Energy storage welding electrode alignment system and method based on pressure sensing and adjustment method

Abstract

The invention provides an energy storage welding electrode alignment system and method based on pressure sensing and an adjusting method.The alignment system comprises a pressure sensing device used for collecting pressure data of all points of a contact face when an upper electrode and a lower electrode make contact; the signal acquisition module is connected with the pressure sensing device and is used for acquiring and primarily processing the pressure signal; the main control processing unit is connected with the signal acquisition module and is used for receiving the pressure data, operating a preset algorithm, calculating pressure distribution related parameters, evaluating electrode contact uniformity and comparing an evaluation result with a preset threshold value to judge whether the electrode is aligned or not; and the display and prompt module is connected with the main control processing unit and is used for displaying the processing result and prompting. The motor alignment system provided by the invention can ensure that the electrode is in a good alignment state before welding each time, so that the quality consistency of welding spots is improved, and the rate of defective products is reduced.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to the field of energy storage welding auxiliary monitoring, and particularly to a pressure-sensing-based energy storage welding electrode alignment system, method and adjustment method. BACKGROUND

[0002] In the energy storage welding process, the alignment of the upper and lower electrodes has a key impact on the welding quality. If the electrodes are not well aligned, it often leads to a decrease in the quality of the welding spot, such as defects such as spatter on the surface of the welding spot, uneven depth of the welding spot indentation, etc. In addition, uneven electrode pressure distribution will reduce the effective pressure that can be applied by the welding tongs, accelerate the wear of components such as electrode rods and welding tongs arms, reduce the rigidity and service life of the equipment, and these factors will further worsen the electrode alignment state in the subsequent welding process, forming a vicious cycle. Therefore, it is necessary to monitor and evaluate the electrode alignment state in real time during the welding process in order to guide the adjustment, which is very necessary for improving the welding quality and reducing equipment wear.

[0003] At present, the commonly used electrode alignment method in the production site mainly relies on manual experience and post-detection. The former has limited accuracy and cannot quantitatively give the alignment degree, and the latter requires actual welding, which is time-consuming and inconvenient for timely feedback adjustment. If the electrode contact pressure distribution can be obtained in real time before welding and the alignment degree can be quantified, the adjustment efficiency of the electrode alignment will be greatly improved, and repeated trial welding and quality risks will be avoided. SUMMARY

[0004] In view of the above-mentioned defects or deficiencies in the prior art, it is desirable to provide a pressure-sensing-based energy storage welding electrode alignment system, method and adjustment method to solve the above problems.

[0005] The first aspect of the present application provides a pressure-sensing-based energy storage welding electrode alignment system, comprising: a pressure sensing device, the pressure sensing device is used for collecting pressure data of each point on the contact surface when the upper and lower electrodes are in contact; a signal acquisition module, the signal acquisition module is connected with the pressure sensing device, and is used for acquiring and preliminarily processing the pressure signal; a main control processing unit, the main control processing unit is connected with the signal acquisition module, and is used for receiving the pressure data, running a predetermined algorithm, calculating pressure distribution related parameters, evaluating the uniformity of the electrode contact, and comparing the evaluation result with a preset threshold to determine whether the electrodes are aligned; a display and prompt module, the display and prompt module is connected with the main control processing unit, and is used for presenting the processing result and giving a prompt.

[0006] According to the technical scheme provided by the embodiment of the present application, the pressure sensing device is a high-precision pressure sensor array, and the sensor array is distributed in a matrix form to cover the entire electrode contact surface.

[0007] According to the technical scheme provided by the embodiment of the application, the sensing elements in the high-precision pressure sensor array are selected from at least one of a piezoresistive pressure sensor, a piezoelectric pressure sensor, or a thin-film flexible pressure sensor.

[0008] According to the technical scheme provided by the embodiment of the application, the pressure distribution related parameters calculated by the master control processing unit at least include the mean value and the standard deviation of the pressure distribution.

[0009] According to the technical scheme provided by the embodiment of the application, the master control processing unit is also responsible for coordinating the control of various components of the system, including setting the sampling rate, processing the sensor calibration parameters, and sending update instructions to the display module.

