A high-precision control method for vehicle frame welding

Abstract

The present invention discloses a high-precision control method for vehicle frame welding, which relates to the technical field related to welding control. The method comprises: obtaining a set of welding positions of a first vehicle frame; performing a force analysis on the first frame to obtain a set of key welding positions; connecting a frame welding device, performing welding control on each position in the set of welding positions according to a welding head, and obtaining a second vehicle frame; identifying a welding data set and welding material information; configuring repair welding control parameters according to the welding data set and welding material information, and outputting the configured repair welding control parameters; the welding head performs repair welding control on the key welding positions of the second frame according to the configured repair welding control parameters, and outputting a third vehicle frame. The method solves the technical problems in the prior art of the difficulty in accurately controlling key welding positions in the frame welding process and the lack of pertinence in the configuration of repair welding parameters, which leads to unstable frame welding quality, and achieves the technical effect of improving the overall welding quality of the frame.

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 vehicle frame welding. Background Art

[0002] As an important tool for urban cleaning and waste disposal, sanitation vehicles require a frame structure with high strength and stability to withstand the demands of use under complex working conditions. As the core load-bearing component of sanitation vehicles, welding quality is a key factor influencing the performance, safety, and service life of the frame during the manufacturing process. However, vehicle frames typically have complex geometric structures and a diverse material combination. Currently, most welding is performed in a single pass, making it difficult to achieve high-precision control of repair welds. For example, different welded parts of the frame have different stress characteristics, and key stress-bearing parts (such as load-bearing beams and connection nodes) require particularly high welding quality. Existing welding control lacks stress analysis and refined welding parameter configuration for key parts, which may result in insufficient local strength of the weld or the formation of cracks, thereby affecting the quality, stability, and service life of the entire frame.

[0003] At present, relevant technologies have technical problems such as the difficulty in accurately controlling key welding positions during frame welding and the lack of targeted configuration of repair welding parameters, which leads to unstable frame welding quality. Summary of the Invention

[0004] This application provides a high-precision control method for frame welding, which solves 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 vehicle frame welding, comprising: obtaining a welding position set of a first frame, where the first frame is an unwelded target frame; 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, to obtain a second frame, where the second frame is the target frame after welding; identifying a welding data set and welding material information of the key welding positions; configuring repair welding control parameters 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 outputting a third frame, where 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 also performed: the first frame is set to 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 based on 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 vehicle 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 a force analysis on each welding position in the welding position set based on 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 critical 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 outputting a set of key welding positions if there are no overlapping welding positions; and covering and retaining overlapping welding positions if there are overlapping welding positions, and outputting a set of key welding positions.

[0009] In a possible implementation, repair welding control parameters are configured based on the welding data set and the welding material information, and the configured repair welding control parameters are output. 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 based on 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 vehicle frame welding further 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: identifying defects at each position in the key welding position set and outputting three-dimensional defect data; performing defect modeling based on the three-dimensional defect data and outputting a three-dimensional defect model; planning the repair welding path for each position based on the three-dimensional defect 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 vehicle 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 larger 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] This application proposes a high-precision control method for vehicle frame welding, which involves obtaining a set of welding positions for a first frame; performing a force analysis on the first frame to obtain a set of key welding positions; connecting a frame welding device, and controlling welding at each position in the set of welding positions using a welding head to obtain a second frame; identifying a welding data set and welding material information; configuring repair welding control parameters based on the welding data set and welding material information, and outputting the configured repair welding control parameters; and controlling repair welding at key welding positions of the second frame using the configured repair welding control parameters to output a third frame. This method solves the technical problems in the prior art of frame welding, such as the difficulty in accurately controlling key welding positions and the lack of targeted repair welding parameter configuration, which results in unstable frame welding quality. The method achieves the technical effect of improving the overall welding quality of the frame. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention are briefly introduced below. Flowcharts are used in this application to illustrate the operations performed by the system according to the embodiments of the present application. It should be understood that the preceding or following operations are not necessarily performed in precise order. Instead, various steps may be processed in reverse order or simultaneously as needed. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

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

[0016] Figure 2A schematic diagram of a process 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 purpose, technical solutions and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings. The described embodiments should not be regarded as limiting this application. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0019] In the following description, reference is made to “some embodiments”, which describes a subset of all possible embodiments, but it will be understood that “some embodiments” may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict, and the terms “first\second” involved are merely to distinguish similar objects and do not represent a specific ordering of the objects. The terms “including” and “having” and any variations are intended to cover non-exclusive inclusions. For example, a process, method, product, or server 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. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application belongs. The terms used herein are for the purpose of describing the embodiments of this application only.

