Welding methods, systems and apparatus for straight weld beads in right-angle weld bevels

Abstract

This application relates to a welding method, system, apparatus, and computer equipment for straight weld beads in a right-angle weld bevel. The method includes: obtaining the welding height, number of welding layers, number of weld beads per layer, and starting layer weld bead of the right-angle weld bevel; upon receiving a welding command, determining the offset of each weld bead relative to the starting layer weld bead based on the welding height, number of welding layers, and number of weld beads; determining each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead; and controlling the welding torch to weld each weld bead sequentially from the starting layer weld bead until the welding of the right-angle weld bevel is completed. This method can improve welding efficiency.

Description

Technical Field

[0001] This application relates to the field of welding technology, and in particular to a welding method, system and apparatus for a straight weld bead in a right-angle weld groove. Background Technology

[0002] With the development of welding technology, for some thick metals with large weld seams, welding only one layer is often insufficient to meet the requirements of high-quality welding. Therefore, such structures often require welding many layers, and each layer requires welding many passes. The welding paths of different layers and different passes are often different.

[0003] In traditional methods, welding is usually done manually layer by layer, or laser vision technology is used. Laser vision sensors are used to identify the shape and size of the weld bevel, create a three-dimensional model of the weld bevel, determine the position of each weld bead, and then perform the welding operation.

[0004] However, traditional laser vision and 3D modeling technologies are costly, requiring specialized laser and modeling equipment. Furthermore, in order to identify the weld bead position, a series of additional recognition algorithms and software are needed, resulting in low welding efficiency in traditional solutions. Summary of the Invention

[0005] Therefore, it is necessary to provide a welding method, apparatus, and computer equipment for a right-angle weld groove with straight weld beads that can improve welding efficiency, in order to address the above-mentioned technical problems.

[0006] In a first aspect, this application provides a welding method for a straight weld bead in a right-angle weld groove. The method includes:

[0007] Obtain the welding height, number of welding layers, number of weld beads per layer, and starting layer weld bead of the right-angle welding bevel;

[0008] Upon receiving a welding instruction, the offset of each weld bead relative to the starting layer weld bead is determined based on the welding height, the number of welding layers, and the number of weld beads.

[0009] Each weld bead is determined based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead;

[0010] The welding torch is controlled to start from the initial layer weld bead and weld each weld bead in sequence until the right-angle weld bead is completed.

[0011] In one embodiment, determining the offset of each weld bead relative to the starting layer weld bead based on the weld height, the number of weld layers, and the number of weld beads includes:

[0012] The weld height of each weld layer is determined based on the weld height and the number of weld layers.

[0013] For each weld layer, the offset of each weld bead relative to the starting layer weld bead is determined based on the weld height of each weld layer, the number of weld beads in the weld layer, and the label of each weld bead in the weld layer.

[0014] In one embodiment, obtaining the initial layer weld bead of the right-angle weld bevel includes:

[0015] The device receives teaching points of a right-angle weld bevel sent by a teaching pendant. The teaching points are used to describe the bevel shape of the right-angle weld bevel, and the teaching points include the arc start point and arc end point of the initial layer weld bevel.

[0016] The starting and ending points of the initial weld bead are used to determine the initial weld bead of the right-angle weld groove.

[0017] In one embodiment, determining each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead includes:

[0018] The starting point of each weld bead is determined based on the arc starting point of the initial layer weld bead and the offset amount.

[0019] The arc termination point of each weld bead is determined based on the arc termination point of the starting layer weld bead and the offset amount.

[0020] Each weld bead is determined based on its arc start point and arc end point.

[0021] In one embodiment, the controlled welding torch starts welding each weld bead sequentially from the initial weld bead until the right-angle weld bead is completed, including:

[0022] The welding torch is controlled to perform welding operations along the starting point of the starting layer weld bead, starting from the arc starting point of the starting layer weld bead. When the welding torch moves to the arc ending point of the starting layer weld bead, the welding torch is controlled to move to the arc starting point of the next weld bead.

[0023] The welding torch is controlled to perform welding operations along the weld bead from the arc starting point. When the welding torch moves to the arc ending point of the weld bead, the process returns to the step of controlling the welding torch to move to the arc starting point of the next weld bead, until the welding of the right-angle weld bead is completed.

[0024] Secondly, this application also provides a welding system for a straight weld bevel at a right angle. The system includes a teach pendant, an electrical control box, and a welding robot; the teach pendant is connected to the electrical control box, and the electrical control box is connected to the welding robot.

[0025] The teach pendant is used to send the teaching point of the right-angle weld bevel, the welding height, the number of welding layers, and the number of weld beads per layer to the electrical box. The teaching point is used to describe the bevel shape of the right-angle weld bevel. The teach pendant is also used to send welding instructions to the electrical box.

[0026] The electrical box is used to receive the teaching point of the right-angle welding bevel, the welding height, the number of welding layers, and the number of weld beads in each layer; determine the starting layer weld bead of the right-angle welding bevel based on the teaching point of the right-angle welding bevel; upon receiving the welding command, determine the offset of each weld bead relative to the starting layer weld bead based on the welding height, the number of welding layers, and the number of weld beads; determine each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead; and send control commands carrying the starting layer weld bead and each weld bead to the welding robot.

