Full-automatic laser welding forming system

Abstract

The invention discloses a full-automatic laser welding forming system, which relates to the technical field of laser welding, and comprises a laser generation and light beam modulation module, a material conveying and positioning module, a welding execution module, a visual inspection and monitoring module, an intelligent self-adaptive control module and an energy recovery and reutilization module, the material module accurately conveys and positions materials; the welding module robot is accurate in operation; the visual module detects welding seams; the intelligent module performs self-adaptive control; the energy module recycles energy. The welding quality is improved, and defects are reduced; the production efficiency is improved and the cost is reduced; operation is simple, and manpower requirements are reduced; energy is saved, environment is protected, and green concept is met; real-time monitoring is achieved, and the product quality and the management level are guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of laser welding, and in particular to a full-automatic laser welding forming system. Background Art

[0002] In modern manufacturing, welding technology, as a key connection process, is widely used in many fields such as aerospace, automobile manufacturing, mechanical engineering, electronic equipment, etc., and plays a vital role in the quality, performance and reliability of products.

[0003] Traditional welding methods, such as manual arc welding and gas shielded welding, can meet basic welding needs to a certain extent, but with the acceleration of industrial automation and the continuous improvement of product quality requirements, their limitations are becoming increasingly prominent. Manual welding is highly dependent on the skill level and experience of the operator, with high labor intensity and low efficiency, and it is difficult to ensure the consistency and stability of welding quality. Moreover, welding defects such as pores, cracks, and lack of fusion are prone to occur during the traditional welding process. These defects not only affect the appearance of the product, but also seriously weaken the structural strength and sealing of the product, reducing the service life and safety of the product.

[0004] In the field of automated welding, although some existing welding systems have improved production efficiency to a certain extent, they still face many challenges. For example, in terms of precise control of welding parameters, it is difficult to adjust welding parameters in real time according to workpieces of different materials, thicknesses and complex shapes, resulting in uneven welding quality. There is a lack of effective means to control thermal deformation during welding, which can easily cause large deformation of the workpiece, affecting subsequent processing and assembly. In addition, in terms of weld tracking and quality inspection, traditional systems are often not very accurate and cannot promptly detect and correct deviations and defects in the welding process, resulting in an increase in scrap rate.

[0005] At the same time, with the increasing prominence of energy issues and the continuous improvement of environmental protection requirements, the high energy consumption and low energy utilization rate of traditional welding systems also need to be solved urgently. Moreover, pollutants such as smoke and exhaust gas generated during traditional welding pose a threat to the environment and the health of operators.

[0006] In summary, the existing welding technology can no longer meet the urgent needs of modern manufacturing industry for efficient, high-precision, high-quality, energy-saving and environmentally friendly welding processes. Therefore, developing a new fully automatic laser welding forming system to realize the automation, intelligence and precision control of the welding process, improve welding quality and efficiency, reduce energy consumption and environmental pollution, has important practical significance and broad application prospects. Summary of the invention

[0007] The fully automatic laser welding forming system proposed in the present invention is to solve the problems mentioned in the above-mentioned prior art.

[0008] In order to achieve the above object, the present invention adopts the following technical solution: a fully automatic laser welding forming system, comprising:

[0009] Laser generation and beam modulation module: using fiber laser, power output range 1000-10000W continuously adjustable, wavelength 1064nm or 1080nm, beam quality factor M 2 <1.1, equipped with a laser power monitor to monitor power fluctuations in real time. When the fluctuation exceeds ±3%, the pump current is adjusted within 5ms to stabilize the power through a closed-loop feedback control system;

[0010] Integrated beam shaping and modulation unit, switches the laser beam between Gaussian, flat-top and annular modes, adjusts the beam energy distribution and polarization state through an acousto-optic modulator or electro-optic modulator, and realizes welding of workpieces of different materials and thicknesses;

[0011] Material conveying and positioning module: including electric conveyor belt, conveying speed 0.05-1.5m / s stepless speed change, conveyor belt surface adopts anti-static and wear-resistant coating, friction coefficient 0.2-0.4;

[0012] Equipped with a multi-degree-of-freedom robotic arm for material grabbing and placement, the end effector automatically adjusts the clamping force and posture according to the shape of the material to adapt to materials of different shapes and sizes to be welded;

[0013] Welding execution module: Install a six-axis industrial robot, with a high-precision laser welding head at the end of the robot. The welding head has an automatic focusing function that changes according to the height of the workpiece surface;

[0014] The welding head is equipped with an intelligent cooling system, which adopts a mixed cooling system of water cooling and air cooling. The water cooling flow rate is 0.3-1.5L / min, and the air cooling air volume is 10-50m 3 / h;

