Welding position adjustment method, device, arc sensor, storage medium and program product

Abstract

This application relates to a welding position adjustment method, apparatus, arc sensor, storage medium, and program product. It is applied to an arc sensor, which is communicatively connected to a welding robot. The method includes: determining a current deviation characteristic index of the welding robot during the welding process based on current change parameters of the welding robot in the current current cycle, wherein the current deviation characteristic index characterizes the difference between the actual welding current and the expected welding current of the welding robot; detecting the welding position offset of the welding robot based on the current deviation characteristic index; and adjusting the welding position of the welding robot based on the welding position offset. This method reduces the limitations of welding position adjustment.

Description

Technical Field

[0001] This application relates to the field of welding technology, and in particular to a welding position adjustment method, apparatus, arc sensor, computer-readable storage medium, and computer program product. Background Technology

[0002] With the continuous development of science and technology, welding technology is also gradually iterating and has become one of the irreplaceable processing technologies in many fields such as automobile manufacturing, shipbuilding, aerospace and machinery manufacturing. At the same time, welding robots have also been widely used. In the process of welding robots, accurate positioning and timely adjustment of the welding position are essential.

[0003] Currently, welding position adjustment is usually achieved by using special types of arc sensors, such as parallel twin-wire arc sensors, rotary scanning arc sensors, and welding torch oscillation arc sensors. However, due to the special mechanical structure design of these special types of arc sensors, which monitor changes in welding current from a physical perspective, their application range is limited. This often results in low welding position adjustment accuracy or poor welding position adjustment effect. Therefore, the current methods for adjusting welding position have high limitations. Summary of the Invention

[0004] Therefore, it is necessary to provide a welding position adjustment method, apparatus, arc sensor, computer-readable storage medium, and computer program product that improves the adjustment limitations of welding position adjustment in order to address the above-mentioned technical problems.

[0005] In a first aspect, this application provides a welding position adjustment method applied to an arc sensor, wherein the arc sensor is communicatively connected to a welding robot; comprising:

[0006] Based on the current change parameters of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot.

[0007] The welding position offset of the welding robot is detected based on the current deviation characteristic index.

[0008] The welding position of the welding robot is adjusted according to the welding position offset.

[0009] In one embodiment, the current deviation characteristic index includes a first current deviation characteristic index; determining the current deviation characteristic index of the welding robot during the welding process based on the current change parameters of the welding robot in the current current cycle includes:

[0010] Extract the first current integral value of the current half-cycle from the current change parameters;

[0011] Based on the first current integral value, query the second current integral value of the preceding half-cycle adjacent to the current half-cycle;

[0012] The first current deviation characteristic index is determined based on the first current integral value and the second current integral value.

[0013] In one embodiment, the welding position offset includes a first horizontal position offset and a second horizontal position offset; detecting the welding position offset of the welding robot based on the current deviation characteristic index includes:

[0014] If the first current deviation characteristic index is less than the first preset characteristic index threshold, then the preset horizontal position offset is used as the first horizontal position offset.

[0015] If the first current deviation characteristic index is greater than or equal to the first preset characteristic index threshold, then the second horizontal position offset is determined based on the first current deviation characteristic index, the first preset characteristic index threshold, and the first preset offset adjustment parameter, wherein the second horizontal position offset is less than or equal to the preset horizontal position offset threshold.

[0016] In one embodiment, the current change parameter includes a third current integral value, and the current deviation characteristic index includes a second current deviation characteristic index; determining the current deviation characteristic index of the welding robot during the welding process based on the current change parameter of the welding robot in the current current cycle includes:

[0017] Obtain the current integral reference value of the welding robot during the welding process;

[0018] The second current deviation characteristic index is determined based on the third current integral value and the current integral reference value.

[0019] In one embodiment, obtaining the current integral reference value of the welding robot during the welding process includes:

[0020] At least one current acquisition cycle of the welding robot during the welding process is obtained;

[0021] When the current acquisition cycle quantity corresponding to all the current acquisition cycles is greater than the preset current acquisition cycle quantity threshold, the fourth current integral value corresponding to each current acquisition cycle is obtained.

[0022] Based on the fourth current integral values, the current integral reference value of the welding robot during the welding process is determined.

[0023] In one embodiment, the welding position offset includes a first vertical position offset and a second vertical position offset; detecting the welding position offset of the welding robot based on the current deviation characteristic index includes:

[0024] If the second current deviation characteristic index is less than the second preset characteristic index threshold, then the preset vertical offset is used as the first vertical position offset.

[0025] If the second current deviation characteristic index is greater than or equal to the second preset characteristic index threshold, then the second vertical position offset is determined based on the second current deviation characteristic index, the second preset characteristic index threshold, the second preset offset adjustment parameter, and the current acquisition cycle, wherein the second vertical position offset is less than or equal to the preset vertical offset threshold.

[0026] Secondly, this application also provides a welding position adjustment device applied to an arc sensor, wherein the arc sensor is communicatively connected to a welding robot; comprising:

[0027] The determination module is used to determine the current deviation characteristic index of the welding robot during the welding process based on the current change parameters of the welding robot in the current current cycle, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot.

[0028] The detection module is used to detect the welding position offset of the welding robot based on the current deviation characteristic index.

[0029] The adjustment module is used to adjust the welding position of the welding robot according to the welding position offset.

[0030] Thirdly, this application also provides an arc sensor, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to perform the following steps:

[0031] Based on the current change parameters of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot; based on the current deviation characteristic index, the welding position offset of the welding robot is detected; based on the welding position offset, the welding position of the welding robot is adjusted.

