obtain a welding position set of the first frame, wherein the first frame is an unwelded target frame, and the target frame may be a frame component that has not yet been welded or a basic frame structure of the frame. Specifically, according to the welding points marked on the frame design drawings and the physical contact areas of the connecting parts (such as beams and columns, cross beams and longitudinal beams, etc.), all points, lines or surface areas that need to be welded are obtained to form a welding position set, including their spatial coordinates, connection methods (such as butt welding, fillet welds, etc.) and welding sequence. Unwelded means that the frame is in an initial assembly state, and the components may have been fixed by clamps or connected by spot welding, but the final welding process has not yet been completed.

[0022] Step S200: performing a stress analysis on the first vehicle frame to obtain a critical welding position set in the welding position set.

[0023] Preferably, before welding the frame of the sanitation vehicle, the welding positions that have an important impact on the overall strength, stiffness and durability of the frame are screened out from all welding positions through mechanical analysis and engineering calculations as a set of key welding positions. Specifically, force analysis refers to evaluating the force distribution of the first frame under different working conditions (such as load, vibration, torsion, etc.) through mechanical methods (such as finite element analysis) to determine the stress concentration areas, key load-bearing parts or connection points prone to failure in the frame structure, including minor auxiliary welding points and major load-bearing welding points, and then obtaining the set of key welding positions in the set of welding positions, that is, screening out the performance of the frame such as load-bearing capacity, connection stability, fatigue resistance, etc. from the set of welding positions. Critical welding points or welds. Specifically, based on mechanical importance, welding points on the main load-bearing path of the frame, such as the intersection of the longitudinal beam and the cross beam, and stress concentration areas, such as welding parts near corners, nodes or large load points, are regarded as key welding positions; based on failure sensitivity, welding points that may fail due to fatigue or fracture, and parts that are prone to desoldering or deformation under extreme vehicle conditions (such as heavy loads, high-speed impacts, etc.) are regarded as key welding positions; based on functional requirements, welding points connecting important structural parts (such as support arms, main beams) and welding parts that play a key role in the overall rigidity and stability of the frame are regarded as key welding positions, providing basic data support for subsequent precise welding control and optimization.

[0024] Further, such as Figure 2As shown, step S200 also includes step S210, setting the first frame in a first state, collecting a first force distribution data set of the first frame in the first state, wherein the first state is a non-load state; step S220, performing a force analysis on each welding position in the welding position set according to the force distribution data set, and identifying a welding position whose force intensity in the first state is greater than a first preset threshold as a key welding position.

[0025] Preferably, before welding the sanitation vehicle frame, the target frame is set to a certain working state (i.e., non-load state), and the force data of its structure in this state is collected. Through force analysis, areas with relatively large force intensity in the welding position set are identified, and these areas are defined as key welding positions. Specifically, by analyzing the stress distribution of the frame in a non-load state (i.e., under the action of its own weight and the environment), a first force distribution data set is obtained, including potential force concentration locations, that is, based on the three-dimensional modeling of the frame, a mechanical simulation tool is used to simulate the force distribution in a non-load state, and the force intensity (such as maximum principal stress, shear stress, etc.) of each welding position is obtained, and the stress value at the welding position and the spatial coordinates and stress direction of each welding position are recorded; then, according to the force distribution data set, the stress distribution of the frame is simulated. A stress analysis is performed on each welding position in the welding position set, that is, for each welding position in the welding position set, its stress intensity is calculated according to the first force distribution data set, for example, the stress characteristics of each position, stress concentration points, stress directions and stress gradients, etc. are determined, and welding positions with stress intensity greater than a first preset threshold are identified as key welding positions, including screening out welding positions with stress intensity exceeding the threshold from the welding position set and marking them in the data, that is, areas that have been subjected to greater stress under no-load conditions, wherein the first preset threshold is a critical value of stress intensity (such as a certain proportion of the material yield strength) set based on the mechanical properties and design specifications of the frame material, providing data support for subsequent repair welding parameter configuration and path planning, making welding control more precise.

