Method and equipment for determining working pressure range of digital ultrasonic welding machine, medium and product

Abstract

The embodiment of the invention relates to the technical field of ultrasonic waves, and discloses a method and equipment for determining the working pressure range of a digital ultrasonic welding machine, a medium and a product. The method comprises the following steps: starting to control a welding head to press down before contacting a welding workpiece, and starting ultrasonic power supply frequency search to collect pressure of the welding head and ultrasonic power supply frequency at different moments; generating a pressure and frequency relation curve; obtaining a first pressure range based on the minimum pressure required by welding and the maximum pressure determined according to a predetermined working frequency range; sampling in the first pressure range to obtain at least two pressure sampling values; performing frequency sweeping under each pressure sampling value to obtain a frequency sweeping curve; obtaining the phase difference of the sweep frequency curve corresponding to each pressure sampling value; and the working pressure range of the digital ultrasonic welding machine is determined according to the phase difference. By the adoption of the scheme, an application worker can conveniently know the performance of the welding machine, and the problem that the welding effect is affected due to the fact that improper working parameters are used is avoided.

Description

Technical Field

[0001] The present application relates to the field of ultrasonic technology, and in particular to a method, device, medium and product for determining the working pressure range of a digital ultrasonic welder. Background Art

[0002] In recent years, with the rapid development of science and technology, the application of ultrasonic welding technology has become more and more extensive.

[0003] Among the existing ultrasonic welding methods, more and more ultrasonic welders use servo or cylinder to control welding pressure. For ultrasonic welding control, different welding pressures are reflected as different loads. Therefore, welding parameters including pressure need to be changed frequently due to application needs. The load variation range is relatively large, which puts higher requirements on the design and control of ultrasonic power supply.

[0004] At present, high-power ultrasonic power supplies all use a full-bridge inverter plus a matching circuit to achieve the output of the driving voltage required by the ultrasonic transducer. Limited by the parameters of the inductor, capacitor and other components used in the matching circuit, this method needs to be combined with the transducer and the operating conditions to obtain a better matching effect, so the range of applicable loads is limited.

[0005] Therefore, for situations where the welding pressure needs to be adjusted, resulting in large load changes, the ultrasonic power supply usually cannot guarantee normal operation in all situations. Therefore, for application personnel, how to understand the range of its control capabilities in advance is an important prerequisite for arranging welding work. Summary of the invention

[0006] One purpose of the present application is to provide a method, device, medium and product for determining the working pressure range of a digital ultrasonic welder, at least to solve the problem that the welding pressure range cannot be well matched due to the limitation of electronic components. The present application starts to control the welding head to press down before contacting the welding workpiece, and starts the ultrasonic power supply frequency search to collect the pressure of the welding head and the ultrasonic power supply frequency at different times; according to the pressure of the welding head and the ultrasonic power supply frequency collected at different times, a pressure-frequency relationship curve is generated; based on the minimum pressure required for welding, and the maximum pressure determined according to the predetermined working frequency range, a first pressure range is obtained; within the first pressure range, at least two pressure sampling values ​​are obtained by sampling according to the preset sampling rules; at each pressure sampling value, a frequency sweep is performed to obtain the frequency sweep curve corresponding to each pressure sampling value; the phase difference of the frequency sweep curve corresponding to each pressure sampling value is obtained; and the working pressure range of the digital ultrasonic welder is determined according to the phase difference. By adopting this scheme, the corresponding actions and data collection can be automatically performed by combining the welding pressure control with the working mode of the digital ultrasonic power supply, and the corresponding curve can be obtained to facilitate the application personnel to understand the performance of the welding machine and avoid the problem of using inappropriate working parameters to affect the welding effect.

[0007] To achieve the above objectives, some embodiments of the present application provide the following aspects:

[0008] In a first aspect, some embodiments of the present application further provide a method for determining a working pressure range of a digital ultrasonic welder, comprising:

[0009] Before contacting the welding workpiece, the welding head starts to press down and the ultrasonic power source frequency search is started to collect the welding head pressure and ultrasonic power source frequency at different times;

[0010] Generate a pressure-frequency relationship curve based on the pressure of the welding head and the frequency of the ultrasonic power supply collected at different times;

[0011] A first pressure range is obtained based on a minimum pressure required for welding and a maximum pressure determined according to a predetermined working frequency range;

[0012] Within the first pressure range, sampling is performed according to a preset sampling rule to obtain at least two pressure sampling values;

[0013] Perform frequency sweep at each pressure sampling value to obtain a frequency sweep curve corresponding to each pressure sampling value;

[0014] Obtaining the phase difference of the frequency sweep curve corresponding to each pressure sampling value;

[0015] The working pressure range of the digital ultrasonic welder is determined according to the phase difference.

[0016] In a second aspect, some embodiments of the present application further provide an electronic device, comprising: one or more processors; and a memory storing computer program instructions, wherein the computer program instructions, when executed, cause the processor to perform the steps of the method described above.

[0017] In a third aspect, some embodiments of the present application further provide a computer-readable medium having computer program instructions stored thereon, wherein the computer program instructions can be executed by a processor to implement the method as described above.

[0018] In a fourth aspect, some embodiments of the present application further provide a computer program product, comprising a computer program / instruction, which implements the steps of the method described above when executed by a processor.

