Method and apparatus for welding automotive parts

Abstract

The application relates to a kind of automobile accessory welding method and device, and to the field of automobile processing, it includes obtaining workbench image information, to obtain the contour of device to be welded;Determine the current welding device based on the contour of device to be welded;Determine the welding processing scheme based on the current welding device;Control the mechanical arm and workbench to execute welding processing operation;Real-time acquisition of mechanical arm position information and workbench position information;Determine the current processing position according to the mechanical arm position information and workbench position information;When the current processing position is inconsistent with the processing position in the welding processing scheme, determine the processing position offset;When there is processing position offset, execute push operation;When the current processing position is consistent with the processing position in the welding processing scheme or after executing the push operation, execute the welding processing operation.The application has the effect of reducing human error by real-time monitoring and adjusting the processing position, ensuring the stability of the welding quality.

Description

Technical Field

[0001] This invention relates to the field of automotive manufacturing, and in particular to a welding method and apparatus for automotive parts. Background Technology

[0002] Currently, automotive welding technology, as a key process in the manufacturing of automobile bodies and core components, has been deeply integrated into the entire process of vehicle research and development, production, and safety assurance, becoming an important technological pillar supporting the high-quality development of the automotive industry.

[0003] Furthermore, welding technology has enabled the optimization of automotive structures. By achieving integrated component design through welding, the number of parts can be reduced. For example, the door frame can be welded as a single unit, resulting in lighter weight, increased body rigidity, and reduced noise and vibration during driving compared to assembling multiple parts. This structural optimization capability is helping automobiles achieve breakthroughs in energy conservation, handling performance, and ride comfort.

[0004] Regarding the aforementioned technologies, existing technologies for welding automotive parts cannot correct the machining position during the welding process. Deviations in the welding position are only discovered through manual inspection after the welding work is completed. This makes it impossible to prevent and correct welding position deviations in a timely manner, resulting in unstable welding quality. Summary of the Invention

[0005] To address the problem of welding position deviation during the welding process, this invention provides a welding method and apparatus for automotive parts.

[0006] In a first aspect, the present invention provides a welding method for automotive parts, employing the following technical solution:

[0007] A welding method for automotive parts, comprising:

[0008] S1: Acquire workbench image information;

[0009] S2: The outline of the device to be welded is obtained by analyzing the image information of the workbench;

[0010] S3: Based on the comparison between the outline of the device to be welded and the preset welding device parameter library, the current welding device is determined;

[0011] S4: Determine a welding processing scheme based on the welding device parameter library and the current welding device. The welding processing scheme includes a robotic arm processing scheme and a workbench processing scheme.

[0012] S5: Control the robotic arm and worktable to perform welding operations according to the welding processing plan;

[0013] S6: During the welding process, the position information of the robotic arm and the position information of the worktable are acquired in real time.

[0014] S7: Determine the current processing position based on the robotic arm position information and the worktable position information;

[0015] S8: Determine the processing position offset when the current processing position is inconsistent with the processing position in the welding processing plan;

[0016] S9: When the processing position offset exists, control the pushing component to perform a pushing operation according to the processing position offset;

[0017] S10: The welding operation is performed when the current processing position is consistent with the processing position in the welding processing plan or after the push operation is completed.

[0018] By adopting the above technical solution, the system can automatically generate a welding processing plan that includes both a robotic arm processing plan and a worktable processing plan. During the execution of this plan, the system acquires the position information of the robotic arm and the worktable in real time, accurately determining whether the current processing position is consistent with the preset plan. Once a deviation in the processing position is detected, the system immediately calculates the offset and controls the push components to make corresponding adjustments, ensuring the accuracy of the welding position. This real-time monitoring and automatic adjustment mechanism effectively solves the problem of welding position deviation during the welding process, significantly improving welding quality and production efficiency.

[0019] Optionally, the method for controlling the pushing component to perform the pushing operation according to the processing position offset includes:

[0020] S90: Determine a pushing scheme based on the processing position offset, the pushing scheme including a pushing distance and a pushing direction;

[0021] S91: When the aforementioned pushing scheme exists, control the pushing component to perform the pushing operation according to the pushing scheme;

[0022] S92: During the execution of the pushing operation, the pushing speed and current pushing distance of the pushing component are acquired in real time;

[0023] S93: When the pushing speed of the pushing component is 0 and the current pushing distance is less than the pushing distance, a preset pushing abnormal signal is output.

[0024] By adopting the above technical solution, a clear pushing distance and direction can be determined based on the processing position offset during the pushing operation. During the pushing process, the speed and current pushing distance of the pushing component are monitored in real time. If the pushing component stops and fails to reach the predetermined pushing distance, a pushing anomaly signal is immediately output. This real-time monitoring and anomaly feedback mechanism ensures the accuracy and reliability of the pushing operation, effectively avoiding welding position deviations caused by incomplete pushing, and further improving welding quality and production efficiency.

[0025] Optional, also includes:

[0026] S94: In response to the push abnormal signal, acquire the current worktable position information in real time, the current worktable position information including worktable position information and welding device position information;

[0027] S95: Determine the corrected processing position offset based on the current worktable position information and the robotic arm position information;

[0028] S96: Determine the target position of the robotic arm by the corrected processing position offset;

[0029] S97: When the target position of the robotic arm exists, a robotic arm movement scheme is formed based on the target position of the robotic arm, the robotic arm movement scheme including the robotic arm adjustment angle and the robotic arm adjustment distance;

[0030] S98: Control the robotic arm to move to the target position of the robotic arm according to the robotic arm movement scheme;

[0031] S99: Continue the welding operation when the robotic arm moves to the target position of the robotic arm.

[0032] By adopting the above technical solution, upon receiving a push anomaly signal, the system immediately acquires the precise position information of the current worktable and welding components. Combined with the real-time position data of the robotic arm, the system can accurately calculate the correction amount for the processing position offset and determine the target position the robotic arm needs to move to. Subsequently, the system generates a robotic arm movement plan that includes adjustments to angle and distance, and controls the robotic arm to move accurately to the target position. This intelligent anomaly handling mechanism effectively solves the welding position deviation problem caused by push anomalies, further improving welding quality and production efficiency.

