A low-pressure outer cylinder welding quality monitoring method, system, equipment and medium

Abstract

The present application discloses a low-pressure outer cylinder welding quality monitoring method, system, equipment and medium, and relates to the field of welding quality detection technology. The present application provides a low-pressure outer cylinder welding quality monitoring method, comprising: obtaining welding characteristic parameters of a first welding section within a preset time period; evaluating a first welding quality score of the first welding section based on a welding quality assessment model according to the welding characteristic parameters, and determining whether the first welding quality score is greater than a first preset threshold; if not, pausing the welding task and issuing an alarm signal; if so, obtaining a second welding quality score of at least one second welding section within the preset time period; estimating an estimated quality score of a third welding section of the low-pressure outer cylinder that is not welded based on all the second welding quality scores and the first welding quality score, and determining whether the estimated quality score is greater than a second preset threshold; and adjusting the welding strategy if the estimated quality score is less than or equal to the second preset threshold.

Description

Technical Field

[0001] The present application relates to the technical field of welding quality detection, and in particular to a method, system, equipment and medium for monitoring the welding quality of a low-pressure outer cylinder. Background Art

[0002] Welding is a crucial step in the manufacturing process of low-pressure outer cylinders, and its quality directly impacts their overall performance, reliability, and service life. Low-pressure outer cylinders are often key components of large-scale industrial equipment (such as steam turbines and generators), subject to complex mechanical and thermal stresses. Poor welding quality can lead to equipment failure, downtime, and even safety accidents, resulting in significant economic losses and casualties.

[0003] In the existing technology, the visual inspection of welding mainly relies on the inspector's naked eye to observe the surface morphology of the weld to determine whether there are obvious defects such as cracks, pores, slag inclusions, etc. This is carried out after the welding is completed and is a post-inspection. It is unable to monitor the quality changes during the welding process in real time, and cannot promptly discover and correct problems that arise during the welding process, resulting in the possibility that welding defects have already expanded or caused other problems. Summary of the Invention

[0004] The main purpose of this application is to provide a low-pressure outer cylinder welding quality monitoring method, system, equipment and medium, aiming to solve the technical problem that the welding quality inspection performed after the low-pressure outer cylinder welding is completed in the existing technology is a post-inspection and cannot monitor the quality changes during the welding process in real time.

[0005] To achieve the above objectives, in a first aspect, the present application provides a low-pressure outer cylinder welding quality monitoring method, comprising:

[0006] Acquire welding characteristic parameters of the first welding section within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, wire consumption information, and welding equipment stability coefficient;

[0007] evaluating a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality assessment model, and determining whether the first welding quality score is greater than a first preset threshold;

[0008] If not, the welding task is suspended and an alarm signal is issued;

[0009] If yes, obtaining a second welding quality score of at least one second welding segment within a preset time period;

[0010] estimating an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all the second welding quality scores and the first welding quality scores, and determining whether the estimated quality score is greater than a second preset threshold;

[0011] If the estimated quality score is less than or equal to a second preset threshold, the welding strategy is adjusted.

[0012] Optionally, the step of evaluating a first welding quality score of the first welding segment based on a welding quality assessment model according to the welding characteristic parameters and determining whether the first welding quality score is greater than a first preset threshold includes: an expression of the welding quality assessment model is:

[0013]

[0014] Where, represents the first welding quality score, represents the image feature item, represents the weight coefficient of the image feature item, represents the acoustic feature item, represents the weight coefficient of the acoustic feature term, Indicates the wire consumables, represents the weight coefficient of the wire consumable item, represents the health compensation gain coefficient, Indicates the current stability coefficient of the welding equipment. represents the mean value of the historical stability coefficient of welding equipment, Represents the standard deviation of the historical stability coefficient of the welding equipment.

[0015] Optionally, the expression of the image feature term is:

[0016]

[0017] Where, represents the weld area, Represents the grayscale value at time t in the weld area (x, y), The standard deviation is Gaussian kernel, represents the weld area, Represents the two-dimensional convolution operator symbol, Represents the ReLU function.

[0018] Optionally, the expression of the acoustic feature term is:

[0019]

[0020] Where B represents the bandwidth normalization factor, and represents the characteristic frequency range, Represents the arc sound time domain signal, represents the short-time Fourier transform operator, represents short-time Fourier transform; Represents the complex value at frequency f in the spectrum corresponding to time point t; represents the imaginary unit, Indicates the sound wave propagation delay compensation, Used to correct the propagation delay of sound waves The phase shift caused by represents a frequency variable.

[0021] Alternatively, the expression for wire consumption is:

[0022]

[0023] Where, Indicates the length of the monitoring time window, represents the decay constant, Indicates time Total wire consumption at Indicates time The instantaneous consumption rate, Indicates the current time point, represents the time-integrated variable.

[0024] Optionally, the step of estimating an estimated quality score of the unwelded third weld section of the low-pressure outer cylinder based on all the second welding quality scores and the first welding quality score, and determining whether the estimated quality score is greater than a second preset threshold includes:

[0025] The expression for the estimated quality score of the third weld segment is:

[0026]

[0027] Where m represents the number of welded sections, k represents the index of the historical weld section, A temporary index variable representing the normalized denominator, represents the attenuation coefficient, represents the gradient of the heat-affected zone, represents the gradient coefficient of the heat-affected zone, Represents the process parameter correction factor.