[0027] The welding robot is used to respond to the control command and, using a welding gun carried at the end of the robotic arm, weld each weld bead sequentially from the initial layer weld bead until the welding of the right-angle weld bead is completed.

[0028] Thirdly, this application also provides a welding apparatus for a straight weld bead in a right-angle weld groove. The apparatus includes:

[0029] The data acquisition module is used to acquire the welding height, number of welding layers, number of weld beads per layer, and starting layer weld beads of the right-angle welding groove.

[0030] The offset calculation module is used to determine the offset of each weld bead relative to the starting layer weld bead based on the welding height, the number of welding layers, and the number of weld beads when a welding command is received.

[0031] The weld bead determination module is used to determine each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead.

[0032] The welding module is used to control the welding gun to weld each weld bead sequentially from the initial layer weld bead until the welding of the right-angle weld bead is completed.

[0033] Fourthly, this application also provides a computer device. The computer device includes a memory and a processor, the memory storing a computer program, and the processor executing the computer program to implement the steps in the above-described embodiments of the welding method for straight weld beads at right-angle weld bevels.

[0034] Fifthly, this application also provides a computer-readable storage medium. The computer-readable storage medium stores a computer program thereon, which, when executed by a processor, implements the steps in the above-described embodiments of the welding method for straight weld beads at right-angle weld bevels.

[0035] Sixthly, this application also provides a computer program product. The computer program product includes a computer program that, when executed by a processor, implements the steps in the above-described welding method embodiment for a straight weld bead at a right-angle weld groove.

[0036] The welding method, system, apparatus, and computer equipment for the straight weld bead of the right-angle weld bead described above differ from traditional solutions that rely on complex and expensive laser vision sensors and related professional modeling equipment. This solution only needs to obtain the welding height, number of welding layers, number of weld beads in each layer, and starting layer weld bead of the right-angle weld bead. Upon receiving the welding command, it calculates the offset of each weld bead relative to the starting layer weld bead based on the above data, and then plans each weld bead. Subsequently, it controls the welding torch to weld each weld bead sequentially from the starting layer weld bead until the welding of the right-angle weld bead is completed. This solution eliminates the time-consuming steps of complex laser recognition, modeling, and tedious algorithm processing, greatly improving the overall welding efficiency. Attached Figure Description

[0037] Figure 1 This is an application environment diagram of a welding method for a right-angle weld groove with a straight weld bead, as shown in one embodiment.

[0038] Figure 2 This is a schematic flowchart of a welding method for a straight weld bead at a right-angle weld groove in one embodiment;

[0039] Figure 3 This is a schematic diagram of the right-angle welding bevel in one embodiment;

[0040] Figure 4 This is a schematic flowchart of a welding method for a straight weld bead at a right-angle weld groove in another embodiment;

[0041] Figure 5 This is a schematic diagram of the structure of multiple weld passes in a right-angle welding bevel in one embodiment;

[0042] Figure 6 This is a schematic flowchart of a welding method for a straight weld bead at a right-angle weld groove in another embodiment;

[0043] Figure 7 This is a flowchart illustrating the welding method for a straight weld bead at a right-angle weld groove in one embodiment.

[0044] Figure 8This is a schematic flowchart illustrating the welding method for a straight weld bead at a right-angle weld groove in a detailed embodiment.

[0045] Figure 9 This is a structural block diagram of a welding system for a right-angle weld groove with a straight weld bead, as shown in one embodiment.

[0046] Figure 10 This is a structural block diagram of a welding device for a straight weld bead at a right-angle weld groove in one embodiment;

[0047] Figure 11 This is an internal structural diagram of a computer device in one embodiment. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0049] The welding method for straight weld beads at right-angle weld bevels provided in this application embodiment can be applied to, for example... Figure 1 In the application environment shown, the welding robot 102 communicates with the control terminal 104 via a network. A data storage system can store the data that the control terminal 104 needs to process. The data storage system can be integrated into the control terminal 104 or placed in the cloud or on another network server.

[0050] Specifically, the operator can send the bevel dimensions, welding height, number of welding layers, number of weld passes per layer, and starting layer weld pass to the control terminal 104 via a teach pendant. The operator can also send welding commands to the control terminal 104 via the teach pendant. The control terminal 104 determines the offset of each weld pass relative to the starting layer weld pass based on the bevel dimensions, welding height, number of welding layers, and number of weld passes. Then, based on the starting layer weld pass and the offset of each weld pass relative to the starting layer weld pass, it determines the position of each individual weld pass. Further, the control terminal 104 controls the welding robot 102 to use the welding torch at the end of its robotic arm to weld each weld pass sequentially, starting from the starting layer weld pass, until the right-angle weld bevel is completed.

[0051] The control terminal 104 can be implemented using a standalone server or a server cluster consisting of multiple servers. It can also be an electrical box that can distribute power to the welding robot 102, control the movement of the welding robot 102, and adjust the welding torch parameters.