[0020] The embodiment of the present application provides a high-precision control method for frame welding, such as Figure 1 As shown, the method includes:

[0021] Step S100: obtaining a set of welding positions of a first vehicle frame, where the first vehicle frame is an unwelded target vehicle frame.

[0022] 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 into shape 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.

[0023] Step S200: performing a stress analysis on the first vehicle frame to obtain a key welding position set in the welding position set.

[0024] Preferably, before welding the sanitation vehicle frame, mechanical analysis and engineering calculations are used to screen out welding positions that have an important impact on the overall strength, stiffness and durability of the frame from all welding positions, 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 secondary auxiliary welds and main load-bearing welds, and then obtain the key welding position set in the welding position set, that is, screen out the performance of the frame such as load-bearing capacity, connection stability, and fatigue resistance from the welding position set. Critical welding points or welds, specifically, based on mechanical importance, the 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 corners, nodes or welding parts near large load points, are regarded as key welding positions; based on failure sensitivity, the welding points that may fail due to fatigue or fracture, and the parts that are prone to desoldering or deformation under extreme working conditions of the vehicle (such as heavy load, high-speed impact, etc.) are regarded as key welding positions; based on functional requirements, the welding points connecting important structural parts (such as support arms, main beams) and the 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.

[0025] 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 the welding position whose force intensity in the first state is greater than a first preset threshold as a key welding position.

[0026] 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. The areas with larger force intensity in the welding position set are identified through force analysis, and these areas are defined as key welding positions. Specifically, by analyzing the stress distribution of the frame in the 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 parts, that is, based on the three-dimensional modeling of the frame, a mechanical simulation tool is used to simulate the force distribution in the non-load state, and the force intensity of each welding position (such as maximum principal stress, shear stress, etc.) 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, 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 based on 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 a stress intensity greater than a first preset threshold are identified as key welding positions, including screening out welding positions with a stress intensity exceeding the threshold from the welding position set and marking them in the data, that is, areas that have been subjected to large 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 accurate.

[0027] Furthermore, step S200 also includes step S230, setting the first frame in 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; 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 the welding positions whose force intensity in the second state is greater than a second preset threshold as key welding positions, wherein the second preset threshold is greater than the first preset threshold.

[0028] 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), and supplementing and optimizing the identification of key welding positions under a non-loaded state, it is used to identify 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 vehicle's own weight, cargo load, impact load and other external forces, to obtain its force data. Similarly, using finite element analysis (FEA), the force distribution of the frame under different load conditions is simulated to generate complete force distribution data, including the force distribution of each welding position under the load conditions. The maximum stress, stress direction, degree of deformation, etc. under the load state are calculated, and the force strength of each welding position under the load state is calculated 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 identifying the welding positions with force strength greater than the second preset threshold as critical 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 screened critical welding positions need to withstand a higher stress level, thereby more accurately identifying the potential weak links of the frame under actual working conditions.

[0029] 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; step S260, if there are overlapping welding positions, covering and retaining them, and outputting a set of key welding positions.

[0030] Preferably, after analyzing the key welding positions of the first frame in the first state (unloaded state) and the second state (loaded state), the results in the two states are compared to determine a 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 overlapping areas are prioritized. 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 stress points 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. The output set of key welding positions includes overlapping positions and non-overlapping welding positions in the two states, thereby achieving high-precision control of the frame repair welding operation and improving the efficiency of the welding operation.

[0031] 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.

[0032] 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) with preliminary welding formation, wherein the frame welding device is used to perform the frame welding task, 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 the component of the frame welding device that performs the welding operation and is responsible for transferring the welding material (such as welding wire or welding rod) through the arc, laser, etc. 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 missing 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.

