Visual tracking array sound wave superposition laser welding platform

Abstract

This application discloses a visual tracking array acoustic wave superposition laser welding platform, which can be applied to the field of laser processing equipment technology. This application involves setting up a welding processing platform, ultrasonic transducer units, an imaging device connecting component, an imaging device, and a control unit. The imaging device connecting component adjusts the height above the welding processing platform. During the welding process, the control unit controls the working excitation mode of the ultrasonic transducer units according to external control signals. The imaging device acquires real-time welding images of the workpiece to be welded within the welding processing platform. The control unit then controls the start / stop state of the ultrasonic transducer units based on the real-time welding images and adjusts the phase of all ultrasonic transducers within the ultrasonic transducer units to achieve in-phase acoustic wave output. This allows for stable control of the energy peak along the welding path through the constructive interference principle of acoustic waves, thereby effectively improving welding quality and stability.

Description

Technical Field

[0001] This application relates to the field of laser processing equipment technology, and in particular to a visual tracking array acoustic wave superposition laser welding platform. Background Technology

[0002] In the field of laser welding, the interaction between the laser spot and the workpiece directly determines the welding quality. Ultrasonic-assisted technology, by introducing high-frequency mechanical vibration, can significantly improve the fluidity of the molten pool, refine the grain structure, and reduce porosity defects, making it an important means to improve welding performance. However, existing ultrasonic-assisted laser welding technologies are limited by external oscillator designs, requiring complex fixtures and coupling devices to transmit vibration energy. This results in low system integration, significant energy loss, and difficulty in dynamically matching the real-time movement trajectory of the laser spot. Internal oscillator solutions often employ uniform arrangement or simple double-row layouts, failing to achieve stable control of the energy peak along the welding path through the constructive interference principle of acoustic waves, leading to significant attenuation of weld depth in the weld end region. Therefore, it is evident that existing laser welding platforms exhibit poor welding quality and stability.

[0003] In summary, the technical problems existing in the relevant technologies need to be improved. Summary of the Invention

[0004] The main objective of this application is to propose a visual tracking array acoustic wave superposition laser welding platform, which can effectively improve welding quality and welding stability.

[0005] To achieve the above objectives, one aspect of this application proposes a visual tracking array acoustic wave superposition laser welding platform, the welding platform comprising:

[0006] Welding processing platform;

[0007] An ultrasonic transducer unit is installed inside the welding processing platform according to a preset installation rule.

[0008] An imaging device connection component, one end of which is fixed to the side of the welding processing platform;

[0009] An imaging device is fixed to the other end of an imaging device connecting component, and its height above the welding processing platform is adjusted via the imaging device connecting component; the imaging device is used to acquire real-time welding images of the object to be welded within the welding processing platform.

[0010] The control unit is located on the side of the welding platform and is used to control the working excitation mode of the ultrasonic transducer unit according to the external control signal, control the start and stop status of the ultrasonic transducer unit according to the real-time welding image, and adjust the phase of all ultrasonic transducers in the ultrasonic transducer unit to achieve in-phase sound wave output.

[0011] In some embodiments, the welding platform includes a welding frame and a welding plate, the welding plate being disposed above the welding frame, and a connecting joint being provided on the lower surface of the welding plate, wherein the ultrasonic transducer unit is fixed to the lower part of the welding plate through the connecting joint.

[0012] In some embodiments, the ultrasonic transducer unit includes a first dense ultrasonic transducer column, a second dense ultrasonic transducer column, a first sparse ultrasonic transducer column, and a second sparse ultrasonic transducer column; the first dense ultrasonic transducer column and the second dense ultrasonic transducer column are symmetrically arranged about a central axis below the welding plate; the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column are symmetrically arranged about a central axis below the welding plate, with the first sparse ultrasonic transducer column located outside the first dense ultrasonic transducer column and the second sparse ultrasonic transducer column located outside the second dense ultrasonic transducer column.

[0013] In some embodiments, the number of ultrasonic transducers on the first dense ultrasonic transducer column and the second dense ultrasonic transducer column is greater than the number of ultrasonic transducers on the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column; the ultrasonic transducers on the first dense ultrasonic transducer column, the second dense ultrasonic transducer column, the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column are all electrically connected in parallel.