[0015] Visual inspection and monitoring module: Equipped with a stereo vision camera to obtain three-dimensional information of the welding area, and with the image recognition algorithm, it can detect the weld width, depth, and gap geometric parameters in real time, and detect weld surface defects, including pores, cracks, and lack of fusion;

[0016] An intelligent monitoring system is equipped to display various parameters, material status, and weld quality information during the welding process in real time. The monitoring system has a remote access function, and management personnel can view the monitoring screen in real time within a range of 100m through the network and intervene in abnormal situations in a timely manner;

[0017] Intelligent adaptive control module: built-in high-performance computing chip, running intelligent control algorithm, through real-time acquisition of laser power P, welding speed v, molten pool temperature T, weld geometry parameters in the welding process, set the weld width w, depth h, use machine learning model to predict welding quality trend, according to the prediction results, dynamically adjust the laser power and welding speed in the welding process, the adjustment formula is P new =P+k1×ΔQ, where P new is the new laser power, k1 is the power adjustment coefficient, ΔQ is the power adjustment calculated based on the quality trend, and v new =v+k2×Δv, where v new is the new welding speed, k2 is the speed adjustment coefficient, and Δv is the speed adjustment amount;

[0018] Energy recovery and reuse module: Use energy recovery device to recover excess laser energy and heat energy during welding. Suppose the recovered laser energy is E r , the recovery efficiency η satisfies Where E total is the total laser energy, η≥30%, the recovered energy is converted into electrical energy or other usable energy forms and stored through the energy conversion unit, and the conversion efficiency μ satisfies Where E usable is the usable energy, μ ≥ 30%;

[0019] The stored energy is used for auxiliary power supply of the system itself, including powering the control system and sensor equipment, or fed back to the laser generation module to reduce the overall energy consumption of the system.

[0020] Furthermore, in the laser generation and beam modulation module, the laser adopts a modular design, including a laser generator module, a power regulation module, a beam transmission module and a heat dissipation module. The laser generator module adopts a plug-in structure, and can be quickly positioned and installed through guide rails and positioning pins when replaced; the power regulation module adopts digital power control technology, and outputs control signals through the DAC digital-to-analog converter chip to achieve precise control of the laser power. The beam transmission module adopts fiber coupling technology, the fiber core diameter is 50-100μm, and the numerical aperture is 0.1-0.2; the heat dissipation module adopts liquid cooling, the coolant is a mixture of deionized water and ethylene glycol, the coolant flow rate is 2-5L / min, and the heat dissipation efficiency is over 90%.

[0021] Furthermore, in the material conveying and positioning module, an infrared sensor array is installed on both sides of the conveyor belt, and the sensor adopts a counter-radiation structure composed of an infrared light-emitting diode and a photodiode; when the material blocks the light, the photodiode generates an electrical signal change, and the signal is amplified, filtered and converted by an A / D analog-to-digital converter and then transmitted to the control system. The control system calculates the material position offset based on the signal change, and corrects it through an adjustment device driven by a servo motor, and the adjustment device adopts a ball screw transmission mechanism.

[0022] Furthermore, in the welding execution module, the joints of the industrial robot adopt a combination of a harmonic reducer and a magnetorheological fluid damper; the harmonic reducer adopts a structure composed of a flexible wheel, a rigid wheel and a wave generator, and the magnetorheological fluid damper changes the damping characteristics according to the change of magnetic field intensity. The magnetic field intensity is controlled by electric current. By real-time monitoring of the movement state of the robot joints, the damping force is adjusted to improve the movement smoothness by 40%-60%.

[0023] Furthermore, in the visual inspection and monitoring module, the visual camera is equipped with automatic dimming, automatic defogger, and automatic cleaning functions; the automatic dimming system adopts an ambient light sensor and an automatic aperture lens. The ambient light sensor detects light intensity in the range of 50-15000lux. The automatic aperture lens automatically adjusts the aperture size according to the light intensity, and the adjustment range is F1.4-F16. The automatic defogger system heats the lens surface through a heating element with a heating power of 5-10W, and evaporates and removes fog on the lens surface within 1s. The automatic cleaning system adopts a combination of air blowing and brush cleaning, and the air blowing pressure is 0.1-0.3MPa.

[0024] Furthermore, the control system supports seamless connection with the enterprise production management system MES and realizes data transmission through the Ethernet interface. After receiving the production task order, the control system parses the order information, including the workpiece model and welding process requirements, and searches for matching welding process parameters from the local database. If there are no matching parameters in the local database, it automatically requests download from the cloud server. After welding is completed, the control system packages the welding data and quality report in XML or JSON format and uploads it to the MES system to realize information management of the production process.