[0010] According to the technical scheme provided by the embodiment of the application, the processing results presented by the display and prompt module include a pressure distribution heat map and a flatness index percentage reflecting the uniformity of electrode contact.

[0011] According to the technical scheme provided by the embodiment of the application, the prompting mode of the display and prompt module is at least one of light prompting or voice reminding, and the prompting is triggered when the electrode alignment degree reaches a preset threshold.

[0012] According to the technical scheme provided by the embodiment of the application, a power supply module is also included, which provides stable power for the pressure sensing device, the signal acquisition module, the master control processing unit, and the display and prompt module. The power supply module is selected from an existing power source of a welding machine or an independent direct current power source.

[0013] The second aspect of the application provides a pressure sensing based energy storage welding electrode alignment method, which is applied to the pressure sensing based energy storage welding electrode alignment system as described above. The method comprises: After starting the system, the upper and lower electrodes of the energy storage welding machine are brought into contact with each other, and the real-time pressure data of each point on the contact surface is collected by the pressure sensing device in the system; The signal acquisition module acquires the pressure signal output by the pressure sensing device, and after preliminary processing of the pressure signal, transmits it to the master control processing unit; The master control processing unit receives the preliminary processed pressure data, runs a predetermined algorithm to calculate the pressure distribution related parameters, and at the same time evaluates the percentage of electrode contact uniformity; The master control processing unit compares the percentage of contact uniformity with a preset threshold to determine whether the electrodes are aligned, and transmits the determination result and the pressure distribution parameters to the display and prompt module; The display and prompt module displays the pressure distribution in the form of a heat map, and at the same time displays the percentage of contact uniformity.

[0014] The third aspect of the application provides a pressure-sensing-based energy storage welding electrode alignment adjustment method, which is applied to the pressure-sensing-based energy storage welding electrode alignment system as described above, and the method comprises the following steps: Before energy storage welding production, the pressure data when the upper and lower electrodes are in contact are continuously collected by the pressure sensing device of the system, at least two groups of different initial electrode contact positions are set, and the pressure distribution data corresponding to each group of positions is obtained respectively; The main control processing unit analyzes each group of pressure distribution data, calculates the contact uniformity percentage of each group of data, and selects the position with the highest contact uniformity percentage as the initial reference alignment position; During the formal welding process, after completing the set number of weldings, the system triggers to re-perform pressure data collection and uniformity evaluation, and judges whether the contact uniformity of the current electrode position still meets the preset threshold; If the current contact uniformity is lower than the preset threshold, the main control processing unit generates an electrode adjustment direction prompt according to the pressure abnormal area in the pressure distribution thermal map, and outputs the prompt through the display and prompt module; After the operator adjusts the electrode position according to the adjustment direction prompt, the system collects pressure data again and evaluates the uniformity until the threshold is met, so as to realize dynamic alignment maintenance.

[0015] Compared with the prior art, the application has the beneficial effects that: by collecting the pressure data of each point on the contact surface when the upper and lower electrodes are in contact through the pressure sensing device, and combining the preliminary processing of the signal collection module and the algorithm analysis of the main control processing unit, the electrode contact pressure distribution can be obtained in real time and the contact uniformity can be quantitatively evaluated, solving the problems of low precision, inability to quantify, time-consuming post-detection and difficulty in timely feedback caused by relying on manual experience in the prior art; at the same time, the display and prompt module can intuitively present the processing results and give prompts, so that the operator can quickly judge whether the electrode is aligned, without repeated welding, effectively improving the electrode alignment adjustment efficiency, reducing welding point quality defects, reducing equipment wear and tear, and prolonging the service life of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0016] Other features, objects and advantages of the application will become more apparent after reading the detailed description of the non-limiting embodiments made by referring to the following drawings: Figure 1 A structural schematic diagram of the pressure-sensing-based energy storage welding electrode alignment system provided for embodiment 1 is shown; Figure 2 A step flowchart of the pressure-sensing-based energy storage welding electrode alignment method provided for embodiment 2 is shown; Figure 3 A step flowchart of the pressure-sensing-based energy storage welding electrode alignment adjustment method provided for embodiment 3 is shown.