[0019] Compared with the related art, in the solution provided by the embodiment of the present application, the welding head is controlled to be pressed down before contacting the welding workpiece, and the ultrasonic power supply frequency search is started to collect the pressure of the welding head and the ultrasonic power supply frequency at different times; according to the pressure of the welding head and the ultrasonic power supply frequency collected at different times, a pressure-frequency relationship curve is generated; based on the minimum pressure required for welding and the maximum pressure determined according to the predetermined working frequency range, a first pressure range is obtained; within the first pressure range, at least two pressure sampling values ​​are obtained by sampling according to a preset sampling rule; at each pressure sampling value, a frequency sweep is performed to obtain a frequency sweep curve corresponding to each pressure sampling value; the phase difference of the frequency sweep curve corresponding to each pressure sampling value is obtained; and the working pressure range of the digital ultrasonic welder is determined according to the phase difference. By adopting this solution, the corresponding actions and data collection can be automatically performed by combining the welding pressure control with the working mode of the digital ultrasonic power supply, and the corresponding curve can be obtained to facilitate the application personnel to understand the performance of the welding machine and avoid the problem of using inappropriate working parameters to affect the welding effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] One or more embodiments are exemplarily described by pictures in the corresponding drawings, and these exemplified descriptions do not constitute limitations on the embodiments. Elements with the same reference numerals in the drawings represent similar elements, and unless otherwise stated, the figures in the drawings do not constitute proportional limitations.

[0021] Figure 1 An exemplary flow chart of a method for determining a working pressure range of a digital ultrasonic welder according to some embodiments of the present application;

[0022] Figure 2 A schematic diagram of a pressure-frequency relationship curve provided according to some embodiments of the present application;

[0023] Figure 3A schematic diagram of a frequency sweep curve with a pressure of F1 provided according to some embodiments of the present application;

[0024] Figure 4 A schematic diagram of a frequency sweep curve with a pressure of F2 provided according to some embodiments of the present application;

[0025] Figure 5 A schematic diagram of a pressure-phase difference curve provided according to some embodiments of the present application;

[0026] Figure 6 An exemplary structural diagram of the electronic device is disclosed. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0028] First embodiment

[0029] The first embodiment of the present application relates to a method for determining the working pressure range of a digital ultrasonic welder. Figure 1 As shown, the method is executed by a management tool, and the method may include the following steps:

[0030] Step S101, before contacting the welding workpiece, the welding head starts to be pressed down, and the ultrasonic power source frequency search is started to collect the pressure of the welding head and the ultrasonic power source frequency at different times;

[0031] Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the two surfaces of the objects rub against each other to form a fusion between the molecular layers. The ultrasonic generator converts 50 / 60 Hz current into 15, 20, 30 or 40KHz electrical energy. The converted high-frequency electrical energy is converted again into mechanical movement of the same frequency through the transducer. The mechanical movement is then transmitted to the welding head through a set of amplitude-changing rod devices that can change the amplitude. The welding head transmits the received vibration energy to the joint of the workpiece to be welded. In this area, the vibration energy is converted into heat energy by friction to melt the plastic. Welding methods include fusion welding, in which the ultrasonic ultra-high frequency vibrating welding head generates friction heat at the joint surface of the two pieces of plastic under moderate pressure, causing them to melt and join instantly. Riveting welding, in which the ultrasonic ultra-high frequency vibrating welding head presses the protruding tip of the plastic product, causing it to heat and melt instantly into a rivet shape, so that materials of different materials are mechanically riveted together. Embedding: With the conduction of the welding head and appropriate pressure, the metal parts are squeezed into the reserved plastic holes instantly and fixed at a certain depth. Molding: The concave welding head is pressed on the outer ring of the plastic product. After the welding head emits ultrasonic ultra-high frequency vibration, the plastic is melted and formed and wrapped around the metal object to fix it. Spot welding: Two pieces of plastic are welded at different points without pre-designing welding lines, or for relatively large workpieces, workpieces that are not suitable for designing welding lines, spot welding is performed to achieve the welding effect. Cutting and sealing: Using the working principle of ultrasonic instantaneous oscillation, chemical fiber fabrics are cut. It has the advantages of fast welding speed, high welding strength, good sealing, low cost, clean and pollution-free, and stable welding process.

[0032] Ultrasonic welding power supply control is mainly to enable the ultrasonic welding power supply to stably and efficiently output the required high-frequency electrical energy to drive the transducer to produce stable mechanical vibration, thereby achieving high-quality ultrasonic welding. At the same time, through precise power supply control, the welding parameters can be adjusted according to different welding materials, workpiece shapes and welding requirements, the welding process can be optimized, the welding efficiency and quality can be improved, and the service life of the equipment can be extended. Frequency automatic tracking, because the resonant frequency of the ultrasonic transducer will drift with factors such as ambient temperature and load changes, it is necessary to adopt frequency automatic tracking technology to monitor the operating frequency of the transducer in real time and automatically adjust the output frequency of the ultrasonic power supply to keep it near the resonant frequency of the transducer to ensure that the transducer can obtain the maximum mechanical vibration efficiency and improve the welding effect and stability. Power control, according to the characteristics of the welding material, the thickness and size of the workpiece and other factors, the output power of the ultrasonic power supply is accurately controlled to provide appropriate welding energy. Power control methods include constant power control, time-power control, etc., and the power can be adjusted by adjusting the output voltage, current and other parameters of the power supply to ensure the consistency of welding quality. Phase difference control monitors and controls the voltage and current phase difference at both ends of the ultrasonic transducer to optimize the energy transfer and conversion during the welding process. By adjusting the phase difference, the transducer can better absorb and convert electrical energy into mechanical energy, improving welding efficiency and quality.

[0033] The welding head is the component in the welding equipment that directly contacts the weldment and transfers energy to achieve welding. Its shape, material and performance will affect the welding quality and effect.

[0034] The frequency sweep curve can be a curve obtained by a frequency sweep operation. It reflects the relationship between a physical quantity (such as voltage, current, amplitude, etc.) and the frequency change within a certain frequency range. In ultrasonic welding, it can be used to analyze and evaluate the relevant characteristics of the welding process.

