A welding method, system, intelligent terminal, and storage medium for a double aluminum tube joint.
By opening holes at the ends of aluminum tubes and inserting sleeves, combining spot welding and full-scale welding, optimizing the welding path, and using gravity to control the flow of the molten pool, the problem of uneven welding strength in existing aluminum tubes was solved, achieving efficient and stable welding results.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- STATE GRID SHANXI POWER TRANSMISSION & DISTRIBUTION PROJECT CO
- Filing Date
- 2025-09-30
- Publication Date
- 2026-07-31
AI Technical Summary
Existing aluminum tube welding methods rely on preset trajectories and lack dynamic adjustment, resulting in uneven welding strength and reduced overall strength.
Holes are opened at the ends of aluminum tubes and sleeves are installed. Spot welding and full welding are combined to optimize the welding path. Image analysis and real-time monitoring feedback are introduced to control the flow of the molten pool. Segmented welding is performed and gravity is utilized.
It significantly enhances the structural integrity and connection strength of the double aluminum tube joint, improves welding quality and durability, optimizes production efficiency and intelligence level, and avoids welding defects.
Smart Images
Figure CN121104420B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of welding technology, and in particular to a welding method, system, smart terminal and storage medium for a double aluminum tube joint. Background Technology
[0002] Aluminum tube welding plays an important role in industrial applications, especially in fields with high requirements for lightweight design and corrosion resistance.
[0003] The relevant technology uses a preset welding path method when welding aluminum tubes. This method sets a programmed trajectory according to the welding requirements of the aluminum tube and controls the welding head to move along the programmed trajectory while welding, thereby achieving the welding of the aluminum tube.
[0004] Regarding the aforementioned technologies, the method of pre-setting welding paths relies heavily on programmed trajectories and lacks dynamic adjustment capabilities, resulting in uneven welding strength and reduced overall strength. Summary of the Invention
[0005] To improve the strength of double aluminum tube joints, this application provides a welding method, system, smart terminal, and storage medium for double aluminum tube joints.
[0006] Firstly, this application provides a welding method for a double aluminum tube joint, employing the following technical solution: A welding method for a double aluminum tube joint, comprising: A first hole is made at the first end of the first aluminum tube; A second hole is opened at the first end of the second aluminum tube; A sleeve is placed inside the first end of the first aluminum tube, such that the length of the sleeve protruding from the first aluminum tube reaches a preset length. Align the first end of the first aluminum tube with the first end of the second aluminum tube; The first end of the first aluminum tube and the first end of the second aluminum tube are spliced together to obtain a double aluminum tube joint. The length of the sleeve in the double aluminum tube joint inside the first aluminum tube is greater than the first length, and the length of the sleeve inside the second aluminum tube is greater than the second length. Spot welding is performed on the circumferential seam of the double aluminum tube joint to form a weld point; Welding is performed on the circumferential seam, the first hole, and the second hole on the double aluminum tube joint to obtain the finished double aluminum tube joint.
[0007] By adopting the above technical solution, after drilling holes at the ends of the first and second aluminum tubes and inserting sleeves, splicing and welding are performed. This method significantly enhances the structural integrity and connection strength of the double aluminum tube joint. The pre-designed insertion length of the sleeves provides effective support inside both tubes, increasing the mechanical reinforcement of the joint and effectively preventing breakage and deformation at the weld. The combination of step-by-step spot welding and subsequent full welding operations ensures the stability and reliability of the welding process, avoiding the problem of thermal stress concentration caused by one-time welding, thereby improving the overall quality and durability of the final product and achieving a robust and well-sealed pipe connection.
[0008] Optionally, obtain the first position information of the weld joint; Based on the first position information, the distance from the welding head to the circumferential seam is calculated to obtain the first distance; Based on the first position information, the distance from the welding head to the first hole is calculated to obtain the second distance; Based on the first position information, the distance from the welding head to the second hole is calculated to obtain the third distance; Sort the first distance, the second distance, and the third distance in ascending order to obtain a distance sort; The circumferential seam, the first hole, and the second hole are sorted according to the distance to obtain the processing sequence; According to the processing sequence, the circumferential seam, the first hole and the second hole are welded sequentially to obtain the finished product of the double aluminum tube joint.
[0009] By employing the aforementioned technical solution, the distances between the welding torch and the circumferential seam, the first hole position, and the second hole position are calculated, and the welding sequence is determined accordingly. This method optimizes the welding path and significantly improves production efficiency. This distance-based processing sequence minimizes the idle stroke of the welding torch and the repetitive positioning time, making the welding process more coherent and efficient. Simultaneously, orderly welding helps to evenly distribute heat input, avoiding localized overheating or deformation caused by concentrated heating, thereby ensuring the stability and consistency of welding quality and achieving precise control and resource optimization in the automated welding process.
[0010] Optionally, obtain a region image of the welded area; A welding score is generated based on the image of the area. Extract the target welding score from the welding score and obtain the welding adjustment area corresponding to the target welding score, wherein the target welding score is less than a preset welding score threshold; If the number of welding adjustment areas is one, then a correction operation is performed on the welding adjustment area; If the number of welding adjustment areas is at least two, then the distance from the welding head to the welding adjustment area is obtained to obtain a distance set; The welding adjustment area is corrected according to the distance sorting within the distance set.
