Welding processing method, device, apparatus, and storage medium

Abstract

The application discloses a welding processing method, device and equipment and a storage medium, and relates to the technical field of welding processing. The steps of the welding processing method comprise the following steps: acquiring a size deviation type of a current workpiece to be welded; wherein the size deviation type comprises at least one of a gap deviation, a hole position deviation and an assembly misplacement deviation; determining a size deviation value of the current workpiece to be welded according to the size deviation type; determining a power compensation value mapped by the size deviation value based on a preset mapping relationship; determining an actual power value according to a preset power value and the power compensation value; and applying the actual power value when welding the current workpiece to be welded. In the foregoing manner, the welding power can be adapted to the specific size deviation of the workpiece in real time, quality problems such as overburning and insufficient penetration caused by parameter mismatch can be avoided, and the stability and consistency of the weld quality are improved.

Description

Technical Field

[0001] This invention relates to the field of welding processing technology, and in particular to a welding processing method, apparatus, equipment, and storage medium. Background Technology

[0002] In the field of welding manufacturing, the actual condition of the workpiece (such as dimensional deviations and assembly accuracy) often differs from the design standards, and the stability of the welding process directly depends on the adaptability of the welding parameters. In traditional welding processes, welding parameters are mostly preset fixed values, and their adjustment mainly relies on manual experience or offline calibration. It is difficult to respond to the dynamic changes of the workpiece in real time, and fixed parameters cannot adapt to the dimensional deviations of the workpiece (such as gaps and misalignments), which easily leads to unstable weld quality (such as overheating and insufficient penetration), increasing rework rates and production costs. Summary of the Invention

[0003] The main objective of this invention is to propose a welding processing method, apparatus, equipment, and storage medium, which aims to solve the problem of unstable quality in traditional fixed-parameter welding by dynamically identifying workpiece dimensional deviations and adjusting the welding power accordingly, thereby achieving improved quality, reduced costs, and intelligent welding.

[0004] To achieve the above objectives, the welding process proposed in this invention includes the following steps:

[0005] Obtain the dimensional deviation type of the current workpiece to be welded; wherein, the dimensional deviation type includes at least one of clearance deviation, hole position deviation, and assembly misalignment deviation;

[0006] The dimensional deviation value of the current workpiece to be welded is determined according to the dimensional deviation type; the power compensation value mapped by the dimensional deviation value is determined based on the preset mapping relationship.

[0007] The actual power value is determined based on the preset power value and the power compensation value;

[0008] The actual power value is applied when welding the current workpiece.

[0009] In one embodiment, the step of applying the actual power value when welding the current workpiece further includes:

[0010] Perform quality inspection on the welds of the currently welded workpiece and obtain the corresponding quality inspection results;

[0011] The mapping relationship is updated based on the quality inspection results of at least one preceding welded workpiece to determine the power compensation value for subsequent workpieces to be welded.

[0012] In one embodiment, the step of performing quality inspection on the weld bead of the currently welded workpiece and obtaining the corresponding quality inspection result includes:

[0013] Acquire a three-dimensional image of the weld bead of the currently welded workpiece;

[0014] The three-dimensional image is compared with the three-dimensional reference image of the preset weld bead corresponding to the material and welding process of the currently welded workpiece.

[0015] When a difference is found between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead, the core features of the weld bead of the currently welded workpiece are obtained.

[0016] The core features of the weld bead of the currently welded workpiece are compared with the core features of the preset weld bead using a feature matching algorithm.

[0017] Based on the comparison results, the similarity between the weld bead of the currently welded workpiece and the preset weld bead is determined;

[0018] If the similarity is higher than or equal to a preset threshold, the currently welded workpiece is determined to be a qualified product; if the similarity is lower than the preset threshold, the currently welded workpiece is determined to be a non-qualified product.

[0019] In one embodiment, the step of obtaining the core features of the weld bead of the currently welded workpiece when a difference exists between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead includes:

[0020] Perform a difference operation on the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead to generate a difference map;

[0021] Based on the difference map, target areas with geometrical differences on the weld bead are identified;

[0022] Geometric morphological features are extracted from the target area as the core features, and the geometric morphological features include at least one of weld width, weld reinforcement, undercut depth, and spatter height.

[0023] In one embodiment, the step of updating the mapping relationship based on the quality inspection results of at least one preceding welded workpiece for determining the power compensation value of subsequent workpieces to be welded includes:

[0024] The welded workpieces that are determined to be unqualified products are selected from the accumulated quality inspection results, and the corresponding dimensional deviation type and power compensation value are associated with them;

[0025] Based on the core features and dimensional deviation type of the welded workpiece that is determined to be a non-conforming product, the defect type corresponding to the welded workpiece that is determined to be a non-conforming product is determined.

[0026] Based on the defect type, an adjustment strategy for the mapping relationship is determined to increase or decrease the power compensation value.

[0027] In one embodiment, the step of determining the dimensional deviation value of the current workpiece to be welded based on the dimensional deviation type includes:

[0028] Obtain the key dimensional parameters of the current workpiece to be welded; wherein, the key dimensional parameters include at least one of the gap at the joint of the workpiece to be welded, the actual position of the positioning hole on the workpiece to be welded, and the alignment amount of the joint edge of the workpiece to be welded;

[0029] The difference between the key dimension parameter and the preset standard dimension under the dimension deviation type is calculated to obtain the dimension deviation value.

[0030] In one embodiment, the mapping relationship includes:

[0031] When the key size parameter includes one, the power compensation value is the sub-compensation value corresponding to the key size parameter;

[0032] When the key dimension parameters include multiple parameters, the power compensation value is the sum of the sub-compensation values ​​corresponding to the multiple key dimension parameters; and each sub-compensation value corresponding to the key dimension parameter is configured with a different weight coefficient, which is preset according to the degree of influence of the multiple key dimension parameters on the welding quality or dynamically adjusted based on historical quality inspection results.

[0033] The present invention also provides a welding processing apparatus, comprising:

[0034] The visual dimension measurement module is used to obtain the dimensional deviation value of the current workpiece to be welded;

[0035] The mapping relationship decision module is connected to the visual size measurement module and is used to determine the power compensation value mapped by the size deviation value based on the preset mapping relationship.

[0036] The welding parameter dynamic compensation module, connected to the mapping relationship decision module, is used to determine the actual power value based on the preset power value and the power compensation value, and control the welding equipment to apply the actual power value.

[0037] The welding execution module is used to apply the actual power value to the current workpiece to be welded in order to complete the welding.

[0038] The present invention also provides a welding processing apparatus, the apparatus including a memory, a processor, and a welding processing program stored in the memory and executable on the processor, the welding processing program being configured to implement the welding processing method as described above.

[0039] The present invention also provides a storage medium storing a welding process program, which, when executed by a processor, implements the welding process method as described above.