[0014] In some embodiments, the imaging device connection component includes a first connecting plate, a second connecting plate, and a third connecting plate; the first connecting plate is perpendicular to the surface of the welding processing platform and one end of the first connecting plate is fixed to the side of the welding processing platform; the second connecting plate is parallel to the surface of the welding processing platform and one end of the second connecting plate is connected to the other end of the first connecting plate; the third connecting plate is perpendicular to the surface of the welding processing platform and one end of the third connecting plate is movably connected to the second connecting plate; the imaging device is movably connected to the third connecting plate.

[0015] In some embodiments, the horizontal distances from the first sparse ultrasonic transducer array and the second sparse ultrasonic transducer array to the central axis satisfy the following relationship with the horizontal distances from the first dense ultrasonic transducer array and the second dense ultrasonic transducer array to the central axis:

[0016] d S ≥αd D ;

[0017] Where α represents a constant and α∈[1.2,2]; d S d represents the horizontal distance from the first sparse ultrasonic transducer array or the second sparse ultrasonic transducer array to the central axis; D This indicates the horizontal distance from the first or second dense ultrasonic transducer array to the central axis.

[0018] In some embodiments, phase compensation is performed on each excitation oscillator in the ultrasonic transducer unit through a preset phase compensation mechanism; wherein, the calculation formula for the preset phase compensation amount in the preset phase compensation mechanism is as follows:

[0019]

[0020] In the formula, This indicates the preset phase compensation amount. λ represents the wavelength of the sound wave, v represents the speed of sound, f represents the excitation frequency, and π represents pi.

[0021] In some embodiments, the operating excitation mode includes a high-frequency small-amplitude mode or a low-frequency large-amplitude mode.

[0022] In some embodiments, the second connecting plate is provided with a waist hole, and one end of the third connecting plate is movably connected to the waist hole on the second connecting plate.

[0023] In some embodiments, controlling the start / stop state of the ultrasonic transducer unit based on the real-time welding image and adjusting the phase of all ultrasonic transducers within the ultrasonic transducer unit to achieve in-phase sound wave output includes:

[0024] Analyze the real-time welding trajectory based on the real-time welding images;

[0025] The real-time weld position is determined based on the real-time welding trajectory.

[0026] The start / stop status of the first sparse ultrasonic transducer array and the second sparse ultrasonic transducer array in the ultrasonic transducer unit is controlled according to the real-time weld position, and the phase of all ultrasonic transducers in the ultrasonic transducer unit is adjusted to achieve in-phase sound wave output.

[0027] The embodiments of this application include at least the following beneficial effects: This application provides a visual tracking array acoustic wave superposition laser welding platform. This scheme sets up a welding processing platform, an ultrasonic transducer unit, an imaging device connecting component, an imaging device, and a control unit. The ultrasonic transducer unit is set inside the welding processing platform according to a preset installation rule. One end of the camera connecting component is fixed to the side of the welding processing platform, and the imaging device is fixed to the other end of the imaging device connecting component. The height of the imaging device above the welding processing platform is adjusted by the imaging device connecting component. Then, during the welding process, the control unit controls the working excitation mode of the ultrasonic transducer unit according to the external control signal. The imaging device acquires the real-time welding image of the object to be welded in the welding processing platform. The control unit controls the start and stop state of the ultrasonic transducer unit according to the real-time welding image and adjusts the phase of all ultrasonic transducers in the ultrasonic transducer unit to achieve in-phase output of sound waves. Thus, the energy peak on the welding path can be stably controlled by the principle of constructive interference of sound waves, thereby effectively improving the welding quality and welding stability. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the visual tracking array acoustic wave superposition laser welding platform provided in the embodiments of this application;

[0029] Figure 2 This is a schematic diagram of the ultrasonic transducer arrangement provided in the embodiments of this application;

[0030] Figure 3 This is a schematic diagram of ultrasonic operation provided in an embodiment of this application;

[0031] Figure 4 This is a schematic diagram illustrating the working principle of the visual tracking array acoustic wave superposition laser welding platform provided in the embodiments of this application. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit it. In the following description, when referring to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with those of this application; they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this application as detailed in the appended claims.

[0033] It is understood that the terms “first,” “second,” etc., used in this application may be used herein to describe various concepts, but unless otherwise stated, these concepts are not limited by these terms. These terms are only used to distinguish one concept from another. For example, without departing from the scope of the embodiments of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the words “if,” “when,” or “in response to a determination” as used herein may be interpreted as “when…” or “when…” or “in response to a determination.”