[0017] Fig. 1 is a pressure sensing device; 2 is a signal acquisition module; 3 is a main control processing unit; 4 is a display and prompt module; 5 is a power supply module. DETAILED DESCRIPTION

[0018] The application will be further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific examples described herein are intended to be illustrative only and not limiting of the application. In addition, it should be noted that only the parts related to the application are shown in the drawings for ease of description.

[0019] It should be noted that the embodiments and features in the embodiments in the present application can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and examples.

[0020] Example 1 Please refer to Figure 1 The present application provides a pressure sensing-based energy storage welding electrode alignment system, comprising: A pressure sensing device 1 is used to collect pressure data of each point on the contact surface when the upper and lower electrodes are in contact; A signal acquisition module 2 is connected with the pressure sensing device 1, used to acquire and preliminarily process the pressure signal; A main control processing unit 3 is connected with the signal acquisition module 2, used to receive the pressure data, run a predetermined algorithm, calculate the pressure distribution related parameters, evaluate the electrode contact uniformity, and compare the evaluation result with a preset threshold to determine whether the electrodes are aligned; A display and prompt module 4 is connected with the main control processing unit 3, used to present the processing result and give a prompt.

[0021] Specifically, when deploying the pressure sensing-based energy storage welding electrode alignment system in practice, the assembly and connection of each core component need to be completed to ensure that each technical feature functions stably. Among them, the pressure sensing device 1 needs to be fixed on the contact area of the upper and lower electrodes of the energy storage welding device. Its installation position needs to cover the complete range of electrode contact, so as to accurately capture the pressure data of each point on the contact surface when the upper and lower electrodes are in contact. Whether it is the pressure change of the center area or the edge area of the electrode, it can be collected in real time and without omission, providing basic data support for subsequent judgment of electrode alignment state.

[0022] Then, the signal acquisition module 2 is connected with the pressure sensing device 1 through a wire or a wireless communication interface, and after the connection is completed, a signal path test is required to be performed to ensure that the module can accurately receive the original pressure signal output by the pressure sensing device 1. In the running process, the signal acquisition module 2 will filter the received original signal to remove irrelevant noise such as device vibration and electromagnetic interference, and at the same time, the analog signal will be converted into a digital signal recognizable by the main control processing unit 3 to complete the preliminary processing of the pressure signal and avoid invalid signals affecting subsequent data operation.

[0023] Subsequently, the main control processing unit 3 needs to be connected with the signal acquisition module 2 through a data transmission line to realize real-time reception of the pressure data after preliminary processing. When the data is transmitted, the main control processing unit 3 will start the internal preset data analysis algorithm to operate the pressure data, calculate the distribution rule of the pressure of each contact point, obtain the key parameters reflecting the contact state of the electrode, and then evaluate the uniformity of the electrode contact; at the same time, the main control processing unit 3 will call the alignment threshold value preset in the system, compare the uniformity evaluation result calculated with the threshold value, if the evaluation result meets the threshold value range, it is determined that the electrode is in the alignment state, if it does not meet, it is determined as misalignment, and the core judgment of the electrode alignment state is completed.

[0024] Finally, the display and prompt module 4 needs to be connected with the main control processing unit 3 through a data interface to receive the processing results transmitted by the main control processing unit 3 in real time, including the electrode alignment judgment conclusion, the pressure distribution related parameters, etc. The module will present these results in a form easy for the operator to understand, such as displaying a text report or a data table on the screen, and at the same time, triggering the prompt function according to the judgment result.

[0025] Further, the pressure sensing device 1 is a high-precision pressure sensor array, and the sensor array is distributed in a matrix form to cover the entire electrode contact surface.