[0028] Optionally, if the estimated quality score is less than or equal to a second preset threshold, the step of adjusting the welding strategy includes:

[0029] Do at least one of the following:

[0030] Correct welding process parameters in real time based on deviations in key parameters that lead to insufficient estimated quality scores;

[0031] Weakening caused by equipment failure or component aging resulting in reduced welding quality;

[0032] Reduce welding defects caused by spatial position through path planning or operation correction;

[0033] Forcefully suspend the welding task and start the manual intervention process.

[0034] In a second aspect, the present application provides a low-pressure outer cylinder welding quality monitoring system, comprising:

[0035] a characteristic parameter acquisition module configured to acquire welding characteristic parameters of a first welding segment within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, wire consumption information, and welding equipment stability coefficient;

[0036] a first welding quality score obtaining module configured to evaluate a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality evaluation model, and determine whether the first welding quality score is greater than a first preset threshold;

[0037] If not, the welding task is suspended and an alarm signal is issued;

[0038] If yes, obtaining a second welding quality score of at least one second welding segment within a preset time period;

[0039] an estimated quality score acquisition module configured to estimate an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all second weld quality scores and the first weld quality score, and determine whether the estimated quality score is greater than a second preset threshold;

[0040] The welding strategy adjustment module is configured to adjust the welding strategy if the estimated quality score is less than or equal to a second preset threshold.

[0041] In a third aspect, the present application provides a computer device comprising a memory and a processor, wherein the memory stores a computer program that can be run on the processor, and when the processor executes the computer program, the low-voltage outer cylinder welding quality monitoring method as described above is implemented.

[0042] In a fourth aspect, the present application provides a computer-readable storage medium, characterized in that it stores a computer program that can be loaded and executed by a processor such as the above-mentioned low-voltage outer cylinder welding quality monitoring method.

[0043] Beneficial effects that this application can achieve:

[0044] The low-pressure outer cylinder welding quality monitoring method, system, equipment and medium proposed in the embodiment of the present application have at least the following beneficial effects: by obtaining the welding characteristic parameters of the first welding section within a preset time period and evaluating the first welding quality score based on the welding quality assessment model, the welding quality can be quantitatively assessed in real time. When the first welding quality score is not greater than the first preset threshold, the welding task is promptly suspended and an alarm signal is issued to prevent unqualified welding from continuing; monitoring the welding process from multiple dimensions can more comprehensively and accurately reflect the welding quality status, greatly improving the accuracy and reliability of welding quality assessment compared to single parameter monitoring; and adjusting the welding strategy in a timely manner based on the comparison result between the estimated quality score and the second preset threshold. This method of dynamically adjusting the welding strategy can prevent the occurrence of welding quality problems in advance, improve the stability of the subsequent welding process and the consistency of the welding quality, and improve the overall welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 This is a flow chart of a welding quality monitoring method according to an embodiment of the present application;

[0046] Figure 2 This is a schematic diagram of the upper half of the low-pressure outer cylinder structure;

[0047] Figure 3 This is a schematic diagram of the lower half of the low-pressure outer cylinder structure.

[0048] The realization of the objectives, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0049] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0050] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0051] In the present invention, unless otherwise specified or limited, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can mean fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0052] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of such features. In addition, the meaning of "and / or" appearing throughout the text includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme in which A and B are satisfied at the same time. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0053] Example 1

[0054] Reference Figure 1 The first embodiment of the present application provides a method for monitoring the welding quality of a low-pressure outer cylinder, comprising the following steps:

[0055] S10. Obtain welding characteristic parameters of the first welding section within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, welding wire consumption information, and welding equipment stability coefficient.

[0056] Alternatively, as Figure 2 and Figure 3 The figure shows the upper and lower sections of the overall structure of a nuclear power plant's low-voltage outer cylinder. A support structure facilitates welding of the various shell components. The main body is welded from steel plates and reinforced with ribs. The outer cylinder is a hollow shell. The outer shell is disassembled and trial-assembled using 3D software such as UG or SolidWorks to ensure uniform welding stress distribution and a symmetrical structure.

[0057] Based on welding process requirements and actual production experience, determine an appropriate time period, such as 5 or 10 minutes, that fully reflects the stability of the current welding state. Use a high-resolution industrial camera to capture weld seam images. Mount the camera at an appropriate position and angle to ensure clear capture of the weld seam image of the first weld section. Set camera parameters, such as exposure time, focal length, and frame rate, to ensure image quality. Continuously capture weld seam images at a set frequency (e.g., 10 frames per second) over a preset time period. Use a highly sensitive acoustic sensor to capture arc sound signals. Mount the sensor close to the welding arc to accurately capture arc sound signals. Calibrate the acoustic sensor to ensure it accurately captures changes in arc sound frequency and intensity. Record the arc sound signals in real time over a preset time period and convert them into digital signals for storage. Install a flow sensor or counter in the wire feeding system to measure wire consumption over a preset time period. Regularly read the sensor data to record wire consumption in length or weight. Obtain equipment operating parameters, such as welding current, voltage, wire feed speed, and gas flow, through the welding equipment's control system or sensors. Analyze whether these parameters are within the normal range, as well as the operating stability of the equipment, comprehensively evaluate the health status of the welding equipment, and quantify it as a stability coefficient.

