A laser welding device and welding process for automobile door hem corner

Abstract

The application relates to the technical field of automobile production, in particular to a laser welding device for automobile door hemming corners and a welding process.The welding device comprises a hardware device 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 welding device is composed of a multi-axis manipulator, a laser welding head, a welding piece tooling and a water cooler, and automatic laser welding operation of the automobile door hemming corners is realized by optimizing various laser welding parameters, the problem of virtual welding or overwelding in the prior art is reduced, the welding qualification rate of products is improved, the application has the self-determination function, the reference database is continuously optimized in the operation process, and the accuracy of the self-determination and the operation efficiency are improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of automobile production, and particularly relates to a laser welding device and welding process for automobile door edge bending corners. BACKGROUND

[0002] In the automobile manufacturing process, door plate edge bending is an important process, and its quality is directly related to the flatness and safety of the automobile appearance. Traditionally, the door plate edge bending is mostly welded by resistance welding and other welding methods, but there are problems such as low welding efficiency, large heat-affected zone, easy deformation and welding defects. Especially at the door plate edge bending corner, 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 high efficiency, accuracy, small heat-affected zone and other advantages. However, for the special part of the automobile door plate edge bending corner, the existing laser welding device and process still have some deficiencies, one of which is that the welding effect is not high, and it is easy to be virtual welding or overwelding, and the other is that the judgment of the welding effect depends on manual detection, and the production efficiency is not high, which is difficult to completely meet the production demand. SUMMARY

[0004] The technical problem to be solved by the present application is to solve the deficiencies in the prior art and provide a laser welding device and welding process for automobile door edge bending corners, aiming to at least solve one of the technical problems proposed in the background art.

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

[0006] A laser welding device for automobile door edge bending corners, comprising a hardware device and an electric control system, the electric control system comprising an interactive module, a data processing module, an output module, a detection module, a storage module and an analysis module;

[0007] The interactive module is used for inputting parameters and data feedback, setting welding parameters, selecting welding programs, monitoring welding process and receiving system feedback information through the interactive module, the welding parameters including laser power, welding speed and light-off delay;

[0008] The data processing module is used for data processing and analysis, and generates control instructions to adjust the parameters of the laser welding machine to ensure that the welding process is carried out according to the preset program and conditions;

[0009] The output module is used for converting 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 adjustment;

[0010] The detection module includes a sensor and a detection camera, which are used to monitor the temperature, position, speed, laser beam state during the welding process and the weld imaging after welding in real time;

[0011] The storage module is used to store the welding program, user parameter setting, detected graphic record, system log information, and also stores a variety of reference atlas of weld images;

[0012] The analysis module is used to compare and determine the picture of the weld imaging collected by the detection module with the image stored in the reference atlas, and if the determination is unqualified, a warning is given, and if the determination is qualified, the next welding operation is continued.

[0013] Preferably, the laser welding device for the corner of the automobile door hem has a self-learning function, and can save the detected parameters and pictures in the storage module, and classify the parameters and pictures as qualified and unqualified according to the determination results of the analysis module or manual, and participate in the detection comparison of subsequent welding operations.

[0014] Preferably, the laser welding device for the corner of the automobile door hem has a self-learning function, and can save the detected parameters and pictures in the storage module, and classify the parameters and pictures as qualified and unqualified according to the determination results of the analysis module or manual, and participate in the detection comparison of subsequent welding operations.

[0015] Preferably, the laser welding device for the corner of the automobile door hem has a self-learning function, and can save the detected parameters and pictures in the storage module, and classify the parameters and pictures as qualified and unqualified according to the determination results of the analysis module or manual, and participate in the detection comparison of subsequent welding operations.

[0016] Preferably, the laser welding device for the corner of the automobile door hem has a self-learning function, and can save the detected parameters and pictures in the storage module, and classify the parameters and pictures as qualified and unqualified according to the determination results of the analysis module or manual, and participate in the detection comparison of subsequent welding operations.

[0017] Preferably, the laser welding device for the corner of the automobile door hem further comprises a remote monitoring center, and the analysis module is also connected with the remote monitoring center, which is used for remote fault diagnosis and technical support.

[0018] Preferably, the laser welding device for the corner of the automobile door hem has a self-learning function, and can save the detected parameters and pictures in the storage module, and classify the parameters and pictures as qualified and unqualified according to the determination results of the analysis module or manual, and participate in the detection comparison of subsequent welding operations.

