Laser welding device and welding process for edge covering corner of automobile door

Abstract

The invention relates to the technical field of automobile production, in particular to a laser welding device and process for an automobile door wrapping edge corner, the welding device comprises hardware equipment and an electric control system, and the electric control system comprises an interaction module, a data processing module, an output module, a detection module, a storage module and an analysis module. The multi-axis manipulator, the laser welding head, the welding part tool and the water cooler are arranged to form the welding device, and various laser welding parameters are optimized to realize automatic laser welding operation of the edge covering corner of the automobile door, so that the problem of insufficient welding or over-welding in the prior art is reduced, the welding qualification rate of products is improved, and the production cost is reduced. The method has an autonomous judgment function, continuously optimizes the reference database in the operation process, and improves the accuracy of autonomous judgment and the operation efficiency.

Description

Technical Field

[0001] The present application belongs to the field of automobile production technology, and in particular, relates to a laser welding device and welding process for automobile door hemming corners. Background Art

[0002] In the automobile manufacturing process, door panel hemming is an important process, and its quality is directly related to the smoothness and safety of the automobile appearance. Traditionally, door panel hemming is mostly welded by resistance welding and other methods, but there are problems such as low welding efficiency, large heat-affected zone, easy deformation and welding defects. Especially at the corners of door panel hemming, due to the complex shape, it is more difficult to ensure the welding quality by traditional welding methods.

[0003] In recent years, laser welding technology has been widely used in the field of automobile manufacturing due to its advantages such as high efficiency, precision, and small heat-affected zone. However, for the special part of the automobile door panel hemming corner, the existing laser welding devices and processes still have shortcomings. First, the welding effect is not high, and it is easy to have false welding or over-welding. Second, the judgment of welding effect depends on manual inspection, and the production efficiency is low, which is difficult to fully meet production needs. Summary of the invention

[0004] The technical problem to be solved by the present invention is: to solve the deficiencies in the prior art, thereby providing a laser welding device and welding process for automobile door hemming corners, aiming to solve at least one of the technical problems raised in the background technology.

[0005] The technical solution adopted by the present invention to solve its technical problem is:

[0006] A laser welding device for automobile door hemming corners, comprising hardware equipment and an electric control system, wherein the electric control system comprises an interaction module, a data processing module, an output module, a detection module, a storage module and an analysis module;

[0007] The interactive module is used to input parameters and data feedback, and the welding parameters are set, the welding program is selected, the welding process is monitored, and the information fed back by the system is received through the interactive module. The welding parameters include: laser power, welding speed, and light-off delay;

[0008] The data processing module is used to process and analyze data and generate control instructions to adjust various parameters of the laser welding machine to ensure that the welding process is carried out according to the preset procedures and conditions;

[0009] The output module is used to convert the control instructions generated by the data processing module into specific electrical signals or mechanical action instructions to control the movement of the laser welding machine, the switching of the laser, and the power regulation;

[0010] The detection module includes sensors and detection cameras for real-time monitoring of temperature, position, speed, laser beam status during welding and welding seam imaging after welding;

[0011] The storage module is used to store welding procedures, user parameter settings, graphic records of detection, and system log information. The storage module also stores reference atlases of various weld images;

[0012] The analysis module is used to compare and judge the weld imaging picture collected by the detection module with the image stored in the reference atlas. If it is judged to be unqualified, an early warning is issued. If it is judged to be qualified, the welding operation of the next welding point is continued.

[0013] Preferably, in the laser welding device for automobile door edging corners of the present invention, the analysis module also has an autonomous learning function, can save the detected parameters and images into the storage module, and classify the parameters and images as qualified or unqualified according to the judgment results of the analysis module or manual, and participate in the detection and comparison of subsequent welding operations.

[0014] Preferably, in the laser welding device for automobile door hemming corners of the present invention, the detection module also includes an image recognition algorithm unit for improving the clarity and accuracy of weld imaging.

[0015] Preferably, in the laser welding device for automobile door hemming corners of the present invention, the storage module also includes a cloud storage unit for uploading part of the non-real-time data to the cloud to achieve remote backup and sharing of data.