[0033] Optionally, the method for controlling the robotic arm to move to the target position according to the robotic arm movement scheme includes:

[0034] S980: Real-time acquisition of the current robotic arm position information;

[0035] S981: Determine the adjustable angle range of the robotic arm corresponding to the current position information based on the preset robotic arm parameter library;

[0036] S982: When the adjustment angle of the robotic arm does not fall within the adjustable angle range of the robotic arm, a worktable movement scheme is determined based on the current robotic arm position information and the current worktable position information;

[0037] S983: When the adjusted angle of the robotic arm falls within the adjustable angle range of the robotic arm, an overlapping area is determined based on the target position of the robotic arm and the current worktable position information;

[0038] S984: When the overlapping area exists, determine the worktable movement scheme based on the current robotic arm position information and the current worktable position information;

[0039] S985: Execute S98 if the overlapping region does not exist;

[0040] S986: When the workbench movement scheme exists, control the workbench to adjust according to the workbench movement scheme.

[0041] By adopting the above technical solution, during the process of controlling the robotic arm to move to the target position, the system acquires the current position information of the robotic arm in real time and determines its adjustable angle range based on a preset robotic arm parameter library. If the adjustment angle of the robotic arm is not within this range, the system generates a workbench movement plan to ensure that the robotic arm can smoothly reach the target position. Simultaneously, if there is an overlapping area, the workbench movement plan is also determined based on the current position information. If there is no overlapping area, the system returns to the step of executing the robotic arm movement. This ensures the accuracy and efficiency of the welding process. This refined control strategy not only improves welding quality but also significantly enhances production efficiency.

[0042] Optionally, the method for controlling the worktable to adjust according to the worktable movement scheme includes:

[0043] S9860: Determine the target position of the welding device based on the aforementioned worktable movement scheme;

[0044] S9861: During the process of adjusting the worktable according to the worktable movement scheme, the worktable movement speed and the worktable rotation speed are acquired in real time.

[0045] S9862: When the moving speed and rotation speed of the worktable are both 0 and the welding device has not moved to the target position of the welding device, the obstacle position is determined and a preset obstacle signal is output.

[0046] Optionally, it also includes a processing method for the presence of the obstacle signal, the method comprising:

[0047] S98620: Generate a modified pushing scheme based on the target position of the welding device, and control the pushing component to push the welding device according to the modified pushing scheme;

[0048] S98621: Obtain the moving speed of the welding device during the execution of the modified push scheme;

[0049] S98622: The contact point position is determined when the moving speed of the welding device is 0 and the welding device has not fallen into the target position of the welding device;

[0050] S98623: Based on the contact point position and the preset cleaning scheme, control the pushing component to push the current welding device;

[0051] S98624: Determine the location of the corrected contact point after executing the cleaning plan;

[0052] S98625: When the position of the corrected contact point coincides with the position of the contact point, a preset manual cleaning signal is output;

[0053] S98626: Execute S98623 to S98625 when the corrected contact point position is inconsistent with the contact point position.

[0054] By adopting the above technical solution, the moving speed of the welding device is acquired in real time during the execution of the corrective pushing scheme to ensure the accuracy and controllability of the pushing process. If the moving speed of the welding device drops to 0 and fails to reach the target position, the system will further determine the contact point position and, based on this position and the preset cleaning scheme, control the pushing component to perform a cleaning operation. After executing the cleaning scheme, the system will again determine the corrected contact point position. If the corrected position matches the original contact point position, a manual cleaning signal will be output to prompt the operator to perform further processing; if they do not match, the system will repeatedly execute the cleaning and position determination steps until the problem is resolved. This intelligent obstacle handling method effectively ensures the continuity and stability of the welding process, improving welding quality and production efficiency.

[0055] Optionally, the method for controlling the pushing component to push the current welding device based on the contact point location and the cleaning scheme includes:

[0056] S98627: Determine the expected movement path of the welding device based on the real-time workbench position information and the position of the contact point;

[0057] S98628: Analyze the current welding device movement path based on the workbench position information;

[0058] S98629: Determine the path deviation when the current welding device movement path is inconsistent with the expected welding device movement path;

[0059] S98630: Determine the current maximum path deviation threshold by comparing the workbench location information with the preset workbench risk area;

[0060] S98631: When the path deviation exceeds the current maximum path deviation threshold, control the pushing component to stop pushing the current welding device;

[0061] S98632: When the pushing component stops pushing the current welding device, a deviation repair scheme is formed based on the path deviation;

[0062] S98633: When the deviation repair scheme exists, control the pushing component to push the current welding device according to the deviation repair scheme.

[0063] By employing the above technical solution, the system analyzes the current movement path of the welding component in real time during component operation and compares it with the expected path. If the path deviation exceeds the maximum allowable threshold, the system immediately stops the pushing operation to avoid potential risks or errors. Subsequently, based on the specific path deviation data, the system generates a deviation correction plan to ensure that the welding component can be redirected to the correct movement path. This dynamic adjustment mechanism not only improves the safety of the pushing process but also further guarantees the accuracy of the welding position and the overall processing quality.

[0064] Optionally, a method for predicting path deviation is also included, which includes:

[0065] S98634: Record the path deviation in real time and generate a path deviation change curve;

[0066] S98635: Determine the expected path deviation based on the path deviation change curve;

[0067] S98636: When the expected path deviation exceeds the current maximum path deviation threshold, control the push component to stop pushing the current welding device.

[0068] By adopting the above technical solution, the system can predict potential future path deviations by recording path deviations in real time and generating change curves. When the predicted path deviation exceeds a set maximum threshold, the system will take measures in advance to control the drive component to stop operating, thereby avoiding welding position errors or equipment damage caused by excessive deviation. This predictive adjustment mechanism not only improves the system's response speed but also significantly enhances the safety and reliability of the welding process, providing further assurance for high-quality welding.

