Welding control method and related device

Abstract

The embodiment of the invention discloses a welding control method and a related device. The welding control method and the related device are used for improving the welding rate. The method is applied to an industrial personal computer of the welding system, the welding system further comprises a plurality of laser units and an image shooting unit, and the method comprises the steps that an appearance image, shot by the image shooting unit, of a to-be-welded target object is obtained, and an image area corresponding to each laser unit on the appearance image is determined; determining the average pixel value of each pixel point in the same image area as the pixel value of the image area; classifying the image areas of which the pixel values are in the same preset pixel value range into the same control subarea, and taking the laser units corresponding to the image areas in the control subarea as the laser units corresponding to the control subarea; and all the laser units corresponding to the control subareas are controlled to output laser according to the output power values corresponding to the control subareas so that the to-be-welded target object can be welded.

Description

TECHNICAL FIELD

[0001] Embodiments of the present application relate to the field of welding, and particularly relate to a welding control method and related device. BACKGROUND

[0002] In order to weld a circuit board to make the circuit board complete in function, the circuit board needs to be welded, and laser welding has been widely used in the heating welding of the circuit board. The existing scheme is to provide a surface laser emitter, an infrared image shooting unit and a closed cavity, the surface laser emitter is placed in the closed cavity, the infrared image shooting unit detects the temperature of the circuit board, when the highest temperature of the circuit board detected by the infrared image shooting unit does not reach a target temperature, the surface laser emitter starts to emit laser with adjusted power, the emitting end of the surface laser emitter is not directly aimed at the circuit board, but at the air in the closed cavity, the laser emitted by the surface laser emitter heats the air in the closed cavity, and the hot air transmits heat to the circuit board to realize the heating welding of the circuit board.

[0003] However, in the existing scheme, there are many devices with different heat absorption capacities on the circuit board, the devices with strong heat absorption capacity rise in temperature quickly and are likely to become the devices with the highest temperature on the circuit board, and the devices with weak heat absorption capacity rise in temperature slowly. Since the highest temperature of the circuit board is used for adjustment, and the hot air transmits heat to all devices at the same time, when the temperature of the device with strong heat absorption capacity reaches the target temperature, the power of the surface laser emitter is maintained at a very small value, and the transmitted energy is very small, while the device with weak heat absorption capacity has not reached the target temperature, which leads to poor welding. SUMMARY

[0004] Embodiments of the present application provide a welding control method and related device for improving the welding rate.

[0005] The first aspect of the embodiments of the present application provides a welding control method applied to an industrial computer of a welding system, the welding system further comprising a plurality of laser units and an image shooting unit, and the method comprises:

[0006] An appearance image of a target object to be welded shot by the image shooting unit is acquired, and an image region corresponding to each of the laser units in the appearance image is determined respectively;

[0007] An average pixel value of each pixel point in the same image region is determined as a pixel value of the image region;

[0008] Image regions with pixel values in the same preset pixel value range are classified into the same control partition, and the laser units corresponding to the image regions in the control partition are taken as the laser units corresponding to the control partition;

[0009] Each laser unit corresponding to the control zone is controlled to output laser according to its respective output power value to weld the target object.

[0010] Optionally, controlling each laser unit corresponding to the control partition to output laser light according to the output power value corresponding to each control partition includes:

[0011] The average pixel value of each image region within the control partition is determined as the partition pixel value of the control partition;

[0012] The laser unit corresponding to the control partition is controlled to output laser light multiple times, and in the nth control process, the laser unit corresponding to the control partition is controlled to output laser light according to the following steps, where n is an integer greater than or equal to 1:

[0013] Based on the current temperature of the target object after being irradiated and welded by the laser, the current object temperature value corresponding to each laser unit in the welding system is determined, and the average value of the current object temperature values ​​corresponding to each laser unit in the same control zone is determined as the current temperature value of the control zone.

[0014] The current output power value of the control partition is calculated based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value.

[0015] The laser unit corresponding to each image region within the control partition is controlled to output laser light based on the current output power value of the control partition.

[0016] Optionally, after controlling the laser units corresponding to each image region within the control partition to output laser light according to the current output power value of the control partition, the method further includes:

[0017] For each of the control zones, if the current temperature value of the control zone reaches the target temperature value, the output power of the laser unit corresponding to each image region in the control zone is adjusted according to the current output power value to ensure that the current temperature value of the control zone is within a preset temperature range, which includes the target temperature value.

[0018] If the current temperature value of the control zone does not reach the target temperature value, the laser unit corresponding to the control zone is controlled to output laser at the maximum value among n output power values ​​until the most recent current temperature value of the control zone reaches the target temperature value.

[0019] If the current temperature value of all the control zones reaches the target temperature value, then after maintaining the output power of the laser unit corresponding to each image area in all the control zones for a preset maintenance period, control all the laser units to stop working.

