Welding method and system based on displacement control

Abstract

The invention discloses a welding method and system based on displacement control, and relates to the technical field of welding control systems.The welding method comprises the steps that before welding operation, a calculation module collects position data of a to-be-welded object based on an image unit and sets a corresponding preset welding path and a simulation graph layer; the calculation module is provided with a plurality of detection points on a preset welding path; before formal welding operation, the displacement driving module drives the welding module to move once based on a preset welding path, preset displacement data in the moving process is generated, and the preset displacement data is uploaded to the calculation module. According to the high-precision welding control system, the image and temperature data are collected in real time, the calculation module can accurately analyze the deviation between the welding path and the actual movement data, the movement path of the welding module is adjusted in time, and therefore high-precision welding control is achieved. According to the system, welding defects caused by path deviation can be effectively reduced, and the welding quality is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of welding control systems, and particularly to a welding method and system based on displacement control. Background Technique

[0002] Welding technology is widely used in multiple industries, especially in fields such as automobile manufacturing, aerospace, and heavy machinery. Existing welding technologies have undergone multiple technological advancements, from traditional manual welding to automated welding, and then to intelligent welding in recent years. Automated welding systems have greatly improved the efficiency and accuracy of welding operations while reducing human errors. Especially in terms of automated path tracking and welding parameter control, existing technologies have been maturely applied in many industrial applications.

[0003] After retrieval, Chinese Patent (Publication No.: CN117506079A) discloses an efficient keyhole welding system and method. This patent includes an image acquisition system, an image processing system, a control system, a wire feeding mechanism, and a swinging welding torch. Without changing the welding current intensity, within a specific range of arc width values and ellipticity values, the original motion state of the welding current is changed in real time by means of electrode rotation and torch swing, achieving the purpose of one-pass filling + capping welding formation on the surface of thick plates and ultra-thick plates. The image acquisition system collects arc-related parameters, and after analysis and judgment by the control system, automatically adjusts the relevant parameters of the welding torch to improve welding efficiency and weld quality.

[0004] Current welding path control methods usually rely on simple preset paths or single feedback mechanisms, and are poorly combined with the changes in real-time welding data and environmental conditions. This makes it difficult to timely identify and correct welding quality problems caused by position deviations, improper adjustment of welding parameters, or external interference during the welding process. To solve these problems, how to combine image acquisition, thermal data analysis, and welding path control to optimize the welding process in real time has become an important direction for the development of welding technology. Therefore, the present invention proposes a welding method and system based on displacement control. Summary of the Invention

[0005] The purpose of the present invention is to provide a welding method and system based on displacement control to solve the problems mentioned in the above background technique.

[0006] The present invention can be realized through the following technical solutions: A welding system based on displacement control includes: a welding module, a displacement driving module, an acquisition module, and a calculation module; The acquisition module includes an image unit and a thermal data unit; Before welding operations, the image unit collects the position data of the object to be welded and uploads it to the calculation module; The calculation module is based on the position data of the object to be welded, and is provided with a corresponding preset welding path and a simulation layer. The calculation module sets a plurality of detection points on the preset welding path; Before the formal welding operation, the displacement driving module drives the welding module to move once based on the preset welding path, and generates preset displacement data during the movement. The displacement driving module uploads the preset movement data to the calculation module as subsequent standard data; And the calculation module divides the preset movement data into multiple sub-data based on each detection point for convenient subsequent comparison; After entering the welding operation, the displacement driving module drives the welding module to perform a secondary movement along the preset welding path. While moving, the welding module performs the welding operation. At the same time, the displacement driving module transmits the actual movement data generated during the secondary movement to the calculation module as calibration data; When the displacement driving module is working, the calculation module compares the preset displacement data with the actual movement data. If the deviation between the two is within the preset displacement deviation threshold, the calculation module generates a virtual welding path in the corresponding area of the simulation layer based on the coincidence range of the actual movement data and the preset displacement data, with the preset displacement data as the basis; The virtual welding path is the ideal welding molten pool part of the welded object generated by the calculation module in the simulation layer based on the welding port of the welding module and in combination with the coincidence range of the preset displacement data and the actual movement data; After the calculation module identifies that the displacement driving module moves to the detection point on the preset welding path, the welding module stops welding, and the image unit and the thermal data unit are started; The image unit collects real-time working image data and uploads it to the calculation module. The working image data includes the position of the object to be welded and the welding molten pool part on its surface; The thermal data unit collects the infrared image of the welding molten pool part of the object to be welded as temperature data and uploads it to the calculation module; By setting a plurality of detection points, a working gap for the welding module can be reserved to avoid the influence of the light generated during welding by the welding module on the data collection of the acquisition module; After receiving the working image data, the calculation module analyzes it to obtain the calibration layer of the actual position of the object to be welded and the actual welding path on the surface of the welded object; The calculation module aligns the calibration layer with the simulation layer, and calculates the deviation degree between the actual welding path and the virtual welding path and the welding quality of the welding part in the actual welding path; Finally, the calculation module detects whether the temperature data, the deviation degree between the actual welding path and the virtual welding path, and the welding quality meet the preset quality requirements; When all items meet the corresponding quality requirements, the calculation module sends a continue working instruction to the displacement driving module and the welding module. While the displacement driving module drives the welding module to move along the preset welding path to the next detection point, the welding module continues to perform the welding operation; When any item does not meet the corresponding quality requirements, the calculation module sends a stop working instruction to the displacement driving module and the welding module, and the calculation module issues a warning message; In this embodiment, the deviation degree between the actual welding path and the virtual welding path is the deviation between the ideal welding pool part and the actual welding path, and its quality requirement is: by comparing the path deviation with the preset path deviation threshold, when the path deviation is less than the path deviation threshold, it meets the quality requirements, otherwise it does not; And ; is the actual welding path at time t; is the virtual welding path at time t; The welding quality meets the preset quality requirements as follows: the calculation module detects the welding pool part in the working image data, and by means of image recognition, detects the integrity of the surface of the welding pool part, such as whether there are cracks, pores, welding defects, etc. on the surface of the welding pool part; At the same time, the calculation module uses the edge detection method to detect whether there are obvious ripples, depressions or irregular shapes on the surface of the welding pool part. If so, it indicates that there may be path deviation or improper welding parameters, and the determination of its welding quality does not meet the quality requirements.