[0034] As used in this application, the terms "at least one", "multiple", "each", "any", etc., "at least one" includes one, two or more, "multiple" includes two or more, "each" refers to each of the corresponding multiples, and "any" refers to any one of the multiples.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0036] In the field of laser welding, the interaction between the laser spot and the workpiece directly determines the welding quality. Ultrasonic-assisted welding technology, by introducing high-frequency mechanical vibration, can significantly improve the fluidity of the molten pool, refine the grain structure, and reduce porosity defects, making it an important means to improve welding performance. However, existing ultrasonic-assisted laser welding technologies are limited by the design of external oscillators, requiring complex fixtures and coupling devices to transmit vibration energy. This results in low system integration, significant energy loss, and difficulty in dynamically matching the real-time movement trajectory of the laser spot, severely limiting its application potential in high-speed, high-response scenarios. Especially for internal oscillator schemes, existing technologies mostly adopt uniform arrangement or simple double-row layout, which cannot achieve stable control of the energy peak along the welding path through the principle of constructive acoustic interference, leading to significant attenuation of weld depth in the weld end region.

[0037] The limitations of existing technologies stem from two core contradictions: First, the ease of installation of external transducers conflicts with the requirements of system integration, resulting in long energy transmission paths and necessitating that the ultrasonic transducers be tightly fitted beneath the processing table. Second, they cannot adapt to dynamic processing requirements, lacking real-time sensing capabilities for beam movement, material properties, and environmental changes. Furthermore, existing transducer arrangement strategies struggle to utilize the acoustic wave superposition effect: on the one hand, the sound field intensity of fixed-position transducers attenuates with distance, leading to energy differences of up to 35% between the center and edge of the weld; on the other hand, single vibration parameters (such as fixed frequency or amplitude) or simple dual-mode switching cannot dynamically adjust the transducer configuration according to the weld position to match the differentiated process requirements of high-precision welding of thin plates (requiring dense high-frequency vibration) and deep-penetration welding of thick plates (requiring wide-amplitude acoustic field superposition).

[0038] Existing ultrasonic-assisted laser welding platforms generally employ a method of mounting ultrasonic transducers at the bottom of the platform, transmitting ultrasonic energy through direct contact with the processing table. However, this design still has several shortcomings: First, due to the external placement of the ultrasonic device, the overall platform structure is bulky and the system complex, not only occupying a large space but also prone to errors or assembly difficulties during platform construction; second, most current equipment only supports fixing the ultrasonic transducer in a single position or simply following its movement along the welding path. Even with an internal design, it is limited to overall start / stop or basic zone control, failing to achieve phase synchronization and energy vector superposition of multiple transducer groups, thus affecting welding quality and process stability.

[0039] In view of this, this application provides a visual tracking array acoustic wave superposition laser welding platform, which can effectively improve welding quality and welding stability.

[0040] The embodiments of this application will be described in detail below with reference to the accompanying drawings:

[0041] Reference Figure 1 This application provides a visual tracking array acoustic wave superposition laser welding platform. The welding platform includes a welding processing platform 110, an ultrasonic transducer unit 120, an imaging device connection component, an imaging device 130, and a control unit 150. The ultrasonic transducer unit 120 is installed inside the welding processing platform 110 according to a preset installation rule; one end of the camera connection component is fixed to the side of the welding processing platform; the imaging device 130 is fixed to the other end of the imaging device connection component, and its height above the welding processing platform is adjusted via the imaging device connection component; the control unit 150 is disposed on the side of the welding processing platform. During operation, after the operator inputs the external control signal corresponding to the working excitation mode in the visual interface, the control unit controls the working excitation mode of the ultrasonic transducer unit according to the external control signal, thereby forming a corresponding ultrasonic field on the welding platform. At the same time, after acquiring real-time welding images of the workpiece to be welded on the welding platform through the imaging device, the control unit controls the start and stop status of the ultrasonic transducer unit according to the real-time welding images, and adjusts the phase of all ultrasonic transducers in the ultrasonic transducer unit to achieve in-phase output of sound waves. Thus, the energy peak value on the welding path can be stably controlled through the principle of constructive interference of sound waves, thereby effectively improving welding quality and welding stability.

[0042] It is understood that the welding platform includes a welding frame and a welding plate. The welding plate is set above the welding frame, and a connecting joint is provided on the lower surface of the welding plate. The ultrasonic transducer unit is fixed to the bottom of the welding plate through the connecting joint, thereby ensuring that the ultrasonic energy can be effectively covered to the welding material area during the welding process.