[0025] Furthermore, a welding method using a fully automatic laser welding forming system is characterized by comprising the following steps:

[0026] System initialization steps: Start the system, control the system to perform self-test, check whether the communication connection of each module and the equipment status are normal, and load the preset welding process parameters, including laser power, welding speed, beam mode, and shielding gas flow, and automatically match the best parameter combination according to the information of the material to be welded;

[0027] Material preparation and positioning steps: The material conveying and positioning module grabs the material to be welded from the silo through the robotic arm according to the control system instructions and places it on the conveyor belt. The conveyor belt transports the material to the welding area. During the transportation process, the infrared sensor monitors the position of the material in real time. After arriving at the welding area, the robotic arm adjusts the material posture again to make it accurately match the welding tooling;

[0028] Laser parameter adjustment steps: The visual inspection and monitoring module scans the welding area to obtain the shape, size, and material information of the material, and feeds it back to the control system. The control system adjusts the laser power, wavelength, beam mode, and energy distribution parameters of the laser generation and beam modulation module based on this information and the preset process parameters;

[0029] Welding execution steps: The industrial robot of the welding execution module moves according to the preset welding path planning algorithm, driving the laser welding head to weld. During the welding process, the welding head monitors the welding temperature and molten pool state parameters in real time and feeds back to the control system. The control system dynamically adjusts the welding speed and laser power parameters based on these feedback information;

[0030] Welding quality inspection and feedback steps: The visual inspection and monitoring modules simultaneously image the welding area and use image recognition algorithms to detect weld quality, including weld geometry parameters and surface defects. The inspection results are transmitted to the control system in real time. The control system determines whether the welding quality is qualified. If qualified, the next round of welding will continue. If unqualified, the control system automatically adjusts the welding parameters according to the type and severity of the defects, including increasing the laser power, reducing the welding speed, and repairing the defects. If the defects are too serious to be repaired, an alarm will be issued to notify the operator to intervene manually, and relevant data will be recorded for quality analysis and traceability.

[0031] Processing steps after welding is completed: After welding is completed, the material conveying and positioning module transports the welded workpiece to the unloading area, and the robotic arm places the workpiece at the designated position. The system automatically records the process parameters and quality inspection result data of this welding and stores them in the database.

[0032] Furthermore, in the material preparation and positioning steps, if there is insufficient material in the silo, the system automatically triggers the material replenishment program, and reminds the operator to replenish materials through sound and light alarms, and suspends the welding task at the same time. The alarm device uses a combination of a buzzer and a red warning light. The control system monitors the remaining amount of material in the silo in real time. When the material is lower than the preset threshold, the alarm is triggered. After suspending the welding task, the system waits for the operator to replenish the material. After the replenishment is completed, the operator confirms through the operation panel, and the system automatically resumes the welding task.

[0033] Furthermore, in the laser parameter adjustment step, when encountering special materials or complex structure workpieces, the control system automatically calls the expert experience parameters in the cloud database, combined with the local optimization algorithm to determine the optimal welding parameters. The cloud database adopts a distributed storage architecture, and data transmission uses SSL encryption; the local optimization algorithm adopts a neural network-based parameter optimization model, which adjusts the model weights by learning from historical welding data. The control system uses the material, shape, and size information of the workpiece as input parameters, and calculates the optimal welding parameters through the model.

[0034] Furthermore, in the welding quality inspection and feedback step, if a weld defect is detected, in addition to recording the data locally, the system automatically sends the defect image, related parameters and processing suggestions to the relevant technicians via email. The system uses SMTP to send emails, and the email server address can be customized by the user.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] In terms of welding quality, the laser generation and beam modulation module can accurately control the laser parameters, and cooperate with the intelligent adaptive control module to dynamically adjust the welding parameters based on real-time collected data, so that the welding quality is stable and consistent, effectively reducing weld defects, improving product structural strength and sealing, and ensuring high-quality welding.

[0037] In terms of production efficiency, the efficient operation of the material conveying and positioning modules, the fast material handling and precise positioning of the multi-degree-of-freedom robotic arms, and the high-speed and stable industrial robots in the welding execution modules have greatly shortened the welding cycle, realized continuous automated production, significantly improved production efficiency, and reduced production costs.

[0038] In terms of operational ease, the system is highly automated and intelligent. Operators only need to perform simple task settings and monitoring without the need for complex manual intervention, which lowers the requirements for operators' skill levels, reduces human errors, and improves the stability and reliability of the production process.

[0039] In terms of energy conservation and environmental protection, the energy recovery and reuse module effectively recovers excess energy, improves energy utilization, reduces energy consumption, and reduces heat emissions to the environment, which is in line with the concept of green manufacturing.

[0040] At the same time, the visual inspection and monitoring module provides real-time, high-precision weld inspection and monitoring, and timely feedback of welding quality information, which facilitates timely discovery and resolution of problems, further guarantees product quality, and improves the company's production management level and market competitiveness. This system fully meets the needs of modern manufacturing industry for efficient, high-quality, energy-saving and environmentally friendly welding processes. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 A schematic block diagram of a fully automatic laser welding forming system proposed by the present invention;

[0042] Figure 2 The present invention provides a schematic block diagram of a fully automatic laser welding forming method. DETAILED DESCRIPTION

[0043] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0045] In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, and it can be the internal connection of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. The present invention will be further described in detail below in conjunction with the accompanying drawings.