[0026] Specifically, in the embodiment, the pressure sensing device 1 adopts a high-precision pressure sensor array, and the design of the array needs to strictly match the size and shape of the contact surface of the upper and lower electrodes of the energy storage weld: if the electrode contact surface is circular, the sensor array is designed to be circularly distributed; if it is rectangular, a rectangular array layout is adopted to ensure that the array can completely cover the entire electrode contact surface without any contact area missing, avoiding the problem of incomplete pressure data collection due to insufficient sensing range.

[0027] Meanwhile, the high-precision pressure sensor array is distributed in a matrix form, and the number of rows and columns of the matrix needs to be determined according to the size of the electrode contact surface and the precision requirement: for example, for a circular rectangular electrode contact surface with a diameter of 20 mm, a 10x10 matrix distribution can be designed, so that the spacing between two adjacent sensing elements is controlled within 2 mm, which can not only ensure the collection accuracy, but also avoid the cost waste caused by excessive density of elements. Through this matrix distribution, when the upper and lower electrodes are in contact, each sensing element in the array can independently collect the pressure data of the corresponding position, forming a pressure data network covering the entire contact surface, which provides high-density and full-range raw data support for the subsequent main control processing unit 3 to analyze the pressure distribution and evaluate the contact uniformity, effectively improving the accuracy of electrode alignment judgment.

[0028] Further, the sensing elements in the high-precision pressure sensor array are selected from at least one of a piezoresistive pressure sensor, a piezoelectric pressure sensor or a thin film flexible pressure sensor.

[0029] Specifically, in the present embodiment, the sensing elements used in the high-precision pressure sensor array have multiple optional types to adapt to the requirements of precision, response speed, installation space and environmental adaptability in different welding scenarios. For example, the sensing elements can be selected from piezoresistive pressure sensors, which have the characteristics of fast response speed, high measurement accuracy and good stability, and are especially suitable for high-frequency sampling scenarios sensitive to dynamic pressure changes; or the sensing elements can also be selected from piezoelectric pressure sensors, which have the advantages of wide frequency response range, high stiffness and high temperature resistance, and are suitable for high-temperature welding environments or occasions requiring capture of instantaneous pressure impact; or the sensing elements can also be selected from thin film flexible pressure sensors, which have good flexibility and adhesion, can adapt to the installation requirements of curved or non-flat electrode contact surfaces, and have the advantages of thin thickness, light weight and strong anti-interference ability, and are especially suitable for complex working conditions with limited space or frequent bending installation.

[0030] Further, the pressure distribution related parameters calculated by the main control processing unit 3 include at least the mean and standard deviation of the pressure distribution.

[0031] Specifically, in the present embodiment, the main control processing unit 3, after receiving the preliminary processed pressure data from the signal acquisition module 2, runs the built-in statistical analysis algorithm to calculate the pressure value set collected by each sensing element on the electrode contact surface, so as to extract the key parameters for quantitatively evaluating the contact uniformity. Among them, the mean value of the pressure distribution (i.e. the arithmetic mean of all sensing point pressure values) is used to reflect the average pressure size borne by the electrode contact surface, and this value helps to judge whether the overall pressure level is within the appropriate range required by the welding process; for example, if the calculated average pressure value is 5000N and the process requires a range of 4800-5200N, it can be preliminarily judged that the overall pressure setting meets the requirements. The standard deviation of the pressure distribution is used to quantify the dispersion degree of each point pressure value relative to the mean value, and the smaller the standard deviation, the more uniform the pressure distribution and the better the electrode alignment; on the contrary, the larger the standard deviation, the more uneven the pressure distribution, and there may be problems such as electrode deflection, uneven contact surface or foreign matter.

[0032] In the actual operation process, the main control processing unit 3 can first form a data set composed of the pressure values of each sensing point, denoted as wherein is the total number of sensing elements. Subsequently, the mean and standard deviation of the data set are calculated. In addition to the mean and standard deviation, the main control processing unit 3 can also calculate other distribution parameters such as range, skewness, kurtosis, etc. as needed to more comprehensively describe the pressure distribution characteristics.

[0033] Further, the main control processing unit 3 is also responsible for coordinating the control of the system components, including setting the sampling rate, processing sensor calibration parameters, and sending update instructions to the display module.