[0043] like Figure 1 and Figure 2 As shown, the ultrasonic transducer unit includes a first dense ultrasonic transducer array 121, a second dense ultrasonic transducer array 122, a first sparse ultrasonic transducer array 123, and a second sparse ultrasonic transducer array 124. The first dense ultrasonic transducer array 121 and the second dense ultrasonic transducer array 122 are symmetrically arranged about a central axis below the welding plate. The first sparse ultrasonic transducer array 123 and the second sparse ultrasonic transducer array 124 are symmetrically arranged about a central axis below the welding plate, with the first sparse ultrasonic transducer array 123 located outside the first dense ultrasonic transducer array 121 and the second sparse ultrasonic transducer array 124 located outside the second dense ultrasonic transducer array 122. Specifically, the number of ultrasonic transducers in the first and second dense ultrasonic transducer columns is greater than the number of ultrasonic transducers in the first and second sparse ultrasonic transducer columns. The ultrasonic transducers in the first, second, first, and second dense, sparse, and second sparse ultrasonic transducer columns are all electrically connected in parallel, ensuring stable and reliable operation of each excitation transducer. In this embodiment, the ultrasonic transducers in the four columns are gradient-distributed, with the middle two columns densely arranged and the outer two columns sparsely arranged. Furthermore, the four columns are independently controlled, thereby stabilizing the energy peak value in the welding area through the principle of acoustic wave superposition.

[0044] It is understandable that, such as Figure 3 As shown, in the four rows of ultrasonic transducers, two densely arranged rows are located at the center of the structure, corresponding to the weld area, and continuously emit ultrasonic signals with consistent phase as the main excitation source. The sparsely arranged transducers on both sides are arranged at a larger spacing; although fewer in number, by adjusting their excitation phase, they can precisely compensate for fluctuations in the central region, achieving dynamic enhancement of the sound pressure peak at the central weld. This embodiment is based on the principle of ultrasonic interference, utilizing the coherence characteristics of ultrasonic waves in spatial propagation to adjust the phase angle of different rows of transducers, so that the sound waves emitted by each transducer form a stable enhanced interference region at the weld center, and always maintain the frequency at the maximum interference superposition state. In actual operation, the start / stop and phase of the sparsely arranged rows of transducers are adjusted in real time by the control unit, forming a phase-coupled array with the densely arranged rows, compensating for sound pressure shifts caused by welding movement, material changes, etc., ensuring that the sound energy density is always concentrated at the center of the weld trajectory. Specifically, Figure 3 The visualization of the isobaric contours, represented by different grayscale regions, reveals the continuous high-intensity sound pressure peak band formed by the welding platform in the central welding region of this embodiment. The central sound pressure peak is stable and symmetrical, indicating that the optimal state of frequency interference can be effectively maintained through the synergistic effect of sparse and dense columns, which is significantly better than the existing schemes of four uniformly arranged columns or the independent operation of dense columns.

[0045] It is understandable that, such as Figure 1 As shown, the imaging device connection component includes a first connecting plate 141, a second connecting plate 142, and a third connecting plate 143. The first connecting plate 141 is perpendicular to the surface of the welding processing platform 110, and one end of the first connecting plate 141 is fixed to the side of the welding processing platform 110, providing an overall support structure. The second connecting plate 142 is parallel to the surface of the welding processing platform 110, and one end of the second connecting plate 142 is connected to the other end of the first connecting plate 141. The third connecting plate 143 is perpendicular to the surface of the welding processing platform 110, and one end of the third connecting plate 143 is movably connected to the second connecting plate 142, allowing the third connecting plate 143 to move laterally on the second connecting plate 142. The imaging device 130 is movably connected to the third connecting plate 143, thereby enabling longitudinal adjustment of the imaging device. Combined with the connection method of the second and third connecting plates, this embodiment can also indirectly adjust the lateral position of the imaging device through the third connecting plate. Specifically, the imaging device connection component of this embodiment can ensure that the imaging device can be accurately positioned and its viewing angle adjusted according to the welding path. In this embodiment, the second connecting plate may also be provided with a waist hole, and one end of the third connecting plate is movably connected to the waist hole on the second connecting plate, so that the third connecting plate maintains the stability of the imaging device when it moves laterally on the second connecting plate.

[0046] It is understood that the control unit in this embodiment is also equipped with four function buttons: an emergency stop button, a start button, a stop button, and a reset button, used to implement basic system control operations. The emergency stop button is used to quickly shut down the system in an emergency to ensure the safety of personnel and equipment; the start button is used to start the system and enter the working state; the stop button is used for pause control during normal operation; and the reset button is used to restore the system to its initial state after troubleshooting. The synchronization module of the control console sets wavelength parameters via the touchscreen and automatically calculates the oscillator phase compensation value. When the system detects an abnormality or malfunction, the warning light above the control console will automatically illuminate and issue an audible and visual alarm to prompt the operator to handle the situation promptly. After the fault is resolved, the system can be restarted using the reset button to restore normal operation.