[0046] Reference Figure 1-2 :A fully automatic laser welding forming system, comprising:

[0047] Laser generation and beam modulation module: using high-power fiber laser, power output range 1000-10000W continuously adjustable, wavelength 1064nm or 1080nm, beam quality factor M 2<1.1. Equipped with a high-precision laser power monitor with a sampling frequency of 2kHz, it monitors power fluctuations in real time. When the fluctuation exceeds ±3%, the pump current is adjusted within 5ms to stabilize the power through a closed-loop feedback control system.

[0048] The integrated beam shaping and modulation unit can switch the laser beam between Gaussian, flat-top, and ring modes. According to the welding material and process requirements, the beam energy distribution and polarization state can be adjusted through an acousto-optic modulator or an electro-optic modulator to achieve precise welding of workpieces of different materials and thicknesses.

[0049] Material conveying and positioning module: Design high-precision electric conveyor belt, conveying speed 0.05-1.5m / s stepless speed change, positioning accuracy up to ±0.3mm. The surface of the conveyor belt adopts anti-static and wear-resistant coating, with a friction coefficient of 0.2-0.4 to prevent the material from absorbing dust and scratching.

[0050] Equipped with a multi-degree-of-freedom robotic arm for material grabbing and placement, with a repeat positioning accuracy of ±0.08mm. The end effector can automatically adjust the clamping force and posture according to the shape of the material to adapt to materials to be welded of different shapes and sizes. The maximum grabbing weight is 15kg, and the single handling time does not exceed 2s.

[0051] Welding execution module: Install a six-axis industrial robot, with a repeatability accuracy of ±0.05mm, a movement speed of 1-3m / s, and an acceleration of 12m / s 2 The end of the robot is equipped with a high-precision laser welding head, which has an automatic focusing function. According to the height change of the workpiece surface, the focal length is adjusted within 0.1s to ensure that the focus is always at the welding position.

[0052] The welding head is equipped with an intelligent cooling system, which adopts a mixed cooling system of water cooling and air cooling. The water cooling flow rate is 0.3-1.5L / min, and the air cooling air volume is 10-50m 3 / h, ensuring that the temperature of the welding head is stable at 40-70℃ during long-term work, thus extending the service life of the welding head.

[0053] Visual inspection and monitoring module: Equipped with a high-definition stereoscopic vision camera with a resolution of more than 25 million pixels and a frame rate of 50 frames per second, it can obtain three-dimensional information of the welding area. With advanced image recognition algorithms, it can detect geometric parameters such as weld width, depth, gap, etc. in real time with an accuracy of 0.05mm. It can also detect weld surface defects such as pores, cracks, and lack of fusion with a defect detection accuracy of 0.1mm.

[0054] An intelligent monitoring system is equipped to display various parameters, material status, weld quality and other information in the welding process in real time, with a display refresh rate of 3Hz. The monitoring system has a remote access function, and managers can view the monitoring screen in real time within a range of 100m through the network and intervene in abnormal situations in a timely manner.

[0055] Intelligent adaptive control module: built-in high-performance computing chip, running intelligent control algorithm. Through real-time collection of multi-dimensional data such as laser power P, welding speed v, molten pool temperature T, weld geometry parameters (set weld width as w, depth as h) during welding, the machine learning model is used to predict the welding quality trend. According to the prediction results, the laser power and welding speed are dynamically adjusted during welding. The adjustment formula is P new =P+k1×ΔQ, where P new is the new laser power, k1 is the power adjustment coefficient, ΔQ is the power adjustment calculated based on the quality trend, and v new =v+k2×Δv, where v new is the new welding speed, k2 is the speed adjustment coefficient, and Δv is the speed adjustment amount, which ensures that the welding quality is stable in the best state and improves the consistency and stability of the welding quality.

[0056] It can automatically identify workpieces of different materials and thicknesses, quickly match the best welding parameter combination based on the preset material database and process knowledge base, and realize intelligent adaptive control of the welding process without frequent manual intervention, thereby improving production efficiency.

[0057] Energy recovery and reuse module: Use high-efficiency energy recovery device to recover excess laser energy and heat energy during welding. Suppose the recovered laser energy is E r , the recovery efficiency η satisfies Where E total is the total laser energy, η≥30%. The recovered energy is converted into electrical energy or other usable energy forms and stored by the energy conversion unit, and the conversion efficiency μ satisfies Where E usable is the usable energy, μ≥30%.