[0058] S20. Evaluate a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality evaluation model, and determine whether the first welding quality score is greater than a first preset threshold.

[0059] Optionally, characteristic parameters such as the weld image information, arc sound signal, wire consumption information, and welding equipment stability coefficient collected for the first weld segment are input into a welding quality assessment model. The model calculates based on the input characteristic parameters and outputs a first welding quality score for the first weld segment, typically using a percentage or ten-point scale. A first preset threshold, such as 80 points (on a percentage scale), is set based on welding quality standards and actual production requirements. The first welding quality score is compared with the first preset threshold to determine whether it exceeds the first preset threshold.

[0060] S30: If the first welding quality score is less than or equal to a first preset threshold, suspend the welding task and issue an alarm signal.

[0061] Optionally, a pause command can be sent through the welding equipment's control system to immediately halt welding operations, including stopping wire feed and cutting off welding current. On-site audio and visual alarms, such as alarm bells and flashing lights, can be activated to alert operators. Simultaneously, the alarm information can be sent to relevant monitoring terminals, such as the workshop manager's mobile phone or computer, so that timely action can be taken.

[0062] S40: If the first welding quality score is greater than a first preset threshold, obtain a second welding quality score of at least one second welding segment within a preset time period.

[0063] Optionally, after the first weld segment, at least one second weld segment is determined according to the welding sequence. The welding time of the second weld segment is earlier than that of the first weld segment. For each second weld segment, the operations of S10 and S20 are repeated to obtain its welding characteristic parameters, and a second weld quality score is evaluated based on the welding quality assessment model.

[0064] S50 , estimating an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all the second welding quality scores and the first welding quality scores, and determining whether the estimated quality score is greater than a second preset threshold.

[0065] Optionally, the first welding quality score and all second welding quality scores can be integrated to analyze welding quality trends. A prediction model can be established using methods such as time series analysis and regression analysis to estimate the quality score of the third weld segment based on the existing welding quality score data. A second preset threshold, such as 75 (out of 100), can be set based on welding quality requirements and subsequent processing needs. The estimated quality score is then compared to the second preset threshold to determine whether it exceeds the second preset threshold.

[0066] S60: If the estimated quality score is less than or equal to a second preset threshold, adjust the welding strategy.

[0067] Optionally, analyze the reasons for the low estimated quality score. Possible causes include inappropriate welding parameters, poor welding material quality, and degraded equipment performance. Based on the analysis results, formulate a corresponding welding strategy adjustment plan, such as adjusting parameters such as welding current, voltage, and welding speed, replacing welding materials, and performing equipment maintenance and servicing. Adjust the welding process according to the adjustment plan and re-monitor the welding quality to ensure effective improvement in welding quality.

[0068] Optionally, if the estimated quality score is greater than a second preset threshold, it indicates that the expected quality of the unwelded weld segment meets the requirements, and the welding strategy is not changed, and welding is continued according to the original welding strategy.

[0069] Example 2

[0070] Based on Example 1, this embodiment provides a method for monitoring the welding quality of a low-pressure outer cylinder, including the following steps:

[0071] S10. Obtain welding characteristic parameters of the first welding section within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, welding wire consumption information, and welding equipment stability coefficient.

[0072] S20. Evaluate a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality evaluation model, and determine whether the first welding quality score is greater than a first preset threshold.

[0073] Optionally, the step of evaluating the first welding quality score of the first welding segment based on the welding characteristic parameters and the welding quality assessment model, and determining whether the first welding quality score is greater than a first preset threshold, includes: the expression of the welding quality assessment model is:

[0074]

[0075] Where, represents the first welding quality score, represents the image feature item, represents the weight coefficient of the image feature item, represents the acoustic feature item, represents the weight coefficient of the acoustic feature term, Indicates the wire consumables, represents the weight coefficient of the wire consumable item, represents the health compensation gain coefficient, Indicates the current stability coefficient of the welding equipment. Represents the mean value of the historical stability coefficient of welding equipment, Represents the standard deviation of the historical stability coefficient of the welding equipment.

[0076] Represents image feature items, which are used to quantify the surface morphology quality of welds (defects such as pores and undercuts).

[0077] Represents the acoustic feature item, which is used to capture arc stability and abnormal discharge characteristics (spatter, short circuit, etc.).

[0078] Represents the wire consumption item, which is used to evaluate wire supply stability and deposition efficiency.

[0079] Weight constraints , .

[0080] Represents the health compensation gain coefficient, which is used to adjust the impact of the health compensation item on the overall score.

[0081] The stability coefficient of the welding equipment is the current stability coefficient, which comprehensively reflects the operating status of the welding equipment at time t, including various performance indicators of the equipment, fault conditions, etc. For example, parameters such as temperature, pressure, and vibration of the equipment can all be used as components of the stability coefficient.

[0082] The average value of the historical stability coefficient of the welding equipment represents the average operating status of the welding equipment in the past period of time. By comparing, we can understand the deviation between the current status of the equipment and the historical average status.

