A laser welding apparatus power control system and control method

Abstract

The application provides a laser welding equipment power control system and a control method, and belongs to the technical field of laser welding equipment power control. The system comprises: an interactive module receiving a power selection instruction; a main control module outputting a waveform control signal according to the power selection instruction; an output module converting the output waveform control signal into a current for driving a laser; a temperature monitoring module collecting laser temperature in real time and transmitting the laser temperature to a control chip of the main control module; the main control module constructing a temperature rise / temperature drop interval linear function based on the collected laser temperature; and according to the relationship between the real-time temperature of the laser and a preset safety temperature threshold, the power selection instruction is used to control the level of the coil of a relay K1 to select a second intermediate signal or a superimposed signal as the output waveform control signal, so as to realize power promotion and temperature cooperative control. The application realizes accurate temperature control while promoting the output power of the laser, prevents overheating damage, and improves welding efficiency and quality.

Description

Technical Field

[0001] This application belongs to the field of power control technology for laser welding equipment, specifically relating to a power control system and control method for laser welding equipment. Background Technology

[0002] In laser welding equipment, the laser generates a large amount of heat. With the widespread application of laser welding in industrial production, the requirements for welding efficiency and quality are becoming increasingly stringent, necessitating higher laser power output capabilities from the equipment. However, there are currently some insurmountable shortcomings in increasing laser power, limiting the performance improvement and application scope of laser welding equipment.

[0003] First, the control method of increasing power using pulse width duty cycle places high demands on the analog signal acquisition rate, requiring a high-speed analog signal acquisition system to ensure accurate capture and control of pulse signal details. However, the introduction of a high-speed analog signal acquisition system increases the overall system complexity and cost, and also makes the overall system debugging and maintenance more difficult. Second, currently, increasing the current often requires increasing the maximum analog signal of the entire cycle. While this method can increase power output to some extent, it leads to heat accumulation. As the current increases, the heat generated by the laser also increases, and current technology struggles to effectively dissipate this heat in a timely manner. Excessive heat accumulation can lead to a decline in laser performance and may even damage the laser, thus affecting the normal operation and lifespan of the equipment. Furthermore, due to the limitations imposed by heat issues, the power increase of the laser is also greatly restricted, failing to fully realize its potential performance. Third, currently, most power regulation and temperature control rely on software control algorithms. However, software control algorithms are usually quite complex, requiring a large amount of computation and data processing. In actual operation, complex algorithms can lead to system response delays, making it difficult to quickly and accurately adjust power and temperature dynamically. Summary of the Invention

[0004] In a first aspect, embodiments of this application provide a power control system for a laser welding equipment, comprising: The interaction module is used to receive power selection commands through knob operation and screen feedback; The main control module is used to output waveform control signals according to the power selection command from the interactive module; the main control module includes: The waveform conversion unit compares the input signal IN with the reference voltage VREF, generates a first intermediate signal TEST1 and a second intermediate signal TEST2, and superimposes the two intermediate signals to obtain the superimposed signal SIGNAL1. The output selection and feedback unit selects the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT through relay K1, and outputs the feedback signal BACK through voltage follower U4. The control chip is used to control the on / off state of the coil of relay K1; The output module converts the output waveform control signal OUT into the current that drives the laser; The temperature monitoring module collects the laser temperature in real time and transmits it to the control chip of the main control module; The main control module constructs a linear function for the heating / cooling interval based on the acquired laser temperature:

[0005] in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; Based on the relationship between the real-time temperature of the laser and the preset safe temperature threshold, the level of the coil of the power selection command control relay K1 is used to select the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT, thereby realizing the coordinated control of power enhancement and temperature.

[0006] Furthermore, the waveform conversion unit includes a first comparator U1, a second comparator U2, and an amplifier U3; The non-inverting input of the first comparator U1 is connected to resistors R1 and R2. The other end of resistor R1 is connected to the input signal IN. The inverting input of the first comparator U1 is connected to the reference voltage VREF. The second end of the second resistor R2 is connected to the output of the first comparator U1 and the inverting input of the first intermediate signal TEST1 and the second comparator U2, and is also connected to a resistor R7. The non-inverting input of the second comparator U2 is connected to the reference voltage VREF and is connected to a resistor R3. The other end of the resistor R3 is connected to the output of the second comparator U2 and the second intermediate signal TEST2, and is connected to a resistor R6. The other end of resistor R6 is connected to the other end of resistor R7, and is connected to the non-inverting input of amplifier U3. Resistors R4 and R5 are connected to the inverting input of amplifier U3. The other end of resistor R4 is grounded, and the other end of resistor R5 is connected to the output of amplifier U3 and the superimposed signal SIGNAL1.

