A welder counter and miss-weld monitoring system

Abstract

This invention belongs to the field of automated monitoring technology for welding equipment. It discloses a welding machine counting and leak-proof welding monitoring system, including a data acquisition module. During the welding process, the system performs multi-channel parallel acquisition of welding operation status data based on a time-slice polling mechanism, embedding the acquired welding operation status data into a parameter hash signature stream to form a tamper-proof real-time signal chain. An abnormal state determination module maps the real-time signal chain to a state transition hypergraph and analyzes the temporal phase offset between state nodes based on a time-window sliding resonance detection algorithm to identify leak-proof welding-related abnormal states and mark the abnormal topology location. A weld point counting correction module corrects the current weld point count value in real time when an abnormal topology location is detected, introducing a cost-benefit balance factor between different nodes and outputting a corrected, reliable weld point count value. This system achieves intelligent monitoring and leak-proof welding, improving operational safety and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of automated monitoring technology for welding equipment, and more specifically, to a welding machine counting and leak-proof welding monitoring system. Background Technology

[0002] Existing welding machine counting and leak detection systems mainly have the following problems:

[0003] Existing methods for preventing weld defects largely rely on threshold judgments based on single-channel current, voltage, or temperature signals. This makes it difficult to accurately identify weld defects in multi-channel, multi-stage welding operations, especially when signals are interfered with or fluctuate, leading to frequent misjudgments or missed detections. Current detection methods typically ignore the temporal phase relationships between different welding states, failing to effectively analyze the dynamic correlations between nodes and struggling to capture phase shift characteristics caused by weld defects. While some methods can detect anomalies, they cannot accurately locate the anomaly within the welding process topology, resulting in inefficient subsequent corrections or manual intervention. Existing systems are mostly post-process analysis, unable to provide real-time alarms and protective controls during the welding process.

[0004] During the welding process, the counting system may be affected by electromagnetic interference, sensor transient errors, or signal loss, leading to discrepancies between the actual weld point count and the system record. Existing systems often use simple threshold or recount methods to correct anomalies, which cannot distinguish the severity of different anomalies and their impact on the counting results, resulting in insufficient accuracy. Overcorrection may introduce false alarms or unnecessary fixture locking; undercorrection may cause missed welds to go undetected, creating quality risks. Existing systems typically correct based on fixed weights or rules, lacking the ability to dynamically adjust according to historical frequency and the scope of anomaly impact.

[0005] In existing technologies, during the welding process, sensor signal noise, transient fluctuations, or occasional anomalies can easily cause short-term deviations in weld point counts. This may lead to premature unlocking or failure to lock the fixture in time, increasing the risk of missed or incorrect welds. Existing technologies typically rely on a single threshold to determine whether the weld point count meets requirements, failing to buffer short-term anomalies or transient fluctuations. The system lacks dynamic monitoring and visual feedback; when welding anomalies occur, operators cannot immediately determine the fixture status and the accuracy of the weld point count, affecting welding quality and safety.

[0006] In view of this, the present invention proposes a welding machine counting and leak prevention monitoring system to solve the above problems. Summary of the Invention

[0007] To overcome the aforementioned deficiencies of the prior art and to achieve the above objectives, the present invention provides the following technical solution: a welding machine counting and leak-proof welding monitoring system, comprising:

[0008] The data acquisition module performs multi-channel parallel acquisition of welding operation status data based on a time-slice polling mechanism during the welding process, and embeds the acquired welding operation status data into a parameter hash signature stream to form a tamper-proof real-time signal chain.

[0009] The abnormal state determination module maps the real-time signal chain into a state transition hypergraph, and analyzes the temporal phase offset between state nodes based on the time window sliding resonance detection algorithm to identify abnormal states related to missing solder joints and mark the abnormal topology location.

[0010] The solder joint count correction module corrects the current solder joint count value in real time when an abnormal topology location is detected, introduces a cost-benefit balance factor between different nodes, and outputs a corrected and reliable solder joint count value.

[0011] The anti-missed solder joint locking module is based on a dual-threshold delay control mechanism. If the reliable solder joint count value reaches the low threshold but does not reach the high threshold, the fixture remains locked and the unlocking is delayed. If the reliable solder joint count value reaches the high threshold and the abnormal label is eliminated, the solenoid valve is driven to unlock the fixture.

[0012] The monitoring results display module receives reliable weld point counts and fixture locking status. Based on a graphical interface, it dynamically generates a visual interface of the welding process status. When an anomaly occurs, it alerts the operator to take measures through graphical and audio prompts.

[0013] Specifically, the method for multi-channel parallel acquisition of welding operation status data includes:

[0014] The acquisition time axis is divided into time slices of equal length by a time slice polling mechanism. Within each time slice, the acquisition tasks of different sensor channels are triggered simultaneously according to the preset channel priority order to obtain welding operation status data.

