Welding device and method based on visual guidance

Abstract

The invention provides a welding device and method based on visual guidance. The device comprises a workbench and a door frame arranged on the workbench, and a calibration positioning module is arranged on the workbench; a welding module and a visual guiding module are arranged on the portal frame; the visual guiding module comprises a CCD camera correspondingly arranged above the electric soldering bit. The control module controls the first transmission mechanism of the calibration positioning module and the second transmission mechanism of the welding module to calibrate and position the electric soldering bit according to the position information, obtained based on the visual guidance module, of the calibration piece. And controlling the welding module to perform welding operation on the calibrated and positioned electric soldering bit. The problems that an electric soldering bit deviates and a welding point position is unstable in the welding process are solved, and the technical effect of remarkably improving the product yield and the equipment utilization rate is achieved.

Description

Technical Field

[0001] The present invention relates to the field of welding technology, and more specifically, to a vision-guided welding device and method. Background Art

[0002] Soldering is a welding method that utilizes a low-melting-point metal solder. Its operation process is as follows: The soldering iron tip is pressed against the PIN foot and the pad of the PCB board at a specific angle to heat both; meanwhile, the solder wire is sent from one side to the soldering iron tip and the PIN foot, and the solder wire is melted by the heat conduction of the soldering iron. As the tin flows, finally, the solder completely wraps the PIN foot and the pad, and then the solder wire and the soldering iron tip are removed to complete the welding process.

[0003] Currently, in the industry, manual debugging of welding positions is generally adopted to ensure welding quality. The debugging personnel manually control the welding equipment to align it with the part to be welded according to the shape, size, and welding requirements of the welded workpiece. However, this manual debugging method has many drawbacks: On the one hand, the debugging accuracy depends to a large extent on the experience and technical level of the operator, which has limitations; on the other hand, in the face of workpieces with complex shapes or production lines that require frequent workpiece replacement, debugging is not only time-consuming and laborious but also prone to errors. In addition, due to problems such as the accuracy error of the equipment itself, insufficient fixture accuracy, and product design and fit clearance during the welding process, welding defects frequently occur.

[0004] Therefore, there is an urgent need for a vision-guided welding device and method that can improve the control accuracy and efficiency of the welding position. Summary of the Invention

[0005] In view of the above problems, the purpose of the present invention is to provide a vision-guided welding device and method to solve at least one problem existing in the prior art.

[0006] According to one aspect of the present invention, there is provided a vision-guided welding device, including a workbench and a gantry arranged on the workbench, and a calibration and positioning module is arranged on the workbench; a welding module and a vision guidance module are arranged on the gantry;

[0007] The calibration and positioning module includes a calibration part and a first transmission mechanism, and the calibration part is movably arranged on the workbench through the first transmission mechanism; the welding point position of the calibration part is the same as that of the product to be welded;

[0008] The welding module includes a soldering iron tip, a second transmission mechanism, and a solder wire feeding mechanism for feeding the solder wire to the soldering iron tip; the soldering iron tip is movably arranged on the gantry through the second transmission mechanism; the calibration part is correspondingly arranged below the soldering iron tip;

[0009] The visual guidance module includes a CCD camera correspondingly arranged above the soldering iron head;

[0010] It further includes a control module, which is used to control the first transmission mechanism of the calibration and positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron head based on the position information of the calibration part obtained by the visual guidance module, and control the welding module to perform welding operations on the soldering iron head after calibration and positioning.

[0011] In addition, an optional technical solution is that it further includes a temperature sensing module, and the temperature sensing module includes a temperature sensor, and the temperature sensor is arranged on the soldering iron head.

[0012] In addition, an optional technical solution is that it further includes a display screen, and the display screen is arranged on the gantry.

[0013] In addition, an optional technical solution is that it further includes a pressure sensing module, and the pressure sensing module includes a pressure sensor, and the pressure sensor is arranged on the drive input end of the soldering iron head.

[0014] On the other hand, the present invention also provides a welding method based on visual guidance, and the method includes: aligning the soldering iron head of the welding module with the calibration part of the calibration and positioning module; the welding point to be welded of the calibration part is the same as the product to be welded;

[0015] Obtaining the position image of the calibration part through the CCD camera of the visual guidance module; obtaining the position information of the part to be calibrated based on the position image of the calibration part;

[0016] Obtaining calibration alignment parameters through the position information of the calibration part, and controlling the first transmission mechanism of the calibration and positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron head based on the calibration alignment parameters;

[0017] Obtaining the position image of the part to be welded through the CCD camera of the visual guidance module; obtaining the position information of the part to be welded based on the position image of the part to be welded;

[0018] Obtaining welding compensation parameters through the position information of the part to be welded, and controlling the welding module to perform welding operations on the part to be welded based on the welding compensation parameters.

[0019] In addition, an optional technical solution is that the method of controlling the welding module to perform welding operations on the part to be welded based on the welding compensation parameters includes,

[0020] Obtaining the real-time welding temperature of the soldering iron head at set time intervals through the temperature sensor of the temperature sensing module, and determining the welding temperature curve based on the real-time welding temperature of the soldering iron head;

[0021] Monitor the welding temperature curve based on a preset temperature curve fluctuation threshold;

[0022] If the fluctuation amplitude of the welding temperature curve is greater than the preset temperature curve fluctuation threshold, an alarm signal is sent and the welding operation is stopped.

[0023] In addition, an optional technical solution is that the welding temperature curve is displayed through a display screen.