[0058] The stored energy is used for auxiliary power supply of the system itself, such as powering low-power devices such as control systems and sensors, or fed back to the laser generation module to reduce the overall energy consumption of the system, improve energy utilization, reduce production costs, and achieve energy conservation and environmental protection.

[0059] In the present invention, in the laser generation and beam modulation module, the laser adopts a modular design, including a laser generator module, a power regulation module, a beam transmission module and a heat dissipation module. The laser generator module adopts a plug-in structure, and is quickly positioned and installed through guide rails and positioning pins when replaced, ensuring that the replaced laser generator is accurately aligned with the system optical path, and the replacement time does not exceed 10 minutes. The power regulation module adopts digital power control technology, outputs control signals through a high-precision DAC (digital-to-analog converter) chip, and the adjustment accuracy reaches 0.1%, thereby achieving precise control of the laser power. The beam transmission module adopts fiber coupling technology, the fiber core diameter is 50-100μm, and the numerical aperture is 0.1-0.2, ensuring that the energy loss of the laser during transmission is less than 10%. The heat dissipation module adopts liquid cooling, the coolant is a mixture of deionized water and ethylene glycol, the coolant flow rate is 2-5L / min, and the heat dissipation efficiency is more than 90%, ensuring the stability of the laser at high power output.

[0060] In the present invention, in the material conveying and positioning module, a high-precision infrared sensor array is installed on both sides of the conveyor belt. The sensor adopts a counter-radiation structure composed of an infrared light-emitting diode and a photodiode, the emission wavelength is 850-950nm, and the sensing distance is 0.1-1m. When the material blocks the light, the photodiode generates an electrical signal change, and the signal is amplified, filtered and A / D (analog-to-digital converter) converted and transmitted to the control system. The control system calculates the material position offset according to the signal change, and corrects it through the adjustment device driven by the servo motor. The adjustment device adopts a ball screw transmission mechanism, the screw pitch is 5-10mm, and the motor drive torque is 0.5-1.5N·m. It can achieve accurate correction of the material position within 0.3s to ensure accurate material transportation.

[0061] In the present invention, in the welding execution module, the joints of the industrial robot adopt a combination of a high-precision harmonic reducer and a magnetorheological fluid damper. The harmonic reducer adopts a structure composed of a flexible wheel, a rigid wheel and a wave generator, with a reduction ratio of 50-100, a transmission accuracy of ±1 arc minute, and a load capacity of 50-100kg. The magnetorheological fluid damper changes the damping characteristics according to the change of magnetic field intensity. The magnetic field intensity is controlled by the current, and the current adjustment range is 0-2A. By real-time monitoring the movement state of the robot joint, the damping force is adjusted to improve the movement stability by 40%-60%, effectively reducing the vibration during welding and improving welding accuracy.

[0062] In the present invention, in the visual detection and monitoring module, the visual camera is equipped with automatic dimming, automatic defogger, and automatic cleaning functions. The automatic dimming system uses an ambient light sensor and an automatic aperture lens. The ambient light sensor detects a light intensity range of 50-15000lux. The automatic aperture lens automatically adjusts the aperture size according to the light intensity, and the adjustment range is F1.4-F16 to ensure that the image brightness is appropriate. The automatic defogger system heats the lens surface through a heating element with a heating power of 5-10W, and can evaporate and remove the fog on the lens surface within 1s. The automatic cleaning system adopts a combination of air blowing and brush cleaning. The air blowing pressure is 0.1-0.3MPa, and the brush material is anti-static nylon. The cleaning cycle can be automatically adjusted according to the environmental dust concentration to ensure image clarity and detection accuracy.

[0063] In the present invention, the control system supports seamless connection with the enterprise production management system (MES), and realizes data transmission through the Ethernet interface with a transmission rate of 100-1000Mbps. After receiving the production task order, the control system parses the order information, including the workpiece model, welding process requirements, etc., and searches for matching welding process parameters from the local database. If there are no matching parameters in the local database, it automatically requests downloading from the cloud server. After welding is completed, the control system packages the welding data (such as actual welding parameters, welding time, quality inspection results, etc.) and quality reports in a specific format (such as XML or JSON) and uploads them to the MES system, realizing the information management of the production process, which is convenient for enterprises to monitor the production progress and quality in real time and analyze data.

[0064] The present invention also discloses a welding method applied to a fully automatic laser welding forming system, comprising the following steps:

[0065] System initialization steps: Start the system, control the system to perform self-test, check whether the communication connection of each module and the equipment status are normal. At the same time, load the preset welding process parameters, including laser power, welding speed, beam mode, shielding gas flow, etc., and automatically match the best parameter combination according to the information of the material to be welded.

[0066] Material preparation and positioning steps: The material conveying and positioning module grabs the material to be welded from the silo through the robotic arm according to the control system instructions and places it on the conveyor belt, which transports the material to the welding area. During the conveying process, the infrared sensor monitors the material position in real time to ensure that the material is accurately in place. After arriving at the welding area, the robotic arm adjusts the material posture again to make it accurately match the welding tooling, and the positioning accuracy is controlled within ±0.5mm.