[0020] Optionally, determining the current object temperature value corresponding to each laser unit in the welding system based on the current object temperature after laser irradiation and welding includes:

[0021] Based on the current temperature of the target object after being irradiated and welded by the laser, the pixel temperature value of each pixel in the image region corresponding to each laser unit is determined.

[0022] For each of the image regions, the average pixel temperature value of each pixel in the image region is determined as the current object temperature value of the corresponding laser unit.

[0023] Optionally, calculating the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value includes:

[0024] When n is 1, the current temperature value of the partition is the temperature value of the nth partition. Then, the power increment is calculated based on the temperature value of the nth partition, the pixel value of the partition, and the preset target temperature value.

[0025] The power increment is determined as the current output power value.

[0026] Optionally, calculating the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value includes:

[0027] When n is 2, the current temperature value of the partition is the nth partition temperature value, then the (n-1)th partition temperature value and the (n-1)th output power value of the control partition are obtained;

[0028] The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the partition pixel value, and the preset target temperature value.

[0029] The sum of the power increment and the (n-1)th output power value is determined as the current output power value, and the current output power value is the nth output power value.

[0030] Optionally, calculating the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value includes:

[0031] When n is an integer greater than or equal to 3, the current temperature value of the partition is the nth partition temperature value, then the (n-1)th partition temperature value, the (n-2)th partition temperature value, and the (n-1)th output power value of the control partition are obtained;

[0032] The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the (n-2)th partition temperature value, the partition pixel value, and the preset target temperature value.

[0033] The sum of the power increment and the (n-1)th output power value is determined as the current output power value, and the current output power value is the nth output power value.

[0034] A second aspect of this application provides an industrial control computer, the industrial control computer comprising:

[0035] The acquisition unit is used to acquire the appearance image of the target object to be welded captured by the image capturing unit, and to determine the image area corresponding to each laser unit on the appearance image.

[0036] A determining unit is configured to determine the average pixel value of each pixel point in the same image region as the pixel value of the image region;

[0037] The classification unit is used to classify image regions whose pixel values ​​are within the same preset pixel value range into the same control partition, and to use the laser unit corresponding to each image region in the control partition as the laser unit corresponding to the control partition.

[0038] The control unit is used to control each laser unit corresponding to the control zone to output laser according to the output power value corresponding to the control zone, so as to weld the target object to be welded.

[0039] A third aspect of this application provides an industrial control computer, including:

[0040] Central processing unit, memory, and input / output interfaces;

[0041] The memory is either a short-term storage memory or a persistent storage memory;

[0042] The central processing unit is configured to communicate with the memory and execute instructions in the memory to perform the aforementioned method.

[0043] A fourth aspect of this application provides a computer-readable storage medium including instructions that, when executed on a computer, cause the computer to perform the aforementioned method.

[0044] As can be seen from the above technical solutions, the embodiments of this application have the following advantages:

[0045] First, the image capture unit acquires an image of the target object to be welded, and the corresponding image area for each laser unit on the image is determined. Then, the average pixel value of each pixel within the same image area is determined as the pixel value of that image area. Image areas with pixel values ​​within the same preset pixel value range are grouped into the same control zone, and the laser units corresponding to each image area within that control zone are designated as the laser units corresponding to that control zone. Finally, each laser unit in the control zone outputs laser light according to its corresponding output power value to weld the target object. Heat absorption capacity is related to the color of the device, and is determined by the pixel values ​​(grayscale or RGB) reflecting the device's color. One laser unit corresponds to one image area, and the color of the device that each laser unit can illuminate corresponds to the pixel value of that image area. The pixel value range corresponds to the color range, or in other words, the heat absorption capacity range. Devices with heat absorption capacity within the same range are defined as the same control zone. Laser units within the same control zone are controlled uniformly, while laser units in different control zones are not controlled uniformly. Simply put, the components are first divided according to their heat absorption capacity. The laser units corresponding to the components with strong heat absorption capacity are controlled uniformly, and the laser units corresponding to the components with weak heat absorption capacity are controlled uniformly. In this way, the temperature of the components with strong and weak heat absorption capacity can be adjusted independently. This ensures that both components can reach the target welding temperature and achieve good welding. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of an embodiment of a welding control method disclosed in this application;

[0047] Figure 2 This is a schematic diagram of the welding system disclosed in this application;

[0048] Figure 3 This is a schematic diagram of another embodiment of a welding control method disclosed in this application;

[0049] Figure 4 This is a schematic diagram of the circuit board partitioning disclosed in this application;

[0050] Figure 5 This is a schematic diagram of multiple sections (laser units) of the area laser emitter disclosed in this application;

[0051] Figure 6This is a schematic diagram of an embodiment of an industrial control computer disclosed in this application;

[0052] Figure 7 This is a schematic diagram of another embodiment of an industrial control computer disclosed in this application. Detailed Implementation

[0053] The present application will be further described in detail below with reference to the accompanying drawings.

[0054] This application provides a welding control method and related apparatus for improving the welding rate.

