Taper pipe diameter self-adaption rate regulation and control weld joint homogenization welding system

Abstract

The invention relates to the technical field of welding, in particular to a taper pipe diameter self-adaption rate regulation and control weld joint homogenization welding system. Comprising a diameter detection module configured to detect the diameter change of the taper pipe in real time, the diameter detection module comprises a welding gun Z-axis position detection unit, and the welding gun Z-axis position detection unit automatically calculates the diameter change information of the taper pipe in a controller algorithm by collecting welding gun Z-axis coordinate data in real time. The diameter detection module only depends on the welding gun Z-axis position detection unit, the taper pipe diameter is inversely calculated through a built-in algorithm of the controller, a laser distance measuring sensor, a visual detection device and the like do not need to be additionally configured, the sensor purchase, installation and later maintenance cost is reduced, meanwhile, the system hardware connection and debugging process is simplified, the hardware configuration cost is reduced, and the system structure is simplified.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding, in particular to a taper pipe diameter self-adaptive speed regulation weld seam uniformization welding system. BACKGROUND

[0002] In the field of welding technology, taper pipe welding is a common and challenging task. Traditional welding equipment and processes have many problems when faced with taper pipe welding. Because the diameter of the taper pipe changes along the axis, if a fixed welding speed and parameters are used, it is easy to cause uneven weld width, insufficient welding or welding defects such as welding through. Although some existing welding systems have certain parameter adjustment functions, they mostly rely on manual adjustment based on experience and cannot achieve real-time and accurate matching of welding parameters and diameter changes of the taper pipe, resulting in low welding efficiency and unstable product quality. In addition, the traditional system has a single means of monitoring weld quality, which makes it difficult to comprehensively and timely detect and feedback problems in the welding process, further affecting the welding quality and production efficiency. Therefore, there is an urgent need for a welding system that can self-adaptively regulate welding speed and ensure weld seam uniformization to meet the modern industry's demand for high-quality and high-efficiency taper pipe welding.

[0003] In view of this, the present application is proposed. SUMMARY

[0004] The present application provides a taper pipe diameter self-adaptive speed regulation weld seam uniformization welding system to solve the problems mentioned in the background art: The taper pipe diameter self-adaptive speed regulation weld seam uniformization welding system proposed by the present application comprises: A diameter detection module configured to detect the diameter change of the taper pipe in real time, the diameter detection module relies on a welding gun Z-axis position detection unit (such as a high-precision encoder) to collect welding gun Z-axis coordinate data in real time; a controller with a mapping algorithm (for example: the relationship between the taper pipe diameter d and the Z-axis coordinate z is d=2*(R-k*z), where R is the maximum radius of the taper pipe and k is the taper coefficient of the taper pipe), the current taper pipe diameter is automatically calculated through the Z-axis coordinate, realizing non-contact and additional sensor-free diameter detection; A controller electrically connected to the diameter detection module, generating a speed regulation instruction based on the taper pipe diameter change information, the controller has a self-adaptive control algorithm that can dynamically adjust the welding speed to match the diameter change of the taper pipe; Welding execution module: electrically connected with the controller, including a welding gun driven by a servo motor and a swing mechanism, the servo motor adjusts the welding gun movement speed according to the speed regulation instruction, and the swing mechanism adjusts the welding gun swing frequency and amplitude according to the weld uniformity requirement; the welding execution module further comprises a wire feeding mechanism (such as a servo wire feeder), and the wire feeding speed can be dynamically adjusted by the controller instruction; the wire feeding speed has a preset matching relationship with the welding speed and the taper pipe diameter (such as wire feeding speed s = 0.5v + 0.2d, v is the welding speed, and d is the diameter), so as to ensure that the welding wire filling amount is adapted to the requirement of the molten pool; Data storage module: electrically connected with the controller, storing a preset welding parameter database and historical welding data, for providing data support for the adaptive control algorithm.

[0005] Further, the adaptive control algorithm for regulating the welding speed includes two modes: Variable speed in sections: presetting the number of sections and the corresponding length of each section, the controller compares the welding gun coordinates with the section length boundary in real time, and switches to the welding speed of the corresponding section; supporting 2-5 sections (can be set), each section has a preset length (such as 50mm / section) and a corresponding speed (such as 10-20mm / s), and the welding gun coordinates automatically switch the speed when reaching the section length boundary; Real-time variable speed: presetting the welding time, the controller continuously dynamically adjusts the welding speed according to the welded time and the welded length, so as to ensure that the welding process matches the preset time; inputting the total welding time (such as 100s), the controller calculates the real-time speed v = remaining length / remaining time through remaining length = total length-welded length and remaining time = total time-welded time; Further, the adaptive control algorithm includes a PID control module and a fuzzy reasoning module, the PID control module is used for real-time adjustment of the welding speed, and the fuzzy reasoning module is used for adjusting the swing mechanism parameters according to the weld uniformity feedback.

[0006] Further, the welding execution module further comprises a cross slide, the cross slide is connected with the servo motor, and high-precision displacement adjustment of the welding gun in horizontal and vertical directions can be realized, and the displacement precision is not less than 0.01mm.

[0007] Further, it further includes an automatic seam finding unit, the automatic seam finding unit detects the overlap distance of the taper pipe welding, automatically calculates the required rotation angle of the workpiece by using the built-in algorithm of the controller, controls the rotation mechanism to drive the taper pipe to rotate to the target angle, and realizes automatic positioning and calibration of the weld.

[0008] Further, the data storage module further stores a mapping relationship database of the taper pipe diameter and the welding parameters, and the controller generates initial welding parameters and dynamically corrects them based on the mapping relationship database and the diameter data detected in real time.

[0009] Further, a human-machine interface is connected with the controller, for displaying real-time welding parameters, welding quality evaluation results and receiving user inputted process parameters.

[0010] Further, the wire feeding speed of the wire feeding mechanism is linked with the welding speed and the diameter of the taper pipe, and the controller adjusts the wire feeding speed in real time through a preset welding speed-diameter-wire feeding speed mapping database, so as to avoid insufficient or excessive filling of the molten pool.

[0011] The present application has the following advantages: the diameter detection module only relies on the Z-axis position detection unit of the welding gun, and the diameter of the conical pipe is calculated through the built-in algorithm of the controller, without the need for additional configuration of laser ranging sensors, visual detection equipment, etc., reducing the cost of sensor procurement, installation and later maintenance, simplifying the system hardware connection and debugging process, reducing the hardware configuration cost, and simplifying the system structure; the adaptive control algorithm built in the controller can dynamically match the diameter change of the conical pipe, and the speed is switched by comparing the welding gun coordinates with the length of the segment, and the real-time speed is calculated by the remaining time / length; the PID control module can quickly correct the speed deviation, avoiding the problems of uneven weld width, insufficient molten pool filling or welding through caused by fixed speed, and improving the consistency of weld quality; the fuzzy reasoning module in the adaptive control algorithm can adjust the swing mechanism parameters according to the weld uniformity feedback (such as molten pool shape, weld flatness), so that the welding gun swing frequency and amplitude are adapted to the current welding speed and the diameter of the conical pipe; combined with the high-precision displacement adjustment of the cross slide (displacement accuracy not less than 0.01mm) in the welding execution module, the welding gun can always be accurately aligned with the weld, reducing defects such as welding deviation, single-sided welding and incomplete fusion; the automatic seam finding unit can accurately adjust by detecting the overlap distance, calculating the rotation angle and controlling the rotation mechanism, without manual moving of the conical pipe and visual comparison of the weld position, which not only reduces the physical burden of the operator, but also avoids positioning failure caused by manual judgment deviation and insufficient manual adjustment accuracy, reducing the dependence on high-experience operators; the diameter of the conical pipe-welding parameter mapping relationship database stored in the data storage module can support the controller to quickly generate initial welding parameters; without manual reference to the process manual and repeated parameter adjustment, the historical welding data can optimize subsequent parameter matching, further shorten the parameter preparation time during production change, and improve the overall welding operation efficiency; the man-machine interface displays the welding parameters (speed, wire feed rate, etc.) and weld quality evaluation results in real time, which is convenient for the operator to intuitively master the working conditions; at the same time, parameter input verification is supported to avoid equipment failure caused by illegal parameters; abnormal conditions (such as unstable molten pool) can be fed back in real time through the interface to help the operator to intervene quickly and reduce the production of defective products; the wire feeding speed of the wire feeding mechanism is linked with the welding speed and the diameter of the conical pipe, and the controller adjusts the wire feed rate in real time through the preset "welding speed-diameter-wire feed rate" mapping database to avoid insufficient molten pool filling (void) or excessive welding (welding tumor); reducing the workload and material loss of later polishing and repair, and reducing production cost; the number and length of segments can be flexibly set for segmented variable speed to adapt to different total length conical pipes in real time, and the diameter-parameter mapping database and wire feeding linkage logic are combined, without the need to frequently disassemble and modify the system or reprogram the control program for different diameters and tapers of the conical pipe, enhancing the system's ability to adapt to multiple specifications of workpieces and reducing the difficulty of production change. BRIEF DESCRIPTION OF DRAWINGS