[0069] Optionally, a method for cleaning impurities may also be included, the method comprising:

[0070] S9863: When the welding device falls into the target position of the welding device, the current processing position is determined and corrected based on the current worktable position information;

[0071] S9864: Determine the location of impurities based on workbench image information analysis;

[0072] S9865: Obtain the current worktable angle when the impurity position and the corrected current processing position are consistent;

[0073] S9866: Perform a preset worktable flipping operation according to the current worktable angle;

[0074] S9867: Determine the location of the impurity to be corrected after the worktable flipping operation;

[0075] S9868: When the location of the impurity to be corrected coincides with the current processing location, a preset manual cleaning signal is output;

[0076] S9869: When the position of the impurity to be corrected is inconsistent with the current processing position to be corrected, the welding operation shall be performed in accordance with the processing plan.

[0077] By employing the above technical solution, the location of impurities can be accurately identified. If the detected impurity location coincides with the corrected processing position, the system will perform a preset flipping operation based on the current worktable angle to more thoroughly clean the impurities. This multi-layered impurity cleaning mechanism not only improves the cleanliness of the welding environment but also further ensures the stability of the welding process and the reliability of product quality.

[0078] Secondly, the present invention provides a welding device for automotive parts, which adopts the following technical solution:

[0079] An automotive parts welding device, employing an automotive parts welding method as described above, includes a welding assembly, a worktable, a loading assembly, a pushing assembly, a support base, and a first rotating assembly and a second rotating assembly that work together to achieve angle adjustment of the worktable in various directions.

[0080] The support base, the first rotating component, the second rotating component, and the worktable are rotatably connected in sequence.

[0081] The workbench is provided with a first sliding groove, and the loading component is embedded in and moves along the length direction within the first sliding groove to drive the device to be welded located on the loading component to move; the loading component is provided with a loading area for supporting the device to be welded; the pushing component is installed at one end of the workbench to push and fix the device to be welded located in the loading area; the welding component for welding the device to be welded is located around the support base.

[0082] By adopting the above technical solution, and utilizing the cooperation of the first and second rotating components, the angle of the worktable can be flexibly adjusted to accommodate components of different shapes and sizes to be welded, improving the adaptability and flexibility of the welding process. Simultaneously, the movement design of the loading component within the sliding track allows the component to be welded to be quickly and accurately positioned for welding, while the pushing component provides stable fixation, ensuring stability during the welding process and correcting for any deviation in the component's direction. The design of the welding components, particularly the combination of the robotic arm and welding torch, achieves automation and precision in the welding process, significantly improving welding efficiency and quality.

[0083] In summary, the present invention has at least one of the following beneficial technical effects:

[0084] The worktable can be flexibly adjusted at multiple angles through the first rotating component and the second rotating component. Combined with the movement design of the loading component along the sliding track, the pushing component can stably fix the welding device and accurately correct the welding position.

[0085] If a positional deviation is detected, the component is adjusted according to the deviation amount by pushing it. If the pushing is abnormal, the position of the robotic arm can be switched and adjusted, or even the worktable can be moved to avoid collisions. No manual intervention is required throughout the process, which effectively reduces welding position deviations caused by human error.

[0086] Issues such as stalling, obstruction, and interference from impurities can be addressed through processing logic involving table flipping and component collisions. Additionally, path deviation prediction is incorporated, and the push will be stopped in advance if the predicted deviation exceeds a threshold. Attached Figure Description

[0087] Figure 1 This is a schematic diagram of the structure of an automotive parts welding device according to an embodiment of this application;

[0088] Figure 2 This is a schematic diagram of the structure of the support base, the first rotating component, the second rotating component, the worktable, and the loading component in the embodiments of this application;

[0089] Figure 3 This is a schematic diagram of the structure of the workbench and the loading platform in the embodiments of this application;

[0090] Figure 4 This is an exploded view of the pushing component in the embodiments of this application;

[0091] Figure 5 This is a flowchart of a welding method for automotive parts according to an embodiment of this application;

[0092] Figure 6 This is a flowchart illustrating the method by which the control and pushing component performs a pushing operation according to the processing position offset in an embodiment of this application.

[0093] The parts referred to by the numbers in the above attached figures are as follows: 1. Welding assembly; 11. Welding base; 12. Rotating plate; 13. Welding bracket; 14. Robotic arm; 15. Welding torch; 2. Workbench; 21. First sliding groove; 3. Loading assembly; 31. Loading base; 32. Loading platform; 33. Loading area; 4. Pushing assembly; 41. Pushing base; 42. Second sliding groove; 43. Pushing column; 44. Pushing gripper; 5. Support base; 6. First rotating assembly; 7. Second rotating assembly. Detailed Implementation

[0094] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0095] This invention discloses a welding apparatus for automotive parts. (Refer to...) Figure 1 An automotive parts welding device includes a welding assembly 1, a worktable 2, a loading assembly 3, a pushing assembly 4, a support base 5, a first rotating assembly 6, and a second rotating assembly 7.

[0096] Reference Figure 1 The welding assembly 1 includes a welding base 11, a welding bracket 13, a robotic arm 14, and a welding torch 15. One end of the welding base 11 is rotatably connected to one end of a rotating plate 12, and the other end of the rotating plate 12 is fixedly connected to the welding bracket 13. A connection hole is provided at the end of the welding bracket 13 away from the rotating plate 12. One end of the robotic arm 14 is embedded in the connection hole to realize the rotation operation of the robotic arm 14. The other end of the robotic arm 14 is fixedly connected to the welding torch 15 for performing welding operations.

[0097] Reference Figure 2 One end of the support base 5 is rotatably connected to the first rotating assembly 6. The side of the first rotating assembly 6 away from the support base 5 is rotatably connected to the second rotating assembly 7. The end of the second rotating assembly 7 away from the support base 5 is fixedly connected to the worktable 2. The end of the worktable 2 away from the support base 5 is fixedly connected to the carrying assembly 3. Several pushing assemblies 4 are located around the carrying assembly 3. To cover the directions of pushing multiple devices to be welded, there are four pushing assemblies here.

[0098] Reference Figure 3 The loading assembly 3 includes a loading base 31 and a loading platform 32. A first sliding groove 21 is provided on the worktable 2. The loading base 31 is embedded in the first sliding groove 21 and moves along the length of the first sliding groove 21. The end of the loading base 31 away from the sliding track is fixedly connected to the loading platform 32. A loading area 33 is provided on the loading platform 32. The loading area 33 is located at the end of the loading platform 32 away from the loading base 31 and is used to place the components to be soldered.