[0032] Fourthly, this application also provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, performs the following steps:

[0033] Based on the current change parameters of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot; based on the current deviation characteristic index, the welding position offset of the welding robot is detected; based on the welding position offset, the welding position of the welding robot is adjusted.

[0034] Fifthly, this application also provides a computer program product, including a computer program that, when executed by a processor, performs the following steps:

[0035] Based on the current change parameters of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot; based on the current deviation characteristic index, the welding position offset of the welding robot is detected; based on the welding position offset, the welding position of the welding robot is adjusted.

[0036] The aforementioned welding position adjustment method, apparatus, arc sensor, computer-readable storage medium, and computer program product first determine the current deviation characteristic index of the welding robot during the welding process by using the current change parameters of the welding robot in the current current change cycle. This current deviation characteristic index characterizes the difference between the actual welding current and the expected welding current of the welding robot. Then, the welding position offset of the welding robot is detected through the current deviation characteristic index. Finally, the welding position is adjusted based on the welding position offset. Thus, relying on the current characteristic index characterizing the difference between the actual and expected welding current, the welding robot's actual welding position objectively reflects the difference between the actual and expected welding positions. The difference in welding position can be addressed by using the welding position offset of the welding robot to achieve precise welding position adjustment. This means that by using a general-purpose arc sensor at the software level to monitor changes in welding current and adjust the welding robot's position, the dependence on the internal physical structure design of the arc sensor for welding position adjustment is eliminated. This overcomes the technical limitations of special types of arc sensors, which have unique mechanical structures and monitor welding current changes at the physical level, leading to limited application ranges and potentially low welding position adjustment accuracy or poor results. Therefore, this method reduces the limitations of welding position adjustment. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments or related technologies of this application, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a flowchart illustrating a welding position adjustment method in one embodiment;

[0039] Figure 2 This is a flowchart illustrating the welding position adjustment method in another embodiment;

[0040] Figure 3 This is a structural block diagram of the welding position adjustment device in one embodiment;

[0041] Figure 4 This is a diagram of the internal structure of an arc sensor in one embodiment. Detailed Implementation

[0042] 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.

[0043] First, it should be understood that an arc sensor is a sensor that uses the characteristics of the welding arc itself to detect signals. It does not require additional devices to be added to the welding torch and has advantages such as good real-time performance, high flexibility and low cost. It is suitable for low-cost automatic welding needs. Arc sensors are widely used in weld seam tracking, especially in arc welding robots, and have become the standard configuration of most arc welding robots. Its application improves the automation level of the welding process, as well as welding quality and production efficiency. However, in the process of adjusting the welding position of the welding robot, it usually relies on special types of arc sensors, such as parallel dual-wire arc sensors, rotary scanning arc sensors, and torch oscillation arc sensors. Among them, the parallel dual-wire arc sensor uses two independent welding wires, which are placed side by side at a certain distance and each forms an independent arc. Its working principle is to use the difference in current generated by the two arcs to determine the lateral position of the welding torch. When the welding torch deviates from the target welding path, the characteristics of the molten pool and the geometry of the weld seam received by the two arcs are different, resulting in a difference in current. By measuring and analyzing these differences, the position of the welding torch can be adjusted in real time to achieve precise weld seam tracking. The parallel dual-wire arc sensor is suitable for multi-layer and multi-pass welding because it can provide continuous and fine path control. The rotary scanning arc sensor utilizes rotation... The relationship between speed and welding current is crucial. During rotation, the arc scans the weld area, detecting changes in weld geometry and gap. This is particularly important for thick plate welding or fillet welds with significant gaps. The rotating arc can more accurately perceive and adjust weld characteristics. By monitoring and adjusting the rotation speed and welding current in real time, the system can precisely determine the welding path, thereby improving welding quality and efficiency. The oscillating arc sensor tracks the path by periodically oscillating the torch in the weld bevel. This oscillation causes the distance between the welding wire tip and the base material to change continuously, resulting in changes in welding current and voltage. By detecting and analyzing these changes, the relative position of the torch and the weld can be determined. The oscillating arc sensor is particularly suitable for V-shaped or U-shaped bevel welding, as well as applications requiring fine adjustments to the weld contour during welding. Torch oscillation not only helps achieve better welding quality but also provides more flexible control when dealing with complex weld geometries.

[0044] The aforementioned special types of arc sensors can all be designed with specific physical structures to adjust the welding position for specific welding scenarios, but they lack versatility. For example, parallel dual-wire arc sensors increase the complexity of the equipment, and simultaneously controlling two independent welding wires and arcs increases system complexity and cost. Furthermore, they require high precision in detecting differences in welding current, necessitating a sophisticated current detection and control system, which may increase the technical difficulty and maintenance costs. Additionally, their applicability is limited, primarily suitable for multi-layer, multi-pass welding, with limited application in other welding types. Rotary scanning arc sensors may experience wear on their mechanical components after prolonged use, leading to increased maintenance needs. Rotary scanning may also be slow to react when detecting rapidly changing weld characteristics, resulting in a slower dynamic response that affects the accuracy of real-time adjustments. In terms of applicability, rotary scanning offers little advantage when welding thin plates or small welds and may be less efficient than other technologies. The mechanical structure of torch-oscillating arc sensors is extremely complex, and the high mechanical complexity of the torch oscillation mechanism may increase the difficulty of maintenance and debugging. High-speed oscillation can lead to weld quality problems, such as unstable weld pool or reduced weld joint strength. In other words, there are limitations to the oscillation frequency. In addition, for certain welding environments or weld types (such as flat welding or welds without beveling), the advantages of oscillation technology are not obvious, or it may not even be applicable. In summary, current methods for adjusting weld position using arc sensors all monitor changes in welding current from a physical perspective, which limits their application range and ultimately leads to low accuracy or poor effect in weld position adjustment. Therefore, there is an urgent need for a welding position adjustment method that reduces the limitations of welding position adjustment.