[0012] Figure 1 The system module diagram of the present application is shown. DETAILED DESCRIPTION

[0013] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0014] One embodiment of the present invention, such as Figure 1 As shown, a tapered tube diameter adaptive rate-controlled weld homogenization welding system includes: Diameter detection module: configured to detect the diameter change of the tapered tube in real time. The diameter detection module includes a welding torch Z-axis position detection unit. The welding torch Z-axis position detection unit automatically calculates the tapered tube diameter change information in the controller algorithm by collecting welding torch Z-axis coordinate data in real time. Controller: Electrically connected to the diameter detection module, generates rate control commands based on the tapered tube diameter change information. The controller has a built-in adaptive control algorithm that can dynamically adjust the welding rate to match the tapered tube diameter change. Welding execution module: electrically connected to the controller, including a welding torch driven by a servo motor and an oscillation mechanism. The servo motor adjusts the moving speed of the welding torch according to the rate control command, and the oscillation mechanism adjusts the oscillation frequency and amplitude of the welding torch according to the weld uniformity requirements. The welding execution module also includes a wire feeding mechanism. The controller is used to dynamically adjust the wire feeding speed according to the welding speed and the diameter of the tapered tube, so as to achieve parameter matching between welding and wire feeding. Data storage module: electrically connected to the controller, it stores a preset welding parameter database and historical welding data to provide data support for the adaptive control algorithm.

[0015] The working principle of the above technical solution is as follows: 1. Initial parameter preparation: The data storage module provides basic support. Before welding, the data storage module pre-stores two types of core data: Preset welding parameter database: contains initial welding parameters (such as the number of segments / segment length / corresponding speed of segmented speed change, preset duration of real-time speed change, matching relationship between wire feed speed and welding speed / diameter, etc.) for different tapered tube materials and specifications (such as maximum radius R, taper coefficient k). Historical welding data: provides a reference for subsequent parameter correction of the adaptive control algorithm.

[0016] The controller reads the data from this module to load the initial parameters, laying the foundation for the welding process.

[0017] 2. Real-time Diameter Detection: The diameter detection module acquires key variables: During the welding process, the welding torch Z-axis position detection unit (such as a high-precision encoder) of the diameter detection module collects the Z-axis coordinate data (denoted as z) of the welding torch in real time every 10 ms and transmits the data to the controller.

[0018] The controller calls the built-in diameter mapping algorithm (for example, the formula: d = 2 * (R - k * z), where R is the maximum radius of the taper pipe and k is the taper coefficient of the taper pipe), automatically calculates the diameter d of the taper pipe at the current welding position through the Z-axis coordinate z, and obtains the diameter change information of the taper pipe in real time without additional sensors, thereby solving the problem of high cost and complexity of traditional laser / vision sensors.

[0019] 3. Intelligent instruction generation: the controller realizes the core control logic: After receiving the real-time diameter d transmitted by the diameter detection module, the controller completes two core calculations through the built-in adaptive control algorithm to generate control instructions: Welding speed control: according to the real-time diameter d and the preset parameters (such as the length boundary of the segmented variable speed, the total time / total length of the real-time variable speed), the welding speed matching the current diameter is dynamically calculated: If it is a segmented variable speed mode: the controller compares the real-time Z-axis coordinate of the welding torch with the preset length boundary to determine the current segment number and calls the welding speed of the corresponding segment; If it is a real-time variable speed mode: the controller calculates the real-time speed v = remaining length / remaining time through the remaining length = total length - welded length and the remaining time = total time - welded time, to ensure that the welding rhythm matches the preset time length; Wire feeding speed control: combined with the real-time welding speed v and the current diameter d, the mapping relationship between the welding speed-diameter-wire feeding speed in the data storage module (for example, s = 0.5v + 0.2d, s is the wire feeding speed) is called to calculate the adaptive wire feeding speed, avoiding insufficient or excessive filling of the molten pool.

[0020] Finally, the controller sends the welding speed instruction and the wire feeding speed instruction to the welding execution module synchronously.

[0021] 4. Precise action execution: the welding execution module realizes the control effect: After receiving the controller instruction, the welding execution module completes the welding action through the cooperation of the three components to ensure the uniformity of the weld: Servo motor: accurately adjusts the speed according to the welding speed instruction to drive the welding torch to move along the weld at a speed matching the diameter; if a cross slide is used, it can also correct the horizontal / vertical displacement of the welding torch in real time (accuracy ≤ 0.01 mm) to ensure that the welding torch is always aligned with the weld; Swing mechanism: adjusts the swing frequency and amplitude of the welding torch according to the weld uniformity requirement (linked with the diameter change and the welding speed) to make the weld evenly heated and the filling material uniformly distributed; Wire feeding mechanism (such as servo wire feeder): adjust the rotation speed of the wire feeding wheel according to the wire feeding speed instruction, realize the linkage matching of the wire feeding speed, the welding speed and the taper pipe diameter, ensure the filling amount of the molten pool to adapt to the current welding working condition, and improve the welding quality stability.

[0022] 5. Closed-loop optimization: continuous dynamic adjustment and data feedback: During the whole welding process, the system is always in a closed-loop state of detection-computation-regulation-execution: The diameter detection module continuously collects the Z-axis coordinates, and the controller updates the diameter d and the regulation instruction in real time to avoid parameter mismatch caused by the change of the taper pipe diameter; The controller also stores the welding parameters (speed, wire feeding amount) adjusted each time and real-time diameter data in the data storage module, which provides a basis for subsequent parameter correction for this welding and forms a positive cycle of data-algorithm-performance for subsequent welding optimization algorithm model of similar taper pipes.

[0023] The effect of the above technical solution is: diameter detection only relies on the welding gun Z-axis position detection unit, without the need for additional laser ranging sensors or vision sensors, reducing the purchase, installation and later maintenance cost of sensors, and simplifying the system hardware structure; the controller can dynamically adjust the welding speed according to the change of the taper pipe diameter, and adjust the frequency and amplitude of the swing mechanism, while the wire feeding speed is matched with the welding speed and the taper pipe diameter, so that the weld is heated more evenly and the molten pool is filled more reasonably, avoiding problems such as uneven weld width, insufficient filling or welding through caused by fixed parameters; the servo motor in the welding execution module drives the cross slide to realize high-precision displacement (precision not less than 0.01mm) of the welding gun, ensuring that the welding gun is always accurately aligned with the weld, greatly reducing defects such as welding deviation and incomplete welding, and dynamic parameter regulation also reduces the probability of problems such as cracks and pores; the preset welding parameter database in the data storage module enables the controller to quickly generate initial welding parameters without the need for manual repeated debugging; the automatic seam finding unit calculates the rotation angle to complete positioning by the lap distance, saving the time of manual seam finding, reducing the manual intervention link as a whole, and improving the welding operation efficiency; supports two modes of segmented variable speed and real-time variable speed, which can adapt to the taper requirements of different taper pipes; the wire feeding speed is dynamically adjusted with the welding speed and the taper pipe diameter, which can also adapt to the molten pool filling requirements of taper pipes of different thicknesses without the need to frequently replace equipment or significantly adjust the system configuration for different specifications of taper pipes; the system automatically completes parameter regulation through adaptive algorithm without the need for manual adjustment of key parameters such as welding speed and wire feeding speed by experienced operators, reducing human operation errors, and even inexperienced operators can ensure basic welding quality.