[0040] The welding method provided by this invention solves the problems of traditional welding processes where fixed parameters cannot respond to dynamic changes in the workpiece in real time, cannot adapt to dimensional deviations leading to unstable weld quality, and increase rework rate and production cost by adopting a dynamic adjustment method that first identifies the type of dimensional deviation of the workpiece to be welded, determines the deviation value, and then obtains the power compensation value based on a preset mapping relationship. Specifically, the method first clarifies the type of dimensional deviation of the workpiece to be welded (covering at least one of gap deviation, hole position deviation, and assembly misalignment deviation), then accurately obtains the corresponding dimensional deviation value for the deviation type, finds the appropriate power compensation value through a preset mapping relationship between the deviation value and the power compensation value, calculates the actual power value by combining the preset power value and the power compensation value, and finally applies the actual power value during the welding process, replacing the traditional fixed parameters and manual / offline calibration mode. This method allows the welding power to be adapted to the specific dimensional deviations of the workpiece in real time, avoiding quality problems such as overheating and insufficient penetration caused by parameter mismatch. It significantly improves the stability and consistency of weld quality, while reducing the frequency of rework, lowering production costs, and enhancing the automation and intelligence of the welding process, enabling precise parameter adjustments without relying on human experience. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0042] Figure 1 This is a schematic flowchart of the first embodiment of the welding process method of the present invention;

[0043] Figure 2 This is a schematic flowchart of the second embodiment of the welding process method of the present invention;

[0044] Figure 3 This is a schematic flowchart of the third embodiment of the welding process method of the present invention;

[0045] Figure 4 This is a schematic flowchart of the fourth embodiment of the welding process method of the present invention;

[0046] Figure 5 This is a schematic flowchart of the fifth embodiment of the welding process method of the present invention;

[0047] Figure 6 This is a structural block diagram of the first embodiment of the welding processing apparatus of the present invention;

[0048] Figure 7 This is a schematic diagram of the welding processing equipment in the hardware operating environment involved in the embodiments of the present invention.

[0049] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0050] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0051] Reference Figure 7 , Figure 7 This is a schematic diagram of the welding processing equipment structure of the hardware operating environment involved in the embodiments of the present invention.

[0052] like Figure 7 As shown, the welding processing equipment may include: a processor 1001, such as a central processing unit (CPU), a communication bus 1002, a user interface 1003, a network interface 1004, and a memory 1005. The communication bus 1002 is used to enable communication between these components. The user interface 1003 may include a display screen and an input unit such as a keyboard; optionally, the user interface 1003 may also include a standard wired interface or a wireless interface. The network interface 1004 may optionally include a standard wired interface or a wireless interface (such as Wireless Fidelity). Fidelity, Wi Fi interface). The memory 1005 can be a high-speed random access memory (RAM) or a stable non-volatile memory (Non-volatile memory). Volatile Memory (NVM), such as disk storage. Alternatively, memory 1005 may be a storage device independent of the aforementioned processor 1001.

[0053] Those skilled in the art will understand that Figure 7The structure shown does not constitute a limitation on the welding processing equipment and may include more or fewer components than shown, or combine certain components, or have different component arrangements.

[0054] like Figure 7 As shown, the memory 1005, which serves as a storage medium, may include an operating system, a network communication module, a user interface module, and a welding processing program.

[0055] exist Figure 7 In the welding processing equipment shown, the network interface 1004 is mainly used for data communication with the network server; the user interface 1003 is mainly used for data interaction with the user; the processor 1001 and the memory 1005 in the welding processing equipment of the present invention can be set in the welding processing equipment. The welding processing equipment calls the welding processing program stored in the memory 1005 through the processor 1001 and executes the welding processing method provided in the embodiment of the present invention.

[0056] Please refer to Figure 1 , Figure 1 This is a schematic flowchart of a first embodiment of a welding process method according to the present invention. In one embodiment, the welding process method proposed by the present invention includes the following steps:

[0057] S100. Obtain the dimensional deviation type of the current workpiece to be welded; wherein, the dimensional deviation type includes at least one of clearance deviation, hole position deviation, and assembly misalignment deviation;

[0058] It should be noted that the execution subject in this embodiment is the control unit of the welding processing equipment. The welding processing equipment includes an input unit, an execution unit, and a control unit, and may also include other functional units or components. This embodiment does not limit these.

[0059] Dimensional deviation type refers to the general category of deviations between the actual assembly state of the workpiece to be welded and the design standard in the dimensional dimension during welding. Its core function is to clarify the specific direction of the workpiece's deviation from the design requirements, providing a precise basis for subsequent targeted adjustment of welding parameters. Specifically, it covers gap deviation, hole position deviation, and assembly misalignment deviation, which can exist individually or in combination.

[0060] Gap deviation specifically refers to the difference between the actual spacing formed at the joint of the workpiece to be welded and the preset spacing specified in the design standard. It includes both the case of "gap too large" where the joint spacing is greater than the design value and the case of "gap too small" where the spacing is less than the design value. This deviation directly affects the welding penetration and weld bead formation effect, and is a type of deviation that needs to be carefully considered when adjusting welding parameters.

[0061] Hole position deviation refers to the difference between the actual center coordinates, hole diameter, or hole axis direction of the pre-set welding positioning holes, assembly holes, and other key holes on the workpiece to be welded and the standard coordinates, dimensions, and directions marked on the design drawings. Common manifestations include hole position translation, deflection, or hole diameter being too large / too small, which can lead to problems such as inaccurate welding positioning and weld offset.

[0062] Assembly misalignment deviation refers to the failure of two or more workpieces to be welded to be precisely aligned according to design requirements during the assembly process, resulting in deviations in the axial direction, planar fit, or radial position of the workpieces. For example, the edges of the workpieces to be welded may be uneven, the axes may not be concentric, or the planes may be misaligned. This deviation will cause uneven stress on the weld and poor weld formation, seriously affecting the strength and sealing of the welded structure.

[0063] In this step, a comprehensive inspection of the assembly status of the workpiece to be welded is first conducted. Using inspection tools such as vision sensors, laser scanners, or high-precision displacement sensors, potential dimensional deviations of the workpiece before welding are captured, identifying the types of dimensional deviations. The inspection focuses on scanning the welding interface and critical assembly positions to ensure no core deviations affecting welding quality are missed. Specific dimensional deviation types include gap deviations, hole position deviations, and assembly misalignment deviations. The system supports the identification of single-type deviations and can also detect multiple types of deviations simultaneously, providing a clear direction for subsequent targeted adjustments to welding parameters.

[0064] S200. Determine the dimensional deviation value of the current workpiece to be welded according to the dimensional deviation type; determine the power compensation value mapped by the dimensional deviation value based on the preset mapping relationship;

[0065] It should be noted that dimensional deviation values ​​are specific numerical parameters derived from identified dimensional deviation types using high-precision testing equipment and quantitative algorithms. These parameters accurately reflect the degree of deviation between the actual state of the workpiece and the design standards. The core of this approach is to transform the "deviation type" from a qualitative description into quantitative data. For example, the gap deviation value is the difference between the actual interface spacing and the designed spacing (a positive value indicates an excessively large gap, and a negative value indicates an excessively small gap); the hole position deviation value is the three-dimensional offset between the actual hole position coordinates and the designed coordinates; and the assembly misalignment deviation value is the actual misalignment distance or angle in the workpiece's alignment direction. This value directly determines the magnitude of welding power compensation and is the core quantitative basis for achieving precise parameter adjustment.