[0024] In addition, an optional technical solution is that the method for controlling the welding module to perform welding operations on the workpiece to be welded based on the welding compensation parameters further includes

[0025] Obtain the real-time bearing pressure value of the workpiece to be welded at set time intervals through the pressure sensor of the pressure sensing module; wherein, the pressure sensor is arranged on the driving input end of the soldering iron head;

[0026] Determine the welding pressure curve based on the real-time bearing pressure value of the workpiece to be welded;

[0027] Monitor the welding pressure curve based on a preset pressure curve fluctuation threshold;

[0028] If the fluctuation amplitude of the welding pressure curve is greater than the preset pressure curve fluctuation threshold, an alarm signal is sent and the welding operation is stopped.

[0029] In addition, an optional technical solution is to update the welding pressure data set based on the welding pressure data corresponding to each welding point of the workpiece to be welded;

[0030] Wherein, the pressure curve fluctuation threshold is determined through the welding pressure data set.

[0031] In a third aspect, the present invention also protects an electronic device, which includes a memory, a processor, and a vision-guided welding program stored on the memory and executable on the processor. When the vision-guided welding program is executed by the processor, the steps of the vision-guided welding method described above are implemented.

[0032] The above-mentioned vision-guided soldering device and method. After the installation of the soldering iron head is completed in the present invention, with the aid of the vision guidance module, the installed soldering iron head and the calibration and positioning module for carrying the parts to be soldered are calibrated. Thereafter, before each soldering of the PCBA, the vision guidance module will take alignment photos, and the soldering iron head will carry out soldering operations based on the points obtained from the photos. The present invention effectively gets rid of the dependence on the high professionalism of the operator, and at the same time greatly reduces the high defective rate caused by problems such as the accuracy error of the equipment itself, the insufficient accuracy of the tooling, and the product design and fitting clearance during the soldering process. The present invention not only solves the problems of the deviation of the soldering iron head and the instability of the soldering points during the soldering process, but also achieves the technical effect of significantly improving the yield rate of the product and the operation rate of the equipment.

[0033] To achieve the above and related purposes, one or more aspects of the present invention include the features that will be described in detail later. The following description and the accompanying drawings illustrate certain exemplary aspects of the present invention in detail. However, these aspects indicate only some of the various ways in which the principles of the present invention can be used. In addition, the present invention is intended to include all these aspects and their equivalents. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] By referring to the following description in conjunction with the accompanying drawings, and with a more comprehensive understanding of the present invention, other objects and results of the present invention will become more apparent and easier to understand. In the drawings:

[0035] Figure 1 FIG. is a schematic structural diagram of a vision-guided soldering device according to an embodiment of the present invention;

[0036] Figure 2 FIG. is another schematic structural diagram of a vision-guided soldering device according to an embodiment of the present invention;

[0037] Figure 3 For Figure 1 the structural schematic diagram at III in;

[0038] Figure 4 FIG. is a schematic flowchart of a vision-guided soldering method according to an embodiment of the present invention;

[0039] Figure 5 FIG. is a schematic internal structural diagram of an electronic device for implementing a vision-guided soldering method provided by an embodiment of the present invention.

[0040] In all the drawings, the same reference numerals indicate similar or corresponding features or functions. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention.

[0042] The following will clearly and elaborately describe the technical solutions in the embodiments of the present application with reference to the accompanying drawings. Among them, in the description of the embodiments of the present application, unless otherwise specified, "and / or" in the text is only an associative relationship describing associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone. These three situations.

[0043] Hereinafter, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as implying or suggesting relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. Additionally, in the description of the embodiments of the present application, "a plurality" means two or more than two.

[0044] The reference to "one embodiment" or "some embodiments" etc. described in this specification means that a specific feature, structure, or characteristic described in connection with the embodiment is included in one or more embodiments of the present application. Thus, the statements "in one embodiment", "in some embodiments", "in other some embodiments", "in still other embodiments", etc. that appear in different places in this specification are not necessarily all referring to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized in other ways. The terms "include", "comprise", "have" and their variants all mean "including but not limited to", unless otherwise specifically emphasized in other ways.

[0045] To describe in detail the vision-guided welding device and method of the present invention, the following will specifically describe the embodiments of the present invention with reference to the accompanying drawings.

[0046] Artificial intelligence technology is a comprehensive discipline with a wide range of fields involved, including both hardware-level technologies and software-level technologies. The basic technologies of artificial intelligence generally include technologies such as sensors, dedicated artificial intelligence chips, cloud computing, distributed storage, big data processing technology, operation / interaction devices, and mechatronics. The software technologies of artificial intelligence mainly include several major directions such as computer vision technology, speech processing technology, natural language processing technology, and machine learning / deep learning.

[0047] Visual guidance is to obtain information such as the position, shape, and posture of an object through machine vision technology, and then guide a robot or automated equipment to perform precise operations. The implementation of visual guidance is through image recognition and processing, feature extraction and matching, and dynamic path planning. Specifically, the visual guidance system captures images through a camera, and then uses image processing algorithms to identify and analyze features in the images, such as the edges, shapes, colors of the objects, etc. The system matches the identified features with a preset model or database to determine the position and posture of the object. According to the recognition results, the system can adjust the motion trajectory of the robotic arm or automated equipment in real time to complete precise operations.