[0026] Furthermore, step S200 also includes step S230, setting the first frame in a second state, collecting a second force distribution data set of the first frame in the second state, wherein the second state is a load state; step S240, performing a force analysis on each welding position in the welding position set according to the second force distribution data set, and identifying a welding position having a force intensity greater than a second preset threshold in the second state as a critical welding position, wherein the second preset threshold is greater than the first preset threshold.

[0027] Preferably, by placing the first frame in a loaded state (second state), collecting its force data under load conditions, conducting in-depth analysis, screening out key welding positions under a higher force standard (i.e., a second preset threshold), supplementing and optimizing the identification of key welding positions under a non-load state, and identifying welding points or areas that are subjected to greater force under more extreme working conditions. Specifically, the frame simulates the working state under actual working conditions, such as bearing the external forces such as the vehicle's own weight, cargo load, and impact load, and obtains its force data. Similarly, finite element analysis (FEA) is used to simulate the force distribution of the frame under different load conditions, and generate complete force distribution data, including each welding position under the load condition. The maximum stress, stress direction, degree of deformation, etc. under the load state, and then calculate the force strength of each welding position under the load state to identify which welding points or welds are in the area of ​​higher stress concentration, including evaluating the force strength of all welding positions according to the second force distribution data set, and marking the welding positions with force strength greater than the second preset threshold as key welding positions, wherein the second preset threshold is usually set according to the design strength, material limit and safety factor of the frame. The second preset threshold is greater than the first preset threshold, indicating that under the load state, the selected key welding positions need to withstand higher stress levels, thereby more accurately identifying the potential weak links of the frame under actual working conditions.

[0028] Furthermore, step S200 also includes step S250, performing overlapping analysis on the key welding positions in the first state and the key welding positions in the second state, and outputting a set of key welding positions if there are no overlapping welding positions; and step S260, covering and retaining overlapping welding positions if there are any, and outputting a set of key welding positions.

[0029] Preferably, after analyzing the key welding positions of the first frame in the first state (non-load state) and the second state (load state), the results in the two states are compared to determine the final set of key welding positions, that is, the welding positions most important to the frame performance are screened out through overlapping analysis, and the repeated areas are given priority. Specifically, the parts identified as key welding positions in both the first state and the second state are used as overlapping welding positions. These positions are stress concentration areas under both working conditions and are key points of stress in the frame structure. Non-overlapping welding positions refer to parts identified as key welding positions in one state, which usually play a key role under specific working conditions, but are not comprehensive. If there are no overlapping welding positions, indicating that the key welding position sets in the first state and the second state are completely independent, the two are merged, and all key welding positions are directly output to form a complete set of key welding positions. If there are overlapping welding positions, the overlapping positions are preferentially covered and retained, and the output key welding position set includes overlapping positions and non-overlapping welding positions in the two states, thereby realizing high-precision frame repair welding operation control and improving the efficiency of welding operations.

[0030] Step S300, connecting a vehicle frame welding device, and controlling welding of each position in the welding position set according to a welding head of the vehicle frame welding device to obtain a second vehicle frame, where the second vehicle frame is a target vehicle frame after welding.

[0031] Preferably, the welding operation is performed one by one on the welding position set on the first frame (unwelded frame) by automated or semi-automated welding equipment to complete the welding process and form a target frame (second frame) that has been initially welded. The frame welding device is used to perform frame welding tasks, such as a welding robot, a manual or automatic welding machine, etc. Specifically, the frame welding device is connected and the welding equipment is debugged to match the frame welding process requirements, including welding parameters (such as current, voltage, welding speed) and welding path. The welding head is a component of the frame welding device that performs the welding operation and is responsible for welding materials (such as welding wire or welding rod) through arc, laser Or other energy sources melt and connect the workpieces, the welding head moves to each welding position according to the welding path, and the welding process is implemented at the welding point to ensure that the strength and size of the weld meet the design requirements; welding control is performed on each position in the welding position set, including setting precise welding parameters (including welding current, voltage, welding speed, heat input, etc.) according to the frame material and welding process requirements, to ensure that the welding head moves according to the predetermined trajectory, without missed welds or biased welds, and the welding quality (such as weld shape, welding depth, etc.) is monitored in real time through sensors and visual systems. The frame after the welding operation is completed serves as the second frame, and all its welding positions have been connected through the welding process.

