Instrument beam assembly arc welding deformation real-time inhibition method based on dynamic parameter optimization

Abstract

The invention relates to an instrument beam assembly arc welding deformation real-time inhibition method based on dynamic parameter optimization, and belongs to the technical field of automobile part production, and the method comprises the following steps: 1, designing a clamp before welding and setting a digital model; 2, the deformation amount L of the deformed part is recorded, a function L (t) of the deformation amount changing along with time is generated, time accumulation of the deformation amount is calculated, the comprehensive deformation rate Z = L / L0 + J / J0 is calculated, L0 is a standard deformation value, and J0 is a standard accumulated value; the step 3 further comprises the steps that the control module improves the reverse deformation force of the clamp by A1 times, A1 = Z / Z0, and Z0 is a first threshold value; and 3, when the comprehensive deformation rate exceeds a first threshold value, the reverse deformation force of the clamp is improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of automobile part production, and particularly relates to a real-time suppression method for arc welding deformation of an instrument cross beam assembly based on dynamic parameter optimization. BACKGROUND

[0002] The instrument cross beam assembly is an important part in an automobile, which is formed by stamping and welding of a plurality of parts.

[0003] Traditional automobile instrument panel cross beam welding has problems such as too large thickness of the support and inaccurate welding seam arrangement. Therefore, the patent CN103440387B discloses a welding optimization method for an automobile instrument panel cross beam. The MCS NASTRAN software is used to divide the existing instrument panel cross beam data into grids, and the CAE analysis model is used to analyze the overall modal and static stiffness of the product. According to the analysis result, the structure of the modal weak part of the product is optimized, the length, quantity and position of the welding seam are optimized, and finally the optimized model is analyzed and verified by the MCS NASTRAN software, thereby improving the overall modal and static stiffness of the automobile instrument panel cross beam.

[0004] However, this method only focuses on the static optimization of the welding seam, and does not consider the dynamic change of thermal deformation in the welding process, so it is difficult to realize online real-time feedback adjustment. For example, when the local temperature rises sharply during welding, causing uneven thermal expansion of the material, timely intervention is needed. However, no measures are taken to offset the deformation trend in the above process. Therefore, a real-time suppression method for arc welding deformation of an instrument cross beam assembly based on dynamic parameter optimization is needed, which can monitor and dynamically adjust the welding deformation, and has high accuracy of monitoring and adjustment. SUMMARY

[0005] To solve the above problems in the prior art, the application provides a real-time suppression method for arc welding deformation of an instrument cross beam assembly based on dynamic parameter optimization, which has the characteristics of being able to monitor and dynamically adjust the welding deformation in real time, and has high accuracy of monitoring and adjustment.

[0006] The purpose of the application can be achieved by the following technical solutions: The real-time suppression method for arc welding deformation of an instrument cross beam assembly based on dynamic parameter optimization comprises the following steps: Step 1: design the clamp before welding and set the digital model; Step 2: monitor the welding position, record the deformation amount of the deformation position, calculate the cumulative value of the deformation amount over time, and calculate the comprehensive deformation rate according to the cumulative value and the deformation amount; Step 3: when the comprehensive deformation rate exceeds the first threshold value, the reverse deformation force of the clamp is increased.

[0007] As a preferred embodiment of the present invention, step two further includes: recording the deformation amount L of the deformed part and generating a function L(t) of the deformation amount changing with time, and calculating the cumulative deformation amount over time. Calculate the overall deformation rate Z = L / L0 + J / J0. Where L0 is the standard deformation value and J0 is the standard cumulative value; step three also includes: the control module increases the reverse deformation force of the fixture by A1 times, A1=Z / Z0, and Z0 is the first threshold.

[0008] As a preferred embodiment of the present invention, step two further includes: calculating the comprehensive deformation rate Z=(k1×L / L0+k2×J / J0) / (k1+k2), Where L0 is the standard deformation value, J0 is the standard cumulative value, and k1 and k2 are pre-input weights; As a preferred technical solution of the present invention, it further includes step four: setting an infrared sensor at the deformed part to monitor the local temperature of the deformed area and upload it to the control module; it further includes step five: the control module calculates the ratio of the local temperature to the standard temperature, denoted as the first ratio, and the ratio of the deformation amount of the deformed part to the standard deformation value, denoted as the second ratio; when the difference between the first ratio and the second ratio exceeds the second threshold, the control module corrects the reverse deformation force of the fixture downward. As a preferred embodiment of the present invention, step five further includes: correcting the reverse deformation force of the control module fixture to A2 times the original value, wherein... , where a is the first ratio, b is the second ratio, and D2 is the second threshold.

[0009] As a preferred technical solution of the present invention, step two further includes: the control module is used to statistically analyze the temperature confidence level around the deformed part, the control module determines whether the confidence level is lower than a preset confidence threshold, and when the determination result is yes, the control module instructs the first threshold to be corrected downward.