[0011] By adopting the above technical solution and introducing an image analysis-based real-time welding quality monitoring and feedback correction mechanism, this method significantly improves the intelligence level of the welding process and the finished product qualification rate. The system can automatically identify defects in the welded area and accurately locate the area that needs adjustment, realizing dynamic control of welding quality. Corrections are prioritized based on the number and distance of the adjustment areas, ensuring efficient and rational processing logic. Prioritizing the processing of the nearest area reduces the time spent moving the welding torch.
[0012] Optionally, during the welding operation of the circumferential seam, a real-time image of the circumferential seam is acquired; In the real-time image, a first position and a second position of the circumferential seam are determined, wherein the first position is lower than the second position; Control the welding head to move to the first position; The welding head is activated, and the welding head is controlled to move along the circumferential seam from the first position to the second position; During the movement of the welding head, the double aluminum tube joint is rotated along a target direction, which is the direction along the circumferential seam from the second position to the first position.
[0013] By adopting the above technical solution, and controlling the welding torch to move from the lower part of the circumferential weld to the upper part while simultaneously rotating the workpiece in the opposite direction, this method effectively overcomes the problem of the molten pool flowing downwards due to gravity in aluminum alloy welding. This operation ensures that the molten metal is always supported by the solidified weld bead during welding, avoiding defects such as burn-through, incomplete penetration, and uneven weld formation. The coordination of rotating the workpiece ensures that the area to be welded is always in the optimal welding position, greatly improving the controllability of the molten pool and the weld formation quality, thereby obtaining a high-strength circumferential weld with a smooth appearance and no internal defects, and improving the overall strength of the joint.
[0014] Optionally, after the rotation angle of the welded length of the circumferential seam reaches a preset length, the real-time image is reacquired; The target length is extracted from the real-time image, and the target length is the maximum length from the outer wall of the sleeve to the inner wall of the double aluminum tube joint; If the target length is greater than a preset length threshold, the target position is determined on the double aluminum tube joint based on the target length; Rotate the double aluminum tube connector so that the target position is located at the top of the double aluminum tube connector; Move the welding head to the target position; The welding head is controlled to perform welding operations on the target position.
[0015] By adopting the above technical solution, and through real-time monitoring of the distance between the top of the sleeve and the top of the joint, and automatic repair welding when the distance exceeds the limit, this method ensures the adequacy of the welding at the joint between the sleeve and the aluminum tube. Dynamic image recognition can accurately identify unwelded areas or gaps that may be exposed due to workpiece rotation and trigger compensatory welding operations in a timely manner. This adaptive welding strategy effectively prevents local incomplete fusion or incomplete welding caused by welding dead angles or thermal deformation, ensuring the complete seal and maximum strength of the connection between the sleeve and the aluminum tube, thereby greatly enhancing the overall structural reliability of the joint.
[0016] Optionally, when performing welding operations on the hole position, a first point and a second point of the hole position are determined, wherein the first point is lower than the second point, and the hole position includes the first hole position and the second hole position; Determine the processing stop position between the first point and the second point; Control the welding head to process from the first point to the processing stop position; Rotate the double aluminum tube connector so that the first point is higher than the second point; Control the welding head to process from the processing stop position to the second point.
[0017] By employing the above technical solution, and dividing the welding process of the hole into two segments with a mid-process workpiece change, this method cleverly utilizes the positive effect of gravity on the weld pool. First, welding proceeds from low to high until the midpoint, effectively controlling the flow of the weld pool. Then, the workpiece is flipped, transforming the original low point into a high point, and welding continues from the break point to the finish line. At this point, the weld pool naturally flows towards the solidified weld bead, preventing accumulation or weld beads at the weld finish line, while ensuring complete fusion of the hole edges. This segmented welding strategy significantly improves the quality of the hole weld, making it more uniform, smooth, and defect-free.
[0018] Optionally, the axis of symmetry of the dual aluminum tube connector and the target plane of the hole position are obtained; The origin position is obtained based on the axis of symmetry and the target plane; Based on the origin position and the first point position, the first line segment is obtained; The second line segment is obtained based on the origin position and the second point position; Generate a third line segment based on the angle between the first line segment and the second line segment; The machining stop position is determined based on the third line segment on the hole.
[0019] By adopting the above technical solution, the termination point generated by calculating the included angle of the line segments ensures the connection between the two welding paths, avoiding repeated welding or missed welding. This positioning method based on mathematical models improves the accuracy and repeatability of welding irregular holes, ensures the consistency and optimization of the segmented welding process, and ultimately obtains high-quality, high-precision hole welds.
[0020] Secondly, this application provides a welding system for double aluminum tube joints, which adopts the following technical solution: A welding system for double aluminum tube joints, comprising: The acquisition module is used to acquire the first end of the first aluminum tube, the first end of the second aluminum tube, and the circumferential seam. A memory for storing a program for the welding method of the double aluminum tube joint; The processor and the program in the memory can be loaded and executed by the processor to implement the welding method of the double aluminum tube joint.
[0021] By adopting the above technical solution, after drilling holes at the ends of the first and second aluminum tubes and inserting sleeves, splicing and welding are performed. This method significantly enhances the structural integrity and connection strength of the double aluminum tube joint. The pre-designed insertion length of the sleeves provides effective support inside both tubes, increasing the mechanical reinforcement of the joint and effectively preventing breakage and deformation at the weld. The combination of step-by-step spot welding and subsequent full welding operations ensures the stability and reliability of the welding process, avoiding the problem of thermal stress concentration caused by one-time welding, thereby improving the overall quality and durability of the final product and achieving a robust and well-sealed pipe connection.