[0007] A further technical improvement of the present invention is that: before a movement, the acquisition module detects the initial position of the welding module to identify whether the welding module is located at the starting point of the preset welding path; When the welding module is not located at the starting point of the preset welding path, the acquisition module uploads the initial position of the welding module to the calculation module, and the calculation module generates a corresponding adjustment path by calculating the distance between the initial position of the welding module and the initial welding part of the object to be welded; When the subsequent displacement driving module drives the welding module to move along the adjustment path, the calculation module real-time monitors the position of the welding module through the acquisition module until the welding module moves to the starting point of the preset welding path of the object to be welded; Finally, the calculation module resets the digit data of the displacement driving module to facilitate subsequent extraction of the preset displacement data.

[0008] A further technical improvement of the present invention is that: the temperature data of the welding pool part includes temperature value, temperature gradient and temperature range, and the method for the calculation module to determine whether the temperature data meets the corresponding quality requirements includes: A1. After receiving the infrared image, the calculation module performs image preprocessing on it, including: Denoising and enhancement: The median filtering method is used to denoise the collected infrared image to eliminate interference caused by environmental factors (such as smoke, welding light, etc.); Image contrast adjustment: Improve the image contrast to ensure obvious temperature differences, facilitating the subsequent extraction of the welding molten pool area; A2. The calculation module uses threshold segmentation to segment the high-temperature area from the infrared image as the welding molten pool area; A3. Based on the boundary of the welding molten pool area, the calculation module uses dividing lines to divide the welding molten pool area into multiple judgment areas along the actual welding path; A4. For each judgment area, the calculation module extracts the corresponding temperature value from the infrared image, that is, converts the brightness value in the infrared image with the calibration data of the infrared sensor used by the thermal data unit to calculate the corresponding temperature value; The calculation module detects whether the temperature values of each judgment area are within the preset temperature threshold range; If the temperature value of each judgment area is within this range, the temperature value meets the quality requirements; If the temperature value of any one judgment area exceeds the temperature threshold range, it indicates that there is a problem in the welding process, which may lead to welding defects; A5. The calculation module uses the temperature values of adjacent judgment areas to calculate the temperature gradient of the welding molten pool part, that is, the temperature change rate of different areas of the welding molten pool part. The specific steps are as follows: The calculation module takes the judgment area closest to the welding module in the welding molten pool part between two detection points (or between a detection point and the starting point or ending point of the preset welding path) in a single welding process as the reference area, calculates the temperature difference between the remaining judgment areas and the reference area, and divides the temperature difference by the distance between the corresponding judgment area and the reference area to obtain the temperature gradient; When the calculation module moves to the detection point of the preset welding path each time, it compares the temperature gradient of the corresponding part in the welding molten pool part with the preset gradient range; When the temperature gradient does not exceed the preset gradient range, it is determined that the temperature gradient meets the quality requirements; When the temperature gradient exceeds the preset gradient range, it indicates that the temperature distribution is uneven and the welding quality may be affected; A6. The calculation module connects the center points of each dividing line as the overall center line of the welding molten pool area; And the calculation module calculates the distances from the two side boundaries of each judgment area to the center line, and then the calculation module calculates the fluctuation of the distances from the two side boundaries of the judgment area to the center line; If the distance fluctuation is not greater than the preset fluctuation threshold range, it indicates that the symmetry of the welding molten pool part is good and the welding quality is stable, then it is determined that the temperature range meets the quality requirements; If the distance fluctuation is greater than the preset fluctuation threshold range, it may indicate that the welding process is unstable or there is a problem with the welding path, then it is determined that the temperature range does not meet the quality requirements; A7. The calculation module detects the temperature value, temperature gradient and temperature range of the welding molten pool part. When any one does not meet the quality requirements, the calculation module determines that the temperature data does not meet the quality requirements.

[0009] A further technical improvement of the present invention is that: the calculation module divides the preset movement data into multiple sub-data based on each detection point; When the calculation module generates the sub-data of the preset displacement data, it binds the sub-data to the first time axis, and the first time axis includes multiple first time points , that is, in the ideal state, the data of each time point of the sub-data matches the corresponding first time point ; When the calculation module collects the actual displacement data, it generates the second time points corresponding to each data of the actual displacement data ; The calculation module calculates the first time points corresponding to the same data in the sub-data and the actual displacement data and the second time points , and calculates the data response delay , .