[0047] In the embodiments of this application, such as Figure 2 As shown, the lateral coordinates of the first dense ultrasonic transducer array, the second dense ultrasonic transducer array, the first sparse ultrasonic transducer array, and the second sparse ultrasonic transducer array on the welding platform are defined as x, ... D1 x D2 x S1 and x S2 The horizontal coordinate (x) of the axis containing the welding center point. C =0. Therefore, the horizontal distance from the oscillator array to the center point is as follows:

[0048] d S=|x S1 |,d D =|x D1 |

[0049] In this embodiment, to achieve the best coherent superposition effect of sound waves, the above columns satisfy the following proportional relationship:

[0050] d S >d D ;

[0051] In a preferred embodiment, the horizontal distances from the first sparse ultrasonic transducer array and the second sparse ultrasonic transducer array to the central axis satisfy the following relationship with the horizontal distances from the first dense ultrasonic transducer array and the second dense ultrasonic transducer array to the central axis:

[0052] d S ≥αd D ;

[0053] Where α represents a constant and α∈[1.2,2]; d S d represents the horizontal distance from the first or second sparse ultrasonic transducer array to the central axis. D This indicates the horizontal distance from the first or second dense ultrasonic transducer array to the central axis.

[0054] This embodiment controls the start-stop timing and emission phase of the sparse ultrasonic transducer array, enabling the dominant frequency ultrasonic waves emitted by the dense ultrasonic transducer array to form continuous peak interference at the welding point. Based on the principle of coherent superposition, the wavelength λ and array spacing d satisfy the following:

[0055] d = nλ + Δd;

[0056] In the formula, n represents an integer, and Δd represents the phase compensation fine-tuning amount. The wavefront can be superimposed and enhanced to maximize the peak sound pressure at the welding point.

[0057] It is understood that in this embodiment, each oscillator array performs phase compensation on each excitation oscillator in the ultrasonic oscillator unit through a preset phase compensation mechanism to optimize the sound field interference effect. Assume the horizontal distance d between the i-th oscillator and the weld center is... i The formula for calculating the preset phase compensation amount is as follows:

[0058]

[0059] In the formula, This indicates the preset phase compensation amount. λ represents the wavelength of the sound wave, v represents the speed of sound, f represents the excitation frequency, and π represents pi.

[0060] The compensation method in this embodiment finely adjusts the initial phase of the wave generated by oscillators at different distances, thereby achieving phase synchronization and spatial coordinated propagation of the sound wave in the target welding area, which significantly improves the interference efficiency and peak superposition capability of the sound wave.

[0061] Specifically, the formula for calculating the total sound pressure at the weld center is as follows:

[0062]

[0063] In the formula, A i Let ω be the sound pressure amplitude of the i-th oscillator, and ω = 2πf be the angular frequency. Let r be the wave number. i The distance from the oscillator to the center of the weld. This is the preset phase of the i-th oscillator.

[0064] Since the oscillator arrangement is symmetrical about the center, and the compensation phase satisfies the following formula:

[0065]

[0066] Then we have:

[0067]

[0068] At this point, all the waveforms of the oscillators are perfectly phase-aligned and superimposed at the same frequency. The sound pressure at the center of the weld can be calculated using the following formula:

[0069] P total =N×A×cos(ωt)=P max ;

[0070] At this point, the theoretically maximum superimposed sound pressure is reached, resulting in optimal sound field stability and concentration. Therefore, under the premise of satisfying the above structural proportions and compensation mechanisms, this embodiment not only achieves enhanced coupling in the spatial sound pressure distribution but also ensures that the interference peak value is always located in the central region of the weld in the time domain, thereby effectively improving welding efficiency and weld quality.