[0055] For circuit boards to function properly, they require pre-soldering to ensure reliable operation. One existing solution uses point lasers for sequential point-to-point soldering, but this is inefficient and time-consuming. Another more common solution involves a surface laser emitter, an infrared imaging unit, and a sealed cavity. The surface laser emitter is placed inside the cavity, and the infrared imaging unit detects the circuit board's temperature. When the highest temperature detected by the infrared imaging unit is below the target temperature, the surface laser emitter activates, adjusting its power to emit laser light. The emitted laser heats the air in the sealed cavity, which then transfers heat to the circuit board, achieving the heating and soldering process. However, in this existing solution, the circuit board often contains many components with varying heat absorption capacities. Components with high heat absorption capacity rise in temperature quickly and tend to become the hottest components on the circuit board, while components with low heat absorption capacity tend to rise in temperature more slowly. If the highest temperature of the circuit board is used for adjustment, when the temperature of the component with strong heat absorption capacity reaches the target temperature, the power of the surface laser emitter remains at a very low value, and very little energy is transferred. At this time, the component with weak heat absorption capacity has not yet reached the target temperature, which leads to poor soldering. If the average or lowest temperature of the circuit board is used for adjustment, the temperature of the component with strong heat absorption capacity can easily become too high, leading to damage. To solve the above problems, this application provides a soldering control method and related apparatus, which distinguishes different control zones according to different heat absorption capacities, and each control zone is controlled independently. In this way, both components with strong and weak heat absorption capacities can reach the target soldering temperature, resulting in good soldering.

[0056] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0057] The terms "first," "second," "third," "fourth," etc., used in the specification, claims, and accompanying drawings of this invention 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 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 a 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.

[0058] The following describes a welding control method according to this application. Please refer to [link / reference]. Figure 1 One embodiment of the welding control method of this application is applied to the industrial control computer of a welding system. The welding system further includes multiple laser units and an image capturing unit. The method includes:

[0059] 101. Acquire the appearance image of the target object to be welded captured by the image capturing unit, and determine the corresponding image area of ​​each laser unit on the appearance image;

[0060] The image acquisition unit captures an image of the object to be welded, and determines the corresponding image area for each laser unit on the image. The object to be welded can be any object, such as a circuit board; specific limitations are not specified here. The image can be a grayscale or RGB image. Specifically, which pixels in the image correspond to which laser unit can be pre-defined. During the segmentation process, the corresponding pixel range can be found on the image based on the laser unit's number, thus forming the corresponding image area.

[0061] 102. The average pixel value of all pixels in the same image region is determined as the pixel value of the image region;

[0062] The average pixel value of all pixels within the same image region is determined as the pixel value of the image region. Specifically, for each image region, the average pixel value of the involved pixels is determined as the corresponding pixel value of the image region. For example, if an image region has four pixels with corresponding pixel values ​​of 1, 2, 3, and 4, then their average value of 2.5 is the pixel value of the image region. It is understandable that a weighted average or other methods can also be used for calculation; the specific method is not limited here.

[0063] 103. Group image regions whose pixel values ​​are within the same preset pixel value range into the same control partition, and use the laser unit corresponding to each image region within the control partition as the laser unit corresponding to the control partition.

[0064] Image regions whose pixel values ​​fall within the same preset pixel value range are grouped into the same control zone, and the laser units corresponding to each image region within a control zone are designated as the laser units corresponding to that control zone. Specifically, there is a one-to-one correspondence between preset pixel value ranges and control zones; one pixel value range corresponds to one control zone. For example, if there are four image regions with pixel values ​​of 1, 2, 3, and 4, there are three preset pixel value ranges: (0.8, 2.6), (2.7, 3.1), and (3.2, 4.3). Therefore, there are three control zones. The image regions with pixel values ​​of 1 and 2 belong to the same control zone, while the other two each belong to their own control zone. Furthermore, each image region within a control zone corresponds to its own unique laser unit, and these laser units also correspond to the same control zone; that is, the control of laser units within the same control zone is unified.

[0065] 104. Each laser unit corresponding to the control zone outputs laser according to its respective output power value to weld the target object.

[0066] Each laser unit corresponding to a control zone outputs laser light according to its respective output power value to weld the target object. For example, if there are three control zones, namely control zone a, control zone b, and control zone c, with 1, 2, and 3 image regions respectively, then in these six image regions, the laser unit corresponding to control zone a is controlled independently, the laser units corresponding to control zone b are controlled independently, and the laser units corresponding to control zone c are controlled independently, and the control of the three control zones does not interfere with each other.