[0022] Thirdly, this application provides a smart terminal, which adopts the following technical solution: A smart terminal includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute the method described in any one of the above.
[0023] Fourthly, this application provides a computer storage medium capable of storing corresponding programs, which facilitates the improvement of the strength of double aluminum pipe joints, and adopts the following technical solution: A computer-readable storage medium storing a computer program that can be loaded by a processor and executed any of the above-described welding methods for double aluminum tube joints.
[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. By drilling holes at the ends of the first and second aluminum tubes and inserting sleeves, splicing and welding are performed. This method significantly enhances the structural integrity and connection strength of the double aluminum tube joint. The pre-designed insertion length of the sleeves provides effective support inside both tubes, increasing the mechanical reinforcement of the joint and effectively preventing breakage and deformation at the weld. The combination of step-by-step spot welding and subsequent full welding operations ensures the stability and reliability of the welding process, avoiding the problem of thermal stress concentration caused by one-time welding, thereby improving the overall quality and durability of the final product and achieving a robust and well-sealed pipe connection. 2. By calculating the distances between the welding torch and the circumferential seam, the first hole position, and the second hole position, and determining the welding sequence accordingly, this method optimizes the welding path and significantly improves production efficiency. This distance-based processing sequence minimizes the idle stroke of the welding torch and the repetitive positioning time, making the welding process more continuous and efficient. Simultaneously, orderly welding helps to evenly distribute heat input, avoiding localized overheating or deformation caused by concentrated heating, thereby ensuring the stability and consistency of welding quality and achieving precise control and resource optimization in the automated welding process. 3. By dividing the welding process of the hole into two segments and changing the workpiece midway, this method cleverly utilizes the positive effect of gravity on the weld pool. First, welding proceeds from low to high until the middle, effectively controlling the flow of the weld pool. Then, the workpiece is flipped to make the original low point a high point, and welding continues from the break point to the end point. At this point, the weld pool naturally flows to the already solidified weld bead, preventing the weld pool from accumulating or forming weld beads at the welding end point, while ensuring complete fusion of the hole edge. This segmented welding strategy significantly improves the forming quality of the hole weld, making it more uniform, smooth, and defect-free. Attached Figure Description
[0025] Figure 1 This is a schematic flowchart of a welding method for a double aluminum tube joint disclosed in an embodiment of this application.
[0026] Figure 2 This is a schematic diagram of a welding method for a double aluminum tube joint disclosed in an embodiment of this application.
[0027] Figure 3 This is a schematic flowchart of a sequential welding method for a double aluminum tube joint disclosed in an embodiment of this application.
[0028] Figure 4 This is a schematic flowchart of a welding repair method for a double aluminum tube joint disclosed in an embodiment of this application.
[0029] Figure 5 This is a schematic flowchart of a welding adjustment method for a double aluminum tube joint disclosed in an embodiment of this application.
[0030] Figure 6This is a schematic diagram of a welding adjustment method for a double aluminum tube joint disclosed in an embodiment of this application.
[0031] Figure 7 This is a schematic flowchart of a second welding adjustment method for a double aluminum tube joint disclosed in an embodiment of this application.
[0032] Figure 8 This is a schematic diagram of a second welding adjustment method for a double aluminum tube joint disclosed in an embodiment of this application.
[0033] Figure 9 This is a schematic flowchart of a hole welding method for a double aluminum tube joint disclosed in an embodiment of this application.
[0034] Figure 10 This is a schematic diagram of a hole welding method for a double aluminum tube joint disclosed in an embodiment of this application.
[0035] Figure 11 This is a flowchart illustrating a method for determining the processing stop position disclosed in an embodiment of this application.
[0036] Figure 12 This is a schematic diagram of a welding system for a double aluminum tube joint disclosed in an embodiment of this application. Detailed Implementation
[0037] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figure 1 To be continued Figure 12 The present application will be further described in detail below with reference to embodiments. 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 application.
[0038] This application discloses a welding method for a double aluminum tube joint. (Refer to...) Figure 1 The method includes: Step S101: Open the first hole at the first end of the first aluminum tube.
[0039] The first holes are distributed circumferentially around the first aluminum tube, meaning they surround the entire circumference of the tube. Simultaneously, the first holes are also distributed axially on the first aluminum tube. For example, referring to Figure 2, the first holes on the first aluminum tube exhibit both circumferential and axial distributions.
[0040] Furthermore, the circumferential spacing of the first holes can be adjusted according to actual needs. For example, one hole can be set every 90 degrees. Similarly, the axial spacing of the first holes can also be adjusted according to actual needs. For example, one hole can be set every 85 mm.
[0041] The maximum length from the first end of the first aluminum tube to the first hole needs to be less than the preset design size to avoid insufficient sleeve length. For example, the design size is 170mm.
[0042] Optionally, before opening the first hole, the first end of the first aluminum tube is chamfered to make the subsequent welding of the first aluminum tube and the second aluminum tube tighter.
[0043] For example, please refer to Figure 2 The first end of the first aluminum tube 21 is chamfered and the first hole 211 is opened.