[0024] In one embodiment of the present application, the welding execution step of the welding execution module is: The welding core instruction issued by the controller and the to-be-welded cone pipe adaptive preset parameter called from the data storage module are received; the received instruction and parameter are subjected to validity check, and a welding execution initial parameter set passing the check is generated; the cross slide is driven based on the initial parameter set, the displacement of the slide table in the horizontal and vertical directions is accurately controlled through the servo motor, the welding torch is moved to the weld starting positioning point of the to-be-welded cone pipe, and a welding torch initial positioning completion signal is generated; The welding torch initial positioning completion signal is received, the servo motor is started to drive the welding torch to start initial movement along the weld trajectory; the real-time diameter data of the cone pipe collected and calculated by the diameter detection module through the welding torch Z-axis position detection unit and the rate regulation instruction dynamically updated by the controller according to the diameter change are real-time received; the deviation value of the current welding torch actual movement speed and the instruction required speed is compared, and the servo motor speed adjustment signal is generated based on the deviation value; the servo motor is driven to fine-tune the speed according to the adjustment signal, so that the welding torch movement speed is always adapted to the real-time diameter of the cone pipe, and a welding torch dynamic speed adaptation signal is generated; The welding torch dynamic speed adaptation signal is received, the swing mechanism is started to operate according to the initial swing parameter; the weld uniformity data is real-time collected by the weld state detection assembly, and the data is transmitted to the fuzzy inference module of the controller; the swing parameter adjustment instruction issued by the fuzzy inference module based on the weld uniformity data is received; the swing trajectory of the drive component of the swing mechanism is optimized according to the adjustment instruction, and a swing parameter dynamic optimization signal is generated; The swing parameter dynamic optimization signal is received, the wire feeding mechanism is started to feed the welding wire at the initial wire feeding speed; the wire feeding speed update instruction generated by the controller based on the welding speed-diameter-wire feeding speed mapping database is real-time received; the current actual wire feeding speed is collected through the speed encoder of the wire feeding mechanism, and the difference value between the actual speed and the instruction speed is compared; the servo motor of the wire feeding mechanism is driven to adjust the speed of the wire feeding wheel according to the difference value, so that the welding wire filling amount accurately matches the demand of the molten pool, and a wire feeding speed dynamic matching signal is generated; The wire feeding speed dynamic matching signal is received, the welding process whole-process monitoring state is entered, the key data is real-time fed back to the controller, and the parameter closed-loop monitoring is formed; when the diameter detection module detects that the welding torch moves to the cone pipe weld end coordinate, the welding end instruction issued by the controller is received, the servo motor is driven to gradually reduce the welding torch movement speed, and the wire feeding mechanism is simultaneously reduced to reduce the wire feeding amount, and the weld is smoothly ended; after the welding operation is completed, the cross slide is driven to drive the welding torch to reset to the initial standby position of the equipment, the swing mechanism and the wire feeding mechanism are closed, a welding execution completion signal is generated, and the welding operation of a single cone pipe weld is completed.

[0025] The working principle of the above technical solution is that the welding core instructions (rate regulation initial instruction, wire feeding speed reference instruction, swing mechanism parameter initial value) issued by the receiving controller and the welding cone pipe adaptive preset parameters (such as welding torch initial positioning coordinates, welding seam trajectory reference data) called from the data storage module are received; the received instructions and parameters are checked for validity (such as whether the welding speed is within the rated range of the device 5-25 mm / s, whether the matching coefficient of the wire feeding speed and the welding speed meets the preset threshold), invalid or conflicting parameters are removed, and an initial parameter set that passes the check is generated; based on the initial parameter set, the cross slide is driven, the displacement of the slide in the horizontal (X-axis) and vertical (Y-axis) directions is accurately controlled by the servo motor, the welding torch is moved to the welding seam starting positioning point of the welding cone pipe, and a welding torch initial positioning completion signal is generated.

[0026] The welding torch initial positioning completion signal is received, the servo motor is started to drive the welding torch to start initial movement along the welding seam trajectory; the real-time diameter data of the cone pipe collected and calculated by the welding torch Z-axis position detection unit through the diameter detection module, and the rate regulation instruction dynamically updated by the controller according to the diameter change are received in real time; the deviation value (such as the current speed 13 mm / s, the instruction speed 15 mm / s, the deviation -2 mm / s) of the current welding torch actual moving speed and the instruction required speed is compared, the servo motor speed adjustment signal is generated based on the deviation value; the servo motor is driven to fine-tune the speed according to the adjustment signal, so that the welding torch moving speed always adapts to the real-time diameter of the cone pipe, and a welding torch dynamic speed adaptation signal is generated.

[0027] The welding torch dynamic speed adaptation signal is received, and the swing mechanism starts to operate according to the initial swing parameters (such as frequency 3 Hz, amplitude 3 mm); the welding seam uniformity data (such as molten pool width, weld edge flatness, molten pool temperature distribution) are collected in real time by the welding seam state detection assembly (such as a visual sensor or a molten pool temperature sensor), and the data are transmitted to the fuzzy inference module of the controller; the swing parameter adjustment instruction (such as amplitude increase 0.2 mm, frequency decrease 0.5 Hz) issued by the fuzzy inference module based on the welding seam uniformity data is received; the driving components of the swing mechanism are driven according to the adjustment instruction to optimize the swing trajectory, so that the welding torch swing state matches the current welding speed and the diameter of the cone pipe, and a swing parameter dynamic optimization signal is generated.

[0028] Receive the swing parameter dynamic optimization signal, start the wire feeding mechanism to start conveying the welding wire at the initial wire feeding speed (such as 6 m / min); receive the wire feeding speed update instruction generated by the controller based on the welding speed-diameter-wire feeding speed mapping database in real time (such as when the welding speed is 15 mm / s and the diameter is 85 mm, the wire feeding speed is adjusted to 6.2 m / min); collect the current actual wire feeding speed through the rotating speed encoder of the wire feeding mechanism, and compare the difference between the actual speed and the instruction speed; drive the servo motor of the wire feeding mechanism to adjust the rotating speed of the wire feeding wheel according to the difference, so that the welding wire filling amount accurately matches the demand of the molten pool (avoiding incomplete filling to cause incomplete fusion or excessive filling to cause welding porosity), and a wire feeding speed dynamic matching signal is generated.

[0029] Receive the wire feeding speed dynamic matching signal, enter the whole-process monitoring state of the welding process, and feed back the key data such as the welding gun position, swing parameter, wire feeding speed and molten pool state to the controller in real time to form a parameter closed-loop monitoring; when the diameter detection module detects that the welding gun moves to the end coordinate of the conical pipe weld, receive the welding end instruction issued by the controller, drive the servo motor to gradually reduce the welding gun moving speed (such as from 15 mm / s to 8 mm / s), and the wire feeding mechanism synchronously reduces the wire feeding amount (such as from 6.2 m / min to 4 m / min), to complete the gentle ending of the weld; after the welding operation is completed, drive the cross slide to reset the welding gun to the initial standby position of the equipment, and at the same time, the swing mechanism and the wire feeding mechanism are closed, and a welding execution completion signal is generated, to complete the welding operation of a single conical pipe weld.

[0030] The effect of the above technical solution is that through the accurate control of the servo motor and the cross slide, the accurate positioning and welding path of the welding gun can be ensured, so that the welding deviation is avoided; the welding gun moving speed is adjusted in real time to adapt to the diameter change of the conical pipe, so that the welding defects are effectively reduced; the weld uniformity data is processed by the fuzzy inference module, the swing trajectory is optimized in real time, and the consistency of the welding quality is ensured; the rotating speed and the wire feeding amount of the wire feeding mechanism are dynamically adjusted according to the real-time welding speed and the diameter change, so that too much or too little wire feeding is avoided, and the stability of the molten pool is ensured; through the real-time feedback and control of the key data, it is ensured that all parameters in the welding process are always kept in the best range, so that the success rate and the quality of the welding are improved; through the gradual reduction of the welding gun speed and the reduction of the wire feeding amount, the weld is smoothly ended, and the welding defects are avoided.

[0031] In an embodiment of the present application, the regulation of the welding speed by the self-adaptive control algorithm includes two modes: Segmented variable speed: preset the number of segments and the corresponding length of each segment, and the controller switches to the welding speed of the corresponding segment by comparing the welding gun coordinates and the segment length boundary in real time; Real-time variable speed: preset the welding time, and the controller continuously and dynamically adjusts the welding speed according to the welded time and the welded length, to ensure that the welding process matches the preset time.