[0048] Embodiment 1

[0049] Figures 1 to 3 The structure of the welding device based on visual guidance according to the embodiment of the present invention has been described as a whole; among them, Figure 1 Fig. shows a schematic structural diagram of a welding device based on visual guidance according to an embodiment of the present invention. Figure 2 Fig. shows another schematic structural diagram of a welding device based on visual guidance according to an embodiment of the present invention. Figure 3 is Figure 1 a schematic structural diagram at position Ⅲ in

[0050] As Figure 1 shown, the welding device based on visual guidance provided in this embodiment includes a workbench 11 and a gantry 12 provided on the workbench 11. A calibration and positioning module 1 is provided on the workbench 11; a welding module and a visual guidance module are provided on the gantry 12; the calibration and positioning module 1 includes a calibration member 2 and a first transmission mechanism, and the calibration member 2 is movably provided on the workbench 11 through the first transmission mechanism; the welding point position of the calibration member 2 is the same as that of the product to be welded; the welding module includes a soldering iron head 13, a second transmission mechanism, and a solder wire feeding mechanism 6 for feeding solder wire to the soldering iron head 13; the soldering iron head 13 is movably provided on the gantry 12 through the second transmission mechanism; the calibration member 2 is correspondingly provided below the soldering iron head 13; the visual guidance module includes a CCD camera 3 correspondingly provided above the soldering iron head 13; it further includes a control module for calibrating and positioning the soldering iron head 13 by controlling the first transmission mechanism of the calibration and positioning module 1 and the second transmission mechanism of the welding module based on the position information of the calibration member 2 obtained by the visual guidance module 3, and controlling the welding module to perform welding operations on the soldering iron head 13 after calibration and positioning. Through a unified calibration process and standard, it is ensured that each welding operation is carried out under the same conditions, reducing the influence of human factors and equipment errors on the welding quality. This helps to improve the consistency and stability of the welding quality and reduce the defective rate of products.

[0051] In a specific implementation process, in addition to the solder wire feeding mechanism 6, the welding module may further include a solder wire placement mechanism 10. Among them, the solder wire feeding mechanism may be an automatic solder wire feeding mechanism including a support base, a feeding component, and a transmission component. The main function of the solder wire placement mechanism 10 is to fix the solder wire reel on the device to ensure that the solder wire can be smoothly conveyed by the feeding mechanism. An exemplary description is as follows: The motor drives the gear to rotate, the pressure wheel presses against the gear, the solder wire is clamped between the gear and the pressure wheel, and is conveyed as the gear rotates. By adjusting the pressure wheel fixing plate, the gap between the pressure wheel and the gear can be adjusted to adapt to solder wires of different sizes.

[0052] In a specific implementation process, the first transmission mechanism may be a motor-driven slide table, which can be set in the Y-axis direction. That is to say, if the setting direction of the gantry is the rear, the slide table can perform linear motion along the front and back of the workbench, and can be a linear guide rail or a ball screw. The transmission can be achieved through gear transmission, chain transmission, belt transmission, etc., and specific limitations are not made here. Exemplarily, the calibration part 2 can perform linear motion in the Y-axis direction on the workbench 11 through the first transmission mechanism. The second transmission mechanism may be a three-axis motion module, usually composed of three axes, respectively controlling the motion of an object in the X-axis, Y-axis, and Z-axis directions. It may include a driving device and transmission mechanisms in three directions. Exemplarily, the soldering iron tip 13 can perform motion in the X-axis, Y-axis, and Z-axis directions on the gantry 12 through the second transmission mechanism.

[0053] In the specific implementation process, the welding points to be welded on the calibration part 2 are the same as those of the product to be welded; specifically, the calibration part can be an analog pin to be welded or a PCBA pad to be welded, and the calibration part has the characteristic of being able to be replaced at any time according to the different models of the parts to be welded. Taking the calibration part as an example of an imitation pin to be welded for exemplary description, it can be quickly replaced according to different welding tasks and the models of the pins to be welded. This means that when facing pins of various models, different sizes and shapes, the welding equipment does not need to perform complex re-adjustment and calibration. Only by replacing the corresponding calibration pin and performing a simple calibration operation can it quickly adapt to the new welding requirements. It should be noted that the shape and size of the calibration pin are similar to the height of the actual pin to be welded, and it can simulate the position and posture of the pin in the real welding scenario. When the welding equipment performs the calibration operation, by placing the calibration pin at the predetermined welding position, it provides a clear and accurate reference target for the equipment. With the help of a high-precision vision guidance system, the equipment can accurately identify the position of the calibration pin, and then adjust the position and angle of the soldering iron tip or other welding tools to ensure its precise alignment with the calibration pin. In this way, during the actual welding process, the soldering iron tip can accurately align with the pin to be welded, avoiding welding defects caused by position deviation, such as solder joint offset, false soldering, short circuit, etc. Among them, after installing the soldering iron tip, using the calibration pin for calibration is an important step to ensure welding quality. By taking a photo of the calibration pin through the vision alignment system to obtain its accurate position information, and then adjusting the position of the soldering iron tip to align it with the center of the calibration pin. This process can eliminate the possible misalignment of the soldering iron tip during the installation process, ensuring that the soldering iron tip can accurately act on the solder joint in subsequent welding. In addition, the calibration pin can also be used to calibrate the vision guidance module itself. By placing the calibration pin at different positions and angles, testing the recognition and positioning ability of the vision system for the position of the pin, and adjusting the parameters of the vision system, such as focal length, exposure time, image processing algorithm, etc., to improve the detection accuracy and reliability of the vision system for the position of the solder joint. This helps to more accurately capture the position of the solder joint during the welding process, providing a reliable basis for the precise guidance of the soldering iron tip. During the welding process, the position and state of the calibration pin can be recorded and traced. If welding quality problems are found during subsequent product inspection or use, by tracing the usage record of the calibration pin, analyzing the calibration status and welding parameters of the welding equipment, the cause of the problem can be quickly located, and corresponding improvement measures can be taken to achieve effective control and continuous improvement of welding quality.

