A welding method and system based on displacement control

Abstract

The present invention discloses a welding method and system based on displacement control, which relates to the technical field of welding control systems and includes: before welding operations, a calculation module calculates the position data of the object to be welded based on an image unit, sets its corresponding preset welding path and simulation layer, and the calculation module sets multiple detection points on the preset welding path; before the formal welding operation, a displacement driving module drives a welding module to move once based on the preset welding path, generates preset displacement data during the movement, and uploads it to the calculation module. The present invention can accurately analyze the deviation between the welding path and the actual movement data through real-time collection of image and temperature data, and timely adjust the movement path of the welding module, thereby realizing high-precision welding control. This system can effectively reduce welding defects caused by path deviation and improve welding quality.

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 has been widely applied 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 precision 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. The patent includes an image acquisition system, an image processing system, a control system, a wire feeding mechanism, and a swing 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 interferences 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;

[0007] The acquisition module includes an image unit and a thermal data unit;

[0008] Before welding operations, the image unit collects the position data of the object to be welded and uploads it to the calculation module;

[0009] The calculation module is provided with a corresponding preset welding path and a simulation layer based on the position data of the object to be welded, and the calculation module sets a plurality of detection points on the preset welding path;

[0010] Before the formal welding operation, the displacement driving module drives the welding module to move once along the preset welding path, 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;

[0011] And the calculation module divides the preset movement data into multiple sub-data based on each detection point for convenient subsequent comparison;

[0012] After entering the welding operation, the displacement driving module drives the welding module to move twice 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 movement to the calculation module as calibration data;

[0013] 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;

[0014] 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;

[0015] After the calculation module recognizes 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;

[0016] 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;

[0017] 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;

[0018] 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;

[0019] 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;

[0020] 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 welded parts in the actual welding path;

[0021] Finally, the calculation module detects whether the temperature data, the deviation between the actual welding path and the virtual welding path, and the welding quality meet the preset quality requirements;

[0022] 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;

[0023] 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;

[0024] In this embodiment, the deviation between the actual welding path and the virtual welding path is the deviation between the ideal welding molten 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;

[0025] And ; is the actual welding path at time t; is the virtual welding path at time t;

[0026] The welding quality meeting the preset quality requirements is: the calculation module detects the welding molten pool part in the working image data, and through the method of image recognition, detects the integrity of the surface of the welding molten pool part, such as whether there are cracks, pores, welding defects, etc. on the surface of the welding molten pool part;

[0027] 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 molten pool part. If so, it indicates that there may be path deviation or improper welding parameters, and the judgment of its welding quality does not meet the quality requirements.

[0028] 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;

[0029] When the welding module is not at the starting point of the preset welding path, the acquisition module uploads the initial position of the welding module to the calculation module. The calculation module calculates the distance between the initial position of the welding module and the initial welding part of the object to be welded, and generates a corresponding adjustment path;

[0030] 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;

[0031] Finally, the calculation module resets the bit data of the displacement driving module to facilitate the subsequent extraction of preset displacement data.

[0032] A further technical improvement of the present invention is that the temperature data of the welding molten pool part includes temperature value, temperature gradient and temperature range. The method for the calculation module to determine whether the temperature data meets the corresponding quality requirements includes:

[0033] A1. After receiving the infrared image, the calculation module performs image preprocessing on it, including:

[0034] Denoising and enhancement: The median filtering method is used to denoise the acquired infrared image to eliminate the interference caused by environmental factors (such as smoke, welding light, etc.);

[0035] Image contrast adjustment: Enhance the image contrast to ensure obvious temperature differences, which is convenient for subsequent extraction of the welding molten pool part;

[0036] A2. The calculation module uses threshold segmentation to segment the high-temperature area from the infrared image as the welding molten pool part;

[0037] 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 into multiple judgment parts along the actual welding path;

[0038] A4. For each judgment 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;

[0039] The calculation module detects whether the temperature value of each judgment part is within the preset temperature threshold range;

[0040] If the temperature value of each judgment part is within this range, the temperature value meets the quality requirements;