[0052] In one embodiment, such as Figure 2 As shown, a welding method for a straight weld bead in a right-angle weld groove is provided, which is applied to... Figure 1The following steps are used as an example to illustrate the control terminal 104, which is an electrical box:

[0053] S100, obtains the welding height, number of welding layers, number of weld beads per layer, and starting layer weld bead of the right-angle welding groove.

[0054] Among them, a right-angle welding bevel is a type of bevel where both sides are at right angles, for example, as shown in the image. Figure 3 As shown, when two relatively thick weldment A and weldment B need to be butt welded, if the edges of weldment A and weldment B are aligned and welded directly, it is difficult to ensure that the root of the weld can be fully penetrated. In this case, weldment A and weldment B can be spliced ​​into a right-angle bevel to improve the welding effect.

[0055] Weld height refers to the total height of the weld seam measured from the surface of the base material. For example, weld seams that need to withstand high pressure often require a larger weld height to enhance weld strength. Figure 3 In the middle, the welding height is The number of welding layers is related to the thickness of the workpiece, the bevel dimensions, and the welding process. For thicker metal workpieces, a single layer may not meet the requirements for weld filling and quality, so it is necessary to divide the weld into multiple layers to gradually complete the filling and shaping. The number of weld passes in each layer also needs to take into account various factors, such as the welding height and bevel width of each layer. For each weld layer, multiple weld passes may be needed to evenly fill the layer; the number of weld passes in each layer is the number of passes per layer. The starting layer may have only one weld pass, which can serve as the root pass, ensuring good fusion of the base material at the weld root. For right-angle weld bevels, the starting layer weld pass can be welded along the bottom or root area of ​​the bevel. Figure 3 In the middle, the initial layer weld bead is ,in The arc initiation point (the location where the welding arc begins to be generated and forms a molten pool on the workpiece during the welding process, i.e., the welding start point). The arc termination point (the position where the arc goes out at the end of the welding process, i.e., the welding end point).

[0056] Specifically, all of the above data can be sent via a teach pendant. For example, the operator manually guides the welding robot's welding torch to the starting and ending points of the initial weld bead, records the coordinates of these points, and sends them to the control box. The control box then determines the initial weld bead. Additionally, the teach pendant teaches three points, and the coordinates of these three points are sent to the control box, allowing the control box to determine the bevel dimensions for the right-angle weld bead. Figure 3 In the middle, these three demonstration points can be Operators can also input welding parameters such as welding height, number of welding layers, and number of weld beads per layer through the teaching pendant's interface. The teaching pendant then sends these welding parameters to the electrical control box.

[0057] S200, upon receiving a welding instruction, determines the offset of each weld bead relative to the starting layer weld bead based on the welding height, the number of welding layers, and the number of weld beads.

[0058] The offset refers to the change in position of the weld bead relative to the starting layer weld bead. It can refer to the change in position in the horizontal direction, the change in position in the vertical direction, or both.

[0059] Following the steps above, when the operator issues a welding command to the electrical box via the teach pendant, the electrical box will use its built-in algorithm to calculate the offset based on the obtained bevel size data, welding height, number of welding layers, and number of weld passes.

[0060] For example, the electrical box will calculate the height of each weld layer based on the welding height and the number of weld layers, and then, in combination with the number of weld beads in each layer, determine the offset of each weld bead in the height direction relative to the starting layer weld bead. Furthermore, the electrical box can also determine the offset of each weld bead in the horizontal direction relative to the starting layer weld bead based on the number of weld beads in each layer.

[0061] S300, each weld bead is determined based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead.

[0062] Following the steps above, given the position of the initial layer weld bead, for subsequent weld beads, the height position of their arc starting point and arc ending point can be determined first based on the offset in the height direction. Then, based on the offset of the weld bead relative to the plane direction of the initial layer weld bead, the horizontal position of its arc starting point and arc ending point can be determined. Finally, based on the height and horizontal positions of the arc starting point and arc ending point, the arc starting point and arc ending point of each weld bead in space can be determined.

[0063] Furthermore, in this embodiment, the shape of the weld bead can be a straight line. Therefore, for each weld bead, after determining the arc start point and arc end point, connecting these two points with a straight line determines the weld bead. In addition, the shape of the weld bead can also be non-linear. Therefore, each weld bead can be determined based on the weld bead, the arc start point and arc end point, and preset shape requirements, such as by using a specific mathematical model to fit the arc start point and arc end point.

[0064] The S400 controls the welding torch to weld each weld bead sequentially from the initial layer until the right-angle weld bevel is completed.

[0065] Following the steps above, after the electrical box determines each weld bead, it can send control commands to the welding robot to control the welding gun at the end of the robotic arm of the welding robot to weld each weld bead sequentially, starting from the initial layer weld bead, until the welding of the right-angle weld bead is completed.

[0066] Specifically, the control box can control the welding torch to perform operations such as arc ignition, arc termination, wire feeding, and gas supply. It can also change the working current and voltage of the welding torch. For example, the control box sends an arc ignition command to the welding torch, causing the welding power supply connected to the torch to output appropriate voltage and current. The arc is ignited at the arc ignition point of the weld bead using a specific arc ignition method. The high temperature generated by the arc instantly melts the base material and filler metal of the workpiece, forming a molten pool. The welding torch moves along the weld bead until it reaches the arc termination point, at which point the control box controls the welding torch to terminate the arc, completing the welding of that weld bead. The above welding operations are performed on each weld bead until the right-angle weld bead is completed.