[0083] The standard deviation of the historical stability coefficient of the welding equipment reflects the degree of fluctuation in the historical operating status of the welding equipment. The larger the standard deviation, the greater the fluctuation in the equipment operating status; the smaller the standard deviation, the more stable the equipment operating status.

[0084] represents the hyperbolic tangent function, The value of is mapped to When near hour, Approaching 0; when Deviation When it is larger, near .

[0085] Optionally, the expression of the image feature term is:

[0086]

[0087] Where, represents the weld area, Represents the grayscale value at time t in the weld area (x, y), The standard deviation is Gaussian kernel, represents the weld area, Represents the two-dimensional convolution operator symbol, represents the Laplace operator, Represents the ReLU function.

[0088] Represents the area of the weld region and is used to normalize the integration results so that the value of the image feature item is not affected by the size of the weld region.

[0089] It reflects the brightness information of the weld image at different positions and time points.

[0090] Used to smooth images and reduce noise interference.

[0091] Represents the weld area, that is, the range of integration is the entire weld area.

[0092] Represents the two-dimensional convolution operator, which convolves the Gaussian kernel with the image to extract local features of the image.

[0093] represents Gaussian kernel convolution ( pixels), which plays a role in suppressing image noise and retaining the macroscopic morphological features of the weld area.

[0094] Represents the Laplace operator, which is used to detect edge and texture information in images and enhance edges and curvature mutation areas (corresponding to defects such as pores and cracks)

[0095] Represents the ReLU function (Rectified Linear Unit), that is , sets the negative values in the convolution result to 0, retains the positive values, and highlights the significant features in the image. Filter the negative responses and only retain the raised defect features (such as weld nodules).

[0096] Image feature items reflect the appearance quality of the weld by extracting detailed information such as the edge and texture of the weld image, such as the weld shape, the presence of cracks, pores and other defects, and play an important role in welding quality assessment. Determines the relative importance of image feature items in the overall evaluation.

[0097] Optionally, the expression of the acoustic feature term is:

[0098]

[0099] Where B represents the bandwidth normalization factor, and represents the characteristic frequency range, Represents the arc sound time domain signal, represents the short-time Fourier transform operator, represents short-time Fourier transform; Represents the complex value at frequency f in the spectrum corresponding to time point t; represents the imaginary unit, Indicates the sound wave propagation delay compensation, Used to correct the propagation delay of sound waves The phase shift caused by represents a frequency variable.

[0100] B represents the bandwidth normalization factor, which is used to normalize the integration result so that the value of the acoustic feature item is not affected by the bandwidth.

[0101] and It represents the characteristic frequency range, which determines the frequency interval of the arc sound signal that needs to be analyzed.

[0102] Represents the arc sound time domain signal, which contains the sound information generated during the arc burning process.

[0103] Represents the short-time Fourier transform operator, which transforms the time domain signal Convert to the frequency domain to obtain the signal amplitude and phase information at different frequencies.

[0104] Represents short-time Fourier transform (window length 32ms, overlap 50%), which is used to extract the time-frequency characteristics of arc sound.

[0105] Indicates the complex value at frequency f in the spectrum corresponding to time point t. For example: if the arc sound signal Frame and calculate STFT near time t, then is the spectrum amplitude and phase of the frame signal at frequency f.

[0106] Represents the imaginary unit, which is used to represent phase information in complex number operations.

[0107] Indicates sound wave propagation delay compensation, which is used to correct the delay difference caused by different sound wave propagation distances. , where c is the speed of sound and d is the distance.

[0108] represents the phase compensation term, which eliminates the acoustic wave propagation delay caused by the sensor position.

[0109] Represents a frequency variable, indicating a specific frequency point in frequency domain analysis.

[0110] Represents the characteristic frequency band integral, which is used to focus on high-frequency components related to welding anomalies (such as spatter and arc instability).

[0111] Used to calculate the amplitude spectrum of the frequency domain signal after delay compensation.

[0112] The acoustic characteristic item reflects the stability and burning state of the arc by analyzing the frequency characteristics of the arc sound. The frequency and amplitude changes of the arc sound are closely related to the parameters such as arc length, arc voltage, welding current, etc. during the welding process, and can indirectly reflect the welding quality. Weight coefficient Determines the relative importance of acoustic feature items in the overall evaluation.

[0113] Optionally, the expression for wire consumption is:

[0114]

[0115] Where, Indicates the length of the monitoring time window, represents the decay constant, Indicates time Total wire consumption at Indicates time The instantaneous consumption rate, Indicates the current time point, represents the time-integrated variable.

[0116] Indicates that in the time window [ ]Total consumption of internal welding wire.

[0117] Indicates the length of the monitoring time window, which determines the time range for calculating wire consumption.

[0118] Represents the attenuation constant, which is used to weight the wire consumption rate at different times so that the recent consumption rate is The impact is greater.

[0119] Indicates time The total wire consumption at that time reflects the cumulative consumption of welding wire over time.

[0120] Indicates time The instantaneous consumption rate, that is, the consumption of welding wire per unit time, reflects the real-time stability of the deposition process.

[0121] is a decay factor, as decreases as the distance from the current moment increases. The farther the wire is, the faster the wire consumption will be. The smaller the contribution.

[0122] Represents the time window integral, evaluating the short-term cumulative effect of wire consumption.

