Precise welding dynamic control method and system

Abstract

The invention provides a precise welding dynamic control method and system.The method comprises the steps that when it is detected that a first welding body and a second welding body get close to a preset limit position and enter a welding state, the moving speed of the first welding body and the moving speed of the second welding body getting close to each other are detected in real time; and the welding power applied between the first welding body and the second welding body by a welding power source is adjusted based on the moving speed and the preset fusion depth. According to the method, the weld penetration is indirectly represented by detecting the approaching rate of the welding body, and then the welding power is dynamically adjusted, namely, a closed-loop control link of the progress rate of the weld penetration and the welding temperature is established, so that the hysteresis quality of direct temperature measurement is effectively avoided, real-time regulation and control are completed in the welding period, and the welding efficiency is improved. The matching error of the heat input and the target fusion depth is reduced, the welding quality consistency is improved, and the defect rate caused by dynamic process fluctuation is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of precision welding, and in particular to a precision welding dynamic control method and system. Background Art

[0002] With the development of precision electronics manufacturing, microelectronic packaging, and miniaturized devices, the requirements for welding process accuracy and consistency are becoming increasingly stringent. In traditional welding processes, temperature control methods mainly rely on direct temperature detection methods such as thermocouples and infrared thermometers. However, in the ultra-short timescale (microsecond level) precision welding process, the response speed of temperature sensors cannot match the instantaneous nature of the welding process, resulting in a lag in real-time control and difficulty in accurately maintaining the target welding temperature.

[0003] In the existing technology, some solutions attempt to adjust parameters by presetting fixed power curves or based on feedback from the molten pool morphology. For example, laser welding systems indirectly evaluate welding quality by monitoring plasma radiation signals, but such methods are not adaptable enough to dynamically changing welding conditions (such as material contact rate and heat conduction differences). In addition, existing power control strategies are mostly based on static models and do not fully consider the dynamic characteristics of the relative movement of the weld body during the welding process. For example, although CNC welding equipment can preset paths, it cannot respond to changes in contact rate in real time, resulting in mismatch between heat input and penetration depth. Summary of the Invention

[0004] The purpose of the present invention is to solve the above technical problems and provide a precision welding dynamic control method and system that can achieve accurate control of temperature and penetration within an ultra-short welding cycle.

[0005] In order to achieve the above object, the present invention provides a precision welding dynamic control method, which includes:

[0006] When it is detected that the first welding body and the second welding body approach each other to a preset limit position and enter a welding state, the moving speed of the first welding body and the second welding body approaching each other is detected in real time;

[0007] The welding power applied by the welding power source between the first welding body and the second welding body is adjusted based on the moving rate and the preset melting depth.

[0008] Preferably, the method for detecting the moving speed includes:

[0009] Acquiring a movement displacement based on a displacement sensor or a rotation parameter of a driving motor that drives the first welding body or the second welding body to move;

[0010] The movement speed is calculated based on the movement displacement and the time taken for the movement displacement to occur.

[0011] Preferably, the welding power includes at least one adjustment parameter of welding current, welding voltage or welding pulse width.

[0012] Preferably, a data table is pre-established, which records the adjustment values of the welding power corresponding to different movement rates at different melting depths; after the movement rate is obtained, the corresponding adjustment value of the welding power is obtained by querying the data table.

[0013] Preferably, the first welding body and the second welding body are welded by resistance welding or direct thermal fusion.

[0014] Preferably, heat energy is applied to the contact surfaces of the first welding body and the second welding body by a plasma heater, so as to weld the first welding body and the second welding body by direct thermal melting.

[0015] Preferably, according to a preset time point, the welding process of the first welding body and the second welding body is divided into an initial stage and a stable stage. In the initial stage, the welding power is adjusted based on the real-time value of the moving rate. In the stable stage, the welding power is adjusted based on the moving average value of the moving rate.

[0016] The present invention also provides a precision welding dynamic control system, which includes a controller. The controller controls the welding power output by the welding power source based on the precision welding dynamic control method as described above.

[0017] The present invention also provides a precision welding dynamic 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 precision welding dynamic control method as described above.

[0021] The present invention also provides a computer-readable storage medium comprising a computer program, wherein the computer program can be executed by a processor to implement the precision welding dynamic control method as described above.