[0071] It is understandable that, in order to achieve stable coherent superposition interference of sound waves in the center region of the weld, the operating frequency of the control unit satisfies the following constraint condition, taking steel as an example:

[0072]

[0073] The corresponding wave number is as follows:

[0074]

[0075] Specifically, this embodiment aims to achieve a high-intensity, stable, and coherent ultrasonic interference field in the weld center region through the synergistic effect of multiple transducers. A theoretical model is used to analyze and design the sound pressure contribution of a single transducer and the array enhancement effect. Each ultrasonic transducer is simplified as an equivalent surface sound source; in the axial near-field region, its sound pressure amplitude can be estimated using the following formula:

[0076]

[0077] In the formula, P1 is the sound pressure amplitude (in Pa) generated by a single oscillator at the target point (the center of the weld); ρ is the density of the workpiece material (e.g., 7850 kg / m³ for steel). 3 c is the speed of sound propagation in the workpiece (approximately 5900 m / s in steel); v is the vibration velocity of the vibrating surface of the oscillator (unit: m / s); a is the effective radiation radius of the oscillator (unit: m); r is the distance between the oscillator and the center of the weld (unit: m).

[0078] In this embodiment, the number of transducers arranged in the first dense ultrasonic transducer column and the second dense ultrasonic transducer column can be set to 11, and the number of transducers arranged in the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column can be 5 per column, for a total of 32 transducers. When all transducers are in the active state and output in the same frequency and phase, sound wave superposition is formed at the center of the weld, and the theoretical maximum sound pressure amplitude is as follows:

[0079] P 总 =N 激活 ×P0;

[0080] In the formula, P0 is the output sound pressure level of a single oscillator, and N... 激活 This represents the number of oscillators currently involved in the interference.

[0081] Preferably, to ensure that the sound waves form a stable coherent interference effect at the center of the weld, the emission signals of each activated oscillator are uniformly phase-adjusted by a phase controller, so that all activated oscillators satisfy the following formula:

[0082]

[0083] In the formula, and These represent the emission phases of the i-th and j-th oscillators, respectively. By maintaining a consistent initial phase, constructive interference of sound waves is ensured within the welding area, thereby enhancing sound pressure and improving weld penetration and uniformity.

[0084] It is understood that the ultrasonic transducer in this embodiment has multiple excitation modes, including a high-frequency small amplitude mode and a low-frequency large amplitude mode, which are suitable for different material thicknesses and welding depth requirements, thereby improving the process adaptability of the welding platform.

[0085] In this embodiment, a vision recognition system is integrated into the welding platform. A front-mounted industrial camera is used as an imaging device to acquire laser spot image information in real time and extract the weld center coordinates (x, y). t y t By combining the spatial layout of the oscillator, a mapping function between the position of the light spot and the arrangement of the oscillator can be established, thereby enabling automatic trimming of the oscillator excitation range and local start-stop control.

[0086] It is understood that the control unit in this embodiment can estimate the sound wave propagation time by combining the path delay model, and adjust the excitation delay and phase compensation of each oscillator in real time. The calculation formula is as follows:

[0087]

[0088] In the formula, Δt o The propagation time delay of the i-th sub-sound wave to the center of the weld is given by This is the corresponding phase compensation value.

[0089] This embodiment uses the compensation control strategy to ensure that the sound waves of all oscillators are synchronously superimposed at the light spot, forming a dynamically controllable sound pressure peak area.

[0090] It is understandable that, in order to accurately model the spatial distribution of the sound pressure field, this embodiment adopts a multi-point phased array superposition model. The variation of the sound pressure at the weld center with time t and spatial coordinates (x, y) can be expressed as follows:

[0091]

[0092] In the formula, A i Let i be the amplitude of the i-th oscillator; It is the spatial distance between the center of the weld and the oscillator; It is the wave number; t represents the phase compensation amount; t represents the time; (x, y) represents the coordinates of the weld center.

[0093] That is, the control unit needs to apply pressure to each oscillator. To achieve in-phase superposition of all sound waves at the center of the weld, and to output maximum sound pressure:

[0094]

[0095] Compared to using only two densely arranged columns, the four-column array configuration in this embodiment, combined with a phase compensation strategy, can dynamically start and stop sparse array elements when the laser trajectory changes, thereby maintaining the resonant frequency of the standing wave cavity.

[0096]

[0097] In the formula, f nLet be the standing wave frequency of the nth mode, v be the speed of sound in the medium, and d be the frequency of the nth mode. S The propagation distance from the sparse oscillator to the center point.

[0098] This embodiment adjusts the effective array length d. s By controlling the start and stop timing of the array elements, the system can always operate in a stable mode, achieving frequency locking of the acoustic field in the center region of the weld:

[0099] f≈f n , making

[0100] This embodiment continuously iterates and adjusts the start-stop state and excitation parameters of the oscillator based on the dynamic changes of the light spot trajectory, thereby achieving precise tracking and adaptive control of the sound field throughout the welding process, significantly improving welding quality and platform response capability.