[0015] Welding operation status data includes electrical parameter data, thermal parameter data, position and motion parameter data, process auxiliary parameter data, and environmental parameter data. Parallel acquisition of data from different sensor channels is achieved through a hardware-layer multi-channel analog-to-digital converter to synchronously read data from different channels, and the timing coordination of acquisition of each channel is controlled by a software-layer scheduler within a time slice.

[0016] Specifically, the method for forming a tamper-proof real-time signal chain includes:

[0017] The welding operation status data of each time slice is packaged with the corresponding timestamp, channel identifier and acquisition parameters to generate the original data packet for that time slice; the parameter hash operation is performed on the original data packet to generate a unique corresponding parameter hash signature;

[0018] The parameter hash signature is concatenated with the hash signature of the previous time slice and then hashed again to form a chain hash association between adjacent time slices; by continuously linking the parameter hash signature of the new time slice with the signature of the previous time slice, a parameter hash signature stream covering the entire welding process is formed.

[0019] If the original data packet of any time slice is tampered with, it is determined that the hash value corresponding to the original data packet will be inconsistent with the chain association, thus realizing the anti-tampering protection of welding operation status data.

[0020] Specifically, the method for mapping a real-time signal chain to a state transition hypergraph includes:

[0021] The received real-time signal chain is parsed into a state sequence in chronological order. Each state node in the state sequence corresponds to the welding operation state data of a time slice. By introducing a multi-dimensional relationship mapping into the state sequence, the nodes not only represent temporal adjacency relationships, but also the correlation relationships between different acquisition channels and different process stages, thus constructing a state transition hypergraph containing different edge relationships.

[0022] The vertices of the state transition hypergraph represent the various state nodes in the welding process, and the hyperedges represent the association and transition relationships between different state nodes. By assigning edge weights to the hypergraph, the time interval, phase difference, and physical quantity correlation between nodes can be reflected.

[0023] Specifically, the method for identifying solder joint defects and marking the location of the abnormal topology includes:

[0024] For any two state nodes in the state transition hypergraph, defined at time point... The phase difference; based on the time window sliding resonance detection algorithm, a length of [value] is defined on the time axis. The sliding time window is used to calculate the phase synchronization index of any two state nodes within the sliding time window at each time point.

[0025] A preset phase synchronization threshold is set. When the phase synchronization index of any two state nodes within the sliding time window is less than the preset phase synchronization threshold, it is determined that there is a missing solder joint related abnormal state between the two state nodes, and the positions of the two state nodes are changed on the state transition hypergraph. Marked as an abnormal topology location.

[0026] Specifically, the method for outputting the corrected reliable solder joint count value includes:

[0027] During the welding process, the system continuously acquires and updates the weld point count value, which represents the weld point count value at a given time point. The detected uncorrected solder joint count; when an abnormal topology location is detected, the set of state nodes corresponding to that abnormal topology location is defined as an anomaly set;

[0028] Each node in the anomaly set is assigned an anomaly correction weight, which is determined based on the severity of the anomaly, the scope of its impact, and its historical frequency. A cost-benefit balancing factor is introduced between different nodes to adjust the balance between the correction magnitude and the system's fault tolerance. A solder joint reliability count correction function is constructed, and the corrected reliability solder joint count value is output.

[0029] Specifically, the method of keeping the clamp in a locked state and delaying the unlocking process includes:

[0030] A low threshold and a high threshold are preset, with the low threshold being less than the high threshold. When the trusted solder joint count first reaches the low threshold, the time point is recorded, and the dual-threshold delay control mechanism is activated. If the trusted solder joint count has not yet reached the high threshold, the system maintains the fixture locked state and delays the unlocking process.

[0031] Specifically, the method for unlocking the clamp by driving the solenoid valve includes:

[0032] If the number of reliable solder joints reaches the preset high threshold, it is determined that the number of solder joints in the current welding operation has reached the preset safety standard, and the marked abnormal topology position has been eliminated, and the system enters the fixture unlocking preparation state.

[0033] The anti-slip welding monitoring terminal sends an unlocking command to the preset solenoid valve control unit. The solenoid valve in the solenoid valve control unit acts as the actuator of the clamp locking mechanism. After receiving the unlocking command, it activates the solenoid coil to change the position of the valve core, thereby releasing the clamp from its locked state.

[0034] Specifically, the method for dynamically generating a visual interface for the welding process status includes:

[0035] The system receives the trusted solder joint count value, the current identifier of the fixture locking status, and the time point of the fixture locking status change, and transmits them to the preset graphics rendering engine. The graphics rendering engine maps the trusted solder joint count value into a dynamic line chart or bar chart according to the preset display template, reflecting the growth trend of the solder joint count.

[0036] The fixture locking status is mapped to a status indicator light or icon. The color and shape of the status indicator light change dynamically with the locking or unlocking status to show the current working status of the fixture. Based on the mapping relationship, the graphics rendering engine arranges the reliable weld point count value, the current identifier of the fixture locking status, and the time point of the fixture locking status change in chronological order to dynamically generate a visual interface of the welding process status.