[0066] The mapping relationship is a pre-established system of rules for associating dimensional deviation values ​​with power compensation values. It is based on extensive experimental data from various materials, plate thicknesses, and welding processes, combined with welding fusion theory and heat conduction principles. This relationship clarifies the specific power compensation value corresponding to each deviation range under different deviation types (e.g., for every 0.5mm increase in gap deviation, the power compensation value increases by 5%), and can be stored in the welding control system. It supports real-time recall, dynamic updates, and flexible adaptation. Its core function is to automatically convert "deviation quantification data" into "parameter compensation instructions," avoiding the subjectivity and lag of manual judgment and ensuring the speed and accuracy of welding parameter adjustments.

[0067] In this step, after identifying the type of dimensional deviation, corresponding quantitative measurement methods are used for different types of deviations to obtain accurate dimensional deviation values: For gap deviations, the difference between the actual distance at the weld joint and the design standard value is measured using methods such as laser ranging or image pixel analysis; for hole position deviations, the actual center coordinates of the preset weld hole are captured using coordinate positioning technology and compared with the design coordinates to calculate the offset; for assembly misalignment deviations, the misalignment amplitude of the workpiece in the axial, radial, or planar directions is measured with reference to the assembly datum surface or datum line of the workpiece. Subsequently, the corresponding power compensation value is determined according to a preset mapping relationship. This mapping relationship is established in advance through the accumulation of a large amount of welding experimental data and the fitting of welding process characteristics of workpieces with different materials and plate thicknesses. It clarifies the corresponding rules of different deviation types, different deviation value ranges, and power compensation values, and this mapping relationship can be stored in the control system, supporting real-time retrieval and dynamic updates to ensure accurate matching between deviation values ​​and power compensation values.

[0068] S300. Determine the actual power value based on the preset power value and the power compensation value;

[0069] It should be noted that the preset power value is a baseline power parameter pre-set based on the basic design attributes of the workpiece to be welded (such as material, plate thickness, weld joint type, and welding method), combined with the conventional welding process requirements under scenarios with no dimensional deviations, and verified through multiple sets of process experiments. It is the core reference for adjusting the welding power, which can stably meet the fusion requirements when the workpiece has no deviations, and provides a unified and reliable basic standard for subsequent power correction for dimensional deviations, avoiding parameter adjustment chaos caused by the lack of a baseline.

[0070] The power compensation value is a directional correction parameter derived by matching the identified dimensional deviation types (such as gap deviation, hole position deviation, and assembly misalignment deviation) and precise dimensional deviation values ​​of the workpiece to be welded through a preset mapping relationship. Its correction direction (positively increasing power or negatively decreasing power) and correction magnitude perfectly adapt to the impact of deviations on welding quality. For example, when the gap is too large, positive compensation is used to enhance penetration; when the gap is too small, negative compensation is used to avoid overheating. Its core function is to compensate for the adaptation gap of the preset power value when dealing with dimensional deviations, achieving precise correction of welding power.

[0071] S400. When welding the current workpiece to be welded, the actual power value is applied.

[0072] The welding method provided by this invention solves the problems of traditional welding processes where fixed parameters cannot respond to dynamic changes in the workpiece in real time, cannot adapt to dimensional deviations leading to unstable weld quality, and increased rework rates and production costs. Specifically, it first identifies the type of dimensional deviation of the workpiece to be welded (covering at least one of gap deviation, hole position deviation, and assembly misalignment deviation), then accurately obtains the corresponding dimensional deviation value for that type. A suitable power compensation value is found through a preset mapping relationship between the deviation value and the power compensation value. The preset power value is combined with the power compensation value to calculate the actual power value, which is then applied during the welding process. This replaces the traditional fixed parameters and manual / offline calibration mode. This method allows the welding power to adapt to the specific dimensional deviation of the workpiece in real time, avoiding quality problems such as overheating and insufficient penetration caused by parameter mismatch. It significantly improves the stability and consistency of weld quality, reduces rework frequency and production costs, and enhances the automation and intelligence of the welding process, achieving precise parameter adjustment without relying on human experience.

[0073] Please refer to Figure 2 , Figure 2 This is a schematic flowchart of a second embodiment of a welding process method according to the present invention. In this embodiment, the following steps are included after step S400:

[0074] S500: Perform quality inspection on the weld bead of the currently welded workpiece and obtain the corresponding quality inspection results;

[0075] It should be noted that weld quality inspection refers to a comprehensive and accurate evaluation process of the weld bead formed after welding, using a combination of various inspection technologies to assess key quality aspects such as surface defects, internal structure, and dimensional parameters. This includes both the identification of visible defects and the exploration of internal properties. The core objective is to achieve an objective and comprehensive judgment of weld quality, avoiding misjudgments caused by relying on a single indicator.

[0076] Quality inspection results are the specific conclusions or data output after weld quality inspection. They include both quantitative indicators (such as measured penetration depth, number and size of pores, and weld width deviation) and qualitative evaluations (such as "qualified", "unqualified", and "minor undercut exists, requiring attention"). Their function is to intuitively reflect the actual effect of the current welding process (especially the actual power value) and provide a quantifiable basis for subsequent decisions such as whether rework is needed and whether the mapping relationship needs to be adjusted.

[0077] In this step, the weld bead of the completed workpiece is inspected in a multi-dimensional and high-precision manner to systematically evaluate whether the welding effect meets the preset quality standards. During the inspection, key indicators such as the appearance of the weld bead (e.g., whether there are defects such as cracks, porosity, undercut, and weld beads), internal performance (e.g., whether the penetration depth and width meet the standards, and whether there is incomplete fusion inside the weld), and dimensional accuracy (e.g., the deviation of weld bead width and reinforcement height from the design values) are assessed using a combination of methods, including visual imaging inspection (capturing weld bead surface features with a high-definition camera), non-destructive testing (e.g., ultrasonic testing and radiographic testing to detect internal defects), and laser scanning (measuring weld bead dimensional parameters). This ensures that the inspection covers the core dimensions of weld bead quality and ultimately generates result data that can quantitatively or qualitatively describe the weld bead quality status. This provides a direct basis for verifying the suitability of the current welding parameters (actual power values) and for subsequent optimization of mapping relationships or adjustment of welding strategies.

[0078] S600. Update the mapping relationship based on the quality inspection result of at least one preceding welded workpiece to determine the power compensation value for subsequent workpieces to be welded.

[0079] It should be noted that "quality inspection results of at least one previously welded workpiece" refers to the weld quality assessment data or conclusions of at least one workpiece that has been welded before the current workpiece to be welded and obtained through quality inspection steps (such as S500). These results include, but are not limited to, quantitative or qualitative information such as weld appearance defects (such as cracks and porosity), internal properties (such as penetration depth and fusion condition), and dimensional accuracy (such as weld width deviation). They are key feedback data reflecting the actual adaptation effect of the preceding welding parameters (especially the power compensation value determined based on the original mapping relationship).

[0080] The "mapping relationship" mentioned in the steps refers to a pre-established system of rules for associating dimensional deviation values ​​with power compensation values ​​(such as rules that different gap deviation values ​​correspond to different power compensation amplitudes). In this step, this mapping relationship will be adjusted and optimized based on "the quality inspection results of at least one previously welded workpiece." That is, if the previous results show that the power compensation corresponding to a certain deviation value leads to quality defects (such as overheating or insufficient penetration), the correspondence between the deviation value and the compensation value will be corrected, making the updated mapping relationship more suitable for the actual welding scenario and improving the accuracy of determining the power compensation value of subsequent workpieces to be welded.