[0034] Specifically, the main control processing unit 3, as the core of the system control, comprehensively coordinates the operation of the system components. In terms of setting the sampling rate, the unit can dynamically adjust the sampling frequency of the signal acquisition module 2 according to different stages of the welding process. For example, a higher sampling rate is used in the initial alignment stage to capture the details of pressure changes, and the sampling rate is appropriately reduced in the stable welding stage to improve system efficiency. In terms of processing sensor calibration parameters, the unit obtains the characteristic parameters of each sensor by executing the calibration program, establishes an accurate correspondence between sensor output and actual pressure, and stores these calibration parameters for real-time measurement, effectively ensuring the accuracy of the pressure data. In terms of sending instructions to the display and prompt module 4, the unit generates display control instructions according to the real-time processing results, including updating the pressure distribution heat map, refreshing the flatness index value, and triggering various state prompts, to ensure that the operator can timely obtain system state information. Through these coordination and control functions, the main control processing unit 3 realizes the efficient collaborative work of the system components, significantly improving the response speed and operational reliability of the entire electrode alignment system.

[0035] Further, the display and prompt module 4 presents the processing results including a pressure distribution heat map and a flatness index percentage reflecting the uniformity of electrode contact.

[0036] Specifically, in this embodiment, the display and prompt module 4 receives the processing result data from the main control processing unit 3 and converts it into intuitive visual information to present to the operator. Among them, the pressure distribution heat map uses color gradient to intuitively display the pressure size distribution of each point on the electrode contact surface. For example, the color gradient from cold to warm is used to represent the change of pressure from low to high: blue represents low pressure area, green represents normal pressure area, and red represents high pressure area. When the electrode is well aligned, the heat map presents a uniform green distribution; when there is pressure concentration, the corresponding area shows red patches, and the operator can immediately identify the poor contact position.

[0037] The flatness index percentage is a quantitative numerical index for accurately reflecting the uniformity of electrode contact. The numerical value is calculated by analyzing the uniformity of pressure distribution, and the contact quality is intuitively displayed in percentage. For example, when the system detects that the pressure distribution is relatively uniform, it displays “contact uniformity: 92%”; when the uniformity decreases, the numerical value decreases accordingly, such as “contact uniformity: 65%”, prompting the operator to adjust the electrode position.

[0038] Further, the display and prompt module 4 triggers at least one of light prompt or voice reminder when the electrode alignment degree reaches the preset threshold.

[0039] Specifically, in this embodiment, the display and prompt module 4 integrates multiple prompt methods to provide clear state feedback to the operator in different working environments. For example, when the system prompts by light, the light prompt uses a multi-color LED indicator light system to deliver state information through different colors and flashing patterns. For example, when the electrode is well aligned and the flatness index reaches the preset threshold (such as 90% or above), the green indicator light is always on; when the alignment state is close to the threshold but needs attention, the yellow indicator light flashes slowly; when the alignment state does not meet the requirements, the red indicator light flashes quickly. This intuitive visual prompt allows the operator to quickly identify the system state from a distance even in a noisy industrial environment.

[0040] Further, it also includes a power supply module 5, which provides stable power for the pressure sensing device 1, the signal acquisition module 2, the main control processing unit 3 and the display and prompt module 4. The power supply module 5 is selected from the existing power supply of the welding machine or an independent DC power supply.

[0041] Specifically, the power supply module 5 can use the existing power supply of the welding machine, realize power supply to each module by adding voltage conversion and voltage stabilizing circuit, or use independent direct current power supply, such as industrial switching power supply or lithium battery pack.

[0042] Embodiment 2 Please refer to Figure 2 On the basis of the above embodiment 1, the embodiment provides a pressure sensing based energy storage welding electrode alignment method, which is applied to the pressure sensing based energy storage welding electrode alignment system as described in embodiment 1, and the method comprises: S10: After starting the system, the upper and lower electrodes of the energy storage welding machine are in contact with each other, and the real-time pressure data of each point on the contact surface is collected by the pressure sensing device 1 in the system.