[0101] It is understood that in this embodiment, when controlling the start-stop state of the ultrasonic transducer unit and adjusting the phase of all ultrasonic transducers in the ultrasonic transducer unit, the real-time welding trajectory can be analyzed based on the real-time welding image, the real-time weld position can be determined based on the real-time welding trajectory, and then the start-stop state of the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column in the ultrasonic transducer unit can be controlled based on the real-time weld position, and the phase of all ultrasonic transducers in the ultrasonic transducer unit can be adjusted to achieve in-phase sound wave output.

[0102] As described above, the welding platform of this embodiment integrates four rows of gradient-arranged ultrasonic transducers into the processing platform. Combined with acoustic wave superposition control, welding speed synchronization, and multi-mode vibration excitation, it constructs a compact, uniformly distributed dual-mode laser welding processing platform. Simultaneously, by integrating a visual recognition system and a phase synchronization algorithm, precise spatial control of ultrasonic excitation is achieved. This welding platform significantly improves ultrasonic energy utilization and welding quality consistency, effectively expanding the application range of the equipment in high-precision, long-weld conditions.

[0103] In some embodiments, the welding process of the welding platform in this embodiment during operation, such as... Figure 4 As shown, in this embodiment, after analyzing the current welding position information based on the information obtained by the imaging device, the selected oscillator group is activated. After synchronizing the phases of all selected oscillators, the excitation mode is selected and the welding process is carried out. Then, it is determined whether the current welding process has completed the entire welding path. If not, the next position information is read and the control logic is executed repeatedly. If it has been completed, all ultrasonic oscillators are turned off and the process data is saved.

[0104] Therefore, it can be seen that the working process of this embodiment, by introducing a visual recognition system to monitor the welding trajectory in real time, enables the ultrasonic transducer to start and stop as needed and move synchronously along the path during the processing, which significantly improves the dynamic response capability and energy coupling efficiency of laser welding.

[0105] In summary, the welding platform and its working process provided in this application have the following beneficial effects:

[0106] First, by embedding the ultrasonic transducer inside the processing platform, the path of ultrasonic waves from the transducer to the welding area is effectively shortened, reducing the complexity of the mechanical structure, avoiding energy loss and system assembly errors caused by external installation, significantly improving system integration and energy utilization, and further optimizing energy transfer efficiency through the acoustic interference design of four rows of transducers.

[0107] Secondly, by controlling the start and stop of the ultrasonic transducer based on the welding speed and combining it with the real-time acquisition of laser spot position information by the visual recognition system, the ultrasonic excitation and laser welding process are dynamically synchronized. This ensures that a stable auxiliary excitation effect can be maintained under different processing rhythms, improving welding consistency and molten pool control capabilities. Combined with phase synchronization technology, the dynamic response accuracy is significantly improved.

[0108] Third, by using a four-column gradient ultrasonic transducer array (dense in the middle and sparse on the outside), the uniformity of the weld sound field is significantly improved through the superposition effect of sound waves, effectively solving the problem of end penetration attenuation.

[0109] Fourth, by providing two ultrasonic excitation modes—high-frequency small amplitude and low-frequency large amplitude—it is suitable for different processing needs such as precision welding of thin plates and deep penetration welding of thick plates. In terms of process flexibility, it is superior to the existing fixed excitation method, expanding the applicability of the platform. Furthermore, the acoustic field control strategy enhances its adaptability to materials of different thicknesses.

[0110] Fifth, the welding platform in this embodiment has a compact overall structure and occupies little space, which is conducive to modular equipment layout and industrial system integration. At the same time, it reduces the dependence on external support structures. The contactless recognition method of the vision system further reduces the need for additional positioning devices, which helps to improve the adaptability of the equipment in automated production lines. The high-density oscillator layout greatly improves space utilization efficiency.