[0045] In one embodiment, such as Figure 1As shown, a welding position adjustment method is provided. This embodiment takes the application of this method to an arc sensor as an example. The arc sensor includes, but is not limited to, a general-purpose arc sensor, a welding torch oscillating arc sensor, a rotary scanning arc sensor, and a parallel dual-wire arc sensor. The arc sensor is communicatively connected to the welding robot, and can adjust the welding position of the welding robot in real time. It can be understood that the arc sensor includes a determination module, a detection module, and an adjustment module. The determination module is used to determine the current deviation characteristic index of the welding robot during the welding process based on the current change parameters of the welding robot in the current current cycle. The current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot. The detection module is used to detect the welding position offset of the welding robot based on the current deviation characteristic index. The adjustment module adjusts the welding position of the welding robot based on the welding position offset. The robot adjusts its welding position. Through information interaction between the determination module, detection module, and adjustment module, it can determine the current deviation characteristic index, which reflects the difference between the actual welding current and the expected welding current, by utilizing the current change parameters of the welding robot in the current current cycle. This current deviation can then reflect the positional difference between the actual and desired welding positions of the welding robot; that is, the welding position offset can be detected. Finally, by quantitatively determining the welding position offset, the welding position of the welding robot is adjusted. In other words, by using a general-purpose arc sensor at the software level to monitor changes in the welding current and adjust the welding position, the robot eliminates the dependence on the internal physical structure design of the arc sensor during welding position adjustment, thus reducing the limitations of welding position adjustment. In this embodiment, the method includes the following steps:

[0046] Step 202: Based on the current change parameters of the welding robot in the current current cycle, determine the current deviation characteristic index of the welding robot during the welding process. The current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot.

[0047] It should be noted that this embodiment uses welding arc tracking technology to adjust the welding position of the welding robot at the software level. Welding arc tracking technology is a technology used to monitor and adjust the position of the welding torch in real time during the welding process, thereby ensuring welding quality. Arc tracking technology mainly achieves real-time monitoring and adjustment of the welding torch position of the welding robot by detecting changes in current and arc voltage. That is, the key to this embodiment is to extract signals from the welding arc signal that can reflect the changes in the offset between the welding torch and the weld center.

[0048] It is understandable that an arc sensor is a sensor that uses the characteristics of the welding arc itself for signal detection. It does not require additional devices on the welding torch and has advantages such as good real-time performance, high flexibility, and low cost. It is suitable for low-cost automated welding needs. Arc sensors can achieve stable control of welding parameters and improve the welding formation effect, especially in the surface formation and fusion of both sides of beveled multi-pass welds of thick plates. Arc sensors are widely used in weld tracking, especially in welding robots. Their application has improved the automation level of the welding process, as well as welding quality and production efficiency. Welding robots can specifically refer to arc welding robots.

[0049] Understandably, the main purpose of welding arc tracking technology is to achieve automatic positioning and control of welds, improve welding quality and efficiency. By tracking the welding arc, weld detection and positioning can be achieved: welding arc tracking technology can detect the position of the weld, helping collaborative robots to accurately position and adjust the welding position, ensuring the quality and accuracy of the weld. In the process of thick plate welding, factors such as workpiece processing errors, assembly errors, and thermal deformation during welding inevitably lead to a certain deviation between the robot's teaching trajectory and the actual welding trajectory, resulting in weld point offset, which can easily cause incomplete weld filling and inconsistent welding quality. Therefore, how to accurately and stably identify and track welds has always been a hot research topic in robotic welding. Therefore, this embodiment essentially utilizes the feedback of current and voltage sensors to achieve precise tracking and compensation of the welding torch position by detecting the relationship between the arc extension and the current magnitude. The welding position adjustment of the welding robot can be performed during the welding of thick plate with large bevels.

[0050] It should be noted that during the welding process of the welding robot, when the distance between the welding torch and the surface of the workpiece changes, the arc length of the arc sensor will also change accordingly, which will affect the magnitude of the welding current. The current cycle can be acquired by the current sensor and transmitted to the arc sensor, or acquired by the voltage sensor and transmitted to the arc sensor. Finally, the arc sensor calculates the current cycle, which can be 1 / 50. The current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot, which can be the current change rate. The current change parameter is used to characterize the change of current over time, which can be the current integral value. It can be understood that the arc sensor can adjust the welding position of the welding robot at any time based on the current deviation characteristic index.

[0051] As an example, step 202 includes: querying the current deviation characteristic index of the welding robot during the welding process based on the current integral value of the welding machine in the current current cycle.

[0052] Step 204: Detect the welding position offset of the welding robot based on the current deviation characteristic index.