[0044] Step S102: Open a second hole at the first end of the second aluminum tube.
[0045] The second hole is similar to the first hole. The second hole is distributed circumferentially on the second aluminum tube and axially on the second aluminum tube.
[0046] The first and second aluminum tubes are identical in material, size, and shape.
[0047] Optionally, the first end of the second aluminum tube may be chamfered before the second hole is drilled.
[0048] The maximum length from the first end of the second aluminum tube to the second hole needs to be less than the preset design size to avoid insufficient sleeve length. For example, the design size is 170mm.
[0049] For example, please refer to Figure 2 The first end of the second aluminum tube 22 is chamfered, and a second hole 221 is opened.
[0050] Step S103: Place a sleeve inside the first end of the first aluminum tube, so that the length of the sleeve protruding from the first aluminum tube reaches the preset length.
[0051] The outer diameter of the sleeve matches the inner diameter of the first aluminum tube. Optionally, the outer diameter of the sleeve is the same as the inner diameter of the first aluminum tube, or the outer diameter of the sleeve is slightly smaller than the inner diameter of the first aluminum tube, so that the sleeve can be inserted into the first aluminum tube and fit snugly inside the first aluminum tube. For example, if the inner diameter of the first aluminum tube is 77 mm, then the outer diameter of the sleeve can be 76 mm.
[0052] The preset length is a pre-defined empirical value. The length of the sleeve protruding from the first aluminum tube reaches the preset length so that the first and second aluminum tubes can be more easily spliced later. For example, the preset length is 170mm.
[0053] In other embodiments, a sleeve may also be placed inside the first end of the second aluminum tube.
[0054] For example, please refer to Figure 2A sleeve 23 is placed inside the first end of the first aluminum tube 21.
[0055] Step S104: Align the first end of the first aluminum tube with the first end of the second aluminum tube.
[0056] For example, please refer to Figure 2 Align the first end of the first aluminum tube with the second end of the second aluminum tube for subsequent operations.
[0057] Step S105: The first end of the first aluminum tube and the first end of the second aluminum tube are spliced together to obtain a double aluminum tube joint. The length of the sleeve in the double aluminum tube joint inside the first aluminum tube is greater than the first length, and the length of the sleeve inside the second aluminum tube is greater than the second length.
[0058] The first length is not less than the maximum length from the first end of the first aluminum tube to the first hole, and the second length is not less than the maximum length from the first end of the second aluminum tube to the second hole. In this case, the sleeve located inside the first and second aluminum tubes can fill the first and second holes, which is beneficial to the subsequent welding process.
[0059] It should be noted that the double aluminum pipe connector in this step is still a semi-finished product.
[0060] For example, please refer to Figure 2 The first end of the first aluminum tube 21 and the first end of the second aluminum tube 21 are spliced together to obtain the double aluminum tube joint 24.
[0061] Step S106: Perform spot welding on the circumferential seam of the double aluminum tube joint to form a weld point.
[0062] The number of solder joints needs to be at least greater than the preset solder joint number threshold to ensure that the first and second aluminum tubes in the double aluminum tube joint will not easily slip relative to each other after the spot welding operation. For example, the solder joint number threshold is 3.
[0063] Furthermore, the angle difference between adjacent solder joints needs to be at least greater than a preset angle; for example, the angle difference between adjacent solder joints needs to be greater than 20 degrees.
[0064] For example, please refer to Figure 2 Spot welding is performed on the circumferential seam of the double aluminum tube joint 24 to form weld point 241.
[0065] Step S107: Weld the circumferential seam, the first hole and the second hole on the double aluminum tube joint to obtain the finished double aluminum tube joint.
[0066] For example, please refer to Figure 2 Welding is performed on the circumferential seam, the first hole, and the second hole on the double aluminum tube joint to form a weld layer 242, thus obtaining the finished double aluminum tube joint.
[0067] By adopting the above technical solution, after drilling holes at the ends of the first and second aluminum tubes and inserting sleeves, splicing and welding are performed. This method significantly enhances the structural integrity and connection strength of the double aluminum tube joint. The pre-designed insertion length of the sleeves provides effective support inside both tubes, increasing the mechanical reinforcement of the joint and effectively preventing breakage and deformation at the weld. The combination of step-by-step spot welding and subsequent full welding operations ensures the stability and reliability of the welding process, avoiding the problem of thermal stress concentration caused by one-time welding, thereby improving the overall quality and durability of the final product and achieving a robust and well-sealed pipe connection.
[0068] In the following embodiments, welding is required for the circumferential seam, the first hole, and the second hole to improve the overall strength of the double aluminum tube joint. Simultaneously, welding efficiency must be ensured during the welding process. This application discloses a sequential welding method for a double aluminum tube joint. (Refer to...) Figure 3 The method includes: Step S301: Obtain the first position information of the welding head.
[0069] The first position information is used to represent the position coordinates of the welding head. In some embodiments, the welding head is located on a welding station, which can move parallel to the axial direction of the double aluminum tube joint, that is, the welding head can move parallel to the axial direction of the double aluminum tube structure. The projected position of the welding head on the side wall of the double aluminum tube joint can be considered as the first position information.
[0070] Step S302: Calculate the distance from the welding head to the circumferential seam based on the first position information to obtain the first distance.