[0032] The working principle of the above technical solution is: 1. Subsection variable speed mode working principle: First, the user will preset the subsection parameters through the man-machine interface according to the taper, length and other specifications of the conical pipe to be welded, including the number of sections to be divided (such as 3 sections), the corresponding axial length of each section (such as 50 mm per section), and the matching welding speed of each section (such as 12 mm / s for the first section, 15 mm / s for the second section, and 13 mm / s for the third section). These parameters will be stored in the data storage module simultaneously.

[0033] After the welding starts, the welding gun Z-axis position detection unit will collect the Z-axis coordinates of the welding gun in real time (such as starting from 0 mm and gradually changing), and transmit the coordinate data to the controller in real time. The controller will continuously compare the current welding gun Z-axis coordinates with the pre-set section length boundaries (such as 50 mm, 100 mm) in the data storage module to determine which section the welding gun is currently in: for example, when the Z-axis coordinates are between 0-50 mm, it is determined to be the first section, and the corresponding 12 mm / s welding speed is retrieved from the data storage module; when the Z-axis coordinates exceed 50 mm and enter the range of 50-100 mm, it is determined to be the second section, and the welding speed is automatically switched to 15 mm / s.

[0034] After determining the corresponding speed, the controller will generate a speed control instruction and send it to the servo motor of the welding execution module. The servo motor adjusts the speed according to the instruction, and finally drives the welding gun to move along the weld at the pre-set speed of the current section, realizing accurate switching of subsection speed.

[0035] 2. Real-time variable speed mode working principle: First, the user also presets two key parameters through the man-machine interface: one is the total welding length of the conical pipe to be welded (which can be determined according to the axial size of the conical pipe), and the other is the desired total time to complete the welding (such as 80 s). These two parameters will also be stored in the data storage module.

[0036] During the welding process, the controller will synchronously track two real-time data: on the one hand, the timer records the consumed welding time (such as when the welding is 30 s, the consumed welding time is 30 s); on the other hand, the Z-axis coordinates collected by the welding gun Z-axis position detection unit are converted into the current welded length (such as when the Z-axis moves 375 mm, it corresponds to a welded length of 375 mm).

[0037] After that, the controller will calculate the current required welding speed in real time based on the logic of total length - welded length = remaining length total time - welded time = remaining time, for example, total length 1000mm, welded 375mm, remaining length 625mm; total time 80s, welded 30s, remaining time 50s, the current required welding speed is 625mm ÷ 50s = 12, 5mm / s.

[0038] After calculating the real-time speed, the controller will immediately generate new speed regulation instructions to the servo motor, and the servo motor will adjust the speed in real time to make the welding gun move at the calculated speed. Subsequently, as the welded time and welded length change, the controller will repeatedly calculate the remaining amount → calculate the real-time speed → send adjustment instructions to ensure that the entire welding work can be completed within the preset total time.

[0039] The effect of the above technical solution is that the PID control module adjusts the welding speed in real time to ensure that the welding process is consistent with the target parameters, avoiding unevenness caused by speed changes; the fuzzy reasoning module adjusts the swing mechanism parameters based on the weld uniformity feedback, making the weld more uniform and reducing stress concentration and material deformation; by automatically adapting to welding conditions, the scheme can flexibly adjust according to the specific needs of the welding task (such as different materials, thicknesses, welding positions, etc.), improving the intelligence and automation level of the system; the high degree of automation of the scheme can reduce the dependence on manual operation, improve the consistency of welding quality, and also improve production efficiency; the flexibility of the system enables it to handle complex welding tasks, especially in mass production, significantly reducing time waste and improving overall work efficiency.

[0040] In one embodiment of the present application, the adaptive control algorithm includes a PID control module and a fuzzy reasoning module, the PID control module is used to adjust the welding speed in real time, and the fuzzy reasoning module is used to adjust the swing mechanism parameters based on the weld uniformity feedback.

[0041] The working principle of the above technical solution is: 1. PID control module: real-time adjustment of welding speed to match the change of cone pipe diameter: The PID control module first receives two types of core data: one is the real-time cone pipe diameter calculated by the diameter detection module through the Z-axis position of the welding gun, and the other is the preset cone pipe diameter-welding speed mapping target value in the data storage module (such as a diameter of 90mm corresponding to a target welding speed of 15mm / s). The module will compare the actual speed requirement corresponding to the real-time diameter with the preset target speed to calculate the deviation value (i.e. speed adjustment requirement).

[0042] Based on the above deviation value, the module calculates the adjustment amount through the proportional (P), integral (I), and derivative (D) three links: Proportional link: directly output the adjustment signal according to the size of the deviation, fast response to diameter change (for example, the larger the deviation, the greater the instantaneous adjustment amplitude, to avoid speed lag); Integral link: cumulative historical deviation, gradually eliminate static deviation (for example, if there is still a small speed deviation after the diameter is stable, the integral link will continue to fine-tune to ensure that the speed accurately matches the target value); Derivative link: according to the trend of deviation change to predict the adjustment direction in advance (for example, if the diameter is detected to decrease rapidly, the welding speed is reduced in advance to avoid the problem of lagging behind the diameter change).

[0043] The PID control module converts the calculated speed adjustment amount into specific speed control instructions and sends them to the servo motor of the welding execution module. The servo motor adjusts the speed in real time according to the instructions, and finally drives the welding torch to move at a speed that adapts to the current cone pipe diameter, achieving dynamic and accurate control of the welding speed.

[0044] 2. Fuzzy reasoning module: optimize the swing mechanism parameters based on the feedback of weld uniformity: The fuzzy reasoning module first receives real-time feedback data related to weld uniformity (such as weld width, molten pool shape stability, and weld flatness information collected by visual detection or molten pool state sensors), and converts these accurate data into fuzzy language variables (such as converting a weld width of 12mm into a weld width deviation, and converting an irregular molten pool edge into poor molten pool stability), and matches the pre-set fuzzy set in the module (such as narrow, moderate, wide stable, relatively stable, and unstable).

[0045] The module calls the pre-set fuzzy rule base (which is established based on a large number of welding process experience, such as if the weld is too wide and the molten pool is unstable → reduce the welding torch swing amplitude, reduce the swing frequency if the weld is too narrow and the molten pool is too deep → increase the swing amplitude, keep the frequency unchanged), according to the current fuzzy weld state, match the corresponding rule item, and infer the adjustment direction and approximate range of the swing parameters (such as reducing the swing amplitude by 2mm and reducing the frequency by 1Hz).

[0046] The fuzzy adjustment amount inferred will be further converted into accurate control instructions (such as converting a 2mm amplitude reduction into specific displacement parameters of the swing mechanism), and sent to the swing mechanism of the welding execution module. The swing mechanism adjusts its swing frequency and amplitude according to the instructions to ensure that the welding torch swing trajectory adapts to the current weld requirements, and finally achieves the effect of uniform weld heating and reasonable filler material distribution.

[0047] 3. Two modules cooperate: form a closed-loop control to ensure welding quality: In actual welding process, the PID control module and the fuzzy reasoning module do not work independently: after the PID module adjusts the welding speed, the weld uniformity may change (for example, increasing the speed may cause the weld to narrow), and the fuzzy reasoning module will capture this change in real time and compensate for the impact of speed changes on the weld by adjusting the swing parameters; conversely, if the weld is still uneven after adjusting the swing parameters, it will also indirectly feedback to the PID module to assist in determining whether the welding speed needs to be fine-tuned. The two form a closed-loop control, which ensures the dual adaptation of welding speed and swing parameters, and maximizes the quality of weld uniformity.

[0048] The effect of the above technical solution is that the PID control module can adjust the welding speed according to real-time feedback to ensure stability and consistency throughout the process, preventing welding defects caused by uneven welding speed; the fuzzy reasoning module adjusts the parameters of the swing mechanism during the welding process based on the feedback of the weld uniformity, which helps to reduce the unevenness in the weld and further improve the welding quality; the dual action of PID control and fuzzy reasoning can precisely control the welding path, speed and wire feed rate, effectively improving the weld quality and avoiding defects caused by improper operation or speed fluctuations; the intelligence of this system allows it to adaptively adjust to different welding conditions (such as material type, thickness, position, etc.), reducing human intervention and improving production efficiency; this solution is not only suitable for conventional welding tasks, but also flexible in dealing with complex welding scenarios, such as complex workpieces that require different welding speeds. It can reduce time waste and improve efficiency in mass production; through the cooperation of high automation and intelligent algorithms, the influence of human factors on welding quality is reduced, thereby improving the stability of the production line and the consistency of the welding quality.