[0054] In a specific implementation process, the control module is used to control the first transmission mechanism of the calibration and positioning module 1 and the second transmission mechanism of the welding module to calibrate and position the soldering iron head 13 based on the position information of the calibration part 2 obtained by the vision guidance module 3, and control the welding module to perform welding operations on the soldering iron head 13 after calibration and positioning. Specifically, after initially aligning the soldering iron head 13 of the welding module with the calibration part 2 of the calibration and positioning module, the control module obtains the first position image of the calibration part 2 through the CCD camera 3 of the vision guidance module; obtains the first position information of the calibration part 2 to be calibrated based on the first position image; obtains calibration alignment parameters through the first position information of the calibration part 2, and controls the first transmission mechanism of the calibration and positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron head 13 based on the calibration alignment parameters; obtains the second position image of the calibration part 2 after calibration and positioning through the CCD camera 3 of the vision guidance module; obtains the second position information of the calibration part 2 based on the second position image; obtains welding compensation parameters through the second position information of the calibration part 2, and controls the welding module to perform welding operations on the parts to be welded based on the welding compensation parameters.

[0055] In a specific embodiment, the welding device based on vision guidance further includes a temperature sensing module, and the temperature sensing module includes a temperature sensor 5, and the temperature sensor 5 is arranged on the soldering iron head. Specifically, the control module obtains the real-time welding temperature of the soldering iron head 13 at a set time interval through the temperature sensor 5 of the temperature sensing module, determines the welding temperature curve based on the real-time welding temperature of the soldering iron head 13; monitors the welding temperature curve based on a preset temperature curve fluctuation threshold; if the fluctuation amplitude of the welding temperature curve is greater than the preset temperature curve fluctuation threshold, an alarm signal is sent and the welding operation is stopped. That is, if the fluctuation of the welding temperature curve does not fall within the range of the preset temperature curve fluctuation threshold, an alarm signal is sent and the welding operation is stopped. For example, within the range of the preset temperature curve fluctuation threshold is between the set highest temperature and the set lowest temperature of the real-time welding temperature. For example, when the median value of the welding temperature standard for soldering is 300 °C and the temperature curve fluctuation threshold is ±5 °C, if the real-time temperature exceeds 305 °C or is lower than 295 °C, an alarm will be triggered and the welding operation will stop. When performing the same solder joint operation, the real-time welding temperature at the first temperature acquisition moment is 304 °C, and 0.2 seconds after the first temperature acquisition moment, the real-time welding temperature at the second temperature acquisition moment is collected as 296 °C. Since the temperature fluctuation amplitude is greater than ±5 °C, an alarm signal is sent and the welding operation is stopped.

[0056] In a specific embodiment, the vision-guided welding device further includes a pressure sensing module. The pressure sensing module includes a pressure sensor 4, and the pressure sensor 4 is disposed on the driving input end of the soldering iron tip. Specifically, the control module obtains the real-time pressure-bearing value of the workpiece to be welded through the pressure sensor of the pressure sensing module at a set time interval. Among them, the pressure sensor is disposed on the driving input end of the soldering iron tip. A welding pressure curve is determined based on the real-time pressure-bearing value of the workpiece to be welded. The welding pressure curve is monitored based on a preset pressure curve fluctuation threshold. If the fluctuation amplitude of the welding pressure curve is greater than the preset pressure curve fluctuation threshold, an alarm signal is issued and the welding operation is stopped. That is, if the fluctuation of the welding pressure curve does not fall within the range of the preset pressure curve fluctuation threshold, an alarm signal is issued and the welding operation is stopped. For example, within the range of the preset pressure curve fluctuation threshold is between the set maximum value and the set minimum value of the real-time welding pressure. For example, when the median value of the welding pressure standard for soldering is 400N and the pressure curve fluctuation threshold is ±1N, if the real-time pressure at a certain welding site exceeds 401N or is lower than 399N, an alarm will be triggered and the welding operation will be stopped.

[0057] In a specific embodiment, the vision-guided welding device further includes a display screen 7, and the display screen 7 is disposed on the gantry 12. The welding temperature curve and the welding pressure curve are displayed through the display screen 7. As Figure 1 and Figure 2As shown in the figure, the vision-guided welding device further includes a temperature industrial control computer 8 and a general industrial control computer 9. Specifically, the temperature industrial control computer is the part of the temperature sensing module responsible for collecting data from temperature sensors, and for data storage and processing. Exemplarily, the temperature industrial control computer can adjust the heating power according to the set target temperature and the actually measured temperature through the PID temperature control algorithm to ensure that the temperature is stable near the set value. The PID parameters (KP, KI, KD) can be optimized according to the actual welding process. Exemplarily, an emergency shutdown button and a temperature adjustment button can be set on the temperature industrial control computer. The temperature industrial control computer is connected to the display screen, and the collected temperature data is displayed on the display screen in the form of a waveform chart through the graphical interface of LabVIEW. Through the human-machine interface (which can be a display screen) of the temperature industrial control computer, the user can input or modify the preset temperature curve of the workpiece to be welded, and the system performs real-time temperature adjustment according to these curves. The real-time temperature of the workpiece to be welded is sampled by an infrared thermometer and fed back to the PLC to form a temperature closed-loop. For the general industrial control computer 9, it can include a data processing module for the pressure sensing module. The pressure control function is implemented in the industrial control computer, and the fieldbus module or board is used for pressure data input and control output. The industrial control computer has strong computing power. Through the human-machine interface (which can be a display screen) of the industrial control computer, the user can input or modify the preset pressure curve of the workpiece to be welded, and the system performs real-time pressure adjustment according to these curves. That is to say, after the system is integrated, the user can easily operate and monitor through the human-machine interface to ensure the high efficiency and high quality of the welding process.

[0058] Embodiment 2

[0059] Figure 4 is a schematic flow chart of a vision-guided welding method according to an embodiment of the present invention; as Figure 4 shown, the vision-guided welding method includes steps S110 to S150.