[0081] In this embodiment, a closed-loop process of "deviation identification - parameter adaptation - quality inspection - rule iteration" is used to achieve intelligent and precise upgrades in welding technology. First, by dynamically identifying workpiece dimensional deviations and adjusting welding power accordingly, the problem of traditional fixed parameters being unable to handle deviations is avoided, significantly reducing defects such as overheating and insufficient penetration, improving weld quality stability and consistency, and reducing rework rates and production costs. Second, the weld quality inspection of S500 provides direct feedback on the parameter adaptation effect, and S600 iteratively updates the mapping relationship based on the previous workpiece inspection results, ensuring that the correspondence between deviation values ​​and power compensation values ​​continuously matches the actual welding scenario, adapting to variables such as equipment status and material fluctuations. Finally, the entire process does not rely on human experience, achieving automated adjustment and continuous optimization of welding parameters, improving the intelligence level and production efficiency of welding processing, enhancing the method's adaptability to different working conditions, and ensuring quality uniformity in mass production.

[0082] Please refer to Figure 3 , Figure 3 This is a schematic flowchart of a third embodiment of a welding process method according to the present invention. In this embodiment, step S500 includes:

[0083] S510. Acquire a three-dimensional image of the weld bead of the currently welded workpiece;

[0084] It should be noted that a 3D image is a digital image data generated by scanning the weld bead formed on a workpiece that has just been welded using professional imaging equipment. The image includes the three-dimensional shape of the weld bead, spatial dimensions (such as weld width, reinforcement height, and three-dimensional coordinates of the cross-sectional profile), surface texture, and subtle defects (such as the three-dimensional distribution of micropores and cracks).

[0085] S520. Compare the features of the three-dimensional image with the three-dimensional reference image of the preset weld bead corresponding to the material and welding process of the currently welded workpiece.

[0086] It should be noted that "the material and welding process of the currently welded workpiece" refers to the material (such as steel, aluminum, alloy, etc.) used in the currently completed welding workpiece and the process method used in the welding process (such as electric arc welding, laser welding, argon arc welding, etc.). These two factors directly determine the quality standards that the weld should have (such as penetration depth, forming characteristics, etc.) and are the key basis for matching the corresponding reference image. Under different materials and processes, the characteristics of qualified welds are different, and reference images need to be selected accordingly.

[0087] The three-dimensional reference image of the pre-set weld bead refers to the standard three-dimensional digital model of the weld bead generated in advance based on the material and welding process of the currently welded workpiece, through a large number of qualified welding experiments and in combination with industry quality standards. It includes the ideal three-dimensional shape (such as cross-sectional profile and surface flatness), dimensional parameters (such as reasonable range of weld width and reinforcement height) and defect-free state (such as no cracks and porosity) that the weld bead should have under the working conditions. It is the "standard template" for judging the quality of the actual weld bead.

[0088] Feature comparison refers to the process of extracting key features (such as edge contour curves, surface texture distribution, height / width variation trends, etc.) between the actual 3D image of the weld and the 3D reference image using digital image processing technology, and comparing these features one by one to analyze the similarities and differences between the two in terms of shape, size, and state, so as to provide preliminary difference information for subsequent accurate determination of weld quality.

[0089] S530. When a difference is found between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead, the core features of the weld bead of the currently welded workpiece are obtained.

[0090] It should be noted that core characteristics refer to the key feature parameters that play a decisive role in weld quality assessment. These are the core indicators that directly affect weld performance (such as strength, sealing, and durability) and whether it meets design requirements. Specifically, these include, but are not limited to: key dimensional parameters of the weld (such as penetration depth—the depth of the weld into the workpiece substrate, weld width—the width of the weld's lateral expansion, and weld reinforcement height—the height of the weld exceeding the workpiece surface); morphological characteristics of the weld (such as whether the cross-sectional profile is symmetrical, whether there are depressions or protrusions, and whether the edge transition is smooth); and defect characteristics that affect quality (such as the length and depth of cracks, the number and diameter of pores, and the width and depth of undercut). These characteristics are the core basis for distinguishing whether a weld is qualified or not. Compared to non-critical minor differences (such as slight surface scratches), these deviations directly relate to the actual function of the weld. Therefore, they need to be extracted and analyzed in the inspection process to provide key quantitative data for subsequent accurate quality assessment.

[0091] S540. Use a feature matching algorithm to compare the core features of the weld bead of the currently welded workpiece with the core features of the preset weld bead;

[0092] Understandably, the core characteristics of a pre-set weld bead refer to the key characteristic parameters that a weld bead should ideally possess, pre-defined based on the material (e.g., steel, aluminum) and welding process (e.g., arc welding, laser welding) of the currently welded workpiece. These parameters are established through numerous qualified welding experiments, combined with industry quality standards and design requirements. These characteristics serve as the benchmark for determining the quality of the weld bead, specifically including: a pre-set penetration range (ensuring the bond strength between the weld bead and the substrate), standard weld width and reinforcement height (meeting structural dimensional requirements), a standardized cross-sectional shape (e.g., a symmetrical trapezoid or arc shape to ensure uniform stress distribution), and a defect-free state (e.g., no cracks, no excessive porosity, no undercut, etc.). Its core function is to serve as a key indicator for a standard template, allowing comparison of the core characteristics of the actual weld bead. Difference analysis quantifies the degree of matching between the two, providing a benchmark for subsequent similarity determination and quality assessment.

[0093] S550. Based on the comparison results, determine the similarity between the weld bead of the currently welded workpiece and the preset weld bead.

[0094] Understandably, "similarity" is an index (usually presented as a percentage) reflecting the degree of matching between the core features of the current weld bead and the core features of the preset weld bead, obtained through quantitative analysis of the comparison results. Its calculation requires considering the weighted impact of each core feature on weld quality—for example, key features such as penetration depth and absence of cracks have higher weights, while secondary features such as surface texture have lower weights. The matching degree of each core feature (such as dimensional deviation rate, morphological conformity, and defect difference) is calculated through weighted averages to obtain a comprehensive similarity value. A higher value indicates a higher degree of conformity between the core features of the actual weld bead and the preset standard weld bead, and the closer the quality is to the ideal state; conversely, a lower value indicates a significant difference, providing a quantifiable core reference for subsequent determination of product qualification based on preset thresholds.

[0095] S560. If the similarity is higher than or equal to a preset threshold, the currently welded workpiece is determined to be a qualified product; if the similarity is lower than the preset threshold, the currently welded workpiece is determined to be an unqualified product.

[0096] In this embodiment, three-dimensional weld bead image acquisition is employed. Compared to two-dimensional images, this method can completely capture the three-dimensional morphology, spatial dimensions, and three-dimensional distribution of minute defects in the weld bead, avoiding the omission of defects such as surface cracks and micropores due to limited viewing angles, thus significantly improving the comprehensiveness of the inspection. Secondly, the reference image is strictly matched to the material and welding process of the current workpiece, ensuring the relevance and adaptability of the comparison standard, avoiding misjudgments caused by universal benchmarks, and improving the accuracy of quality assessment. Furthermore, core features are extracted only when differences are found in the initial comparison, focusing on key quality indicators such as penetration depth and cross-sectional shape, eliminating interference from non-critical minor differences, and balancing inspection accuracy and efficiency. At the same time, feature matching algorithms are used to achieve quantitative comparison of core features, replacing subjective human judgment, reducing human error, and making quality assessment more objective and consistent. In addition, through similarity quantification and preset threshold judgment, clear and unified quality standards are established, facilitating standardized quality inspection in mass production. Moreover, the inspection results can provide accurate and quantifiable feedback data for subsequent mapping relationship updates, helping to optimize welding parameters in a closed loop, and further improving the stability and process adaptability of the overall welding quality.