[0007] Furthermore, the output selection and feedback unit includes a relay K1 and a voltage follower U4; Relay K1 uses a double-pole double-throw switch, including a controlled coil, a first control switch, and a second control switch; A diode D1 is connected in parallel across the two ends of the controlled coil. The positive terminal of the diode D1 is grounded to one end of the coil, and the negative terminal of the diode D1 and the other end of the coil are connected to a control signal CONTROL. The control signal CONTROL is connected to the control chip. The first controlled switch includes a first output terminal, a first input terminal, a second input terminal, and a first switch terminal; The first input terminal is connected to the second intermediate signal TEST2, the second input terminal is connected to the superimposed signal SIGNAL1, the first output terminal is connected to the output waveform control signal OUT, and one end of the first switch terminal is connected to the first output terminal, and the other end is connected to the first input terminal or the second input terminal. The output waveform control signal OUT is connected to the laser; The second controlled switch includes a second output terminal, a third input terminal, a fourth input terminal, and a second switch terminal; The third input terminal is connected to the second intermediate signal TEST2, the fourth input terminal is connected to the superimposed signal SIGNAL1, the second output terminal is connected to the non-inverting input terminal of the voltage follower U4, the inverting input terminal of the voltage follower U4 is connected to the output terminal of the voltage follower U4, and is connected to the feedback signal BACK. The feedback signal BACK is connected to the control chip.

[0008] Furthermore, when the temperature monitoring module divides the heating / cooling range: Based on ambient temperature Based on, according to step size Dividing the heating sub-regions by method and using The cooling sub-intervals are divided by method. It is the number of heating sub-regions. It represents the number of cooling sub-intervals; Each subinterval independently constructs its own linear function. ; Until the temperature reaches the preset safe temperature threshold The division stops when the time comes.

[0009] Furthermore, the control chip performs: Receive feedback signal BACK and target output control signal Comparison; When the deviation exceeds the set proportional threshold, adjust the voltage amplitude of the input signal IN; Real-time closed-loop calibration is performed using voltage follower U4.

[0010] Secondly, embodiments of this application also provide a power control method for laser welding equipment, comprising the following steps: S1. Select the power mode through the interactive module. If the power boost mode is selected, send a boost command to the main control module. S2. The main control module constructs the following linear function based on the collected laser temperature data to divide the temperature rise range and the temperature drop range;

[0011] in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; S3. When the user selects the power boost mode: Set the control signal CONTROL to a high level, so that relay K1 connects the superimposed signal SIGNAL1 with the output waveform control signal OUT; The input signal IN is converted into a superimposed signal SIGNAL1 by the waveform conversion unit. The minimum voltage of the superimposed signal SIGNAL1 is increased to reduce the waveform resolution time. The laser driver power supply of the laser converts the superimposed signal SIGNAL1 into a driving current; S4. When the laser's real-time temperature... greater than the preset safe temperature threshold hour: Setting the control signal CONTROL to a low level causes relay K1 to switch the second intermediate signal TEST2 to the output waveform control signal OUT, thus activating the cooling mode. Based on linear functions Calculate the cooling time until the laser's real-time temperature is reached. Less than or equal to the preset safe temperature threshold Then return to step S3.

[0012] Furthermore, the specific steps of step S2 are as follows: S21. Real-time acquisition of temperature sequences and ambient temperature ; S22. Based on ambient temperature Based on, according to Temperature ranges are divided by step size: by Dividing the heating sub-regions by method and using The cooling sub-intervals are divided by method. It is the number of heating sub-regions. It represents the number of cooling sub-intervals; S23. Perform linear regression on the laser temperature data for each temperature range to calculate the slope coefficient and intercept parameters of the specific linear function:

[0013]

[0014] Where n is the number of sampling points within the temperature range.

[0015] Furthermore, the generation of the superimposed signal SIGNAL1 in step S3 specifically includes: S31. Input the input signal IN and the reference voltage VREF signal into the first comparator U1: When the input signal IN voltage is greater than the reference voltage VREF, the first intermediate signal TEST1 is equal to the input signal IN; When the input signal IN voltage is less than the reference voltage VREF, the first intermediate signal TEST1 equals 0; S32. Input the first intermediate signal TEST1 and the reference voltage VREF into the second comparator U2: When the voltage of the first intermediate signal TEST1 is greater than the reference voltage VREF, the second intermediate signal TEST2 is equal to 0. When the voltage of the first intermediate signal TEST1 is less than or equal to the reference voltage, the voltage of the second intermediate signal TEST2 is equal to the reference voltage VREF; S33. The first intermediate signal TEST1 and the second intermediate signal TEST2 are superimposed by an amplifier:

[0016] in, This indicates superimposed signals.

[0017] Furthermore, the cooling time in step S4 is calculated as follows:

[0018] in, It is the real-time temperature at the start of the cooling process. It is the slope of the current cooling sub-interval. It is a continuous drop in temperature Switch back to power boost mode after a few seconds. It is a preset safe temperature threshold.

