Synchronizer and real-time acquisition system of molten pool image and welding parameters during welding process

Abstract

The application relates to the field of additive automatic control, and discloses a synchronizer and a molten pool image and welding parameter real-time acquisition system in a welding process. The synchronizer comprises a synchronous control unit and multiple pulse signal units. The synchronous control unit is connected with the multiple pulse signal units, can control the frequency and phase of the pulse signals generated by the multiple pulse signal units, and makes the multiple pulse signal units synchronously generate multiple pulse synchronization signals. The molten pool image and welding parameter real-time acquisition system in the welding process comprises a welding machine, a molten pool camera, a welding parameter acquisition device, an upper computer and the synchronizer. The molten pool camera is arranged towards a welding station of the welding machine. The welding parameter acquisition device is connected with the welding machine. The synchronizer is connected with the molten pool camera and the welding parameter acquisition device. The upper computer is connected with the welding machine, the molten pool camera, the welding parameter acquisition device and the synchronizer. The molten pool image and the machining parameter information can be synchronously and real-timely transmitted.

Description

Technical Field

[0001] This application relates to the field of additive manufacturing automation control, specifically to a synchronizer. Furthermore, this application also relates to a real-time acquisition system for molten pool images and welding parameters during the welding process. Background Technology

[0002] Additive manufacturing is a technology that uses the gradual accumulation of materials to create solid parts. In a broad sense, additive manufacturing includes 3D printing, cladding, and welding. During additive manufacturing, a molten pool is typically formed on the base material using lasers and / or electric arcs. Additive materials are melted into the molten pool, and after solidification, the corresponding solid structure is formed. The state of the molten pool can reflect various quality information in additive manufacturing. By acquiring and analyzing molten pool images, potential defects or flaws in the additive manufacturing process can be detected and addressed promptly, ensuring the quality of additive manufacturing.

[0003] The quality of additive manufacturing is typically achieved by controlling processing parameters such as voltage, current, and wire feed speed. Adjustments to these parameters often result in changes to the molten pool image. To achieve automated control and ensure quality in additive manufacturing, it's usually necessary to compare and analyze the molten pool morphology in images acquired at the same time with the processing parameters such as voltage, current, and wire feed speed. Adjustments to the processing parameters are made based on changes in the molten pool morphology to maintain quality. Processing and analysis of the molten pool image typically require a host computer. Therefore, the molten pool image acquired by the camera, along with the processing parameters such as voltage, current, and wire feed speed, must be transmitted to the host computer, ensuring precise matching between different molten pool images and the processing parameters at the same time.

[0004] To ensure accurate matching between the molten pool image and processing parameters, the common method is to deploy a Network Time Protocol (NTP) server on the host computer and deploy NTP clients on each subordinate device. These clients periodically synchronize their time with the NTP server. Simultaneously, when a subordinate device sends data, its local time is included in the data. The host computer then matches the data against the local time in the molten pool image and the local time in the processing parameter information. However, this method requires all subordinate devices to have an NTP client deployed. For resource-constrained subordinate devices such as microcontrollers, deployment is either impossible due to hardware limitations or prohibitively expensive. Furthermore, the inclusion of local time in all data sent by subordinate devices increases the amount of data transmitted, requiring greater bandwidth and impacting real-time performance. The host computer also needs to parse and process the time information in the data, affecting the real-time performance of data acquisition and matching analysis. Moreover, time synchronization errors between the NTP server and subordinate devices can reach hundreds of milliseconds due to network conditions, severely impacting local time consistency and easily leading to data matching errors between different subordinate devices. Summary of the Invention

[0005] To achieve synchronous and real-time transmission of molten pool image data and processing parameter data, this application provides a synchronizer and a real-time acquisition system for molten pool images and welding parameters during the welding process.

[0006] The synchronizer provided in this application adopts the following technical solution: A synchronizer includes a synchronization control unit and a plurality of pulse signal units. The synchronization control unit is connected to the plurality of pulse signal units to control the frequency and phase of the pulse signals generated by the plurality of pulse signal units, so that the plurality of pulse signal units can synchronously generate multiple pulse synchronization signals.

[0007] By adopting the above technical solution, multiple pulse signal units connected to the synchronization control unit can be used to synchronously generate multiple pulse synchronization signals with the same frequency and phase requirements under the control of the synchronization control unit. These signals are used to synchronously trigger multiple different subordinate devices, thereby achieving synchronous operation of different subordinate devices.