[0016] Preferably, in the laser welding device for automobile door hemming corners of the present invention, the analysis module further comprises a feedback unit, and the feedback unit allows manual review and adjustment of the results of the automatic determination, so as to continuously optimize the algorithm model.

[0017] Preferably, the laser welding device for automobile door hemming corners of the present invention further comprises a remote monitoring center, and the analysis module is also connected to the remote monitoring center for remote fault diagnosis and technical support.

[0018] Preferably, in a laser welding device for automobile door hemming corners of the present invention, the hardware equipment includes a multi-axis manipulator, a laser welding head, a welding part tooling and a water cooler.

[0019] A laser welding process for automobile door hemming corners comprises the following steps:

[0020] S1: Preparation before welding: First check whether all parts of the laser welding device are operating normally, confirm that there are no faults in the laser, laser head, robot control system, water cooling system, etc. Then, place the car door panel to be welded on the workbench and fix it with a clamp;

[0021] Or, use a multi-axis manipulator to grab the car door panel to be welded;

[0022] S2: Laser parameter setting: Material thickness and shape characteristics of the corners of the car door panel, set the parameters through the operation interface of the robot control system, laser power is set to 400W-870W, welding speed is set to 30mm / s, and light off delay is 0-0.2s;

[0023] S3: Welding path planning: Use the programming function of the robot control system to plan the welding path. The welding path must be continuous, smooth and cover the entire welding area. In particular, attention should be paid to the planning and adjustment of the path at the corners to ensure the integrity and consistency of the weld. At the same time, considering the shape of the corners, it is necessary to set pause points and acceleration points in the welding path to adjust the movement speed and posture of the robot;

[0024] S4: Start welding: After confirming that all parameters and path settings are correct, start the laser welding device for welding. The robot moves according to the preset welding path and speed. At the same time, the laser emits a laser beam to heat and melt the welding area to form a solid weld.

[0025] S5: Post-weld treatment: After welding is completed, the weld is visually inspected and tested for performance to ensure that the weld has no burst points, no excess height, is well formed and meets strength requirements.

[0026] Preferably, in the laser welding process for automobile door hemming corners of the present invention, the laser power is set to 450W-520W.

[0027] Preferably, in the laser welding process for automobile door hemming corners of the present invention, the light-off delay is set to be 0.2s in advance.

[0028] The beneficial effects of the present invention are:

[0029] (1) The present invention realizes the automatic laser welding operation of the automobile door hemming corner by configuring a welding device including a multi-axis manipulator, a laser welding head, a welding tool and a water cooler, and optimizing various laser welding parameters, thereby reducing the problems of false welding or over-welding in the prior art and improving the welding qualification rate of the product;

[0030] (2) It has the function of autonomous judgment and continuously optimizes the reference database during the operation process, thereby improving the accuracy of autonomous judgment and operation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The technical solution of the present application is further described below in conjunction with the accompanying drawings and embodiments.

[0032] Figure 1 It is a schematic diagram of the module connection relationship of the electric control system of the embodiment of the present application;

[0033] Figure 2 This is a schematic diagram of the appearance of the product before welding according to an embodiment of the present application;

[0034] Figure 3 This is a schematic diagram of the appearance of a qualified product after welding according to an embodiment of the present application;

[0035] Figure 4 This is a schematic diagram of the appearance of the product after welding of test group 1 of the embodiment of the present application;

[0036] Figure 5 yes Figure 4 A schematic diagram of a local enlarged structure;

[0037] Figure 6 This is a schematic diagram of the appearance of the product after welding in test group 2 of the embodiment of the present application;

[0038] Figure 7 yes Figure 6 A schematic diagram of a local enlarged structure;

[0039] Figure 8 This is a schematic diagram of the appearance of the product after welding of test group 3 of the embodiment of the present application;

[0040] Fig. 9 yes Figure 8 A schematic diagram of a local enlarged structure;

[0041] Fig.10 This is a schematic diagram of the appearance of a qualified weld in an embodiment of the present application;

[0042] Fig.11 is a schematic diagram of a workpiece cross section of a qualified weld in an embodiment of the present application;

[0043] Fig.12 Schematic diagram of the operation interface of the embodiment of the present application;

[0044] Fig.13 Reference schematic diagram of the working state of the fixed welding head in the embodiment of the present application;

[0045] Fig.14 Reference schematic diagram of the working state of fixing and clamping a workpiece in the embodiment of the present application; DETAILED DESCRIPTION

[0046] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application may be combined with each other.