[0037] Specifically, the methods for reminding operators to take measures include:

[0038] When an abnormal state is detected during the welding process, based on a preset abnormal prompt template, the relevant area corresponding to the abnormal state is displayed on the visualization interface through a graphics rendering engine. The abnormal information is highlighted in the form of a flashing animation or a pop-up window, and at the same time, a preset warning sound is triggered to remind the operator to take measures.

[0039] Compared with the prior art, the present invention has the following beneficial effects:

[0040] This invention improves the robustness of missing weld identification by mapping welding operation status data to a state transition hypergraph, comprehensively considering temporal adjacency, inter-channel correlation, and process stage relationships. By defining the phase difference between any two state nodes and calculating the phase synchronization index within a sliding time window, it can detect changes in phase consistency between nodes in real time and accurately capture phase mismatch caused by missing welds. Abnormal topology locations are directly marked in the state transition hypergraph, enabling spatial localization and visualization of anomalies, facilitating rapid operator judgment and handling. The detection process uses a sliding window for real-time updates, outputting abnormal results without waiting for the entire welding operation to finish. It can be linked with the system's anti-missing weld locking module to trigger fixture locking or alarms immediately, preventing defective workpieces from flowing into subsequent stages.

[0041] By mapping detected abnormal topology locations to a set of abnormal nodes and assigning correction weights to each node based on severity, impact range, and historical frequency, differentiated and precise corrections can be achieved. Introducing a cost-benefit balancing factor allows for a balance between the risk of missed welds and the risk of misjudgment, ensuring that the correction effectively compensates for errors caused by anomalies while avoiding false alarms due to over-correction. The anomaly correction weights can be dynamically adjusted according to changes in the production environment, equipment aging, and historical data statistics, ensuring the system maintains high-precision counting correction capabilities during long-term operation. The corrected reliable count value directly affects subsequent fixture unlocking and alarm logic, effectively reducing missed welds not reported due to counting errors, thereby improving the overall welding quality control level; and enabling immediate feedback on abnormal states, improving operator response speed and processing efficiency.

[0042] By pre-setting low and high threshold values, and keeping the fixture locked when the low threshold is reached but the high threshold is not, premature unlocking of the fixture due to instantaneous fluctuations is avoided, significantly reducing the risk of missed welds. The dual-threshold control mechanism combined with a delay time allows the system to buffer short-term anomalies or errors in weld point counting, improving the fault tolerance and stability of the welding process. By keeping the fixture locked until the high threshold condition is met, the reliability of the weld point count is ensured, providing an accurate data foundation for weld point count correction and real-time visual monitoring, facilitating timely action by operators. The system automatically controls the fixture state without manual intervention, and the delay mechanism prevents erroneous actions, achieving high reliability and high efficiency management of the welding process. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the structure of a welding machine counting and leak-proof welding monitoring system according to the present invention;

[0044] Figure 2 A flowchart illustrating the method for dynamically generating a visual interface for the welding process status provided by this invention;

[0045] Figure 3 This is a schematic diagram of a welding machine counting and leak prevention monitoring method according to the present invention. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Example 1

[0048] Please see Figure 1 and Figure 2 As shown in Embodiment 1, a welding machine counting and leak-proof welding monitoring system proposed in this invention is further illustrated, including:

[0049] Existing welding machine counting and leak detection systems primarily rely on threshold judgments based on single-channel current, voltage, or temperature signals to identify leaks. However, in multi-channel, multi-stage welding operations, this method struggles to accurately detect leaks, especially when signals are interfered with or fluctuate, easily leading to false positives or false negatives. Furthermore, existing technologies typically ignore the temporal phase relationships between different welding states, failing to effectively analyze the dynamic correlations between state nodes, thus making it difficult to capture phase shift characteristics caused by leaks. While some methods can detect anomalies, they cannot accurately locate the anomaly within the welding process's topology, resulting in inefficient subsequent corrections or manual intervention. Simultaneously, most systems rely primarily on post-process analysis, lacking the ability to provide real-time alarms and protective controls during the welding process.

[0050] During welding counting, the system is susceptible to electromagnetic interference, sensor momentary errors, or signal loss, leading to discrepancies between the actual weld count and the system record. Existing systems often use simple thresholds or recounting methods to correct anomalies, but these methods cannot distinguish the severity of different anomalies and their impact on the counting results, resulting in insufficient correction accuracy. Overcorrection may introduce false alarms or unnecessary fixture locking; undercorrection may cause missed welds to go undetected, posing a quality risk. Furthermore, existing systems mostly rely on fixed weights or rules for correction, lacking the ability to dynamically adjust based on historical frequency and the scope of anomaly impact.

[0051] Existing technologies also suffer from the problem of not effectively buffering fluctuations in weld point counts. During the welding process, due to sensor signal noise, instantaneous fluctuations, or occasional anomalies, weld point counts are prone to short-term deviations, which may cause the fixture to unlock prematurely or fail to lock in time, thereby increasing the risk of missed welds or incorrect welds. Existing systems typically rely on a single threshold to determine whether the weld point count meets the standard, lacking a mechanism for handling short-term anomalies or transient fluctuations. In addition, the system lacks dynamic monitoring and visual feedback. When welding anomalies occur, operators find it difficult to obtain accurate information on the fixture status and weld point counts in a timely manner, affecting welding quality and operational safety.