[0067] In this embodiment, the appearance image of the target object to be welded is first acquired by the image capturing unit, and the corresponding image area of ​​each laser unit on the appearance image is determined. Then, the average pixel value of each pixel in the same image area is determined as the pixel value of the image area. Next, image areas whose pixel values ​​fall within the same preset pixel value range are grouped into the same control partition. The laser units corresponding to each image area within the control partition are then used as the laser units corresponding to the control partition. Finally, each laser unit corresponding to the control partition outputs laser according to its corresponding output power value to weld the target object. The heat absorption capacity is related to the color of the device, and is divided by the pixel value (grayscale or RGB) reflecting the device color. One laser unit corresponds to one image area, and the color of the device that each laser unit can irradiate corresponds to the pixel value of the image area. The pixel value range corresponds to the color range, or in other words, the heat absorption capacity range. Devices with heat absorption capacity within the same range are defined as the same control partition. Laser units within the same control partition are controlled uniformly, while laser units within different control partitions are not controlled uniformly. Simply put, the components are first divided according to their heat absorption capacity. The laser units corresponding to the components with strong heat absorption capacity are controlled uniformly, and the laser units corresponding to the components with weak heat absorption capacity are controlled uniformly. In this way, the temperature of the components with strong and weak heat absorption capacity can be adjusted independently. This ensures that both components can reach the target welding temperature and achieve good welding.

[0068] The welding control method of this application is described in detail below. Please refer to [link / reference]. Figure 2 The welding system involved in this embodiment includes a surface laser emitter, a surface laser power supply, a surface laser controller, an industrial computer, an image capturing unit (e.g., a thermal imager), and a circuit board. The industrial computer is connected to both the surface laser controller and the image capturing unit. The input terminal of the surface laser power supply is connected to the surface laser controller, and the output terminal of the surface laser power supply is connected to the surface laser emitter. The circuit board is a plate-shaped object used to support and connect electronic components, and it has conductive lines and electronic components on it. The image capturing unit can detect the circuit board. The industrial computer is a computer composed of hardware and software used to perform control tasks. The surface laser controller provides control parameters, the surface laser power supply powers the surface laser emitter, and the surface laser emitter provides the welding laser. The area of ​​the circuit board is less than or equal to the area of ​​the surface laser emitter, and the surface laser emitter can be replaced with other heat-generating block-shaped or wire-shaped heating elements.

[0069] Please see Figures 3 to 5 Another embodiment of the welding control method of this application is applied to the industrial control computer of a welding system. The welding system further includes multiple laser units and an image capturing unit. The method includes:

[0070] 301. Acquire the appearance image of the target object to be welded captured by the image capturing unit, and determine the corresponding image area of ​​each laser unit on the appearance image;

[0071] The image acquisition unit captures an image of the target object to be welded, and determines the corresponding image area for each laser unit on the image. The target object can be any object to be welded, such as a circuit board; this is not limited here, but a circuit board is used as an example. The image is a grayscale or RGB image. Specifically, which pixels on the image correspond to which laser unit can be pre-defined. During the segmentation, the corresponding pixel range can be found on the image based on the laser unit's number, forming the corresponding image area. Please refer to [link to relevant documentation]. Figure 4 Each partition on the circuit board corresponds to the irradiation area of ​​a laser unit. Please refer to [link / reference]. Figure 5 Each partition of the surface laser emitter corresponds to an image region.

[0072] 302. The average pixel value of all pixels in the same image region is determined as the pixel value of the image region;

[0073] The average pixel value of all pixels within the same image region is determined as the pixel value of the image region. Specifically, for each image region, the average pixel value of the involved pixels is determined as the corresponding pixel value of the image region. For example, if an image region has four pixels with corresponding pixel values ​​of 1, 2, 3, and 4, then their average value of 2.5 is the pixel value of the image region. It is understandable that a weighted average or other methods can also be used for calculation; the specific method is not limited here.

[0074] 303. Group image regions whose pixel values ​​are within the same preset pixel value range into the same control partition, and use the laser unit corresponding to each image region within the control partition as the laser unit corresponding to the control partition.

[0075] Image regions whose pixel values ​​fall within the same preset pixel value range are grouped into the same control zone, and the laser units corresponding to each image region within a control zone are designated as the laser units corresponding to that control zone. Specifically, there is a one-to-one correspondence between preset pixel value ranges and control zones; one pixel value range corresponds to one control zone. For example, if there are four image regions with pixel values ​​of 1, 2, 3, and 4, there are three preset pixel value ranges: (0.8, 2.6), (2.7, 3.1), and (3.2, 4.3). Therefore, there are three control zones. The image regions with pixel values ​​of 1 and 2 belong to the same control zone, while the other two each belong to their own control zone. Furthermore, each image region within a control zone corresponds to its own unique laser unit, and these laser units also correspond to the same control zone; that is, the control of laser units within the same control zone is unified.

[0076] 304. The average pixel value of each image region within the control partition is determined as the partition pixel value of the control partition;

[0077] The average pixel value of each image region within a control partition is determined as the partition pixel value of that control partition. Specifically, for each control partition, the average pixel value of each image region can be calculated, and this average value is the partition pixel value of the control partition. It is understandable that a weighted average or other methods can also be used based on the pixel values ​​of each image region; these can be set according to actual needs and are not limited here.