[0049] In one embodiment of the present application, the welding execution module further comprises a cross slide, which is connected with the servo motor and can realize high-precision displacement adjustment of the welding torch in the horizontal and vertical directions, with a displacement accuracy of not less than 0.01 mm.

[0050] The working principle of the above technical solution is that the work of the cross slide in the welding execution module is based on the linkage logic of controller instruction→servo motor drive→slide precise displacement, which realizes high-precision position adjustment of the welding torch in the horizontal and vertical directions. The specific process is as follows: The controller will receive two types of key data in real time: one is the diameter change and weld position deviation information fed back by the diameter detection module (welding torch Z-axis position detection unit), and the other is the weld uniformity feedback during the welding process (such as horizontal / vertical offset of the welding torch from the weld). Based on these data, the controller will calculate the horizontal (such as left-right alignment with the weld) and vertical (such as height adjustment to adapt to the change in the diameter of the taper pipe) displacement amount of the welding torch, generate precise displacement adjustment instructions, and send them to the servo motor directly connected with the cross slide.

[0051] The servo motor itself has high-precision control capability. After receiving the displacement instruction, it will accurately adjust its rotation speed and rotation angle according to the instruction requirements (for example, if it needs to move horizontally by 0.05 mm, the motor will drive the transmission structure to rotate by the corresponding angle). At the same time, the encoder of the servo motor will collect the actual rotation data of the motor in real time and feed it back to the controller to form a command-feedback closed loop. Once it finds that the actual rotation deviates from the instruction (for example, due to mechanical resistance, the rotation is insufficient), it will immediately correct the rotation speed to ensure driving accuracy.

[0052] The cross slide table is composed of horizontal (usually X-axis) and vertical (usually Y-axis) slide components. The two components are connected to the servo motor through high-precision ball screws. When the motor rotates, it will drive the ball screw to rotate synchronously, converting the rotary motion of the motor into linear motion of the slide table. For example, when the welding gun position needs to be adjusted horizontally, the servo motor drives the ball screw of the X-axis slide table to rotate, driving the welding gun to move horizontally. When the welding gun height needs to be adjusted to adapt to the change of the cone pipe diameter, the motor drives the Y-axis slide table to operate, realizing the displacement in the vertical direction.

[0053] On the one hand, the guide rail of the cross slide table adopts high-precision design (such as linear guide rail), which can reduce the friction resistance and deviation of the slide table during movement, avoiding displacement deviation caused by insufficient guide rail precision. On the other hand, combined with the real-time feedback correction of the servo motor and the low pitch error of the ball screw (ensuring that the slide table moves a consistent distance for every rotation), the displacement precision is not less than 0.01 mm. Whether it is the initial positioning of the welding gun before welding (aligning the starting point of the weld) or the correction of the welding gun deviation caused by the deformation of the cone pipe and the displacement of the position during the welding process, the high-precision displacement of the cross slide table can ensure that the welding gun is always accurately aligned with the weld, avoiding the problems of welding deviation and missed welding.

[0054] The effect of the above technical solution is that the combination of the cross slide and the servo motor can realize precise displacement adjustment of the welding gun in the horizontal and vertical directions. The displacement accuracy is as high as 0.01 mm, which is crucial for fine welding tasks, especially on complex workpieces that require precise control of the welding path; through high-precision displacement control, the accuracy of the welding path can be ensured, avoiding deviations or errors during welding, significantly improving the uniformity and quality of the welding joint; the servo motor has high responsiveness and stability, and can maintain consistent performance during long-term operation, reducing the impact of unstable equipment or insufficient precision; the system can flexibly cope with various complex welding tasks, especially in high-precision welding applications such as aviation, automobile manufacturing, or high-precision machining fields; by automatically controlling the displacement of the welding gun, the intervention of manual operation is reduced, and welding defects caused by improper operation or judgment errors are reduced, thereby improving the consistency and reliability of the overall welding quality; high-precision welding gun displacement control not only ensures welding quality but also effectively improves production efficiency, especially in batch production, reducing time waste and production stagnation.

[0055] One embodiment of the present application also includes an automatic seam finding unit, which automatically calculates the required rotation angle of the workpiece by detecting the lap distance of the tapered pipe welding, controls the rotation mechanism to rotate the tapered pipe to the target angle, and realizes automatic positioning and calibration of the weld.

[0056] The working principle of the above technical solution is that the working core of the automatic seam finding unit is a coherent process of lap distance detection, rotation angle calculation, and tapered pipe rotation positioning, which realizes automatic alignment of the weld, and the specific steps are as follows in combination with the system module linkage: After the tapered pipe enters the welding station and is fixed to the rotation mechanism, the lap distance sensor pre-installed beside the tapered pipe rotation mechanism will be aligned with the tapered pipe welding lap, and real-time linear distance data (denoted as L) of the lap will be collected. The sensor converts the detected distance signal into an electrical signal and synchronously transmits it to the system controller to provide basic data for subsequent angle calculation.

[0057] After the controller receives the overlap distance L, it will call two key data for calculation: one is the current cone pipe radius r from the diameter detection module (the radius r is obtained by the Z-axis coordinate collected by the Z-axis position detection unit of the welding gun, and is calculated by the built-in diameter mapping algorithm (such as d = 2 * (R - k * z) in the controller, d is the current cone pipe diameter, and r = d / 2); the second is the preset angle conversion logic. The controller calculates the target angle a (such as 12°) that the cone pipe needs to rotate according to the built-in algorithm formula (a = (L / (pi * r))*(180 / pi), angle system), by substituting the overlap distance L and the current radius r, so that the welding seam can be aligned with the welding gun.

[0058] The controller converts the calculated target angle a into a driving instruction of the rotating mechanism, and sends it to the rotating mechanism (such as a servo-driven rotating table) connected with the cone pipe. After receiving the instruction, the rotating mechanism drives the cone pipe to rotate accurately by a angle; during the rotation, the angle encoder of the rotating mechanism will feedback the actual rotation angle in real time, and compare it with the target angle a in the controller. If there is a small deviation (such as insufficient rotation due to mechanical resistance), the controller will immediately correct the driving instruction to ensure that the cone pipe is finally rotated to the target angle. After the rotation stops, the welding seam is aligned with the initial welding position of the welding gun, and the automatic positioning and calibration are completed, which prepares for the arc striking of the welding gun of the subsequent welding execution module.

[0059] The effect of the above technical solution is that the automatic seam finding unit detects and calculates the rotation angle required by the welding workpiece by using the built-in algorithm, automatically adjusts the rotating mechanism, rotates the workpiece to the target position, and realizes the accurate positioning and automatic calibration of the welding seam, greatly improving the accuracy and quality of welding; by controlling the rotating mechanism to adjust the welding angle, the automatic seam finding unit reduces the error of manual operation, ensures that each welding seam meets the predetermined requirements during the welding process, and is especially suitable for high-precision welding tasks; the introduction of this technology greatly reduces the demand for manual operation, realizes higher automation level in the welding process, reduces errors caused by human factors, and improves the overall production efficiency; through the automatic seam finding technology, the positioning and calibration time of the workpiece before welding is greatly shortened, the stagnation caused by manual adjustment is reduced, and the efficiency of the production line is improved; the system can automatically detect and adjust the welding angle of different types of workpieces, especially on complex or irregular shaped workpieces, it can provide accurate welding solutions; the automatic control system not only improves the welding precision, but also enhances the consistency of each welded part, ensuring that each product meets the quality standards.