[0010] The beneficial effects of this invention are as follows: (1) By monitoring the welding part and recording the deformation amount of the deformed part, the welding deformation can be monitored in real time and dynamically adjusted. At the same time, by calculating the cumulative deformation amount over time, the comprehensive deformation rate can be calculated based on the cumulative value and the deformation amount, which can capture the long-term trend of the comprehensive deformation. When long-term and subtle changes occur, they can be captured, thus improving the accuracy of adjustment. (2) By calculating the comprehensive deformation rate by Z=(k1×L / L0+k2×J / J0) / (k1+k2), the weighted calculation of deformation and cumulative deformation can be realized, which can comprehensively consider the influence of instantaneous deformation and long-term cumulative deformation, thus reflecting the actual deformation state more accurately. (3) By monitoring the local temperature of the deformation area and uploading it to the control module; it also includes step five: the control module calculates the ratio of the local temperature to the standard temperature, which is recorded as the first ratio, and the ratio of the deformation amount of the deformation part to the standard deformation value, which is recorded as the second ratio. When the difference between the first ratio and the second ratio exceeds the second threshold, the control module corrects the reverse deformation force of the fixture downwards. This completes the reduction of the reverse deformation force when the correlation between temperature abnormality and deformation amount is poor, the deformation fluctuation caused by other factors is limited, and the reverse force is applied in a limited way, so as to avoid overcorrection leading to structural instability. Attached Figure Description

[0011] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0012] Figure 1 This is a schematic diagram of the steps of the present invention. Detailed Implementation

[0013] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0014] Please see Figure 1 A real-time suppression method for arc welding deformation of instrument crossbeam assembly based on dynamic parameter optimization includes the following steps: Step 1: Design the fixtures and set up the digital model before welding; In this embodiment, the clamp has the function of applying a reverse force; Step 2: Monitor the welded area, record the deformation of the deformed area, calculate the cumulative deformation over time, and calculate the overall deformation rate based on the cumulative value and the deformation amount. The control module is electrically connected to a temperature sensor, which collects the temperature at various points and uploads it to the control module once per second. The control module acquires the deformation of the welded part once per second and generates a function L(t) showing how the deformation changes over time. Then, step three is executed: when the overall deformation rate exceeds the first threshold, the reverse deformation force of the fixture is increased. The control module has the position of each fixture pre-input. Then, the control module determines the fixture closest to the welded part based on the amount of deformation of the welded part, calculates the reverse deformation force of the fixture, and instructs the fixture to change the reverse deformation force of the fixture. For step two, specifically, the deformation amount L of the deformed part is recorded, and a function L(t) is generated to show how the deformation amount changes over time, and the cumulative deformation amount over time is calculated. Calculate the overall deformation rate Z = L / L0 + J / J0. Where L0 is the standard deformation value and J0 is the standard cumulative value; step three also includes: the control module increases the reverse deformation force of the fixture by A1 times, A1=Z / Z0, and Z0 is the first threshold; When the cumulative value is high, it indicates a significant long-term deformation trend. At this time, the integral term J in Z drives the Z value to rise and exceed the first threshold, triggering the reverse deformation force enhancement mechanism and suppressing the continuous deformation trend. Similarly, when the absolute value of the deformation is high, the L term in Z causes Z to rise and exceed the first threshold, which also triggers the enhancement mechanism and effectively suppresses instantaneous large deformation. By monitoring the welded area and recording the deformation amount of the deformed area, welding deformation can be monitored in real time and dynamically adjusted. At the same time, by calculating the cumulative deformation over time, the comprehensive deformation rate can be calculated based on the cumulative value and the deformation amount, which can capture the long-term trend of comprehensive deformation. When long-term and subtle changes occur, they can be captured. The two work together to improve the accuracy of adjustment.

[0015] Alternatively, in step two: calculate the overall deformation rate Z = (k1 × L / L0 + k2 × J / J0) / (k1 + k2). Where L0 is the standard deformation value, J0 is the standard cumulative value, and k1 and k2 are pre-input weights; At this point, by introducing weighting coefficients k1 and k2, the contribution ratio of deformation L and cumulative amount J in the comprehensive deformation rate Z can be adjusted according to different working conditions and production situations. For example, in welding relatively thin materials that are susceptible to long-term cumulative effects, k2 can be increased to highlight the long-term cumulative effect, while in welding relatively thick materials that are less affected by long-term cumulative effects, k1 can be increased to emphasize the instantaneous deformation response. The comprehensive deformation rate is calculated by Z=(k1×L / L0+k2×J / J0) / (k1+k2), which realizes the weighted calculation of deformation and cumulative deformation. It can comprehensively consider the influence of instantaneous deformation and long-term cumulative deformation, thus reflecting the actual deformation state more accurately.