[0008] In one specific implementation, the pulse signal unit is capable of generating pulse width modulation pulses, and the synchronization control unit is capable of adjusting the phase of the pulse signal generated by each pulse signal unit, thereby individually adjusting the lead time of the pulse signals generated by different pulse signal units.

[0009] By adopting the above technical solution, the pulse width modulation pulses generated by the pulse signal unit enable different pulse signal units to produce pulse signals with different pulse widths. This allows for adaptation to the different trigger pulse durations of different subordinate devices, ensuring that all subordinate devices can be reliably triggered. By using multiple pulse width signal units to generate multiple pulse width modulation pulses, the phase of the pulse signal generated by each pulse signal unit can be adjusted independently, thereby allowing for individual adjustment of the lead time of each pulse signal. This is used to control subordinate devices with different signal acquisition times, enabling different subordinate devices to complete signal acquisition and transmit the acquired signals synchronously.

[0010] In one specific implementation, the synchronization control unit and the multiple pulse signal units are all implemented using a microprocessor. The synchronizer also includes a multi-channel synchronization signal output interface unit and an external IO enable interface unit. The multi-channel synchronization signal output interface unit includes a multi-channel pulse signal output interface and is connected to multiple GPIO pins of the microprocessor. The external IO enable interface unit includes an enable signal input interface and is connected to another GPIO pin of the microprocessor.

[0011] By adopting the above technical solution, a microprocessor is used to implement a synchronization control unit and multiple pulse signal units. This not only improves the synchronization of the multiple pulse signal units but also allows for flexible setting of the frequency, pulse width, and pulse phase of different pulse synchronization signals, resulting in higher resolution for the pulse signal units. By connecting multiple GPIO pins of the microprocessor to a multi-channel synchronization signal output interface unit and an external IO enable interface unit, the pulse synchronization signals output by the microprocessor and the enable signals input to the microprocessor can be processed. This reduces the impact of output and input signals on the microprocessor while outputting pulse synchronization signals compatible with subordinate devices and receiving external control signals.

[0012] In one specific implementation, the multi-channel synchronization signal output interface unit further includes an opto-isolation module and an output pulse shaping module. The input terminal of the opto-isolation module is connected to multiple GPIO pins of the microprocessor, and the output terminal is connected to the output pulse shaping module to obtain the multi-channel pulse synchronization signal generated by the microprocessor. The signal is then transmitted to the output pulse shaping module through a channel isolated from the microprocessor. The output pulse shaping module is connected to the multi-channel pulse signal output interface to process the pulse synchronization signal and output it through the multi-channel pulse signal output interface.

[0013] By adopting the above technical solution, and utilizing an opto-isolation module connected to multiple GPIO pins of the microprocessor, electrical isolation can be achieved between the output pulse shaping module and the microprocessor, reducing the impact of external circuits and modules on the microprocessor. The output pulse shaping module can process the pulse synchronization signal to generate pulse synchronization signal outputs with levels and impedances that meet the triggering requirements of different subordinate devices, ensuring effective synchronous triggering of different subordinate devices.

[0014] The real-time acquisition system for molten pool images and welding parameters during the welding process provided in this application adopts the following technical solution: A real-time acquisition system for molten pool images and welding parameters during welding includes a welding machine, a molten pool camera, a welding parameter acquisition device, a host computer, and a synchronizer provided in this application. The molten pool camera is positioned facing the welding station of the welding machine to acquire molten pool images during welding machine operation. The welding parameter acquisition device is connected to the welding machine to acquire welding parameter signals during welding machine operation. The synchronizer is connected to both the molten pool camera and the welding parameter acquisition device to generate synchronization signals and control the molten pool camera and welding parameter acquisition device to synchronously acquire the molten pool images and welding parameter signals. The host computer is connected to the welding machine, the molten pool camera, the welding parameter acquisition device, and the synchronizer to control the working state of the molten pool camera and the welding parameter acquisition device, synchronously receive and process the molten pool images and welding parameter signals, and adjust the welding parameters of the welding machine according to the processing results.

[0015] By adopting the above technical solution, the synchronizer provided in this application generates a synchronization signal to control the molten pool camera and welding parameter acquisition device to synchronously acquire molten pool images and welding parameter signals. This ensures the synchronous acquisition and transmission of molten pool images and welding parameters, guarantees the precise correspondence between the molten pool image and the welding parameter signal, and ensures the precise matching of the molten pool image acquired by the host computer with the welding parameters at the same time. Using the welding parameter acquisition device connected to the welding process, multiple welding parameters such as voltage, current, and wire feed speed can be simultaneously acquired, ensuring the synchronous acquisition of multiple welding parameters and accurate matching with the molten pool image at the same time.