[0053] It should be noted that the welding position offset is used to characterize the difference between the actual welding position and the expected welding position of the welding robot. It can be understood that there is a certain mapping relationship between the current deviation characteristic index and the welding position offset, thus enabling the tracking and compensation of welding torch position changes using current change parameters. It can be understood that technicians can export the current deviation characteristic index over a certain period as a current deviation characteristic index graph. If the welding robot is in a normal state during the welding process, the change in the current deviation characteristic index is small. If the welding robot is gradually deviating during the welding process, that is, the change in the current deviation characteristic index is large. When the difference between the actual welding current and the expected welding current during the welding process is large, it is necessary to rely on the mapping relationship between the current deviation characteristic index and the welding position offset to detect the corresponding welding position offset.

[0054] As an example, step 204 includes: querying the welding position offset of the welding robot based on the current deviation characteristic index.

[0055] Step 206: Adjust the welding position of the welding robot according to the welding position offset.

[0056] It should be noted that during the process of adjusting the welding position of the welding robot, the welding position offset is the adjustment amount for adjusting the welding position of the welding robot. It can be understood that the welding position adjustment system of the arc sensor is suitable for welding thick plates with large bevels in the welding process. This welding task usually has the requirements of high precision and stability. Therefore, the welding position can be compensated in real time by the welding position offset.

[0057] As an example, step 206 includes: compensating the welding position offset for the current welding position of the welding robot, and using the compensated welding position as the current welding position of the welding robot.

[0058] In the aforementioned welding position adjustment method, firstly, by analyzing the current changes of the welding robot during the current cycle, a current deviation characteristic index is determined, representing the difference between the actual welding current and the expected welding current during the welding process. Then, relying on the mapping relationship between the battery deviation characteristic index and the welding position offset, the welding position offset is obtained from the battery deviation characteristic index. Finally, based on the welding position offset, the current welding position of the welding robot is compensated, and the compensated welding position is taken as the current welding position of the welding robot. Thus, relying on the current characteristic index representing the difference between the actual and expected welding current of the welding robot, the actual welding position and the expected welding position of the welding robot can be objectively reflected. The difference between them, thus relying on the welding position offset of the welding robot, can achieve the purpose of precise welding position adjustment of the welding robot. That is, by using a general arc sensor to monitor the changes in welding current from the software level, the welding position of the welding robot can be adjusted. This eliminates the dependence on the internal physical structure design of the arc sensor when adjusting the welding position. Therefore, it overcomes the technical defects caused by the special mechanical structure design of special types of arc sensors, which limit their application range due to the physical monitoring of changes in welding current, and thus easily leads to low welding position adjustment accuracy or poor welding position adjustment effect. Therefore, it reduces the adjustment limitations of welding position adjustment.

[0059] In one embodiment, such as Figure 2 As shown, the current deviation characteristic index includes a first current deviation characteristic index; based on the current change parameters of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, including:

[0060] Step 302: Extract the first current integral value of the current half-cycle from the current change parameters.

[0061] It should be noted that different welding processes have different requirements for welding accuracy in different welding directions. The current deviation characteristic index includes the first current deviation characteristic index, which is used to characterize the difference between the actual welding current and the expected welding current of the welding robot in different current cycles. The first current deviation characteristic index is specifically the rate of change of the current integral value. The current half cycle refers to the first half cycle within the current current cycle. It can be understood that the arc sensor will collect the welding current at fixed time intervals during the welding process of the welding robot.

[0062] As an example, step 302 includes: integrating the collected welding current value to obtain the total current integral value in the current current cycle, and selecting the first current integral value belonging to the current half-cycle from the total current integral value in the current current cycle. Specifically, the selection method can be based on a time identifier.

[0063] Step 304: Based on the first current integral value, query the second current integral value of the preceding half-cycle adjacent to the current half-cycle.

[0064] It should be noted that the first half-cycle adjacent to the current half-cycle refers to the half-cycle that is closest to the current half-cycle in the previous current cycle. For example, assuming the current current cycle is the first current cycle, and the current cycle that is before and adjacent to the current current cycle is the second current cycle, then the current half-cycle is the first half-cycle within the first current cycle, and the first half-cycle adjacent to the current half-cycle is the second half-cycle within the second current cycle.

[0065] As an example, step 304 includes: querying the second current integral value of the preceding half-cycle adjacent to the current half-cycle based on the first current integral value.

[0066] Step 306: Determine the first current deviation characteristic index based on the first current integral value and the second current integral value.

[0067] It should be noted that, in order to highlight the changes in the integral value of the current in different half-cycles, the first current deviation characteristic index can be obtained by solving the first current integral value and the second current integral value. For example, in one feasible approach, the ratio of the first current integral value and the second current integral value can be used as the current deviation characteristic index.

[0068] As an example, step 306 includes: determining the ratio of the first current integral value and the second current integral value as a first current deviation characteristic index.

[0069] In this embodiment, when focusing on the horizontal welding position compensation of the welding robot during the welding process, the current integral value of the welding robot during the welding process can be determined by observing the change of the welding current of the welding robot with time in different current cycles. Finally, the ratio of the first current integral value and the second current integral value is determined as the first current deviation characteristic index. That is, the current deviation characteristic index reflecting the difference between the actual welding current and the expected welding current of the welding robot in different current cycles is obtained, so as to calculate the welding position offset in the subsequent process. Therefore, it lays the foundation for accurately detecting the horizontal offset of the welding position of the welding robot.