[0097] Please refer to Figure 4 , Figure 4 This is a schematic flowchart of a fourth embodiment of a welding process method according to the present invention. In this embodiment, step S530 includes:

[0098] S531. Perform a difference operation on the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead to generate a difference map;

[0099] It should be noted that the difference operation is a calculation process that uses digital image processing algorithms to calculate the difference in pixel values ​​(such as depth values ​​and grayscale values) at corresponding three-dimensional coordinate points between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead. Specifically, a subtraction operation is performed on the three-dimensional parameters (such as the height of a point and the depth from the reference surface) at the same spatial location in the two images to obtain the deviation value at that location. This quantifies the spatial difference between the actual weld bead and the reference weld bead, providing a data basis for subsequent location of the difference area.

[0100] The difference map is a visualization image generated after the difference operation. It intuitively presents the difference distribution between the actual weld bead 3D image and the reference image through color or grayscale gradient. Areas with a deviation value of zero (no difference) are usually displayed in neutral colors, while areas with larger deviation values ​​(more significant differences) are marked with specific bright colors (such as red and blue). It can quickly locate areas in the actual weld bead that do not conform to the reference shape, thus narrowing the scope for subsequent extraction of core features.

[0101] S532. Based on the difference map, identify the target areas on the weld where there are geometric differences;

[0102] It should be noted that geometric morphological differences refer to the differences in spatial shape and structural dimensions between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead. Specifically, the actual weld bead deviates from the reference weld bead in terms of geometric attributes such as outline, height, width, and surface flatness (e.g., the weld bead is wider than the reference in a certain place, the excess height of a certain section exceeds the standard range, and there are local depressions). It is the core morphological feature reflecting the weld bead quality deviation.

[0103] The target region refers to the specific spatial area on the actual weld that exhibits geometrical differences, as identified by the difference map. Specifically, it is the localized area highlighted in the difference map that does not conform to the baseline weld shape (e.g., an area where the width of a weld segment exceeds the standard, or an edge area with undercut). This region is the focus for subsequent extraction of core features. By focusing on the target region, invalid analysis of areas without differences can be avoided, thus improving feature extraction efficiency.

[0104] S533. Extract geometric morphological features from the target area as the core features, wherein the geometric morphological features include at least one of weld width, weld reinforcement height, undercut depth, and spatter height.

[0105] It should be noted that weld width refers to the maximum dimension of the weld bead in the transverse direction (perpendicular to the welding direction), that is, the straight-line distance between the two edges of the weld bead. It is a key parameter reflecting whether the transverse formation of the weld bead meets the design requirements. Too wide a weld bead may result in excessive heat input, while too narrow a weld bead may result in insufficient fusion, which directly affects the welding strength.

[0106] Weld reinforcement refers to the vertical height of the highest point of the weld bead surface above the surface of the base material of the workpiece to be welded. It is a core indicator for measuring the longitudinal formation of the weld bead. Too high reinforcement will lead to stress concentration, while too low reinforcement may fail to meet the sealing or structural strength requirements. It must be controlled within a preset range.

[0107] Undercut depth refers to the maximum depth of the local depression (i.e., undercut defect) that appears at the junction of the weld edge and the base material. It is an important parameter reflecting the forming quality of the weld edge. Excessive undercut will weaken the effective cross-sectional area of ​​the base material and reduce the load-bearing capacity of the welded structure. It is a defect feature that needs to be strictly controlled.

[0108] Spatter height refers to the maximum height of the protrusion formed after the molten droplets solidify on the weld surface or nearby base material during the welding process. It is an auxiliary indicator for evaluating the stability of the welding process. Excessive spatter will affect the appearance of the weld and subsequent processing (such as painting and assembly). Too much or too high spatter usually means that the welding parameters need to be optimized.

[0109] In this embodiment, the step employs a progressive design: generating a difference map through differential operations, identifying the target region based on the difference map, and extracting core features from the target region. This approach leverages differential operations to quantify the differences between the actual weld and the reference weld, avoiding subjective errors from manual comparison and accurately capturing subtle geometric differences to prevent defect omissions. Furthermore, by focusing on target regions with differences, it reduces invalid data processing, significantly improving feature extraction efficiency. It also specifically extracts key geometric features directly related to weld strength and forming quality, such as weld width, reinforcement height, and undercut depth, providing accurate core data for subsequent quantitative comparison and similarity calculation. Simultaneously, it automates and standardizes difference localization, region focusing, and feature extraction, ensuring data consistency and providing reliable support for subsequent quality judgment and mapping relationship updates. This further enhances the accuracy of welding quality inspection and the ability to optimize the process loop.

[0110] Please refer to Figure 5 , Figure 5 This is a schematic flowchart of a fifth embodiment of a welding process method according to the present invention. In one embodiment, step S600 includes:

[0111] S610. Select the welded workpieces that are determined to be unqualified products from the accumulated quality inspection results, and associate them with the corresponding dimensional deviation type and power compensation value;

[0112] It should be noted that the cumulative quality inspection results refer to the collection and storage of quality inspection results (including pass / fail judgment, similarity values, core feature data, etc.) obtained through the S500 step for all welded workpieces within a certain period (such as after every 1500 welds or after each batch of production). These cumulative results are not isolated data of a single workpiece, but rather a batch sample formed through continuous accumulation. They can reflect the welding quality patterns corresponding to different dimensional deviation types and different power compensation values ​​(such as the common characteristics of repeated non-compliance under a certain type of deviation), providing a sufficient sample size for screening non-conforming products and analyzing the causes of defects, avoiding the influence of randomness from single data, and ensuring the scientific nature of subsequent mapping adjustments.

[0113] S620. Based on the core features and dimensional deviation type of the welded workpiece that is determined to be a non-conforming product, determine the defect type corresponding to the welded workpiece that is determined to be a non-conforming product.

[0114] It is understood that the core features of the welded workpieces that are determined to be unqualified products refer to the key geometric morphological features (such as excessive undercut depth, abnormal weld reinforcement, excessive spatter height, etc.) extracted through step S533 from the welded workpieces that are determined to be unqualified. These features are specific data that quantify the degree of defects.

[0115] Defect type refers to the specific quality problem category determined comprehensively based on the core features and dimensional deviations of the defective workpiece. For example, if the core features show insufficient penetration and narrow weld width, and the corresponding dimensional deviation is "excessive gap," then the defect type can be determined as "poor fusion." If the core features show overheating marks in the weld bead and abnormally increased weld height, and the corresponding deviation is "excessive gap," then the defect type can be determined as "overheating defect." Defect type serves as a bridge connecting quality problems and parameter adjustments, clarifying the specific causes of nonconformity.

[0116] S630. Based on the defect type, determine an adjustment strategy for the mapping relationship to increase or decrease the power compensation value.