[0016] In one specific implementation, the host computer can acquire the welding voltage, welding current, and wire feed speed of the welding machine based on the welding parameter signals. The host computer can store the molten pool image and the corresponding welding voltage, welding current, and wire feed speed, and perform deep learning based on the stored data, thereby automatically adjusting the welding voltage, welding current, and wire feed speed of the welding machine according to the correspondence between the real-time acquired molten pool image and the corresponding welding parameter signals.

[0017] By adopting the above technical solution and utilizing deep learning of the relationship between the molten pool image signal and the corresponding welding voltage, welding current and wire feed speed, a correspondence between the molten pool image shape and the welding voltage, welding current and wire feed speed can be formed. This allows for automatic adjustment of the welding voltage, welding current and wire feed speed during the welding process based on the shape of the molten pool image, thus forming automatic control of the welding parameters during the welding process and ensuring the stability of the welding quality.

[0018] In one specific implementation, the host computer can detect frame drops in the molten pool camera and discard the corresponding welding parameter signal when frame drops are detected.

[0019] By adopting the above technical solution, the frame dropping phenomenon of the molten pool camera can be detected by analyzing the molten pool image obtained by the host computer and the molten pool camera. When frame dropping occurs, the welding parameter signal corresponding to the lost frame is discarded, ensuring that the molten pool image and the welding parameter signal are always strictly synchronized and correspond one-to-one.

[0020] In one specific implementation, the molten pool camera includes an image acquisition trigger module and a laser illumination source. The image acquisition trigger module is connected to the synchronizer and the laser illumination source respectively, so that it can trigger the laser illumination source to emit pulsed illumination laser under the control of the synchronization signal, and simultaneously trigger the molten pool camera to acquire molten pool images.

[0021] By adopting the above technical solution, the image acquisition trigger module installed in the molten pool camera can be used to trigger the laser illumination source to emit pulsed illumination laser under the control of the pulse synchronization signal, and to acquire molten pool images, thus ensuring the timeliness of molten pool image acquisition and the quality of the acquired molten pool images.

[0022] In one specific implementation, the welding parameter acquisition device includes an enable control module, a parameter acquisition trigger module, and an Ethernet interface. The enable control module and the Ethernet interface are respectively connected to the host computer, and the parameter acquisition trigger module is connected to the synchronizer.

[0023] By adopting the above technical solution, the enable control module connected to the parameter acquisition trigger module can receive acquisition enable configuration information from the host computer and control the working state of the parameter acquisition trigger module, so that the parameter acquisition trigger module can synchronously acquire welding parameters such as welding voltage, welding current, and wire feeding speed under the trigger of the pulse synchronization signal.

[0024] In one specific implementation, the welding parameter acquisition device further includes a counter, which is connected to the parameter acquisition trigger module, and the welding parameter signal contains the counting information generated by the counter.

[0025] By adopting the above technical solution, the counter set in the welding parameter acquisition device can increment by 1 when each pulse synchronization signal is received, thereby adding sequence information to each acquired welding parameter signal. This facilitates the pairing of the synchronously acquired welding parameter signal and the molten pool image by the host computer, which is beneficial for the processing and utilization of each frame of molten pool image and the synchronously acquired welding parameter signal.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. By controlling the frequency and phase of the pulse signals generated by multiple pulse signal units through the synchronous control unit, multiple pulse synchronization signals with the same frequency and controllable phase are generated. Thus, the synchronous acquisition of information such as molten pool image and welding parameters during the welding process can be controlled by multiple pulse synchronization signals, and information such as molten pool image, welding voltage, welding current, and wire feed speed that are strictly matched in time can be obtained.

[0027] 2. By implementing a microprocessor-based synchronization control unit and multiple pulse signal units, the frequency and phase of the pulse synchronization signal can be flexibly controlled by software, and the pulse width of the pulse width modulation pulse can be easily controlled. The signal generator has higher resolution and can more accurately control the frequency and phase of multiple pulse synchronization signals. Multiple pulse synchronization signals can achieve higher-precision synchronization according to the set requirements.

[0028] 3. By controlling the molten pool camera and welding data acquisition device to work synchronously through multi-channel pulse synchronization signals, the time for the molten pool camera to acquire molten pool images and the time for the welding data acquisition device to acquire welding parameters such as welding voltage, welding current, and wire feed speed can be kept consistent. Furthermore, by precisely setting the lead time of the pulse synchronization signal transmitted to the molten pool camera, the molten pool camera can start acquiring molten pool images a certain time in advance. This makes the molten pool images acquired over a longer period of time more closely matched with the welding parameter information acquired over a shorter period of time, thereby improving the synchronization of information acquired at different times when transmitted to the host computer.