[0041] If the temperature value of any one judgment part exceeds the temperature threshold range, it indicates that there is a problem in the welding process, which may lead to welding defects;

[0042] A5. The calculation module calculates the temperature gradient of the welded molten pool part using the temperature values of the adjacent determination parts, that is, the temperature change rate of different regions of the welded molten pool part. The specific steps are as follows:

[0043] The calculation module takes the determination part closest to the welding module in the welded 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 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;

[0044] 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 welded molten pool part with the preset gradient range;

[0045] When the temperature gradient does not exceed the preset gradient range, it is determined that the temperature gradient meets the quality requirements;

[0046] When the temperature gradient exceeds the preset gradient range, it indicates that the temperature distribution is uneven and the welding quality may be affected;

[0047] A6. The calculation module connects the center points of each dividing line as the overall center line of the welded molten pool part;

[0048] And the calculation module calculates the distances from the two side boundaries of each determination part to the center line, and then calculates the distance fluctuation of the two side boundaries of the determination part to the center line;

[0049] If the distance fluctuation is not greater than the preset fluctuation threshold range, it indicates that the symmetry of the welded molten pool part is good and the welding quality is stable, then it is determined that the temperature range meets the quality requirements;

[0050] 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;

[0051] A7. The calculation module detects the temperature value, temperature gradient and temperature range of the welded 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.

[0052] A further technical improvement of the present invention is that: based on each detection point, the calculation module divides the preset movement data into multiple sub-data;

[0053] 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 ;

[0054] When the calculation module collects the actual displacement data, it generates the second time point corresponding to each data of the actual displacement data ;

[0055] 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 , and calculates the data response delay , .

[0056] A further technical improvement of the present invention lies in that: 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 method includes:

[0057] 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 ;

[0058] 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

[0059] A further technical improvement of the present invention lies in 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;

[0060] is the noise data at time point , is the vibration data at time point ;

[0061] The calculation module synchronizes the actual displacement data with the noise data and vibration data on the second time axis to ensure that the data corresponding to each time point corresponds;

[0062] And the calculation module will associate the noise data, vibration data with the actual displacement data: ; is the actual displacement data at time point ;

[0063] If at a certain time If the noise data or vibration data exceeds the preset noise threshold or vibration threshold, record this time point and use it as the detection time point.

[0064] 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;

[0065] 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.

[0066] A further technical improvement of the present invention is that the calculation module transmits the warning values of the noise data and vibration data to the processing environment monitoring unit;

[0067] 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;

[0068] Based on the warning signal, the calculation module controls the welding module and the displacement driving module to stop working, 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;

[0069] 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.

[0070] The present invention also discloses a welding method based on displacement control, and this method includes the following steps:

[0071] S1. Before the welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module;

[0072] Based on the position data, the calculation module generates a preset welding path and a simulation layer, and the calculation module sets multiple detection points along the preset welding path;

[0073] S2. The displacement driving module drives the welding module to move once along a preset welding path, generates preset displacement data and uploads it to the calculation module as standard data;

[0074] S3. 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;

[0075] 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 and the preset displacement data;

[0076] 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;

[0077] The thermal data unit collects an infrared image of the welding molten pool part of the object to be welded as temperature data and uploads it to the calculation module;

[0078] 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;

[0079] 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;

[0080] 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;

[0081] When all items meet the corresponding quality requirements, the displacement driving module drives the welding module to move along the preset welding path to the next detection point, and at the same time the welding module continues to perform the welding operation;

[0082] 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.

[0083] Compared with the prior art, the present invention has the following beneficial effects:

[0084] 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, thereby realizing high-precision welding control. This system can effectively reduce welding defects caused by path deviation and improve welding quality;

[0085] Moreover, the present invention can perform integrity detection on the welding molten pool part through image recognition technology, timely discover 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 judge whether the welding quality meets the preset standards, ensure that every step in the welding process reaches high standards, and through automatic 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;

[0086] 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

[0087] For the convenience of those skilled in the art to understand, the present invention will be further described below with reference to the accompanying drawings.