[0010] A further technical improvement of the present invention is that: the calculation module is based on whether the area of the welding molten pool part between adjacent detection points meets the quality requirements, and the processing method for the response delay includes: When the area of the welding molten pool part meets the quality requirements, the calculation module realigns the actual displacement data and the preset displacement data at the starting detection point, that is, when the welding module moves to the next detection point, the two are rematched at the corresponding path starting point with the same data as the anchor point, ; When the area of the welding molten pool part does not meet the quality requirements, the calculation module exports and records the response delay for later inspection.

[0011] A further technical improvement of the present invention is that: the acquisition module includes a processing environment monitoring unit, and the processing environment monitoring unit is used to collect the noise data and vibration data in the processing environment according to the second time axis respectively when the welding module performs welding operations and in the format of; is the noise data at the time point , and is the vibration data at the time point ; The calculation module synchronizes the actual displacement data with the noise data and the vibration data on the second time axis to ensure that the data at each time point corresponds; And the calculation module will correlate the noise data, the vibration data with the actual displacement data: ; is the actual displacement data at the time point ; If the noise data or the vibration data at a certain time exceeds the preset noise threshold or vibration threshold, record the time point as the detection time point.

[0012] A further technical improvement of the present invention is that: when the welding module moves to the detection point and temporarily stops welding, the calculation module obtains the actual displacement data at the detection time point through the acquisition module, and compares the part corresponding to the detection time point in the virtual welding path with the part corresponding to the detection time point in the actual welding path; If the deviation degree between the actual welding path and the virtual welding path does not meet the quality requirements, and the position where the quality requirements are not met is the same as the part corresponding to the detection time point of the two, the calculation module determines that the welding operation may be affected by environmental factors, and further adjusts the welding parameters (such as welding current, welding speed, etc.) to reduce the influence of environmental interference on the path, and records the actual values of the noise data and the vibration data at the detection time point as the warning values of the subsequent noise data and vibration data.

[0013] A further technical improvement of the present invention is that: the calculation module transmits the warning values of the noise data and the vibration data to the processing environment monitoring unit; The processing environment monitoring unit compares the noise data and the vibration data collected in real time with the warning values in real time. When any one of the real-time noise data and the real-time vibration data exceeds the corresponding warning value, the processing environment monitoring unit sends a warning signal to the calculation module; The calculation module controls the welding module and the displacement driving module to stop working based on the warning signal, and detects the welding molten pool part of the object to be welded through the acquisition module, and calculates whether the temperature data, the deviation degree between the actual welding path and the virtual welding path, and the welding quality meet the preset quality requirements; When the calculation module determines that all items meet the quality requirements, the calculation module decreases the warning values corresponding to the noise data and the vibration data.

[0014] The present invention also discloses a welding method based on displacement control, which includes the following steps: S1. Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module; Based on the position data, the calculation module generates a preset welding path and a simulation layer, and the calculation module sets a plurality of detection points along the preset welding path; S2. The displacement driving module drives the welding module to move once along the preset welding path, and generates preset displacement data and uploads it to the calculation module as standard data; During the welding operation, the displacement driving module drives the welding module to move twice, and the calculation module collects the actual welding path data in real time as calibration data; The calculation module compares the preset displacement data with the actual path data. If the deviation between the actual movement data and the preset displacement data is within the preset displacement deviation threshold, the calculation module generates a corresponding virtual welding path in the simulation layer based on the coincidence range of the actual movement data with the preset displacement data; S4. After the displacement driving module reaches the detection point, the image unit collects real-time working image data and uploads it to the calculation module; The thermal data unit collects the infrared image of the welding molten pool part of the object to be welded as temperature data and uploads it to the calculation module; S5. After receiving the working image data, the calculation module analyzes it to obtain the calibration layer of the actual position of the object to be welded and the actual welding path on the surface of the welded object; The calculation module aligns the calibration layer with the simulation layer, and calculates the deviation degree between the actual welding path and the virtual welding path and the welding quality of the welding part in the actual welding path; Finally, the calculation module detects whether the temperature data, the deviation degree between the actual welding path and the virtual welding path, and the welding quality meet the preset quality requirements; When all items meet the corresponding quality requirements, the displacement driving module drives the welding module to move to the next detection point along the preset welding path, and at the same time the welding module continues to perform the welding operation; When any item does not meet the corresponding quality requirements, the calculation module sends a stop work instruction to the displacement driving module and the welding module, and the calculation module issues a warning message.