[0029] 4. By setting a counter in the welding data acquisition device, counting information can be added to the welding parameter information. This allows the host computer to match the welding parameters with the corresponding molten pool image through the counting information, ensuring that the molten pool image and the welding parameters at the same time can be correctly matched, and preventing mismatch between the molten pool image and the welding parameters caused by external interference such as frame loss in the molten pool image. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of one embodiment of the synchronizer of this application.

[0031] Figure 2This is a schematic diagram of the microprocessor portion of the synchronizer in one embodiment of this application.

[0032] Figure 3 This is a schematic diagram of a multi-channel synchronization signal output interface unit circuit in one embodiment of the synchronizer of this application.

[0033] Figure 4 This is a schematic diagram of the external I / O enable interface unit circuit in one embodiment of the synchronizer of this application.

[0034] Figure 5 This is a schematic diagram of the status indication unit circuit in one embodiment of the synchronizer of this application.

[0035] Figure 6 This is a schematic diagram of the structural principle of an embodiment of the real-time acquisition system for molten pool images and welding parameters during the welding process of this application.

[0036] Figure 7 This is a control timing diagram of one embodiment of the real-time acquisition system for molten pool images and welding parameters during the welding process of this application.

[0037] Explanation of reference numerals in the attached diagram: 1. Synchronizer; 11. Synchronization control unit; 12. Pulse signal unit; 13. Multi-channel synchronization signal output interface unit; 131. Multi-channel pulse signal output interface; 132. Opto-isolation module; 133. Output pulse shaping module; 14. External IO enable interface unit; 141. Enable signal input interface; 2. Welding machine; 3. Molten pool camera; 31. Image acquisition trigger module; 32. Laser illumination source; 4. Welding parameter acquisition device; 41. Enable control module; 42. Parameter acquisition trigger module; 43. Ethernet interface; 44. Counter; 5. Host computer. Detailed Implementation

[0038] The specific embodiments of this application will now be described in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this application.

[0039] In the description of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0040] One embodiment of the synchronizer in this application is as follows: Figure 1As shown, the system includes a synchronization control unit 11 and multiple pulse signal units 12. The synchronization control unit 11 can be any circuit unit capable of generating synchronization control signals, such as a microprocessor or microcontroller that generates synchronization control signals in conjunction with software, or an electronic circuit unit that generates synchronization control signals purely in hardware. The synchronization control unit 11 is connected to each of the multiple pulse signal units 12, and can transmit synchronization control signals to each pulse signal unit 12, triggering the pulse signal unit 12 to generate a pulse synchronization signal.

[0041] The trigger pulse signal unit 12 can be any circuit unit capable of generating pulse signals at a set frequency. It can be a microprocessor, microcontroller, or other device that generates pulse signals under software control, or it can be a purely hardware pulse forming circuit. The trigger pulse signal unit 12 can be activated under the control of an external trigger signal, and the frequency of the generated pulse signal can be changed under the control of an external signal. Multiple pulse signal units 12 can synchronously generate pulse synchronization signals under the trigger of the synchronization control signal generated by the synchronization control unit 11, thereby ensuring that the multiple pulse synchronization signals generated by the multiple pulse signal units 12 remain synchronized according to the set requirements.

[0042] In some embodiments of the synchronizer of this application, the pulse signal unit 12 is an electronic circuit capable of generating pulse width modulation (PWM) pulses. The pulse signal unit 12 can also change the pulse width under the control of an external control signal, thereby ensuring that the duration of the pulse synchronization signal can meet the triggering requirements of the subordinate device it controls, and ensuring that the subordinate device can be reliably triggered by the pulse synchronization signal.

[0043] The synchronization control unit 11 can also adjust the phase of the pulse signal generated by each pulse signal unit 12 through the synchronization control signal, so that the pulse synchronization signal generated by the corresponding pulse signal unit 12 can lead the pulse synchronization signal generated by other pulse signal units 12 by a set length, thus forming synchronization based on a fixed lead time.

[0044] Since different pulse synchronization signals control different subordinate devices, and these devices have different operation durations, it is usually necessary to give the subordinate devices with longer operation durations a fixed lead time in order to ensure that devices with different operation durations remain synchronized during the set operation period.

