Wide-resistance-domain self-adaptive precision welding method and control system

Abstract

The invention discloses a wide-resistance-domain self-adaptive precision welding method and a control system, and the method comprises the steps: detecting the contact resistance between a first welding body and a second welding body to obtain a first resistance; when the first resistance is greater than or equal to a preset resistance threshold value, burning the contact part between the first welding body and the second welding body, and detecting the contact resistance between the first welding body and the second welding body again after burning to obtain a second resistance; when the second resistance is larger than or equal to the resistance threshold value, the contact part between the first welding body and the second welding body is burnt, so that the first welding body and the second welding body are welded together; and when the first resistance or the second resistance is smaller than the resistance threshold value, the first welding body and the second welding body are welded together based on a resistance welding method. The welding method covers a wide resistance domain scene from near-zero resistance to infinite resistance, the welding mode can be adaptively selected according to the contact condition of the to-be-welded material, and the differentiated requirements of a user under different working conditions are met.

Description

Technical Field

[0001] The present invention relates to the field of precision welding technology, and in particular to a wide resistance range adaptive precision welding method and a precision welding control system. Background Art

[0002] Precision welding technology is widely used in the automotive, aerospace, electronics, and precision components industries. Resistance welding is a common welding method that connects materials through Joule heat generated by contact resistance. For example, in the carbide sawtooth welding process, a metal indenter is typically used to push the alloy tip onto the surface of the sawtooth substrate. This creates a series circuit between the indenter, the alloy tip, and the substrate, and the resistance of the circuit created by contact between the indenter and the substrate is used to heat and melt the material.

[0003] However, traditional resistance welding technology relies on preset current, voltage, and pressure parameters, making it difficult to adapt to the dynamic changes in contact resistance caused by material differences, surface oxidation, or contaminants during the actual welding process. For example, when there is oil or coating (such as galvanized sheet, sealant) on the workpiece surface, the contact resistance may increase significantly, and traditional welding equipment cannot sense and adjust parameters in real time, which can easily lead to insufficient weld nugget size, increased spatter, or decreased welding strength. For another example, current resistance welding equipment cannot weld non-conductors or materials with low conductivity. Summary of the Invention

[0004] The purpose of the present invention is to solve the above technical problems and provide a wide resistance range adaptive precision welding method and precision welding control system that can cover contact resistances of different sizes and adaptively select corresponding welding modes.

[0005] In order to achieve the above object, the present invention provides a wide resistance range adaptive precision welding method, which comprises:

[0006] When it is detected that the first welding body and the second welding body are close to each other to a preset limit position, the contact resistance between the first welding body and the second welding body is detected to obtain a first resistance;

[0007] When the first resistance is greater than or equal to a preset resistance threshold, burning the contact portion between the first welding body and the second welding body based on a first heating parameter, and after burning, detecting the contact resistance between the first welding body and the second welding body again to obtain a second resistance;

[0008] When the second resistance is greater than or equal to the resistance threshold, burning the contact portion between the first welding body and the second welding body based on a second heating parameter so that the first welding body and the second welding body are welded together;

[0009] When the first resistance or the second resistance is less than the resistance threshold, the first welding body and the second welding body are welded together using a resistance welding method.

[0010] Preferably, before welding based on the resistance welding method, the contact portion between the first welding body and the second welding body is burned based on a third heating parameter to increase the contact resistance between the first welding body and the second welding body.

[0011] Preferably, during the process of welding the first welding body and the second welding body by burning or resistance welding, the first welding body and / or the second welding body are continuously pushed to move so that the penetration depth of the first welding body and the second welding body reaches a preset value.

[0012] Preferably, the contact portion between the first welding body and the second welding body is burned by a plasma heater.

[0013] Preferably, at least one of the first heating parameter, the second heating parameter and the third heating parameter comprises a combination of current intensity, power-on time and pulse frequency for driving the heater to operate.

[0014] Preferably, the contact resistance between the first welding body and the second welding body is detected based on a voltage value between the first welding body and the second welding body.

[0015] Preferably, the first welding body and the second welding body are conductive bodies or non-conductive bodies.

[0016] The present invention also provides a precision welding control system, which includes a controller. The controller controls an actuator to weld a first welding body and a second welding body together based on the wide resistance range adaptive precision welding method described above.