[0070] In one embodiment, the welding position offset includes a first horizontal position offset and a second horizontal position offset; detecting the welding position offset of the welding robot based on current deviation characteristic indicators includes:

[0071] If the first current deviation characteristic index is less than the first preset characteristic index threshold, then the preset horizontal position offset is used as the first horizontal position offset; if the first current deviation characteristic index is greater than or equal to the first preset characteristic index threshold, then the second horizontal position offset is determined according to the first current deviation characteristic index, the first preset characteristic index threshold and the first preset offset adjustment parameter, wherein the second horizontal position offset is less than or equal to the preset horizontal position offset threshold.

[0072] It should be noted that for welding processes that focus on the horizontal displacement of the welding robot's welding torch, a first preset characteristic index threshold is set to detect the welding position displacement of the welding robot in real time. Specifically, during the tracking of the welding robot's left and right displacement, the following parameters need to be set on the arc sensor: 1) Current integral value change rate threshold (first preset characteristic index threshold): This is an adjustable parameter used to determine whether the current integral value change rate (first current deviation characteristic index) exceeds the current integral value change rate threshold; 2) Basic correction rate (first preset offset adjustment parameter): This is an adjustable parameter representing the adjustment rate of the correction amount per unit current integral value change rate exceeding the threshold; 3) Maximum single adjustment distance: An internal parameter; for example, assuming the welding process is oscillating welding, it is fixed at 1 / 2 of the oscillating welding amplitude; 4) Cumulative maximum adjustment distance: This is an adjustable hyperparameter representing the maximum allowed total adjustment distance.

[0073] As an example, if the first current deviation characteristic index is less than the first preset characteristic index threshold, then the preset horizontal position offset is used as the first horizontal position offset, wherein the preset horizontal position offset can specifically be zero; if the first current deviation characteristic value is greater than or equal to the first preset characteristic index threshold, then the first current deviation characteristic index, the first preset characteristic index threshold, and the first preset offset adjustment parameter are jointly input into the preset horizontal position offset calculation formula to calculate the second horizontal position offset, wherein the second horizontal position offset is less than or equal to the preset horizontal position offset threshold, wherein the preset horizontal position offset threshold can specifically be the single maximum adjustment distance and / or the cumulative maximum adjustment distance, that is, the single adjustment distance of the welding position offset adjusted by the welding robot in the horizontal direction is not greater than the single maximum adjustment distance, and the total adjustment distance of the welding position offset adjusted in the horizontal direction is not greater than the cumulative maximum distance, wherein the expression of the preset horizontal position offset calculation formula is as follows:

[0074]

[0075] in, This is the offset of the second horizontal position. The first current deviation characteristic index, Adjust the parameters for the first preset offset. The first preset feature index threshold.

[0076] In this embodiment, a first preset feature index threshold is set during the detection of the welding position offset of the welding robot. Based on the relationship between the first current deviation feature index and the first preset feature index threshold, the second horizontal position offset is detected by different detection methods. This achieves the goal of accurately detecting the horizontal position offset of the welding robot, thus laying the foundation for improving the accuracy of adjusting the horizontal welding position of the welding robot.

[0077] In one embodiment, the current change parameter includes a third current integral value, and the current deviation characteristic index includes a second current deviation characteristic index; based on the current change parameter of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, including:

[0078] Obtain the current integral reference value of the welding robot during the welding process; determine the second current deviation characteristic index based on the third current integral value and the current integral reference value.

[0079] It should be noted that different welding processes have different requirements for welding accuracy in different welding directions. The current deviation characteristic index includes a second current deviation characteristic index, which is used to characterize the benchmark difference between the actual welding current and the expected welding current of the welding robot in different current cycles. That is, the difference between the current integral value and the benchmark current integral value in each current cycle. The second current deviation characteristic value is specifically the rate of change of the current integral value. The current integral benchmark value is used to characterize the current integral value of the welding robot during the benchmark current acquisition period. The current integral benchmark value can be preset.

[0080] As an example, the current integral reference value of the welding robot during the welding process is obtained; the ratio between the third current integral value and the current integral reference value is determined as the second current characteristic index. In this embodiment, focusing on compensation for the welding position of the welding robot in the vertical direction during the welding process, the third current integral value of the welding robot within a single cycle can be determined, and the reference current integral value for the reference current acquisition period of the welding robot can be obtained. The ratio between the third current integral value and the reference current integral value is determined as the second current deviation characteristic index. That is, a current deviation characteristic index reflecting the reference difference between the actual welding current and the expected welding current of the welding robot in different current cycles is obtained. Therefore, this lays the foundation for accurately detecting the vertical offset of the welding position of the welding robot.

[0081] In one embodiment, obtaining the current integral reference value of the welding robot during the welding process includes:

[0082] Acquire at least one current acquisition cycle of the welding robot during the welding process; when the current acquisition cycle quantity corresponding to all current acquisition cycles is greater than the preset current acquisition cycle quantity threshold, acquire the fourth current integral value corresponding to each current acquisition cycle; determine the current integral reference value of the welding robot during the welding process based on each fourth current integral value.

[0083] It should be noted that for welding processes that focus on the vertical offset of the welding robot's welding torch, when obtaining the second current deviation characteristic parameter, it is necessary to determine the current integral reference value of the welding robot during the welding process. The preset acquisition period threshold is the reference current acquisition time (BasePeriod), which is an adjustable hyperparameter representing the time period for acquiring the reference current.