[0047] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the scope of protection of the present application. In addition, the terms "first", "second", etc. are used only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the invention, unless otherwise specified, "multiple" means two or more.

[0048] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood by specific circumstances.

[0049] The technical solution of the present application will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0050] Example

[0051] The present embodiment provides a laser welding device for the corners of automobile door edging, which is used for welding the edging position of automobile galvanized door panels. This position is a three-layer galvanized plate structure. The specific structure is three layers of 0.7mm thick galvanized plates stacked together, glued in the middle, and welded in the form of a 2-4mm diameter circle or a 2-4mm wide 8mm long straight line or other methods. After welding and forming, the surface layer is required to be welded to the galvanized plate layer below it (welding after glue adhesion plays a reinforcement role), the welding surface is smooth, without burst points or defects, without protrusions, and the third layer on the back has no marks or deformation.

[0052] A laser welding device for automobile door hemming corners includes hardware equipment and an electronic control system. The electronic control system includes an interaction module, a data processing module, an output module, a detection module, a storage module and an analysis module. The connection relationship thereof refers to Figure 1 .

[0053] Specifically, the interactive module serves as a bridge between the user and the system. In this embodiment, a touch screen and a data input and output interface are selected as interactive hardware for operators to input parameters and data display feedback. The interactive module is used to set welding parameters, select welding procedures, monitor the welding process, and receive system feedback information. The welding parameters include: laser power, welding speed, and light-off delay.

[0054] The data processing module is used to process and analyze data and generate control instructions to adjust various parameters of the laser welding machine to ensure that the welding process is carried out according to the preset procedures and conditions.

[0055] The output module is used to convert the control instructions generated by the data processing module into specific electrical signals or mechanical action instructions to control the movement of the laser welding machine, the switching of the laser, and the power regulation.

[0056] The detection module includes sensors and detection cameras, which are used to monitor the temperature, position, speed, laser beam status during the welding process and weld imaging after welding in real time.

[0057] The detection module also includes an image recognition algorithm unit to improve the clarity and accuracy of weld imaging.

[0058] The storage module is used to store welding procedures, user parameter settings, graphic records of inspections, and system log information. The storage module also stores reference maps of various weld images. The storage module also includes a cloud storage unit, which is used to upload some non-real-time data to the cloud to achieve remote backup and sharing of data.

[0059] The analysis module is used to compare the images of the weld after welding collected by the detection module with the images stored in the reference atlas, and to compare and judge the collected parameters with the reference parameters. If it is judged to be unqualified, an early warning will be issued. The early warning method can be a warning light, buzzer, etc. If it is judged to be qualified, the welding operation will continue to be performed on the next welding point, and the collected data, pictures and judgment results will be classified and recorded in the storage module as reference data and atlas for subsequent analysis. During the operation, the database of reference atlas and reference data will be enriched, thereby improving the accuracy of the system's automatic judgment.

[0060] The analysis module also includes a feedback unit, which allows manual review and adjustment of the results of automatic determination to continuously optimize the algorithm model.

[0061] Preferably, the laser welding device for automobile door hemming corners of this embodiment further includes a remote monitoring center, and the analysis module is also connected to the remote monitoring center for remote fault diagnosis and technical support.

[0062] Preferably, in a laser welding device for automobile door edging corners of the present embodiment, the analysis module also has the function of autonomous learning, and can save the detected parameters and images into the storage module, and classify the parameters and images as qualified or unqualified according to the judgment results of the analysis module or manual, and participate in the detection and comparison of subsequent welding operations.