[0043] Specifically, in step S10, after starting the system, the operator controls the energy storage welding equipment to slowly close the upper electrode and the lower electrode until the two electrodes are completely in contact. The pressure sensing device 1 in the system starts to work immediately and collects the real-time pressure data of each point on the contact surface. For example, in a sensor array with a 10x10 matrix distribution, 100 sensing elements measure the pressure synchronously at a sampling frequency of 1000 times per second, and the pressure distribution of the entire electrode contact surface is obtained comprehensively. This step ensures that the system can obtain complete and accurate initial pressure data before the welding operation starts.

[0044] S20: The signal acquisition module 2 acquires the pressure signal output by the pressure sensing device 1, and after preliminary processing of the pressure signal, transmits it to the main control processing unit 3.

[0045] Specifically, in step S20, the signal acquisition module 2 acquires the original pressure signal output by the pressure sensing device 1 in real time and performs preliminary processing. The processing process includes: first, using a low-pass filter to eliminate high-frequency noise interference caused by equipment vibration, then converting the analog signal to a digital signal through a 16-bit high-precision analog-to-digital converter, and finally standardizing and packaging the data. The processed digital signal is transmitted to the main control processing unit 3 at a rate of 1000 frames per second through the SPI communication interface, ensuring the real-time and accuracy of data transmission.

[0046] S30: The main control processing unit 3 receives the preliminary processed pressure data, runs a predetermined algorithm to calculate the pressure distribution related parameters, and evaluates the electrode contact uniformity percentage at the same time.

[0047] Specifically, in step S30, after receiving the pressure data from the signal acquisition module 2, the main control processing unit 3 runs the built-in statistical analysis algorithm. The algorithm first calculates the mean value of the pressure distribution, reflecting the overall pressure level; then calculates the standard deviation, assessing the degree of dispersion of the pressure distribution; and finally calculates the electrode contact uniformity percentage by synthesizing these parameters. For example, the system may calculate that the current pressure mean value is 5000N, the standard deviation is 180N, and then obtain an evaluation result that the contact uniformity is 85%.

[0048] S40: The main control processing unit 3 compares the contact uniformity percentage with the preset threshold value to determine whether the electrode is aligned, and transmits the determination result and the pressure distribution parameters to the display and prompt module 4.

[0049] Specifically, in step S40, the main control processing unit 3 compares the calculated contact uniformity percentage with the preset threshold value. For example, if the preset threshold value is 80% and the current uniformity is 85%, it is determined that the electrode is well aligned; if the uniformity is 75%, it is determined that it is not aligned. The determination result is transmitted to the display and prompt module 4 in real time through the serial communication interface together with the pressure distribution parameters, providing a decision basis for the operator.

[0050] S50: The display and prompt module 4 displays the pressure distribution in the form of a heat map, and displays the contact uniformity percentage.

[0051] Specifically, in step S50, after receiving the processing result, the display and prompt module 4 presents it to the operator in an intuitive way. On the display screen, the pressure distribution is dynamically displayed in the form of a heat map, using a color gradient to intuitively reflect the pressure size distribution; at the same time, the contact uniformity percentage value is displayed in real time at a prominent position on the screen, such as "contact uniformity: 85%". This visual display method enables the operator to quickly and accurately understand the electrode alignment state.

[0052] Embodiment 3 Please refer to Figure 3 On the basis of the above-mentioned embodiment 1, the present embodiment provides a pressure-sensing-based energy storage welding electrode alignment adjustment method, which is applied to the pressure-sensing-based energy storage welding electrode alignment system as described in embodiment 1, and the method comprises: S100: Before energy storage welding production, the pressure data when the upper and lower electrodes are in contact is continuously collected by the pressure sensing device 1 of the system, at least 2 different initial electrode contact positions are set, and the pressure distribution data corresponding to each group of positions is obtained respectively.