[0067] Laser parameter adjustment steps: The visual inspection and monitoring module scans the welding area to obtain information such as the shape, size, and material of the material, and feeds it back to the control system. Based on this information and the preset process parameters, the control system adjusts the laser power, wavelength, beam mode, energy distribution and other parameters of the laser generation and beam modulation module to ensure that the laser beam perfectly matches the workpiece to be welded, and the adjustment time does not exceed 5s.

[0068] Welding execution steps: The industrial robot of the welding execution module moves according to the preset welding path planning algorithm, driving the laser welding head to weld. During the welding process, the welding head monitors the welding temperature, molten pool status and other parameters in real time and feeds back to the control system. Based on this feedback information, the control system dynamically adjusts parameters such as welding speed and laser power to ensure a stable welding process and beautiful weld formation. At the same time, the shielding gas supply system accurately controls the type, flow and pressure of the shielding gas according to the welding process requirements to prevent weld oxidation.

[0069] Welding quality inspection and feedback steps: The visual inspection and monitoring modules simultaneously image the welding area and use image recognition algorithms to detect weld quality, including weld geometry parameters, surface defects, etc. The inspection results are transmitted to the control system in real time, and the control system determines whether the welding quality is qualified. If qualified, the next round of welding will continue; if unqualified, the control system will automatically adjust the welding parameters according to the type and severity of the defect, such as increasing the laser power, reducing the welding speed, etc., to repair the defect. If the defect is too serious to be repaired, an alarm will be issued to notify the operator to intervene manually, and the relevant data will be recorded for quality analysis and traceability.

[0070] Processing steps after welding: After welding, the material conveying and positioning module conveys the welded workpiece to the unloading area, and the robot arm places the workpiece at the designated location. The system automatically records the process parameters, quality inspection results and other data of this welding and stores them in the database. At the same time, the equipment is cleaned and maintained, such as cleaning the welding head, replacing the protective lens, checking the conveyor belt, etc., to prepare for the next welding.

[0071] In the present invention, during the material preparation and positioning steps, if there is insufficient material in the silo, the system automatically triggers the material replenishment program, reminds the operator to replenish the material through an audible and visual alarm, and suspends the welding task at the same time. The alarm device uses a combination of a buzzer and a red warning light. The buzzer sound pressure level is 85-105dB, the frequency is 2-3kHz, and the red warning light flashes at a frequency of 2-3Hz. The control system monitors the remaining amount of material in the silo in real time, and triggers an alarm when the material is lower than a preset threshold (such as the remaining material can support less than 5 welding times). After suspending the welding task, the system waits for the operator to replenish the material. After the replenishment is completed, the operator confirms through the operation panel, and the system automatically resumes the welding task.

[0072] In the present invention, in the laser parameter adjustment step, when encountering special materials or complex structure workpieces, the control system automatically calls the expert experience parameters in the cloud database, combined with the local optimization algorithm, and quickly determines the optimal welding parameters within 8 seconds. The cloud database adopts a distributed storage architecture, with 10-100 data storage nodes, and data transmission is encrypted using SSL (Secure Sockets Layer Protocol) to ensure data security. The local optimization algorithm adopts a parameter optimization model based on a neural network. By learning from historical welding data, the model weights are continuously adjusted to improve the accuracy of parameter optimization. The control system uses information such as the material, shape, and size of the workpiece as input parameters, and calculates the optimal welding parameters through the model to ensure welding quality and efficiency.

[0073] In the present invention, in the welding quality inspection and feedback step, if a weld defect is detected, in addition to recording the data locally, the system automatically sends the defect image, related parameters and processing suggestions to the relevant technicians via email. The system uses SMTP (Simple Mail Transfer Protocol) to send emails, and the email server address can be customized by the user. The email content includes the defect image (sent as an attachment, the image format is JPEG or PNG, and the resolution is 100-500dpi), weld geometry parameters (such as width, depth, length, etc.), defect type (such as pores, cracks, lack of fusion, etc.), welding process parameters (laser power, welding speed, etc.) and processing suggestions (such as adjusting welding parameters, checking equipment status, etc.). The email sending time does not exceed 0.5s, which is convenient for timely processing and process improvement.