[0123] represents the time integral variable. During the integration process, from Change to , used to calculate the total amount of welding wire consumed during this time period.

[0124] Indicates the current time point, which is the upper limit of the integral and the lower limit of the integral Together they define the monitoring time window.

[0125] The wire consumption item reflects the stability and efficiency of the welding process by calculating the wire consumption within the monitoring time window. The change in wire consumption rate may be related to factors such as welding parameters and welding process. Abnormal wire consumption may indicate the existence of welding quality problems. Weight coefficient Determines the relative importance of wire consumables in the overall assessment.

[0126] To facilitate understanding, the following examples are given:

[0127] It is now necessary to evaluate the welding quality during the girth welding process of the low-pressure outer casing of the turbine.

[0128] Assume that the initial parameters are set as follows:

[0129] Welding position: flat welding;

[0130] Weight distribution: , , =0.3;

[0131] Health compensation buff: ;

[0132] Equipment stability factor: , , ;

[0133] Monitoring time window: , ;

[0134] Acoustic characteristic frequency band: , , ;

[0135] Image processing parameters: Pixels, weld area .

[0136] The calculation process is as follows:

[0137] Assume that after the weld image is processed at a certain moment: the Laplace-Gaussian convolution result distribution is: the positive response area accounts for 15% (pores, undercut defects); the average positive response intensity is .

[0138] .

[0139] Arc sound analysis results: The energy integral value of the characteristic frequency band is (Unit: Pa²·s / Hz); the effective energy after phase compensation is .

[0140] .

[0141] Normalization processing (assuming the maximum historical value is 50):

[0142] .

[0143] The wire consumption data for the past 30 seconds is as follows:

[0144]

[0145] Calculate the integral term:

[0146] ;

[0147] Normalization processing (theoretical value ):

[0148] .

[0149] Calculation of health compensation factor:

[0150] Normalized health bias: ;

[0151] .

[0152] First welding quality score:

[0153] The first welding quality score is greater than the first preset threshold value of 0.6, indicating that the first welding quality is qualified.

[0154] S30: If the first welding quality score is less than or equal to a first preset threshold, suspend the welding task and issue an alarm signal.

[0155] S40: If the first welding quality score is greater than a first preset threshold, obtain a second welding quality score of at least one second welding segment within a preset time period.

[0156] Specifically, the second welding segment is a welding segment that has been completed. The method for obtaining the second welding quality score of the second welding segment is the same as the method for obtaining the first welding quality score of the first welding segment. This is to distinguish the current welding segment from the welding segment that has been completed. In fact, the second welding segment is dynamically changing, that is, the area to be welded is divided into multiple welding segments. The first welding segment is currently being welded. When the first welding segment is completed, it will be added to the second welding segment set.

[0157] S50 , estimating an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all the second welding quality scores and the first welding quality scores, and determining whether the estimated quality score is greater than a second preset threshold.

[0158] Optionally, the step of estimating an estimated quality score of the unwelded third weld section of the low-pressure outer cylinder based on all the second welding quality scores and the first welding quality score, and determining whether the estimated quality score is greater than a second preset threshold includes:

[0159] The expression for the estimated quality score of the third weld segment is:

[0160]

[0161] Where, represents the estimated quality score of the third weld segment, m represents the number of welded weld segments, k represents the index of the historical weld segment, A temporary index variable representing the normalized denominator, represents the quality score of the kth weld segment, represents the attenuation coefficient, represents the gradient of the heat-affected zone, represents the gradient coefficient of the heat-affected zone, Represents the process parameter correction factor.

[0162] m represents the number of welded segments, including the first weld segment and all second weld segments.

[0163] k represents the index of the historical welding segment, , which means the 1st to mth welded segments in sequence.

[0164] A temporary index variable representing the normalized denominator, Both and k represent the index of the welded weld segment (1 to m), traversing all historical data. K is bound to the specific weld segment in the numerator and used to calculate its score Contribution, It is only used for summation calculation in the denominator and is not directly related to a specific weld segment. It is a local variable in the mathematical expression.

[0165] It represents the attenuation coefficient, which determines the decay rate of the influence of the historical weld quality score on the current estimated score over time (weld sequence).

[0166] , giving higher weight to the recent welding section, the weight is Attenuation reflects the temporal continuity of the welding process, and the recent process status has a greater impact on the prediction.

[0167] By taking a weighted average of the quality scores of historical weld sections, historical weld sections closer to the current estimated weld section have a greater impact on the estimated score, while historical weld sections farther away have a smaller impact. This allows for more rational use of historical welding data and reflects the quality trend of the welding process.

[0168] The heat-affected zone gradient reflects the influence of the heat-affected zone on weld quality during welding. For example, during welding, temperature changes and microstructural transformations in the heat-affected zone can affect weld quality. The heat-affected zone gradient can be calculated by analyzing the temperature and stress fields in the weld area.

[0169] The expression is .

[0170] In the formula It represents the mass gradient and is used to calculate the mass change rate per unit length of adjacent weld segments, reflecting the cumulative effect of welding heat. If the mass of the last segment decreases rapidly, it indicates that there is an abnormality in the heat-affected zone (HAZ).