[0019] A laser welding process for the corner of the automobile door hem includes the following steps:

[0020] S1: Pre-weld preparation: First check whether each part of the laser welding device is running normally, confirm that the laser, laser head, robot control system, water cooling system and other systems are fault-free, then place the automobile door panel to be welded on the workbench and fix it with the clamp;

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

[0022] S2: Laser parameter setting: The material thickness and shape characteristics of the automobile door panel hem corner are set through the operation interface of the robot control system, the laser power is set to 400W-870W, the welding speed is set to 30mm / s, and the 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 needs to be continuous, smooth and cover the entire welding area, especially the corner, pay attention to the planning and adjustment of the path to ensure the integrity and consistency of the weld, and consider the shape of the corner to set the pause point and acceleration point in the welding path to adjust the motion 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, while the laser emits a laser beam to heat and melt the welding area, forming a firm weld;

[0025] S5: Post-welding treatment: After welding, the weld is inspected for appearance and performance to ensure that the weld has no blowout, no excess height, good forming and meets the strength requirements.

[0026] Preferably, the laser power of the laser welding process for the automobile door hem corner of the application is set to 450W-520W.

[0027] Preferably, the laser welding process for the automobile door hem corner of the application sets the light-off delay to 0.2s in advance.

[0028] The beneficial effects of the application are:

[0029] (1) The application sets up a welding device composed of a multi-axis robot, a laser welding head, a welding part tooling and a water cooler, optimizes various laser welding parameters, and realizes automatic laser welding of the automobile door hem corner, reducing the problems of virtual welding or overwelding in the prior art, and improving the welding qualification rate of the product;

[0030] (2) It has a self-determination function and continuously optimizes the reference database during operation, improving the accuracy of self-determination and operation efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0031] The technical solutions of the present application are further illustrated below in combination with the drawings and embodiments.

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

[0033] Figure 2 is a schematic diagram of the appearance of the product before welding of the embodiment of the present application.

[0034] Figure 3 is a schematic diagram of the appearance of the qualified product after welding of the embodiment of the present application.

[0035] Figure 4 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 is a schematic diagram of the appearance of the product after welding of test group 2 of the embodiment of the present application. Figure 4

[0037] Figure 6 is a schematic diagram of the appearance of the product after welding of test group 3 of the embodiment of the present application.

[0038] Figure 7 is a schematic diagram of the appearance of the qualified weld of the embodiment of the present application. Figure 6

[0039] Figure 8 is a schematic diagram of the cross section of the workpiece of the qualified weld of the embodiment of the present application.

[0040] Figure 9 is a schematic diagram of the cross section of the workpiece of the qualified weld of the embodiment of the present application. Figure 8

[0041] Figure 10 is a schematic diagram of the cross section of the workpiece of the qualified weld of the embodiment of the present application.

[0042] Figure 11 is a schematic diagram of the cross section of the workpiece of the qualified weld of the embodiment of the present application.

[0043] Figure 12 is a schematic diagram of the operation interface of the embodiment of the present application.

[0044] Figure 13 is a schematic diagram of the working state of the fixed welding head of the embodiment of the present application.

[0045] Figure 14 is a schematic diagram of the working state of the fixed clamping workpiece of the embodiment of the present application. DETAILED DESCRIPTION

[0046] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict.

[0047] ​​​In the description of the present application, it needs to be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the scope of protection of the present application. In addition, the terms "first", "second" and the like are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second" and the like can be explicitly or implicitly included one or more. In the description of the present application, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0048] In the description of the present application, it needs to be understood that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connection" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through intermediate medium, or the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood through specific circumstances.

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

[0050] Embodiment

[0051] The present embodiment provides a laser welding device for the corner of the automobile door hemming, which is used for welding the hemming position of the automobile galvanized door plate. The position is a three-layer galvanized plate structure, and the structure specifically is that three layers of 0.7mm thick galvanized plate are laminated, the middle part is pasted with glue, the welding form is a circle with a diameter of 2-4mm or a straight line with a width of 2-4mm and a length of 8mm or other forms, and the surface of the first layer and the second layer below the first layer is welded after the welding forming (the welding plays a reinforcing role after the gluing), the welding surface is smooth without burst point defects, and the third layer on the convex back surface has no mark and deformation.