[0117] It should be noted that the adjustment strategy refers to the specific modification plan formulated based on the identified defect type for the corresponding rule of "size deviation value - power compensation value" in the mapping relationship. Its core is to eliminate the parameter adaptation problem that causes the defect by adjusting the size or direction of the compensation value, so as to make the power compensation of subsequent welding more accurate. For example: If the defect type is "poor fusion" (core features show insufficient penetration and insufficient weld width), and the corresponding dimensional deviation type is "excessive gap", it means that the power compensation value corresponding to the gap deviation value in the original mapping relationship is too small (insufficient heat input). The adjustment strategy is to "increase the power compensation value corresponding to the gap deviation value range" (e.g., if the original compensation value is +5%, adjust it to +8%) to increase heat input and ensure sufficient fusion. If the defect type is "overheating defect" (core features show overmelting at the weld edge and abnormal weld height), and the corresponding dimensional deviation type is "excessive gap", it means that the power compensation value corresponding to the gap deviation value in the original mapping relationship is too large (excessive heat input). The adjustment strategy is to "decrease the power compensation value corresponding to the gap deviation value range" (e.g., if the original compensation value is +3%, adjust it to -2%) to reduce heat input and avoid overheating.

[0118] In this embodiment, by screening out non-conforming products from cumulative quality inspection results and associating them with corresponding dimensional deviation types and power compensation values, the analysis is ensured to focus on key parameters that truly affect quality, thus improving the targeting of optimization. Combining core features and dimensional deviation types to determine defect types overcomes the limitation of knowing only that a product is non-conforming but not understanding the cause, providing a clear direction for adjusting the mapping relationship and avoiding blind trial and error. Then, based on the defect type, adjustment strategies are formulated (such as increasing the compensation value of the corresponding deviation when there is poor fusion, and decreasing the compensation value when there is overheating), so that the mapping relationship update directly addresses the actual quality problem. Ultimately, this achieves accurate matching between the power compensation value of subsequent workpieces to be welded and the actual deviation scenario, continuously reducing the non-conforming rate. Simultaneously, it allows the welding process to adapt to variables such as equipment status and material fluctuations, significantly improving the stability of quality and the robustness of the process in mass production.

[0119] In one embodiment, step S200 includes:

[0120] S210. Obtain the key dimension parameters of the current workpiece to be welded; wherein, the key dimension parameters include at least one of the gap at the joint of the workpiece to be welded, the actual position of the positioning hole on the workpiece to be welded, and the alignment amount of the joint edge of the workpiece to be welded.

[0121] It is known that the gap at the joint of two workpieces to be welded refers to the actual distance between the interfaces of the two workpieces to be welded, that is, the width of the gap between the mating surfaces. It is a core parameter for determining whether there is a gap deviation, which directly affects the weld penetration and weld bead formation. It needs to be compared with the preset standard gap to determine the deviation.

[0122] The actual position of the positioning holes on the workpiece to be welded refers to the spatial coordinates (such as three-dimensional position, distance from the reference plane, relative spacing between holes, etc.) of the holes used for welding positioning and assembly on the workpiece. This parameter needs to be compared with the standard position marked on the design drawings to determine the hole position deviation, ensure the positioning accuracy during welding, and avoid weld seam offset.

[0123] The alignment of the butt joint edges of two workpieces to be welded refers to the quantified value of the degree of alignment of the butt joint edges of the two workpieces after assembly, along or perpendicular to the welding direction. For example, whether the butt joint edges are flush, the existence of height differences or front-to-back misalignment distances are key criteria for judging assembly misalignment deviations, which directly affect the uniformity of stress on the weld and the structural sealing performance.

[0124] S220. Calculate the difference between the key dimension parameter and the preset standard dimension under the dimension deviation type to obtain the dimension deviation value.

[0125] It should be noted that the preset standard dimension under the aforementioned dimensional deviation type refers to the ideal standard value or range that the key dimensional parameter should reach under a deviation-free state, determined in advance based on the design drawings, welding process specifications, and qualified product production standards for each specific dimensional deviation type (such as clearance deviation, hole position deviation, and assembly misalignment deviation). For example, for the "clearance deviation" type, the preset standard dimension is the preset standard clearance at the joint of the workpiece to be welded (such as the 2mm clearance required by the design); for the "hole position deviation" type, the preset standard dimension is the design standard position coordinates of the positioning hole on the workpiece to be welded (such as the three-dimensional coordinates of the hole center marked on the drawing); for the "assembly misalignment deviation" type, the preset standard dimension is the standard alignment amount of the joint edge of the workpiece to be welded (such as the joint edge being flush as required by the design, with an alignment difference of 0). The preset standard dimension under this dimensional deviation type is the core benchmark for measuring whether there is a deviation in the key dimensional parameter and calculating the dimensional deviation value. By subtracting it from the actually obtained key dimensional parameter, the dimensional deviation value can be quantified.

[0126] In this embodiment, by acquiring key dimensional parameters such as the gap at the joint of the workpiece to be welded, the actual position of the positioning hole, and the alignment of the joint edge, the core dimensions prone to deviations during welding are covered, ensuring that no deviation is missed. At the same time, for different types of dimensional deviations, the difference between the key dimensional parameters and the corresponding preset standard dimensions is calculated to obtain the dimensional deviation value, realizing the quantitative characterization of the deviation, replacing the vague qualitative description, and ensuring the accurate correspondence between the deviation value and the specific deviation type. This avoids the ambiguity in deviation positioning caused by general calculations, and provides accurate and targeted basic data for subsequent determination of power compensation values ​​based on deviation values. This ensures the accuracy of welding parameter adjustment from the source and helps to improve the quality of the weld.

[0127] In one embodiment, the mapping relationship includes:

[0128] A: When the key dimension parameter includes one, the power compensation value is the sub-compensation value corresponding to the key dimension parameter;

[0129] It should be noted that for gap deviation type, the calculation formula for sub-compensation value is ΔP=Kv×Gap (where ΔP is the power compensation value, Kv is the compensation coefficient of gap deviation, and Gap is the size deviation value of gap amount). For example, when the size deviation value of gap amount ΔGap is ±0.2mm and the compensation coefficient Kv is 100W / mm, the corresponding power compensation value is ±20W. The influence of gap deviation on weld fusion can be addressed by adjusting the power.

[0130] For hole position deviation type, the calculation formula for sub-compensation value is ΔP=Ky×Δy (where Ky is the compensation coefficient of hole position deviation, and Δy is the deviation value between the actual position of the positioning hole and the standard position). For example, when the hole position deviation value Δy is ±0.1mm and the compensation coefficient Ky is 80W / mm, the corresponding power compensation value is ±8W to adapt to the influence of hole position deviation on welding positioning accuracy.

[0131] For assembly misalignment, the formula for calculating the sub-compensation value is ΔP=Kc×C (where Kc is the compensation coefficient for assembly misalignment and C is the deviation value of the butt joint alignment). For example, when the alignment deviation value C is 0.1mm and the compensation coefficient Kc is 150W / mm, the corresponding power compensation value is ±15W, which is used to balance the influence of misalignment deviation on the uniformity of weld stress.

[0132] B: When the key dimension parameters include multiple parameters, the power compensation value is the sum of the sub-compensation values ​​corresponding to the multiple key dimension parameters; and each sub-compensation value corresponding to the key dimension parameter is configured with a different weight coefficient, which is preset according to the degree of influence of the multiple key dimension parameters on the welding quality or dynamically adjusted based on historical quality inspection results.