[0171] It represents the attenuation factor, which is affected by the exponential attenuation gradient according to the distance d, in accordance with the law of heat conduction. The farther the distance, the smaller the effect.

[0172] Indicates the heat affected zone gradient coefficient, which is used to adjust the influence of the heat affected zone gradient on the estimated quality score. According to the characteristics of the welding process and the importance of the heat affected zone, the heat affected zone gradient can be adjusted. For example, if the heat affected zone has a greater impact on the welding quality, The value can be increased appropriately.

[0173] Considering the influence of heat-affected zone on welding quality, by introducing heat-affected zone gradient and corresponding coefficient, the estimated quality score can more accurately reflect the heat-affecting factors in the welding process and improve the accuracy of the estimation.

[0174] against :

[0175] Indicates different categories of process parameters. For example, May indicate welding current, Indicates welding voltage, represents the substrate temperature gradient, Indicates ambient humidity, etc.

[0176] It is the process parameter correction factor, which is based on the specific process parameter value Correct the estimated quality score. The correction factor can be calculated based on experimental data, empirical formula or theoretical model. For example, for welding current , if the welding current is within the appropriate range, The value is close to 1; if the welding current is too large or too small, The value of will be reduced accordingly to reflect the negative impact of welding current on welding quality.

[0177]

[0178] Where, represents the theoretical optimal value, Indicates the theoretical maximum value.

[0179] When the parameter Deviation from the optimal value When the deviation is less than 0.05, the score decays in a square relationship to strengthen the process discipline: small deviations will result in slight deductions, and large deviations will result in severe penalties (for example, a 64% deduction for a current deviation of ±8%).

[0180] When the limit is exceeded, the correction factor is forcibly set to 0.2 to avoid unreasonable predictions under extreme working conditions and trigger the parameter reconstruction mechanism.

[0181] Multi-parameter joint correction (current, gas, humidity, temperature gradient) conforms to the multi-factor coupling characteristics of welding quality.

[0182] Considering the impact of process parameters on welding quality, by correcting different process parameters, the estimated quality score can more accurately reflect the quality under actual welding process conditions. Different process parameter combinations will lead to changes in welding quality. By introducing process parameter correction factors, the estimated score can be fine-tuned.

[0183] S60: If the estimated quality score is less than or equal to a second preset threshold, adjust the welding strategy.

[0184] Optionally, if the estimated quality score is greater than a second preset threshold, it indicates that the expected quality of the unwelded weld segment meets the requirements, and the welding strategy is not changed, and welding is continued according to the original welding strategy.

[0185] Optionally, if the estimated quality score is less than or equal to a second preset threshold, the step of adjusting the welding strategy includes:

[0186] Do at least one of the following:

[0187] S601, correcting welding process parameters in real time based on key parameter deviations that lead to insufficient estimated quality scores;

[0188] Optionally, first determine which welding process parameters have the greatest impact on the estimated quality score. For example, welding current, welding voltage, welding speed, wire stickout length, etc. Compare the actual welding process parameters to the preset optimal parameter range to identify parameters with significant deviations.

[0189] Analyze the historical and current data of these parameters using data analysis tools, such as statistical process control (SPC) charts, to identify trends and the extent of deviations. For example, if the welding current is consistently below the optimal range and the deviations are large, then the welding current is one of the key parameters that is causing the estimated quality score to fall short.

[0190] Based on the magnitude and direction of key parameter deviations, the control parameters of the welding equipment are adjusted in real time. For example, if the welding current is too low, the output current of the welding power supply can be increased to correct it; if the welding speed is too fast, the movement speed of the welding carriage can be reduced.

[0191] Establish a feedback mechanism for parameter corrections to ensure that the corrected parameters are reflected in the welding process in real time. For example, use sensors to monitor changes in welding parameters in real time and feed this data back to the control system, which then adjusts the parameters accordingly. Continuously monitor the corrected welding process to evaluate the effectiveness of the corrections. If the estimated quality score is still insufficient, further analysis is needed to determine the cause and adjust the correction strategy.

[0192] S602, weakening due to equipment failure or component aging caused by the decline in welding quality;

[0193] Optionally, conduct a comprehensive inspection of the welding equipment, including the electrical, mechanical, and control systems. Use specialized inspection tools and methods, such as vibration analysis, infrared thermal imaging, and electrical performance testing, to promptly identify signs of equipment failure and component degradation. Establish a database of equipment failures and component degradation, recording information such as the type, time of occurrence, and severity of the failures and degradation. By analyzing this database, predict potential failures and degradation issues and take preventative measures.

[0194] In the event of equipment failure, repair and replace faulty parts promptly. During repairs, strictly follow the equipment manufacturer's maintenance manual to ensure quality repairs. For aging components, develop a reasonable replacement plan based on the component's service life and performance. When replacing components, select reliable and stable components to ensure normal operation of the equipment.

[0195] Optimize the welding process and reduce dependence on equipment performance. For example, adjust welding parameters to reduce the requirements for equipment accuracy and stability; adopt redundant design so that when a component fails, other components can continue to work, ensuring the continuity of the welding process.