[0067] The above-mentioned welding method for straight weld beads in right-angle weld bevels differs from traditional solutions that rely on complex and expensive laser vision sensors and related professional modeling equipment. This solution only needs to obtain the welding height, number of welding layers, number of weld beads in each layer, and starting layer weld bead of the right-angle weld bevel. Upon receiving the welding command, it calculates the offset of each weld bead relative to the starting layer weld bead based on the above data, and then plans each weld bead. Subsequently, it controls the welding torch to weld each weld bead sequentially from the starting layer weld bead until the welding of the right-angle weld bevel is completed. This solution eliminates the time-consuming steps of complex laser recognition, modeling, and tedious algorithm processing, greatly improving the overall welding efficiency.

[0068] In one embodiment, such as Figure 4 As shown, S200 includes:

[0069] S210, determine the weld height of each weld layer based on the welding height and the number of welding layers.

[0070] S220, for each layer of weld, the offset of each weld bead relative to the starting layer weld bead is determined based on the weld height of each layer of weld, the number of weld beads in the weld, and the label of each weld bead in the weld.

[0071] The weld bead number indicates which layer of weld the weld bead belongs to and which pass it is in that layer of weld. The weld bead number can be preset to distinguish different weld beads.

[0072] Specifically, to achieve uniform and reasonable weld filling, the total welding height needs to be distributed across each weld layer. The method for calculating the height of each weld layer is to divide the total welding height by the number of weld layers. For example, if the welding height is... The number of welding layers is The weld height of each weld layer It can be shown in equation (1):

[0073] (1)

[0074] Furthermore, three demonstration points for right-angle welding bevels were determined. ,like Figure 5 As shown, the two right-angled side vectors of the right-angled welding bevels of weldment A and weldment B are respectively and The hypotenuse vector is In this embodiment, the starting and ending points of each weld bead are set on the hypotenuse, and the weld bead is a straight line. Therefore, the formulas for calculating the right-angled side vector in each layer of weld are shown in equations (2) and (3), and the formula for calculating the hypotenuse vector in each layer of weld is shown in equation (4).

[0075] (2)

[0076] (3)

[0077] (4)

[0078] The first weld bead is the starting weld bead, which can be used... Figure 5 vectors in This indicates that the number of weld passes in each subsequent weld layer is... Weld bead number is Then, except for the first layer, the offset of each weld bead in each layer of weld is... As shown in equation (5):

[0079] (5)

[0080] For example, if the second weld layer has two weld passes, then C=2, and the offsets of the two weld passes are as follows:

[0081]

[0082]

[0083] Combination Figure 5 It can be seen that, since the initial layer weld bead is Then the two weld passes of the second layer weld are respectively and .

[0084] Similarly, assuming the third weld layer has 3 weld passes, then C=3, and the offsets of these three weld passes are as follows:

[0085]

[0086]

[0087]

[0088] Correspondingly, the three weld passes of the third layer weld are as follows: Figure 5 In , , The offset of each weld bead in subsequent layers of weld is similar.

[0089] In this embodiment, the offset calculation formula described above can accurately plan the offset of each weld bead in each weld layer relative to the starting weld bead, ensuring a uniform distribution of weld beads in each weld layer. This not only improves welding efficiency but also increases welding strength. Furthermore, for right-angle weld bevels with the same shape, the offset calculation method described above can be directly reused, enabling automated batch welding without the need for additional equipment, thus significantly reducing welding costs.

[0090] In one embodiment, obtaining the initial layer weld bead of a right-angle weld bead includes: receiving a teaching point of the right-angle weld bead sent by a teaching pendant, the teaching point being used to describe the bead shape of the right-angle weld bead, the teaching point including the arc start point and arc end point of the initial layer weld bead, and determining the initial layer weld bead of the right-angle weld bead based on the arc start point and arc end point of the initial layer weld bead.

[0091] Specifically, in the preparation stage before welding, the operator can manually control the welding equipment (e.g., using a joystick to control the robotic arm of a welding robot to move the welding torch, or directly moving a handheld welding device) to move it along the key part of the right-angle welding bevel. During this process, the teach pendant will record the coordinate information of the position traversed by the welding torch at a certain sampling frequency or according to the operator's manual triggering recording method. These recorded coordinate points are the teach points. For example, as mentioned above... Figure 3 As shown, , All of these are demonstration points.

[0092] For the initial weld bead, the operator can move the welding torch along the intended path of the initial weld bead, starting from the arc initiation point and ending at the arc termination point. For example, in Figure 3 Right angle welding bevel At the designated point, after the operator positions the welding torch, the teach pendant records the coordinates of that location, which is the teaching point corresponding to the arc initiation point of the initial layer weld bead. Then, the operator moves the welding torch along the welding direction of the initial weld bead (which can be preset) until it reaches the end point of the initial weld bead. At this point, the teach pendant will also record the coordinates of the end point, forming a teach point. For example... Figure 3 In .