[0032] Step S400, identifying the welding data set and welding material information of the key welding position.

[0033] Preferably, non-destructive testing methods such as laser scanning, X-ray detection, and ultrasonic detection are used to accurately measure the key welding positions to obtain welding data sets and welding material information related to the key welding positions. Specifically, the welding data set refers to various types of data related to the welding process and quality recorded or detected during the welding process, including but not limited to real-time recording of welding current, voltage, welding speed, heat input, etc., welding results, weld size (such as weld width, thickness, welding depth, etc.), weld geometry and uniformity, and detection results of welding defects (such as pores, cracks, slag inclusions, etc.) through sensors of welding equipment; welding material information includes materials used in the welding process and their performance data, which may include parent material information, that is, the type, composition, and mechanical properties of the basic materials (such as high-strength steel, aluminum alloy, etc.) constituting the frame, welding materials, the type of welding wire, welding rod or filler material used (such as model and specification), and the melting point, thermal conductivity, tensile strength and other characteristics of the welding material, material compatibility, that is, the physical and chemical compatibility between the welding material and the parent material (such as fusion degree and formation of intermetallic compounds). By analyzing the welding data set, the welding quality is evaluated to ensure that the welding effects at key welding locations meet the requirements, laying the foundation for the final quality and performance assurance of the frame.

[0034] Step S500, configuring the repair welding control parameters according to the welding data set and the welding material information, and outputting the configured repair welding control parameters.

[0035] Preferably, the repair welding control parameter configuration is performed based on the identified sanitation vehicle welding data set and welding material information, that is, the precise parameter configuration required for repair welding is determined through analysis and optimization, which is used to guide the welding equipment to perform the repair welding operation and ensure that the quality and performance of the repair welding part meet the design requirements. Specifically, after the initial welding is completed (that is, the second frame is formed), there may be some weld defects (such as pores, cracks, incomplete fusion, etc.) or uneven weld quality. These parts need to be repaired and optimized by repair welding, thereby repairing the welding defects, ensuring the integrity and strength of the weld, and improving the appearance quality and consistency of the welding area; then, the current, voltage, heat input and other parameters in the welding process are analyzed to understand whether there is a parameter deviation in the initial welding, and identify the specific defects of the repair welding part. The defect type and distribution are determined according to the characteristics of the parent material and welding material (such as melting point, thermal conductivity, and strength). At the same time, the metal compatibility between the welding material and the parent material is considered to avoid new defects after repair welding, and then the repair welding control parameters are configured. For example, based on the historical parameters in the welding data set, and combined with the defect detection results, the parameters are optimized according to the welding material information to ensure the strength and toughness of the repair welding area. This may include adjusting the welding current and voltage to a range suitable for repair welding to ensure that the depth and width of the welding area are uniform; optimizing the welding speed according to the size and position of the repair welding part to avoid overheating or discontinuous welds; controlling the heat input to avoid overburning of the parent material or excessive heat-affected zone; and determining the type, diameter, and conveying speed of the repair welding material. By analyzing the welding data and material properties, accurate repair welding process parameters are formulated to ensure that the repair welding quality meets the design requirements, thereby improving the automation and efficiency of the repair welding process.

[0036] Furthermore, step S500 also includes step S510, extracting repair welding related features of the welding data set and the welding material information, including geometric features of the defect area and thermal sensitivity features of the material; step S520, performing repair welding analysis based on the geometric features of the defect area and the thermal sensitivity features of the material, and outputting repair welding control parameters that meet preset repair welding quality, wherein the repair welding control parameters include welding speed, welding current and welding voltage.