[0053] Specifically, in step S100, before the formal production of the energy storage welding, the operator first sets at least two groups of different initial electrode contact positions. For example, three groups of positions can be set: the first group is the device calibration position, the second group is offset to the right by 2 mm, and the third group is inclined forward by 1 degree. The system continuously collects pressure data when the upper and lower electrodes are in contact at each group of positions through the pressure sensing device 1. The collection time of each group of positions lasts for 5 seconds to ensure that stable pressure distribution data is obtained. The system automatically records and stores the complete pressure distribution data set corresponding to each group of positions.

[0054] S200: The master control processing unit 3 analyzes each group of pressure distribution data and calculates the contact uniformity percentage of each group of data to select the position with the highest contact uniformity percentage as the initial reference alignment position.

[0055] Specifically, in step S200, the master control processing unit 3 analyzes each group of pressure distribution data in detail and calculates the contact uniformity percentage of each group of data. For example, the system calculates that the uniformity of the first group of positions is 78%, the second group is 85%, and the third group is 72%. By comparing the uniformity indicators of each group of data, the system automatically selects the position with the highest contact uniformity percentage (in this example, the second group of positions) as the initial reference alignment position and saves this position parameter as the reference for subsequent welding.

[0056] S300: During the formal welding process, after completing the set number of weldings, the system triggers the pressure data collection and uniformity evaluation to be performed again to determine whether the contact uniformity of the current electrode position still meets the preset threshold.

[0057] Specifically, in step S300, during the formal welding process, the system sets the pressure data collection and uniformity evaluation program to be triggered automatically after 50 weldings are completed. When the set number of weldings is reached, the system pauses the welding operation, controls the electrode to close, and re-collects the pressure data at the current position. The master control processing unit 3 calculates the current pressure distribution parameters and contact uniformity percentage and compares them with the preset threshold (such as 80%) to determine whether the contact uniformity of the current electrode position still meets the requirements.

[0058] S400: If the current contact uniformity is lower than the preset threshold, the master control processing unit 3 generates an electrode adjustment direction prompt based on the pressure abnormal area in the pressure distribution thermal map and outputs it through the display and prompt module 4.

[0059] Specifically, in step S400, if the monitoring finds that the current contact uniformity is lower than the preset threshold, the main control processing unit 3 generates specific electrode adjustment direction prompts according to the pressure abnormal area in the pressure distribution heat map. For example, when the heat map shows that the right side pressure is significantly higher than the left side, the system generates an adjustment prompt of "fine-tune 0.5mm to the left"; when it shows that the front side pressure is insufficient, the prompt is "adjust 0.3 degrees to the rear inclination". These adjustment instructions are clearly output in the form of text and arrow indications through the display and prompt module 4.

[0060] S500: After the operator adjusts the electrode position according to the adjustment direction prompt, the system collects pressure data again and evaluates the uniformity until it meets the threshold to achieve dynamic alignment maintenance.

[0061] Specifically, in step S500, after the operator fine-tunes the electrode position according to the adjustment direction prompt, the system collects pressure data again and re-evaluates the uniformity. If the adjusted contact uniformity is still below the threshold, the system will generate further fine-tuning guidance; if it reaches or exceeds the threshold, the current position parameters are recorded, and the welding operation continues. Through this iterative adjustment and verification process, dynamic maintenance of the electrode alignment state is achieved, ensuring that the optimal alignment state is maintained throughout the entire welding process.

[0062] The above description is only the preferred embodiment of the present application and the explanation of the applied technical principles. Those skilled in the art should understand that the scope of the invention involved in the present application is not limited to the technical solutions formed by the specific combination of the above technical features, and should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the inventive concept. For example, the above features can be replaced with similar functional technical features disclosed in the present application (but not limited to) to form technical solutions.

Claims

1. A pressure-sensing based energy storage welding electrode alignment system, comprising: It comprises: a pressure sensing device (1) for collecting pressure data of each point on the contact surface when the upper and lower electrodes are in contact; a signal acquisition module (2) connected with the pressure sensing device (1) for acquiring and preliminarily processing the pressure signal; a main control processing unit (3) connected with the signal acquisition module (2) for receiving the pressure data, running a predetermined algorithm, calculating the pressure distribution related parameters, evaluating the electrode contact uniformity, and comparing the evaluation result with a preset threshold to determine whether the electrodes are aligned; a display and prompt module (4) connected with the main control processing unit (3) for presenting the processing result and prompting.