[0035] Among them, the welding workpiece refers to objects such as parts that need to be connected through welding technology, and is the object of the welding operation.

[0036] The welding head can be a component on the ultrasonic welding equipment that directly contacts the welding workpiece and is used to transmit ultrasonic energy to achieve welding.

[0037] Pressure refers to the magnitude of the force applied by the welding head to the welding workpiece, reflecting factors such as the tightness of contact during welding.

[0038] The frequency of the ultrasonic power supply is the parameter output by the ultrasonic power supply that determines the speed of ultrasonic vibration. Different frequencies will affect the welding effect.

[0039] In this solution, the downward pressure is controlled by moving the welding head toward the direction of the welding workpiece according to the set program or instructions through the corresponding mechanical transmission mechanism or electrical control module to achieve a suitable contact position. The purpose is to allow the welding head to contact the workpiece and prepare for welding.

[0040] Starting the frequency search can be the operation process in which the ultrasonic power supply automatically and sequentially changes its output frequency within a specific frequency range according to certain setting rules. Through the frequency search, the best frequency that best suits the current welding workpiece and welding conditions can be found, or the various parameters related to welding under different frequencies can be fully obtained, providing a data basis for the subsequent determination of appropriate welding parameters.

[0041] The pressure data of the welding head is obtained by the pressure sensor installed on the equipment, and the power supply frequency data is obtained by using the data acquisition module connected to the ultrasonic power supply. The pressure values ​​and frequency values ​​corresponding to these different moments are collected and recorded for subsequent analysis and processing.

[0042] Step S102, generating a pressure-frequency relationship curve according to the pressure of the welding head and the frequency of the ultrasonic power supply collected at different times;

[0043] The pressure-frequency relationship curve can be a graph formed by connecting the points corresponding to the pressure and frequency data collected at different times, with the welding head pressure as the horizontal axis and the ultrasonic power frequency as the vertical axis, to intuitively present the correlation changes between the two.

[0044] In this scheme, the generation method is to use the pressure and frequency data collected at different times, and through the corresponding data analysis software or the calculation module that comes with the equipment, these discrete data points are fitted into a continuous curve according to the mathematical correspondence, so as to clearly show the change pattern between pressure and frequency, which is convenient for subsequent related judgments and operations based on the curve.

[0045] In this solution, optionally, before contacting the welding workpiece, the welding head starts to be controlled to be pressed down, and after the ultrasonic power source frequency search is started, the method further includes:

[0046] When the preset termination condition is met, the welding head pressing down and the generator frequency searching are stopped, and the data recording is completed.

[0047] The preset termination condition can be set in advance based on factors such as welding process requirements, equipment operation safety specifications, data collection integrity, etc., and is used to determine when to end the welding head pressure and the generator frequency sweep operation. Related standards or rules, such as reaching the specified frequency search time, collecting a sufficient number of data points, and the occurrence of specific welding parameter changes can all be used as preset termination conditions.

[0048] Data recording refers to the storage of various welding-related data information collected during the welding process, such as welding head pressure, ultrasonic power frequency, frequency search curve, phase difference, etc., in a specific format through a storage device (such as a built-in storage chip in the equipment, an external data storage hard disk, etc.) for subsequent reference, analysis, and use for process optimization and other purposes.

[0049] Stopping the downward pressure is done by sending a stop command to the mechanical or electrical actuator that controls the movement of the welding head, causing it to stop moving toward the welding workpiece. This is to prevent the welding head from being over-pressed to cause damage to the workpiece or to prevent the welding process from not meeting the requirements, and to ensure that the operation is completed according to the established specifications.

[0050] Stopping the frequency sweep can be to send a stop frequency sweep operation instruction to the control system of the ultrasonic power generator, so that the generator stops automatically switching the frequency within the frequency range, avoiding unnecessary energy consumption and ensuring that data collection ends at the appropriate node, thereby ensuring the validity and accuracy of the collected data.

[0051] Through the built-in data acquisition and recording program in the equipment, the various welding-related data collected previously are stored in the corresponding storage medium in an orderly manner according to the preset data format (such as table format, specific coding format, etc.), thereby completing the entire data recording process and facilitating the subsequent review and analysis of the welding process and results.

[0052] In this solution, optionally, the preset termination condition includes the welding head pressure reaching a predetermined maximum pressure, or the ultrasonic power supply frequency search alarm.

[0053] Among them, the predetermined maximum pressure can be the upper limit value of the pressure that the welding head can apply, which is set before the welding operation begins, based on multiple factors such as the material properties, structural characteristics of the welding workpiece, and the performance of the welding equipment itself. Once the welding head pressure reaches this value, the relevant conditions in the preset termination conditions are met, and the corresponding operation needs to be stopped to avoid adverse effects on the workpiece or equipment.

[0054] The ultrasonic power supply frequency search alarm can be a warning signal issued by the ultrasonic power supply itself during the frequency sweep process when it detects situations that do not meet the normal operating requirements, such as abnormal deviation of the output frequency from the set range, hidden faults in the internal circuit, and related parameters exceeding the normal fluctuation range during the frequency sweep. This reminds the operator that there is a problem with the current frequency sweep. This situation is also set as one of the preset termination conditions. After being triggered, related operations need to be stopped to ensure safety and avoid invalid data collection.

[0055] This solution can be to monitor in real time the numerical value of the pressure applied by the welding head to the welding workpiece through a pressure sensor installed in the relevant part of the welding head. When the pressure data fed back by the sensor is equal to the pre-set maximum pressure value, it is determined that this condition has been met, and subsequent operations should be stopped according to the rules.