[0196] S603. Reduce welding defects caused by spatial position through path planning or operation correction;

[0197] Optionally, perform a detailed analysis of the spatial position of the welded workpiece to identify potential welding difficulties and defect-prone areas. For example, complex workpieces may present problems such as cramped space and poor welding angles. Use 3D modeling software to simulate the welding process and predict weld quality at different spatial locations. The simulation results can help identify areas requiring attention and potential defect types.

[0198] Based on the results of spatial position analysis, the welding path is optimized. For example, the motion trajectory of the welding robot is adjusted to avoid complex operations in narrow spaces; multi-pass welding processes are used to reduce the thickness of a single weld and reduce the welding difficulty.

[0199] During the welding process, the welding quality is monitored in real time. When welding defects caused by spatial position are found, the welding path or operation method is adjusted in time. For example, the weld seam tracking system can automatically adjust the welding path to ensure the quality of the weld.

[0200] S604: Forcefully suspend the welding task and start the manual intervention process.

[0201] Optionally, specify conditions that will force the welding task to be suspended, such as when the estimated quality score falls below a certain threshold, when a serious equipment failure or safety hazard occurs, etc. These conditions can be set according to the requirements and quality standards of the welding process.

[0202] Set up corresponding alarm and pause mechanisms in the welding control system. When the pause conditions are met, the system automatically sends an alarm signal and pauses the welding task.

[0203] When a welding task is suspended, the manual intervention process is immediately initiated. The relevant technicians and quality management personnel are notified to arrive at the site to conduct a comprehensive assessment of the welding situation.

[0204] Technicians inspect and debug welding equipment to eliminate equipment failures; quality management personnel analyze welding quality to determine the reasons for the insufficient estimated quality score.

[0205] Based on the evaluation results, formulate appropriate solutions. If it is necessary to adjust welding process parameters, replace equipment components, or modify the welding path, follow the corresponding procedures.

[0206] After the problem is solved, the welding equipment is re-debugged and tested to ensure that the welding quality meets the requirements before resuming the welding task.

[0207] Example 3

[0208] Based on Example 1, this embodiment provides a low-pressure outer cylinder welding quality monitoring system, including:

[0209] a characteristic parameter acquisition module configured to acquire welding characteristic parameters of a first welding segment within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, wire consumption information, and welding equipment stability coefficient;

[0210] a first welding quality score obtaining module configured to evaluate a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality evaluation model, and determine whether the first welding quality score is greater than a first preset threshold;

[0211] If not, the welding task is suspended and an alarm signal is issued;

[0212] If yes, obtaining a second welding quality score of at least one second welding segment within a preset time period;

[0213] an estimated quality score acquisition module configured to estimate an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all second weld quality scores and the first weld quality score, and determine whether the estimated quality score is greater than a second preset threshold;

[0214] The welding strategy adjustment module is configured to adjust the welding strategy if the estimated quality score is less than or equal to a second preset threshold.

[0215] Example 4

[0216] This embodiment provides a computer device, including a memory and a processor, wherein the memory stores a computer program that can be run on the processor, and when the processor executes the computer program, it implements any of the above-mentioned low-pressure outer cylinder welding quality monitoring methods.

[0217] Example 5

[0218] This embodiment provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed by the above-mentioned low-voltage outer cylinder welding quality monitoring method.

[0219] In some embodiments, the computer-readable storage medium may be a memory device such as FRAM, ROM, PROM, EPROM, EEPROM, flash memory, magnetic surface mount memory, optical disk, or CD-ROM; or various devices including any one or any combination of the above memories. The computer may be various computing devices including smart terminals and servers.

[0220] In the above embodiments of the present disclosure, the description of each embodiment has its own focus. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0221] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. Among them, the device embodiments described above are only exemplary. For example, the division of units can be a logical function division. In actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of units or modules, which can be electrical or other forms.

[0222] Units described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple units. Some or all of the units may be selected to achieve the purpose of the present embodiment according to actual needs.

[0223] In addition, the functional units in the various embodiments of the present disclosure may be integrated into a single processing unit, or each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or software functional units.

[0224] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable non-volatile storage medium. Based on this understanding, the technical solution of the present invention is essentially or the part that contributes to the prior art or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a non-volatile storage medium, including a number of instructions for enabling a computer device (which can be a personal computer, server or network device, etc.) to execute all or part of the steps of the various embodiments of the present invention. The aforementioned non-volatile storage medium includes: U disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), mobile hard disk, magnetic disk or optical disk and other media that can store program code.