[0037] Preferably, through in-depth analysis of the welding data set and welding material information, features related to repair welding (such as geometric features of the defect area and thermal sensitivity of the welding material) are extracted, and then repair welding process analysis is performed based on these features to determine repair welding control parameters (welding speed, current, voltage) that meet design requirements and quality standards. Specifically, feature extraction is performed on the welding data set, such as using non-destructive testing (such as X-ray, ultrasonic testing) to obtain geometric features of the defect area, including the location, shape, size, distribution of the defect (such as the length and depth of the crack, the diameter of the pores, etc.), and the relative position of the defect area to the surrounding welds; feature extraction is performed on the welding material information, such as using the material performance database or test data to obtain the thermal sensitivity of the welding material, combining the material composition analysis and the actual working conditions to evaluate its thermal response, and obtain the thermal sensitivity characteristics of the material, including the melting point, thermal expansion coefficient, thermal conductivity, etc.

[0038] Preferably, repair welding analysis is performed based on the geometric characteristics of the defect area and the thermal sensitivity characteristics of the material to determine how to adjust the welding parameters to repair the defect area in the best way while ensuring the consistency of the weld and the raw material performance. Specifically, large-sized defects (such as long cracks) may require higher heat input to ensure sufficient melting, small-sized defects (such as pores) require smaller heat input to avoid excessive melting or too large a heat-affected zone, and highly heat-sensitive materials require more sophisticated thermal control to avoid welding deformation, burn-through, or too large a heat-affected zone. For low thermal conductivity materials, the welding speed needs to be optimized to avoid excessive heat concentration, and repair welding analysis is obtained. The result is the welding control parameters, which mainly include welding speed, welding current and welding voltage. The speed of the welding head movement is controlled, which affects the weld width, penetration and heat input. Fast movement is suitable for highly heat-sensitive materials to reduce the heat-affected zone, and slow movement is suitable for large-sized defects to ensure full fusion. The welding current determines the molten pool temperature and penetration. For thin-walled structures or highly heat-sensitive materials, low current is required, and for thick-walled structures or large defects, higher current is required. The welding voltage controls the length of the arc and the stability of the welding. Too high voltage can easily lead to spatter and unstable welding, while too low voltage may lead to incomplete fusion. These parameters ensure that the welding repair process can both repair defects and meet the preset quality standards, thereby achieving efficient, high-precision and high-quality welding repair.

[0039] Furthermore, step S520 also includes step S521, analyzing the geometric features of the defect area to determine whether the defect depth in the geometric features of the defect area is greater than or equal to a preset defect depth; step S522, if the defect depth in the geometric features of the defect area is greater than or equal to the preset defect depth, updating the repair welding control parameters with the filling amount index as a new control parameter item.

[0040] Preferably, the geometric features of the defect area are analyzed, and according to the defect depth in the geometric features of the defect area, it is determined whether it is necessary to repair deeper defects through additional control parameters (such as filling amount index), wherein the defect depth refers to the maximum vertical depth of the problem in the weld, and defects with greater depth may directly affect the strength and bearing capacity of the weld. Specifically, if the defect depth in the geometric features of the defect area is greater than or equal to the preset defect depth, it is considered that the defect has a greater impact on the performance of the weld, and it is necessary to strengthen the repair welding measures, that is, to add new parameters for processing, including updating the repair welding control parameters with the filling amount index as the new control parameter item, wherein the filling amount index refers to the volume of welding material that needs to be filled during the repair welding process to repair deeper defects, and the required amount of filling material is calculated based on the defect depth and cross-sectional shape, and the input rate and amount of welding material are adjusted considering the actual situation of molten pool expansion, and finally the filling amount index is added to the repair welding control parameters, and the welding speed, welding current and welding voltage are adjusted to match the newly added material requirements, and the defects with greater depth are further repaired more accurately to ensure that the geometric integrity and mechanical properties of the weld meet the preset requirements, thereby improving the welding quality and efficiency.

[0041] Step S600, the welding head of the frame welding device performs repair welding control on each position in the key welding position set of the second frame according to the configured repair welding control parameters, and outputs a third frame, where the third frame is the target frame after repair welding.