[0056] Corresponding fault detection modules and alarm trigger mechanisms can be set up inside the ultrasonic power supply. During the frequency scanning process, these modules will continuously monitor and analyze various parameters of the frequency scanning (such as frequency, current, voltage, etc.). Once an abnormal situation is detected that meets the pre-set alarm trigger standard, an alarm will be issued by emitting sound and light signals to inform the operator of the current frequency scanning condition, thereby triggering the preset termination conditions to take effect, and subsequent operations need to be stopped accordingly.

[0057] Figure 2 Schematic diagram of the relationship between pressure and frequency according to some embodiments of the present application. Figure 2 As shown in the figure, the operating frequency range [f d1 ,f d2 ] and the minimum pressure required for welding to obtain the first pressure range [F1, F2], where F1 is the minimum pressure required for welding, and F2 is the corresponding frequency f in the pressure-frequency curve d2 pressure value.

[0058] Step S103, obtaining a first pressure range based on a minimum pressure required for welding and a maximum pressure determined according to a predetermined working frequency range;

[0059] The minimum pressure may be the minimum pressure value applied by the welding head to the workpiece during the welding process to ensure that the welding joint forms a reliable connection. A good welding effect may not be achieved if the pressure is lower than this value.

[0060] The operating frequency range can be a range of ultrasonic power frequency suitable for welding operations, which is determined in advance based on factors such as the material and shape of the welding workpiece and the performance of the ultrasonic welding equipment itself.

[0061] The maximum pressure can be the highest pressure value allowed to be applied by the welding head to the workpiece under the conditions corresponding to the predetermined working frequency range during welding, taking into account that the workpiece will not be damaged or suffer other adverse conditions due to excessive pressure.

[0062] The first pressure range is a pressure value range defined by comprehensively considering the minimum pressure required for welding and the maximum pressure determined based on the working frequency range. Subsequent operations will be performed within this range.

[0063] For the minimum pressure, this solution determines the specific value through experience data from previous welding of this or similar workpieces, welding process standard requirements, etc.; for the operating frequency range, it is confirmed based on workpiece material property analysis, equipment technical manual recommendations, etc.; for the maximum pressure, the specific value is obtained after comprehensive consideration of factors such as the operating frequency range and the workpiece's pressure-bearing capacity; finally, by comparing the minimum and maximum pressure values, the first pressure range is defined to limit the range for subsequent sampling and other operations.

[0064] In this solution, optionally, the predetermined operating frequency range is determined based on the design parameters of the adopted ultrasonic transducer and the welding head.

[0065] Among them, the ultrasonic transducer is a device that can convert electrical energy into mechanical energy (in ultrasonic welding, it usually converts the input electrical energy into mechanical energy in the form of ultrasonic vibration), or perform reverse conversion. It is a key component in ultrasonic welding equipment, and its performance parameters have an important influence on the generation and effect of ultrasonic waves in the entire welding process.

[0066] The design parameters of the welding head may include specific specifications of the welding head's shape, size, material, resonant frequency, and many other aspects. These parameters determine the welding head's efficiency in transmitting ultrasonic energy during welding, its contact characteristics with the workpiece, and the adaptive vibration frequency range, and play a key role in the welding effect.

[0067] The operating frequency range can be the range of ultrasonic power supply output frequencies that are suitable for the equipment to carry out welding work normally and efficiently during ultrasonic welding operations. Welding within this range can ensure welding quality and stable operation of the equipment. It is an important parameter range determined based on the characteristics of related components.

[0068] This solution can first obtain key performance parameters such as rated frequency, frequency bandwidth, etc. given in the instructions, technical manuals and other materials of the ultrasonic transducer, and at the same time organize the design parameters specified in the welding head design, such as resonant frequency, adaptable frequency range, etc., and then comprehensively consider the coordinated adaptability of the two in actual welding work. Through theoretical calculation, simulation analysis or reference to experience data of previous welding with similar equipment, etc., the working frequency range suitable for this welding operation can be clarified, providing a basis for operations such as frequency adjustment in subsequent welding processes.

[0069] Through such an arrangement, the present invention can obtain a reasonable first pressure range for calculating the subsequent working pressure range, thereby improving the control accuracy of the digital ultrasonic welding machine.

[0070] Step S104, within the first pressure range, sampling is performed according to a preset sampling rule to obtain at least two pressure sampling values;

[0071] Among them, the preset sampling rules can be the regulations on how to select pressure sampling points (such as sampling intervals, sampling quantities, etc.) that are pre-established before pressure sampling based on factors such as welding process requirements and data analysis accuracy requirements.

[0072] The pressure sampling value is a specific pressure value selected within the first pressure range according to a preset sampling rule, and is used for subsequent further analysis of welding-related characteristics under different pressures.

[0073] The sampling method is based on preset sampling rules, such as selecting at equal intervals or selecting specific pressure values ​​within the first pressure range according to a specific ratio, and using the data acquisition function of the equipment to obtain these corresponding pressure values. The purpose is to obtain multiple representative pressure points for subsequent operations and analysis such as frequency scanning.

[0074] In this solution, optionally, within the first pressure range, sampling is performed according to a preset sampling rule to obtain at least two pressure sampling values, including:

[0075] In the first pressure range, the pressure sampling value is obtained by increasing the preset pressure interval each time.

[0076] Among them, the preset pressure interval can be a pressure difference between two adjacent pressure sampling values ​​that is pre-set based on factors such as the size of the first pressure range, the required sampling accuracy, and subsequent data analysis requirements. It stipulates the step size of the pressure increase each time a pressure sampling value is obtained, which can ensure that the sampling value distribution is reasonable and complies with the established sampling rules.