[0063] In actual work, various weld images and parameter storage modules are imported in advance as reference maps and reference data, and then the equipment parameters are set and the equipment is adjusted to allow welding operations to proceed normally. The welding operation is started. During the welding process, the detection module records the welding data in real time and makes automatic judgments. Qualified welds are stored separately from unqualified welds, and can be transferred to different workstations by robots or manually unloaded to different workstations, such as setting NG areas and OK areas.

[0064] For welds that are judged to be qualified, manual spot checks can be carried out. For welds that are judged to be unqualified, manual review must be carried out. After manual review, the results are saved to the reference atlas and reference database of the storage module to participate in the inspection and comparison of subsequent welding operations, further improving the accuracy of the system's judgment.

[0065] Preferably, the laser welding device for automobile door edging corners of this embodiment comprises hardware equipment including a multi-axis manipulator, a laser, a welding tooling and a water cooler. The laser adopts a continuous fiber laser with a power of 2000W, a laser wavelength of 1064nm, and a welding focal length of F-300mm.

[0066] This embodiment also provides a laser welding process for automobile door hemming corners, comprising the following steps:

[0067] S1: Preparation before welding: First check whether the components of the laser welding device are operating normally, confirm that the laser, laser head, robot control system, water cooling system, etc. are fault-free, then place the car door panel to be welded on the workbench and fix it with a fixture. It should be noted that the fixture can be installed on the multi-axis manipulator to clamp the product (refer to Fig.13 ), fix the laser welding head to perform clamping processing, or position and clamp the door panel on a fixed clamping table, and install the laser welding head on a multi-axis manipulator (refer to Fig.14 ), the laser welding head is driven by a multi-axis manipulator to move and weld the door panel.

[0068] S2: Laser parameter debugging and setting. In this embodiment, according to the material and shape characteristics of the corners of the automobile door panel, the parameters are set through the operation interface of the robot control system, specifically, the movement path of the manipulator, laser welding power, welding speed and light-off delay parameters are formulated. The light-off delay refers to the time difference between the robot startup speed and the laser light emission.

[0069] Reference Fig.12 For the operation interface, please refer to the test data in the table below for parameter selection;

[0070]

[0071] Reference Figure 4-9 From the test data in the above table, it can be seen that when the welding power is adjusted to 500W, the welding speed is 30mm / s, and the light is turned off 0.2s in advance, the fusion state of the welding formation is good.

[0072] Install the above optimal parameter data (test group 3) to set the laser parameters and further test the effect of the welding gas;

[0073]

[0074] According to the above test data (oil and water do not show well in the picture, so the picture is not placed), the temperature of the water cooler has little effect on the oil on the lens, and the oil and water content in the gas will affect the welding effect. Therefore, it is necessary to use water-free and oil-free gas as the protective gas for laser welding operations.

[0075] S3: Welding path planning: Use the programming function of the robot control system to plan the welding path. The welding path must be continuous, smooth and cover the entire welding area. In particular, attention should be paid to the planning and adjustment of the path at the corners to ensure the integrity and consistency of the weld. At the same time, considering the special shape and welding difficulty of the corners, appropriate pause points and acceleration points should be set in the welding path to adjust the movement speed and posture of the robot;

[0076] S4: Start welding: After confirming that all parameters and path settings are correct, start the laser welding device for welding. The robot moves according to the preset welding path and speed. At the same time, the laser emits a laser beam to heat and melt the welding area to form a solid weld.

[0077] S5: Post-weld processing: After welding is completed, the products with unqualified welds determined by the system are subjected to appearance inspection and performance test one by one. For the products with qualified welds determined by the system, a certain proportion of spot checks are carried out, and manual verification is carried out. The records with inconsistent or different results from the system judgment are adjusted and changed. Fig.10 and Fig.11 Qualified welds should have no bursting points, no excess height, good forming and meet strength requirements.

[0078] It should be noted that each product needs to have an identity mark, such as a QR code or barcode mark on the surface. The detection camera on the welding equipment can enter the product number during welding and match the detection results with the product to facilitate subsequent inquiries and adjustments to the judgment results.