[0060] In an embodiment of the present application, the automatic seam finding method of the automatic seam finding unit comprises: Acquire the basic parameters of the to-be-welded conical pipe and the initial state data of the rotating mechanism; perform effectiveness screening on the acquired basic parameters and initial state data to generate a standard conical pipe basic parameter set and a rotating mechanism initial state set; use a lap distance sensor to collect the initial distance of the lap joint of the conical pipe to generate an initial lap distance data set; perform outlier rejection and mean optimization on the initial lap distance data set to generate accurate lap distance data; Call the current conical pipe radius r calculated by the diameter detection module in real time, combine the accurate lap distance data, and perform preliminary angle calculation through the angle conversion algorithm built in the controller to generate an initial target rotation angle value; perform rationality checking on the initial target rotation angle value to generate target rotation angle data that passes the checking; based on the target rotation angle data and the initial angle of the rotating mechanism, calculate the actual angle difference value that the rotating mechanism needs to rotate to generate a rotation angle difference value instruction; According to the rotation angle difference value instruction, drive the rotating mechanism to perform a pre-rotation operation, and simultaneously collect actual rotation angle data in real time through the angle encoder built in the rotating mechanism; compare the real-time collected actual rotation angle data with the target rotation angle data to calculate an angle deviation value; based on the angle deviation value, generate a rotating mechanism fine-tuning signal to control the rotating mechanism to gradually correct the rotation angle and generate a rotation angle accurate adaptation signal; After receiving the rotation angle accurate adaptation signal, start the weld seam position detection component to collect image data of the current conical pipe weld seam position to generate real-time weld seam position image data; compare the real-time weld seam position image data with a pre-set weld seam target position image template to analyze whether the weld seam is accurately aligned with the initial welding point of the welding gun to generate a weld seam position checking result; if the checking result is that there is a deviation, generate a secondary fine-tuning instruction of the rotating mechanism based on the deviation direction to drive the rotating mechanism to complete secondary correction and generate a weld seam accurate positioning signal; After receiving the weld seam accurate positioning signal, record the key data of this automatic seam finding and store it in the data storage module to generate a seam finding data archive record; send a weld seam positioning completion instruction to the controller to trigger the controller to update the initial welding position parameters of the welding gun synchronously; control the rotating mechanism to lock the current position to generate an automatic seam finding completion signal to provide the weld seam positioning basis for the welding execution module to start the welding operation.

[0061] The working principle of the above technical solution is: obtaining the basic parameters of the to-be-welded conical pipe (such as the maximum radius R of the conical pipe, the taper coefficient k of the conical pipe, and the designed overlap width standard value of the weld) and the initial state data of the rotating mechanism (such as the current angle of the rotating table and the detected value of the axis deviation of the conical pipe after being fixed); performing effectiveness screening on the obtained basic parameters and initial state data (such as eliminating the conical pipe radius data that exceeds the equipment adaptation range and correcting the angle acquisition error of the rotating table), generating a standard conical pipe basic parameter set and a rotating mechanism initial state set; using an overlap distance sensor (such as an infrared distance sensor) to collect the initial distance of the overlap of the conical pipe, generating an initial overlap distance data set; performing outlier elimination (such as filtering the jumping data caused by dust interference) and mean value optimization on the initial overlap distance data set, and generating accurate overlap distance data.

[0062] The current conical pipe radius r calculated by the diameter detection module in real time (r = d / 2, d = 2*(R-kz) is calculated by the formula of the Z-axis coordinate of the welding gun) is combined with the accurate overlap distance data, and the initial target rotation angle value is generated by performing preliminary angle calculation through the angle conversion algorithm (α = (L / (πr))*(180 / π), where α is the target rotation angle, and L is the accurate overlap distance) built in the controller. The initial target rotation angle value is reasonably checked (such as judging whether the angle exceeds the maximum range ±90° of single rotation of the rotating mechanism or whether the position deviation is within the allowable threshold of the designed weld), and the target rotation angle data that passes the check is generated. Based on the target rotation angle data and the initial angle of the rotating mechanism, the actual angle difference value that the rotating mechanism needs to rotate is calculated, and the rotation angle difference value instruction is generated.

[0063] According to the rotation angle difference value instruction, the rotating mechanism (such as a servo rotating table) is driven to perform a pre-rotation operation, and the actual rotation angle data is collected in real time through the angle encoder built in the rotating mechanism; the real-time collected actual rotation angle data is compared with the target rotation angle data, and the angle deviation value (such as a target angle of 12°, an actual rotation of 11.5°, and a deviation of 0.5°) is calculated; based on the angle deviation value, the rotating mechanism fine tuning signal is generated, and the rotating mechanism is controlled to gradually correct the rotation angle (such as fine tuning 0.1° each time until the deviation is ≤0.05°), and the rotation angle accurate adaptation signal is generated.

[0064] After receiving the rotation angle precision adaptation signal, the weld seam position detection component (such as a visual sensor) is started to collect images of the current conical pipe weld seam position, and real-time weld seam position image data is generated. The real-time weld seam position image data is compared with the preset weld seam target position image template to analyze whether the weld seam is accurately aligned with the initial welding point of the welding gun, and a weld seam position verification result (such as alignment qualified or 0.2mm horizontal deviation) is generated. If the verification result is a deviation, a secondary fine adjustment instruction of the rotation mechanism is generated based on the deviation direction (horizontal / vertical) (such as an additional rotation of 0.3° of the rotation mechanism when the horizontal deviation is 0.2mm), and the rotation mechanism is driven to complete secondary correction, and a weld seam precision positioning signal is generated.

[0065] After receiving the weld seam precision positioning signal, the key data of this automatic seam finding (such as the overlap distance, target rotation angle, and actual rotation deviation value) is recorded and stored in the data storage module to generate a seam finding data archive record. A weld seam positioning completion instruction is sent to the controller to trigger the controller to update the initial welding position parameters of the welding gun synchronously. The current position of the rotation mechanism is locked to avoid the conical pipe from deviating in the subsequent welding process, and an automatic seam finding completion signal is generated to provide a weld seam positioning basis for the welding execution module to start welding work The effect of the above technical solution is that through the control of the automatic seam finding unit, the system can automatically calculate and adjust the rotation angle of the workpiece to ensure accurate butt joint of the weld seam, avoid human operation errors, and improve welding precision. The degree of automation is high, and manual intervention is reduced. In particular, in the welding of complex workpieces, work efficiency can be significantly improved, and production cycle can be shortened. The system collects the basic parameters of the conical pipe, the overlap distance, and the actual rotation angle data, uses built-in algorithms for optimization to ensure the precision and consistency of each welding point, and improves the welding quality. The system has the functions of real-time collection of angle data, deviation correction, and fine adjustment to ensure accurate alignment of the weld seam during the welding process and reduce deviation. The automatic seam finding method of the system can effectively adapt to welding workpieces of various shapes and sizes, especially irregular shapes and high-quality workpieces, providing high flexibility and precise control. All key data in the welding process is recorded and stored for subsequent traceability and quality control. This way improves the controllability and quality monitoring capability of production.

[0066] In an embodiment of the present application, the data storage module also stores a mapping relationship database of the diameter of the conical pipe and the welding parameters, and the controller generates initial welding parameters based on the mapping relationship database and the real-time detected diameter data and performs dynamic correction.

[0067] The working principle of the above technical solution is as follows: before the system is put into use, the technical personnel will collect the matching data of the cone pipe diameter-welding parameter through a large number of welding process tests (for different materials and specifications of the cone pipe), such as the diameter of 80 mm corresponding to the welding speed of 12 mm / s, the wire feeding speed of 5.8 m / min, and the welding gun swing amplitude of 3 mm, the diameter of 90 mm corresponding to the welding speed of 15 mm / s, the wire feeding speed of 6 m / min, and the swing amplitude of 3.5 mm, etc. These verified diameter-parameter corresponding relationships are arranged into a structured mapping relationship database and stored in the data storage module, which becomes the benchmark template for subsequent parameter generation. When the to-be-welded cone pipe enters the work station, the diameter detection module will first collect the initial Z-axis coordinate through the welding gun Z-axis position detection unit, and the controller will calculate the initial diameter of the cone pipe (such as d=85 mm) according to the built-in algorithm (such as d=2*(R-k*z)). Subsequently, the controller will send a data calling request to the data storage module, retrieve the welding parameters most matched with the diameter of 85 mm from the mapping relationship database (if there is no exactly the same diameter in the database, the interpolation algorithm of the adjacent diameter parameters will be automatically used for calculation, such as taking the intermediate value of the parameters corresponding to the diameters of 80 mm and 90 mm), quickly generate the initial parameters of this welding (such as the welding speed of 13.5 mm / s, the wire feeding speed of 5.9 m / min), and synchronously transmit to the welding execution module for standby. After the welding starts, the diameter detection module will continuously collect the Z-axis coordinate of the welding gun, and the controller will calculate the change of the diameter of the cone pipe in real time (such as the diameter gradually decreasing from 85 mm to 80 mm). The controller will compare the real-time diameter data with the benchmark diameter corresponding to the welding parameters being used, and if the diameter deviation exceeds the preset threshold (such as ±2 mm), the mapping relationship database of the data storage module will be called again to obtain the target parameters corresponding to the real-time diameter. At the same time, the controller will also adjust the target parameters in combination with the feedback data in the welding process (such as the weld uniformity and the molten pool state) (such as if the weld is too narrow, the swing amplitude can be increased by 0.2 mm based on the mapping parameters), form the final parameters after correction, and send them to the welding execution module to adjust the welding speed, the wire feeding speed, or the swing mechanism parameters. In addition, the real-time diameter-final parameter-welding quality data after each correction will be synchronously stored back to the data storage module, continuously optimizing the accuracy of the mapping relationship database, and providing more accurate parameter reference for subsequent welding of the same type of cone pipe.