[0078] 305. In the nth control process, the laser units corresponding to the control partition are controlled to output lasers multiple times according to the following steps, where n is an integer greater than or equal to 1: a. Based on the current object temperature after the target object is irradiated by the laser, determine the current object temperature value corresponding to each laser unit in the welding system, and determine the average value of the current object temperature values ​​corresponding to each laser unit in the same control partition as the current temperature value of the control partition; b. Calculate the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value; c. Control the laser units corresponding to each image area in the control partition to output lasers according to the current output power value of the control partition.

[0079] In the nth control process, the laser units corresponding to the control partitions are controlled to output lasers multiple times according to the following steps, where n is an integer greater than or equal to 1: a. Based on the current object temperature after being irradiated and welded by the laser, the current object temperature value corresponding to each laser unit in the welding system is determined, and the average value of the current object temperature values ​​corresponding to the laser units of the same control partition is determined as the current temperature value of the control partition; b. The current output power value of the control partition is calculated based on at least the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value; c. The laser units corresponding to each image area within the control partition are controlled to output lasers based on the current output power value of the control partition. Specifically, for each control, the current object temperature value corresponding to each laser unit is first determined based on the current object temperature of the object to be welded, and the current temperature value of each control partition is determined. Then, the current output power value of each control partition is calculated, and finally, the laser units of each control partition are controlled to emit lasers based on the current output power value.

[0080] Regarding step a, specifically, firstly, based on the current temperature of the target object after laser irradiation and welding, the pixel temperature value of each pixel in the image region corresponding to each laser unit is determined. Then, for each image region, the average value of the pixel temperature values ​​of each pixel in the image region is determined as the current object temperature value of the corresponding laser unit. Finally, the current temperature value of the control zone is determined based on the average value of the current object temperature values ​​corresponding to each laser unit. Specifically, the image capturing unit can acquire the current object temperature of the target object to be welded, storing it in the form of a thermal image. Then, based on a preset algorithm, the pixel temperature value of each pixel in each image region is determined from the thermal image. The average or weighted average of the pixel temperature values ​​is determined as the current object temperature value of the corresponding laser unit, and finally, the current temperature value of the control zone is calculated. It can be understood that the current temperature value of the zone can be calculated by averaging or by weighted averaging; the specific method is not limited here.

[0081] Regarding step b, there are at least three implementation methods. In the first implementation method, when n is 1, the current temperature value of the partition is the nth partition temperature value. The power increment is calculated based on the nth partition temperature value, the partition pixel value, and the preset target temperature value. This power increment is then determined as the current output power value. In the second implementation method, when n is 2, the current temperature value of the partition is the nth partition temperature value. The (n-1)th partition temperature value and the (n-1)th output power value of the control partition are obtained first. The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the partition pixel value, and the preset target temperature value. Finally, the sum of the power increment and the (n-1)th output power value is determined as the current output power value, where the current output power value is the nth output power value. In the third implementation, when n is an integer greater than or equal to 3, the current temperature value of the partition is the nth partition temperature value. Then, the (n-1)th partition temperature value, the (n-2)th partition temperature value, and the (n-1)th output power value of the control partition are first obtained. Then, the power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the (n-2)th partition temperature value, the partition pixel value, and the preset target temperature value. Finally, the sum of the power increment and the (n-1)th output power value is determined as the current output power value, where the current output power value is the nth output power value.

[0082] The three implementation methods are explained based on the following formula:

[0083] ;

[0084] Where, if n is 1, then and If n is 0, then if n is 2, then =0;

[0085] For power increment, This is the preset error change amount. The preset instantaneous error value, The acceleration of the preset error change, The preset ratio constant, For the partition pixel values, This is the preset minimum value. The difference between the nth partition temperature value and the target temperature value. This is the difference between the (n-1)th partition temperature value and the target temperature value. This is the difference between the (n-2)th partition temperature value and the target temperature value.

[0086] 306. For each control zone, if the current temperature value of the control zone reaches the target temperature value, the output power of the laser unit corresponding to each image area in the control zone is adjusted according to the current output power value to ensure that the current temperature value of the control zone is within the preset temperature range.

[0087] For each control zone, if the current temperature value of that control zone reaches the target temperature value, the output power of the laser units corresponding to each image area within that control zone is adjusted according to the current output power value. This ensures that the current temperature value of the control zone remains within a preset temperature range, which includes the target temperature value; in other words, the preset temperature range is a range centered on the target temperature value, allowing for slight fluctuations above and below it. Specifically, regardless of the control zone, as long as the current temperature value of that control zone reaches the target temperature value, the output power of the laser units is controlled based on the current output power value, and the system continues to operate.

[0088] 307. If the current temperature value of the controlled zone does not reach the target temperature value, the laser unit corresponding to the controlled zone will output laser at the maximum value among n output power values ​​until the most recent current temperature value of the controlled zone reaches the target temperature value.