[0077] Figure 3 It is a schematic diagram of a frequency sweep curve with a pressure of F1 provided according to some embodiments of the present application. Figure 4 FIG. 1 is a schematic diagram of a frequency sweep curve with a pressure of F2 provided according to some embodiments of the present application. Figure 3 and Figure 4 As shown in the figure, when the pressure changes, the frequency sweep curve will change to a certain extent.

[0078] This solution first defines the starting pressure value and the ending pressure value of the first pressure range, and starts from the starting pressure value, with the preset pressure interval as the increment, and calculates the subsequent pressure values ​​in sequence, and records and collects these pressure values ​​calculated by gradual increments as pressure sampling values. For example, if the starting pressure is 10N and the preset pressure interval is 2N, then pressure sampling values ​​such as 10N, 12N, 14N, etc. can be obtained in sequence. In this way, it is ensured that a suitable and sufficient number of pressure sampling values ​​can be obtained as required within the first pressure range for subsequent frequency scanning and other related operations and analysis.

[0079] Through such a setting, the present solution can ensure the rationality of each pressure sampling value and can evenly cover the first pressure range, so that the obtained results are continuous, providing a data basis for the subsequent determination of the working pressure range.

[0080] Step S105, performing frequency sweep at each pressure sampling value to obtain a frequency sweep curve corresponding to each pressure sampling value;

[0081] The frequency sweep curve is a curve drawn by starting the ultrasonic power supply to sweep the frequency at a specific pressure sampling value. The frequency corresponding to different sweeping moments and related welding parameters (such as amplitude and other parameters that can indirectly reflect the welding status) are used to reflect the changes in the frequency sweeping process under the pressure.

[0082] The frequency scanning method is similar to starting the frequency search in step S101. Under the conditions corresponding to the set pressure sampling values, the ultrasonic power supply is operated to automatically scan the frequency, and the frequency and other data in this process are collected. The purpose is to obtain the corresponding frequency scanning curves under different pressure sampling values ​​to analyze the influence of pressure on the frequency scanning effect.

[0083] Through the above-mentioned frequency sweeping operation and supporting data collection and recording, the collected data are sorted in time sequence or frequency sequence to form a curve that can intuitively reflect the frequency sweeping situation, that is, the frequency sweeping curve corresponding to each pressure sampling value, for subsequent analysis and comparison.

[0084] Step S106, obtaining the phase difference of the frequency sweep curve corresponding to each pressure sampling value;

[0085] Among them, the phase difference is in the sweep frequency curve corresponding to each pressure sampling value, which refers to the difference between the phases of two sinusoidal alternating currents of the same frequency. In ultrasonic welding, it can reflect the differences in vibration and other aspects during the welding process under different pressures, which is of great significance for analyzing the welding status.

[0086] The acquisition method can be to use a professional signal analysis instrument or a phase detection module that comes with the equipment to analyze and process the electrical signals involved in the sweep frequency curve corresponding to each pressure sampling value, and extract the corresponding phase difference value, so as to subsequently determine the working pressure range based on the phase difference.

[0087] Step S107, determining the working pressure range of the digital ultrasonic welder according to the phase difference.

[0088] The working pressure range of the digital ultrasonic welder can be the pressure value range that is finally determined to be suitable for the digital ultrasonic welder to perform normal, efficient and stable welding operations. Welding within this range can ensure welding quality.

[0089] The determination method is to further accurately define the pressure range suitable for welding work from the first pressure range and other related intervals based on the phase difference data of the sweep frequency curve corresponding to each pressure sampling value obtained in the previous step through specific algorithms, comparison standards or empirical judgment rules, so as to guide the actual welding operation and ensure the welding effect.

[0090] Before contacting the welding workpiece, start controlling the welding head to press down, and start the ultrasonic power supply frequency search to collect the pressure of the welding head and the ultrasonic power supply frequency at different times; generate a pressure-frequency relationship curve based on the pressure of the welding head and the ultrasonic power supply frequency collected at different times; based on the minimum pressure required for welding and the maximum pressure determined according to the predetermined working frequency range, obtain a first pressure range; within the first pressure range, sample according to the preset sampling rules to obtain at least two pressure sampling values; perform frequency sweeping at each pressure sampling value to obtain a frequency sweeping curve corresponding to each pressure sampling value; obtain the phase difference of the frequency sweeping curve corresponding to each pressure sampling value; determine the working pressure range of the digital ultrasonic welder based on the phase difference. By adopting this solution, by combining the welding pressure control with the working mode of the digital ultrasonic power supply, the corresponding actions and data collection can be automatically performed, and the corresponding curve can be obtained to facilitate the application personnel to understand the performance of the welding machine and avoid the problem of using inappropriate working parameters to affect the welding effect.

[0091] In one embodiment, optionally, determining the working pressure range of the digital ultrasonic welder according to the phase difference includes:

[0092] Obtain the minimum phase difference of the frequency sweep curve corresponding to each pressure sampling value;

[0093] Constructing a pressure-phase difference minimum curve;

[0094] The minimum pressure required for welding is used as the first threshold of the working pressure range, and the second threshold of the working pressure range is determined by the pressure-phase difference minimum value curve.

[0095] Figure 5 Schematic diagram of pressure-phase difference curve provided according to some embodiments of the present application. Figure 5 As shown, it includes a phase difference minimum curve and a phase difference maximum curve. Since the maximum phase difference is π / 2 regardless of the pressure sampling value, the phase difference maximum curve is a straight line.

[0096] The minimum phase difference value may be obtained by respectively calculating the maximum phase difference value and the minimum phase difference value in the frequency sweep curve corresponding to each pressure sampling value, and performing subsequent calculations based on the minimum phase difference value.