[0093] In addition, to more accurately describe the shape of the initial weld bead, multiple intermediate teaching points may be recorded intermittently between the arc initiation and arc termination points, forming a set of teaching points related to the initial weld bead. These teaching points are then sent to the electrical control box. Furthermore, after receiving the teaching points from the teaching pendant, the electrical control box can determine the initial weld bead of the right-angle welding groove based on the arc initiation and arc termination points of the initial weld bead.

[0094] In this embodiment, based on the teaching points issued by the teaching pendant, key information of the right-angle welding groove can be accurately obtained. Then, based on the teaching points, information such as the shape of the right-angle welding groove and the initial layer weld bead can be analyzed, providing a data foundation for subsequent high-quality and high-efficiency welding.

[0095] In one embodiment, such as Figure 6 As shown, S300 includes:

[0096] S310, determine the starting point of each weld bead based on the starting point and offset of the initial layer weld bead, determine the ending point of each weld bead based on the ending point and offset of the initial layer weld bead, and determine each weld bead based on the starting point and ending point of each weld bead.

[0097] Following the above embodiments, taking straight weld beads as an example, after determining the starting and ending points of each weld bead, the corresponding weld bead can be determined. Therefore, given the known offset of each weld bead relative to the starting layer weld bead, to simplify the calculation, it is only necessary to calculate the point after the offset between any two points on the starting layer weld bead, and then connect the offset points to determine the corresponding weld bead. Furthermore, the starting and ending points on the starting layer weld bead can be selected, and the starting and ending points of the weld bead can be calculated based on the offset, finally determining the weld bead.

[0098] For example, in Figure 5 In the middle, the arc starting point of the initial layer weld bead is Based on the offset calculated in the above embodiments, the starting points of the two weld passes on the second layer weld are respectively and Similarly, the arc termination point of the initial layer weld bead is The arc termination points of the two weld passes on the second layer weld are respectively and Similarly, the starting and ending points of each weld bead on other weld layers can be calculated. Furthermore, after determining the starting and ending points of each weld bead, the line segment connecting the starting and ending points represents the corresponding weld bead.

[0099] In this embodiment, based on the arc start point and arc end point of the initial layer weld bead, the arc start point and arc end point of each weld bead can be accurately determined, providing an accurate basis for subsequent orderly control of the welding torch to perform welding operations along the weld bead, thereby improving welding efficiency and welding quality.

[0100] In one embodiment, such as Figure 7 As shown, S400 includes:

[0101] S410 controls the welding torch to perform welding operations along the initial layer weld bead, starting from the arc ignition point.

[0102] S420: When the welding torch moves to the end point of the starting layer weld bead, control the welding torch to move to the start point of the next weld bead.

[0103] S430 controls the welding torch to start from the arc starting point of the weld bead and perform welding operations along the weld bead. When the welding torch moves to the arc ending point of the weld bead, it returns to S420 until the welding of the right angle weld bead is completed.

[0104] Specifically, at the start of welding, the electrical box can send an arc-starting command to the welding robot, causing the welding torch (hereinafter referred to as the welding torch) at the end of the robotic arm of the welding robot to weld along the starting layer weld bead according to the preset arc-starting parameters (arc-starting voltage, arc-starting current, etc.). When the welding torch moves to the arc-ending point along the starting layer weld bead, it means that the welding of the starting layer weld bead is about to end. At this time, an arc-ending operation is required, such as the circular arc-ending method, the back-welding arc-ending method, and the repeated arc-breaking method.

[0105] After completing the arc-closing operation of the initial weld bead, the control box precisely controls the welding torch to move quickly and smoothly to the arc-closing point of the next weld bead, based on the previously determined coordinates. For each weld bead, an arc-closing operation is performed upon reaching its arc-closing point, similar to the initial weld bead operation. When the welding torch moves along the weld bead to the arc-closing point, an arc-closing operation is performed. After arc-closing, the welding torch is controlled to move to the arc-closing point of the next weld bead to perform the welding operation. This process is repeated until the welding and arc-closing operations of the last weld bead are completed, confirming that all weld beads of the entire right-angle weld bead have been welded.

[0106] In this embodiment, by rigorously and systematically controlling the welding torch to perform welding operations sequentially according to the arc start point, arc end point, and weld bead of each weld bead until the welding of the right-angle weld bead is completed, welding efficiency is improved.

[0107] To provide a more detailed and clear explanation of the welding method for straight weld beads in right-angle weld grooves provided in this application, the following description is in conjunction with the appendix. Figure 8 and oneA detailed embodiment will be explained, which includes the following steps:

[0108] S801, obtains the welding height, number of welding layers, and number of weld beads per layer of the right-angle welding groove, receives the teaching point of the right-angle welding groove sent by the teaching pendant, and determines the slope starting layer weld bead of the right-angle welding groove based on the arc start point and arc end point of the starting layer weld bead.

[0109] S802, based on the welding height and the number of welding layers, determine the weld height of each weld layer, and for each weld layer, determine the offset of each weld bead relative to the starting layer weld bead based on the weld height of each weld layer, the number of weld passes in the weld, and the label of each weld pass in the weld.