[0089] If the current temperature of a controlled zone does not reach the target temperature, the laser unit corresponding to that zone outputs the laser at the maximum value among n output power values ​​until the most recent current temperature of the controlled zone reaches the target temperature. Specifically, regardless of which controlled zone, if its current temperature does not meet the standard, the corresponding laser unit outputs the laser at the maximum value among n output power values. If each output power value is higher than the previous one, the current temperature of the target object to be welded can be re-acquired and processed (i.e., n is incremented by one) to update the nth output power value, thereby calculating the current temperature of the controlled zone, until the current temperature of the controlled zone reaches the target temperature.

[0090] 308. If the current temperature value of all control zones reaches the target temperature value, then after maintaining the output power of the laser units corresponding to each image area in all control zones for a preset duration, control all laser units to stop working.

[0091] If the current temperature value of all control zones reaches the target temperature value, then after maintaining the output power of the laser units corresponding to each image area in all control zones for a preset duration, all laser units will be stopped. Specifically, after the current temperature value of all control zones reaches the requirement, it will be maintained for a period of time before all laser units stop working.

[0092] In this embodiment, firstly, an image of the target object to be welded is acquired by the image capturing unit, and the corresponding image area for each laser unit on the image is determined. Then, the average pixel value of each pixel in the same image area is determined as the pixel value of the image area. Next, image areas whose pixel values ​​fall within the same preset pixel value range are grouped into the same control partition. The laser units corresponding to each image area within the control partition are then designated as the laser units corresponding to that control partition. Finally, each laser unit in the control partition outputs laser light according to its corresponding output power value to weld the target object. Heat absorption capacity is related to the color of the device, and is divided by the pixel values ​​(grayscale or RGB) reflecting the device color. One laser unit corresponds to one image area, and the color of the device that each laser unit can illuminate corresponds to the pixel value of the image area. The pixel value range corresponds to the color range, or in other words, the heat absorption capacity range. Devices with heat absorption capacity within the same range are defined as the same control partition. Laser units within the same control partition are controlled uniformly, while laser units in different control partitions are not controlled uniformly. Simply put, the components are first divided according to their heat absorption capacity. The laser units corresponding to the components with strong heat absorption capacity are controlled uniformly, and the laser units corresponding to the components with weak heat absorption capacity are controlled uniformly. In this way, the temperature of the components with strong and weak heat absorption capacity can be adjusted independently. This ensures that both components can reach the target welding temperature and achieve good welding.

[0093] The welding control method of this application has been described above; the industrial control computer of this application will be described below. Please refer to... Figure 6 This application provides an industrial control computer, which includes:

[0094] The acquisition unit 601 is used to acquire the appearance image of the target object to be welded captured by the image capturing unit, and to determine the image area corresponding to each laser unit on the appearance image.

[0095] The determining unit 602 is used to determine the average pixel value of each pixel in the same image region as the pixel value of the image region.

[0096] The classification unit 603 is used to classify image regions whose pixel values ​​are within the same preset pixel value range into the same control partition, and to use the laser unit corresponding to each image region in the control partition as the laser unit corresponding to the control partition.

[0097] The control unit 604 is used to control each laser unit corresponding to the control zone to output laser according to the output power value corresponding to the control zone, so as to weld the target object to be welded.

[0098] In this embodiment, the acquisition unit 601 first acquires the appearance image of the target object to be welded captured by the image capturing unit, and determines the image area corresponding to each laser unit on the appearance image. Then, the determination unit 602 determines the average pixel value of each pixel point in the same image area as the pixel value of the image area. Next, the classification unit 603 classifies image areas whose pixel values ​​are within the same preset pixel value range into the same control partition, and uses the laser units corresponding to each image area within the control partition as the laser units corresponding to the control partition. Finally, the control unit 604 controls each laser unit corresponding to the control partition to output laser according to the output power value corresponding to the control partition, in order to weld the target object. The heat absorption capacity is related to the color of the device, and is divided by the pixel value (grayscale or RGB) reflecting the device color. One laser unit corresponds to one image area, and the color of the device that each laser unit can irradiate corresponds to the pixel value of the image area. The pixel value range corresponds to the color range, or in other words, the heat absorption capacity range. That is, the area where devices with the same heat absorption capacity are located is determined as the same control partition. Laser units involved in the same control partition are uniformly controlled, while laser units involved in different control partitions are not uniformly controlled. Simply put, the components are first divided according to their heat absorption capacity. The laser units corresponding to the components with strong heat absorption capacity are controlled uniformly, and the laser units corresponding to the components with weak heat absorption capacity are controlled uniformly. In this way, the temperature of the components with strong and weak heat absorption capacity can be adjusted independently. This ensures that both components can reach the target welding temperature and achieve good welding.

[0099] The industrial control computer of this application is described in detail below. This application provides an industrial control computer, which includes:

[0100] The acquisition unit is used to acquire the appearance image of the target object to be welded captured by the image capturing unit, and to determine the image area corresponding to each laser unit on the appearance image.

[0101] The determining unit is used to determine the average pixel value of each pixel in the same image region as the pixel value of the image region.

[0102] The classification unit is used to classify image regions whose pixel values ​​are within the same preset pixel value range into the same control partition, and to use the laser unit corresponding to each image region in the control partition as the laser unit corresponding to the control partition.