[0071] The first distance refers to the shortest distance from the weld joint to the circumferential seam. For example, if the first position information refers to the projected position of the weld joint on the sidewall of the double aluminum tube joint, then the shortest distance between the circumferential seam and the projected position is determined on the sidewall of the double aluminum tube joint to obtain the first distance.
[0072] Step S303: Calculate the distance from the welding head to the first hole position based on the first position information to obtain the second distance.
[0073] The second distance refers to the shortest distance from the welding head to the first hole. For example, if the first position information refers to the projected position of the welding head on the sidewall of the double aluminum tube joint, then the shortest distance between the first hole and the projected position is determined on the sidewall of the double aluminum tube joint to obtain the second distance.
[0074] Step S304: Based on the first position information, calculate the distance from the welding head to the second hole to obtain the third distance.
[0075] The third distance refers to the shortest distance from the welding head to the second hole. For example, if the first position information refers to the projected position of the welding head on the sidewall of the double aluminum tube joint, then the shortest distance between the second hole and the projected position is determined on the sidewall of the double aluminum tube joint to obtain the third distance.
[0076] Step S305: Sort the first distance, second distance and third distance in ascending order to obtain the distance sort.
[0077] For example, if the first distance is 20mm, the second distance is 15mm, and the third distance is 25mm, then the first distance, the second distance, and the third distance are sorted in ascending order to get the distance sorting as second distance - first distance - third distance.
[0078] Step S306: Sort the circumferential seam, the first hole position and the second hole position according to the distance to obtain the processing sequence.
[0079] For example, when the distance order is second distance - first distance - third distance, the processing sequence is first hole - circumferential seam - second hole.
[0080] Step S307: Following the processing sequence, weld the circumferential seam, the first hole, and the second hole in sequence to obtain the finished product of the double aluminum tube joint.
[0081] When welding the circumferential seam, the first hole, and the second hole sequentially according to the processing order, the welding operation can be completed in the shortest possible time to ensure welding efficiency.
[0082] By employing the aforementioned technical solution, the distances between the welding torch and the circumferential seam, the first hole position, and the second hole position are calculated, and the welding sequence is determined accordingly. This method optimizes the welding path and significantly improves production efficiency. This distance-based processing sequence minimizes the idle stroke of the welding torch and the repetitive positioning time, making the welding process more coherent and efficient. Simultaneously, orderly welding helps to evenly distribute heat input, avoiding localized overheating or deformation caused by concentrated heating, thereby ensuring the stability and consistency of welding quality and achieving precise control and resource optimization in the automated welding process.
[0083] In the following embodiments, poor welding quality may occur during the welding of the double aluminum tube joint. In such cases, it is necessary to repair the already welded areas to ensure the overall welding quality. This application discloses a welding repair method for a double aluminum tube joint. (Refer to...) Figure 4 The method includes: Step S401: Obtain an image of the welded area.
[0084] The welded area refers to the area where welding operations have been completed. The welded area includes all or part of the area containing the circumferential seam, the first hole, and the second hole. For example, when welding operations are performed sequentially in the order of the circumferential seam, the first hole, and the second hole, the circumferential seam can be considered a welded area when welding the first hole. At the same time, the first hole, where welding operations have been completed, can also be considered a welded area.
[0085] For example, a camera is used to photograph the double aluminum tube joint to obtain an image of the joint. The welded area is then identified within the joint image.
[0086] Step S402: Generate a welding score based on the area image.
[0087] Welding scores are used to quantify the welding quality of welded areas within a region image.
[0088] For example, surface features of the welded areas are extracted from the region image. These surface features include at least one of surface smoothness, color, and flatness. The surface features are then quantified to obtain a weld score.
[0089] Step S403: Extract the target welding score from the welding score and obtain the welding adjustment area corresponding to the target welding score. The target welding score is less than the preset welding score threshold.
[0090] The welding score threshold is a preset empirical value. For example, when the welding score range is 0-10, the welding score threshold can be 7.
[0091] Step S404: If the number of welding adjustment areas is one, then perform a correction operation on the welding adjustment area.
[0092] If there is only one welding adjustment area, a correction operation can be performed directly on that area. The correction operation is used to repair the welding condition within the welding adjustment area, thereby improving its welding score.
[0093] Step S405: If the number of welding adjustment areas is at least two, then obtain the distance from the welding head to the welding adjustment area to obtain a distance set.
[0094] The distance set includes at least two distances from the welding head to the welding adjustment area.
[0095] For example, the projected position of the welding head onto the sidewall of the double aluminum tube joint is obtained. The distance from the projected position to each welding adjustment area is obtained to obtain a distance set.
[0096] Step S406: Based on the distance sorting in the distance set, perform correction operations on the welding adjustment area.
[0097] For example, the welding adjustment area is corrected according to the distance within the distance set, in order from nearest to farthest. This makes the correction operation of the welding adjustment area as fast as possible.
[0098] By adopting the above technical solution and introducing an image analysis-based real-time welding quality monitoring and feedback correction mechanism, this method significantly improves the intelligence level of the welding process and the finished product qualification rate. The system can automatically identify defects in the welded area and accurately locate the area that needs adjustment, realizing dynamic control of welding quality. Corrections are prioritized based on the number and distance of the adjustment areas, ensuring efficient and rational processing logic. Prioritizing the processing of the nearest area reduces the time spent moving the welding torch.