[0042] Preferably, a welding device is used to perform a repair welding operation on the identified key welding positions in the second frame formed by preliminary welding, to repair weld defects or improve the welding quality of key parts, and finally obtain a welded finished product (third frame) that meets the design requirements, wherein the second frame is a frame after the preliminary welding is completed, and all welding positions are connected, but there may be welding quality problems. Specifically, the second frame is repaired and controlled according to the configured repair welding control parameters, that is, the welding head operates according to the optimized repair welding parameters (such as current, voltage, welding speed, heat input, etc.) to ensure that the welding process meets the preset standards, and at the same time accurately controls the heat input to avoid new damage to the parent material or surrounding welds during the repair welding process. The welding head covers the defective areas in the key welding position set one by one according to the planned path to ensure that the repair welding effect is consistent with the design requirements. The welding head of the welding device is used to perform precise repair welding operations on the key welding positions of the second frame according to the configured repair welding control parameters, repair weld defects, improve welding quality, and finally obtain a target frame (i.e., the third frame) after repair welding that meets the performance and quality requirements.

[0043] Furthermore, step S600 also includes step S610, performing defect identification on each position in the key welding position set and outputting defect three-dimensional data; step S620, performing defect modeling based on the defect three-dimensional data and outputting a defect three-dimensional model; step S630, planning a repair welding path for each position based on the defect three-dimensional model, and the welding head controls the repair welding according to the planned repair welding path.

[0044] Preferably, defect identification is performed on each position in the set of key welding positions, that is, non-destructive testing technology (such as laser scanning, X-ray or ultrasonic testing, etc.) is used to identify defects (such as cracks, pores, lack of fusion, etc.) in key welding positions, and their three-dimensional characteristics are accurately located and measured, and defect three-dimensional data, including three-dimensional coordinates, shape and size data of the defects, are output; then defect modeling is performed based on the defect three-dimensional data, that is, the three-dimensional data is visualized using three-dimensional modeling software (such as SolidWorks, CATIA) to generate an accurate three-dimensional model, that is, the defect three-dimensional model; then, repair welding paths are planned for each position based on the defect three-dimensional model, including planning the movement path of the welding head, calculating the starting point, end point, direction and speed of each path segment, ensuring that the welding material accurately fills the defects during the repair welding process, and finally the welding head is controlled according to the planned repair welding path, and precise operations are performed according to the specific location and shape of the defect, so as to improve the quality, reliability, welding efficiency and consistency of the repair welding, and achieve high-quality repair of the weld.

[0045] Further, step S600 also includes step S640, wherein the welding head of the frame welding device is a detachable component, including a first welding head and a second welding head, and the welding granularity of the first welding head is greater than the granularity of the second welding head; step S650, wherein the first welding head is switched when the welding head of the frame welding device performs welding control on each position in the welding position set, and the second welding head is switched when the welding head of the frame welding device performs repair welding control on each position in the key welding position set.

[0046] Preferably, the welding head of the frame welding device is a detachable component, which is convenient for selecting a suitable welding head according to different working conditions, including a first welding head and a second welding head. The welding granularity of the first welding head is larger than that of the second welding head. The welding granularity refers to the welding range that the welding head can cover in a single welding operation, which is usually determined by the design of the welding head (such as weld width and weld spot diameter). A large granularity means a wide welding range, but the fineness may be relatively low. Specifically, the first welding head has a large welding granularity, which is suitable for covering a large range of welding areas and is used for efficient welding of ordinary welding positions, with relatively low welding accuracy requirements. The second welding head has a small welding granularity, which is suitable for high-precision welding. It is used to perform fine repair welding control on key welding positions and is suitable for processing areas with extremely high requirements on welding quality, especially key load-bearing parts or complex structure areas; when the welding head of the frame welding device performs welding control on each position in the welding position set, the first welding head is switched to ensure the frame welding efficiency, and when the welding head of the frame welding device performs repair welding control on each position in the key welding position set, the second welding head is switched to ensure the repair welding quality, and during the switching process, the welding device automatically adjusts the welding parameters (such as current and voltage) to adapt to the characteristics of the new welding head, which not only improves the adaptability and intelligence level of the welding process, but also significantly improves the overall quality and efficiency of the frame welding.