[0074] The above are only preferred specific implementation modes of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solutions and inventive concepts of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A fully automatic laser welding forming system, characterized in that: include: Laser generation and beam modulation module: using fiber laser, power output range 1000-10000W continuously adjustable, wavelength 1064nm or 1080nm, beam quality factor M 2 <1.1, equipped with a laser power monitor to monitor power fluctuations in real time. When the fluctuation exceeds ±3%, the pump current is adjusted within 5ms to stabilize the power through a closed-loop feedback control system; Integrated beam shaping and modulation unit, switches the laser beam between Gaussian, flat-top and annular modes, adjusts the beam energy distribution and polarization state through an acousto-optic modulator or electro-optic modulator, and realizes welding of workpieces of different materials and thicknesses; Material conveying and positioning module: including electric conveyor belt, conveying speed 0.05-1.5m / s stepless speed change, conveyor belt surface adopts anti-static and wear-resistant coating, friction coefficient 0.2-0.4; Equipped with a multi-degree-of-freedom robotic arm for material grabbing and placement, the end effector automatically adjusts the clamping force and posture according to the shape of the material to adapt to materials of different shapes and sizes to be welded; Welding execution module: Install a six-axis industrial robot, with a high-precision laser welding head at the end of the robot. The welding head has an automatic focusing function that changes according to the height of the workpiece surface; The welding head is equipped with an intelligent cooling system, which adopts a mixed cooling system of water cooling and air cooling. The water cooling flow rate is 0.3-1.5L / min, and the air cooling air volume is 10-50m 3 / h; Visual inspection and monitoring module: Equipped with a stereo vision camera to obtain three-dimensional information of the welding area, and with the image recognition algorithm, it can detect the weld width, depth, and gap geometric parameters in real time, and detect weld surface defects, including pores, cracks, and lack of fusion; An intelligent monitoring system is equipped to display various parameters, material status, and weld quality information during the welding process in real time. The monitoring system has a remote access function, and management personnel can view the monitoring screen in real time within a range of 100m through the network and intervene in abnormal situations in a timely manner; Intelligent adaptive control module: built-in high-performance computing chip, running intelligent control algorithm, through real-time acquisition of laser power P, welding speed v, molten pool temperature T, weld geometry parameters in the welding process, set the weld width w, depth h, use machine learning model to predict welding quality trend, according to the prediction results, dynamically adjust the laser power and welding speed in the welding process, the adjustment formula is P new =P+k1×ΔQ, where P new is the new laser power, k1 is the power adjustment coefficient, ΔQ is the power adjustment calculated based on the quality trend, and v new =v+k2×Δv, where v new is the new welding speed, k2 is the speed adjustment coefficient, and Δv is the speed adjustment amount; Energy recovery and reuse module: Use energy recovery device to recover excess laser energy and heat energy during welding. Suppose the recovered laser energy is E r , the recovery efficiency η satisfies Where E total is the total laser energy, η≥30%, the recovered energy is converted into electrical energy or other usable energy forms and stored through the energy conversion unit, and the conversion efficiency μ satisfies Where E usable is the usable energy, μ ≥ 30%; The stored energy is used for auxiliary power supply of the system itself, including powering the control system and sensor equipment, or fed back to the laser generation module to reduce the overall energy consumption of the system.

2. The fully automatic laser welding forming system according to claim 1 is characterized in that: In the laser generation and beam modulation module, the laser adopts a modular design, including a laser generator module, a power regulation module, a beam transmission module and a heat dissipation module. The laser generator module adopts a plug-in structure, and can be quickly positioned and installed through guide rails and positioning pins when replaced; the power regulation module adopts digital power control technology, and outputs control signals through the DAC digital-to-analog converter chip to achieve precise control of the laser power. The beam transmission module adopts fiber coupling technology, the fiber core diameter is 50-100μm, and the numerical aperture is 0.1-0.2; the heat dissipation module adopts liquid cooling, the coolant is a mixture of deionized water and ethylene glycol, the coolant flow rate is 2-5L / min, and the heat dissipation efficiency is over 90%.

3. The fully automatic laser welding forming system according to claim 1 is characterized in that: In the material conveying and positioning module, infrared sensor arrays are installed on both sides of the conveyor belt. The sensors adopt a counter-radiation structure composed of infrared light-emitting diodes and photodiodes. When the material blocks the light, the photodiode generates an electrical signal change, and the signal is amplified, filtered and converted by an A / D analog-to-digital converter before being transmitted to the control system. The control system calculates the material position offset based on the signal change and corrects it through an adjustment device driven by a servo motor. The adjustment device adopts a ball screw transmission mechanism.

4. The fully automatic laser welding forming system according to claim 1 is characterized in that: In the welding execution module, the joints of the industrial robot use a combination of a harmonic reducer and a magnetorheological fluid damper; the harmonic reducer uses a structure composed of a flexible wheel, a rigid wheel and a wave generator, and the magnetorheological fluid damper changes the damping characteristics according to the change of magnetic field intensity. The magnetic field intensity is controlled by current. By real-time monitoring of the movement state of the robot joints, the damping force is adjusted to improve the movement smoothness by 40%-60%.