[0060] S110. Align the soldering iron head 13 of the welding module with the calibration part 2 of the calibration and positioning module; the welding point to be welded of the calibration part 2 is the same as that of the product to be welded.

[0061] S120. Obtain the position image of the calibration part through the CCD camera 3 of the vision guidance module; obtain the position information of the part to be calibrated based on the position image of the calibration part 2.

[0062] It should be noted that the vision guidance module includes a CCD camera, a coaxial optical lens, a light source, etc. The CCD camera is used to capture images, the coaxial optical lens ensures uniform illumination of light, and the light source provides necessary lighting. Working principle: The CCD camera takes pictures of the feature positions on the calibration part through a dedicated industrial lens and light source. An image processing machine (such as a PC) collects and processes the image data, and performs position calculations to determine the actual position of the calibration part. By comparing with the previously set reference position, the actual offset value is calculated, and the alignment platform movement is controlled to move the calibration part to the set reference position.

[0063] S130. Obtain calibration alignment parameters through the position information of the calibration part 2, and control the first transmission mechanism of the calibration positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron head 13 based on the calibration alignment parameters.

[0064] It should be noted that the welding point to be welded on the calibration part is the same as that of the product to be welded; specifically, the calibration part can be an analog soldering Pin or a PCBA pad to be welded. The calibration part has the characteristic that it can be replaced at any time according to the model of the part to be welded. That is to say, in the specific implementation process, after replacing the soldering iron head, align the soldering iron head 13 with the calibration part 2 of the calibration positioning module to obtain the calibration position information of the calibration part, and then compare the calibration position information of the calibration part with the preset theoretical position information of the calibration part to obtain calibration alignment parameters. Then, manual adjustment is performed according to the calibration alignment parameters to complete the calibration and positioning of the soldering iron head. Or, the control system sets and adjusts the deviation according to the calibration alignment parameters, and the first transmission mechanism of the calibration positioning module and the second transmission mechanism of the welding module perform alignment compensation adjustment.

[0065] S140. Obtain the position image of the part to be welded through the CCD camera of the vision guidance module; obtain the position information of the part to be welded based on the position image of the part to be welded.

[0066] It should be noted that the position image of the part to be welded is the position image of the part to be welded in the fixture of the part to be welded. The part to be welded is placed in the fixture of the part to be welded so that the distance between the part to be welded and the installation origin of the fixture of the part to be welded is a set distance. Through the position image of the part to be welded, obtain the gap distance between the part to be welded and other installation points of the fixture of the part to be welded.

[0067] S150. Obtain welding compensation parameters through the position information of the part to be welded, and control the welding module to perform welding operations on the part to be welded based on the welding compensation parameters. It should be noted that according to the obtained gap distance between the part to be welded and other installation points of the fixture of the part to be welded, and the preset welding accuracy, determine the gap compensation (i.e., the welding compensation parameter).

[0068] In a specific embodiment, the method for controlling the welding module to perform a welding operation on a workpiece to be welded based on the welding compensation parameters further includes steps S210 to S230.

[0069] S210. The real-time welding temperature of the soldering iron head is obtained by the temperature sensor of the temperature sensing module at a set time interval, and a welding temperature curve is determined based on the real-time welding temperature of the soldering iron head. An exemplary description is as follows. The temperature data of the soldering iron head is collected in real time by the temperature sensor and transmitted to the processor unit for processing. The processor unit transfers the temperature data to a computer, and uses software (such as LabVIEW) to dynamically display and alarm the welding temperature data each time in the form of a curve. Using the LabVIEW software in the computer, the welding temperature data each time is saved to facilitate data analysis by management personnel. This helps to trace the welding process, improve the production process, and enhance product consistency and stability.

[0070] S220. Monitor the welding temperature curve based on a preset temperature curve fluctuation threshold.

[0071] S230. If the fluctuation of the welding temperature curve is greater than the preset temperature curve fluctuation threshold, an alarm signal is issued and the welding operation is stopped.

[0072] It should be noted that in the field of soldering technology, the temperature sensing modules in the prior art are all arranged at the solder feeding head, and the detection is carried out by detecting the melting temperature of the solder wire. The temperature sensing module at the solder feeding head needs to be adjusted according to different welding positions and the usage of the solder wire, which increases the complexity of the operation and the time cost, and it is impossible to detect the entire welding process in real time. However, in the present invention, the temperature sensor is arranged at the soldering iron head and is used to detect the real-time temperature during the contact process between the soldering iron head and the PCBA pad. In order to ensure the real-time performance of the welding temperature curve, the time interval for the temperature sensor to obtain the real-time welding temperature of the soldering iron head can be 100 milliseconds to 2 seconds. For the preset temperature curve fluctuation threshold, it can be ±5°C. The following is an exemplary description. Before the processor unit and the temperature sensor (such as the MAX6675 type signal processor, DW-616FD-2C dual-color focusing type coaxial laser aiming online infrared thermometer) perform data communication, the SPI interface needs to be configured. The K-type thermocouple collects the welding temperature data and transmits it to the MAX6675 type signal processor. The MAX6675 type signal processor amplifies, cold-end compensates, linearizes and performs A / D conversion on the welding temperature data signal and then transmits it to the processor unit. The processor unit transmits the welding temperature data to the computer, and preset a temperature range in the processor unit to judge whether the welding temperature data is within the temperature range. For example, if there is a phenomenon that the welding temperature is higher than the set maximum temperature or the welding temperature is lower than the set minimum temperature, an alarm will be issued and the welding will be stopped, otherwise the data will be displayed. Using the LabVIEW software in the computer, the welding temperature data each time is dynamically displayed in the form of a curve and an alarm is issued, which is convenient for the management personnel to monitor the entire welding process.