[0052] A laser welding device for the corner of the automobile door hemming, comprising a hardware device and an electric control system, the electric control system comprising an interaction module, a data processing module, an output module, a detection module, a storage module and an analysis module, and the connection relationship is referred to Figure 1 .

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

[0054] The data processing module is used for data processing and analysis to generate control instructions to adjust the parameters of the laser welding machine to ensure that the welding process is carried out according to the preset program 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 adjustment.

[0056] The detection module includes sensors and detection cameras for real-time monitoring of temperature, position, speed, laser beam state, and weld imaging after welding.

[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 programs, user parameter settings, detected image records, and system log information. The storage module also stores a variety of reference images of welds. 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.

[0059] The analysis module is used to compare the images of the welded welds collected by the detection module with the images stored in the reference atlas, and to compare the collected parameters with the reference parameters and make a judgment. If the judgment is not qualified, a warning is given, which can be in the form of a warning light, buzzer, etc. If the judgment is qualified, the next welding operation is continued, and the collected data, pictures, and judgment results are classified and recorded in the storage module as reference data and atlas for subsequent analysis. The database of reference atlas and reference data is enriched during the operation process, thereby improving the accuracy of automatic judgment.

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

[0061] Preferably, the laser welding device for the corner of the automobile door hemming of the present embodiment 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.

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

[0063] In actual work, various weld pictures and parameters are imported into the storage module in advance as reference atlas and reference data, then the equipment parameters are set and the equipment is modulated to normal welding operation, the welding operation is started, and in the welding process, the welding data is recorded in real time and automatic judgment is performed, the qualified and unqualified welding parts are stored separately, and can be transplanted to different stations by mechanical hand unloading or manually unloaded to different stations, such as setting NG area and OK area.

[0064] For the qualified welding parts, manual spot check can be performed, and for the unqualified welding parts, manual review must be performed, and after manual review, the results are saved to the reference atlas and reference database of the storage module, participate in the detection comparison of subsequent welding operations, and further improve the accuracy of system judgment.

[0065] Preferably, the laser welding device for the corner of the automobile door hem of the embodiment has a self-learning function, and can save the detected parameters and pictures into the storage module, and classify the parameters and pictures as qualified and unqualified according to the judgment results of the analysis module or manual, and participate in the detection comparison of subsequent welding operations, and further improve the accuracy of system judgment.

[0066] The embodiment also provides a laser welding process for the corner of the automobile door hem, which comprises the following steps:

[0067] S1: preparation before welding: first, check whether each part of the laser welding device is normally running, confirm that the laser, laser head, robot control system, water cooling system and the like are fault-free, then place the automobile door plate to be welded on the workbench and fix it using a clamp, it should be noted that the product can be clamped by installing a clamp on the multi-axis robot (refer to Figure 13 ), or the door plate is positioned and clamped on the fixed clamping table, and the laser welding head is installed on the multi-axis robot (refer to Figure 14 ), and the multi-axis robot drives the laser welding head to move to perform welding operation on the door plate.

[0068] S2: laser parameter debugging and setting, in the embodiment, according to the material and shape characteristics of the corner of the automobile door hem, the parameters are set through the operation interface of the robot control system, specifically, the movement path of the robot, the laser welding power, the welding speed and the light-off delay parameter are set, the light-off delay refers to the time difference between the starting speed of the robot and the light-out of the laser.

[0069] Referring to Figure 12 the operation interface, the selection of parameters please refer to the test data in the following table;

[0070]

[0071] Referring to Figures 4-9 , from the test data in the above table, 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 welded molding is good.

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

[0073]

[0074] According to the above test data (the oil-water effect on the picture is not good, no picture is placed), the temperature of the water cooling machine has little effect on the oil stain of the lens, and the oil and water content in the gas will affect the welding effect, therefore, water-free and oil-free gas should be used as the protective gas for laser welding operation.

[0075] S3: Welding path planning: use the programming function of the robot control system to plan the welding path, the welding path needs to be continuous, smooth and cover the entire welding area, especially the corners, pay attention to the planning and adjustment of the path to ensure the integrity and consistency of the weld, and consider the special shape of the corner and the welding difficulty, set appropriate pause points and acceleration points in the welding path to adjust the motion 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, and the laser emits a laser beam to heat and melt the welding area, forming a firm weld.