[0022] Compared with the existing technology, the precision welding dynamic control method provided by the above technical solution of the present invention indirectly characterizes the penetration depth by detecting the approach rate of the weld body, and then dynamically adjusts the welding power, which is equivalent to establishing a closed-loop control link between the progression rate of the weld body penetration depth and the welding temperature. This effectively avoids the lag of direct temperature measurement, completes real-time regulation within the welding cycle, reduces the matching error between heat input and target penetration depth, improves the consistency of welding quality, and reduces the defect rate caused by dynamic process fluctuations. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a flow chart of the precision welding dynamic control method in an embodiment of the present invention. DETAILED DESCRIPTION

[0024] 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.

[0025] This embodiment discloses a dynamic control method for precision welding, particularly suitable for welding processes with ultra-short welding cycles (e.g., within tens of microseconds). This control method, through real-time detection of the weld body approach rate and the establishment of a dynamic rate-power mapping relationship, indirectly achieves closed-loop control of penetration depth (temperature). This overcomes the technical bottleneck of direct temperature measurement in microsecond-level welding and improves process stability in dynamic scenarios.

[0026] like Figure 1 , the control method comprises the following steps:

[0027] S1: When it is detected that the first welding body and the second welding body approach each other to a preset limit position and enter a welding state, the moving speed of the first welding body and the second welding body approaching each other is detected in real time;

[0028] S2: adjusting the welding power applied by the welding power source between the first welding body and the second welding body based on the moving rate and the preset melting depth.

[0029] It should be noted that the contact pressure between the first welding body and the second welding body can be detected by a pressure sensor to determine whether the two are close to the preset limit position, or the working current of the driving motor that drives the first welding body or the second welding body to move can be used to determine whether the two are close to the preset limit position.

[0030] When the first and second weld bodies approach each other to the limit position and the welding power supply outputs current, the welding state is entered. At this time, the movement rate of the first and second weld bodies approaching each other is detected. This movement rate represents the progress of the penetration depth between the first and second weld bodies.

[0031] In traditional welding processes, direct temperature measurement using sensors is not possible due to sensor response delays (the microsecond welding cycle is much shorter than the millisecond response time of thermocouple / infrared temperature measurement). However, this embodiment indirectly characterizes weld penetration by detecting the weld body approach rate (a parameter measurable at the μs level), and then dynamically adjusts the welding power, effectively establishing a closed-loop control link between the weld body penetration rate and the welding temperature. This avoids the lag associated with direct temperature measurement, enabling real-time control within the welding cycle and miniaturizing the error in matching heat input with target penetration. This approach is particularly suitable for precise temperature control of high-melting-point materials or micro-weld joints.

[0032] Secondly, during welding, the weld contact velocity changes dynamically due to factors such as mechanical vibration and material deformation. Traditional fixed-power modes cannot adaptively adjust, leading to fluctuations in weld penetration (e.g., insufficient weld penetration during a sudden increase in weld velocity, or excessive weld penetration during a sudden decrease in weld velocity). This embodiment uses "dynamic mapping of weld velocity and welding power" to compensate for heat input in real time. As a result, weld penetration uniformity is significantly improved, defects such as cold welds and porosity are reduced, and the yield rate is effectively increased in high-speed continuous welding scenarios.

[0033] Furthermore, while traditional methods require complex temperature profiles to be pre-set for different material combinations, the control method in this embodiment uses the movement rate as the core control variable. By adjusting the movement rate-welding power relationship, it can adapt to different materials (such as copper-aluminum heterogeneous welding) and different weld sizes. This reduces welding process debugging time and can automatically adapt to the dynamic deformation of the welding object.

[0034] On the other hand, the detection method of the moving speed includes:

[0035] Acquiring a movement displacement based on a displacement sensor or a rotation parameter of a driving motor that drives the first welding body or the second welding body to move;

[0036] The movement rate is calculated based on the movement distance and the time it takes for the movement distance to occur.

[0037] On the other hand, the welding power includes at least one adjustment parameter of welding current, welding voltage or welding pulse width. For example, the welding power output by the welding power source is adjusted by adjusting the welding current.

[0038] Alternatively, a data table can be pre-created based on historical test data. This table records the movement rate and welding power corresponding to different weld depths. Once the movement rate is obtained, the corresponding welding power can be obtained by querying the data table. For different usage scenarios, users can adjust the data in the data table to meet their welding requirements.

[0039] In addition, you can configure a calculation formula between the movement rate and the welding power adjustment value corresponding to different melting depths. In this way, when the user sets the melting depth, the control program substitutes the generated movement rate into the corresponding calculation formula to calculate the welding power adjustment value.

[0040] Furthermore, an AI model can be used to process the movement rate to generate a corresponding welding power adjustment value.

[0041] On the other hand, the first welding body and the second welding body may be welded based on resistance welding or direct heat fusion.