[0073] In addition, an optional technical solution is that the method for controlling the welding module to perform welding operations on the workpiece to be welded based on the welding compensation parameters further includes steps S310 to S330.

[0074] S310. Obtain the real-time pressure-bearing value of the workpiece to be welded by the pressure sensor of the pressure sensing module at a set time interval; wherein, the pressure sensor is arranged on the driving input end of the soldering iron head.

[0075] S320. Determine the welding pressure curve based on the real-time pressure-bearing value of the workpiece to be welded.

[0076] S330. Monitor the welding pressure curve based on a preset pressure curve fluctuation threshold.

[0077] S340. If the fluctuation amplitude of the welding pressure curve is greater than the preset pressure curve fluctuation threshold, an alarm signal is sent and the welding operation is stopped. Herein, an exemplary illustration is as follows. The PID temperature control algorithm is used to control the temperature of the soldering iron tip by adjusting the proportional coefficient (KP), integral coefficient (KI), and derivative coefficient (KD). For example, KP = 1.0, KI = 0.1, KD = 0.01 can be set, and these parameters can be optimized according to the actual welding process. The PID control signal is calculated every certain time (such as 100 milliseconds), and the heating power of the soldering iron tip is adjusted according to the deviation between the current temperature and the target temperature to ensure that the temperature is stable near the set value.

[0078] It should be noted that in the field of soldering technology, the pressure sensors in the prior art are all used to determine whether the workpiece to be welded is under pressure to generally judge whether the welding process is proceeding smoothly. The relationship between the force value of the pressure and the welding accuracy of the workpiece to be welded is not considered. In the present invention, the pressure sensor is arranged at the pressure input end of the soldering iron tip (i.e., the handle) to detect the real-time pressure value during the contact process between the soldering iron tip and the PCBA pad. To ensure the real-time performance of the welding pressure curve, the time interval for the pressure sensor to obtain the real-time welding pressure of the soldering iron tip can be 0.5 to 2 seconds. For the preset pressure curve fluctuation threshold, it can be ±1N. An exemplary illustration is as follows. The pressure change during the spot welding process is monitored in real time through a high-precision pressure sensor. The pressure sensor converts the pressure signal into a voltage signal for output, and after being processed by a filtering and differential amplification circuit, it is converted into a single-ended voltage signal for output. The output voltage is zero-adjusted through a subtraction circuit, and after filtering and clamping, it is output for ADC sampling. A welding recorder (such as SPATZ Multi04) is used to record, analyze, and monitor all important process parameters, such as welding current, voltage, pressure, and displacement. The recorder can save the parameters and data fluctuation conditions of each welding for traceability and improvement of the welding process. In addition, during the spot welding operation, the pressure sensor will monitor the pressure value in real time. Once the pressure value exceeds the preset reasonable range, whether it is too large or too small, the system will immediately trigger the alarm mechanism and stop the welding operation at the same time. This measure can effectively prevent the workpiece to be welded from being damaged due to excessive pressure, and also prevent the situation where the soldering iron tip is not in full contact with the PCBA pad or not in contact at all due to too small pressure, thereby reducing the defective rate.

[0079] In the specific implementation process, the welding temperature curve and the welding pressure curve are displayed in real time through the display screen, so that the operator can conduct manual monitoring on the welding operation process. Update the welding pressure data set based on the welding pressure data corresponding to each welding point of the workpiece to be welded; wherein, the welding pressure curve fluctuation threshold is determined through the welding pressure data set. Update the welding temperature data set based on the welding temperature curve data corresponding to each welding point of the workpiece to be welded; wherein, the welding temperature curve fluctuation threshold is determined through the welding temperature data set. That is to say, during the welding process, the position and state of the calibration Pin can be recorded and traced, and the welding pressure value and the welding temperature value at each point during the welding process can also be recorded and traced. If welding quality problems are found during subsequent product inspection or use, the pressure state and temperature state of the welding equipment can be analyzed through the welding pressure value and the welding temperature value at each point, quickly locate the cause of the problem, and take corresponding improvement measures, so as to achieve effective control and continuous improvement of welding quality.

[0080] For more specific implementation manners of the above-mentioned vision-guided welding method, reference can be made to the description of the embodiments of the vision-guided welding device mentioned above, which will not be elaborated here one by one. The above-mentioned vision-guided welding method and the vision-guided welding device can be applied to scenarios such as the PCB plug-in welding process of a laser soldering robot, the control of the solder penetration amount in the welding of automotive products, and the scenarios of dotting solder paste and laser welding in the production of voice coil motors (VCM), etc.

[0081] As Figure 5 shown, the present invention also correspondingly provides an electronic device 5 for a wearing detection method.

[0082] The electronic device 5 may include a processor 50, a memory 51, and a bus, and may further include a computer program stored in the memory 51 and executable on the processor 50, such as a vision-guided welding program 52. The memory 51 may further include both an internal storage unit of the vision-guided welding device and an external storage device. The memory 51 can be used not only to store installed application software and various types of data, such as the code of the vision-guided welding program, etc., but also to temporarily store data that has been output or will be output.

[0083] The electronic device 5 may include a processor 50, a memory 51, and a bus. It may also include a computer program stored in the memory 51 and executable on the processor 50, such as a vision-guided welding program 52. The memory 51 may further include both an internal storage unit of the vision-guided welding device and an external storage device. The memory 51 can be used not only to store application software installed on the device and various types of data, such as the code of the vision-guided welding program, etc., but also to temporarily store data that has been output or is to be output.