5. The fully automatic laser welding forming system according to claim 1 is characterized in that: In the visual inspection and monitoring module, the visual camera is equipped with automatic dimming, automatic defogger, and automatic cleaning functions; the automatic dimming system uses an ambient light sensor and an automatic aperture lens. The ambient light sensor detects light intensity in the range of 50-15000lux. The automatic aperture lens automatically adjusts the aperture size according to the light intensity, and the adjustment range is F1.4-F16. The automatic defogger system heats the lens surface through a heating element with a heating power of 5-10W, and evaporates the fog on the lens surface within 1s. The automatic cleaning system uses a combination of air blowing and brush cleaning, and the air blowing pressure is 0.1-0.3MPa.

6. The fully automatic laser welding forming system according to claim 1, characterized in that: The control system supports seamless connection with the enterprise production management system MES and realizes data transmission through the Ethernet interface. After receiving the production task order, the control system parses the order information, including the workpiece model and welding process requirements, and searches for matching welding process parameters from the local database. If there are no matching parameters in the local database, it automatically requests download from the cloud server. After welding is completed, the control system packages the welding data and quality report in XML or JSON format and uploads it to the MES system to realize information management of the production process.

7. A welding method using the fully automatic laser welding forming system according to any one of claims 1 to 6, characterized in that: The following steps are involved: System initialization steps: Start the system, control the system to perform self-test, check whether the communication connection of each module and the equipment status are normal, and load the preset welding process parameters, including laser power, welding speed, beam mode, and shielding gas flow, and automatically match the best parameter combination according to the information of the material to be welded; Material preparation and positioning steps: The material conveying and positioning module grabs the material to be welded from the silo through the robotic arm according to the control system instructions and places it on the conveyor belt. The conveyor belt transports the material to the welding area. During the transportation process, the infrared sensor monitors the position of the material in real time. After arriving at the welding area, the robotic arm adjusts the material posture again to make it accurately match the welding tooling; Laser parameter adjustment steps: The visual inspection and monitoring module scans the welding area to obtain the shape, size, and material information of the material, and feeds it back to the control system. The control system adjusts the laser power, wavelength, beam mode, and energy distribution parameters of the laser generation and beam modulation module based on this information and the preset process parameters; Welding execution steps: The industrial robot of the welding execution module moves according to the preset welding path planning algorithm, driving the laser welding head to weld. During the welding process, the welding head monitors the welding temperature and molten pool state parameters in real time and feeds back to the control system. The control system dynamically adjusts the welding speed and laser power parameters based on these feedback information; Welding quality inspection and feedback steps: The visual inspection and monitoring modules simultaneously image the welding area and use image recognition algorithms to detect weld quality, including weld geometry parameters and surface defects. The inspection results are transmitted to the control system in real time. The control system determines whether the welding quality is qualified. If qualified, the next round of welding will continue. If unqualified, the control system automatically adjusts the welding parameters according to the type and severity of the defects, including increasing the laser power, reducing the welding speed, and repairing the defects. If the defects are too serious to be repaired, an alarm will be issued to notify the operator to intervene manually, and relevant data will be recorded for quality analysis and traceability. Processing steps after welding is completed: After welding is completed, the material conveying and positioning module transports the welded workpiece to the unloading area, and the robotic arm places the workpiece at the designated position. The system automatically records the process parameters and quality inspection result data of this welding and stores them in the database.

8. According to the welding method applied to the fully automatic laser welding forming system described in claim 7, in the material preparation and positioning steps, if there is insufficient material in the silo, the system automatically triggers the material replenishment program, and reminds the operator to replenish the material through an audible and visual alarm, and suspends the welding task at the same time. The alarm device adopts a combination of a buzzer and a red warning light. The control system monitors the remaining amount of material in the silo in real time. When the material is lower than a preset threshold, an alarm is triggered. After suspending the welding task, the system waits for the operator to replenish the material. After the replenishment is completed, the operator confirms through the operation panel, and the system automatically resumes the welding task.

9. According to the welding method applied to the fully automatic laser welding forming system described in claim 7, in the laser parameter adjustment step, when encountering a workpiece of special material or complex structure, the control system automatically calls the expert experience parameters in the cloud database, combined with the local optimization algorithm, to determine the optimal welding parameters, the cloud database adopts a distributed storage architecture, and the data transmission adopts SSL encryption; the local optimization algorithm adopts a parameter optimization model based on a neural network, and adjusts the model weights by learning from historical welding data. The control system uses the material, shape, and size information of the workpiece as input parameters, and calculates the optimal welding parameters through the model.

10. According to the welding method applied to the fully automatic laser welding forming system described in claim 7, in the welding quality inspection and feedback step, if a weld defect is detected, in addition to recording the data locally, the system also automatically sends the defect image, related parameters and processing suggestions to the relevant technicians via email. The system uses SMTP to send emails, and the email server address can be customized by the user.

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