[0084] As an example, at least one current acquisition cycle of the welding robot during the welding process is obtained; it is detected whether the current acquisition cycle quantity, which is commonly identified by each current acquisition cycle, is greater than a preset current acquisition cycle quantity threshold. If the current acquisition cycle quantity is greater than the preset current acquisition cycle quantity threshold, the fourth current integral value corresponding to each current acquisition cycle is obtained; the average of each fourth current integral value is calculated to obtain the current integral reference value of the welding robot during the welding process. This embodiment obtains the current integral reference value by statistically analyzing the current acquisition cycle quantity of the welding robot during the welding process, and by calculating the average of the current integral values ​​of multiple current acquisition cycles when the current acquisition cycle quantity reaches the preset current acquisition cycle quantity threshold. This provides a reliable basis for calculating the second current deviation characteristic index, thus laying the foundation for improving the accuracy of the second current deviation characteristic index.

[0085] In one embodiment, the welding position offset includes a first vertical position offset and a second vertical position offset; detecting the welding position offset of the welding robot based on current deviation characteristic indicators includes:

[0086] If the second current deviation characteristic index is less than the second preset characteristic index threshold, then the preset vertical offset is used as the first vertical position offset; if the second current deviation characteristic index is greater than or equal to the second preset characteristic index threshold, then the second vertical position offset is determined according to the second current deviation characteristic index, the second preset characteristic index threshold, the second preset offset adjustment parameter and the current acquisition cycle, wherein the second vertical position offset is less than or equal to the preset vertical offset threshold.

[0087] It should be noted that, in the process of tracking the vertical offset of the welding position of the welding robot, the following parameters also need to be set on the arc sensor: 1) Relative reference current change rate threshold (threshold2): This is the second preset characteristic index threshold, an adjustable hyperparameter used to determine whether the current change exceeds the threshold; 2) Basic correction rate (rate): This is the second preset offset adjustment parameter, an adjustable hyperparameter, representing the adjustment rate of the correction amount for each unit of current change exceeding the threshold; 3) Maximum adjustment distance per time: An adjustable hyperparameter representing the maximum distance of each correction; 4) Cumulative maximum adjustment distance (MaxD): An adjustable hyperparameter representing the maximum value of the total allowable correction distance.

[0088] As an example, if the second current deviation characteristic index is less than the second preset characteristic index threshold, then the preset vertical offset is used as the first vertical position offset, where the preset vertical offset can specifically be zero; if the second current deviation characteristic value is greater than or equal to the second preset characteristic index threshold, then the second current deviation characteristic index, the second preset characteristic index threshold, the second preset offset adjustment parameter, and the current acquisition cycle are input together into the preset vertical position offset calculation formula to obtain the second vertical position offset, where the second vertical position offset is less than or equal to the preset vertical position offset threshold, where the preset vertical position offset threshold can specifically be the single maximum adjustment distance and / or the cumulative maximum adjustment distance, that is, the single adjustment distance of the welding position offset adjusted by the welding robot in the vertical direction is not greater than the single maximum adjustment distance, and the total adjustment distance of the welding position offset adjusted in the vertical direction is not greater than the cumulative maximum distance, where the expression of the preset vertical position offset calculation formula is as follows:

[0089]

[0090] This is the offset of the second vertical position. This is the second current deviation characteristic index. Adjust the parameters for the second preset offset. The second preset feature index threshold is , and Base is the current acquisition cycle.

[0091] It is understandable that, regardless of still They all have a direction, among which, The direction (+ / - sign) is consistent with the positive and negative directions of the half-cycle with the smaller current integral value. Direction (+ / - sign) and The symbols must be consistent.

[0092] In this embodiment, a second preset feature index threshold is set during the detection of the welding position offset of the welding robot. Based on the relationship between the second current deviation feature index and the second preset feature index threshold, the second vertical position offset is detected by different detection methods. This achieves the goal of accurately detecting the offset of the welding robot in the vertical position, thus laying the foundation for improving the accuracy of adjusting the welding robot in the vertical welding position.

[0093] It is understood that this application, by applying correction algorithms in different directions to adjust the welding position of the welding robot, can compensate for the horizontal and / or vertical position offset of the welding robot. Furthermore, by applying the compensation value to the robot's end-effector trajectory, effective correction of deviations can be achieved. Since the arc sensor has the ability to simultaneously detect and compensate for vertical and horizontal deviations, this means that the system can detect changes in the welding torch position in the vertical and horizontal directions and correct the deviations through corresponding correction algorithm compensation measures. This makes the actual welding position of the welding robot more accurate during the welding process. Before welding begins, the weld end point, arc tracking parameters, and welding parameters are usually set and adjusted to the optimal value based on the actual welding situation. On this basis, the welding position of the welding robot is then adjusted.

[0094] The welding position adjustment method of this application embodiment can achieve the following effects: 1) During the welding of thick plates, factors such as workpiece processing errors, assembly errors, and thermal deformation during welding inevitably lead to a certain deviation between the robot teaching trajectory and the actual welding trajectory; weld point offset occurs, which easily causes incomplete weld filling and results in inconsistent welding quality. This application embodiment solves the above problems and can accurately and stably identify and track the weld; 2) The algorithm has low complexity and collects the current at the swing end, which has high real-time performance; 3) Improved weld quality: By monitoring the changes in the welding torch position in real time and adjusting the welding parameters to compensate for the vertical and horizontal deviations, the accuracy of the welding torch position during welding can be ensured, welding deviations can be reduced, and the quality and consistency of the weld can be improved; 4) Improved welding efficiency: The arc tracking system can automatically detect changes in the welding torch position and adjust the welding parameters in real time to maintain a suitable distance between the welding torch and the weld; This can reduce the need for manual adjustment and improve welding efficiency and productivity. 5) Flat Weld Control: For thick plates with large bevels, the arc sensor can perform lateral compensation using the oscillating welding technique. Oscillating welding is a technique that achieves uniform weld filling by alternating left and right movements of the welding torch. The arc sensor can automatically control the left and right movement of the welding torch based on changes in the shape and position of the weld, achieving flat weld filling and improving the weld's appearance and mechanical properties. Welding Parameter Optimization: The arc sensor uses feedback from current and voltage sensors to identify changes in the welding torch position. By analyzing the relationship between current magnitude and electrode extension, welding parameters can be optimized. This improves welding stability and consistency, and reduces the occurrence of welding defects.