[0045] In a preferred embodiment of the synchronizer in this application, the synchronization control unit 11 and the plurality of pulse signal units 12 are both implemented using a microprocessor, such as... Figure 2The microprocessor RP2040 is shown as an implementation. The RP2040 is an Arm dual-core microprocessor with a clock speed of 200MHz. It internally incorporates several hardware signal generators, each with nanosecond-level resolution, offering high resolution. These hardware signal generators can generate PWM pulse signals. The generation of these pulse signals is hardware-based, eliminating the need for microprocessor core time. This allows the microprocessor to allocate more core time to communication and configuration functions, resulting in high real-time performance. The frequency of the pulse signals generated by the hardware signal generators can be set within the range of 20-500Hz, adapting to different operating durations of subordinate devices. The pulse signal width can be set within the range of 10-250µs, adapting to the high-level trigger signal duration requirements of different subordinate devices. Each hardware signal generator can generate pulse signals with individually set lead times within the range of 0-250µs, ensuring synchronization between subordinate devices with different operating durations during the set operating period. Control of the pulse signal frequency, width, and lead time is implemented through software, offering convenient and highly precise adjustment. The development of software to control the RP2040 microprocessor is existing technology in the relevant field. The microprocessor manufacturer has also provided support materials for software development. The relevant software can be developed by technical personnel in the relevant field based on existing technology.

[0046] The synchronizer also has features such as Figure 3 The multi-channel synchronization signal output interface unit 13 shown has multiple pulse signal output interfaces 131. Each synchronization signal channel of the multi-channel synchronization signal output interface unit 13 is connected to a GPIO pin of the microprocessor RP2040. Each pulse synchronization signal generated by the microprocessor is isolated, amplified and shaped by the multi-channel synchronization signal output interface unit 13 and then output through the multi-channel pulse signal output interface 131 to form an output pulse synchronization signal that meets the triggering requirements of the subordinate devices, thus ensuring reliable triggering of the subordinate devices.

[0047] The synchronizer also has features such as Figure 4 The external I / O enable interface unit 14 is shown. The external I / O enable interface unit 14 is mainly composed of EL357N optocouplers. The external enable signal is transmitted to the light-emitting diode of the optocoupler through the enable signal input interface 141. The phototransistor of the optocoupler is connected to a +3.3V power supply and connected to another GPIO pin of the microprocessor RP2040. While ensuring that the external enable signal is isolated from the microprocessor, the external enable signal is used to control the enable state of the synchronizer.

[0048] As one specific implementation of the synchronizer in this application, such as Figure 3As shown, the multi-channel synchronous signal output interface unit 13 includes an opto-isolation module 132, an output pulse shaping module 133, and a multi-channel pulse signal output interface 131. The opto-isolation module 132 uses an IS2801-4 four-channel optocoupler. The four light-emitting diodes of the opto-isolation module 132 are connected to ground GND through resistor array RN1, respectively. The collectors of the four phototransistors of the opto-isolation module 132 are all connected to a +24V power supply, and the emitters are grounded through resistor array RN2, and connected to the output pulse shaping module 133 through resistors R2-R4, respectively. The four pulse synchronization signals output from the GPIO18, GPIO20, GPIO22 and GPIO24 pins of the microprocessor RP2040 drive four light-emitting diodes to emit light. The four phototransistors generate corresponding pulse synchronization signals under the action of the light signals emitted by the four light-emitting diodes. These signals are connected to the output pulse shaping module 133 through resistors R2-R4 to achieve isolation between the output pulse synchronization signals and the input pulse synchronization signals.

[0049] The output pulse shaping module 133 is designed and formed by the load controller chip ITS4141NHUMA1. The load controller chip ITS4141NHUMA1 shapes and amplifies the pulse synchronization signal transmitted from the opto-isolation module 132, improves the load driving capability of the pulse synchronization signal, forms a higher power output pulse synchronization signal, and transmits it to the multi-channel pulse signal output interface 131 for output, ensuring that the pulse synchronization signal can reliably trigger the subordinate equipment.

[0050] The synchronizer in this application may also include a status indication unit, such as... Figure 5 As shown, the status indicator unit includes a power indicator LED D1, a running LED D2, and an enable LED D3. The power indicator LED D1 is connected to the +3.3V power supply of the microprocessor RP2040, the running LED D2 is connected to the GPIO14 pin of the microprocessor RP2040, and the enable LED D3 is connected to the GPIO13 pin of the microprocessor RP2040. These LEDs are used to indicate the power status, running status, and enable status of the synchronizer in this application, respectively.