[0068] The effect of the above technical solution is that: through the mapping relationship database, the controller can automatically adjust the welding parameters according to the actual diameter data of the cone pipe. This dynamic correction capability ensures that each workpiece can obtain the optimal welding parameters, improving the welding quality; the mapping relationship database ensures that even in the batch production process, the parameters of each welding workpiece can always remain consistent according to the accurate matching of diameter and welding parameters, reducing the quality fluctuations caused by parameter mismatch; this technology can adjust the welding parameters in real time according to the diameters of different cone pipes, has high adaptability, and can effectively cope with welding workpieces of different specifications and shapes, especially suitable for large-scale and multi-type production tasks on the production line; the automatic generation and correction of welding parameters greatly reduces the complexity of manual operation, improving the intelligent level of the welding process. The operator only needs to monitor simply, and the system can automatically adjust the parameters, reducing the possibility of human error; since the welding parameters can be dynamically adjusted according to real-time data, the production line can flexibly cope with the needs of different workpieces, improving the flexibility and efficiency of production, and reducing the time for setting and adjusting.

[0069] Through accurate welding parameter matching, waste caused by inaccurate welding parameters (such as excessive welding, material loss, etc.) is avoided, thereby optimizing the use of resources and reducing production costs; by storing and associating diameter data and welding parameters, all key data in the welding process can be accurately recorded, providing complete production records and providing a basis for later quality monitoring and problem tracing.

[0070] One embodiment of the present application also includes a human-computer interaction interface connected with the controller for displaying real-time welding parameters, weld quality evaluation results and receiving user input process parameters.

[0071] The working principle of the above technical solution is that: the core of the human-computer interaction interface is a bidirectional data interaction bridge between the operator and the system controller, which realizes a closed loop of real-time information display-user instruction input-data collaborative processing through real-time connection with the controller. The specific process can be divided into three parts: 1. Data interaction basis: real-time connection with the controller: The human-computer interaction interface (such as touch screen, display with keyboard) establishes a stable communication connection with the controller through a special data line to ensure the timeliness and accuracy of data transmission between the two - the controller can synchronously send the welding-related data collected and processed in real time to the interface, and the interface can quickly feedback the user's input instructions to the controller, forming a bidirectional data channel.

[0072] 2. Real-time information display: let the operator intuitively master the welding state: Data acquisition and transmission: during the welding process, the controller will collect two types of core data in real time: Real-time welding parameters: including welding speed, wire feed speed, welding torch oscillation frequency / amplitude obtained from welding execution module, current cone pipe diameter obtained from diameter detection module, etc. Weld quality evaluation results: quality score, defect prompt, etc. generated by the controller based on visual detection data (such as weld width, molten pool state) or algorithm analysis (such as whether there is undercut, porosity).

[0073] The controller will transmit these data in real time to the human-computer interaction interface in a preset format (such as structured data frame).

[0074] Interface visualization: After receiving the data, the human-computer interaction interface will display it in a form that is easy for the operator to understand: Real-time welding parameters are presented in the form of numbers + dynamic charts (such as welding speed displayed as the current value 15 mm / s, with a line chart showing the speed change trend in the past 1 minute); Weld quality evaluation results are presented in the form of text prompts + status icons (such as weld uniformity is good with a green check icon, and there is a slight undercut with a yellow warning icon), so that the operator can quickly understand whether the welding is normal without analyzing the original data.

[0075] 3、User process parameter input: to realize personalized welding setting: Parameter input operation: Before or during welding (when you need to pause and adjust), the operator can input process parameters through the touch screen, physical buttons or virtual keyboard of the human-computer interaction interface according to the specifications of the pipe to be welded (such as diameter range, material) or process requirements, including: Preset process parameters: such as the number of segments in the segmented speed mode (3 segments), the length of each segment (50 mm), the corresponding speed (12 / 15 / 13 mm / s), the preset welding time in the real-time speed mode (80 s), and the initial value of the wire feed speed (6 m / min), etc. Workpiece basic information: such as the maximum diameter of the cone pipe and the taper coefficient (used for the controller to call the mapping relationship database of the data storage module).

[0076] Input verification and instruction transmission: The human-computer interaction interface will perform basic legality verification on the user input parameters (such as whether the welding speed exceeds the allowed range of 5-25 mm / s, and whether the number of segments is within the range of 2-5 segments), and if the parameters are abnormal, the interface will pop up a prompt (such as welding speed exceeds the upper limit, please re-enter); if the parameters are legal, the interface will convert the input process parameters into a format that the controller can recognize and transmit to the controller.

[0077] Controller response processing: after receiving the instruction, the controller will combine the preset database of the data storage module (such as the cone pipe diameter-welding parameter mapping relationship) to generate the initial welding parameters or adjust the parameters of the adaptive control algorithm (such as modifying the segment length boundary of the segmented variable speed), and synchronously feedback the adjusted parameters to the human-computer interaction interface to let the operator confirm that the parameters have taken effect.

[0078] The effect of the above technical solution is that through the human-computer interaction interface, the operator can real-time view the welding parameters and input adjustment parameters as needed. This improves the user's control ability over the welding process and also ensures the accuracy of the process parameters; the system not only automatically performs the welding task, but also real-time evaluates the weld quality and provides feedback to the operator. This instant evaluation function helps to discover and correct any problems in the welding process in a timely manner, thereby improving the quality of the final welded part; the introduction of the human-computer interaction interface makes the interaction between the operator and the system more intuitive and convenient, thereby reducing the complexity of the operation. The user can directly view the welding status, parameters and quality evaluation results on the interface, further improving the work efficiency; the user can adjust the process parameters through the interface according to actual production needs, and the system will dynamically generate and adjust the welding process according to these parameters. This flexibility not only adapts to the needs of different workpieces, but also optimizes the use of resources in the production process, reducing costs; through real-time monitoring and feedback of welding data, the system can not only automatically adjust the welding parameters, but also adjust the production process according to the feedback, which greatly reduces human intervention and improves the accuracy of quality control; the system can flexibly cope with welding tasks of different sizes and shapes, and records all production data, enhancing the traceability of post-production quality and providing solid data support for quality control and optimization.

[0079] In one embodiment of the present application, the wire feeding speed of the wire feeding mechanism is linked with the welding speed and the cone pipe diameter, and the controller adjusts the wire feeding speed in real time through the preset welding speed-diameter-wire feeding speed mapping database to avoid insufficient or excessive filling of the molten pool.

[0080] The working principle of the above technical solution is that the core of this technical solution is the preset mapping database as the reference, real-time parameter collection as the basis, and controller dynamic matching as the core. Through the linkage logic of the wire feeding mechanism with the welding speed and the cone pipe diameter, the precise control of the molten pool filling amount is realized. The specific process can be divided into four steps according to the modified manuscript file content: 1. Pre-set mapping database: build parameter matching foundation In the system debugging phase, technicians will collect the optimal matching data of welding speed-cone pipe diameter-wire feed speed through a large number of process tests (for different cone pipe materials and diameter specifications) - for example, when the welding speed is 12 mm / s and the cone pipe diameter is 90 mm, the corresponding wire feed speed is 6 m / min; when the welding speed is 15 mm / s and the cone pipe diameter is 85 mm, the corresponding wire feed speed is 6, 2 m / min, etc. These actually verified parameter combinations will be sorted into a structured welding speed-diameter-wire feed speed mapping database and stored in the data storage module, becoming a reference template for subsequent wire feed speed adjustment.