[0088] Figure 1 is the system block diagram of the present invention;

[0089] Figure 2 is the logical schematic diagram of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0090] In order 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 their effects of the present invention.

[0091] Embodiment 1

[0092] 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;

[0093] The collection module includes an image unit and a thermal data unit;

[0094] Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module;

[0095] 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 a plurality of detection points on the preset welding path;

[0096] 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;

[0097] When the welding module is not at the starting point of the preset welding path, the acquisition module uploads the initial position of the welding module to the calculation module. The calculation module calculates the distance between the initial position of the welding module and the initial welding part of the object to be welded, and generates a corresponding adjustment path.

[0098] 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.

[0099] Finally, the calculation module resets the bit data of the displacement driving module to facilitate the subsequent extraction of preset displacement data.

[0100] Before the formal welding operation, the displacement driving module drives the welding module to make a move 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 the subsequent standard data.

[0101] And the calculation module divides the preset movement data into multiple sub-data based on each detection point for subsequent comparison.

[0102] 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.

[0103] Both the preset displacement data and the actual movement data include the following data generated during the movement:

[0104] Welding speed and direction;

[0105] Control parameters: such as current, voltage, welding arc length, etc.;

[0106] 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.

[0107] 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.

[0108] The image unit acquires 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.

[0109] The hot data unit collects the infrared image of the welding molten pool part of the object to be welded and uploads it as temperature data to the calculation module;

[0110] 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;

[0111] 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;

[0112] 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;

[0113] 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;

[0114] 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;

[0115] 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;

[0116] 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:

[0117] A1. After receiving the infrared image, the calculation module performs image preprocessing on it, including:

[0118] 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.);

[0119] Image contrast adjustment: Improve the image contrast to ensure obvious temperature differences and facilitate the subsequent extraction of the welding molten pool part;

[0120] 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;

[0121] And the calculation module uses an edge detection algorithm to determine the boundary of the welding molten pool area. In this embodiment, the calculation module uses the Canny algorithm to extract the edge line of the welding molten pool area;

[0122] 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 determination areas along the actual welding path;

[0123] A4. For each determination 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, and calculates the corresponding temperature value;

[0124] The calculation module detects whether the temperature value of each determination area is within the preset temperature threshold range;

[0125] If the temperature value of each determination area is within this range, the temperature value meets the quality requirements;

[0126] If the temperature value of any one determination area exceeds the temperature threshold range, it indicates that there is a problem in the welding process, which may lead to welding defects;

[0127] A5. The calculation module uses the temperature values of adjacent determination 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 area. The specific steps are as follows:

[0128] The calculation module takes the determination area closest to the welding module in the welding molten pool part between two detection points (or 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 determination areas and the reference area, and divides the temperature difference by the distance between the corresponding determination area and the reference area to obtain the temperature gradient;

[0129] 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;

[0130] When the temperature gradient does not exceed the preset gradient range, it is determined that the temperature gradient meets the quality requirements;

[0131] When the temperature gradient exceeds the preset gradient range, it indicates that the temperature distribution is uneven and the welding quality may be affected;

[0132] If the materials of the objects to be welded are the same or similar, directly apply the above temperature gradient threshold for judgment;

[0133] 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;

[0134] A6. The calculation module connects the center points of each dividing line as the overall center line of the welded molten pool part;

[0135] And the calculation module calculates the distances from the two side boundaries of each determination part to the center line, and then calculates the distance fluctuation of the two side boundaries of the determination part to the center line;

[0136] In this embodiment, the standard deviation method is used to calculate the distance fluctuation, specifically:

[0137] ; where, 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;

[0138] If the distance fluctuation is not greater than the preset fluctuation threshold range, it indicates that the symmetry of the welded molten pool part is good and the welding quality is stable, then it is determined that the temperature range meets the quality requirements;

[0139] 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;

[0140] In this embodiment, the fluctuation threshold range is set based on the welding port of the welding module;

[0141] A7. The calculation module detects the temperature value, temperature gradient and temperature range of the welded 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;