[0099] In the following embodiments, due to the influence of gravity, the gap between the sleeve and the aluminum tube exhibits a characteristic of being larger at the top and smaller at the bottom. Therefore, when welding the circumferential seam, attention must be paid to this gap characteristic to improve the welding quality. Thus, this application discloses a welding adjustment method for a double aluminum tube joint. (Refer to...) Figure 5 The method includes: Step S501: Acquire a real-time image of the circumferential seam during the welding operation.
[0100] The real-time image is an image that includes the circumferential seam. For example, a camera is used to photograph a double aluminum tube joint to obtain an image of the joint. The real-time image of the circumferential seam is then identified within the joint image.
[0101] Step S502: Determine the first and second positions of the circumferential seam in the real-time image, with the first position being lower than the second position.
[0102] The first position needs to be higher than the lowest point of the circumferential seam. Further, two arcs are formed on the circumferential seam by determining the first and second positions; the shorter of the two arcs is taken as the target arc. Any point on the target arc is higher than the lowest point of the circumferential seam.
[0103] In some embodiments, the first position and the second position are two adjacent solder joints.
[0104] In some embodiments, the coordinates of the center of the circumferential seam are obtained. A first radius from the first position to the center coordinates is obtained. A second radius from the second position to the center coordinates is obtained, and the first and second radii lie within the plane of the circumferential seam. The angle formed by the first radius, the second radius, and the center coordinates is a preset angle, for example, 60 degrees.
[0105] For example, please refer to Figure 6 The first position 601 and the second position 602 are determined on the circumferential seam.
[0106] Step S503: Control the welding head to move to the first position.
[0107] Control the welding head to move to the first position in order to proceed with the subsequent welding process.
[0108] Step S504: Open the welding head and control the welding head to move along the circumferential seam from the first position to the second position.
[0109] For example, please refer to Figure 6 After the welding head is turned on, the welding head is controlled to move along the target arc from the first position 601 to the second position 602.
[0110] Step S505: During the movement of the welding head, rotate the double aluminum tube joint along the target direction, which is the direction from the second position to the first position along the circumferential seam.
[0111] For example, please refer to Figure 6 During the movement of the welding head, the double aluminum tube joint 24 is rotated along the target direction, which is the direction from the second position 602 to the first position 601 along the circumferential seam.
[0112] By adopting the above technical solution, and controlling the welding torch to move from the lower part of the circumferential weld to the upper part while simultaneously rotating the workpiece in the opposite direction, this method effectively overcomes the problem of the molten pool flowing downwards due to gravity in aluminum alloy welding. This operation ensures that the molten metal is always supported by the solidified weld bead during welding, avoiding defects such as burn-through, incomplete penetration, and uneven weld formation. The coordination of rotating the workpiece ensures that the area to be welded is always in the optimal welding position, greatly improving the controllability of the molten pool and the weld formation quality, thereby obtaining a high-strength circumferential weld with a smooth appearance and no internal defects, and improving the overall strength of the joint.
[0113] This application discloses a second method for welding and adjusting a double aluminum tube joint. (Refer to...) Figure 7 The method includes: Step S701: After the welded length of the circumferential seam reaches the preset length, reacquire the real-time image.
[0114] The preset length is a pre-defined empirical value. For example, the preset length is 50% of the total weld length.
[0115] Step S702: Extract the target length from the real-time image. The target length is the maximum length from the outer wall of the sleeve to the inner wall of the double aluminum tube joint.
[0116] Because the sleeve is affected by gravity, it cannot be guaranteed that the distance from all points on the sleeve to the inner wall of the aluminum tube will be equal when welding the circumferential seam. Please refer to... Figure 8 There is a distance L between the sleeve 23 and the upper inner wall of the aluminum tube, while the sleeve 23 is tightly fitted to the lower inner wall of the aluminum tube.
[0117] For example, since part of the circumferential seam has been welded, it is not possible to observe the length from the outer wall of the sleeve to the inner wall of the double aluminum tube joint. Therefore, only the observable length from the outer wall of the sleeve to the inner wall of the double aluminum tube joint is obtained from the real-time image.
[0118] Step S703: If the target length is greater than the preset length threshold, determine the target position on the double aluminum tube joint according to the target length.
[0119] The length threshold is a preset empirical value, for example, the length threshold is 0.5mm.
[0120] For example, the target position is determined by the location of the target length on the circumferential seam.
[0121] Step S704: Rotate the double aluminum tube connector so that the target position is at the top of the double aluminum tube connector.
[0122] Optionally, rotate the double aluminum tube fitting so that the target position is on top of the double aluminum tube fitting for subsequent welding operations.
[0123] Step S705: Move the welding head to the target position.
[0124] Step S706: Control the welding head to perform welding operations on the target position.
[0125] When the welding head performs welding operations on the target position, the solder is also affected by gravity, which allows it to fully enter the gap between the sleeve and the aluminum tube, thus improving the welding quality.
[0126] By adopting the above technical solution, the adequacy of the welding at the joint between the sleeve and the aluminum tube is ensured. Dynamic image recognition can accurately identify unwelded areas or gaps that may be exposed due to workpiece rotation and trigger compensatory welding operations in a timely manner. This adaptive welding strategy effectively prevents local incomplete fusion or incomplete welding caused by welding dead angles or thermal deformation, ensuring a complete seal and maximum strength between the sleeve and the aluminum tube, thereby greatly enhancing the overall structural reliability of the joint.