[0016] In the above process, not all deformation is caused by thermal deformation. It may also involve the effects of multiple factors such as mechanical stress release and changes in material structure. In this case, the effect of applying reverse force is limited, and the reverse deformation force needs to be reduced to avoid overcorrection leading to structural instability. At this point, it often manifests as the correlation between the first ratio and the second ratio deviating from the normal range; To this end, the method also includes step four: setting an infrared sensor at the deformed part to monitor the local temperature of the deformed area and upload it to the control module; it also includes step five: the control module calculates the ratio of the local temperature to the standard temperature, which is recorded as the first ratio, and the ratio of the deformation amount of the deformed part to the standard deformation value, which is recorded as the second ratio. When the difference between the first ratio and the second ratio exceeds the second threshold, the control module corrects the reverse deformation force of the fixture downward. Specifically, step five also includes: correcting the reverse deformation force of the control module fixture to A2 times the original value, wherein... , where a is the first ratio, b is the second ratio, and D2 is the second threshold; When the difference between the first ratio and the second ratio is too large, it indicates that the temperature change and the deformation response are not matched, and there may be complex deformation factors that are not dominated by heat. In this case, the reverse force is dynamically reduced by the A2 coefficient to avoid overcorrection due to misjudgment of a single parameter. The process includes monitoring the local temperature of the deformation area and uploading it to the control module; step five: the control module calculates the ratio of the local temperature to the standard temperature, denoted as the first ratio, and the ratio of the deformation amount of the deformed part to the standard deformation value, denoted as the second ratio. When the difference between the first ratio and the second ratio exceeds a second threshold, the control module corrects the reverse deformation force of the fixture downwards. This reduces the reverse deformation force when the correlation between temperature anomalies and deformation amount is poor, and deformation fluctuations caused by other factors are limited, thus avoiding overcorrection that could lead to structural instability.

[0017] In some cases, there may be local temperature anomalies or local temperature statistical anomalies. Therefore, step two also includes: the control module is used to statistically analyze the temperature confidence level around the deformed part, and the control module determines whether the confidence level is lower than the preset confidence threshold. When the determination result is yes, the control module instructs the first threshold to be corrected downward. Specifically, the confidence level is determined as follows: after monitoring the local temperature of the deformation area and uploading it to the control module, the control module arranges the local temperature data in reverse chronological order, and then calculates the variance of a fixed number of the latest uploaded temperature data. When the variance is too large, it indicates that there is an abnormal change in local temperature, and the collected temperature value cannot well represent the actual value, resulting in a low confidence level. In this case, the first threshold needs to be lowered to prevent false alarms.

[0018] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for real-time suppression of arc welding deformation in instrument beam assemblies based on dynamic parameter optimization, characterized in that: The method comprises the following steps: Step 1: design the fixture before welding and set the digital model; Step 2: monitor the welding position, record the deformation of the deformation position, and calculate the accumulation of the deformation in time, calculate the comprehensive deformation rate according to the accumulated value and the deformation; Step 3: when the comprehensive deformation rate exceeds the first threshold value, the reverse deformation force of the fixture is increased.

2. The method of claim 1, wherein the method is a real-time method for suppressing distortion of a crossbeam assembly of a welding instrument based on dynamic parameter optimization. The step two further comprises: recording the deformation L of the deformation part and generating a function L(t) of the deformation over time, and calculating the accumulation of the deformation over time , and then the control module calculates a comprehensive deformation rate Z=L / L0+J / J0, wherein L0 is a standard deformation value and J0 is a standard accumulation value; the step three further comprises: the control module increases the reverse deformation force of the clamp by A1 times, A1=Z / Z0, and Z0 is a first threshold value.

3. The method of claim 1, wherein the method is a real-time method for suppressing the distortion of the arc welding of the instrument beam assembly based on the dynamic parameter optimization. The step two further comprises: calculating a comprehensive deformation rate Z=(k1×L / L0+k2×J / J0) / (k1+k2), wherein L0 is a standard deformation value, J0 is a standard cumulative value, and k1 and k2 are pre-input weights.

4. The method of claim 1, wherein the method is a real-time method for suppressing distortion of a crossbeam assembly of a welding instrument based on dynamic parameter optimization. It also includes step 4: setting an infrared sensor at the deformation position to monitor the local temperature of the deformation area and upload it to the control module; it also includes step 5: the control module calculates the ratio of the local temperature to the standard temperature, which is recorded as the first ratio, and the ratio of the deformation of the deformation position to the standard deformation value, which is recorded as the second ratio, when the difference between the first ratio and the second ratio exceeds the second threshold value, the control module corrects the reverse deformation force of the fixture downward.

5. The method of claim 4, wherein the method is a real-time method of suppressing distortion in arc welding of an instrument beam assembly based on dynamic parameter optimization. The step five further comprises: the reverse deformation force of the module clamp is controlled to be A2 times of the original value, wherein a is a first ratio, b is a second ratio, and D2 is a second threshold value.

6. The method of claim 1, wherein: The step 2 also includes: the control module is used for counting the temperature confidence degree around the deformation deformation position, and the control module judges whether the confidence degree is lower than the pre-set confidence threshold value, when the judgment result is yes, the control module instructs the first threshold value to be corrected downward.

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