[0142] In this embodiment, the deviation degree between the actual welding path and the virtual welding path is the deviation between the ideal welded molten 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;

[0143] And ; is the actual welding path at time t; is the virtual welding path at time t;

[0144] The welding quality meeting the preset quality requirements is as follows: The calculation module detects the welding molten pool part in the working image data, and detects the integrity of the surface of the welding molten pool part through image recognition methods, such as whether there are cracks, pores, welding defects, etc. on the surface of the welding molten pool part;

[0145] At the same time, the calculation module uses edge detection methods to detect whether there are obvious ripples, depressions or irregular shapes on the surface of the welding molten 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.

[0146] Embodiment 2

[0147] A welding system based on displacement control includes: a welding module, a displacement driving module, a collection module, and a calculation module;

[0148] The collection module includes an image unit and a thermal data unit;

[0149] Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module;

[0150] 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;

[0151] Before the formal welding operation, the displacement driving module drives the welding module to move once along the preset welding path, 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;

[0152] And the calculation module divides the preset movement data into multiple sub-data based on each detection point for convenient subsequent comparison;

[0153] After entering the welding operation, the displacement driving module drives the welding module to move a second time along the preset welding path. At the same time of moving, the welding module performs welding operation, and 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;

[0154] 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;

[0155] After the calculation module recognizes 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;

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] 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.

[0164] 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 ;

[0165] When the calculation module collects the actual displacement data, it generates the second time points corresponding to each data of the actual displacement data ;

[0166] The calculation module calculates the first time points and the second time points corresponding to the same data in the sub-data and the actual displacement data, and calculates the data response delay , .

[0167] 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;

[0168] 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:

[0169] 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. ;

[0170] 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.

[0171] Embodiment 3

[0172] A welding system based on displacement control includes: a welding module, a displacement driving module, a collection module, and a calculation module;

[0173] The collection module includes an image unit and a thermal data unit;

[0174] Before welding operation, the image unit collects the position data of the object to be welded and uploads it to the calculation module;

[0175] Based on the position data of the object to be welded, the calculation module sets corresponding preset welding paths and simulation layers, and the calculation module sets multiple detection points on the preset welding paths;

[0176] Before the formal welding operation, the displacement driving module drives the welding module to move once along the preset welding path, 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;

[0177] And the calculation module divides the preset movement data into multiple sub - data based on each detection point for subsequent comparison;

[0178] After entering the welding operation, the displacement driving module drives the welding module to move twice along the preset welding path. At the same time, the welding module performs welding operations, and the displacement driving module transmits the actual movement data generated during the second movement to the calculation module as calibration data;

[0179] 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.

[0180] 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 activated.

[0181] 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 welded molten pool part on its surface.

[0182] 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 calculation module.

[0183] 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.

[0184] 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.

[0185] 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 parts in the actual welding path.

[0186] 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.

[0187] 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.

[0188] 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.

[0189] The acquisition module includes a processing environment monitoring unit. 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 in the and format during the welding operation of the welding module.

[0190] is the noise data at the time point , is the vibration data at the time point ;

[0191] The calculation module synchronizes the actual displacement data with the noise data and vibration data on the second time axis to ensure that the data corresponding to each time point corresponds;

[0192] And the calculation module will correlate the noise data, vibration data with the actual displacement data: ; is the actual displacement data at the time point ;

[0193] If the noise data or vibration data at a certain time exceeds the preset noise threshold or vibration threshold, record the time point as the detection time point.

[0194] 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;

[0195] 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.

[0196] The calculation module transmits the warning values of the noise data and vibration data to the processing environment monitoring unit;

[0197] 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;

[0198] 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, 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;

[0199] 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.

[0200] 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 precise parameters required in the actual welding process for the system and ensure the adaptability and stability of the system under various working conditions.