[0127] In the following embodiments, during the welding of the hole positions, the sleeve is also affected by gravity, causing the gap between the sleeve and the aluminum tube to be wider at the top and narrower at the bottom. Therefore, when welding the sleeve, attention needs to be paid to the characteristics of the gap to improve the welding quality. Therefore, this application discloses a hole welding method for a double aluminum tube joint. (Refer to...) Figure 9 The method includes: Step S901: When performing welding operation on the hole position, determine the first point and the second point of the hole position. The first point is lower than the second point. The hole position includes the first hole position and the second hole position.
[0128] Optionally, the first point is the lowest point on the hole, and the second point is the highest point on the hole. For example, please refer to... Figure 10 The first point A and the second point B on the first hole position 211.
[0129] Step S902: Determine the processing stop position between the first point and the second point.
[0130] The method for determining the processing stop position can be referred to Figure 11 The embodiments shown are not described in detail here.
[0131] For example, please refer to Figure 10 The processing stop position is the straight line OP.
[0132] Step S903: Control the welding head to process from the first point to the processing stop position.
[0133] For example, please refer to Figure 10 Control the welding head to move from the first point A to the position of the straight line OP along the direction of the up arrow.
[0134] Step S904: Rotate the double aluminum tube connector so that the first point is higher than the second point.
[0135] When starting to rotate the double aluminum tube connector, it is necessary to ensure that the height of the hole rises.
[0136] Step S905: Control the welding head to process from the second point to the processing stop position.
[0137] For example, please refer to Figure 10 Control the welding head to move from the second point B to the position of the straight line OP along the direction of the up arrow.
[0138] By employing the above technical solution, and dividing the welding process of the hole into two segments with a mid-process workpiece change, this method cleverly utilizes the positive effect of gravity on the weld pool. First, welding proceeds from low to high until the midpoint, effectively controlling the flow of the weld pool. Then, the workpiece is flipped, transforming the original low point into a high point, and welding continues from the break point to the finish line. At this point, the weld pool naturally flows towards the solidified weld bead, preventing accumulation or weld beads at the weld finish line, while ensuring complete fusion of the hole edges. This segmented welding strategy significantly improves the quality of the hole weld, making it more uniform, smooth, and defect-free.
[0139] This application discloses a method for determining the processing stop position. (Refer to...) Figure 11 The method includes: Step S1101: Obtain the axis of symmetry of the double aluminum tube connector and the target plane of the hole position.
[0140] Optionally, the axis of symmetry refers to the axis of the double aluminum tube joint.
[0141] In some embodiments, a target plane is created passing through the first and second points, such that the target plane is perpendicular to the axis of the double aluminum tube joint.
[0142] In some other embodiments, several planes perpendicular to the axis of the double aluminum tube joint are constructed. Several boundary lines are obtained between these planes and the finite curved surfaces corresponding to the hole positions. The longest boundary line among these boundary lines is selected to obtain the target boundary line. A target plane corresponding to the target boundary line is determined from the several planes.
[0143] Step S1102: Obtain the position of the origin based on the axis of symmetry and the target plane.
[0144] The origin is obtained by finding the intersection of the axis of symmetry and the target plane.
[0145] Step S1103: Obtain the first line segment based on the origin position and the first point position.
[0146] Connect the origin and the first point to obtain the first line segment.
[0147] Step S1104: Obtain the second line segment based on the position of the origin and the position of the second point.
[0148] Connect the origin and the second point to obtain the second line segment.
[0149] Step S1105: Generate the third line segment based on the angle between the first and second line segments.
[0150] For example, given that both the first and second line segments are located in the target plane, an angle bisector is drawn through the origin to bisect the angle between the first and second line segments in the target plane. A third line segment is then drawn through the origin such that the angle between the third line segment and the angle bisector is equal to a preset error angle (e.g., 10 degrees), and the angle between the third line segment and the first line segment is greater than the angle between the third line segment and the second line segment.
[0151] Step S1106: Determine the machining stop position based on the third line segment on the hole position.
[0152] The intersection of the third line segment and the finite surface where the hole is located is taken as the machining termination point.
[0153] By adopting the above technical solution, the termination point generated by calculating the included angle of the line segments ensures the connection between the two welding paths, avoiding repeated welding or missed welding. This positioning method based on mathematical models improves the accuracy and repeatability of welding irregular holes, ensures the consistency and optimization of the segmented welding process, and ultimately obtains high-quality, high-precision hole welds.
[0154] Based on the same inventive concept, this application provides a welding system for a double aluminum tube joint. Please refer to... Figure 12 The system includes: Acquisition module 1201 is used to acquire the first end of the first aluminum tube, the first end of the second aluminum tube, and the circumferential seam; The memory 1202 is used to store the program for the welding method of the double aluminum tube joint; The processor 1203 can load and execute programs in the memory to implement the welding method for the double aluminum tube joint.
[0155] By adopting the above technical solution, after drilling holes at the ends of the first and second aluminum tubes and inserting sleeves, splicing and welding are performed. This method significantly enhances the structural integrity and connection strength of the double aluminum tube joint. The pre-designed insertion length of the sleeves provides effective support inside both tubes, increasing the mechanical reinforcement of the joint and effectively preventing breakage and deformation at the weld. The combination of step-by-step spot welding and subsequent full welding operations ensures the stability and reliability of the welding process, avoiding the problem of thermal stress concentration caused by one-time welding, thereby improving the overall quality and durability of the final product and achieving a robust and well-sealed pipe connection.