[0052] To effectively solve the above problems, this invention proposes a welding machine counting and leak-proof welding monitoring system, comprising:

[0053] The data acquisition module performs multi-channel parallel acquisition of welding operation status data based on a time-slice polling mechanism during the welding process, and embeds the acquired welding operation status data into a parameter hash signature stream to form a tamper-proof real-time signal chain.

[0054] The abnormal state determination module maps the real-time signal chain into a state transition hypergraph, and analyzes the temporal phase offset between state nodes based on the time window sliding resonance detection algorithm to identify abnormal states related to missing solder joints and mark the abnormal topology location.

[0055] The solder joint count correction module corrects the current solder joint count value in real time when an abnormal topology location is detected, introduces a cost-benefit balance factor between different nodes, and outputs a corrected and reliable solder joint count value.

[0056] The anti-missed solder joint locking module is based on a dual-threshold delay control mechanism. If the reliable solder joint count value reaches the low threshold but does not reach the high threshold, the fixture remains locked and the unlocking is delayed. If the reliable solder joint count value reaches the high threshold and the abnormal label is eliminated, the solenoid valve is driven to unlock the fixture.

[0057] The monitoring results display module receives reliable weld point counts and fixture locking status. Based on a graphical interface, it dynamically generates a visual interface of the welding process status. When an anomaly occurs, it alerts the operator to take measures through graphical and audio prompts.

[0058] Methods for multi-channel parallel acquisition of welding operation status data include:

[0059] The acquisition time axis is divided into time slices of equal length by a time slice polling mechanism. Within each time slice, the acquisition tasks of different sensor channels are triggered simultaneously according to the preset channel priority order to obtain welding operation status data.

[0060] Welding operation status data includes electrical parameter data, thermal parameter data, position and motion parameter data, process auxiliary parameter data, and environmental parameter data. Parallel acquisition of data from different sensor channels is achieved through a hardware-layer multi-channel analog-to-digital converter to synchronously read data from different channels, and the timing coordination of acquisition of each channel is controlled by a software-layer scheduler within a time slice.

[0061] Methods for forming a tamper-proof real-time signal chain include:

[0062] The welding operation status data of each time slice is packaged with the corresponding timestamp, channel identifier and acquisition parameters to generate the original data packet for that time slice; the parameter hash operation is performed on the original data packet to generate a unique corresponding parameter hash signature;

[0063] The parameter hash signature is concatenated with the hash signature of the previous time slice and then hashed again to form a chain hash association between adjacent time slices; by continuously linking the parameter hash signature of the new time slice with the signature of the previous time slice, a parameter hash signature stream covering the entire welding process is formed.

[0064] If the original data packet of any time slice is tampered with, it is determined that the hash value corresponding to the original data packet will be inconsistent with the chain association, thus realizing the anti-tampering protection of welding operation status data.

[0065] Methods for mapping real-time signal chains to state transition hypergraphs include:

[0066] The received real-time signal chain is parsed into a state sequence in chronological order. Each state node in the state sequence corresponds to the welding operation state data of a time slice. By introducing a multi-dimensional relationship mapping into the state sequence, the nodes not only represent temporal adjacency relationships, but also the correlation relationships between different acquisition channels and different process stages, thus constructing a state transition hypergraph containing different edge relationships.

[0067] The vertices of the state transition hypergraph represent the various state nodes in the welding process, and the hyperedges represent the association and transition relationships between different state nodes. By assigning edge weights to the hypergraph, the time interval, phase difference, and physical quantity correlation between nodes can be reflected.

[0068] The time interval is attenuated based on the time difference between nodes to ensure that nodes with similar times are more correlated; the phase difference is measured by calculating the cosine value of the phase difference between node signals to measure the synchronization degree between nodes; the correlation of physical quantities is reflected by the correlation coefficient or similarity between statistical feature vectors to reflect the consistency of physical characteristics between nodes.

[0069] Methods for identifying solder joint defects and marking the location of abnormal topologies include:

[0070] For any two state nodes in the state transition hypergraph, defined at time point... The phase difference between any two state nodes at time points; The phase difference is: ;in, Represents a node With nodes At the point of time The phase difference; and This represents any two state nodes in the state transition hypergraph; Index representing a point in time; Represents a node The phase value at a given time point can be obtained by extracting the corresponding welding operation status data. Represents a node Phase value at a given time point;

[0071] Based on the time-window sliding resonance detection algorithm, a length of [value] is defined on the time axis. The sliding time window is used to calculate the phase synchronization index between any two state nodes within the sliding time window at each time point.

[0072] The phase synchronization index is: ;in, Represents a node With nodes At the point of time Phase synchronization index (resonance coefficient); This represents the sampling time point within the sliding time window, with a value range of [value range missing]. ; Indicates the phase difference at time point The cosine value represents the degree of phase consistency; a value of 1 indicates complete synchronization, and a value of -1 indicates complete opposites.