[0084] Among them, the memory 51 includes at least one type of readable storage medium, which includes flash memory, mobile hard disks, multimedia cards, card-type memories (such as SD or DX memories, etc.), magnetic memories, magnetic disks, optical discs, etc. In some embodiments, the memory 51 can be an internal storage unit of the electronic device 5, such as the mobile hard disk of the electronic device 5. In other embodiments, the memory 51 can also be an external storage device of the electronic device 5, such as a plug-in mobile hard disk, a Smart Media Card (SMC), a Secure Digital (SD) card, a Flash Card, etc., equipped on the electronic device 5. Further, the memory 51 can also include both an internal storage unit and an external storage device of the electronic device 5. The memory 51 can be used not only to store application software installed on the electronic device 5 and various types of data, such as the code of the vision-guided welding program, etc., but also to temporarily store data that has been output or is to be output.

[0085] In some embodiments, the processor 50 can be composed of integrated circuits. For example, it can be composed of a single packaged integrated circuit, or can be composed of multiple integrated circuits with the same or different functions, including a combination of one or more Central Processing Units (CPUs), microprocessors, digital processing chips, graphics processors, and various control chips, etc. The processor 50 is the control core (Control Unit) of the electronic device, connecting all components of the entire electronic device through various interfaces and lines. By running or executing programs or modules (such as the vision-guided welding program, etc.) stored in the memory 51, and by calling data stored in the memory 51, it performs various functions of the electronic device 5 and processes data.

[0086] The bus may be a Peripheral Component Interconnect (PCI) bus, an Extended Industry Standard Architecture (EISA) bus, or the like. The bus can be divided into an address bus, a data bus, a control bus, etc. The bus is arranged to implement connection communication between the memory 51 and at least one processor 50, etc.

[0087] Figure 5 Only an electronic device with components is shown. Those skilled in the art can understand that Figure 5 The shown structure does not constitute a limitation on the electronic device 5, and it may include fewer or more components than shown, or combine certain components, or have different component arrangements.

[0088] For example, although not shown, the electronic device 5 may further include a power source (such as a battery) for powering each component. Preferably, the power source can be logically connected to the at least one processor 50 through a power management device, so as to implement functions such as charging management, discharging management, and power consumption management through the power management device. The power source may also include any components such as one or more DC or AC power sources, a recharge device, a power failure detection circuit, a power converter or inverter, a power status indicator, etc. The electronic device 5 may also include various sensors, a Bluetooth module, a Wi-Fi module, etc., which will not be elaborated here.

[0089] Further, the electronic device 5 may further include a network interface. Optionally, the network interface may include a wired interface and / or a wireless interface (such as a WI-FI interface, a Bluetooth interface, etc.), which is generally used to establish a communication connection between the electronic device 5 and other electronic devices.

[0090] Optionally, the electronic device 5 may further include a user interface. The user interface may be a display, an input unit (such as a keyboard), and optionally, the user interface may also be a standard wired interface or a wireless interface. Optionally, in some embodiments, the display may be an LED display, a liquid crystal display, a touch liquid crystal display, and an OLED (Organic Light-Emitting Diode) toucher, etc. Among them, the display may also be appropriately referred to as a display screen or a display unit, which is used to display the information processed in the electronic device 5 and to display a visual user interface.

[0091] It should be understood that the above embodiments are only for illustration purposes and are not limited by this structure in the scope of the patent application.

[0092] The welding program 52 based on visual guidance stored in the memory 51 of the electronic device 5 is a combination of multiple instructions. When running in the processor 50, it can achieve: aligning the soldering iron head of the welding module with the calibration part of the calibration and positioning module; the welding point to be welded of the calibration part is the same as the product to be welded; obtaining the position image of the calibration part through the CCD camera of the visual guidance module; obtaining the position information of the part to be calibrated based on the position image of the calibration part; obtaining the calibration alignment parameters through the position information of the calibration part, and controlling the first transmission mechanism of the calibration and positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron head based on the calibration alignment parameters; obtaining the position image of the part to be welded through the CCD camera of the visual guidance module; obtaining the position information of the part to be welded based on the position image of the part to be welded; obtaining the welding compensation parameters through the position information of the part to be welded, and controlling the welding module to perform welding operations on the part to be welded based on the welding compensation parameters.

[0093] Specifically, for the specific implementation method of the above instructions by the processor 50, reference can be made to Figure 1 the description of the relevant steps in the corresponding embodiment, which will not be elaborated here. Further, if the modules / units integrated in the electronic device 5 are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. The computer-readable medium may include: any entity or device capable of carrying the computer program code, recording medium, USB flash drive, mobile hard disk, magnetic disk, optical disc, computer memory, read-only memory (ROM, Read-Only Memory).

[0094] The embodiment of the present invention also provides a computer-readable storage medium. The storage medium may be non-volatile or volatile. The storage medium stores a computer program, and when the computer program is executed by a processor, it can achieve: aligning the soldering iron head of the welding module with the calibration part of the calibration and positioning module; the welding point to be welded of the calibration part is the same as the product to be welded; obtaining the position image of the calibration part through the CCD camera of the visual guidance module; obtaining the position information of the part to be calibrated based on the position image of the calibration part; obtaining the calibration alignment parameters through the position information of the calibration part, and controlling the first transmission mechanism of the calibration and positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron head based on the calibration alignment parameters; obtaining the position image of the part to be welded through the CCD camera of the visual guidance module; obtaining the position information of the part to be welded based on the position image of the part to be welded; obtaining the welding compensation parameters through the position information of the part to be welded, and controlling the welding module to perform welding operations on the part to be welded based on the welding compensation parameters.

[0095] Specifically, when the computer program is executed by a processor, the specific implementation method can refer to the description of the relevant steps in the embodiment of the wearing detection method, which will not be elaborated here.