[0099] Reference Figure 4 The pushing assembly 4 includes a pushing base 41, a pushing column 43, and a pushing gripper 44. One end of the pushing base 41 is fixedly connected to the end of the worktable 2 away from the supporting base 5, and the other end of the pushing base 41 has a second sliding groove 42. One end of the pushing column 43 is embedded in the second sliding groove 42, and the other end of the pushing column 43 is fixedly connected to the pushing gripper 44. The pushing gripper 44 is used to push the position of the device to be welded on the loading area 33, and to fix the position of the device to be welded when the pushing gripper is not pushing the device to be welded.

[0100] Based on the same inventive concept, embodiments of the present invention provide a welding method for automotive parts.

[0101] Reference Figure 5 A welding method for automotive parts, comprising:

[0102] Step S1: Obtain workbench image information.

[0103] The workbench image information refers to the image information corresponding to the end of the workbench 2 that carries the device to be soldered, which is captured by a camera installed above the workbench 2.

[0104] Step S2: Analyze the image information of the workbench to obtain the outline of the device to be welded.

[0105] The outline of the component to be welded refers to the extraction of edge and shape information of the component by analyzing and processing the image information of the workbench through the image acquisition module, thus forming the outline of the component. The image processing algorithm used by the image acquisition module can be Canny edge detection algorithm, Sobel edge detection algorithm, or Laplacian edge detection algorithm, etc. These algorithms can effectively extract edge information from the image, thereby forming an accurate outline of the component to be welded.

[0106] Step S3: Based on the comparison between the outline of the device to be welded and the preset welding device parameter library, determine the current welding device.

[0107] The welding component parameter library refers to a database pre-stored in the system containing parameter information for various possible automotive parts to be welded, such as size, shape, and material characteristics. The current welding component refers to the component currently placed on worktable 2. The outline of the component to be welded, obtained through image processing, is compared with the parameters in the welding component parameter library. A shape matching algorithm is used to determine which specific automotive part from the welding component parameters the component currently placed on worktable 2 is.

[0108] Step S4: Determine the welding processing scheme based on the welding device parameter library and the current welding device. The welding processing scheme includes the robotic arm processing scheme and the worktable processing scheme.

[0109] The robotic arm machining scheme refers to the plan for determining the specific motion trajectory, welding speed, welding pressure, and other parameters of the robotic arm 14 during the welding process, based on the current welding components and information such as the performance parameters, reachability, and optimal working posture of the robotic arm 14. The worktable machining scheme, on the other hand, refers to adjusting the position, angle, and rotation speed of the worktable 2 according to the size, shape, and welding requirements of the current welding components to ensure that the components are in the optimal welding position during the welding process.

[0110] Step S5: Control the robotic arm 14 and the worktable 2 to perform welding operations according to the welding processing plan.

[0111] Welding work refers to the robotic arm 14 precisely performing welding operations on the current welding device according to preset parameters such as motion trajectory, welding speed, and welding pressure; at the same time, the worktable 2 cooperates according to adjusted parameters such as position, angle, and rotation speed to ensure that the device is always in the optimal welding position during the welding process. The two work together to complete the welding processing operation.

[0112] Step S6: Acquire the position information of the robotic arm and the position information of the worktable in real time during the welding process.

[0113] The robotic arm position information refers to the real-time coordinate position, motion posture, and joint angles of the robotic arm 14 during the welding operation. This information can be collected by encoders and sensors installed on the robotic arm 14. The worktable position information refers to the real-time position coordinates, rotation angle, and tilt angle of the worktable 2 in three-dimensional space, which is obtained through real-time monitoring using linear encoders and angle encoders.

[0114] Step S7: Determine the current processing position based on the position information of the robotic arm and the position information of the worktable.

[0115] The current processing position refers to the specific spatial position reached by the robotic arm 14 and the worktable 2 during the welding process. This position is obtained by capturing the position of the welding torch 15 on the robotic arm 14 with a camera, and then mapping the spray position of the welding torch 15 to coordinates on the corresponding horizontal plane of the worktable 2. This position is directly related to whether the welding point accurately falls on the preset welding area of ​​the component to be welded.

[0116] Step S8: Determine the machining position offset when the current machining position is inconsistent with the machining position in the welding machining plan.

[0117] The machining position offset refers to the deviation between the current machining position and the preset machining position in the welding machining plan. If the current position is inconsistent with the machining position in the welding machining plan, it indicates a positional deviation during the welding process. This deviation may affect the welding quality, leading to weak welds or inaccurate welding positions. Therefore, the machining position offset is determined. The machining offset is obtained by using a camera to determine the coordinates of the current machining position and the coordinates of the machining position in the welding machining plan, and calculating the difference between the two coordinates. This difference includes displacement deviations in the horizontal, vertical, and depth directions.

[0118] Step S9: When there is a machining position offset, control the push component 4 to perform a push operation according to the machining position offset.

[0119] The pushing operation refers to the operation of controlling the pushing component 4 to push the welding device. When there is a machining position offset, the system will precisely control the pushing component 4 according to this offset, so that it pushes the welding device in a predetermined direction and distance to correct the position deviation during the welding process.

[0120] Step S10: Perform the welding operation when the current processing position matches the processing position in the welding processing plan or after the push operation is completed.

[0121] The welding operation refers to the process where, after the pushing operation is completed and the welding components are adjusted to the correct position, the robotic arm 14 and the worktable 2 continue to execute the subsequent welding steps according to the originally set welding plan. Once the pushing operation is completed, it indicates that the positional deviation during the welding process has been corrected, and the welding operation can then continue.

[0122] The method for controlling the push component 4 to perform the push operation according to the processing position offset includes:

[0123] Step S90: Determine the pushing scheme based on the machining position offset. The pushing scheme includes the pushing distance and the pushing direction.

[0124] The pushing distance refers to the specific length that the pushing component 4 needs to move. This length is precisely calculated based on the processing position offset to ensure that the welding device can be accurately pushed to the processing position in the welding process plan. The pushing direction refers to the direction of movement of the pushing component 4 when performing the pushing operation. This direction is consistent with the direction of the processing position offset, thereby ensuring the effectiveness of the pushing operation.

[0125] Step S91: When a pushing scheme exists, control the pushing component 4 to perform the pushing operation according to the pushing scheme.