[0073] A preset phase synchronization threshold is set. When the phase synchronization index of any two state nodes within the sliding time window is less than the preset phase synchronization threshold, it is determined that there is a missing solder joint related abnormal state between the two state nodes, and the positions of the two state nodes are changed on the state transition hypergraph. Marked as an abnormal topology location.

[0074] This solution addresses the following problems with existing technologies: Current incomplete weld detection relies heavily on threshold judgments of single-channel current, voltage, or temperature signals, making it difficult to accurately identify incomplete welds in multi-channel, multi-stage welding operations, especially when signals are interfered with or fluctuate, leading to frequent misjudgments or missed detections. Existing detection methods typically ignore the temporal phase relationships between different welding states, failing to effectively analyze the dynamic correlations between nodes and struggling to capture phase shift characteristics caused by incomplete welds. While some methods can detect anomalies, they cannot accurately locate the anomaly within the welding process topology, resulting in low efficiency for subsequent corrections or manual intervention. Existing systems are mostly post-process analysis, unable to provide real-time alarms and protective controls during the welding process.

[0075] Compared to existing technologies, the advantages are as follows: Mapping welding operation status data to a state transition hypergraph, comprehensively considering temporal adjacency, inter-channel correlation, and process stage relationships, improves the robustness of incomplete weld identification. By defining the phase difference between any two state nodes and calculating the phase synchronization index within the sliding time window, it is possible to detect changes in phase consistency between nodes in real time and accurately capture phase mismatch caused by incomplete welds. The abnormal topology location is directly marked in the state transition hypergraph, realizing spatial positioning and visualization of anomalies, facilitating rapid judgment and handling by operators; the detection process uses a sliding window for real-time updates, outputting abnormal results without waiting for the entire welding operation to end, and can be linked with the incomplete weld locking module of this system to trigger fixture locking or alarms immediately, preventing unqualified workpieces from flowing into subsequent stages.

[0076] Methods for outputting corrected, reliable solder joint count values ​​include:

[0077] During the welding process, the system continuously acquires and updates the weld point count value, which represents the weld point count value at a given time point. The detected uncorrected solder joint count value; when an abnormal topology location is detected, the set of state nodes corresponding to the abnormal topology location is defined as an abnormal set, which contains the node indices that may cause solder joint count errors;

[0078] Each node in the anomaly set is assigned an anomaly correction weight, which is determined based on the severity of the anomaly, the scope of its impact, and its historical frequency. A cost-benefit balancing factor is introduced between different nodes to adjust the balance between the correction magnitude and the system's fault tolerance. A solder joint reliability count correction function is constructed, and the corrected reliability solder joint count value is output.

[0079] The solder joint confidence count correction function is: ;in, Indicates at a point in time The reliable solder joint count value; Indicates a point in time The detected uncorrected solder joint count; This represents the cost-benefit balance factor, used to adjust the weight of the abnormal correction amount in the final count, balancing the risk of misjudgment and the risk of missing solder. Indicates a point in time The detected set of anomalies; The anomaly correction weight can be calculated based on parameters such as node importance, detection confidence, and process stage. This represents the index of an abnormal node in the anomaly set;

[0080] This solution addresses the following problems in existing technologies: During the welding process, the counting system may be affected by electromagnetic interference, sensor transient errors, or signal loss, leading to discrepancies between the actual weld point count and the system record. Existing systems often use simple threshold or recounting methods to correct anomalies, failing to distinguish the severity of different anomalies and their impact on the counting results, resulting in insufficient accuracy. Overcorrection may introduce misjudgments, leading to false alarms or unnecessary fixture locking; undercorrection may cause missed welds to go undetected, creating quality risks. Existing systems typically correct based on fixed weights or rules, lacking dynamic adjustments based on historical frequency and the scope of anomaly impact.

[0081] Compared to existing technologies, the advantages are as follows: By mapping detected abnormal topological locations to a set of abnormal nodes and assigning correction weights to each node based on severity, impact range, and historical frequency, differentiated and precise corrections can be achieved. By introducing a cost-benefit balancing factor, a balance can be struck between the risk of missed welds and the risk of misjudgment, ensuring that the correction results effectively compensate for errors caused by anomalies while avoiding false alarms due to over-correction. The anomaly correction weights can be dynamically adjusted according to changes in the production environment, equipment aging, and historical data statistics, ensuring that the system maintains high-precision counting correction capabilities during long-term operation. The corrected reliable count value directly affects subsequent fixture unlocking and alarm logic, effectively reducing missed welds not reported due to counting errors, thereby improving the overall welding quality control level. Real-time feedback of abnormal states is achieved, improving the operator's response speed and processing efficiency.

[0082] Methods for keeping the clamp locked and delaying the unlocking process include:

[0083] A low threshold and a high threshold are preset, with the low threshold being less than the high threshold. When the trusted solder joint count first reaches the low threshold, the time point is recorded, and the dual-threshold delay control mechanism is activated. If the trusted solder joint count has not yet reached the high threshold, the system maintains the fixture locked state and delays the unlocking process.