[0095] It should be understood that although the steps in the flowcharts of the above embodiments 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 above embodiments 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.

[0096] Based on the same inventive concept, this application also provides a welding position adjustment device for implementing the welding position adjustment method described above. The solution provided by this device is similar to the solution described in the above method; therefore, the specific limitations in one or more welding position adjustment device embodiments provided below can be found in the limitations of the welding position adjustment method described above, and will not be repeated here.

[0097] In one exemplary embodiment, such as Figure 3 As shown, a welding position adjustment device is provided, applied to an arc sensor, which is communicatively connected to a welding robot; it includes: a determining module 401, a detecting module 402, and an adjusting module 403, wherein:

[0098] The determining module 401 is used to determine the current deviation characteristic index of the welding robot during the welding process based on the current change parameters of the welding robot in the current current cycle, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot.

[0099] The determination module 402 is used to detect the welding position offset of the welding robot based on the current deviation characteristic index.

[0100] The test module 403 is used to adjust the welding position of the welding robot according to the welding position offset.

[0101] In one embodiment, the current deviation characteristic index includes a first current deviation characteristic index; the determining module 401 is further configured to:

[0102] Extract the first current integral value of the current half-cycle from the current change parameters; based on the first current integral value, query the second current integral value of the preceding half-cycle adjacent to the current half-cycle; determine the first current deviation characteristic index based on the first current integral value and the second current integral value.

[0103] In one embodiment, the welding position offset includes a first horizontal position offset and a second horizontal position offset; the detection module 402 is further configured to:

[0104] If the first current deviation characteristic index is less than the first preset characteristic index threshold, then the preset horizontal position offset is used as the first horizontal position offset; if the first current deviation characteristic index is greater than or equal to the first preset characteristic index threshold, then the second horizontal position offset is determined according to the first current deviation characteristic index, the first preset characteristic index threshold and the first preset offset adjustment parameter, wherein the second horizontal position offset is less than or equal to the preset horizontal position offset threshold.

[0105] In one embodiment, the current change parameter includes a third current integral value, and the current deviation characteristic index includes a second current deviation characteristic index; the determining module 401 is further configured to:

[0106] Obtain the current integral reference value of the welding robot during the welding process; determine the second current deviation characteristic index based on the third current integral value and the current integral reference value.

[0107] In one embodiment, the determining module 401 is further configured to:

[0108] At least one current acquisition cycle of the welding robot during the welding process is obtained; when the current acquisition cycle quantity corresponding to all the current acquisition cycles is greater than a preset current acquisition cycle quantity threshold, a fourth current integral value corresponding to each current acquisition cycle is obtained; based on each fourth current integral value, a current integral reference value of the welding robot during the welding process is determined.

[0109] In one embodiment, the welding position offset includes a first vertical position offset and a second vertical position offset; the detection module 402 is further configured to:

[0110] If the second current deviation characteristic index is less than the second preset characteristic index threshold, then the preset vertical offset is used as the first vertical position offset; if the second current deviation characteristic index is greater than or equal to the second preset characteristic index threshold, then the second vertical position offset is determined according to the second current deviation characteristic index, the second preset characteristic index threshold, the second preset offset adjustment parameter and the current acquisition cycle, wherein the second vertical position offset is less than or equal to the preset vertical offset threshold.

[0111] Each module in the aforementioned welding position adjustment device can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of the arc sensor in hardware form or independent of it, or stored in the memory of the arc sensor in software form, so that the processor can call and execute the corresponding operations of each module.

[0112] In one exemplary embodiment, an arc sensor is provided, which can be a terminal, and its internal structure diagram can be as follows. Figure 4As shown. The arc sensor includes a processor, memory, input / output interface, communication interface, display unit, and input device. The processor, memory, and input / output interface are connected via a system bus, and the communication interface, display unit, and input device are also connected to the system bus via the input / output interface. The processor of the arc sensor provides computational and control capabilities. The memory of the arc sensor includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores the operating system and computer program. The internal memory provides an environment for the operation of the operating system and computer program in the non-volatile storage medium. The input / output interface of the arc sensor is used for exchanging information between the processor and external devices. The communication interface of the arc sensor is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, mobile cellular networks, NFC (Near Field Communication), or other technologies. When the computer program is executed by the processor, it implements a welding position adjustment method. Those skilled in the art will understand that... Figure 4 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 arc sensor to which the present application is applied. A specific arc sensor may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0113] In one embodiment, an arc sensor is also provided, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps in the above method embodiments.

[0114] In one embodiment, a computer-readable storage medium is provided having a computer program stored thereon that, when executed by a processor, implements the steps in the above method embodiments.

[0115] 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 method embodiments.

[0116] 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.

[0117] 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.