[0019] Furthermore, it also includes feedback control steps: The feedback signal BACK is output through the voltage follower U4; Calculate the feedback signal BACK and the target output control signal deviation :

[0020] in, It is the target output control signal voltage, It is the voltage of the feedback signal; When the deviation The first set ratio greater than the reference voltage VREF At this time, the input signal IN is adjusted as follows:

[0021] in, It is the adjusted input signal IN voltage. It is the voltage of the input signal IN. It is the second set ratio.

[0022] As can be seen from the above technical solutions, this application has the following advantages: The power control system and control method for laser welding equipment provided in this application solve the current problem of difficulty in coordinating laser power enhancement and thermal management through hardware circuit design and real-time temperature control algorithm. It achieves precise temperature control while increasing laser output power, preventing overheating damage and improving welding efficiency and quality. Attached Figure Description

[0023] To more clearly illustrate the technical solution of this application, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the power control system of the laser welding equipment of the present invention.

[0025] Figure 2 This is a circuit diagram of the waveform conversion unit of the present invention.

[0026] Figure 3 This is a circuit diagram of the output selection and feedback unit of the present invention.

[0027] Figure 4 This is a schematic flowchart of the power control method for laser welding equipment according to the present invention.

[0028] Figure 5 This is a schematic diagram of the waveform of the input signal IN of the present invention.

[0029] Figure 6 This is a waveform diagram of the first intermediate signal TEST1 of the present invention.

[0030] Figure 7This is a waveform diagram of the second intermediate signal TEST2 of the present invention.

[0031] Figure 8 This is a schematic diagram of the waveform of the superimposed signal SIGINAL1 of the present invention. Detailed Implementation

[0032] Various embodiments of this disclosure will be described more fully in the following detailed description of the power control system for laser welding equipment. This disclosure may have various embodiments, and adjustments and changes may be made therein. However, it should be understood that there is no intention to limit the various embodiments of this disclosure to the specific embodiments disclosed herein, but rather this disclosure should be understood to cover all adjustments, equivalents, and / or alternatives falling within the spirit and scope of the various embodiments of this disclosure.

[0033] For example, in laser welding equipment applications, the laser generates a large amount of heat during operation. As industrial production demands higher efficiency and quality in laser welding, the equipment requires higher power output. However, there are currently many drawbacks to increasing laser power: First, pulse width duty cycle control requires extremely high analog signal acquisition rates. Precise control of the pulse signal necessitates a high-speed analog signal acquisition system, which undoubtedly increases system complexity, cost, and the difficulty of debugging and maintenance. Second, increasing the current typically requires increasing the maximum analog signal per cycle. While this can increase power to some extent, it leads to heat accumulation. Increased current results in increased heat generation in the laser, and current heat dissipation technology is insufficient, leading to decreased laser performance, shortened lifespan, and limited power enhancement potential. Third, current methods largely rely on complex software algorithms for power and temperature control. These algorithms involve large computational loads and complex data processing, easily causing system response delays and hindering rapid and accurate dynamic adjustment of power and temperature. Given the safe current increase potential of lasers, a new hardware-based control scheme is urgently needed. Through circuit innovation and real-time temperature control algorithms, efficient power enhancement can be achieved, balancing power output and thermal management.

[0034] To address the aforementioned issues, this embodiment provides a power control system for laser welding equipment. Through hardware circuitry and temperature control algorithms, it achieves efficient enhancement of laser power and coordinated temperature control, ensuring the safe and stable operation of the laser and improving welding efficiency and quality.

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Please see Figure 1The diagram shown is a schematic of a power control system for a laser welding equipment in a specific embodiment. The system includes: The interaction module is used to receive power selection commands through knob operation and screen feedback; The main control module is used to output waveform control signals according to the power selection command from the interactive module; the main control module includes: The waveform conversion unit compares the input signal IN with the reference voltage VREF, generates a first intermediate signal TEST1 and a second intermediate signal TEST2, and superimposes the two intermediate signals to obtain the superimposed signal SIGNAL1. The output selection and feedback unit selects the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT through relay K1, and outputs the feedback signal BACK through voltage follower U4. The control chip is used to control the on / off state of the coil of relay K1; The output module converts the output waveform control signal OUT into the current that drives the laser; The temperature monitoring module collects the laser temperature in real time and transmits it to the control chip of the main control module; The main control module constructs a linear function for the heating / cooling interval based on the acquired laser temperature:

[0037] in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; Based on the relationship between the real-time temperature of the laser and the preset safe temperature threshold, the level of the coil of the power selection command control relay K1 is used to select the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT, so as to realize the coordinated control of power enhancement and temperature. It should be noted that the interactive module uses a knob operation and screen feedback, providing operators with a convenient and intuitive human-machine interface for quick selection of power modes; the main control module can flexibly adjust the output waveform control signal according to temperature and power commands, ensuring that the laser operates stably at a suitable power within a safe temperature range, thus improving the stability and quality of the welding process; the output module efficiently converts the waveform control signal into drive current, ensuring precise power output of the laser and improving electro-optical conversion efficiency; the temperature monitoring module collects temperature data in real time and feeds it back to the main control module, thereby enabling timely response to temperature changes, dynamic adjustment of control strategies, and realization of closed-loop control.