[0103] The control unit is used to control each laser unit corresponding to the control zone to output laser according to the output power value of the control zone, so as to weld the target object to be welded.

[0104] The control unit is specifically used for:

[0105] The average pixel value of each image region within the control partition is determined as the partition pixel value of the control partition;

[0106] The laser unit corresponding to the control zone is controlled to output laser light multiple times. In the nth control process, the laser unit corresponding to the control zone is controlled to output laser light according to the following steps, where n is an integer greater than or equal to 1:

[0107] Based on the current temperature of the target object after being irradiated by the laser, the current object temperature value corresponding to each laser unit in the welding system is determined, and the average value of the current object temperature values ​​corresponding to each laser unit in the same control zone is determined as the current temperature value of the control zone.

[0108] The current output power value of the control zone is calculated based on at least the current temperature value of the control zone, the pixel value of the control zone, and the preset target temperature value.

[0109] The laser output of each image region within the control zone is controlled based on the current output power value of the control zone.

[0110] Industrial control computers also include a processing unit, used for:

[0111] For each control zone, if the current temperature value of the control zone reaches the target temperature value, the output power of the laser unit corresponding to each image area in the control zone is adjusted according to the current output power value to ensure that the current temperature value of the control zone is within the preset temperature range, which includes the target temperature value.

[0112] If the current temperature value of the controlled partition has not reached the target temperature value, the laser unit corresponding to the controlled partition will output laser at the maximum value among n output power values ​​until the most recent current temperature value of the controlled partition reaches the target temperature value.

[0113] If the current temperature value of all control zones reaches the target temperature value, then after maintaining the output power of the laser units corresponding to each image area in all control zones for a preset duration, control all laser units to stop working.

[0114] The control unit is specifically used for:

[0115] Based on the current temperature of the target object after being irradiated by the laser, the pixel temperature value of each pixel in the image region corresponding to each laser unit is determined.

[0116] For each image region, the average pixel temperature value of each pixel in the image region is determined as the current object temperature value of the corresponding laser unit.

[0117] The control unit is specifically used for:

[0118] When n is 1, the current temperature value of the partition is the temperature value of the nth partition. The power increment is calculated based on the temperature value of the nth partition, the partition pixel value, and the preset target temperature value.

[0119] The power increment is determined as the current output power value.

[0120] The control unit is specifically used for:

[0121] When n is 2, the current temperature value of the partition is the nth partition temperature value, then the (n-1)th partition temperature value and the (n-1)th output power value of the controlled partition are obtained;

[0122] The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the partition pixel value, and the preset target temperature value.

[0123] The sum of the power increment and the output power value of the (n-1)th time is determined as the current output power value, and the current output power value is the output power value of the nth time.

[0124] The control unit is specifically used for:

[0125] When n is an integer greater than or equal to 3, the current temperature value of the partition is the nth partition temperature value, then the (n-1)th partition temperature value, the (n-2)th partition temperature value, and the (n-1)th output power value of the controlled partition are obtained;

[0126] The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the (n-2)th partition temperature value, the partition pixel value, and the preset target temperature value.

[0127] The sum of the power increment and the output power value of the (n-1)th time is determined as the current output power value, and the current output power value is the output power value of the nth time.

[0128] The functions and processes performed by each unit in the industrial control computer in this embodiment are the same as those described above. Figures 1 to 5 The functions and processes performed by the industrial control computer are similar, so they will not be described in detail here.

[0129] Figure 7 This is a schematic diagram of an industrial control computer structure provided in an embodiment of this application. The industrial control computer 700 may include one or more central processing units (CPUs) 701 and a memory 705, in which one or more application programs or data are stored.

[0130] The memory 705 can be volatile or persistent storage. The program stored in the memory 705 can include one or more modules, each module including a series of instruction operations on the industrial computer 700. Furthermore, the central processing unit 701 can be configured to communicate with the memory 705 and execute the series of instruction operations stored in the memory 705 on the industrial computer 700.

[0131] The industrial computer 700 may also include one or more power supplies 702, one or more wired or wireless network interfaces 703, one or more input / output interfaces 704, and / or one or more operating systems, such as Windows Server™, Mac OS X™, Unix™, Linux™, FreeBSD™, etc.

[0132] The central processing unit 701 can perform the aforementioned... Figures 1 to 5 The specific operations performed by the industrial control computer in the illustrated embodiment will not be described in detail here.

[0133] This application also provides a computer-readable storage medium including instructions that, when executed on a computer, cause the computer to perform the methods described in the foregoing embodiments.

[0134] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0135] It should be noted that although the steps in the flowcharts of the various embodiments are drawn sequentially according to the arrows, unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the various embodiments may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages in other steps.

[0136] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units 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, or indirect coupling or communication connection between apparatuses or units, and may be electrical, mechanical, or other forms.

[0137] The units described 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.