[0033] Step S400: Identify the welding data set and welding material information of the key welding position.

[0034] Preferably, non-destructive testing methods such as laser scanning, X-ray testing, and ultrasonic testing are used to accurately measure key welding locations to obtain welding data sets and welding material information related to the key welding locations. 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. by sensors of the welding equipment, welding results, weld dimensions (such as weld width, thickness, weld depth, etc.), weld geometry and uniformity, and detection results of welding defects (such as porosity, cracks, slag inclusions, etc.). Welding material information includes materials used in the welding process and their performance data, which may include base material information, i.e., the type, composition, and mechanical properties of the basic material (such as high-strength steel, aluminum alloy, etc.) constituting the vehicle frame; welding materials, the type (such as model and specification) of the welding wire, welding rod, or filler material used; and properties such as the melting point, thermal conductivity, and tensile strength of the welding material; and material compatibility, i.e., the physical and chemical compatibility between the welding material and the base material (such as fusion degree and intermetallic compound formation). By analyzing welding data sets, 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 vehicle frame.

[0035] Step S500 , configuring repair welding control parameters according to the welding data set and the welding material information, and outputting the configured repair welding control parameters.

[0036] Preferably, the repair welding control parameter configuration is performed based on the identified sanitation vehicle welding data set and welding material information, that is, through analysis and optimization, the precise parameter configuration required for repair welding is determined 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 energy input and welding process required for repair welding are determined based on the characteristics of the base material and welding material (such as melting point, thermal conductivity, and strength). The metal compatibility between the welding material and the base material is also considered to avoid the generation of new defects after repair welding. The repair welding control parameters are then 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 uniform depth and width of the weld area; optimizing the welding speed according to the size and location of the repair welding area to avoid overheating or discontinuous welds; controlling the heat input to avoid overburning of the base material or excessive expansion of the heat-affected zone; and determining the type, diameter, and conveying speed of the repair welding material. By analyzing the welding data and material properties, precise 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.

[0037] 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 the preset repair welding quality, wherein the repair welding control parameters include welding speed, welding current and welding voltage.

[0038] Preferably, through in-depth analysis of the welding data set and welding material information, features related to repair welding (such as the geometric features of the defect area and the thermal sensitivity of the welding material) are extracted, and then the repair welding process analysis is performed based on these features to determine the repair welding control parameters (welding speed, current, voltage) that meet the 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 and ultrasonic testing) to obtain the 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 pore, etc.), and the relative position of the defect area and 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 characteristics of the welding material, combining the material composition analysis and actual working conditions to evaluate its thermal response, and obtain the material's thermal sensitivity characteristics, including melting point, thermal expansion coefficient, thermal conductivity, etc.

[0039] 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 properties. Specifically, large-scale defects (such as long cracks) may require higher heat input to ensure sufficient melting, and small-scale defects (such as pores) require smaller heat input to avoid excessive melting or excessive heat-affected zone. Highly heat-sensitive materials require more precise thermal control to avoid welding deformation, burn-through or excessive heat-affected zone. For low thermal conductivity materials, the welding speed needs to be optimized to avoid excessive heat concentration to obtain repair welding analysis. The results, namely the repair welding control parameters, mainly include welding speed, welding current and welding voltage. Among them, 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 sufficient 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 a voltage can easily lead to spatter and unstable welding, while too low a voltage may result in incomplete fusion. These parameters ensure that the repair welding process can both repair defects and meet preset quality standards, thereby achieving efficient, high-precision and high-quality welding repairs.

[0040] 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 the 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.

[0041] Preferably, the geometric characteristics of the defect area are analyzed, and based on the defect depth in the geometric characteristics of the defect area, it is determined whether additional control parameters (such as a filling amount index) are needed to repair deeper defects. The defect depth refers to the maximum vertical depth of the problem in the weld. Defects with larger depths may directly affect the strength and load-bearing capacity of the weld. Specifically, if the defect depth in the geometric characteristics 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 weld performance 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 a new control parameter item. The filling amount index refers to the volume of welding material required to be filled during the repair welding process to repair deeper defects. The required amount of filling material is calculated based on the defect depth and cross-sectional shape. Considering the actual situation of the molten pool expansion, the input rate and amount of the welding material are adjusted. 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. This further performs more accurate repairs on deep defects, ensures that the geometric integrity and mechanical properties of the weld meet the preset requirements, and thus improves welding quality and efficiency.