[0038] This embodiment achieves precise coordinated control of power enhancement and temperature through the collaborative work of various modules. This satisfies the high power output requirements of laser welding equipment while avoiding the risk of laser overheating and damage, thus improving the performance and reliability of the equipment.

[0039] Furthermore, as a refinement and extension of the specific implementation methods described above, and to fully illustrate the specific implementation process in this embodiment, another laser welding equipment power control system is provided, which includes: The interaction module is used to receive power selection commands through knob operation and screen feedback; The main control module is used to output waveform control signals according to the power selection command from the interactive module; the main control module includes: The waveform conversion unit compares the input signal IN with the reference voltage VREF, generates a first intermediate signal TEST1 and a second intermediate signal TEST2, and superimposes the two intermediate signals to obtain the superimposed signal SIGNAL1. The output selection and feedback unit selects the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT through relay K1, and outputs the feedback signal BACK through voltage follower U4. The control chip is used to control the on / off state of the coil of relay K1; The output module converts the output waveform control signal OUT into the current that drives the laser; The temperature monitoring module collects the laser temperature in real time and transmits it to the control chip of the main control module; The main control module constructs a linear function for the heating / cooling interval based on the acquired laser temperature:

[0040] in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; Based on the relationship between the real-time temperature of the laser and the preset safe temperature threshold, the level of the coil of the power selection command control relay K1 is used to select the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT, so as to realize the coordinated control of power enhancement and temperature. like Figure 2 As shown, the waveform conversion unit includes a first comparator U1, a second comparator U2, and an amplifier U3; The non-inverting input of the first comparator U1 is connected to resistors R1 and R2. The other end of resistor R1 is connected to the input signal IN. The inverting input of the first comparator U1 is connected to the reference voltage VREF. The second end of the second resistor R2 is connected to the output of the first comparator U1 and the inverting input of the first intermediate signal TEST1 and the second comparator U2, and is also connected to a resistor R7. The non-inverting input of the second comparator U2 is connected to the reference voltage VREF and is connected to a resistor R3. The other end of the resistor R3 is connected to the output of the second comparator U2 and the second intermediate signal TEST2, and is connected to a resistor R6. The other end of resistor R6 is connected to the other end of resistor R7, and is connected to the non-inverting input of amplifier U3. Resistors R4 and R5 are connected to the inverting input of amplifier U3. The other end of resistor R4 is grounded, and the other end of resistor R5 is connected to the output of amplifier U3 and the superimposed signal SIGNAL1. like Figure 3 As shown, the output selection and feedback unit includes a relay K1 and a voltage follower U4; Relay K1 uses a double-pole double-throw switch, including a controlled coil, a first control switch, and a second control switch; A diode D1 is connected in parallel across the two ends of the controlled coil. The positive terminal of the diode D1 is grounded to one end of the coil, and the negative terminal of the diode D1 and the other end of the coil are connected to a control signal CONTROL. The control signal CONTROL is connected to the control chip. The first controlled switch includes a first output terminal, a first input terminal, a second input terminal, and a first switch terminal; The first input terminal is connected to the second intermediate signal TEST2, the second input terminal is connected to the superimposed signal SIGNAL1, the first output terminal is connected to the output waveform control signal OUT, and one end of the first switch terminal is connected to the first output terminal, and the other end is connected to the first input terminal or the second input terminal. The output waveform control signal OUT is connected to the laser; The second controlled switch includes a second output terminal, a third input terminal, a fourth input terminal, and a second switch terminal; The third input terminal is connected to the second intermediate signal TEST2, the fourth input terminal is connected to the superimposed signal SIGNAL1, the second output terminal is connected to the non-inverting input terminal of the voltage follower U4, the inverting input terminal of the voltage follower U4 is connected to the output terminal of the voltage follower U4, and is connected to the feedback signal BACK. The feedback signal BACK is connected to the control chip. When the temperature monitoring module divides the heating / cooling intervals: Based on ambient temperature Based on, according to step size Dividing the heating sub-regions by method and using The cooling sub-intervals are divided by method. It is the number of heating sub-regions. It represents the number of cooling sub-intervals; For example, Pick ; Each subinterval independently constructs its own linear function. ; Until the temperature reaches the preset safe temperature threshold Stop dividing when the time is right; The control chip performs: Receive feedback signal BACK and target output control signal Comparison; When the deviation exceeds the set proportional threshold, adjust the voltage amplitude of the input signal IN; Real-time closed-loop calibration is performed using voltage follower U4; Specifically, U1 and U2 are LM393 series comparators, U3 and U4 are LM358 series operational amplifiers, D1 is an LL4148 diode, K1 relay is a G6K-2F-Y-TR double-pole double-throw type, R1, R2, R3, R5, R6, and R7 are all 1K resistors, and R4 is approximately half the size of R5, i.e., a 510-ohm resistor; the input terminal IN and the device receiving the feedback signal BACK are MCU microcontrollers or other chips with programmable logic, and VREF represents the output voltage of the voltage reference source, i.e., the voltage value when the power reaches 100%; In this embodiment, the input signal IN waveform is a square wave, and pulse output is achieved by controlling the frequency; similarly, other waveforms such as sawtooth waves and sine waves can also be used, and pulse output or intermittent output mode can be achieved by controlling the duty cycle. This circuit can also achieve the corresponding functions.