[0138] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0139] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

Claims

1. A welding control method, characterized in that, An industrial control computer used in a welding system, the welding system further including multiple laser units and an image capturing unit, the method comprising: The image capture unit captures an image of the target object to be welded, and the laser unit determines the corresponding image area on the image. The average pixel value of each pixel in the same image region is determined as the pixel value of the image region. Image regions whose pixel values ​​are within the same preset pixel value range are grouped into the same control partition, and the laser units corresponding to each image region within the control partition are used as the laser units corresponding to the control partition. Each laser unit corresponding to the control zone is controlled to output laser according to its respective output power value to weld the target object.

2. The welding control method according to claim 1, characterized in that, The control of each laser unit corresponding to the control partition to output laser according to the output power value corresponding to the control partition includes: The average pixel value of each image region within the control partition is determined as the partition pixel value of the control partition; The laser unit corresponding to the control partition is controlled to output laser light multiple times, and in the nth control process, the laser unit corresponding to the control partition is controlled to output laser light according to the following steps, where n is an integer greater than or equal to 1: Based on the current temperature of the target object after being irradiated and welded by the laser, the current object temperature value corresponding to each laser unit in the welding system is determined, and the average value of the current object temperature values ​​corresponding to each laser unit in the same control zone is determined as the current temperature value of the control zone. The current output power value of the control partition is calculated based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value. The laser unit corresponding to each image region within the control partition is controlled to output laser light based on the current output power value of the control partition.

3. The welding control method according to claim 2, characterized in that, After controlling the laser units corresponding to each image region within the control partition to output laser light according to the current output power value of the control partition, the method further includes: For each of the control zones, if the current temperature value of the control zone reaches the target temperature value, the output power of the laser unit corresponding to each image region in the control zone is adjusted according to the current output power value to ensure that the current temperature value of the control zone is within a preset temperature range, which includes the target temperature value. If the current temperature value of the control zone does not reach the target temperature value, the laser unit corresponding to the control zone is controlled to output laser at the maximum value among n output power values ​​until the most recent current temperature value of the control zone reaches the target temperature value. If the current temperature value of all the control zones reaches the target temperature value, then after maintaining the output power of the laser unit corresponding to each image area in all the control zones for a preset maintenance period, control all the laser units to stop working.

4. The welding control method according to claim 2, characterized in that, The step of determining the current object temperature value corresponding to each laser unit in the welding system based on the current object temperature after laser irradiation and welding includes: Based on the current temperature of the target object after being irradiated and welded by the laser, the pixel temperature value of each pixel in the image region corresponding to each laser unit is determined. For each of the image regions, the average pixel temperature value of each pixel in the image region is determined as the current object temperature value of the corresponding laser unit.

5. The welding control method according to claim 2, characterized in that, The step of calculating the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value includes: When n is 1, the current temperature value of the partition is the temperature value of the nth partition. Then, the power increment is calculated based on the temperature value of the nth partition, the pixel value of the partition, and the preset target temperature value. The power increment is determined as the current output power value.

6. The welding control method according to claim 2, characterized in that, The step of calculating the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value includes: When n is 2, the current temperature value of the partition is the nth partition temperature value, then the (n-1)th partition temperature value and the (n-1)th output power value of the control partition are obtained; The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the partition pixel value, and the preset target temperature value. The sum of the power increment and the (n-1)th output power value is determined as the current output power value, and the current output power value is the nth output power value.

7. The welding control method according to claim 2, characterized in that, The step of calculating the current output power value of the control partition based at least on the current temperature value of the control partition, the pixel value of the control partition, and the preset target temperature value includes: When n is an integer greater than or equal to 3, the current temperature value of the partition is the nth partition temperature value, then the (n-1)th partition temperature value, the (n-2)th partition temperature value, and the (n-1)th output power value of the control partition are obtained; The power increment is calculated based on the nth partition temperature value, the (n-1)th partition temperature value, the (n-2)th partition temperature value, the partition pixel value, and the preset target temperature value. The sum of the power increment and the (n-1)th output power value is determined as the current output power value, and the current output power value is the nth output power value.

8. An industrial control computer, characterized in that, include: The acquisition unit is used to acquire the appearance image of the target object to be welded captured by the image capturing unit, and to determine the image area corresponding to each laser unit on the appearance image. A determining unit is configured to determine the average pixel value of each pixel point in the same image region as the pixel value of the image region; The classification unit is used to classify image regions whose pixel values ​​are within the same preset pixel value range into the same control partition, and to use the laser unit corresponding to each image region in the control partition as the laser unit corresponding to the control partition. The control unit is used to control each laser unit corresponding to the control zone to output laser according to the output power value corresponding to the control zone, so as to weld the target object to be welded.

9. An industrial control computer, characterized in that, include: Central processing unit, memory, and input / output interfaces; The memory is either a short-term storage memory or a persistent storage memory; The central processing unit is configured to communicate with the memory and execute instructions in the memory to perform the method according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, Includes instructions that, when executed on a computer, cause the computer to perform the method as described in any one of claims 1 to 7.

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