[0015] Compared with the prior art, the present invention has the following beneficial effects: By collecting image and temperature data in real time, the calculation module of the present invention can accurately analyze the deviation between the welding path and the actual movement data, and timely adjust the movement path of the welding module, so as to achieve high-precision welding control. This system can effectively reduce welding defects caused by path deviation and improve welding quality; Moreover, the present invention can perform integrity detection on the welding molten pool part through image recognition technology, promptly detect and correct welding defects (such as cracks, pores, surface ripples, etc.). By analyzing the surface morphology of the welding molten pool, the calculation module can determine whether the welding quality meets the preset standards, ensuring that every step in the welding process reaches high standards. And through automated path adjustment and real-time welding quality monitoring, the system reduces the need for manual intervention and inspection, shortens the production cycle, and significantly improves production efficiency; On the other hand, when the quality requirements during the welding process do not meet the preset standards, the system will automatically issue a warning and avoid production interruption or equipment damage by stopping the operation or adjusting the working path, which can effectively reduce the potential risks brought by improper operation or equipment failure. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For the convenience of those skilled in the art to understand, the present invention will be further described below in conjunction with the accompanying drawings.

[0017] Figure 1 is the system block diagram of the present invention; Figure 2 is the logic schematic diagram of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] To further elaborate on the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following will, in conjunction with the accompanying drawings and preferred embodiments, detail the specific embodiments, structures, features, and effects of the present invention as follows.

[0019] Embodiment 1 Please refer to Figure 1-2 As shown, the present invention provides a welding system based on displacement control, including: a welding module, a displacement driving module, a collection module, and a calculation module; The collection module includes an image unit and a thermal data unit; Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module; Based on the position data of the object to be welded, the calculation module is provided with a corresponding preset welding path and a simulation layer, and the calculation module sets multiple detection points on the preset welding path; Before each movement, the collection module detects the initial position of the welding module to identify whether the welding module is located at the starting point of the preset welding path; When the welding module is not located at the starting point of the preset welding path, the collection module uploads the initial position of the welding module to the calculation module, and the calculation module generates a corresponding adjustment path by calculating the distance between the initial position of the welding module and the initial welding part of the object to be welded; When the subsequent displacement driving module drives the welding module to move along the adjustment path, the calculation module monitors the position of the welding module in real time through the acquisition module until the welding module moves to the starting point of the preset welding path of the object to be welded; Finally, the calculation module resets the digit data of the displacement driving module to facilitate subsequent extraction of the preset displacement data; Before the formal welding operation, the displacement driving module drives the welding module to make a move based on the preset welding path, generates the preset displacement data during the movement, and the displacement driving module uploads the preset movement data to the calculation module as the subsequent standard data; And the calculation module divides the preset movement data into multiple sub-data based on each detection point for subsequent comparison; After entering the welding operation, the displacement driving module drives the welding module to make a second move along the preset welding path, and while moving, the welding module performs the welding operation. At the same time, the displacement driving module transmits the actual movement data generated during the second move to the calculation module as calibration data; Both the preset displacement data and the actual movement data include the following data generated during the movement: Welding speed and direction; Control parameters: such as current, voltage, welding arc length, etc.; When the displacement driving module is working, the calculation module compares the preset displacement data with the actual movement data. If the deviation between the two is within the preset displacement deviation threshold, the calculation module generates a virtual welding path in the corresponding area of the simulation layer based on the coincidence range of the actual movement data and the preset displacement data with the preset displacement data as the basis; After the calculation module identifies that the displacement driving module moves to the detection point on the preset welding path, the welding module stops welding, and the image unit and the thermal data unit are started; The image unit collects real-time working image data and uploads it to the calculation module. The working image data includes the position of the object to be welded and the welding molten pool part on its surface; The thermal data unit collects the infrared image of the welding molten pool part of the object to be welded as temperature data and uploads it to the calculation module; By setting multiple detection points, the working gap of the welding module can be reserved to avoid the influence of the light generated during welding by the welding module on the data acquisition of the acquisition module; After receiving the working image data, the calculation module analyzes it to obtain the calibration layer of the actual position of the object to be welded and the actual welding path on the surface of the welded object. The actual welding path is the welding molten pool part between adjacent detection points; The calculation module aligns the calibration layer with the simulation layer and calculates the deviation degree between the actual welding path and the virtual welding path and the welding quality of the welded part in the actual welding path; Finally, the calculation module detects the temperature data, the deviation between the actual welding path and the virtual welding path, and whether the welding quality meets the preset quality requirements. When all items meet the corresponding quality requirements, the calculation module sends a continue working instruction to the displacement driving module and the welding module. While the displacement driving module drives the welding module to move along the preset welding path to the next detection point, the welding module continues to perform the welding operation. When any item does not meet the corresponding quality requirements, the calculation module sends a stop working instruction to the displacement driving module and the welding module, and the calculation module issues a warning message. The temperature data of the welding molten pool part includes temperature value, temperature gradient and temperature range. The method for the calculation module to detect whether the temperature data meets the corresponding quality requirements includes: A1. After receiving the infrared image, the calculation module performs image preprocessing on it, including: Denoising and enhancement: The median filtering method is used to denoise the collected infrared image to eliminate the interference caused by environmental factors (such as smoke, welding light, etc.). Image contrast adjustment: Improve the image contrast to ensure obvious temperature differences and facilitate the subsequent extraction of the welding molten pool part. A2. The calculation module uses threshold segmentation to segment the high-temperature area from the infrared image as the welding molten pool part. In actual production, the welding molten pool part usually appears as a red or white high-temperature area. And the calculation module uses an edge detection algorithm to determine the boundary of the welding molten pool part. In this embodiment, the calculation module uses the Canny algorithm to extract the edge line of the welding molten pool part. A3. Based on the boundary of the welding molten pool part, the calculation module uses a dividing line to divide the welding molten pool part along the actual welding path into multiple determination parts. A4. For each determination part, the calculation module extracts the corresponding temperature value from the infrared image, that is, converts the brightness value in the infrared image with the calibration data of the infrared sensor used by the thermal data unit to calculate the corresponding temperature value. The calculation module detects whether the temperature value of each determination part is within the preset temperature threshold range. If the temperature value of each determination part is within this range, the temperature value meets the quality requirements. If the temperature value of any one determination part exceeds the temperature threshold range, it indicates that there is a problem in the welding process, which may lead to welding defects. A5. The calculation module uses the temperature values of adjacent determination parts to calculate the temperature gradient of the welding molten pool part, that is, the temperature change rate of different regions of the welding molten pool part. The specific steps are as follows: The calculation module takes the part of the welding molten pool closest to the determination part of the welding module between two detection points (or between a detection point and the starting or ending point of a preset welding path) in a single welding process as the reference part, calculates the temperature difference between the remaining determination parts and the reference part, and divides the temperature difference by the distance between the corresponding determination part and the reference part to obtain the temperature gradient; When the calculation module moves to the detection point of the preset welding path each time, it compares the temperature gradient of the corresponding part in the welding molten pool part with the preset gradient range; When the temperature gradient does not exceed the preset gradient range, it is determined that the temperature gradient meets the quality requirements; When the temperature gradient exceeds the preset gradient range, it indicates that the temperature distribution is uneven and the welding quality may be affected; If the materials of the objects to be welded are the same or similar, directly apply the above temperature gradient threshold for judgment; If the materials are different, consider the heat conduction performance and temperature change range of different materials, and adjust the temperature gradient threshold to avoid misjudgment caused by material differences; A6. The calculation module connects the center points of each dividing line as the overall center line of the welding molten pool part; And the calculation module calculates the distances from the two side boundaries of each determination part to the center line, and then the calculation module calculates the distance fluctuation of the two side boundaries of the determination part to the center line; In this embodiment, the standard deviation method is used to calculate the distance fluctuation, specifically: ; In the formula, and are the distances from the center line to the left and right in the i-th determination part respectively; and are the average values of the distances from the center line to the left and right in the i-th determination part respectively; n is the number of determination parts; If the distance fluctuation is not greater than the preset fluctuation threshold range, it indicates that the symmetry of the welding molten pool part is good and the welding quality is stable, then it is determined that the temperature range meets the quality requirements; If the distance fluctuation is greater than the preset fluctuation threshold range, it may indicate that the welding process is unstable or there is a problem with the welding path, then it is determined that the temperature range does not meet the quality requirements; In this embodiment, the fluctuation threshold range is set based on the welding port of the welding module; A7. The calculation module detects the temperature value, temperature gradient and temperature range of the welding molten pool part. When any one does not meet the quality requirements, the calculation module determines that the temperature data does not meet the quality requirements; In this embodiment, the deviation degree between the actual welding path and the virtual welding path is the deviation between the ideal welding pool part and the actual welding path, and its quality requirement is: by taking the path deviation and comparing it with a preset path deviation threshold, when the path deviation is less than the path deviation threshold, it meets the quality requirements; otherwise, it does not. And ; is the actual welding path at time t; is the virtual welding path at time t; The welding quality meeting the preset quality requirements means that the calculation module detects the welding pool part in the working image data. By means of image recognition, the integrity of the surface of the welding pool part is detected, such as whether there are cracks, pores, welding defects, etc. on the surface of the welding pool part; At the same time, the calculation module uses the edge detection method to check whether there are obvious ripples, depressions or irregular shapes on the surface of the welding pool part. If so, it indicates that there may be path deviation or improper welding parameters, and the determination of its welding quality does not meet the quality requirements.