[0111] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0112] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0113] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0114] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0115] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0116] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of the units described above is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0117] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0118] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A visual tracking array acoustic wave superposition laser welding platform, characterized in that, The welding platform includes: Welding processing platform; An ultrasonic transducer unit is installed inside the welding processing platform according to a preset installation rule. An imaging device connecting component, one end of which is fixed to the side of the welding processing platform; An imaging device is fixed to the other end of an imaging device connecting component, and its height above the welding processing platform is adjusted via the imaging device connecting component; the imaging device is used to acquire real-time welding images of the object to be welded within the welding processing platform. The control unit is located on the side of the welding processing platform. It is used to control the working excitation mode of the ultrasonic transducer unit according to the external control signal, control the start and stop status of the ultrasonic transducer unit according to the real-time welding image, and adjust the phase of all ultrasonic transducers in the ultrasonic transducer unit to achieve in-phase sound wave output. The welding platform includes a welding frame and a welding plate. The welding plate is disposed above the welding frame, and a connecting joint is provided on the lower surface of the welding plate. The ultrasonic transducer unit is fixed to the lower part of the welding plate through the connecting joint. The ultrasonic transducer unit includes a first dense ultrasonic transducer array, a second dense ultrasonic transducer array, a first sparse ultrasonic transducer array, and a second sparse ultrasonic transducer array; the first dense ultrasonic transducer array and the second dense ultrasonic transducer array are symmetrically arranged about a central axis below the welding plate; the first sparse ultrasonic transducer array and the second sparse ultrasonic transducer array are symmetrically arranged about a central axis below the welding plate, with the first sparse ultrasonic transducer array located outside the first dense ultrasonic transducer array and the second sparse ultrasonic transducer array located outside the second dense ultrasonic transducer array. The horizontal distances from the first sparse ultrasonic transducer array and the second sparse ultrasonic transducer array to the central axis satisfy the following relationship with the horizontal distances from the first dense ultrasonic transducer array and the second dense ultrasonic transducer array to the central axis: ； in, Describing a constant and ; This represents the horizontal distance from the first sparse ultrasonic transducer array or the second sparse ultrasonic transducer array to the central axis; This represents the horizontal distance from the first or second dense ultrasonic transducer array to the central axis. During the welding platform operation, the transducers in the first and second dense ultrasonic transducer columns serve as the main excitation sources and continuously emit ultrasonic signals with consistent phase. The control unit is used to adjust the start-up, stop-start, and phase of the transducers in the first and second sparse ultrasonic transducer columns in real time to compensate for the fluctuation changes of ultrasonic waves generated by the transducers in the first and second dense ultrasonic transducer columns in the middle region of the weld, thereby achieving dynamic enhancement of the sound pressure peak value of the central weld.

2. The welding platform according to claim 1, characterized in that, The number of ultrasonic transducers in the first dense ultrasonic transducer column and the second dense ultrasonic transducer column is greater than the number of ultrasonic transducers in the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column; the ultrasonic transducers in the first dense ultrasonic transducer column, the second dense ultrasonic transducer column, the first sparse ultrasonic transducer column and the second sparse ultrasonic transducer column are all electrically connected in parallel.

3. The welding platform according to claim 1, characterized in that, The imaging device connection component includes a first connecting plate, a second connecting plate, and a third connecting plate; the first connecting plate is perpendicular to the surface of the welding processing platform and one end of the first connecting plate is fixed to the side of the welding processing platform; the second connecting plate is parallel to the surface of the welding processing platform and one end of the second connecting plate is connected to the other end of the first connecting plate; the third connecting plate is perpendicular to the surface of the welding processing platform and one end of the third connecting plate is movably connected to the second connecting plate; the imaging device is movably connected to the third connecting plate.

4. The welding platform according to claim 1, characterized in that, Phase compensation is performed on each excitation oscillator in the ultrasonic transducer unit through a preset phase compensation mechanism; wherein, the calculation formula for the preset phase compensation amount in the preset phase compensation mechanism is as follows: ； In the formula, This indicates the preset phase compensation amount. Indicates the wavelength of the sound wave. Indicates the speed of sound. Indicates the excitation frequency. It represents pi (π).

5. The welding platform according to claim 1, characterized in that, The operating excitation modes include high-frequency small-amplitude mode or low-frequency large-amplitude mode.

6. The welding platform according to claim 3, characterized in that, The second connecting plate is provided with a waist hole, and one end of the third connecting plate is movably connected to the waist hole on the second connecting plate.

7. The welding platform according to claim 1, characterized in that, The step of controlling the start / stop state of the ultrasonic transducer unit based on the real-time welding image and adjusting the phase of all ultrasonic transducers within the ultrasonic transducer unit to achieve in-phase sound wave output includes: Analyze the real-time welding trajectory based on the real-time welding images; The real-time weld position is determined based on the real-time welding trajectory. The start / stop status of the first sparse ultrasonic transducer array and the second sparse ultrasonic transducer array in the ultrasonic transducer unit is controlled according to the real-time weld position, and the phase of all ultrasonic transducers in the ultrasonic transducer unit is adjusted to achieve in-phase sound wave output.

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