[0126] When a pushing scheme exists, it indicates that the positional relationship between the robotic arm 14 and the worktable 2 will cause welding deviations, and the system has already calculated the specific distance and direction that the pushing component 4 needs to move based on the processing position offset. At this time, the pushing component 4 can be controlled to perform the pushing operation according to the pushing scheme.

[0127] Step S92: During the execution of the pushing operation, the pushing speed and current pushing distance of the pushing component are obtained in real time.

[0128] The pushing speed of the pushing component refers to the real-time movement rate of the pushing component 4 during the pushing operation. This rate can be monitored and obtained in real time by a speed sensor installed on the pushing component 4 to ensure the smoothness and controllability of the pushing process. The current pushing distance refers to the total distance moved by the pushing component 4 from its starting position to the current moment. This data can be accurately measured by an encoder on the pushing component 4, thereby allowing real-time monitoring of the progress of the pushing operation.

[0129] Step S93: When the pushing speed of the pushing component is 0 and the current pushing distance is less than the pushing distance, output a preset pushing abnormal signal.

[0130] The push abnormality signal is a signal used to indicate that there is an abnormal state in the current push component 4. When the push speed of the push component is 0 and the current push distance is less than the push distance, it means that the push component 4 has stalled during the push operation and has not yet reached the predetermined push distance. This may be due to mechanical failure, impurities, or other abnormal conditions.

[0131] This also includes:

[0132] Step S94: In response to the abnormal push signal, acquire the current worktable position information in real time. The current worktable position information includes the worktable position information and the welding device position information.

[0133] The welding device position information refers to the specific coordinate position of the welding device on the worktable 2. This information is determined by the outline of the welding device obtained through the analysis of the worktable image information.

[0134] Step S95: Determine the offset of the corrected processing position based on the current worktable position information and the robotic arm position information.

[0135] The correction of machining position offset refers to the amount of offset correction made by adjusting the robotic arm 14 to make the current machining position consistent with the machining position in the welding process plan. When there is a push abnormality signal, it means that the current welding device on the worktable 2 cannot be pushed by the push component 4 to make the current machining position consistent with the machining position in the welding process plan. Therefore, the correction of machining position offset is determined for subsequent adjustment of the robotic arm 14.

[0136] Step S96: Determine the target position of the robotic arm by correcting the machining position offset.

[0137] The target position of the robotic arm refers to the position that the robotic arm 14 needs to reach after adjustment based on the corrected machining position offset. The purpose is to ensure that the welding operation of the robotic arm 14 can accurately correspond to the machining position in the welding machining plan.

[0138] Step S97: When the target position of the robotic arm exists, a robotic arm movement plan is formed, which includes the robotic arm adjustment angle and the robotic arm adjustment distance.

[0139] The robotic arm adjustment angle refers to the angle that the robotic arm 14 needs to rotate during its movement. The robotic arm adjustment distance refers to the straight-line distance that the robotic arm 14 needs to move from its current position to the target position. This distance is calculated based on the correction of the machining position offset and the robotic arm adjustment angle.

[0140] Step S98: Control the robotic arm 14 to move to the target position of the robotic arm according to the robotic arm movement plan.

[0141] Step S99: Continue the welding operation when the robotic arm 14 moves to the target position.

[0142] When the robotic arm 14 moves to the target position, it means that the robotic arm 14 has completed the position adjustment according to the correction of the processing position offset. At this time, its welding operation can accurately correspond to the processing position in the welding processing plan and execute the welding processing operation.

[0143] Reference Figure 6 The method for controlling the robotic arm 14 to move to the target position according to the robotic arm movement plan includes:

[0144] Step S980: Obtain the current position information of the robotic arm in real time.

[0145] The current position information of the robotic arm refers to the real-time coordinate position, motion posture, and real-time angle data of each joint of the robotic arm 14 during the execution of the movement operation. This information is collected and transmitted in real time through encoders installed on key parts of the robotic arm 14, which can accurately reflect the actual position and motion state of the robotic arm 14 in three-dimensional space.

[0146] Step S981: Determine the adjustable angle range of the robotic arm corresponding to the current position information based on the preset robotic arm parameter library.

[0147] The robotic arm parameter library refers to a database pre-stored in the system that covers parameters such as the robotic arm 14's range of motion, maximum and minimum rotation angles, and motion limitations in different postures. By querying this database, the system can determine the adjustable angle range given the current robotic arm position.

[0148] Step S982: When the angle adjustment of the robotic arm does not fall within the adjustable angle range of the robotic arm, determine the worktable movement scheme based on the current position information of the robotic arm and the current position information of the worktable.

[0149] The workbench movement plan refers to the planned movement of workbench 2. When the robot arm's angle adjustment cannot fall within its adjustable angle range, it means that the target position cannot be reached by relying solely on the robot arm 14's own adjustment. Therefore, it is necessary to determine the movement position of workbench 2 by using the current robot arm position information and the current workbench position information.

[0150] Step S983: When the robot arm adjusts its angle and falls within the adjustable angle range of the robot arm, determine the overlapping area based on the target position of the robot arm and the current position information of the worktable.

[0151] The overlapping area refers to the region where the target position of the robotic arm intersects with the current position information of the worktable. When the adjusted angle of the robotic arm falls within the adjustable angle range of the robotic arm, it means that the robotic arm 14 can reach the target position through its own adjustment. At this time, it is necessary to consider whether the robotic arm 14 and the worktable 2 will collide, because at this time it has deviated from the welding operation that was executed in the preset process when the current processing position was consistent with the processing position in the welding processing plan. Therefore, in the welding operation that deviates from the preset process, adjusting the robotic arm 14 may cause the robotic arm 14 and the worktable 2 to collide.

[0152] Step S984: When there is an overlapping area, determine the worktable movement plan based on the current robotic arm position information and the current worktable position information.

[0153] When there is an overlapping area, it means that the robotic arm 14 will collide with the worktable 2 during the adjustment process. In order to avoid the collision between the robotic arm 14 and the worktable 2, the worktable movement plan is determined by the current position information of the robotic arm and the current position information of the worktable to adjust the position of the worktable 2, so as to avoid the worktable 2 appearing on the movement path of the robotic arm 14 and satisfying the spraying position of the welding gun 15 of the robotic arm 14.