[0084] The dual-threshold delay control mechanism is as follows: ;in, This indicates a preset low threshold value; This indicates a preset high threshold value; This indicates the time point at which the reliable solder joint count first reaches the low threshold. Indicates the preset delay time;

[0085] This solution addresses the following problems in existing technologies: In existing technologies, during the welding process, sensor signal noise, instantaneous fluctuations, or occasional anomalies can easily cause short-term deviations in weld point counts, potentially leading to premature unlocking or failure to lock the fixture in time, thus increasing the risk of missed or incorrect welds. Existing technologies typically rely on a single threshold to determine whether the weld point count meets requirements, failing to buffer short-term anomalies or transient fluctuations. The system lacks dynamic monitoring and visual feedback; when welding anomalies occur, operators cannot immediately determine the fixture status and the accuracy of the weld point count, affecting welding quality and safety.

[0086] Compared to existing technologies, the advantages are as follows: By preset low and high threshold values, and keeping the fixture locked when the low threshold is reached but the high threshold is not, premature unlocking of the fixture due to instantaneous fluctuations is avoided, significantly reducing the risk of missed welds. The dual-threshold control mechanism combined with a delay time enables the system to buffer short-term anomalies or errors in weld point counting, improving the fault tolerance and stability of the welding process. By keeping the fixture locked until the high threshold condition is met, the reliability of the weld point count value is ensured, providing an accurate data basis for weld point count correction and real-time visual monitoring, facilitating timely action by operators; the system automatically controls the fixture state without manual intervention, and the delay mechanism prevents erroneous actions, achieving high reliability and high efficiency management of the welding process.

[0087] Methods for driving the solenoid valve to unlock the clamp include:

[0088] If the number of reliable solder joints reaches the preset high threshold, it is determined that the number of solder joints in the current welding operation has reached the preset safety standard, and the marked abnormal topology position has been eliminated, and the system enters the fixture unlocking preparation state.

[0089] The anti-slip welding monitoring terminal sends an unlocking command to the preset solenoid valve control unit. The solenoid valve in the solenoid valve control unit acts as the actuator of the clamp locking mechanism. After receiving the unlocking command, it activates the solenoid coil to change the position of the valve core, thereby releasing the clamp from its locked state.

[0090] Methods for dynamically generating a visual interface for the welding process status include:

[0091] The system receives the trusted solder joint count value, the current identifier of the fixture locking status (such as "locked" or "unlocked"), and the time point of the fixture locking status change, and transmits them to the preset graphics rendering engine. The graphics rendering engine maps the trusted solder joint count value into a dynamic line chart or bar chart according to the preset display template to reflect the growth trend of the solder joint count. The preset display template includes the interface layout structure, graphic element style, data mapping rules, refresh rate, and abnormal prompt design.

[0092] The fixture locking status is mapped to a status indicator light or icon. The color and shape of the status indicator light change dynamically with the locking or unlocking status to show the current working status of the fixture. Based on the mapping relationship, the graphics rendering engine arranges the reliable weld point count value, the current identifier of the fixture locking status, and the time point of the fixture locking status change in chronological order to dynamically generate a visual interface of the welding process status.

[0093] Methods for reminding operators to take action include:

[0094] When an abnormal state is detected during the welding process, based on a preset abnormal prompt template, the relevant area corresponding to the abnormal state is displayed on the visualization interface through a graphics rendering engine. The abnormal information is highlighted in the form of a flashing animation or a pop-up window, and at the same time, a preset warning sound is triggered to remind the operator to take measures.

[0095] The preset low threshold is set by staff based on historical data analysis results. This historical analysis process includes the system collecting multiple thresholds and calculating their average value as a reference to obtain the preset low threshold. Similarly, the preset high threshold and preset phase synchronization threshold are also set by staff based on the system's historical operating data and the specific application scenario requirements.

[0096] In this embodiment, by mapping welding operation status data to a state transition hypergraph, the robustness of incomplete weld identification is improved by comprehensively considering temporal adjacency, inter-channel correlation, and process stage relationships. By defining the phase difference between any two state nodes and calculating the phase synchronization index within the sliding time window, changes in phase consistency between nodes can be detected in real time, accurately capturing phase mismatch caused by incomplete welds. The abnormal topology location is directly marked in the state transition hypergraph, enabling spatial localization and visualization of anomalies, facilitating rapid judgment and handling by operators. The detection process uses a sliding window for real-time updates, outputting abnormal results without waiting for the entire welding operation to end. It can be linked with the incomplete weld locking module of this system to trigger fixture locking or alarms immediately, preventing unqualified workpieces from flowing into subsequent stages.