[0041] like Figure 4 As shown, the following are embodiments of the laser welding equipment power control method provided in this disclosure. This method and the laser welding equipment power enhancement control system of the above embodiments belong to the same inventive concept. For details not described in detail in the embodiments of the laser welding equipment power enhancement control method, please refer to the embodiments of the laser welding equipment power enhancement control system described above.

[0042] The method includes the following steps: S1. Select the power mode through the interactive module. If the power boost mode is selected, send a boost command to the main control module. S2. The main control module constructs the following linear function based on the collected laser temperature data to divide the temperature rise range and the temperature drop range;

[0043] in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; S3. When the user selects the power boost mode: Set the control signal CONTROL to a high level, so that relay K1 connects the superimposed signal SIGNAL1 with the output waveform control signal OUT; The input signal IN is converted into a superimposed signal SIGNAL1 by the waveform conversion unit. The minimum voltage of the superimposed signal SIGNAL1 is increased to reduce the waveform resolution time. The laser driver power supply of the laser converts the superimposed signal SIGNAL1 into a driving current; S4. When the laser's real-time temperature... greater than the preset safe temperature threshold hour: Setting the control signal CONTROL to a low level causes relay K1 to switch the second intermediate signal TEST2 to the output waveform control signal OUT, thus activating the cooling mode. Based on linear functions Calculate the cooling time until the laser's real-time temperature is reached. Less than or equal to the preset safe temperature threshold Then return to step S3.

[0044] This embodiment realizes automated and intelligent control of power enhancement and temperature management throughout the entire process from power selection of the interactive module to temperature monitoring, waveform control signal generation, power adjustment and temperature control, thereby improving the performance of laser welding equipment.

[0045] Furthermore, as a refinement and extension of the specific implementation of the above embodiments, in order to fully illustrate the specific implementation process in this embodiment, another laser welding equipment power control method is provided, which includes the following steps: S1. Select the power mode through the interactive module. If the power boost mode is selected, send a boost command to the main control module. S2. The main control module constructs the following linear function based on the collected laser temperature data to divide the temperature rise range and the temperature drop range;

[0046] in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; The specific steps of step S2 are as follows: S21. Real-time acquisition of temperature sequences and ambient temperature ; S22. Based on ambient temperature Based on, according to Temperature ranges are divided by step size: by Dividing the heating sub-regions by method and using The cooling sub-intervals are divided by method. It is the number of heating sub-regions. It represents the number of cooling sub-intervals; S23. Perform linear regression on the laser temperature data for each temperature range to calculate the specific linear function:

[0047] ; Where n is the number of sampling points within the temperature range; For example, suppose there are n observation points in a certain temperature range: Time series: ; Temperature sequence: T 1, T 2,…, Tn ; Determine based on needs The objective function is to find the optimal slope coefficient parameters. and intercept parameter ; Construct the objective function using the sum of squared residuals:

[0048] Let T1 represent the actual value, and let T1 represent the actual value. The predicted value is defined with the objective of minimizing the sum of squared errors. Minimize the sum of squared residuals for the slope coefficient parameter. and intercept parameter Take the derivative and set it to zero; First, let's consider the intercept parameter in the objective function. Differentiate:

[0049] Simplifying, we get: (1) Then, consider the slope coefficient parameter in the objective function. Differentiate:

[0050] Simplifying, we get: (2) From equation (1), we get:

[0051] The calculated intercept parameters Substituting into equation (2), we get: ; S3. When the user selects the power boost mode: Set the control signal CONTROL to a high level, so that relay K1 connects the superimposed signal SIGNAL1 with the output waveform control signal OUT; The input signal IN is converted into a superimposed signal SIGNAL1 by the waveform conversion unit. The minimum voltage of the superimposed signal SIGNAL1 is increased to reduce the waveform resolution time. The laser driver power supply of the laser converts the superimposed signal SIGNAL1 into a driving current; The generation of the superimposed signal SIGNAL1 in step S3 specifically includes: S31. Input the input signal IN and the reference voltage VREF signal into the first comparator U1: When the input signal IN voltage is greater than the reference voltage VREF, the first intermediate signal TEST1 is equal to the input signal IN; When the input signal IN voltage is less than the reference voltage VREF, the first intermediate signal TEST1 equals 0; S32. Input the first intermediate signal TEST1 and the reference voltage VREF into the second comparator U2: When the voltage of the first intermediate signal TEST1 is greater than the reference voltage VREF, the second intermediate signal TEST2 is equal to 0. When the voltage of the first intermediate signal TEST1 is less than or equal to the reference voltage, the voltage of the second intermediate signal TEST2 is equal to the reference voltage VREF; S33. The first intermediate signal TEST1 and the second intermediate signal TEST2 are superimposed by an amplifier: ; in, Indicates superimposed signals; It should be noted that resistors R6 and R7 are used for current limiting; S4. When the laser's real-time temperature... greater than the preset safe temperature threshold hour: Setting the control signal CONTROL to a low level causes relay K1 to switch the second intermediate signal TEST2 to the output waveform control signal OUT, thus activating the cooling mode. Based on linear functions Calculate the cooling time until the laser's real-time temperature is reached. Less than or equal to the preset safe temperature threshold Then return to step S3; The cooling time in step S4 is calculated as follows:

[0052] in, It is the real-time temperature at the start of the cooling process. It is the slope of the current cooling sub-interval. It is a continuous drop in temperature Switch back to power boost mode after a few seconds. It is a preset safe temperature threshold; It also includes feedback control steps: The feedback signal BACK is output through the voltage follower U4; Calculate the feedback signal BACK and the target output control signal deviation :

[0053] in, It is the target output control signal voltage, It is the voltage of the feedback signal; When the deviation The first set ratio greater than the reference voltage VREF Time (e.g.) Take 0.1, The input signal IN is adjusted as follows:

[0054] in, It is the adjusted input signal IN voltage. It is the voltage of the input signal IN. It is the second set ratio, for example Take 0.5; After power output, the laser temperature is read intermittently using a point sampling method. A linear function T=aS+D is constructed based on time S and real-time temperature T. This function is divided into two main categories in practical applications: a heating range and a cooling range. Each range is further divided according to the ambient temperature Th+5 until a preset safe temperature threshold is reached. This establishes multiple sub-interval functions; subsequently, the light emission time and heat dissipation time are adjusted according to the target temperature Tc. Specifically, firstly, based on the set ambient temperature Th and the preset safe temperature threshold... 1. Target temperature Tc parameter, determine the corresponding temperature range; Then, when outputting power, the system first confirms whether power needs to be increased through information from the interaction module; during the power selection phase, a power selection operation is performed; when increasing or decreasing power, if the power range is 100% or below, normal power data is sent; if the power range exceeds 100%, power increase data is sent. If power boost is not selected, when the input signal IN is input to... Figure 5 When the inputs are consistent, the output of the second intermediate signal TEST2 will be synchronized with it. At this time, the control signal CONTROL is in a low-level state, the relay K1 coil will not be energized, and the second intermediate signal TEST2 is connected to the output waveform control signal OUT. Therefore, the waveform output of the output waveform control signal OUT is completely consistent with the waveform output of the second intermediate signal TEST2, so that the output waveform control signal OUT can control the laser driver power supply. After receiving the waveform signal, the laser driver power supply converts it into an average voltage and outputs a corresponding current according to the average voltage to achieve precise control of the laser.

[0055] If boosting is selected, when the input signal IN is Figure 5 When the input is as shown, the control signal CONTROL is high, the relay K1 coil is energized, and the superimposed signal SIGNAL1 is connected to the output waveform control signal OUT. That is, the waveform output of the output waveform control signal OUT is consistent with the waveform output of the superimposed signal SIGNAL1, so that the output waveform control signal OUT can control the laser driver power supply. The waveform output by the laser driver power supply is the same as the waveform when the power boost is not used, except that the minimum voltage is increased, which can reduce the waveform resolution time. Subsequently, the waveform is converted into an average voltage, and the system outputs a corresponding current according to the average voltage, thereby controlling the operation of the laser.

[0056] During power boosting, the input signal IN first passes through the current-limiting resistor R1 and is then compared with the reference voltage VREF. When the input signal IN is higher than the reference voltage VREF, the first comparator U1 outputs a high-impedance state, pulling up the resistor R1 to keep the first intermediate signal TEST1 voltage consistent with the input signal IN. When the input signal IN is lower than the reference voltage VREF, the first comparator U1 switches to an open-circuit output, and the first intermediate signal TEST1 voltage becomes the same as the GND voltage. Figure 6As shown; next, the first intermediate signal TEST1 voltage is compared with the reference voltage VREF at the input of the second comparator U2; when the first intermediate signal TEST1 voltage is higher than the reference voltage VREF, the second comparator U2 adopts an open-circuit output, and the second intermediate signal TEST2 voltage is consistent with the GND voltage; when the first intermediate signal TEST1 voltage is lower than the reference voltage VREF, the second comparator U2 outputs a high-impedance state, and through the pull-up resistor R3, the second intermediate signal TEST2 voltage is consistent with the reference voltage VREF, as shown. Figure 7 As shown; finally, the second intermediate signal TEST2, passing through the current-limiting resistor R6, and the first intermediate signal TEST1, passing through the current-limiting resistor R7, are input together to amplifier U3, realizing the superposition of the first intermediate signal TEST1 and the second intermediate signal TEST2, thereby generating the superimposed signal SIGNAL1, as shown. Figure 8 As shown.