[0110] S803, based on the arc starting point and offset of the initial layer weld bead, determine the arc starting point of each weld bead; based on the arc ending point and offset of the initial layer weld bead, determine the arc ending point of each weld bead; based on the arc starting point and the arc ending point of each weld bead, determine each weld bead.

[0111] S804 controls the welding torch to perform welding operations along the initial layer weld bead, starting from the arc ignition point.

[0112] S805, when the welding torch moves to the end point of the starting layer weld, control the welding torch to move to the start point of the next weld.

[0113] S806 controls the welding torch to start from the arc starting point of the weld bead and perform welding operations along the weld bead. When the welding torch moves to the arc ending point of the weld bead, it returns to S805 until the welding of the right angle weld bead is completed.

[0114] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0115] In one embodiment, this application provides a welding system 500 for a straight weld bevel at a right angle, such as... Figure 9As shown, the welding system 500 for right-angle weld bevels and straight weld beads includes a teach pendant 510, an electrical box 520, and a welding robot 530. The teach pendant 510 is connected to the electrical box 520, and the electrical box 520 is connected to the welding robot 530.

[0116] The teach pendant 510 is used to send the teaching point of the right-angle weld bevel, the welding height, the number of welding layers, and the number of weld passes per layer to the electrical box 520. The teaching point is used to describe the bevel shape of the right-angle weld bevel. It also sends welding instructions to the electrical box 520.

[0117] Electrical box 520 is used to receive the teaching point of the right-angle welding bevel, welding height, number of welding layers, and number of weld beads per layer. Based on the teaching point of the right-angle welding bevel, it determines the starting layer weld bead of the right-angle welding bevel. Upon receiving a welding command, it determines the offset of each weld bead relative to the starting layer weld bead based on the welding height, number of welding layers, and number of weld beads. Based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead, it determines each weld bead. It then sends control commands carrying the starting layer weld bead and each weld bead to the welding robot 530.

[0118] The welding robot 530 is used to respond to control commands and weld each weld bead sequentially from the initial layer weld bead using a welding torch carried at the end of the robotic arm, until the welding of the right-angle weld bead is completed.

[0119] The teach pendant 510 is a handheld device for robot programming and operation control, allowing operators to transmit various task instructions and parameter information to the electrical control box 520 and the welding robot 530 through manual operation and graphical interface input. For example, the operator can manually control the movement of the robotic arm of the welding robot 530, moving the welding torch along the desired welding path. During this process, the teach pendant 510 records the key position points (i.e., teach points) traversed by the welding torch. These points contain spatial coordinate information used to describe the welding path, such as the shape of the right-angle weld bevel, the starting point and ending point of the initial weld bead, etc. In addition, the teach pendant 510 can also set various welding-related parameters, such as welding height, number of weld layers, and number of weld beads per layer, and send these welding parameters to the electrical control box 520, providing basic data for subsequent welding process planning. After completing the teaching and parameter setting, the operator can send welding instructions to the electrical control box 520 through the teach pendant 510 to start the entire welding process.

[0120] The electrical box 520 is used to receive various instructions and data from the teach pendant 510, process and calculate them, and generate specific instructions to control the welding robot 530 in order to coordinate and manage the electrical equipment and parameters throughout the welding process. For example, based on the teaching point of the right-angle welding bevel sent by the teach pendant 510 and various welding parameters, the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead are determined. After receiving the welding instruction, the electrical box 520 combines the starting layer weld bead and the calculated offset to accurately determine the arc starting point, arc ending point and welding path of each weld bead, and generate detailed control instructions to control the welding robot 530 to perform welding operations along the weld bead.

[0121] The welding robot 530 is a device used to perform welding tasks. Its robotic arm carries a welding torch at its end. The robotic arm typically has multiple degrees of freedom, which allows it to move the welding torch flexibly to the designated welding position and perform welding operations on right-angle weld bevels according to the weld bead and welding parameters.

[0122] It should be noted that the solution provided by this system is similar to the solution described in the above method. Therefore, the specific limitations of the welding system 500 for right-angle weld groove straight weld bead can be found in the limitations of the welding method for right-angle weld groove straight weld bead described above, and will not be repeated here.

[0123] Based on the same inventive concept, this application also provides a welding apparatus for a right-angle weld groove straight weld bead, used to implement the welding method for the right-angle weld groove straight weld bead described above. The solution provided by this apparatus is similar to the solution described in the above method. Therefore, the specific limitations of one or more welding apparatus embodiments for right-angle weld groove straight weld bead provided below can be found in the limitations of the welding method for right-angle weld groove straight weld bead described above, and will not be repeated here.

[0124] In one embodiment, such as Figure 10 As shown, a welding apparatus 600 for straight weld beads in right-angle weld bevels is provided, comprising: a data acquisition module 610, an offset calculation module 620, a weld bead determination module 630, and a welding module 640, wherein:

[0125] The data acquisition module 610 is used to acquire the welding height, number of welding layers, number of weld beads in each layer, and starting layer weld beads of the right-angle welding groove.

[0126] The offset calculation module 620 is used to determine the offset of each weld bead relative to the starting layer weld bead based on the welding height, the number of welding layers, and the number of weld beads when a welding command is received.