[0154] Step S985: If there is no overlapping region, proceed to step S98.

[0155] When there is no overlapping area, it means that the robotic arm 14 will not collide with the worktable 2 during the process of adjusting to the target position. At this time, the robotic arm 14 can be directly controlled to move according to the robotic arm movement plan, that is, to execute step S98, so that the robotic arm 14 can smoothly reach the target position of the robotic arm.

[0156] Step S986: When a worktable movement plan exists, control worktable 2 to adjust worktable 2 according to the worktable movement plan.

[0157] The method for adjusting worktable 2 according to the worktable movement scheme includes:

[0158] Step S9860: Determine the target position of the welding device based on the worktable movement scheme.

[0159] The target position of the welding device refers to the precise coordinate position that the welding device should reach after moving with the worktable 2 under the planned worktable movement scheme. The calculation of this position needs to take into account the distance and direction of the worktable 2 movement, as well as the relative position of the welding device on the worktable 2.

[0160] Step S9861: During the process of adjusting the worktable 2 according to the worktable movement scheme, the worktable movement speed and the worktable rotation speed are acquired in real time.

[0161] The table movement speed refers to the real-time rate at which the table 2 moves in the horizontal direction. This rate can be monitored and obtained in real time by a linear encoder installed at the bottom of the support base 5. The table rotation speed refers to the angle that the table 2 rotates per unit time during rotation. This data is measured in real time by an angle encoder installed on the corresponding rotation shafts of the first rotation component 6 and the second rotation component 7.

[0162] Step S9862: When both the table movement speed and the table rotation speed are 0 and the welding device has not moved to the target position of the welding device, determine the position of the obstacle and output the preset obstacle signal.

[0163] The obstacle location refers to the specific coordinate area where an object obstructs the normal movement of workbench 2 or the welding device to the target position during the movement of workbench 2. The obstacle signal is a signal used to indicate to the system that an obstacle exists near workbench 2 that is hindering its movement. When the workbench's moving speed and rotation speed are both 0, and the welding device has not moved to its target position, it indicates that workbench 2 has stalled during the adjustment process according to the movement plan, causing the welding device to fail to reach the target position. This is likely due to an obstacle in the movement path of workbench 2, and the specific location of the obstacle needs to be determined.

[0164] This also includes a method for handling the presence of obstacle signals, which includes:

[0165] Step S98620: Generate a modified push scheme based on the target position of the welding device, and control the push component 4 to push the welding device according to the modified push scheme.

[0166] The revised propulsion scheme refers to the replanning of the movement path and propulsion parameters of the propulsion component 4 based on the target position of the welding device. Because the worktable 2 is restricted by obstacles and cannot move the welding device to the target position, the propulsion component 4 on the worktable 2 can be used to move the welding device to the target position.

[0167] Step S98621: Obtain the moving speed of the welding device during the execution of the modified push scheme.

[0168] The welding device moving speed refers to the moving speed of the welding device during the pushing process of component 4.

[0169] Step S98622: Determine the contact point position when the moving speed of the welding device is 0 and the welding device has not fallen into the target position of the welding device.

[0170] The contact point location refers to the specific coordinates at which the pushing component 4 comes into contact with the welding device during the pushing process. When the welding device's moving speed is 0 and it does not fall into the target position of the welding device, it indicates that the pushing component 4 may have encountered an obstacle while pushing the welding device, causing the welding device to be unable to continue moving. In this case, it is necessary to determine the specific location of the contact point in order to perform subsequent operations.

[0171] Step S98623: Based on the contact point location and the preset cleaning scheme, control the push component 4 to push the current welding device.

[0172] The clearing scheme refers to the scheme of controlling the push component 4 to clear obstacles. Specifically, it refers to the scheme of controlling the component to hit the contact point back and forth, so that the obstacle is removed from the movement path of the control component.

[0173] Step S98624: Determine the location of the corrected contact point after executing the cleaning plan.

[0174] The corrected contact point position refers to the location where, after the cleaning plan is completed, the push component 4 is unable to move the welding device again. The presence of a corrected contact point position indicates that an obstacle has reappeared that is affecting the movement of the welding device.

[0175] Step S98625: When the corrected contact point position is consistent with the contact point position, output a preset manual cleaning signal.

[0176] The manual cleanup signal is used to alert the operator that there are obstacles requiring manual intervention. When the corrected contact point position matches the original contact point position, it indicates that the original obstacle was not effectively removed after the cleanup plan was executed. In this case, the system determines that the automatic cleanup mechanism alone cannot solve the problem, and therefore outputs a manual cleanup signal, prompting the operator to manually intervene and clear obstacles on workbench 2 or the path of the welding components to ensure the welding process can proceed smoothly.

[0177] Step S98626: When the corrected contact point position is inconsistent with the contact point position, proceed from step S98623 to step S98625.

[0178] When the corrected contact point position and the contact point position are inconsistent, it means that after the cleaning plan is executed, the drive component 4 encountered an obstacle at the new contact point position. At this time, it is necessary to control the drive component 4 to perform a new round of cleaning operation based on the new contact point position, that is, the corrected contact point position and the cleaning plan.

[0179] The method for controlling the push component 4 to push the current welding device based on the contact point location and cleaning scheme includes:

[0180] Step S98627: Determine the expected movement path of the welding device based on the real-time workbench position information and contact point position.

[0181] The expected movement path of the welding device refers to the path that the welding device will take under the action of the pushing component 4, which is planned based on the real-time worktable position information and the contact point position.

[0182] Step S98628: Analyze the workbench position information to obtain the current movement path of the welding device.

[0183] The current welding device movement path refers to the path that the welding device travels during the actual pushing process.

[0184] Step S98629: Determine the path deviation when the current welding device movement path is inconsistent with the expected welding device movement path.

[0185] Path deviation refers to the difference between the current moving path of the welding device and the expected moving path of the welding device. This difference is determined by comparing the angle between the two paths. If the current moving path of the welding device is inconsistent with the expected moving path of the welding device, it indicates that the pusher jaw 44 has become loose during the impact contact point positioning process, causing the position of the welding device to shift during the impact, thus changing the relative position of the welding device and the worktable 2.