[0057] Meanwhile, the signal is fed back to the feedback signal BACK through the voltage follower U4 circuit; if the feedback signal BACK is inconsistent with the preset waveform control signal OUT, the output of the input signal IN can be adjusted in real time to ensure continuous and stable output; when D1 is used as a switching signal circuit, it can absorb overshoot voltage and effectively prevent the relay K1 from being damaged. Simultaneously, the laser temperature is monitored in real time, and the time required for each interval is saved to establish a linear function of heating and cooling, T=aS+D; based on the target temperature T c Calculate the ambient temperature T h Target temperature T c Reaching and exceeding the preset safe temperature threshold Cooling down to the target temperature T c The required time is determined by the real-time temperature T. Then, the ambient temperature T h Less than the target temperature T c The temperature output continues. The ambient temperature T is then displayed. h Greater than the target temperature T c When the control signal CONTROL is low, the second intermediate signal TEST2 is connected to the output waveform control signal OUT, switching the power output mode for cooling. The cooling time is determined by the heating and cooling functions. When the ambient temperature T... h Less than the target temperature T c Continuous output; ambient temperature T h Greater than the target temperature T c When the temperature drops, the power output is switched back to increase.

[0058] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0059] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A laser welding apparatus power control system, characterized by, include: The interaction module is used to receive power selection commands through knob operation and screen feedback; The main control module is used to output waveform control signals according to the power selection command of the interactive module; The main control module includes: The waveform conversion unit compares the input signal IN with the reference voltage VREF, generates a first intermediate signal TEST1 and a second intermediate signal TEST2, and superimposes the two intermediate signals to obtain the superimposed signal SIGNAL1. The output selection and feedback unit selects the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT through relay K1, and outputs the feedback signal BACK through voltage follower U4. The control chip is used to control the on / off state of the coil of relay K1; The output module converts the output waveform control signal OUT into the current that drives the laser; The temperature monitoring module collects the laser temperature in real time and transmits it to the control chip of the main control module; The main control module constructs a linear function for the heating / cooling interval based on the acquired laser temperature: wherein, is the real-time laser temperature, is the time variable, is the slope coefficient parameter, is the intercept parameter; Based on the relationship between the real-time temperature of the laser and the preset safe temperature threshold, the level of the coil of the power selection command control relay K1 is used to select the second intermediate signal TEST2 or the superimposed signal SIGNAL1 as the output waveform control signal OUT, thereby realizing the coordinated control of power enhancement and temperature.

2. The power control system for laser welding equipment according to claim 1, characterized in that, The waveform conversion unit includes a first comparator U1, a second comparator U2, and an amplifier U3; The non-inverting input of the first comparator U1 is connected to resistors R1 and R2. The other end of resistor R1 is connected to the input signal IN. The inverting input of the first comparator U1 is connected to the reference voltage VREF. The second end of the second resistor R2 is connected to the output of the first comparator U1 and the inverting input of the first intermediate signal TEST1 and the second comparator U2, and is also connected to a resistor R7. The non-inverting input of the second comparator U2 is connected to the reference voltage VREF and is connected to a resistor R3. The other end of the resistor R3 is connected to the output of the second comparator U2 and the second intermediate signal TEST2, and is connected to a resistor R6. The other end of resistor R6 is connected to the other end of resistor R7, and is connected to the non-inverting input of amplifier U3. Resistors R4 and R5 are connected to the inverting input of amplifier U3. The other end of resistor R4 is grounded, and the other end of resistor R5 is connected to the output of amplifier U3 and the superimposed signal SIGNAL1.

3. The power control system for laser welding equipment according to claim 1, characterized in that, The output selection and feedback unit includes a relay K1 and a voltage follower U4; Relay K1 uses a double-pole double-throw switch, including a controlled coil, a first control switch, and a second control switch; A diode D1 is connected in parallel across the two ends of the controlled coil. The positive terminal of the diode D1 is grounded to one end of the coil, and the negative terminal of the diode D1 and the other end of the coil are connected to a control signal CONTROL. The control signal CONTROL is connected to the control chip. The first controlled switch includes a first output terminal, a first input terminal, a second input terminal, and a first switch terminal; The first input terminal is connected to the second intermediate signal TEST2, the second input terminal is connected to the superimposed signal SIGNAL1, the first output terminal is connected to the output waveform control signal OUT, and one end of the first switch terminal is connected to the first output terminal, and the other end is connected to the first input terminal or the second input terminal. The output waveform control signal OUT is connected to the laser; The second controlled switch includes a second output terminal, a third input terminal, a fourth input terminal, and a second switch terminal; The third input terminal is connected to the second intermediate signal TEST2, the fourth input terminal is connected to the superimposed signal SIGNAL1, the second output terminal is connected to the non-inverting input terminal of the voltage follower U4, the inverting input terminal of the voltage follower U4 is connected to the output terminal of the voltage follower U4, and is connected to the feedback signal BACK. The feedback signal BACK is connected to the control chip.