[0133] It should be noted that the specific calculation is performed using the composite deviation compensation formula ΔP=Σ(Kn×ΔDn) (where ΔP is the total power compensation value, Kn is the compensation coefficient for the nth type of dimensional deviation, ΔDn is the deviation value of the nth key dimensional parameter, and Σ represents the summation of each sub-compensation value); and each sub-compensation value corresponding to the key dimensional parameter is configured with a different weight coefficient. This weight coefficient is preset according to the degree of influence of each parameter on the welding quality (e.g., when the gap deviation has a greater impact on the penetration depth, its weight is higher than that of the hole position deviation), or it is dynamically adjusted based on historical quality inspection results (e.g., if a certain parameter frequently causes defects in actual welding, its weight is increased).

[0134] For example, if the workpiece to be welded simultaneously has gap deviation and hole position deviation, where the gap deviation value ΔGap = 0.2mm (corresponding to a sub-compensation value of 20W, based on the gap deviation formula ΔP = Kv × Gap, Kv = 100W / mm), and the hole position deviation value ΔT = 0.1mm (corresponding to a sub-compensation value of 8W, based on the hole position deviation formula ΔP = Ky × Δy, Ky = 80W / mm), and both have a weight coefficient of 1 (meaning their influence is roughly equal under preset conditions), then the total power compensation value is 20W + 8W = 28W. Through this superposition calculation combined with weight allocation, it can comprehensively respond to the superimposed effects of multiple deviations and distinguish the importance of parameters through weighting, making the power compensation more aligned with the quality requirements of complex scenarios and reducing weld defects caused by the interaction of multiple deviations.

[0135] In addition, refer to Figure 6 The present invention also proposes a welding processing apparatus, the welding processing apparatus comprising:

[0136] The visual dimension measurement module 10 is used to obtain the dimensional deviation value of the current workpiece to be welded;

[0137] The mapping relationship decision module 20 is connected to the visual size measurement module 10 and is used to determine the power compensation value mapped by the size deviation value based on the preset mapping relationship.

[0138] The welding parameter dynamic compensation module 30 is connected to the mapping relationship decision module 20 and is used to determine the actual power value based on the preset power value and the power compensation value, and control the welding equipment to apply the actual power value.

[0139] The welding execution module 40 is used to apply the actual power value to the current workpiece to be welded in order to complete the welding.

[0140] It should be noted that the visual dimension measurement module 10 typically integrates industrial-grade optical sensing components, such as high-resolution cameras or laser scanners. Its housing is often made of high-strength metal materials (such as stainless steel) to withstand dust, vibration, and temperature fluctuations in the welding environment. The overall structure is compact and can be mounted on the side or above the welding station via a bracket, ensuring that the sensing components can be stably aligned with the mating area of ​​the workpiece to be welded. This module captures the morphological features of the workpiece's mating area (such as the relative distribution of edges and the spatial arrangement of positioning structures) through optical imaging or laser projection. Then, it analyzes and processes this feature information using built-in image processing algorithms, ultimately outputting quantitative data reflecting the workpiece's assembly state, providing a basis for subsequent parameter adjustments.

[0141] The mapping relationship decision module 20 is typically centered around an embedded control unit, encased in a metal shell (such as aluminum alloy) with electromagnetic shielding. Internally, it integrates a memory chip and a processing unit. The memory chip pre-stores mapping relationship data (i.e., the association rules between different assembly state characteristics and corresponding power adjustment amounts) established based on numerous welding experiments and process specifications. This module connects to the visual dimension measurement module 10 via a data interface. After receiving the quantized data output by the module, the processing unit quickly retrieves the stored mapping relationships for matching calculations. Based on the current assembly state characteristics of the workpiece, it determines the corresponding power compensation parameters and transmits these parameters to the next-level module. Its structural design emphasizes signal transmission stability and typically provides multiple standard interfaces for easy interfacing with different models of upstream and downstream modules.

[0142] The welding parameter dynamic compensation module 30 includes a power adjustment circuit and a microcontroller chip. The circuit is encapsulated in a high-temperature resistant insulating material (such as a ceramic substrate), and the outer shell is made of aluminum alloy with heat dissipation fins to efficiently dissipate the heat generated during power adjustment. One end of this module is connected to the mapping relationship decision module 20 to receive power compensation parameters, and the other end is connected to a preset base power signal (i.e., a reference welding power set for a standard assembly state). The microcontroller chip performs real-time calculations based on the base power signal and power compensation parameters to obtain the actual power value adapted to the current workpiece assembly state. Subsequently, the power adjustment circuit converts this power value into an electrical signal (such as a current or voltage adjustment signal) that can drive the welding equipment, precisely controlling the output power of the welding equipment and ensuring that the power can be dynamically adjusted according to changes in the workpiece assembly state.

[0143] The welding execution module 40 mainly consists of a welding execution mechanism and an energy output component. The welding execution mechanism is mostly a multi-axis robotic arm or a precision guide rail slide, made of high-strength alloy steel, possessing high motion accuracy and load capacity, and can drive the energy output component to move stably along a preset welding path. The core components of the energy output component (such as an arc welding torch or laser welding head) are made of high-temperature resistant alloy materials (such as copper alloy) to withstand the impact of high-temperature arc or laser energy during the welding process. After receiving the actual power control signal from the welding parameter dynamic compensation module 30, the energy output component generates a corresponding welding heat source (arc, laser, etc.) according to the signal, and under the drive of the execution mechanism, the heat source is precisely applied to the butt joint area of ​​the workpiece to be welded, causing the workpiece material to melt, fuse, and solidify at the set power, ultimately forming a weld that meets the quality requirements, completing the entire welding process.

[0144] In this embodiment, the welding processing device constructs a fully automated and precise welding system through a modular collaborative design of "visual size measurement module 10 - mapping relationship decision module 20 - welding parameter dynamic compensation module 30 - welding execution module 40". The visual size measurement module 10 provides real-time and reliable size deviation data for subsequent power compensation, avoiding errors and delays in manual measurement. The mapping relationship decision module 20 quickly matches targeted power compensation values ​​based on preset mapping relationships to adapt to single or multiple size deviation scenarios. The welding parameter dynamic compensation module 30 determines the actual welding power by combining the basic power value and the compensation value, realizing dynamic parameter adaptation to avoid the limitations of fixed parameters in dealing with deviations. The welding execution module 40 accurately applies the actual power to ensure the consistency of process implementation. The entire device can complete the closed-loop collaboration of deviation identification, parameter adjustment and welding execution without manual intervention, which not only greatly improves welding efficiency, but also reduces defects such as poor fusion and overheating through precise compensation to reduce the defect rate. It can also adapt to different types of size deviation scenarios, enhance the flexibility and stability of welding processing, and help standardize the control of welding quality in mass production.

[0145] In one embodiment, the welding processing apparatus further includes a quality inspection module 50, which is used to perform quality inspection on the weld bead after welding of the currently welded workpiece and obtain the corresponding quality inspection result; the quality inspection module 50 is electrically connected to the mapping relationship decision module 20.