[0017] The present invention also provides a precision welding control system, which includes:

[0018] one or more processors;

[0019] Memory;

[0020] and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the programs including instructions for executing the wide resistance range adaptive precision welding method as described above.

[0021] The present invention also provides a computer-readable storage medium, which includes a computer program. The computer program can be executed by a processor to implement the wide resistance range adaptive precision welding method as described above.

[0022] Compared with the prior art, the precision welding method provided by the above technical solution of the present invention can dynamically judge the conductive state of the welding interface by detecting the contact resistance in real time and setting the resistance threshold for judging the resistance state. When the contact surface is cleaned by burning and judged to be in a high resistance or insulation state, it automatically switches to the hot melt welding mode, and directly melts the weld body through controllable burning; when it is in a low resistance state, the contact resistance is actively increased and then the resistance welding mode is executed, and efficient welding is achieved through Joule heat. It can be seen that the above welding method covers a wide resistance range scenario from near-zero resistance to infinite resistance (insulator), is suitable for the welding needs of metals, non-metals and composite materials, and can adaptively select the welding mode according to the contact conditions of the materials to be welded, to meet the differentiated needs of users under different working conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Flowchart of the precision welding method in an embodiment of the present invention.

[0024] Figure 2 Schematic diagram of the planar structure of two bodies to be welded in contact with each other in an embodiment of the present invention.

[0025] Figure 3 Schematic diagram of the planar structure of two non-contact bodies to be welded in an embodiment of the present invention. DETAILED DESCRIPTION

[0026] In order to explain the technical content, structural features, achieved objectives and effects of the present invention in detail, the following is a detailed description in conjunction with the embodiments and the accompanying drawings.

[0027] This embodiment discloses a precision welding method for adaptively welding low-resistance conductors, high-resistance conductors, and non-conductors.

[0028] like Figure 1 , the welding method comprises the following steps:

[0029] S1: Detect whether the first welding body H1 and the second welding body H2 are close to each other to the preset limit position. If so (such as Figure 2 ), then enter S2, if not (such as Figure 3 ), then return.

[0030] S2: Detecting the contact resistance between the first welding body H1 and the second welding body H2 to obtain a first resistance.

[0031] S3: Determine whether the first resistance is greater than or equal to a preset resistance threshold. If yes, proceed to S4; if not, proceed to S8.

[0032] S4: Burning the contact portion Q between the first welding body H1 and the second welding body H2 based on the first heating parameter to perform high-temperature cleaning on the contact portion Q between the first welding body H1 and the second welding body H2.

[0033] S5: After burning, the contact resistance between the first welding body H1 and the second welding body H2 is detected again to obtain a second resistance.

[0034] S6: Determine whether the second resistance is greater than or equal to a preset resistance threshold. If yes, proceed to S7; if not, proceed to S8.

[0035] S7: Burning the contact portion Q between the first welding body H1 and the second welding body H2 based on the second heating parameter, so that the first welding body H1 and the second welding body H2 are welded together.

[0036] S8: Welding the first welding body H1 and the second welding body H2 together using a resistance welding method.

[0037] In this embodiment, the first welding body H1 and the second welding body H2 can be conductive or non-conductive.

[0038] In the above step S3, when it is judged that the first resistance is greater than or equal to the resistance threshold, it means that there is any of the following conditions on the contact surface between the two objects to be welded (the first welding body H1 and the second welding body H2), such as oil stains, oxidation, or at least one of the two objects to be welded is a non-conductor or a high-resistance conductor. Therefore, it is necessary to perform high-temperature cleaning on the contact surface between the two objects to be welded and further judge the specific situation.

[0039] Then, in step S6, when it is determined that the current second resistor is still in a high-resistance state (that is, greater than or equal to the resistance threshold), since the contact surface has been cleaned, it is confirmed that at least one of the two objects to be welded is a non-conductor or a high-resistance conductor, which is not suitable for resistance welding. Therefore, welding is performed by directly hot-melting the contact surface.

[0040] When the first resistor or the second resistor is in a low resistance state, it indicates that the current condition meets the requirements of resistance welding. Therefore, the two objects to be welded are welded based on resistance welding.

[0041] On the other hand, before welding by the resistance welding method, the contact portion Q between the first welding body H1 and the second welding body H2 is burned based on the third heating parameter to increase the contact resistance between the first welding body H1 and the second welding body H2.