[0020] Embodiment 2 A welding system based on displacement control includes: a welding module, a displacement driving module, a collection module, and a calculation module; The collection module includes an image unit and a thermal data unit; Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module; Based on the position data of the object to be welded, the calculation module sets a corresponding preset welding path and a simulation layer, and the calculation module sets multiple detection points on the preset welding path; Before the formal welding operation, the displacement driving module drives the welding module to make a first movement based on the preset welding path and generates preset displacement data during the movement. And the displacement driving module uploads the preset movement data to the calculation module as subsequent standard data; And the calculation module divides the preset movement data into multiple sub-data based on each detection point for convenient subsequent comparison; After entering the welding operation, the displacement driving module drives the welding module to make a second movement along the preset welding path. And during the movement, the welding module performs the welding operation. At the same time, the displacement driving module transmits the actual movement data generated during the second movement to the calculation module as calibration data; When the displacement driving module is working, the calculation module compares the preset displacement data with the actual movement data. If the deviation between the two is within the preset displacement deviation threshold, the calculation module generates a virtual welding path in the corresponding area of the simulation layer based on the coincidence range of the actual movement data and the preset displacement data, with the preset displacement data as the basis. After the calculation module identifies that the displacement driving module has moved to the detection point on the preset welding path, the welding module stops welding, and the image unit and the thermal data unit are started. The image unit collects real-time working image data and uploads it to the calculation module. The working image data includes the position of the object to be welded and the welding molten pool part on its surface. The thermal data unit collects the infrared image of the welding molten pool part of the object to be welded as temperature data and uploads it to the calculation module. By setting multiple detection points, a working gap for the welding module can be reserved to avoid the influence of the light generated during welding by the welding module on the data collection of the acquisition module. After receiving the working image data, the calculation module analyzes it to obtain the calibration layer of the actual position of the object to be welded and the actual welding path on the surface of the welded object. The calculation module aligns the calibration layer with the simulation layer and calculates the deviation degree between the actual welding path and the virtual welding path and the welding quality of the welding parts in the actual welding path. Finally, the calculation module detects whether the temperature data, the deviation degree between the actual welding path and the virtual welding path, and the welding quality meet the preset quality requirements. When all items meet the corresponding quality requirements, the calculation module sends a continue working instruction to the displacement driving module and the welding module. While the displacement driving module drives the welding module to move along the preset welding path to the next detection point, the welding module continues to perform the welding operation. When any item does not meet the corresponding quality requirements, the calculation module sends a stop working instruction to the displacement driving module and the welding module, and the calculation module issues a warning message.