[0096] In several embodiments provided by the present invention, it should be understood that the disclosed devices, apparatuses, and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of the modules is only a logical function division, and there can be other division methods in actual implementation.

[0097] The modules described as separate components may or may not be physically separated, and the components shown as modules may or may not be physical units, that is, they can be located in one place, or distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0098] In addition, in each embodiment of the present invention, the functional modules can be integrated in a processing unit, or each unit can exist physically alone, or two or more units can be integrated in one unit. The above integrated units can be implemented in the form of hardware, or in the form of hardware plus software functional modules.

[0099] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms.

[0100] Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present invention. Any associated drawing marks in the claims should not be regarded as limiting the claimed rights.

[0101] In addition, obviously, the term "including" does not exclude other units or steps, and the singular does not exclude the plural. The multiple units or apparatuses stated in the apparatus claims can also be implemented by one unit or apparatus through software or hardware.

[0102] As described above by way of example with reference to the drawings, a vision-guided welding apparatus and a vision-guided welding method according to the present invention are described. However, those skilled in the art should understand that various improvements can be made to the above vision-guided welding method and vision-guided welding apparatus proposed by the present invention without departing from the content of the present invention. Therefore, the protection scope of the present invention should be determined by the content of the appended claims.

Claims

1. A welding device based on vision guidance, characterized in that: It comprises a workbench and a gantry arranged on the workbench, wherein a calibration and positioning module is arranged on the workbench; a welding module and a visual guidance module are arranged on the gantry; The calibration and positioning module comprises a calibration piece and a first transmission mechanism, and the calibration piece is movably arranged on the workbench through the first transmission mechanism; the to-be-welded point of the calibration piece is the same as the to-be-welded product; The welding module comprises an electric soldering iron head, a second transmission mechanism and a tin wire feeding mechanism for feeding tin wire to the electric soldering iron head; the electric soldering iron head is movably arranged on the door frame through the second transmission mechanism; the calibration piece is correspondingly arranged below the electric soldering iron head; The visual guidance module includes a CCD camera correspondingly arranged above the electric soldering iron head; It also includes a control module, which is used to control the first transmission mechanism of the calibration and positioning module and the second transmission mechanism of the welding module to calibrate and position the soldering iron tip based on the position information of the calibration part obtained by the visual guidance module, and control the welding module to perform welding operations on the soldering iron tip after the calibration and positioning are completed.

2. The vision-guided welding device according to claim 1, characterized in that: It also includes a temperature sensing module, which includes a temperature sensor, and the temperature sensor is arranged on the electric soldering iron head.

3. The vision-guided welding device according to claim 1, characterized in that: It also includes a display screen, which is arranged on the door frame.

4. The vision-guided welding device according to claim 1, characterized in that: It also includes a pressure sensing module, which includes a pressure sensor, and the pressure sensor is arranged on the driving input end of the electric soldering iron head.

5. A welding method based on vision guidance, the method comprising: Align the electric soldering iron tip of the welding module with the calibration piece of the calibration and positioning module; The points to be welded of the calibration piece are the same as those of the product to be welded; The position image of the calibration part is obtained by using the CCD camera of the visual guidance module; Acquiring position information of the part to be calibrated based on the position image of the calibration part; Acquire calibration alignment parameters through the position information of the calibration piece, and control the first transmission mechanism of the calibration positioning module and the second transmission mechanism of the welding module to calibrate and position the electric soldering iron tip based on the calibration alignment parameters; The position image of the parts to be welded is obtained through the CCD camera of the visual guidance module; Acquiring position information of the parts to be welded based on the position image of the parts to be welded; Welding compensation parameters are obtained through the position information of the workpiece to be welded, and the welding module is controlled to perform welding operations on the workpiece to be welded based on the welding compensation parameters.

6. The vision-guided welding method according to claim 5, characterized in that: A method for controlling the welding module to perform welding operations on a workpiece based on the welding compensation parameters, include, Acquiring the real-time welding temperature of the electric soldering iron tip through the temperature sensor of the temperature sensing module at a set time interval, and determining the welding temperature curve based on the real-time welding temperature of the electric soldering iron tip; Monitoring the welding temperature curve based on a preset temperature curve fluctuation threshold; If the fluctuation amplitude of the welding temperature curve is greater than the preset temperature curve fluctuation threshold, an alarm signal is issued and the welding operation is stopped.

7. The vision-guided welding method according to claim 6, characterized in that: The welding temperature curve is displayed on a display screen.

8. The vision-guided welding method according to claim 5, characterized in that: The method for controlling the welding module to perform welding operation on the workpiece to be welded based on the welding compensation parameter also includes: The pressure sensor of the pressure sensing module obtains the real-time pressure value of the workpiece to be welded at a set time interval; wherein the pressure sensor is arranged on the driving input end of the electric soldering iron head; Determining a welding pressure curve based on the real-time pressure value of the workpiece to be welded; Monitoring the welding pressure curve based on a preset pressure curve fluctuation threshold; If the fluctuation amplitude of the welding pressure curve is greater than the preset pressure curve fluctuation threshold, an alarm signal is issued and the welding operation is stopped.

9. The vision-guided welding method according to claim 8, characterized in that: The welding pressure data set is updated based on the welding pressure data corresponding to each welding point of the workpiece to be welded; Wherein, the pressure curve fluctuation threshold is determined by the welding pressure data set.

10. An electronic device, characterized in that: The electronic device includes a memory, a processor, and a vision-guided welding program stored in the memory and executable on the processor, wherein the vision-guided welding program, when executed by the processor, implements the steps of the vision-guided welding method as described in any one of claims 5 to 9.

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