[0051] An embodiment of the real-time acquisition system for molten pool images and welding parameters during the welding process described in this application, such as... Figure 6As shown, the system includes a welding machine 2, a molten pool camera 3, a welding parameter acquisition device 4, a host computer 5, and a synchronizer 1 according to any embodiment of this application. The welding machine 2 can be any laser welding or arc welding machine, capable of feeding welding wire to the welding position of the workpiece, and melting the welding wire and adjacent workpiece material to form a molten pool through laser or arc welding, thereby performing welding processing on the workpiece. The molten pool camera 3 is mounted on the welding machine 2 or located adjacent to the welding machine 2, with its imaging lens facing the welding station of the welding machine 2, for acquiring images of the molten pool formed during welding by the welding machine 2.

[0052] The welding parameter acquisition device 4 can be any device capable of acquiring welding parameters of the welding machine 2, such as the WLSCADA welding data acquisition equipment manufactured and publicly sold by our company. The welding parameter acquisition device 4 is connected to the welding machine 2 and can acquire welding parameter signals such as welding voltage, welding current, and wire feed speed when the welding machine 2 is working under the control of external signals.

[0053] Synchronizer 1 is connected to molten pool camera 3 and welding parameter acquisition device 4 respectively. It is used to transmit the pulse synchronization signal generated by synchronizer 1 to molten pool camera 3 and welding parameter acquisition device 4, control molten pool camera 3 and welding parameter acquisition device 4 to operate synchronously, and synchronously acquire molten pool image and welding parameters such as welding voltage, welding current and wire feeding speed at the same moment during the welding process of welding machine 2, so as to ensure that the molten pool image and welding parameters are acquired at the same time and that there is a strict one-to-one correspondence in output and storage.

[0054] The host computer 5 is typically an industrial control computer, but a suitable personal computer can also be used. The host computer 5 connects to the welding machine 2 via an industrial bus or Ethernet, and can issue commands to adjust the welding parameters of the welding machine 2, thereby controlling its operating status. The host computer 5 connects to the molten pool camera 3 (not shown in the figure) via USB or Ethernet, and can acquire the molten pool image captured by the molten pool camera 3 and adjust its trigger parameters. The host computer 5 connects to the welding parameter acquisition device 4 via Ethernet, and can acquire the welding parameters collected by the welding parameter acquisition device 4 and enable the welding parameter acquisition device 4. The host computer 5 connects to the synchronizer 1 via a communication interface, and can enable the synchronizer 1.

[0055] The host computer 5 can synchronously receive the molten pool image acquired by the molten pool camera 3 and the welding parameter data such as welding voltage, current, and wire feeding speed acquired by the welding parameter acquisition device 4. It can match the molten pool image shape with the welding parameters such as welding voltage, current, and wire feeding speed, and adjust the welding parameters of the welding machine 2 according to the matching result to ensure the normal molten pool image shape, thereby ensuring the welding quality of the welding machine 2 during the welding process.

[0056] In some embodiments of the real-time acquisition system for molten pool images and welding parameters during the welding process described in this application, the host computer 5 can store molten pool images acquired synchronously at the same time during the welding process, as well as welding parameters such as welding voltage, welding current, and wire feed speed, in a storage device to form a knowledge base. From the numerous data in the knowledge base, the molten pool morphology is matched with the welding voltage, welding current, and wire feed speed, and the correspondence between welding voltage, welding current, wire feed speed, and molten pool morphology is learned through deep learning. Therefore, when molten pool formation is abnormal, i.e., welding quality is abnormal, one or more of the welding voltage, welding current, and wire feed speed can be automatically adjusted based on the deep learning results, thereby ensuring that molten pool formation remains normal throughout the welding process and guaranteeing stable and reliable welding results.

[0057] By utilizing the molten pool images, welding voltage, welding current, and wire feeding speed stored in the storage device, the upper computer 5 can also review the molten pool images during the welding process and the welding voltage, welding current, and wire feeding speed corresponding to each frame of the image, thus reviewing the welding process, ensuring the traceability of the welding process, and improving the control level of welding quality.

[0058] In a preferred embodiment of the real-time acquisition system for molten pool images and welding parameters during the welding process of this application, the host computer 5 can also detect molten pool images acquired at adjacent times and detect frame loss phenomena of the molten pool camera 3. When frame loss is detected during the continuous acquisition of molten pool images by the molten pool camera 3, the welding parameter signal corresponding to the lost frame acquired by the welding parameter acquisition device 4 is discarded to ensure a strict one-to-one correspondence between the molten pool image and the welding parameter signal.