[0127] The weld bead determination module 630 is used to determine each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead.

[0128] The welding module 640 is used to control the welding torch to weld each weld bead sequentially from the initial layer weld bead until the right-angle weld bead is completed.

[0129] In one embodiment, the offset calculation module 620 is further configured to determine the weld height of each weld layer based on the weld height and the number of weld layers, and for each weld layer, determine the offset of each weld bead relative to the starting layer weld bead based on the weld height of each weld layer, the number of weld passes in the weld, and the label of each weld pass in the weld.

[0130] In one embodiment, the data acquisition module 610 is further configured to receive teaching points of the right-angle weld bevel sent by the teaching pendant. The teaching points are used to describe the bevel shape of the right-angle weld bevel. The teaching points include the arc start point and arc end point of the initial layer weld bevel. Based on the arc start point and arc end point of the initial layer weld bevel, the initial layer weld bevel of the right-angle weld bevel is determined.

[0131] In one embodiment, the weld bead determination module 630 is further configured to determine the starting point of each weld bead based on the starting point and offset of the starting layer weld bead, determine the ending point of each weld bead based on the ending point and offset of the starting layer weld bead, and determine each weld bead based on the starting point and ending point of each weld bead.

[0132] In one embodiment, the welding module 640 is further configured to control the welding torch to perform welding operations along the starting point of the starting layer weld bead, and when the welding torch moves to the ending point of the starting layer weld bead, control the welding torch to move to the starting point of the next weld bead, control the welding torch to perform welding operations along the weld bead from the starting point of the weld bead, and when the welding torch moves to the ending point of the weld bead, return to the step of controlling the welding torch to move to the starting point of the next weld bead, until the welding of the right angle weld bead is completed.

[0133] Each module in the welding device for the straight weld bevel of the right-angle weld can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of a computer device in hardware form or independent of it, or stored in the memory of a computer device in software form, so that the processor can call and execute the operations corresponding to each module.

[0134] In one embodiment, a computer device is provided, which may be a server, and its internal structure diagram may be as follows: Figure 11As shown, this computer device includes a processor, memory, input / output (I / O) interfaces, and a communication interface. The processor, memory, and I / O interfaces are connected via a system bus, and the communication interface is also connected to the system bus via the I / O interfaces. The processor provides computational and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system, computer programs, and a database. The internal memory provides the environment for the operating system and computer programs stored in the non-volatile storage media. The database stores data such as the welding height and number of welding layers for right-angle weld bevels. The I / O interfaces are used for information exchange between the processor and external devices. The communication interface is used for communication with external terminals via a network connection. When the computer program is executed by the processor, it implements a welding method for straight weld beads in right-angle weld bevels.

[0135] Those skilled in the art will understand that Figure 11 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer device to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0136] In one embodiment, a computer device is provided, including a memory and a processor, the memory storing a computer program, the processor executing the computer program to implement the steps in the above-described embodiment of the welding method for teaching a weld bevel.

[0137] In one embodiment, a computer-readable storage medium is provided having a computer program stored thereon, which, when executed by a processor, implements the steps in the above-described welding method embodiment for teaching a weld bevel.

[0138] In one embodiment, a computer program product is provided, including a computer program that, when executed by a processor, implements the steps in the above-described embodiment of the welding method for teaching a weld bevel.

[0139] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, data stored, data displayed, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of related data must comply with the relevant laws, regulations and standards of the relevant countries and regions.

[0140] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments described above. Any references to memory, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM can take many forms, such as Static Random Access Memory (SRAM) or Dynamic Random Access Memory (DRAM). The databases involved in the embodiments provided in this application may include at least one type of relational database and non-relational database. Non-relational databases may include, but are not limited to, blockchain-based distributed databases. The processors involved in the embodiments provided in this application may be general-purpose processors, central processing units, graphics processing units, digital signal processors, programmable logic devices, quantum computing-based data processing logic devices, etc., and are not limited to these.

[0141] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0142] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A welding method for a straight weld bead at a right angle weld groove, characterized in that, The method includes: Obtain the welding height, number of welding layers, number of weld beads per layer, and starting layer weld bead of the right-angle welding bevel; Upon receiving a welding instruction, the weld height of each weld layer is determined based on the welding height and the number of weld layers. For each weld layer, the offset of each weld bead relative to the starting weld bead is determined based on the weld height of that weld layer, the number of weld passes in the weld, and the label of each weld pass in the weld. The offset is used to characterize the amount of spatial position change of subsequent weld passes relative to the starting weld bead in the vertical or horizontal direction. Each weld bead is determined based on the initial layer weld bead and the offset of each weld bead relative to the initial layer weld bead; wherein, the arc starting point and arc ending point of each weld bead are determined, and the straight line connecting the arc starting point and the arc ending point is taken as the corresponding weld bead; the arc starting point indicates the position where the welding arc begins to be generated and forms a molten pool on the workpiece during the welding process, and the arc ending point indicates the position where the arc is extinguished at the end of the welding process; The welding torch is controlled to weld each weld bead sequentially from the initial layer weld bead until the welding of the right-angle weld bead is completed; wherein, for right-angle weld beads with the same shape and structure, the calculated offset template is reused to generate weld beads.