[0021] When the calculation module generates sub-data of the preset displacement data, it binds the sub-data to the first time axis, and the first time axis includes multiple first time points , that is, in the ideal state, the data of each time point of the sub-data matches the corresponding first time point ; When the calculation module collects the actual displacement data, it generates the second time points corresponding to each data of the actual displacement data ; The calculation module calculates the first time points corresponding to the same data in the sub-data and the actual displacement data and the second time points , and calculates the data response delay , .

[0022] Within the same sub - data of the preset displacement data, there are multiple response delays When there are multiple response delays, take the lowest value; Based on whether the area of the welding molten pool part between adjacent detection points meets the quality requirements, the calculation module processes the response delay The processing methods include: When the area of the welding molten pool part meets the quality requirements, the calculation module realigns the actual displacement data and the preset displacement data at the starting detection point. That is, when the welding module moves to the next detection point, the two are rematched with the same data as the anchor point at the corresponding path starting point. ; When the area of the welding molten pool part does not meet the quality requirements, the calculation module exports and records the response delay for subsequent inspection backup.

[0023] Embodiment 3 A welding system based on displacement control includes: a welding module, a displacement driving module, a collection module, and a calculation module; The collection module includes an image unit and a thermal data unit; Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module; Based on the position data of the object to be welded, the calculation module sets a corresponding preset welding path and a simulation layer, and the calculation module sets multiple detection points on the preset welding path; Before the formal welding operation, the displacement driving module drives the welding module to move once along the preset welding path and generates the preset displacement data during the movement. And the displacement driving module uploads the preset movement data to the calculation module as the subsequent standard data; And the calculation module divides the preset movement data into multiple sub - data based on each detection point for subsequent comparison; After entering the welding operation, the displacement driving module drives the welding module to move twice along the preset welding path. And during the movement, the welding module performs welding operations. At the same time, the displacement driving module transmits the actual movement data generated during the second movement to the calculation module as calibration data; When the displacement driving module is working, the calculation module compares the preset displacement data with the actual movement data. If the deviation between the two is within the preset displacement deviation threshold, the calculation module generates a virtual welding path in the corresponding area of the simulation layer based on the coincidence range of the actual movement data and the preset displacement data, with the preset displacement data as the basis; After the computing module recognizes that the displacement driving module has moved to the detection point on the preset welding path, the welding module stops welding, and the image unit and the thermal data unit are activated; The image unit collects real-time working image data and uploads it to the computing module. The working image data includes the position of the object to be welded and the welded molten pool part on its surface; The thermal data unit collects the infrared image of the welded molten pool part of the object to be welded as temperature data and uploads it to the computing module; By setting multiple detection points, the working gap of the welding module can be reserved to avoid the influence of the light generated during welding by the welding module on the data collection of the acquisition module; After receiving the working image data, the computing module analyzes it to obtain the calibration layer of the actual position of the object to be welded and the actual welding path on the surface of the welded object; The computing module aligns the calibration layer with the simulation layer and calculates the deviation degree between the actual welding path and the virtual welding path and the welding quality of the welded parts in the actual welding path; Finally, the computing module detects whether the temperature data, the deviation degree between the actual welding path and the virtual welding path, and the welding quality meet the preset quality requirements; When all items meet the corresponding quality requirements, the computing module sends a continue working instruction to the displacement driving module and the welding module. While the displacement driving module drives the welding module to move along the preset welding path to the next detection point, the welding module continues to perform the welding operation; When any item does not meet the corresponding quality requirements, the computing module sends a stop working instruction to the displacement driving module and the welding module, and the computing module issues a warning message.

[0024] The acquisition module includes a processing environment monitoring unit. The processing environment monitoring unit is used to, when the welding module performs the welding operation, collect the noise data and vibration data in the processing environment according to the second time axis respectively in and format; is the noise data at the time point and is the vibration data at the time point ; The computing module synchronizes the actual displacement data with the noise data and vibration data on the second time axis to ensure that the data at each time point corresponds; And the computing module will correlate the noise data, vibration data with the actual displacement data: ; is the actual displacement data at the time point ; If at a certain time If the noise data or vibration data exceeds the preset noise threshold or vibration threshold, record this time point as the detection time point.