2. The pressure-sense based energy storage electrode alignment system of claim 1, wherein, The pressure sensing device (1) is a high-precision pressure sensor array, and the sensor array is distributed in a matrix form to cover the entire electrode contact surface.

3. The pressure-sense-based energy storage electrode alignment system of claim 2, wherein, The sensing elements in the high-precision pressure sensor array are selected from at least one of a piezoresistive pressure sensor, a piezoelectric pressure sensor, or a thin-film flexible pressure sensor.

4. The pressure-sense-based energy storage electrode alignment system of claim 3, wherein, The pressure distribution related parameters calculated by the main control processing unit (3) include at least the mean and standard deviation of the pressure distribution.

5. The pressure-sense-based energy storage electrode alignment system of claim 4, wherein, The main control processing unit (3) is also responsible for coordinating the control of the components of the system, including setting the sampling rate, processing the sensor calibration parameters, and sending update instructions to the display module.

6. The pressure-sense-based energy storage electrode alignment system of claim 5, wherein, The processing result presented by the display and prompt module (4) includes a pressure distribution heat map and a flatness index percentage reflecting the electrode contact uniformity.

7. The pressure-sense-based energy storage electrode alignment system of claim 6, wherein, The prompt mode of the display and prompt module (4) is at least one of light prompt or voice reminder, which is triggered when the electrode alignment degree reaches the preset threshold.

8. The pressure-sense-based energy storage electrode alignment system of claim 7, wherein, It also includes a power supply module (5) for providing stable power to the pressure sensing device (1), the signal acquisition module (2), the main control processing unit (3), and the display and prompt module (4), which is selected from the existing power supply of the welding machine or an independent direct current power supply.

9. A pressure-sensing based energy storage electrode alignment method, comprising: The method is applied to the pressure sensing based energy storage welding electrode alignment system as claimed in any one of claims 1-8, and the method comprises: After starting the system, the upper and lower electrodes of the energy storage welding machine are in contact with each other, and the real-time pressure data of each point on the contact surface is collected by the pressure sensing device (1) in the system; The signal acquisition module (2) acquires the pressure signal output by the pressure sensing device (1), and after preliminarily processing the pressure signal, transmits it to the main control processing unit (3); The main control processing unit (3) receives the preliminarily processed pressure data, runs a predetermined algorithm to calculate the pressure distribution related parameters, and evaluates the electrode contact uniformity percentage; The main control processing unit (3) compares the contact uniformity percentage with a preset threshold to determine whether the electrodes are aligned, and transmits the determination result and the pressure distribution parameters to the display and prompt module (4); The display and prompt module (4) displays the pressure distribution in the form of a heat map, and displays the contact uniformity percentage.

10. A pressure-sensing based energy storage electrode alignment adjustment method, characterized in that, The method is applied to the pressure sensing based energy storage welding electrode alignment system as claimed in any one of claims 1-8, and the method comprises: Before the production of the energy storage welding, the pressure data when the upper and lower electrodes are in contact are continuously collected by the pressure sensing device (1) of the system, at least two groups of different initial electrode contact positions are set, and the pressure distribution data corresponding to each group of positions are obtained respectively; The main control processing unit (3) analyzes each group of pressure distribution data, calculates the contact uniformity percentage of each group of data, and selects the position with the highest contact uniformity percentage as the initial reference alignment position; During the formal welding process, after completing the set number of weldings, the system triggers to re-perform pressure data collection and uniformity evaluation to determine whether the contact uniformity of the current electrode position still meets the preset threshold; If the current contact uniformity is lower than the preset threshold, the main control processing unit (3) generates an electrode adjustment direction prompt according to the pressure abnormal area in the pressure distribution thermal map, and outputs it through the display and prompt module (4); After the operator adjusts the electrode position according to the adjustment direction prompt, the system collects pressure data again and evaluates the uniformity until it meets the threshold, so as to realize dynamic alignment maintenance.

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