[0097] By mapping detected abnormal topology locations to a set of abnormal nodes and assigning correction weights to each node based on severity, impact range, and historical frequency, differentiated and precise corrections can be achieved. Introducing a cost-benefit balancing factor allows for a balance between the risk of missed welds and the risk of misjudgment, ensuring that the correction effectively compensates for errors caused by anomalies while avoiding false alarms due to over-correction. The anomaly correction weights can be dynamically adjusted according to changes in the production environment, equipment aging, and historical data statistics, ensuring the system maintains high-precision counting correction capabilities during long-term operation. The corrected reliable count value directly affects subsequent fixture unlocking and alarm logic, effectively reducing missed welds not reported due to counting errors, thereby improving the overall welding quality control level; and enabling immediate feedback on abnormal states, improving operator response speed and processing efficiency.

[0098] By pre-setting low and high threshold values, and keeping the fixture locked when the low threshold is reached but the high threshold is not, premature unlocking of the fixture due to instantaneous fluctuations is avoided, significantly reducing the risk of missed welds. The dual-threshold control mechanism combined with a delay time allows the system to buffer short-term anomalies or errors in weld point counting, improving the fault tolerance and stability of the welding process. By keeping the fixture locked until the high threshold condition is met, the reliability of the weld point count is ensured, providing an accurate data foundation for weld point count correction and real-time visual monitoring, facilitating timely action by operators. The system automatically controls the fixture state without manual intervention, and the delay mechanism prevents erroneous actions, achieving high reliability and high efficiency management of the welding process.

[0099] Example 2

[0100] Please see Figure 3 As shown, the parts not described in detail in this embodiment are described in Embodiment 1. A welding machine counting and leak detection method is provided, including:

[0101] S1. During the welding process, welding operation status data is collected in parallel through multiple channels based on a time-slice polling mechanism, and the collected welding operation status data is embedded in the parameter hash signature stream to form a real-time signal chain that can be prevented from being tampered with.

[0102] S2. Map the real-time signal chain into a state transition hypergraph, and analyze the temporal phase offset between state nodes based on the time window sliding resonance detection algorithm to identify abnormal states related to missing solder joints and mark the abnormal topology locations.

[0103] S3. When an abnormal topology location is detected, the current solder joint count value is corrected in real time, a cost-benefit balance factor is introduced between different nodes, and the corrected reliable solder joint count value is output.

[0104] S4. Based on the dual-threshold delay control mechanism, if the trusted solder joint count value reaches the low threshold but does not reach the high threshold, the fixture remains locked and the unlocking is delayed; if the trusted solder joint count value reaches the high threshold and the abnormal label is eliminated, the solenoid valve is driven to unlock the fixture.

[0105] S5. Receive reliable weld point count values ​​and fixture locking status. Based on a graphical interface, dynamically generate a visual interface of the welding process status. When an anomaly occurs, remind the operator to take measures through graphical and audio prompts.

[0106] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters and thresholds in the formulas are set by those skilled in the art according to the actual situation.

[0107] The above description is merely a preferred embodiment of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for users of ordinary technical skills, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A welding machine counting and leak-proof welding monitoring system, characterized in that, include: The data acquisition module performs multi-channel parallel acquisition of welding operation status data based on a time-slice polling mechanism during the welding process, and embeds the acquired welding operation status data into a parameter hash signature stream to form a tamper-proof real-time signal chain. The abnormal state determination module maps the real-time signal chain into a state transition hypergraph, and analyzes the temporal phase offset between state nodes based on the time window sliding resonance detection algorithm to identify abnormal states related to missing solder joints and mark the abnormal topology location. The method for mapping a real-time signal chain to a state transition hypergraph includes: The received real-time signal chain is parsed into a state sequence in chronological order. Each state node in the state sequence corresponds to the welding operation state data of a time slice. By introducing a multi-dimensional relationship mapping into the state sequence, the nodes not only represent temporal adjacency relationships, but also the correlation relationships between different acquisition channels and different process stages, thus constructing a state transition hypergraph containing different edge relationships. The vertices of the state transition hypergraph represent the various state nodes in the welding process, and the hyperedges represent the association and transition relationships between different state nodes; the time interval, phase difference and physical quantity correlation between nodes are reflected by assigning edge weights to the hypergraph. The method for identifying solder joint defects and marking the location of the defects includes: For any two state nodes in the state transition hypergraph, the phase difference at time point t is defined; based on the time window sliding resonance detection algorithm, a sliding time window of length W is defined on the time axis, and the phase synchronization index of any two state nodes within the sliding time window is calculated at each time point. A preset phase synchronization threshold is set. When the phase synchronization index of any two state nodes within the sliding time window is less than the preset phase synchronization threshold, it is determined that there is a missing solder joint related abnormal state between the two state nodes, and the positions of the two state nodes are marked as abnormal topology positions on the state transition hypergraph. The solder joint count correction module corrects the current solder joint count value in real time when an abnormal topology location is detected, introduces a cost-benefit balance factor between different nodes, and outputs a corrected and reliable solder joint count value. The anti-missed solder joint locking module is based on a dual-threshold delay control mechanism. If the reliable solder joint count value reaches the low threshold but does not reach the high threshold, the fixture remains locked and the unlocking is delayed. If the reliable solder joint count value reaches the high threshold and the abnormal label is eliminated, the solenoid valve is driven to unlock the fixture. The monitoring results display module receives reliable weld point counts and fixture locking status. Based on a graphical interface, it dynamically generates a visual interface of the welding process status. When an anomaly occurs, it alerts the operator to take measures through graphical and audio prompts.