4. The power control system for laser welding equipment according to claim 1, characterized in that, When the temperature monitoring module divides the heating / cooling intervals: Based on ambient temperature Based on, according to step size Dividing the heating sub-regions by method and using The cooling sub-intervals are divided by method. It is the number of heating sub-regions. It represents the number of cooling sub-intervals; Each subinterval independently constructs its own linear function. ; Until the temperature reaches the preset safe temperature threshold The division stops when the time comes.

5. The power control system for laser welding equipment according to claim 1, characterized in that, The control chip performs: Receive feedback signal BACK and target output control signal Comparison; When the deviation exceeds the set proportional threshold, adjust the voltage amplitude of the input signal IN; Real-time closed-loop calibration is performed using voltage follower U4.

6. A power control method for laser welding equipment, characterized in that, Includes the following steps: S1. Select the power mode through the interactive module. If the power boost mode is selected, send a boost command to the main control module. S2. The main control module constructs the following linear function based on the collected laser temperature data to divide the temperature rise range and the temperature drop range; in, For real-time laser temperature, Time variable, For the slope coefficient parameter, For intercept parameters; S3. When the user selects the power boost mode: Set the control signal CONTROL to a high level, so that relay K1 connects the superimposed signal SIGNAL1 with the output waveform control signal OUT; The input signal IN is converted into a superimposed signal SIGNAL1 by the waveform conversion unit. The minimum voltage of the superimposed signal SIGNAL1 is increased to reduce the waveform resolution time. The laser driver power supply of the laser converts the superimposed signal SIGNAL1 into a driving current; S4. When the laser's real-time temperature... greater than the preset safe temperature threshold hour: Setting the control signal CONTROL to a low level causes relay K1 to switch the second intermediate signal TEST2 to the output waveform control signal OUT, thus activating the cooling mode. Based on linear functions Calculate the cooling time until the laser's real-time temperature is reached. Less than or equal to the preset safe temperature threshold Then return to step S3.

7. The power control method for laser welding equipment according to claim 6, characterized in that, The specific steps of step S2 are as follows: S21. Real-time acquisition of temperature sequences and ambient temperature ; S22. Based on ambient temperature Based on, according to Temperature ranges are divided by step size: by Dividing the heating sub-regions by method and using The cooling sub-intervals are divided by method. It is the number of heating sub-regions. It represents the number of cooling sub-intervals; S23. Perform linear regression on the laser temperature data for each temperature range to calculate the slope coefficient and intercept parameters of the specific linear function: ； Where n is the number of sampling points within the temperature range.

8. The power control method for laser welding equipment according to claim 6, characterized in that, The generation of the superimposed signal SIGNAL1 in step S3 specifically includes: S31. Input the input signal IN and the reference voltage VREF signal into the first comparator U1: When the input signal IN voltage is greater than the reference voltage VREF, the first intermediate signal TEST1 is equal to the input signal IN; When the input signal IN voltage is less than the reference voltage VREF, the first intermediate signal TEST1 equals 0; S32. Input the first intermediate signal TEST1 and the reference voltage VREF into the second comparator U2: When the voltage of the first intermediate signal TEST1 is greater than the reference voltage VREF, the second intermediate signal TEST2 is equal to 0. When the voltage of the first intermediate signal TEST1 is less than or equal to the reference voltage, the voltage of the second intermediate signal TEST2 is equal to the reference voltage VREF; S33. The first intermediate signal TEST1 and the second intermediate signal TEST2 are superimposed by an amplifier: in, This indicates superimposed signals.

9. The power control method for laser welding equipment according to claim 6, characterized in that, The cooling time in step S4 is calculated as follows: in, It is the real-time temperature at the start of the cooling process. It is the slope of the current cooling sub-interval. It is a continuous drop in temperature Switch back to power boost mode after a few seconds. It is a preset safe temperature threshold.

10. The power control method for laser welding equipment according to claim 6, characterized in that, It also includes feedback control steps: The feedback signal BACK is output through the voltage follower U4; Calculate the feedback signal BACK and the target output control signal deviation : in, It is the target output control signal voltage, It is the voltage of the feedback signal; When the deviation The first set ratio greater than the reference voltage VREF At this time, the input signal IN is adjusted as follows: in, It is the adjusted input signal IN voltage. It is the voltage of the input signal IN. It is the second set ratio.

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