[0097] The pressure-phase difference minimum value curve can be a curve formed by connecting the data points of different pressure sampling values ​​and their corresponding phase difference minimum values, with the pressure sampling value as the horizontal coordinate and the phase difference minimum value of the sweep frequency curve under each corresponding pressure sampling value as the vertical coordinate. This curve intuitively shows the correlation between the pressure change and the phase difference minimum value, which helps to further analyze and determine the working pressure range.

[0098] The first threshold, that is, the lower limit of the working pressure range, means that the minimum pressure required for welding is set as the first threshold here, which means that the working pressure cannot be lower than this value, otherwise the basic quality and effect of welding cannot be guaranteed. It is one of the important boundary conditions for defining the working pressure range.

[0099] The second threshold, that is, the upper limit of the working pressure range, is determined by analyzing and judging the pressure-phase difference minimum curve, and together with the first threshold, defines a suitable working pressure range for the digital ultrasonic welder, ensuring that welding within this range can achieve better welding quality and equipment operating status.

[0100] This solution can be to first organize the two sets of data, namely, each pressure sampling value and the corresponding minimum phase difference value that has been obtained, and then use drawing software, data analysis tools or the curve drawing function module that comes with the equipment to mark these data points in the plane rectangular coordinate system in turn according to the mathematical coordinate correspondence, and connect these points by connecting lines to form a pressure-phase difference minimum value curve, which is used to intuitively present the change law between the two and provide a visual basis for determining the working pressure range.

[0101] The second threshold value can be determined by analyzing the constructed pressure-phase difference minimum curve, such as observing the trend of the curve, finding a specific turning point in the curve (such as a point where the slope changes significantly, etc.), combining previous welding experience and the requirements for the relationship between phase difference and pressure in relevant welding process standards, etc., to comprehensively determine the appropriate pressure value as the second threshold value, thereby determining the working pressure range of the digital ultrasonic welder together with the first threshold value (the minimum pressure required for welding), and ensuring that the welding operation can be carried out within a reasonable pressure range.

[0102] In one embodiment, optionally, determining a second threshold value of the working pressure range based on the pressure-phase difference minimum curve includes:

[0103] The pressure corresponding to the standard phase difference in the pressure-phase difference minimum curve is determined as the second threshold value of the working pressure range; wherein the standard phase difference is selected based on the control capability of the ultrasonic power supply.

[0104] Among them, the standard phase difference can be a specific phase difference value selected according to the control capability of the ultrasonic power supply itself. It is used as a reference standard to find the corresponding pressure value in the pressure-phase difference minimum curve, and then determine the second threshold of the working pressure range, reflecting the more ideal welding-related phase difference state under this control capability.

[0105] The control capability of an ultrasonic power supply can be the performance level and operable range of the ultrasonic power supply in adjusting the output frequency, controlling the output power, maintaining a stable electrical signal, etc. For example, the frequency range it can accurately control, the power range it can adjust, etc. These capabilities will affect parameters such as the phase difference in the welding process, and are also the basis for selecting the standard phase difference.

[0106] This solution is to search for the pressure value corresponding to the selected standard phase difference value in the constructed pressure-phase difference minimum curve, accurately find the pressure value that meets the conditions through data matching, coordinate positioning and other means, and then define and set this pressure value as the second threshold of the working pressure range. Together with the first threshold mentioned above, which takes the minimum pressure required for welding as the minimum pressure, the complete working pressure range is defined, providing accurate pressure range limitation for the actual welding operation of the digital ultrasonic welder.

[0107] This embodiment also provides a preferred implementation.

[0108] First, determine the working frequency under different pressures. The steps include:

[0109] S1: Control the welding head to press down, and before contacting the welding workpiece, the ultrasonic power supply starts frequency search;

[0110] S2: Control the welding head to continue to press down slowly, and the ultrasonic power supply keeps searching the frequency, and collects and records the pressure and ultrasonic power supply frequency at different times in real time;

[0111] S3: When the welding head pressure reaches the preset maximum pressure or the ultrasonic power supply frequency search alarm, the welding head pressure and generator frequency search are stopped, and data recording is completed;

[0112] S4: Generate a pressure-frequency relationship curve, and the working frequency range [f d1 ,f d2 ] and the minimum pressure required for welding to obtain the first pressure range [F1, F2], where F1 is the minimum pressure required for welding, and F2 is the corresponding frequency f in the pressure-frequency curve d2 pressure value.

[0113] Afterwards, multiple pressure positions are selected within the pressure range [F1, F2] for frequency sweep, and the upper and lower limits of the phase difference obtained by each frequency sweep are recorded. The specific steps are as follows:

[0114] S5: Control the welding head to slowly press down until the pressure reaches F1, and start the ultrasonic generator to sweep the frequency. The sweep frequency range is [f d1 ,f d2 ], record the frequency sweep curve;

[0115] S6: Control the welding head to continue pressing down until the pressure increases by a pressure interval F compared to the previous pressure. d , start the ultrasonic generator to sweep frequency again, the sweep frequency range is [f d1 ,f d2 ], record the frequency sweep curve;

[0116] S7: Repeat the above steps and record the frequency sweep curve W each time. n Until the current pressure reaches or exceeds F2, the last frequency sweep curve is recorded as W N .

[0117] After obtaining the above frequency sweep curve W1-W N After that, the curve data is analyzed, and the maximum and minimum phase difference values ​​in each frequency sweep curve are extracted to obtain the pressure-phase difference curve.

[0118] According to the above pressure-phase difference curve, the pressure range [F s1 , F s2 ]. Among them, F s1 =F1,F s2 is the pressure value of the phase difference P2 corresponding to the phase difference of the minimum phase difference curve. Among them, P2 is selected according to the control ability of the ultrasonic power supply and is generally not greater than -π / 4.