[0059] In some embodiments of the real-time acquisition system for molten pool images and welding parameters during the welding process described in this application, such as... Figure 6 As shown, the molten pool camera 3 is equipped with an image acquisition trigger module 31 and a laser illumination source 32. The image acquisition trigger module 31 is used to trigger the molten pool camera 3 to acquire molten pool images, and the laser illumination source 32 is used to illuminate the molten pool area when the molten pool camera 3 acquires molten pool images, ensuring the quality of the acquired molten pool images. The image acquisition trigger module 31 is connected to both the synchronizer 1 and the laser illumination source 32. When it receives a pulse synchronization signal generated by the synchronizer 1, it triggers the molten pool camera 3 to acquire a frame of molten pool image on the rising edge of the pulse synchronization signal, and simultaneously triggers the laser illumination source 32 to emit a high-intensity pulsed illumination laser for several microseconds, ensuring the clarity of the acquired molten pool image.

[0060] Because the molten pool image contains image information from different parts of the molten pool, it contains a large amount of information. Compared to the welding parameters such as welding voltage, current, and wire feed speed collected by the welding parameter acquisition device 4, the amount of information to be collected is much larger, and the information acquisition process takes longer. This results in the welding parameter acquisition being completed much earlier than the molten pool image acquisition, causing the transmission time of the welding parameter information to be earlier than the transmission time of the molten pool image. Consequently, the host computer 5 acquires the welding parameter information earlier than the molten pool image, affecting the synchronous acquisition of the molten pool image and the welding parameter information. Therefore, a certain lead time is usually set for the pulse synchronization signal transmitted from the synchronizer 1 to the molten pool camera 3, so that the molten pool camera 3 starts acquiring the molten pool image earlier, improving the synchronization of the completion and transmission of the molten pool image and the welding parameter information acquisition.

[0061] In some embodiments of the real-time acquisition system for molten pool images and welding parameters during the welding process described in this application, such as... Figure 6 As shown, the welding parameter acquisition device 4 is equipped with an enable control module 41, a parameter acquisition trigger module 42, and an Ethernet interface 43. The control timing of one embodiment of the real-time acquisition system for molten pool images and welding parameters during the welding process of this application is as follows: Figure 7 As shown, the enable control module 41 is connected to the host computer 5 and can control the enable state of the welding parameter acquisition device 4 through the host computer 5. If necessary, such as when frame loss occurs in the molten pool image, the host computer 5 can reset the acquisition enable signal transmitted to the welding parameter acquisition device 4 to reset the welding parameter acquisition device 4.

[0062] Ethernet interface 43 forms a signal connection interface for welding parameter acquisition device 4, which can form an Ethernet connection with host computer 5 and transmit the acquired welding parameter information to host computer 5.

[0063] The parameter acquisition trigger module 42 is connected to the synchronizer 1 and can trigger the welding parameter acquisition device 4 to acquire welding parameter information such as welding voltage, current, and wire feeding speed on the rising edge of each pulse synchronization signal issued by the synchronizer 1.

[0064] In a preferred embodiment of the real-time acquisition system for molten pool images and welding parameters during the welding process of this application, such as... Figure 6 As shown, the welding parameter acquisition device 4 is also equipped with a counter 44, which is connected to the parameter acquisition trigger module 42. When the parameter acquisition trigger module 42 receives the pulse synchronization information, it can increment the count at the rising edge of each pulse synchronization information and add the count result to the welding parameters such as welding voltage, current, and wire feeding speed to form a welding parameter signal that is transmitted to the host computer 5 through the Ethernet interface 43.

[0065] The high-resolution, high-precision synchronization signal of the synchronizer enables real-time matching of each frame of the molten pool camera with the voltage, current, and wire feed speed during the welding process.

[0066] The real-time acquisition system for molten pool images and welding parameters during the welding process described in this application does not require an additional NTP server to be built on the host computer, nor does it require additional NTP clients to be built on subordinate devices. This reduces the need for software environment construction, improves program stability, and saves hardware resources that may be required during the NTP client setup process. At the same time, it avoids time errors during NTP service time synchronization and improves the matching accuracy of the acquired data.

[0067] In the description of this application, the references to terms such as "an embodiment," "specific embodiment," and "preferred embodiment" indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this application, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0068] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A synchronizer, characterized in that, It includes a synchronization control unit (11) and multiple pulse signal units (12). The synchronization control unit (11) is connected to the multiple pulse signal units (12) to control the frequency and phase of the pulse signals generated by the multiple pulse signal units (12), so that the multiple pulse signal units (12) can synchronously generate multiple pulse synchronization signals. The synchronization control unit (11) can adjust the phase of the pulse signal generated by each pulse signal unit (12) respectively, thereby individually adjusting the lead time of the pulse signals generated by different pulse signal units (12).