[0201] The above are only the preferred embodiments of the present invention, and do not impose any form of limitation on the present invention. Although the present invention has been disclosed above with the preferred embodiments, 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 above-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 according to 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: A welding module, a displacement driving module, a data acquisition module, and a calculation module, characterized in that: The data acquisition module acquires real-time working image data through an image unit and acquires temperature data of the welding molten pool part through a thermal data unit; The calculation module sets a preset welding path and a simulation layer for 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, based on the overlapping range of the two, a virtual welding path is generated in the corresponding area of the simulation layer based on the preset displacement data; When the displacement driving module moves to each set of detection points, the calculation module obtains a calibration layer of the actual position of the welded object and the actual welding path on the surface of the welded object through the corresponding working image data; The calculation module aligns the calibration layer with the simulation layer, calculates the deviation degree 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 judge whether it meets the preset quality requirements; The acquisition module includes a processing environment monitoring unit, which is used to collect noise data and vibration data in the processing environment according to the second time axis when the welding module performs welding operations; The calculation module synchronizes the actual displacement data and the noise data and the vibration data on the second time axis and correlates them as follows: ; is the actual displacement data at the time point If a certain time the noise data or vibration data exceeds a preset noise threshold or vibration threshold, take this time point as a detection time point for recording; 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 degree between the actual welding path and the virtual welding path does not meet the corresponding quality requirements, and the molten pool welding part with the deviation degree not meeting the quality requirements is the same as the corresponding part at the detection time point of the two, the calculation module takes the actual values of the noise data and vibration data at the detection time point as the warning values of the noise data and vibration data; 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 acquired 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; The calculation module controls the welding module and the displacement driving module to stop working based on the warning signal, and calculates whether the temperature data, deviation degree, and 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 vibration data.

2. The welding system based on displacement control according to claim 1, wherein, When the deviation degree, welding quality, and temperature data all 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 one of the deviation degree, welding quality, or temperature data 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.

3. The welding system based on displacement control according to claim 1, wherein The temperature data of the welding molten pool part includes a temperature value, a temperature gradient, and a temperature range. The method for the calculation module to judge whether the temperature data meets the corresponding quality requirements includes: A1. After receiving the infrared image, the calculation 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 molten pool part and determines the boundary of the welding molten pool part. A3. Based on the boundary of the welding molten pool part, the calculation module uses dividing lines to divide the welding molten pool part along the actual welding path into multiple judgment parts. A4. For each judgment part, the calculation module extracts the corresponding temperature value from the infrared image. The calculation module detects whether the temperature values of each judgment part are within the preset temperature threshold range. If the temperature values of each judgment part are within this range, the temperature values meet the quality requirements. If the temperature value of any one judgment part exceeds the temperature threshold range, it does not meet the quality requirements. A5. The calculation module calculates the temperature gradient of the welding molten pool part using the temperature values of adjacent judgment parts, including: The calculation module takes the judgment part closest to the welding module in the welding molten pool part between two detection points in a single welding process as the reference part, calculates the temperature difference between the remaining judgment parts and the reference part, and divides the temperature difference by the distance between the corresponding judgment part and the reference part to obtain the temperature gradient. And 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 is determined that the temperature gradient does not meet the quality requirements. 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 judgment part to the center line, and then the calculation module calculates the distance fluctuation of the two side boundaries of the judgment part to the center 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 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.

4. A welding system based on displacement control according to claim 1, wherein The calculation module divides the preset movement data into multiple sub-data based on each detection point. 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 a plurality of first time points ; 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 point corresponding to the same data in the sub-data and the actual displacement data and the second time point , and calculates the data response delay , .

5. The welding system based on displacement control according to claim 4, characterized in that The calculation module determines the response delay based on whether the area of the weld pool part between adjacent detection points meets the quality requirements. The processing method 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. When the area of the welding molten pool does not meet the quality requirements, the calculation module will delay the response Export and record it.

6. A welding method based on displacement control, characterized in that, This method uses the welding system according to any one of claims 1-5, including the following steps: S1. Before the 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 multiple 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 the standard data. S3. During the welding operation process, the displacement driving module drives the welding module for secondary movement, 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 overlapping range of the actual movement data and the preset displacement data; S4. After the displacement driving module reaches the detection point, the image unit collects the 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 along the preset welding path to the next detection point, 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.

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