2. The method according to claim 1, characterized in that, Obtaining the initial weld bead of a right-angle weld bevel includes: The device receives teaching points of a right-angle weld bevel sent by a teaching pendant. The teaching points are used to describe the bevel shape of the right-angle weld bevel, and the teaching points include the arc start point and arc end point of the initial layer weld bevel. The starting and ending points of the initial weld bead are used to determine the initial weld bead of the right-angle weld groove.

3. The method according to claim 2, characterized in that, Determining each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead includes: The starting point of each weld bead is determined based on the arc starting point of the initial layer weld bead and the offset amount. The arc termination point of each weld bead is determined based on the arc termination point of the starting layer weld bead and the offset amount. Each weld bead is determined based on its arc start point and arc end point.

4. The method according to any one of claims 1 to 3, characterized in that, The controlled welding torch starts welding each weld bead sequentially from the initial weld bead until the right-angle weld bead is completed, including: The welding torch is controlled to perform welding operations along the starting point of the starting layer weld bead, starting from the arc starting point of the starting layer weld bead. When the welding torch moves to the arc ending point of the starting layer weld bead, the welding torch is controlled to move to the arc starting point of the next weld bead. The welding torch is controlled to perform welding operations along the weld bead from the arc starting point. When the welding torch moves to the arc ending point of the weld bead, the process returns to the step of controlling the welding torch to move to the arc starting point of the next weld bead, until the welding of the right-angle weld bead is completed.

5. A welding system for a straight weld bevel at a right angle, characterized in that, The system includes a teach pendant, an electrical box, and a welding robot, wherein the teach pendant is connected to the electrical box, and the electrical box is connected to the welding robot; The teach pendant is used to send the teaching point of the right-angle weld bevel, the welding height, the number of welding layers, and the number of weld beads per layer to the electrical box. The teaching point is used to describe the bevel shape of the right-angle weld bevel. The teach pendant is also used to send welding instructions to the electrical box. The electrical box is used to receive the teaching point of the right-angle weld bevel, the welding height, the number of welding layers, and the number of weld beads in each layer. Based on the teaching point of the right-angle weld bevel, it determines the starting layer weld bead of the right-angle weld bevel. Upon receiving the welding command, it determines the weld height of each layer weld bead based on the welding height and the number of welding layers. For each layer weld bead, it determines the offset of each weld bead relative to the starting layer weld bead based on the weld height of that layer weld bead, the number of weld beads in the weld bead, and the label of each weld bead in the weld bead. The offset is used to characterize the subsequent weld bead... The spatial positional change of the starting layer weld bead in the vertical or horizontal direction; each weld bead is determined based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead; wherein, the arc starting point and arc ending point of each weld bead are determined, and the straight line connecting the arc starting point and the arc ending point is taken as the corresponding weld bead; the arc starting point indicates the position where the welding arc begins to be generated and forms a molten pool on the workpiece during the welding process, and the arc ending point indicates the position where the arc is extinguished at the end of the welding process; control commands carrying the starting layer weld bead and each weld bead are sent to the welding robot. The welding robot is used to respond to the control command and weld each weld bead sequentially from the starting layer weld bead using a welding gun carried at the end of the robotic arm until the welding of the right-angle weld bead is completed. For right-angle weld beads with the same shape and structure, the calculated offset template is reused to generate the weld bead.

6. A welding apparatus for a straight weld bevel at a right angle, characterized in that, The device includes: The data acquisition module is used to acquire the welding height, number of welding layers, number of weld beads per layer, and starting layer weld beads of the right-angle welding groove. The offset calculation module is used to determine the weld height of each weld layer according to the weld height and the number of weld layers when a welding command is received, and for each weld layer, determine the offset of each weld bead relative to the starting weld bead according to the weld height of the weld layer, the number of weld beads in the weld, and the label of each weld bead in the weld. The offset is used to characterize the amount of spatial position change of subsequent weld beads relative to the starting weld bead in the vertical or horizontal direction. The weld bead determination module is used to determine each weld bead based on the starting layer weld bead and the offset of each weld bead relative to the starting layer weld bead; wherein, by determining the arc start point and arc end point of each weld bead, and taking the straight line connecting the arc start point and arc end point as the corresponding weld bead; the arc start point indicates the position where the welding arc begins to be generated and forms a molten pool on the workpiece during the welding process, and the arc end point indicates the position where the arc is extinguished at the end of the welding process; The welding module is used to control the welding gun to weld each weld bead sequentially from the initial layer weld bead until the welding of the right-angle weld bead is completed; wherein, for right-angle weld beads with the same shape and structure, the calculated offset template is reused to generate the weld bead.

7. The apparatus according to claim 6, characterized in that, The data acquisition module is also used for: The system receives teaching points for right-angle weld bevels sent by a teaching pendant. These teaching points describe the bevel shape of the right-angle weld bevel and include the arc start point and arc end point of the initial layer weld bevel. Based on the arc start point and arc end point of the initial layer weld bevel, the system determines the initial layer weld bevel of the right-angle weld bevel.

8. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 4.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 4.

10. A computer program product, comprising a computer program, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 4.

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