[0077] S5: Post-welding treatment: after welding, the system determines unqualified welds one by one for appearance inspection and performance test, a certain proportion of the system-determined qualified welds are checked manually, and the results of the manual check are adjusted and changed if they are inconsistent with or different from the system-determined results, referring to Figure 10 and Figure 11 , qualified welds should ensure no burst points, no excess height, good molding and meet the strength requirements.

[0078] It should be noted that each product needs to be set with an identity mark, such as a two-dimensional code or a bar code mark on the surface, and the detection camera on the welding equipment can record the product mark during welding, and the detection results can be matched with the product, which is convenient for subsequent query and adjustment of the determination results.

[0079] With the above ideal embodiments according to the present application as the inspiration, through the above description, relevant staff can make various changes and modifications without deviating from the scope of the technical idea of the present application. The technical scope of the present application is not limited to the content of the specification, and the technical scope must be determined according to the scope of claims.

Claims

1. A laser welding device for corner trimming of automobile doors, comprising hardware 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 for inputting parameters and providing data feedback. Through the interactive module, welding parameters can be set, welding programs can be selected, the welding process can be monitored, and information feedback from the system can be received. The welding parameters include: laser power, welding speed, and laser off delay. The data processing module is used to process and analyze data, generate control commands, and adjust various parameters of the laser welding machine to ensure that the welding process is carried out according to the preset program and conditions. The output module is used to convert the control commands generated by the data processing module into specific electrical signals or mechanical action commands to control the movement of the laser welding machine, the switching on and off of the laser, and the power adjustment. The detection module includes sensors and a detection camera, used to monitor the temperature, position, speed, laser beam status during the welding process and the weld seam imaging after welding in real time. The storage module is used to store welding programs, user parameter settings, detection graphic records, 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 image of the weld seam acquired by the detection module with the image stored in the reference atlas. If the judgment is unqualified, an early warning is issued. If the judgment is qualified, the welding operation continues to the next weld point. The analysis module also has a self-learning function, which can save the detected parameters and images to the storage module, and classify the parameters and images as qualified and unqualified according to the judgment results of the analysis module or human judgment, and participate in the detection and comparison of subsequent welding operations. The detection module includes an image recognition algorithm unit to improve the clarity and accuracy of weld seam imaging; 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; The analysis module also includes a feedback unit, which allows manual review and adjustment of the automatically determined results to continuously optimize the algorithm model. It also includes a remote monitoring center, and the analysis module is connected to the remote monitoring center for remote fault diagnosis and technical support.

2. The laser welding device for corner trimming of automobile doors according to claim 1, characterized in that, The hardware equipment includes a multi-axis robotic arm, a laser welding head, welding fixtures, and a water cooler.

3. A laser welding process for corner trim on automotive doors as described in claim 1 or 2, characterized in that, Includes the following steps: S1: Pre-welding preparation: First, check whether each component of the laser welding device is operating normally, and confirm that the laser, laser head, robot control system and water cooling system are fault-free. Then, place the car door panel to be welded on the workbench and fix it with a clamp. Alternatively, a multi-axis robotic arm can be used to grip the car door panel to be welded; S2: Laser parameter settings: The material thickness and shape characteristics of the corner of the car door panel edge are set through the operation interface of the robot control system. The laser power is set to 400W-870W, the welding speed is set to 30mm / s, and the laser off delay is 0-0.2s. S3: Welding Path Planning: Utilize 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. Special attention should be paid to the planning and adjustment of the path at corners to ensure the integrity and consistency of the weld. At the same time, considering the shape of the corners, pause points and acceleration points need to be set in the welding path to adjust the robot's movement speed and posture. S4: Start Welding: After confirming that all parameters and path settings are correct, start the laser welding device to perform welding. The robot moves according to the preset welding path and speed, while the laser emits a laser beam to heat and melt the welding area to form a strong weld. S5: Post-weld treatment: After welding is completed, the weld is visually inspected and its performance is tested to ensure that the weld has no bursts, no excess weld, good shape and meets the strength requirements.

4. The laser welding process for the corner of an automobile door edge according to claim 3, characterized in that, The laser power is set to 450W-520W.

5. The laser welding process for the corner of an automobile door edge according to claim 4, characterized in that, The light-off delay is set to 0.2 seconds in advance.

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