[0042] Specifically, a plasma heater applies heat energy to the contact surfaces of the first and second weld bodies to weld the first and second weld bodies by direct heat fusion. During the welding process, the plasma heater continuously sprays a plasma stream onto the contact surfaces of the first and second weld bodies to heat the contact surfaces, causing them to melt and thereby weld the first and second weld bodies together.

[0043] When resistance welding is used for welding, the first welding body and the second welding body are connected to the power circuit output by the welding power supply. After the first welding body contacts the second welding body, contact resistance is generated on the contact surface. The contact resistance is heated under the action of the driving current of the power circuit, thereby melting the contact surface between the first welding body and the second welding body, and then welding the two together.

[0044] On the other hand, according to the preset time point, the welding process of the first weld body and the second weld body is divided into an initial stage and a stable stage. In the initial stage, the welding power is adjusted based on the real-time value of the moving rate. In the stable stage, the welding power is adjusted based on the moving average value of the moving rate.

[0045] For example, in the initial stage (0-5μs), the welding power is dynamically adjusted based on the real-time value of the moving speed. In the stable stage (5-30μs), the moving average of the moving speed is calculated and the welding power is adjusted based on the moving average.

[0046] In this embodiment, real-time rate regulation is used in the initial stage to quickly respond to transient impacts and position deviations (such as sudden displacement changes caused by uneven material surfaces) at the moment of contact between the two weld bodies. Dynamic compensation is performed by sampling real-time values at high frequencies, effectively solving the problem of cold welds caused by sudden acceleration changes in the initial stage of welding. In the stable stage, a moving average filtering algorithm (such as a time window of 5-10μs) is used to effectively filter out rate jitter caused by interference noise and mechanical vibration, thereby establishing a stable correspondence between welding energy input and the molten state of the material. The differentiated setting of the control parameters in the two stages enables the system to have both rapid response and anti-interference capabilities.

[0047] In another preferred embodiment of the present invention, a precision welding dynamic control system is also disclosed, which includes a controller. The controller controls the welding power output by the welding power source based on the precision welding dynamic control method in the above embodiment.

[0048] The present invention also discloses another precision welding dynamic 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 dynamic control 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 module in the precision welding dynamic control system of the embodiment of the present application, or to execute the precision welding dynamic control method of the method embodiment of the present application.

[0049] 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 dynamic control 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 disk (SSD).

[0050] 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 dynamic control method.

[0051] 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 precision welding dynamic control method, characterized in that: include: When it is detected that the first welding body and the second welding body approach each other to a preset limit position and enter a welding state, the moving speed of the first welding body and the second welding body approaching each other is detected in real time; The welding power applied by the welding power source between the first welding body and the second welding body is adjusted based on the moving rate and the preset melting depth.

2. The precision welding dynamic control method according to claim 1, characterized in that: The method for detecting the moving speed includes: Acquiring a movement displacement based on a displacement sensor or a rotation parameter of a driving motor that drives the first welding body or the second welding body to move; The movement speed is calculated based on the movement displacement and the time taken for the movement displacement to occur.

3. The precision welding dynamic control method according to claim 1, characterized in that: The welding power includes at least one adjustment parameter of welding current, welding voltage or welding pulse width.

4. The precision welding dynamic control method according to claim 1, characterized in that: A data table is pre-established, which records the adjustment values of the welding power corresponding to different movement rates at different melting depths; after the movement rate is obtained, the corresponding adjustment value of the welding power is obtained by querying the data table.

5. The precision welding dynamic control method according to claim 1, characterized in that: The first welding body and the second welding body are welded by resistance welding or direct thermal fusion.

6. The precision welding dynamic control method according to claim 5, characterized in that: Thermal energy is applied to contact surfaces of the first welding body and the second welding body by a plasma heater, so as to weld the first welding body and the second welding body by direct thermal fusion.

7. The precision welding dynamic control method according to claim 1, characterized in that: According to the preset time point, the welding process of the first welding body and the second welding body is divided into an initial stage and a stable stage. In the initial stage, the welding power is adjusted based on the real-time value of the moving rate. In the stable stage, the welding power is adjusted based on the moving average value of the moving rate.

8. A precision welding dynamic control system, characterized in that: The invention comprises a controller, which controls the welding power output by the welding power source based on the precision welding dynamic control method according to any one of claims 1 to 7.

9. A precision welding dynamic 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 configured to be executed by the one or more processors, the programs including instructions for executing the precision welding dynamic control method according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that The invention comprises a computer program, which can be executed by a processor to implement the precision welding dynamic control method according to any one of claims 1 to 7.

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