[0118] 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 position adjustment method characterized by, The method is applied to an arc sensor, which is communicatively connected to a welding robot; the method includes: Based on the current change parameters of the welding robot in the current current cycle, the current deviation characteristic index of the welding robot during the welding process is determined, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot. The welding position offset of the welding robot is detected based on the current deviation characteristic index. The welding position of the welding robot is adjusted according to the welding position offset, wherein the current deviation characteristic index includes a first current deviation characteristic index; determining the current deviation characteristic index of the welding robot during the welding process based on the current change parameters of the welding robot in the current current cycle includes: Extract the first current integral value of the current half-cycle from the current change parameters; based on the first current integral value, query the second current integral value of the preceding half-cycle adjacent to the current half-cycle, wherein the preceding half-cycle adjacent to the current half-cycle refers to the half-cycle closest to the current half-cycle in the preceding current cycle; determine the ratio of the first current integral value and the second current integral value as the current deviation characteristic index; the welding position offset includes a first horizontal position offset and a second horizontal position offset; the step of detecting the welding position offset of the welding robot based on the current deviation characteristic index includes: If the first current deviation characteristic index is less than the first preset characteristic index threshold, then the preset horizontal position offset is used as the first horizontal position offset; if the first current deviation characteristic index is greater than or equal to the first preset characteristic index threshold, then the second horizontal position offset is determined according to the first current deviation characteristic index, the first preset characteristic index threshold, and the first preset offset adjustment parameter, wherein the second horizontal position offset is less than or equal to the preset horizontal position offset threshold; the current change parameter includes a third current integral value, and the current deviation characteristic index includes a second current deviation characteristic index; determining the current deviation characteristic index of the welding robot during the welding process according to the current change parameter of the welding robot in the current current cycle includes: At least one current acquisition cycle of the welding robot during the welding process is obtained; when the total current acquisition cycle corresponding to all the current acquisition cycles is greater than a preset current acquisition cycle threshold, a fourth current integral value corresponding to each of the current acquisition cycles is obtained; based on each of the fourth current integral values, a current integral reference value of the welding robot during the welding process is determined; based on the third current integral value and the current integral reference value, a second current deviation characteristic index is determined; the welding position offset includes a first vertical position offset and a second vertical position offset; the step of detecting the welding position offset of the welding robot based on the current deviation characteristic index includes: If the second current deviation characteristic index is less than the second preset characteristic index threshold, then the preset vertical offset is used as the first vertical position offset; if the second current deviation characteristic index is greater than or equal to the second preset characteristic index threshold, then the second vertical position offset is determined according to the second current deviation characteristic index, the second preset characteristic index threshold, the second preset offset adjustment parameter and the current acquisition cycle, wherein the second vertical position offset is less than or equal to the preset vertical offset threshold.

2. A welding position adjustment device characterized by, An arc sensor is applied to a welding robot and is communicatively connected to it; the device includes: The determination module is used to determine the current deviation characteristic index of the welding robot during the welding process based on the current change parameters of the welding robot in the current current cycle, wherein the current deviation characteristic index is used to characterize the difference between the actual welding current and the expected welding current of the welding robot. The detection module is used to detect the welding position offset of the welding robot based on the current deviation characteristic index. The adjustment module is used to adjust the welding position of the welding robot according to the welding position offset, wherein the current deviation characteristic index includes a first current deviation characteristic index; the determination module is further used to: extract the first current integral value of the current half-cycle from the current change parameters; query the second current integral value of the preceding half-cycle adjacent to the current half-cycle based on the first current integral value, wherein the preceding half-cycle adjacent to the current half-cycle refers to the half-cycle closest to the current half-cycle in the preceding current cycle adjacent to the current half-cycle; determine the ratio of the first current integral value and the second current integral value as the current deviation characteristic index; the welding position offset includes a first horizontal position offset and The detection module is further configured to: if the first current deviation characteristic index is less than the first preset characteristic index threshold, then use the preset horizontal position offset as the first horizontal position offset; if the first current deviation characteristic index is greater than or equal to the first preset characteristic index threshold, then determine the second horizontal position offset according to the first current deviation characteristic index, the first preset characteristic index threshold, and the first preset offset adjustment parameter, wherein the second horizontal position offset is less than or equal to the preset horizontal position offset threshold; the current change parameter includes the third current integral value, and the current deviation characteristic index includes the second current deviation characteristic index; the determining module is further configured to: The detection module acquires at least one current acquisition cycle during the welding process of the welding robot; when the total current acquisition cycle value corresponding to all the current acquisition cycles is greater than a preset current acquisition cycle value threshold, it acquires a fourth current integral value corresponding to each of the current acquisition cycles; it determines a current integral reference value for the welding robot during the welding process based on each of the fourth current integral values; it determines a second current deviation characteristic index based on the third current integral value and the current integral reference value; the welding position offset includes a first vertical position offset and a second vertical position offset; the detection module is further configured to: If the second current deviation characteristic index is less than the second preset characteristic index threshold, then the preset vertical offset is used as the first vertical position offset; if the second current deviation characteristic index is greater than or equal to the second preset characteristic index threshold, then the second vertical position offset is determined according to the second current deviation characteristic index, the second preset characteristic index threshold, the second preset offset adjustment parameter and the current acquisition cycle, wherein the second vertical position offset is less than or equal to the preset vertical offset threshold.

3. An arc sensor comprising a memory and a processor, the memory storing a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method of claim 1.

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

5. 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 of claim 1.

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