[0186] Step S98630: Determine the current maximum path deviation threshold by comparing the workbench position information with the preset workbench risk area.

[0187] The risk area of ​​the workbench refers to specific areas on workbench 2 where there is a potential risk. These areas are specifically where the push gripper 44 cannot clamp the welding device. The current maximum path deviation threshold refers to the maximum permissible range within the risk area of ​​the workbench where the welding device may shift due to the gripper loosening.

[0188] Step S98631: When the path deviation exceeds the current maximum path deviation threshold, control the push component 4 to stop pushing the current welding device.

[0189] When the path deviation exceeds the current maximum path deviation threshold, it indicates that the positional offset of the welding device has exceeded the safe range, which may cause uncontrollable movement or damage to the welding device during the pushing process. At this time, the system will immediately control the pushing component 4 to stop the pushing operation.

[0190] Step S98632: When the pushing component 4 stops pushing the current welding device, a deviation repair scheme is formed based on the path deviation.

[0191] The deviation repair scheme refers to the pushing strategy of the pushing component 4, which is formulated based on the specific value and direction of the path deviation. It aims to correct the positional offset of the welding device and bring it back to the expected movement path.

[0192] Step S98633: When a deviation repair plan exists, control the drive component 4 to drive the current welding device according to the deviation repair plan.

[0193] This also includes a method for predicting path deviation, which includes:

[0194] Step S98634: Record the path deviation in real time and generate a path deviation change curve.

[0195] A path deviation change curve is a curve that plots the trend of deviation by using time as the horizontal axis and path deviation as the vertical axis, through continuous data points.

[0196] Step S98635: Determine the expected path deviation based on the path deviation change curve.

[0197] Path deviation prediction refers to the predicted future path deviation value based on the path deviation change curve. This prediction process involves taking the first derivative of the current curve as a function to obtain the rate of change of the current curve, and then using this rate of change to further estimate the next path deviation value.

[0198] Step S98636: When the expected path deviation exceeds the current maximum path deviation threshold, control the push component 4 to stop pushing the current welding device.

[0199] When the expected path deviation exceeds the current maximum path deviation threshold, it indicates that the system predicts that the welding device may exceed the safe range in the future. Therefore, the system controls the push component 4 to stop the push operation in advance.

[0200] This also includes a method for cleaning impurities, which includes:

[0201] Step S9863: When the welding device falls into the target position of the welding device, the current processing position is determined and corrected based on the current position information of the worktable 2.

[0202] The current processing position correction refers to the position that needs to be processed in the current welding operation, which is obtained based on the target position of the welding device and the relative position of the welding device to the processing position.

[0203] Step S9864: Analyze the image information of the workbench to obtain the location of the impurities.

[0204] The location of an impurity refers to the specific coordinates of a foreign object that may affect the welding quality and exists on the surface of workbench 2 or around the welding device. This location information can be obtained by capturing images of the workbench using a high-definition camera installed above the workstation, and then analyzing and identifying the images using image processing algorithms to accurately locate the area where the impurity is located. Here, the image processing algorithm can be an edge recognition algorithm, which is a common technique and will not be elaborated on here.

[0205] Step S9865: Obtain the current table angle when the impurity position and the current machining position are consistent.

[0206] The current worktable angle refers to the relative angle of the current worktable 2 within a preset reference plane. The reference plane is a horizontal plane set at the end of the worktable 2 closest to the loading assembly 3. This angle information can be obtained by encoders installed on the first rotating assembly 6 and the second rotating assembly 7. When the location of the impurity coincides with the current machining position, it indicates that the current welding process may be affected by the impurity.

[0207] Step S9866: Perform the preset worktable flipping operation according to the current worktable angle.

[0208] The worktable flipping operation refers to controlling the worktable 2 to flip at a specific angle based on the current angle information of the worktable 2, through the first rotating component 6 and the second rotating component 7. By changing the spatial posture of the worktable 2, impurities that were originally located at the current processing position are caused to slide off or deviate due to gravity, thereby eliminating their potential impact on welding quality. Because the current angle of the worktable is the angle at which the current processing position is corrected, the flipping operation needs to be stopped after flipping to that angle.

[0209] Step S9867: Determine the location of the impurities to be corrected after the worktable is flipped.

[0210] Correcting the impurity position refers to the impurity position re-determined through image recognition technology after the workbench flipping operation is completed.

[0211] Step S9868: When the position of the impurity is corrected and the current processing position is corrected, a preset manual cleaning signal is output.

[0212] The manual cleaning signal here serves the same purpose as the manual cleaning signal mentioned above: to alert the operator that there are impurities requiring manual intervention. When the corrected impurity position matches the corrected current processing position, it indicates that the flipping operation cannot remove the impurities from the soldered components, so a manual cleaning signal is output to notify manual intervention.

[0213] Step S9869: When the position of the impurity to be corrected is inconsistent with the current processing position, perform the welding operation according to the processing plan.

[0214] When the position of the impurity being corrected is inconsistent with the current processing position, it means that the table flipping operation has successfully moved the impurity away from the current processing position. At this time, the welding processing area is no longer affected by the impurity, so the system can continue to perform the welding processing operation according to the processing plan.