[0079] Based on the above ideal embodiments of this application, the relevant staff can make various changes and modifications without departing from the technical concept of this application through the above description. The technical scope of this application is not limited to the content in the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A laser welding device for automobile door hemming corners, comprising hardware equipment and an electronic control system, characterized in that: The electronic control system includes an interaction module, a data processing module, an output module, a detection module, a storage module and an analysis module; The interactive module is used to input parameters and data feedback, and the welding parameters are set, the welding program is selected, the welding process is monitored, and the information fed back by the system is received through the interactive module. The welding parameters include: laser power, welding speed, and light-off delay; The data processing module is used to process and analyze data and generate control instructions to adjust various parameters of the laser welding machine to ensure that the welding process is carried out according to the preset procedures and conditions; The output module is used to convert the control instructions generated by the data processing module into specific electrical signals or mechanical action instructions to control the movement of the laser welding machine, the switching of the laser, and the power regulation; The detection module includes sensors and detection cameras for real-time monitoring of temperature, position, speed, laser beam status during welding and welding seam imaging after welding; The storage module is used to store welding procedures, user parameter settings, graphic records of detection, and system log information. The storage module also stores reference atlases of various weld images; The analysis module is used to compare and judge the weld imaging picture collected by the detection module with the image stored in the reference atlas. If it is judged to be unqualified, an early warning is issued. If it is judged to be qualified, the welding operation of the next welding point is continued.

2. A laser welding device for automobile door hemming corners according to claim 1, characterized in that: The analysis module also has the function of autonomous learning, which can save the detected parameters and pictures into the storage module, and classify the parameters and pictures as qualified or unqualified according to the judgment results of the analysis module or manual, and participate in the detection and comparison of subsequent welding operations.

3. A laser welding device for automobile door hemming corners according to claim 2, characterized in that: The detection module also includes an image recognition algorithm unit for improving the clarity and accuracy of weld imaging.

4. A laser welding device for automobile door hemming corners according to claim 3, characterized in that: The storage module also includes a cloud storage unit for uploading some non-real-time data to the cloud to achieve remote backup and sharing of data.

5. A laser welding device for automobile door hemming corners according to claim 4, characterized in that: The analysis module also includes a feedback unit, which allows manual review and adjustment of the results of the automatic determination, so as to continuously optimize the algorithm model.

6. The laser welding device for automobile door hemming corner according to claim 5, characterized in that: It also includes a remote monitoring center, and the analysis module is also connected to the remote monitoring center for remote fault diagnosis and technical support.

7. A laser welding device for automobile door hemming corners according to claim 1 or 6, characterized in that: The hardware equipment includes a multi-axis manipulator, a laser welding head, a welding tool and a water cooler.

8. A laser welding process for automobile door hemming corners, characterized in that: The following steps are involved: S1: Preparation before welding: First check whether all parts of the laser welding device are operating normally, confirm that there are no faults in the laser, laser head, robot control system, water cooling system, etc. Then, place the car door panel to be welded on the workbench and fix it with a clamp; Or, use a multi-axis manipulator to grab the car door panel to be welded; S2: Laser parameter setting: Material thickness and shape characteristics of the corners of the car door panel, set the parameters through the operation interface of the robot control system, laser power is set to 400W-870W, welding speed is set to 30mm / s, and light off delay is 0-0.2s; S3: Welding path planning: Use the programming function of the robot control system to plan the welding path. The welding path must be continuous, smooth and cover the entire welding area. In particular, attention should be paid to the planning and adjustment of the path at the corners to ensure the integrity and consistency of the weld. At the same time, considering the shape of the corners, it is necessary to set pause points and acceleration points in the welding path to adjust the movement speed and posture of the robot; S4: Start welding: After confirming that all parameters and path settings are correct, start the laser welding device for welding. The robot moves according to the preset welding path and speed. At the same time, the laser emits a laser beam to heat and melt the welding area to form a solid weld. S5: Post-weld treatment: After welding is completed, the weld is visually inspected and tested for performance to ensure that the weld has no burst points, no excess height, is well formed and meets strength requirements.

9. The laser welding process for automobile door hemming corners according to claim 8, characterized in that: The laser power is set to 450W-520W.

10. The laser welding process for automobile door hemming corners according to claim 9, characterized in that: The light-off delay is set to be 0.2s in advance.

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