[0042] It should be noted that in the actual implementation process, it is necessary to push one of the objects to be welded (such as the first welding body H1) toward the other welding object (such as the second welding body H2) through the conductive rod G. The conductive rod G is connected to the electrode of the welding power supply. In this way, there will be resistance at multiple points in the welding circuit, which are:

[0043] The resistance of the first welding body H1 itself is named as resistance A;

[0044] The resistance of the second welding body H2 itself is named as resistance B;

[0045] The resistance of the conductive rod G itself is named resistance C;

[0046] The contact resistance between the conductive rod G and the first welding body H1 is named as resistance D;

[0047] The contact resistance between the first welding body H1 and the second welding body H2 is named as resistance E.

[0048] The first resistance and the second resistance detected are both resistance E.

[0049] It can be seen that in the welding circuit, all five resistors mentioned above will generate heat, but only the heat generated by resistor E is effective. Therefore, before welding, appropriately increasing the resistance value of resistor E, for example, from 2 milliohms to 3 milliohms, will significantly improve the heating efficiency of resistor E, which is beneficial to improving welding quality and energy efficiency.

[0050] In this regard, for a conductor, since the resistance value is proportional to the temperature, that is, the higher the temperature, the greater the resistance, the contact resistance between the two can be increased by increasing the temperature of the contact portion Q between the first welding body H1 and the second welding body H2.

[0051] It should also be noted that before performing resistance welding, the extent to which the contact resistance between the first welding body H1 and the second welding body H2 is increased by heating can be determined by multiple adjustments based on the welding effect.

[0052] On the other hand, after the contact portion Q between the first welding body H1 and the second welding body H2 is burned based on the first heating parameter, it is again determined whether the first welding body H1 and the second welding body H2 have reached a preset limit position. If not, the first welding body H1 and / or the second welding body H2 are driven to move so that the first welding body H1 and the second welding body H2 approach each other to the preset limit position. In this embodiment, by re-determining the contact distance between the first welding body H1 and the second welding body H2, it is possible to avoid the influence of the contact resistance detection value caused by the excessive distance caused by the removal of debris on the contact surface between the two.

[0053] On the other hand, during the process of welding the first welding body H1 and the second welding body H2 based on the burning method or the resistance welding method, the first welding body H1 and / or the second welding body H2 are continuously pushed to move so that the penetration depth of the first welding body H1 and the second welding body H2 reaches a preset value, thereby meeting the welding strength requirements.

[0054] On the other hand, the contact portion Q between the first welding body H1 and the second welding body H2 can be burned by a plasma heater. It should be noted that the contact portion Q can also be burned by other methods well known to those skilled in the art, such as laser.

[0055] Then, at least one of the first heating parameter, the second heating parameter and the third heating parameter includes a combination of current intensity, power-on time and pulse frequency for driving the heater to operate.

[0056] It should be noted that the specific configurations of the first heating parameter, the second heating parameter and the third heating parameter can be debugged multiple times according to the actual production conditions and the final welding quality, and their specific values are not limited here.

[0057] On the other hand, the contact resistance between the first welding body H1 and the second welding body H2 is detected based on the voltage value between the first welding body H1 and the second welding body H2.

[0058] Since the voltage output by the welding power supply can be considered constant, the voltage value at each point in the load circuit formed by the first welding body H1, the second welding body H2, and the conductive rod G is proportional to the resistance. Therefore, the contact resistance can be calculated using the detected voltage value between the first welding body H1 and the second welding body H2 and a preset conversion parameter. Of course, the contact resistance between the first welding body H1 and the second welding body H2 can also be detected using other commonly used resistance detection methods, which are not limited here.

[0059] In summary, the present invention discloses a wide resistance range adaptive precision welding method, which can dynamically determine the conductive state of the welding interface by detecting the contact resistance in real time and setting a resistance threshold for resistance state judgment.

[0060] When the contact surface is cleaned by burning and judged to be in a high resistance or insulation state, it automatically switches to hot melt welding mode and directly melts the weld body through controlled burning.

[0061] When in a low-resistance state, the contact resistance is actively increased and resistance welding mode is performed, achieving efficient welding through Joule heat.

[0062] It can be seen that the above welding method covers a wide resistance range from near-zero resistance to infinite resistance (insulator), is suitable for the welding needs of metals, non-metals and composite materials, and can adaptively select the contact mode according to the contact conditions of the materials to be welded, meeting the differentiated needs of users under different working conditions.