[0146] It should be noted that the quality inspection module 50 adopts a compact structural design. The outer shell is made of stainless steel that is resistant to high and low temperatures and electromagnetic interference. It can be mounted next to the welding execution module via an adjustable bracket, ensuring that the inspection angle completely covers the entire extension area of ​​the weld bead, adapting to the welding quality inspection needs of workpieces of different shapes and materials. The module integrates high-resolution vision inspection components (such as macro cameras and laser contour sensors) and an embedded image processing unit. The lenses of the core inspection components are treated with an anti-spatter coating, and the circuit board of the image processing unit is mounted on a ceramic substrate to improve dust resistance and high-temperature resistance in the welding environment, ensuring long-term stable operation. The module's inspection process is achieved through the coordinated use of visual acquisition and feature analysis. The vision inspection components perform omnidirectional imaging or contour scanning of the weld bead after welding, capturing feature information such as the surface morphology, cross-sectional contour, and edge transitions. Subsequently, the image processing unit calls a preset quality analysis algorithm to quantitatively evaluate these feature information, identifying the presence of quality problems such as surface depressions, edge undercut, and spatter residue, and generating quantitative inspection results including weld bead morphology consistency, defect type, and degree, forming a complete quality data archive.

[0147] The quality inspection module 50 establishes a stable connection with the mapping relationship decision module through a standardized electrical signal interface, transmitting the generated quality inspection results to the mapping relationship decision module in real time. This connection design enables the module not only to independently and accurately determine the weld quality, but also to provide real and effective feedback data for the optimization of the mapping relationship. Based on the accumulated quality inspection results, the mapping relationship decision module can dynamically adjust the association rules between different assembly state characteristics and power compensation values, making the power compensation more in line with the actual welding quality requirements. This constructs a closed-loop process system of "inspection-feedback-optimization," further improving the stability and quality controllability of welding processing.

[0148] Since this device adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0149] Furthermore, embodiments of the present invention also propose a storage medium storing a welding process program, which, when executed by a processor, implements the steps of the welding process method described above.

[0150] Since this storage medium adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0151] It should be noted that the workflow described above is merely illustrative and does not limit the scope of protection of this invention. In practical applications, those skilled in the art can select some or all of the workflow to achieve the purpose of this embodiment according to actual needs, and no restrictions are imposed here.

[0152] In addition, for technical details not described in detail in this embodiment, please refer to the welding processing method provided in any embodiment of the present invention, which will not be repeated here.

[0153] Furthermore, it should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0154] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0155] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as read-only memory (ROM) / RAM, magnetic disk, optical disk) and includes several instructions to cause a terminal device (which may be a mobile phone, computer, server, or network device, etc.) to execute the methods described in the various embodiments of the present invention.

[0156] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A welding process, characterized in that, Includes the following steps: Obtain the dimensional deviation type of the current workpiece to be welded; wherein, the dimensional deviation type includes at least one of clearance deviation, hole position deviation, and assembly misalignment deviation; The dimensional deviation value of the current workpiece to be welded is determined according to the dimensional deviation type; the power compensation value mapped by the dimensional deviation value is determined based on the preset mapping relationship. The actual power value is determined based on the preset power value and the power compensation value; When welding the current workpiece to be welded, the actual power value is applied; The step of applying the actual power value when welding the current workpiece further includes: Perform quality inspection on the welds of the currently welded workpiece and obtain the corresponding quality inspection results; The mapping relationship is updated based on the quality inspection results of at least one previously welded workpiece to determine the power compensation value for subsequent workpieces to be welded. The steps of performing quality inspection on the weld bead of the currently welded workpiece and obtaining the corresponding quality inspection results include: Acquire a three-dimensional image of the weld bead of the currently welded workpiece; The three-dimensional image is compared with the three-dimensional reference image of the preset weld bead corresponding to the material and welding process of the currently welded workpiece. When a difference is found between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead, the core features of the weld bead of the currently welded workpiece are obtained. The core features of the weld bead of the currently welded workpiece are compared with the core features of the preset weld bead using a feature matching algorithm. Based on the comparison results, the similarity between the weld bead of the currently welded workpiece and the preset weld bead is determined; If the similarity is higher than or equal to a preset threshold, the currently welded workpiece is determined to be a qualified product; if the similarity is lower than the preset threshold, the currently welded workpiece is determined to be a defective product. The step of updating the mapping relationship based on the quality inspection results of at least one previously welded workpiece for determining the power compensation value of subsequent workpieces to be welded includes: The welded workpieces that are determined to be unqualified products are selected from the accumulated quality inspection results, and the corresponding dimensional deviation type and power compensation value are associated with them; Based on the core features and dimensional deviation type of the welded workpiece that is determined to be a non-conforming product, the defect type corresponding to the welded workpiece that is determined to be a non-conforming product is determined. Based on the defect type, an adjustment strategy for the mapping relationship is determined to increase or decrease the power compensation value.

2. The welding process method as described in claim 1, characterized in that, The step of obtaining the core features of the weld bead of the currently welded workpiece when there is a difference between the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead includes: Perform a difference operation on the three-dimensional image of the weld bead and the three-dimensional reference image of the preset weld bead to generate a difference map; Based on the difference map, target areas with geometrical differences on the weld bead are identified; Geometric morphological features are extracted from the target area as the core features, and the geometric morphological features include at least one of weld width, weld reinforcement, undercut depth, and spatter height.

3. The welding process method as described in claim 1, characterized in that, The step of determining the dimensional deviation value of the current workpiece to be welded based on the dimensional deviation type includes: Obtain the key dimensional parameters of the current workpiece to be welded; wherein, the key dimensional parameters include at least one of the gap at the joint of the workpiece to be welded, the actual position of the positioning hole on the workpiece to be welded, and the alignment amount of the joint edge of the workpiece to be welded; The difference between the key dimension parameter and the preset standard dimension under the dimension deviation type is calculated to obtain the dimension deviation value.

4. The welding process method as described in claim 3, characterized in that, The mapping relationship includes: When the key size parameter includes one, the power compensation value is the sub-compensation value corresponding to the key size parameter; When the key dimension parameters include multiple parameters, the power compensation value is the sum of the sub-compensation values ​​corresponding to the multiple key dimension parameters; and each sub-compensation value corresponding to the key dimension parameter is configured with a different weight coefficient, which is preset according to the degree of influence of the multiple key dimension parameters on the welding quality or dynamically adjusted based on historical quality inspection results.

5. A welding processing apparatus for implementing the welding processing method as described in any one of claims 1 to 4, characterized in that, The welding processing apparatus includes: The visual dimension measurement module is used to obtain the dimensional deviation value of the current workpiece to be welded; The mapping relationship decision module is connected to the visual size measurement module and is used to determine the power compensation value mapped by the size deviation value based on the preset mapping relationship. The welding parameter dynamic compensation module, connected to the mapping relationship decision module, is used to determine the actual power value based on the preset power value and the power compensation value, and control the welding equipment to apply the actual power value. The welding execution module is used to apply the actual power value to the current workpiece to be welded in order to complete the welding.

6. A welding processing equipment, characterized in that, The device includes a memory, a processor, and a welding process program stored in the memory and executable on the processor, the welding process program being configured to implement the welding process method as described in any one of claims 1 to 4.

7. A storage medium, characterized in that, The storage medium stores a welding process program, which, when executed by a processor, implements the welding process method as described in any one of claims 1 to 4.

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