[0025] When the welding module moves to the detection point and temporarily stops welding, the calculation module obtains the actual displacement data at the detection time point through the acquisition module, and compares the part corresponding to the detection time point in the virtual welding path with the part corresponding to the detection time point in the actual welding path; If the deviation degree between the actual welding path and the virtual welding path does not meet the quality requirements, and the position where the quality requirements are not met is the same as the part corresponding to the detection time point of the two, the calculation module determines that the welding operation may be affected by environmental factors, and further adjusts the welding parameters (such as welding current, welding speed, etc.) to reduce the influence of environmental interference on the path, and records the actual values of the noise data and vibration data at the detection time point as the warning values of the subsequent noise data and vibration data.

[0026] The calculation module transmits the warning values of the noise data and vibration data to the processing environment monitoring unit; The processing environment monitoring unit compares the real-time collected noise data and vibration data with the warning values in real time. When any one of the real-time noise data and real-time vibration data exceeds the corresponding warning value, the processing environment monitoring unit sends a warning signal to the calculation module; Based on the warning signal, the calculation module controls the welding module and the displacement drive module to stop working, and detects the welding molten pool part of the workpiece to be welded through the acquisition module, calculates the temperature data, the deviation degree between the actual welding path and the virtual welding path, and whether the welding quality meets the preset quality requirements; When the calculation module determines that all items meet the quality requirements, the calculation module decreases the warning values corresponding to the noise data and vibration data.

[0027] Each threshold mentioned in the text is obtained through debugging and verification by experiments on welded parts of different materials and welding equipment of different models. These experimental data provide the accurate parameters required in the actual welding process for the system, and ensure the adaptability and stability of the system under various working conditions.

[0028] The above is only a preferred embodiment of the present invention, and does not impose any form of limitation on the present invention. Although the present invention has been disclosed above with a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to equivalent embodiments by using the disclosed technical content within the scope of the technical solution of the present invention. However, as long as it does not depart from the content of the technical solution of the present invention, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A welding system based on displacement control, comprising: The welding module, displacement drive module, acquisition module and calculation module are characterized by: The acquisition module acquires real-time working image data through the image unit and acquires temperature data of the welding pool through the thermal data unit; The calculation module sets a preset welding path and a simulation layer of the object to be welded, and sets a plurality of detection points on the preset welding path; The displacement driving module drives the welding module to move along the preset welding path to generate actual movement data; The calculation module compares the preset displacement data with the actual movement data. If the deviation between the two is within the preset displacement deviation threshold, a virtual welding path is generated in the corresponding area of ​​the simulation layer based on the preset displacement data based on the overlap range of the two. Each time the displacement driving module moves to a set of detection points, the calculation module obtains the calibration layer of the actual position of the welding object and the actual welding path of the surface of the welding object through the corresponding working image data; The calculation module aligns the calibration layer with the simulation layer, calculates the deviation between the actual welding path and the virtual welding path and the welding quality of the actual welding path, and combines the temperature data to determine whether it meets the preset quality requirements.

2. A welding system based on displacement control according to claim 1, characterized in that: When the deviation, welding quality and temperature data all meet the corresponding quality requirements, the calculation module sends a continue work instruction to the displacement drive module and the welding module. The displacement drive module drives the welding module to move to the next detection point along the preset welding path, while the welding module continues to perform the welding operation; When any of the difference, welding quality or temperature data does not meet the corresponding quality requirements, the calculation module sends a stop work instruction to the drive module and the welding module, and the calculation module issues a warning message.

3. A welding system based on displacement control according to claim 1, characterized in that: The temperature data of the welding pool includes temperature value, temperature gradient and temperature range. The method of calculating whether the temperature data meets the corresponding quality requirements includes: A1. After receiving the infrared image, the computing module performs image preprocessing on it; A2. The calculation module uses threshold segmentation to segment the high-temperature area from the infrared image as the welding pool area, and determines the boundary of the welding pool area; A3. The calculation module divides the welding pool into multiple determination areas along the actual welding path using a separation line based on the boundary of the welding pool area; A4, the calculation module extracts the corresponding temperature value from the infrared image for each determination part; The calculation module detects whether the temperature value of each determination part is within a preset temperature threshold range; If the temperature value of each determination part is within the range, the temperature value meets the quality requirements; If the temperature value of any judgment part exceeds the temperature threshold range, it does not meet the quality requirements; A5. The calculation module uses the temperature values ​​of adjacent determination positions to calculate the temperature gradient of the welding pool, including: The calculation module takes the determination position of the welding pool between two detection points in a single welding process that is closest to the welding module as the reference position, calculates the temperature difference between the remaining determination positions and the reference position, and divides the temperature difference by the distance between the corresponding determination position and the reference position, thereby obtaining the temperature gradient; And the calculation module compares the temperature gradient of the corresponding part of the welding pool part with the preset gradient range each time it moves to the detection point of the preset welding path; When the temperature gradient does not exceed the preset gradient range, it is determined that the temperature gradient meets the quality requirements; When the temperature gradient exceeds the preset gradient range, it is determined that the temperature gradient does not meet the quality requirements; A6. The calculation module connects the center points of each separation line as the overall middle line of the welding pool; And the calculation module calculates the distance from the boundary of both sides of each determination part to the middle line, and then the calculation module calculates the fluctuation of the distance from the boundary of both sides of the determination part to the middle line; If the distance fluctuation is greater than the preset fluctuation threshold range, it is determined that the temperature range does not meet the quality requirements; If the distance fluctuation is not greater than the preset fluctuation threshold range, it is determined that the temperature range meets the quality requirements; A7. The calculation module detects the temperature value, temperature gradient and temperature range of the welding pool. When any one of them does not meet the quality requirements, the calculation module determines that the temperature data does not meet the quality requirements.