[0081] 2. Real-time parameter acquisition: Obtain linkage calculation basis During the welding process, the controller will synchronously collect two types of key real-time data to provide a basis for wire feed speed adjustment. Real-time welding speed: The output result from the adaptive control algorithm (such as the current speed determined by the controller according to the welding torch coordinate to determine the section number under the segmented variable speed mode; the real-time speed calculated according to the remaining time / length under the real-time variable speed mode), which directly reflects the pace of the welding torch moving along the weld. Real-time cone pipe diameter: The Z-axis coordinate is collected by the welding torch Z-axis position detection unit of the diameter detection module, and the diameter mapping algorithm (such as d = 2 * (R - k * z)) built-in the controller is used to calculate it, which reflects the wall thickness requirement of the current welding position.

[0082] These two types of data will be transmitted to the controller in real time to ensure the timeliness of parameter linkage.

[0083] 3. Controller dynamic matching: Calculate accurate wire feed speed After receiving the real-time welding speed and cone pipe diameter, the controller will immediately call the welding speed-diameter-wire feed speed mapping database in the data storage module to perform parameter matching and calculation. If the real-time welding speed and cone pipe diameter are completely consistent with a set of parameters in the database (such as speed 12 mm / s and diameter 90 mm), the corresponding wire feed speed (6 m / min) is directly retrieved. If there is no complete matching item in the database (such as speed 13 mm / s and diameter 88 mm), the controller will calculate the adaptive wire feed speed (such as 6, 1 m / min) through the interpolation algorithm (based on the change rule of adjacent parameters in the database) to avoid matching deviation caused by parameter discontinuity.

[0084] At the same time, the controller will also fine-tune the calculation result in combination with the weld quality feedback (such as appropriately increasing the wire feed speed by 0.1-0.2 m / min when the visual detection shows that the molten pool is too shallow), to ensure that the wire feed amount completely adapts to the actual requirement of the molten pool.

[0085] 4. Wire feeder execution: precise wire feeding and closed-loop correction The controller converts the calculated wire feeding speed command into an electrical signal and sends it to the wire feeding mechanism (such as a servo wire feeder) of the welding execution module: After receiving the command, the wire feeding mechanism adjusts the speed of the wire feeding wheel through the servo motor to accurately feed the welding wire into the molten pool at the calculated speed; The wire feeding mechanism's built-in speed encoder collects the actual speed of the wire feeding wheel in real time, converts it into the actual wire feeding speed, and feeds it back to the controller; The controller compares the actual wire feeding speed with the target wire feeding speed. If there is a deviation (such as the actual speed being lower than the target value due to welding wire resistance), the driving command is immediately corrected to adjust the wire feeding wheel speed, ensuring that the wire feeding speed always matches the target value, avoiding the problem of insufficient molten pool filling (slow wire feeding) or excessive molten pool filling (fast wire feeding).

[0086] The effect of the above technical solution is: by linking the wire feeding speed with the welding speed and the cone pipe diameter, the system can accurately control the wire feeding amount, avoiding the problem of insufficient molten pool filling (defects) or excessive molten pool filling (waste) caused by improper wire feeding. This automatic adjustment ensures the stability of the welding quality; since the wire feeding speed is dynamically adjusted according to the actual welding speed and the cone pipe diameter, the system can always maintain the optimal wire feeding amount, ensuring consistent quality of each weld. Especially in batch production, this precise control greatly reduces quality fluctuations; by mapping the database to adjust the wire feeding speed in real time, the system can accurately match the welding speed and wire feeding speed ratio according to the needs of the welding task, thereby improving welding efficiency and reducing production waste caused by improper parameter settings; the flexibility of this solution makes it suitable for welding requirements of different cone pipe diameters. By adjusting the wire feeding speed in real time, the system can optimize according to the requirements of different workpieces, adapt to various welding conditions and process changes, and improve the adaptability and flexibility of the production line. The system automatically adjusts the wire feeding speed through the pre-set mapping database, reducing the need for manual intervention. The operator does not need to manually set the wire feeding parameters for each workpiece, and the automatic adjustment process improves the automation level of the production line and reduces the risk of human error; real-time adjustment of wire feeding speed effectively avoids waste of resources during welding, especially waste of welding wire. In addition, by avoiding insufficient or excessive molten pool filling, welding defects such as porosity and cracks are effectively controlled, thereby improving the overall welding quality; dynamically adjusting the wire feeding speed ensures that every link in the welding process is in the best working state, improves the stability of the process, and allows the operator to monitor and adjust parameters in real time, further improving the controllability and predictability of the process.

[0087] It will be apparent to those skilled in the art that various modifications and variations can be made to the present application without departing from the spirit or scope of the application. Thus, it is intended that the present application cover modifications and variations of this application provided they come within the scope of the appended claims and their equivalents.

Claims

1. A tapered tube diameter self-adapting rate governing weld seam homogenization welding system, characterized by: The application relates to a welding device for a conical pipe, which comprises the following parts: a diameter detection module configured to detect the diameter change of the conical pipe in real time, the diameter detection module comprising a welding gun Z-axis position detection unit, which automatically calculates the diameter change information of the conical pipe in a controller algorithm by collecting welding gun Z-axis coordinate data in real time; a controller electrically connected with the diameter detection module, which generates a rate control instruction based on the diameter change information of the conical pipe, and which is internally provided with an adaptive control algorithm and can dynamically adjust the welding rate to match the diameter change of the conical pipe; a welding execution module electrically connected with the controller, which comprises a welding gun driven by a servo motor and a swing mechanism, the servo motor adjusts the moving speed of the welding gun according to the rate control instruction, and the swing mechanism adjusts the swing frequency and amplitude of the welding gun according to the welding seam uniformity requirement; the welding execution module further comprises a wire feeding mechanism; the controller is used for dynamically adjusting the wire feeding speed according to the welding speed and the diameter change of the conical pipe, so that the parameters of welding and wire feeding are matched; a data storage module electrically connected with the controller, which stores a preset welding parameter database and historical welding data and is used for providing data support for the adaptive control algorithm.

2. The cone pipe diameter self-adapting rate governing seam homogenization welding system of claim 1, wherein: The adaptive control algorithm comprises two modes for regulating the welding speed: segmented variable speed: a preset number of segments and a corresponding length of each segment are set, and the controller compares the welding gun coordinates with the segment length boundary in real time, so as to switch to the welding speed of the corresponding segment; real-time variable speed: a preset welding time length is set, and the controller dynamically adjusts the welding speed according to the welded time length and the welded length, so as to ensure that the welding process matches the preset time length.

3. The cone pipe diameter self-adapting rate governing seam equalization welding system of claim 1, wherein: The adaptive control algorithm comprises a PID control module and a fuzzy reasoning module, the PID control module is used for adjusting the welding speed in real time, and the fuzzy reasoning module is used for adjusting the swing mechanism parameters according to the welding seam uniformity feedback.

4. The cone pipe diameter self-adapting rate governing seam equalization welding system of claim 1, wherein: The welding execution module further comprises a cross slide, which is connected with the servo motor and can realize high-precision displacement adjustment of the welding gun in the horizontal and vertical directions, and the displacement precision is not less than 0.01 mm.

5. The cone pipe diameter self-adapting rate governing seam equalization welding system of claim 1, wherein: The welding device further comprises an automatic seam finding unit, which detects the lap distance of the conical pipe welding, automatically calculates the required rotation angle of the workpiece by using the built-in algorithm of the controller, controls a rotating mechanism to drive the conical pipe to rotate to a target angle, and realizes automatic positioning and calibration of the welding seam.

6. The cone pipe diameter self-adapting rate governing seam equalization welding system of claim 1, wherein: The data storage module further stores a mapping relationship database of the diameter of the conical pipe and the welding parameters, the controller generates initial welding parameters based on the mapping relationship database and the diameter data detected in real time and dynamically corrects the initial welding parameters.

7. The cone pipe diameter self-adapting rate governing seam equalization welding system of claim 1, wherein: The welding device further comprises a man-machine interaction interface, which is connected with the controller and is used for displaying real-time welding parameters, welding seam quality evaluation results and receiving user input process parameters.

8. The cone pipe diameter self-adapting rate governing seam equalization welding system of claim 1, wherein: The wire feeding speed of the wire feeding mechanism is linked with the welding speed and the diameter of the conical pipe, the controller adjusts the wire feeding speed in real time by using a preset welding speed-diameter-wire feeding speed mapping database, so as to avoid insufficient or excessive filling of the molten pool.

Images