[0042] In step S600, 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 outputs a third frame, which is the target frame after the repair welding.

[0043] Preferably, a welding device is used to perform repair welding operations on identified critical weld locations in the second frame formed by preliminary welding, repairing weld defects or improving weld quality at key locations, ultimately obtaining a welded product (a third frame) that meets design requirements. The second frame is the frame after preliminary welding, with all weld locations connected, but there may be weld quality issues. Specifically, the second frame is repair welded according to configured repair welding control parameters. Specifically, the welding head operates according to optimized repair welding parameters (such as current, voltage, welding speed, heat input, etc.) to ensure that the welding process meets preset standards. Heat input is precisely controlled to avoid new damage to the base material or surrounding welds during the repair welding process. The welding head covers defective areas in the set of critical weld locations one by one along a planned path, ensuring that the repair welding effect is consistent with design requirements. The welding head of the welding device is used to perform precise repair welding operations on the key weld locations of the second frame according to the configured repair welding control parameters, repairing weld defects and improving weld quality, ultimately obtaining a target frame (i.e., the third frame) after repair welding that meets performance and quality requirements.

[0044] 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 the 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.

[0045] Preferably, defects are identified at 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 the three-dimensional coordinates, shape and size data of the defect; 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 defect 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 position and shape of the defect, thereby improving the quality, reliability, welding efficiency and consistency of the repair welding, and achieving high-quality repair of the weld.

[0046] Furthermore, 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 larger 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.

[0047] Preferably, the welding head of the vehicle 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 point diameter). A large granularity means a wide welding range, but the fineness may be relatively low. Specifically, the welding granularity of the first welding head is large, which is suitable for covering a large range of welding areas and is used for efficient welding of common welding positions with relatively low welding precision requirements. The welding granularity of the second welding head is small, 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 structural 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.

[0048] The above specific embodiments do not constitute a limitation to the scope of protection of this application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent replacements and improvements made within the spirit and principles of this application should be included in the scope of protection of this application. In some cases, the actions or steps recorded in this application can be performed in an order different from that in the embodiments and can still achieve the desired results. In addition, the processes depicted in the accompanying drawings do 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 vehicle 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 from the welding position set; Connecting a vehicle frame welding device, and controlling welding at each position in the welding position set according to a welding head of the 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; Configure repair welding control parameters according to the welding data set and the welding material information, and output the configured repair welding control parameters; The welding head of the frame welding device controls the repair welding of each position in the set of key welding positions 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 the repair welding; Performing a stress analysis on the first vehicle frame to obtain key welding positions in the welding position set includes: 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; performing a force analysis on each welding position in the welding position set according to the force distribution data set, and identifying welding positions having a force intensity greater than a first preset threshold in the first state as key welding positions; 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 loaded state; performing a force analysis on each welding position in the welding position set according to the second force distribution data set, and identifying welding positions having a force intensity greater than a second preset threshold in the second state as key welding positions, wherein the second preset threshold is greater than the first preset threshold; The method includes configuring repair welding control parameters according to the welding data set and the welding material information, and outputting the configured repair welding control parameters. Extracting repair welding related features from the welding data set and the welding material information, including geometric features of defect areas and thermal sensitivity features of materials; A repair welding analysis is performed based on the geometric characteristics of the defect area and the thermal sensitivity characteristics 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.

2. A high-precision control method for vehicle frame welding according to claim 1, characterized in that: Performing an 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 no overlapping welding positions exist; If there are overlapping welding positions, they are covered and retained, and the key welding position set is output.

3. A high-precision control method for vehicle frame welding according to claim 1, characterized in that: 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 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.

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

5. A high-precision control method for vehicle frame welding according to claim 1, characterized in that: The welding head of the vehicle 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 larger than that of the second welding head; 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.

Images