4. A welding system based on displacement control according to claim 1, characterized in that: The calculation module divides the preset movement data into multiple segments of sub-data based on each detection point; When generating sub-data of the preset displacement data, the calculation module binds the sub-data to the first time axis, and the first time axis includes a plurality of first time points. ; When the calculation module collects the actual displacement data, it generates the second time point corresponding to each data of the actual displacement data. ; The calculation module calculates the first time point corresponding to the same data in the sub-data and the actual displacement data and the second time point , calculate data response delay , .

5. A welding system based on displacement control according to claim 4, characterized in that: The calculation module calculates the response delay based on whether the welding pool area between adjacent detection points meets the quality requirements. The treatment methods include: When the welding pool area meets the quality requirements, the calculation module realigns the actual displacement data and the preset displacement data at the starting detection point; When the weld pool area does not meet the quality requirements, the calculation module will respond with a delay Export and record.

6. A welding system based on displacement control according to claim 1, characterized in that: The acquisition module includes a processing environment monitoring unit, which is used to monitor the noise data in the processing environment when the welding module performs welding operations. and vibration data Collecting according to a second time axis; The calculation module combines the actual displacement data with the noise data and vibration data Synchronize on the second timeline and associate as: ; For time point The actual displacement data at ; If a certain time If the noise data or vibration data exceeds the preset noise threshold or vibration threshold, the time point Recorded as the detection time point.

7. A welding system based on displacement control according to claim 6, characterized in that: When the welding module moves to the detection point, the calculation module obtains the actual displacement data at the detection time point through the acquisition module, and compares the molten pool welding part corresponding to the detection time point in the virtual welding path with the molten pool welding part corresponding to the detection time point in the actual welding path; If the deviation between the actual welding path and the virtual welding path does not meet the corresponding quality requirements, and the molten pool welding part where the deviation does not meet the quality requirements is the same as the part at the corresponding detection time points of the two, the calculation module uses the actual values ​​of the noise data and the vibration data at the detection time points as the warning values ​​of the noise data and the vibration data.

8. A welding system based on displacement control according to claim 7, characterized in that: The calculation module transmits the warning values ​​of the noise data and the vibration data to the processing environment monitoring unit; The processing environment monitoring unit compares the real-time collected noise data and vibration data with the warning value in real time. When any one of the real-time noise data and the real-time vibration data exceeds the corresponding warning value, the processing environment monitoring unit sends a warning signal to the calculation module; The calculation module controls the welding module and the displacement driving module to stop working based on the warning signal, and calculates the temperature data, the deviation and whether the welding quality meets the preset quality requirements; When the calculation module determines that all items meet the quality requirements, the calculation module lowers the warning values ​​corresponding to the noise data and vibration data.

9. A welding method based on displacement control, characterized in that: The method uses a welding system according to any one of claims 1 to 8, comprising the following steps: S1. Before welding, the image unit collects the position data of the object to be welded and uploads it to the calculation module; The calculation module generates a preset welding path and a simulation layer based on the position data, and the calculation module sets a plurality of detection points along the preset welding path; S2, the displacement driving module drives the welding module to move once along the preset welding path, and generates preset displacement data and uploads it to the calculation module as standard data; S3. During the welding operation, the displacement drive module drives the welding module to move twice, and the calculation module collects the actual welding path data in real time as calibration data; The calculation module compares the preset displacement data with the actual path data. If the deviation between the actual movement data and the preset displacement data is within the preset displacement deviation threshold, the calculation module generates a corresponding virtual welding path in the simulation layer based on the overlap range of the actual movement data to the preset displacement data. S4, after the displacement driving module reaches the detection point, the image unit collects real-time working image data and uploads it to the calculation module; The thermal data unit collects infrared images of the welding pool of the object to be welded and uploads them to the calculation module as temperature data; S5. After receiving the working image data, the computing module analyzes the data to obtain the calibration layer of the actual position of the object to be welded and the actual welding path of the surface of the welded object; The calculation module aligns the calibration layer with the simulation layer, and calculates the deviation between the actual welding path and the virtual welding path and the welding quality of the welding part in the actual welding path; Finally, the calculation module detects the temperature data, the deviation between the actual welding path and the virtual welding path, and whether the welding quality meets the preset quality requirements; When all items meet the corresponding quality requirements, the displacement drive module drives the welding module to move to the next inspection point along the preset welding path, and at the same time the welding module continues to perform the welding operation; When any item does not meet the corresponding quality requirements, the calculation module sends a stop-work instruction to the drive module and the welding module, and the calculation module issues a warning message.

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