[0119] This solution, by combining the working mode of the welding machine pressure control and the digital ultrasonic power supply, automatically performs corresponding actions and data collection, and obtains corresponding curves to facilitate application personnel to understand the performance of the welding machine and avoid using inappropriate working parameters to affect the welding effect.

[0120] In addition, some embodiments of the present application also provide an electronic device. The electronic device may be a digital computer in various forms, such as a laptop computer, a desktop computer, a workbench, a personal digital assistant, a server, a blade server, a mainframe computer, etc. The electronic device may also be a mobile device in various forms, such as a personal digital assistant, a cellular phone, a smart phone, a wearable device, and other similar computing devices.

[0121] The electronic device includes: one or more processors; and a memory storing computer program instructions, wherein when the computer program instructions are executed, the processor executes the steps of the method provided in any one or more of the above embodiments. Figure 6 An exemplary structural diagram of the electronic device is disclosed. Figure 6 As shown, the electronic device includes: one or more processors 601, memory 602, and interfaces for connecting various components, including high-speed interfaces and low-speed interfaces. The various components are connected to each other using different buses and can be installed on a common mainboard or installed in other ways as needed. The processor can process instructions executed in the electronic device, including instructions stored in or on the memory to display the graphical information of the GUI on an external input / output device (such as a display device coupled to the interface). In some other embodiments, if necessary, multiple processors and / or multiple buses can be used together with multiple memories and multiple memories. Similarly, multiple electronic devices can be connected, and each device provides some necessary operations (for example, as a server array, a group of blade servers, or a multi-processor system). Among them, the components shown in this article, their connections and relationships, and their functions are only used as examples, and are not intended to limit the implementation of the present application described and / or required herein.

[0122] The electronic device may further include: an input device 603 and an output device 604. The processor 601, the memory 602, the input device 603 and the output device 604 may be connected via a bus or other means. Figure 6 The example of connecting through bus is taken in the following.

[0123] The input device 603 can receive input digital or character information, and generate key signal input related to the user settings and function control of the electronic device, such as a touch screen, a keypad, a mouse, a track pad, a touch pad, an indicator rod, one or more mouse buttons, a trackball, a joystick and other input devices. The output device 604 may include a display device, an auxiliary lighting device (e.g., an LED) and a tactile feedback device (e.g., a vibration motor), etc. The display device may include, but is not limited to, a liquid crystal display (LCD), a light emitting diode (LED) display and a plasma display. In some embodiments, the display device may be a touch screen.

[0124] In order to provide interaction with the user, the electronic device may be a computer. The computer has: a display device (e.g., a cathode ray tube (CRT) or an LCD monitor) for displaying information to the user; and a keyboard and a pointing device (e.g., a mouse or a trackball), through which the user can provide input to the computer. Other types of devices may also be used to provide interaction with the user; for example, the feedback provided to the user may be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user may be received in any form (including acoustic input, voice input, or tactile input).

[0125] In the embodiments of the present application, a computer program / instruction is stored on a computer-readable medium, and when the computer program / instruction is executed by a processor, the steps of the method provided by any one or more of the above embodiments are implemented. The computer-readable medium may be included in the electronic device described in the above embodiments; or it may exist independently without being assembled into the device. The above computer-readable medium carries one or more computer-readable instructions.

[0126] The memory 602 can be used as a non-transient computer-readable storage medium, which can be used to store non-transient software programs, non-transient computer executable programs and modules. The processor 601 executes various functional applications and data processing of the server by running the non-transient software programs, instructions and modules stored in the memory 602, so as to implement the program instructions / modules corresponding to the method provided by any one or more of the above embodiments in the embodiments of the present application.

[0127] The memory 602 may include a program storage area and a data storage area, wherein the program storage area may store an operating system, an application required for at least one function; the data storage area may store data created according to the use of the electronic device, etc. In addition, the memory 602 may include a high-speed random access memory, and may also include a non-transient memory, such as at least one disk storage device, a flash memory device, or other non-transient solid-state storage devices. In some embodiments, the memory 602 may optionally include a memory remotely arranged relative to the processor 601, and these remote memories may be connected to the electronic device via a network. Examples of the above-mentioned network include, but are not limited to, the Internet, an intranet, a local area network, a mobile communication network, and combinations thereof.

[0128] It should be noted that the computer-readable medium described in the present application may be a computer-readable signal medium or a computer-readable storage medium or any combination of the above two. The computer-readable medium may be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared or semiconductor system, device or device, or any combination of the above. More specific examples of computer-readable storage media may include, but are not limited to: an electrical connection with one or more wires, a portable computer disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM, Erasable Programmable Read-Only Memory or flash memory), an optical fiber, a portable compact disk read-only memory (CD-ROM, Compact Disc Read-Only Memory), an optical storage device, a magnetic storage device, or any suitable combination of the above. In the present application, a computer-readable medium may be any tangible medium containing or storing a program that can be used by or in combination with an instruction execution system, device or device.

[0129] Computer readable media include permanent and non-permanent, removable and non-removable media, and can be implemented by any method or technology to store information. Information can be computer readable instructions, data structures, program modules or other data. Examples of computer storage media include, but are not limited to, phase-change random-access memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, read-only compact disk (CD-ROM), digital versatile disk (DVD) or other optical storage, magnetic cassettes, magnetic tape disk storage or other magnetic storage devices or any other non-transmission medium that can be used to store information that can be accessed by a computing device.