[0215] The above description is merely a preferred embodiment of the present invention. 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 those skilled in the art, 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 method of welding an automotive component, characterized by, Comprise: S1: Obtain workbench image information; S2: Through the workbench image information analysis, to get the device to be welded contour; S3: Based on the device to be welded contour and the preset welding device parameter library comparison, to determine the current welding device; S4: Based on the welding device parameter library and the current welding device determine welding processing scheme, the welding processing scheme includes mechanical arm processing scheme and workbench processing scheme; S5: Control mechanical arm (14) and workbench (2) according to the welding processing scheme executes welding processing operation; S6: In the execution of the welding processing process, real-time acquisition of mechanical arm position information and workbench position information; S7: According to the mechanical arm position information and the workbench position information determine the current processing position; S8: When the current processing position and the processing position in the welding processing scheme are inconsistent, determine the processing position offset; S9: When there is the processing position offset, control the pusher assembly (4) according to the processing position offset executes push operation; S10: When the current processing position and the processing position in the welding processing scheme are consistent or after executing the push operation, execute the welding processing operation; Wherein, the method for controlling the pusher assembly (4) according to the processing position offset executes push operation includes: S90: Based on the processing position offset determines the push scheme, the push scheme includes push distance and push direction; S91: When there is the push scheme, control the pusher assembly (4) according to push scheme executes push operation; S92: In the process of executing the push operation, real-time acquisition of pusher assembly push speed and current push distance; S93: When the pusher assembly push speed is 0 and the current push distance is less than the push distance, output preset push exception signal; Wherein, also includes: S94: In response to the push exception signal, real-time acquisition of current workbench position information, the current workbench position information includes workbench position information and welding device position information; S95: According to the current workbench position information and the mechanical arm position information determine the correction processing position offset; S96: Through the correction processing position offset determines the mechanical arm target position; S97: When there is the mechanical arm target position, according to the mechanical arm target position forms mechanical arm movement scheme, the mechanical arm movement scheme includes mechanical arm adjustment angle and mechanical arm adjustment distance; S98: Control mechanical arm (14) according to the mechanical arm movement scheme moves to the mechanical arm target position; S99: When mechanical arm (14) moves to the mechanical arm target position, continue to execute welding processing operation; Wherein, the method for controlling mechanical arm according to the mechanical arm movement scheme moves to the mechanical arm target position includes: S980: Real-time acquisition of current mechanical arm position information; S981: Based on the preset mechanical arm parameter library determines the mechanical arm adjustable angle range corresponding to the current mechanical arm position information; S982: determining a worktable moving scheme based on the current worktable position information and the current robot position information when the robot adjustment angle does not fall into the robot adjustable angle range; S983: determining an overlapping area based on the robot target position and the current worktable position information when the robot adjustment angle falls into the robot adjustable angle range; S984: determining a worktable moving scheme based on the current worktable position information and the current robot position information when the overlapping area exists; S985: executing S98 when the overlapping area does not exist; S986: controlling the worktable (2) to adjust the worktable (2) according to the worktable moving scheme when the worktable moving scheme exists.

2. The method of claim 1, wherein The method for controlling the worktable (2) to adjust the worktable (2) according to the worktable moving scheme comprises: S9860: determining a welding device target position based on the worktable moving scheme; S9861: acquiring a worktable moving speed and a worktable rotating speed in real time during the adjustment of the worktable (2) according to the worktable moving scheme; S9862: determining an obstacle position when the worktable moving speed and the worktable rotating speed are both 0 and the welding device has not moved to the welding device target position, and outputting a preset obstacle signal.

3. The method of claim 2, wherein the welding is performed by a laser beam. Further comprising a processing method when the obstacle signal exists, which comprises: S98620: generating a correction pushing scheme according to the welding device target position, and controlling the pushing assembly (4) to push the welding device according to the correction pushing scheme; S98621: acquiring a welding device moving speed during the execution of the correction pushing scheme; S98622: determining a contact point position when the welding device moving speed is 0 and the welding device has not fallen into the welding device target position; S98623: controlling the pushing assembly (4) to push the current welding device based on the contact point position and a preset cleaning scheme; S98624: determining a correction contact point position after the execution of the cleaning scheme; S98625: outputting a preset manual cleaning signal when the correction contact point position is consistent with the contact point position; S98626: executing S98623 to S98625 when the correction contact point position is not consistent with the contact point position.

4. The method of claim 3, wherein the welding is performed by a laser beam. The method for controlling the pushing assembly (4) to push the current welding device based on the contact point position and the cleaning scheme comprises: S98627: determining a predicted welding device moving path based on real-time worktable position information and the contact point position; S98628: analyzing the worktable position information to obtain a current welding device moving path; S98629: determining a path deviation when the current welding device moving path is not consistent with the predicted welding device moving path; S98630: determining a current maximum path deviation threshold value through the worktable position information and a preset worktable risk area; S98631: controlling the pushing assembly (4) to stop pushing the current welding device when the path deviation exceeds the current maximum path deviation threshold value; S98632: forming a deviation repair scheme based on the path deviation when the pushing assembly (4) stops pushing the current welding device; S98633: controlling the pushing assembly (4) to push the current welding device according to the deviation repair scheme when the deviation repair scheme exists.

5. The method of claim 4, wherein the welding is performed by a laser beam. The method also includes a method for predicting path deviation, which comprises: S98634: recording the path deviation in real time and generating a path deviation change curve; S98635: determining a predicted path deviation based on the path deviation change curve; S98636: controlling the pushing assembly (4) to stop pushing the current welding device when the predicted path deviation exceeds the current maximum path deviation threshold.

6. The method of claim 2, wherein The method also includes a method for cleaning impurities, which comprises: S9863: determining a corrected current processing position based on the current workbench position information when the welding device falls into the target position of the welding device; S9864: analyzing based on the workbench image information to obtain the impurity position; S9865: obtaining the current workbench angle when the impurity position and the corrected current processing position are consistent; S9866: performing a preset workbench overturning operation according to the current workbench angle; S9867: determining a corrected impurity position after the workbench overturning operation; S9868: outputting a preset manual cleaning signal when the corrected impurity position and the corrected current processing position are consistent; S9869: performing a welding processing operation according to the processing scheme when the corrected impurity position and the corrected current processing position are inconsistent.

7. An automobile parts welding device applied to the automobile parts welding method according to any one of claims 1 to 6, characterized in that: The welding assembly (1), the workbench (2), the carrying assembly (3), the pushing assembly (4), the support base (5), the first rotating assembly (6) and the second rotating assembly (7) cooperate to realize angle adjustment of the workbench (2) in each direction; The support base (5), the first rotating assembly (6), the second rotating assembly (7) and the workbench (2) are sequentially rotatably connected; The workbench (2) is provided with a first sliding groove (21), and the carrying assembly (3) is embedded in and moves along the length direction in the first sliding groove (21) to drive the welding device on the carrying assembly (3) to move; the carrying assembly (3) is provided with a carrying area (33) for carrying the welding device; the pushing assembly (4) is installed at one end of the workbench (2) to push and fix the welding device on the carrying area (33); and the welding assembly (1) for welding the welding device is located around the support base (5).

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