[0047] The above specific implementation manner does not constitute a limitation to the protection scope of the present application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be performed in an order different from that in the embodiment and can still achieve the desired results. In addition, the process depicted in the accompanying drawings does not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. A high-precision control method for frame welding, characterized in that: The method comprises: Acquire a welding position set of a first frame, where the first frame is an unwelded target frame; Performing a stress analysis on the first vehicle frame to obtain a key welding position set in the welding position set; Connecting a vehicle frame welding device, and controlling welding of each position in the welding position set according to a welding head of the vehicle frame welding device to obtain a second vehicle frame, where the second vehicle frame is a target vehicle frame after welding; Identifying welding data sets and welding material information of the critical welding locations; Performing repair welding control parameter configuration according to the welding data set and the welding material information, and outputting the configured repair welding control parameters; The welding head of the frame welding device performs repair welding control on each position in the key welding position set of the second frame according to the configured repair welding control parameters, and outputs a third frame, where the third frame is the target frame after repair welding.

2. A high-precision control method for frame welding as claimed in claim 1, characterized in that: Performing a stress analysis on the first frame to obtain key welding positions in the welding position set, the method comprising: Setting the first frame in a first state, and collecting a first force distribution data set of the first frame in the first state, wherein the first state is a non-load state; A force analysis is performed on each welding position in the welding position set according to the force distribution data set, and welding positions with a force intensity greater than a first preset threshold in the first state are identified as key welding positions.

3. A high-precision control method for frame welding as claimed in claim 2, characterized in that: The method further comprises: Setting the first frame to a second state, and collecting a second force distribution data set of the first frame in the second state, wherein the second state is a load state; A force analysis is performed on each welding position in the welding position set according to the second force distribution data set, and welding positions with force intensity greater than a second preset threshold in the second state are identified as key welding positions, wherein the second preset threshold is greater than the first preset threshold.

4. A high-precision control method for frame welding as claimed in claim 3, characterized in that: Performing overlap analysis on the key welding positions in the first state and the key welding positions in the second state, and outputting a set of key welding positions if there are no overlapping welding positions; If there are overlapping welding positions, they are covered and retained, and a set of key welding positions is output.

5. A high-precision control method for frame welding as claimed in claim 1, characterized in that: Performing repair welding control parameter configuration according to the welding data set and the welding material information, and outputting the configured repair welding control parameters, the method comprising: Extracting repair welding related features from the welding data set and the welding material information, including geometric features of defective areas and thermal sensitivity features of materials; The repair welding analysis is performed according to the geometric characteristics of the defect area and the thermal sensitivity characteristics of the material, and the repair welding control parameters that meet the preset repair welding quality are output, wherein the repair welding control parameters include welding speed, welding current and welding voltage.

6. A high-precision control method for frame welding as claimed in claim 5, characterized in that: Analyze the geometric features of the defect area to determine whether the defect depth in the geometric features of the defect area is greater than or equal to a preset defect depth; If the defect depth in the defect area geometric feature is greater than or equal to the preset defect depth, the repair welding control parameter is updated with the filling amount index as a new control parameter item.

7. A high-precision control method for frame welding as claimed in claim 1, characterized in that: The welding head of the frame welding device performs repair welding control on each position in the key welding position set of the second frame according to the configured repair welding control parameters, and the method includes: Perform defect identification on each position in the set of key welding positions and output three-dimensional defect data; Perform defect modeling according to the defect three-dimensional data, and output the defect three-dimensional model; The repair welding path is planned for each position according to the defect three-dimensional model, and the welding head is controlled according to the planned repair welding path.

8. A high-precision control method for frame welding as claimed in claim 1, characterized in that: The welding head of the frame welding device is a detachable component, including a first welding head and a second welding head, and the welding particle size of the first welding head is larger than that of the second welding head; Wherein, when the welding head of the frame welding device performs welding control on each position in the welding position set, the first welding head is switched, and when the welding head of the frame welding device performs repair welding control on each position in the key welding position set, the second welding head is switched.

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