[0063] In another preferred embodiment of the present invention, a precision welding control system is disclosed, which includes a controller. The controller controls an actuator to weld the first welding body H1 and the second welding body H2 together based on the above-mentioned precision welding method.

[0064] The present invention also discloses another precision welding control system, which includes one or more processors, a memory, and one or more programs, wherein the one or more programs are stored in the memory and are configured to be executed by the one or more processors, and the program includes instructions for executing the precision welding method as described above. The processor can adopt a general central processing unit (CPU), a microprocessor, an application specific integrated circuit (ASIC), or one or more integrated circuits for executing relevant programs to implement the functions required to be performed by the modules in the precision welding control system of the embodiment of the present application, or to execute the precision welding method of the method embodiment of the present application.

[0065] The present invention also discloses a computer-readable storage medium, which includes a computer program, and the computer program can be executed by a processor to complete the precision welding method as described above. The computer-readable storage medium can be any available medium that can be accessed by a computer or a data storage device such as a server or a data center that includes one or more available media. The available medium can be a read-only memory (ROM), or a random access memory (RAM), or a magnetic medium, such as a floppy disk, a hard disk, a tape, a magnetic disk, or an optical medium, such as a digital versatile disc (DVD), or a semiconductor medium, such as a solid state drive (SSD).

[0066] The present application also discloses a computer program product or computer program, which includes computer instructions stored in a computer-readable storage medium. A processor of an electronic device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the electronic device to perform the above-described precision welding method.

[0067] The above disclosure is only the preferred embodiment of the present invention, which certainly cannot be used to limit the scope of the present invention. Therefore, equivalent changes made according to the scope of the patent application of the present invention are still within the scope of the present invention.

Claims

1. A wide resistance range adaptive precision welding method, characterized in that: include: When it is detected that the first welding body and the second welding body are close to each other to a preset limit position, the contact resistance between the first welding body and the second welding body is detected to obtain a first resistance; When the first resistance is greater than or equal to a preset resistance threshold, burning the contact portion between the first welding body and the second welding body based on a first heating parameter, and after burning, detecting the contact resistance between the first welding body and the second welding body again to obtain a second resistance; When the second resistance is greater than or equal to the resistance threshold, burning the contact portion between the first welding body and the second welding body based on a second heating parameter so that the first welding body and the second welding body are welded together; When the first resistance or the second resistance is less than the resistance threshold, the first welding body and the second welding body are welded together using a resistance welding method.

2. The wide resistance range adaptive precision welding method according to claim 1, characterized in that: Before welding based on the resistance welding method, the contact portion between the first welding body and the second welding body is burned based on a third heating parameter to increase the contact resistance between the first welding body and the second welding body.

3. The wide resistance range adaptive precision welding method according to claim 1, characterized in that: During the process of welding the first welding body and the second welding body by burning or resistance welding, the first welding body and / or the second welding body are continuously pushed to move so that the penetration depth of the first welding body and the second welding body reaches a preset value.

4. The wide resistance range adaptive precision welding method according to claim 1, characterized in that: The contact portion between the first welding body and the second welding body is burned by a plasma heater.

5. The wide resistance range adaptive precision welding method according to claim 1, characterized in that: At least one of the first heating parameter, the second heating parameter and the third heating parameter comprises a combination of current intensity, power-on time and pulse frequency for driving the heater to operate.

6. The wide resistance range adaptive precision welding method according to claim 1, characterized in that: A contact resistance between the first welding body and the second welding body is detected based on a voltage value between the first welding body and the second welding body.

7. The wide resistance range adaptive precision welding method according to claim 1, characterized in that: The first welding body and the second welding body are conductive bodies or non-conductive bodies.

8. A precision welding control system, characterized in that: The method comprises a controller, which controls an actuator to weld a first welding body and a second welding body together based on the wide resistance range adaptive precision welding method according to any one of claims 1 to 7.

9. A precision welding control system, characterized in that: include: one or more processors; Memory; and one or more programs, wherein the one or more programs are stored in the memory and are configured to be executed by the one or more processors, the programs including instructions for executing the wide resistance range adaptive precision welding method as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that The method comprises a computer program, which can be executed by a processor to complete the wide resistance range adaptive precision welding method according to any one of claims 1 to 7.

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