[0130] Computer program code for performing the operations of the present application may be written in one or more programming languages ​​or a combination thereof, including object-oriented programming languages, such as Java, Smalltalk, C++, and conventional procedural programming languages, such as "C" or similar programming languages. The program code may be executed entirely on the user's computer, partially on the user's computer, as an independent software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the case of a remote computer, the remote computer may be connected to the user's computer via any type of network, including a local area network (LAN) or a wide area network (WAN), or may be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0131] In the above-described embodiments, it can be implemented in whole or in part by software, hardware, firmware or any combination thereof. For example, it can be implemented by using a dedicated integrated circuit (ASIC, Application-Specific Integrated Circuit), a general-purpose computer or any other similar hardware device. In certain embodiments, the software program of the present application can be executed by a processor to implement the above steps or functions. Similarly, the software program of the present application (including relevant data structures) can be stored in a computer-readable recording medium, for example, a RAM memory, a magnetic or optical drive or a floppy disk and similar devices. In addition, some steps or functions of the present application can be implemented by hardware, for example, as a circuit that cooperates with a processor to perform each step or function.

[0132] The computer program product provided in the embodiment of the present application includes one or more computer programs / instructions, which, when executed by the processor, generate in whole or in part the process or function described in the embodiment of the present application. The computer may be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions may be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions may be transmitted from a website site, a computer, a server, or a data center by wired (e.g., coaxial cable, optical fiber, digital subscriber line (DSL, Digital Subscriber Line) or wireless (e.g., infrared, wireless, microwave, etc.) mode to another website site, computer, server, or data center. The computer-readable storage medium may be any available medium that a computer can access or a data storage device such as a server or a data center that includes one or more available media integrations. The available medium may be a magnetic medium, (e.g., a floppy disk, a hard disk, a tape), an optical medium (e.g., a DVD), or a semiconductor medium (e.g., a solid state drive, SSD, solid statedisk), etc.

[0133] The flow chart or block diagram in the accompanying drawings shows the possible architecture, function and operation of the equipment, method and computer program product according to various embodiments of the present application. In this regard, each box in the flow chart or block diagram can represent a module, a program segment or a part of a code, and the module, the program segment or a part of the code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order from the order marked in the accompanying drawings. For example, two boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or flow chart, and the combination of the boxes in the block diagram and / or flow chart can be implemented with a dedicated system for hardware that performs a specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0134] The scope of the present application is defined by the appended claims rather than the above description, and it is intended that all changes that fall within the meaning and scope of the equivalent elements of the claims are included in the present application. Any figure mark in the claims should not be regarded as limiting the claims involved. In addition, it is clear that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. Multiple units or devices stated in the device claim may also be implemented by one unit or device through software or hardware. The words "first", "second", etc. are only used to distinguish the description, and do not indicate any particular order, nor can they be understood as indicating or implying relative importance.

[0135] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily mention changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims, and the above embodiments should be regarded as exemplary and non-restrictive.

Claims

1. A method for determining the working pressure range of a digital ultrasonic welder, characterized in that: The method comprises: Before contacting the welding workpiece, the welding head starts to press down and the ultrasonic power source frequency search is started to collect the welding head pressure and ultrasonic power source frequency at different times; Generate a pressure-frequency relationship curve based on the pressure of the welding head and the frequency of the ultrasonic power supply collected at different times; A first pressure range is obtained based on a minimum pressure required for welding and a maximum pressure determined according to a predetermined working frequency range; Within the first pressure range, sampling is performed according to a preset sampling rule to obtain at least two pressure sampling values; Perform frequency sweep at each pressure sampling value to obtain a frequency sweep curve corresponding to each pressure sampling value; Obtaining the phase difference of the frequency sweep curve corresponding to each pressure sampling value; The working pressure range of the digital ultrasonic welder is determined according to the phase difference.

2. The method according to claim 1, characterized in that The working pressure range of the digital ultrasonic welder is determined according to the phase difference, including: Obtain the minimum phase difference of the frequency sweep curve corresponding to each pressure sampling value; Constructing a pressure-phase difference minimum curve; The minimum pressure required for welding is used as the first threshold of the working pressure range, and the second threshold of the working pressure range is determined by the pressure-phase difference minimum value curve.

3. The method according to claim 2, characterized in that Determining a second threshold value of the working pressure range using the pressure-phase difference minimum value curve includes: The pressure corresponding to the standard phase difference in the pressure-phase difference minimum curve is determined as the second threshold value of the working pressure range; wherein the standard phase difference is selected based on the control capability of the ultrasonic power supply.

4. The method according to claim 1, characterized in that: After the welding head is controlled to be pressed down before contacting the welding workpiece and the ultrasonic power source is started to search for frequency, the method further includes: When the preset termination condition is met, the welding head pressing down and the generator frequency searching are stopped, and the data recording is completed.

5. The method according to claim 4, characterized in that The preset termination condition includes the welding head pressure reaching a predetermined maximum pressure, or the ultrasonic power supply frequency search alarm.

6. The method according to claim 1, characterized in that The predetermined operating frequency range is determined based on the adopted ultrasonic transducer and the design parameters of the welding head.

7. The method according to claim 1, characterized in that In the first pressure range, sampling is performed according to a preset sampling rule to obtain at least two pressure sampling values, including: In the first pressure range, the pressure sampling value is obtained by increasing the preset pressure interval each time.

8. An electronic device, characterized in that: The electronic device comprises: one or more processors; and A memory storing computer program instructions, which, when executed, cause the processor to perform the steps of the method as claimed in any one of claims 1 to 7.

9. A computer readable medium having a computer program / instructions stored thereon, characterized in that: When the computer program / instructions are executed by a processor, the steps of the method according to any one of claims 1 to 7 are implemented.

10. A computer program product comprising a computer program / instructions, characterized in that When the computer program / instructions are executed by a processor, the steps of the method according to any one of claims 1 to 7 are implemented.

Images