[0225] The above are only preferred embodiments of the present application and do not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A method for monitoring the welding quality of a low-pressure outer cylinder, characterized in that: include: Acquire welding characteristic parameters of the first welding section within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, wire consumption information, and welding equipment stability coefficient; evaluating a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality assessment model, and determining whether the first welding quality score is greater than a first preset threshold; If not, the welding task is suspended and an alarm signal is issued; If yes, obtaining a second welding quality score of at least one second welding segment within a preset time period; estimating an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all the second welding quality scores and the first welding quality scores, and determining whether the estimated quality score is greater than a second preset threshold; If the estimated quality score is less than or equal to a second preset threshold, adjusting the welding strategy; The expression of the welding quality assessment model is: Where, represents the first welding quality score, represents the image feature item, represents the weight coefficient of the image feature item, represents the acoustic feature item, represents the weight coefficient of the acoustic feature term, Indicates the wire consumables, represents the weight coefficient of the wire consumable item, represents the health compensation gain coefficient, Indicates the current stability coefficient of the welding equipment. represents the mean value of the historical stability coefficient of welding equipment, Indicates the standard deviation of the historical stability coefficient of the welding equipment; The expression of image feature term is: Where, represents the weld area, Represents the grayscale value at time t in the weld area (x, y), The standard deviation is Gaussian kernel, represents the weld area, Represents the two-dimensional convolution operator symbol, represents the Laplace operator, Represents the ReLU function; The expression of the acoustic characteristic term is: Where B represents the bandwidth normalization factor, and represents the characteristic frequency range, Represents the arc sound time domain signal, represents the short-time Fourier transform operator, represents short-time Fourier transform; Represents the complex value at frequency f in the spectrum corresponding to time point t; represents the imaginary unit, Indicates the sound wave propagation delay compensation, Used to correct the propagation delay of sound waves The phase shift caused by represents a frequency variable; The expression of wire consumption is: Where, Indicates the length of the monitoring time window, represents the decay constant, Indicates time Total wire consumption at Indicates time The instantaneous consumption rate, Indicates the current time point, represents the time-integrated variable; The expression for the estimated quality score of the third weld segment is: Where m represents the number of welded sections, k represents the index of the historical weld section, A temporary index variable representing the normalized denominator, represents the quality score of the kth weld segment, represents the attenuation coefficient, represents the gradient of the heat-affected zone, represents the gradient coefficient of the heat-affected zone, Represents the process parameter correction factor.

2. The low-pressure outer cylinder welding quality monitoring method according to claim 1, characterized in that: If the estimated quality score is less than or equal to a second preset threshold, the step of adjusting the welding strategy comprises: Do at least one of the following: Correct welding process parameters in real time based on deviations in key parameters that lead to insufficient estimated quality scores; Weakening caused by equipment failure or component aging resulting in reduced welding quality; Reduce welding defects caused by spatial position through path planning or operation correction; Forcefully suspend the welding task and start the manual intervention process.

3. A low-pressure outer cylinder welding quality monitoring system, characterized in that: include: a characteristic parameter acquisition module configured to acquire welding characteristic parameters of a first welding segment within a preset time period, wherein the welding characteristic parameters include at least one of weld image information, arc sound signal, wire consumption information, and welding equipment stability coefficient; a first welding quality score obtaining module configured to evaluate a first welding quality score of the first welding segment based on the welding characteristic parameters and a welding quality evaluation model, and determine whether the first welding quality score is greater than a first preset threshold; If not, the welding task is suspended and an alarm signal is issued; If yes, obtaining a second welding quality score of at least one second welding segment within a preset time period; an estimated quality score acquisition module configured to estimate an estimated quality score of a third unwelded weld section of the low-pressure outer cylinder based on all second weld quality scores and the first weld quality score, and determine whether the estimated quality score is greater than a second preset threshold; a welding strategy adjustment module configured to adjust the welding strategy if the estimated quality score is less than or equal to a second preset threshold; The expression of the welding quality assessment model is: Where, represents the first welding quality score, represents the image feature item, represents the weight coefficient of the image feature item, represents the acoustic feature item, represents the weight coefficient of the acoustic feature term, Indicates the wire consumables, represents the weight coefficient of the wire consumable item, represents the health compensation gain coefficient, Indicates the current stability coefficient of the welding equipment. represents the mean value of the historical stability coefficient of welding equipment, Indicates the standard deviation of the historical stability coefficient of the welding equipment; The expression of image feature term is: Where, represents the weld area, Represents the grayscale value at time t in the weld area (x, y), The standard deviation is Gaussian kernel, represents the weld area, Represents the two-dimensional convolution operator symbol, represents the Laplace operator, Represents the ReLU function; The expression of the acoustic characteristic term is: Where B represents the bandwidth normalization factor, and represents the characteristic frequency range, Represents the arc sound time domain signal, represents the short-time Fourier transform operator, represents short-time Fourier transform; Represents the complex value at frequency f in the spectrum corresponding to time point t; represents the imaginary unit, Indicates the sound wave propagation delay compensation, Used to correct the propagation delay of sound waves The phase shift caused by represents a frequency variable; The expression of wire consumption is: Where, Indicates the length of the monitoring time window, represents the decay constant, Indicates time Total wire consumption at Indicates time The instantaneous consumption rate, Indicates the current time point, represents the time-integrated variable; The expression for the estimated quality score of the third weld segment is: Where m represents the number of welded sections, k represents the index of the historical weld section, A temporary index variable representing the normalized denominator, represents the quality score of the kth weld segment, represents the attenuation coefficient, represents the gradient of the heat-affected zone, represents the gradient coefficient of the heat-affected zone, Represents the process parameter correction factor.

4. A computer device, characterized in that: It comprises a memory and a processor, wherein the memory stores a computer program that can be run on the processor, and when the processor executes the computer program, the low-voltage outer cylinder welding quality monitoring method according to claim 1 or 2 is implemented.

5. A computer-readable storage medium, characterized in that A computer program is stored which can be loaded by a processor and executes the method for monitoring the welding quality of a low-voltage outer cylinder according to claim 1 or 2.

Images