[0156] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.
[0157] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed to perform a welding method for a double aluminum tube joint.
[0158] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.
[0159] Based on the same inventive concept, this application provides a smart terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed to perform a welding method for double aluminum tube joints.
[0160] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.
[0161] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.
Claims
1. A method of welding a double aluminum pipe joint, characterized by, include: A first hole is made at the first end of the first aluminum tube; A second hole is opened at the first end of the second aluminum tube; A sleeve is placed inside the first end of the first aluminum tube, such that the length of the sleeve protruding from the first aluminum tube reaches a preset length. Align the first end of the first aluminum tube with the first end of the second aluminum tube; The first end of the first aluminum tube and the first end of the second aluminum tube are spliced together to obtain a double aluminum tube joint. The length of the sleeve in the double aluminum tube joint inside the first aluminum tube is greater than the first length, and the length of the sleeve inside the second aluminum tube is greater than the second length. The first length is not less than the maximum length from the first end of the first aluminum tube to the first hole, and the second length is not less than the maximum length from the first end of the second aluminum tube to the second hole. Spot welding is performed on the circumferential seam of the double aluminum tube joint to form a weld point; Welding is performed on the circumferential seam, the first hole, and the second hole on the double aluminum tube joint to obtain the finished double aluminum tube joint; The step of welding the circumferential seam, the first hole, and the second hole on the double aluminum tube joint to obtain the finished double aluminum tube joint includes: acquiring first position information of the welding head; calculating the distance from the welding head to the circumferential seam based on the first position information to obtain a first distance; calculating the distance from the welding head to the first hole based on the first position information to obtain a second distance; calculating the distance from the welding head to the second hole based on the first position information to obtain a third distance; sorting the first distance, the second distance, and the third distance in ascending order to obtain a distance sort; sorting the circumferential seam, the first hole, and the second hole according to the distance sort to obtain a processing order; and performing welding operations on the circumferential seam, the first hole, and the second hole sequentially according to the processing order to obtain the finished double aluminum tube joint. During the welding operation of the circumferential seam, a real-time image of the circumferential seam is acquired; a first position and a second position of the circumferential seam are determined in the real-time image, wherein the first position is lower than the second position; the welding head is controlled to move to the first position; the welding head is activated, and the welding head is controlled to move along the circumferential seam from the first position to the second position; during the movement of the welding head, the double aluminum tube connector is rotated along a target direction, wherein the target direction is the direction along the circumferential seam from the second position to the first position; When performing welding operations on the hole positions, a first point and a second point of the hole positions are determined, with the first point being lower than the second point. The hole positions include the first hole position and the second hole position. A processing stop position is determined between the first point and the second point. The welding head is controlled to process from the first point to the processing stop position. The double aluminum tube joint is rotated so that the first point is higher than the second point. The welding head is controlled to process from the processing stop position to the second point.
2. The method of welding a double aluminum pipe joint according to claim 1, characterized by, The method further includes: Obtain a region image of the welded area; A welding score is generated based on the image of the area. Extract the target welding score from the welding score and obtain the welding adjustment area corresponding to the target welding score, wherein the target welding score is less than a preset welding score threshold; If the number of welding adjustment areas is one, then a correction operation is performed on the welding adjustment area; If the number of welding adjustment areas is at least two, then the distance from the welding head to the welding adjustment area is obtained to obtain a distance set; The welding adjustment area is corrected according to the distance sorting within the distance set.
3. The method of welding a double aluminum pipe joint according to claim 1, wherein The method further includes: After the rotation angle of the welded length of the circumferential seam reaches the preset length, the real-time image is reacquired. The target length is extracted from the real-time image, and the target length is the maximum length from the outer wall of the sleeve to the inner wall of the double aluminum tube joint; If the target length is greater than a preset length threshold, the target position is determined on the double aluminum tube joint based on the target length; Rotate the double aluminum tube connector so that the target position is located at the top of the double aluminum tube connector; Move the welding head to the target position; The welding head is controlled to perform welding operations on the target position.
4. The method of welding a double aluminum pipe joint according to claim 1, characterized by, Determining the processing stop position between the first point and the second point includes: Obtain the axis of symmetry of the double aluminum tube connector and the target plane of the hole position; The origin position is obtained based on the axis of symmetry and the target plane; Based on the origin position and the first point position, the first line segment is obtained; The second line segment is obtained based on the origin position and the second point position; Generate a third line segment based on the angle between the first line segment and the second line segment; The machining stop position is determined based on the third line segment on the hole.
5. A system for welding a double aluminum pipe joint, characterized by, The system is used to perform the welding method for the double aluminum tube joint as described in any one of claims 1 to 4, comprising: The acquisition module is used to acquire the first end of the first aluminum tube, the first end of the second aluminum tube, and the circumferential seam. A memory for storing a program for the welding method of the double aluminum tube joint; The processor and the program in the memory can be loaded and executed by the processor to implement the welding method of the double aluminum tube joint.
6. A smart terminal, characterized by It includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as described in any one of claims 1 to 4.
7. A computer-readable storage medium, characterized in that, The computer program is stored that can be loaded by a processor and executed as described in any one of claims 1 to 4.