2. The welding machine counting and leak-proof welding monitoring system according to claim 1, characterized in that, The method for multi-channel parallel acquisition of welding operation status data includes: The acquisition time axis is divided into time slices of equal length by a time slice polling mechanism. Within each time slice, the acquisition tasks of different sensor channels are triggered simultaneously according to the preset channel priority order to obtain welding operation status data. Welding operation status data includes electrical parameter data, thermal parameter data, position and motion parameter data, process auxiliary parameter data, and environmental parameter data. Parallel acquisition of data from different sensor channels is achieved through a hardware-layer multi-channel analog-to-digital converter to synchronously read data from different channels, and the timing coordination of acquisition of each channel is controlled by a software-layer scheduler within a time slice.

3. The welding machine counting and leak-proof welding monitoring system according to claim 2, characterized in that, The method for forming a tamper-proof real-time signal chain includes: The welding operation status data of each time slice is packaged with the corresponding timestamp, channel identifier and acquisition parameters to generate the original data packet for that time slice; the parameter hash operation is performed on the original data packet to generate a unique corresponding parameter hash signature; The parameter hash signature is concatenated with the hash signature of the previous time slice and then hashed again to form a chain hash association between adjacent time slices; by continuously linking the parameter hash signature of the new time slice with the signature of the previous time slice, a parameter hash signature stream covering the entire welding process is formed. If the original data packet of any time slice is tampered with, it is determined that the hash value corresponding to the original data packet will be inconsistent with the chain association, thus realizing the anti-tampering protection of welding operation status data.

4. The welding machine counting and leak-proof welding monitoring system according to claim 3, characterized in that, The method for outputting the corrected reliable solder joint count value includes: During the welding process, the system continuously acquires and updates the weld point count value, which represents the uncorrected weld point count value detected at time point t; when an abnormal topology location is detected, the set of state nodes corresponding to the abnormal topology location is defined as an anomaly set. Each node in the anomaly set is assigned an anomaly correction weight, which is determined based on the severity of the anomaly, the scope of its impact, and its historical frequency. A cost-benefit balancing factor is introduced between different nodes to adjust the balance between the correction magnitude and the system's fault tolerance. A solder joint reliability count correction function is constructed, and the corrected reliability solder joint count value is output.

5. The welding machine counting and leak-proof welding monitoring system according to claim 4, characterized in that, The method for keeping the clamp locked and delaying the unlocking process includes: A low threshold and a high threshold are preset, with the low threshold being less than the high threshold. When the trusted solder joint count first reaches the low threshold, the time point is recorded, and the dual-threshold delay control mechanism is activated. If the trusted solder joint count has not yet reached the high threshold, the system maintains the fixture locked state and delays the unlocking process.

6. The welding machine counting and leak-proof welding monitoring system according to claim 5, characterized in that, The method for unlocking the clamp by driving the solenoid valve includes: If the number of reliable solder joints reaches the preset high threshold, it is determined that the number of solder joints in the current welding operation has reached the preset safety standard, and the marked abnormal topology position has been eliminated, and the system enters the fixture unlocking preparation state. The anti-slip welding monitoring terminal sends an unlocking command to the preset solenoid valve control unit. The solenoid valve in the solenoid valve control unit acts as the actuator of the clamp locking mechanism. After receiving the unlocking command, it activates the solenoid coil to change the position of the valve core, thereby releasing the clamp from its locked state.

7. The welding machine counting and leak-proof welding monitoring system according to claim 6, characterized in that, The method for dynamically generating a visual interface for the welding process status includes: The system receives the trusted solder joint count value, the current identifier of the fixture locking status, and the time point of the fixture locking status change, and transmits them to the preset graphics rendering engine. The graphics rendering engine maps the trusted solder joint count value into a dynamic line chart or bar chart according to the preset display template, reflecting the growth trend of the solder joint count. The fixture locking status is mapped to a status indicator light or icon. The color and shape of the status indicator light change dynamically with the locking or unlocking status to show the current working status of the fixture. Based on the mapping relationship, the graphics rendering engine arranges the reliable weld point count value, the current identifier of the fixture locking status, and the time point of the fixture locking status change in chronological order to dynamically generate a visual interface of the welding process status.

8. The welding machine counting and leak-proof welding monitoring system according to claim 7, characterized in that, The methods for reminding operators to take action include: When an abnormal state is detected during the welding process, based on a preset abnormal prompt template, the relevant area corresponding to the abnormal state is displayed on the visualization interface through a graphics rendering engine. The abnormal information is highlighted in the form of a flashing animation or a pop-up window, and at the same time, a preset warning sound is triggered to remind the operator to take measures.

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