2. The synchronizer according to claim 1, characterized in that, The pulse signal unit (12) is capable of generating pulse width modulation pulses.

3. The synchronizer according to claim 2, characterized in that, The synchronization control unit (11) and multiple pulse signal units (12) are both implemented using a microprocessor. The synchronizer also includes a multi-channel synchronization signal output interface unit (13) and an external IO enable interface unit (14). The multi-channel synchronization signal output interface unit (13) includes a multi-channel pulse signal output interface (131). The multi-channel synchronization signal output interface unit (13) is connected to multiple GPIO pins of the microprocessor. The external IO enable interface unit (14) includes an enable signal input interface (141). The external IO enable interface unit (14) is connected to another GPIO pin of the microprocessor.

4. The synchronizer according to claim 3, characterized in that, The multi-channel synchronization signal output interface unit (13) further includes an opto-isolation module (132) and an output pulse shaping module (133). The input end of the opto-isolation module (132) is connected to multiple GPIO pins of the microprocessor, and the output end is connected to the output pulse shaping module (133) to obtain the multi-channel pulse synchronization signal generated by the microprocessor and transmit it to the output pulse shaping module (133) through a channel isolated from the microprocessor. The output pulse shaping module (133) is connected to the multi-channel pulse signal output interface (131) so that the pulse synchronization signal can be processed and output through the multi-channel pulse signal output interface (131).

5. A real-time acquisition system for molten pool images and welding parameters during welding, characterized in that, The system includes a welding machine (2), a molten pool camera (3), a welding parameter acquisition device (4), a host computer (5), and a synchronizer (1) according to any one of claims 1-4. The molten pool camera (3) is positioned facing the welding station of the welding machine (2) to acquire images of the molten pool when the welding machine (2) is working. The welding parameter acquisition device (4) is connected to the welding machine (2) to acquire welding parameter signals when the welding machine (2) is working. The synchronizer (1) is connected to both the molten pool camera (3) and the welding parameter acquisition device (4). The upper computer (5) is connected to the welding machine (2), the welding pool camera (3), the welding parameter acquisition device (4) and the synchronizer (1) respectively, so as to generate a synchronization signal and control the welding pool camera (3) and the welding parameter acquisition device (4) to synchronously acquire the welding pool image and the welding parameter signal.

6. The real-time acquisition system for molten pool images and welding parameters during welding as described in claim 5, characterized in that, The host computer (5) can obtain the welding voltage, welding current and wire feeding speed of the welding machine (2) according to the welding parameter signal. The host computer (5) can store the molten pool image and the corresponding welding voltage, welding current and wire feeding speed, and perform deep learning according to the stored data, so as to automatically adjust the welding voltage, welding current and wire feeding speed of the welding machine (2) according to the correspondence between the real-time collected molten pool image and the corresponding welding parameter signal.

7. The real-time acquisition system for molten pool images and welding parameters during welding as described in claim 6, characterized in that, The host computer (5) can detect the frame dropping phenomenon of the molten pool camera (3) and discard the corresponding welding parameter signal when the frame dropping of the molten pool camera (3) is detected.

8. The real-time acquisition system for molten pool images and welding parameters during welding as described in claim 5, characterized in that, The molten pool camera (3) includes an image acquisition trigger module (31) and a laser illumination source (32). The image acquisition trigger module (31) is connected to the synchronizer (1) and the laser illumination source (32) respectively, so that the laser illumination source (32) can be triggered to emit pulsed illumination laser under the control of the synchronization signal, and the molten pool camera (3) can be triggered to acquire molten pool images at the same time.

9. The real-time acquisition system for molten pool images and welding parameters during the welding process according to any one of claims 5-8, characterized in that, The welding parameter acquisition device (4) includes an enable control module (41), a parameter acquisition trigger module (42), and an Ethernet interface (43). The enable control module (41) and the Ethernet interface (43) are respectively connected to the host computer (5), and the parameter acquisition trigger module (42) is connected to the synchronizer (1).

10. The real-time acquisition system for molten pool images and welding parameters during welding according to claim 9, characterized in that, The welding parameter acquisition device (4) further includes a counter (44), which is connected to the parameter acquisition trigger module (42). The welding parameter signal contains the counting information generated by the counter (44).

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