Tube plate round hole intelligent welding decision and path optimization method and system based on template

Abstract

The invention relates to the technical field of industrial automatic round hole welding, in particular to a template-based intelligent welding decision and path optimization method and system for tube plate round holes, the system comprises a CAD module, a file module, a template module and a function module, and all the modules realize data interaction through an internal data bus and communicate with external welding equipment through a Modbus TCP protocol; the method comprises the steps of (1) system initialization, (2) processing file importing, (3) template application, (4) path priority ranking, (5) user interaction modification, (6) data issuing and (7) processing state monitoring. According to the scheme, 3D scanning hardware is not needed, the problems that in the prior art, decision making efficiency is low, process consistency is poor, data modification is difficult, and cost is high can be solved, high-precision, high-efficiency and flexible tube plate round hole welding is achieved, cost is reduced, and welding seam quality consistency is improved.

Description

Technical Field

[0001] This invention relates to the field of industrial automation circular hole welding technology, and in particular to a template-based intelligent welding decision and path optimization method and system for circular hole welding in tube sheets, which includes welding point acquisition, priority selection, and welding path planning. Background Technology

[0002] In the field of industrial automation circular hole welding technology, the accuracy and efficiency of tube sheet circular hole welding directly affect production quality, and current mainstream welding solutions have significant technical shortcomings. Existing solutions mainly include three categories: manual welding, fixed programmed control, and vision-based solutions based on 3D scanners. 1. Manual welding relies on operators to visually judge the position of the round holes, manually mark the welding sequence, or plan the path according to CAD files. This not only takes a long time to make decisions, but is also prone to marking errors due to human operation, resulting in poor process consistency. 2. Fixed programmed control adopts a preset scheme. The equipment is driven by importing a point table. The welding path is relatively fixed and cannot be modified for a specific point. Once the program is issued, it cannot be adjusted again. If modification is required, the data needs to be re-exported. Repeated manual teaching is required before processing to achieve accurate processing results. 3. Vision solutions based on 3D scanners require multiple scans by a 3D camera to acquire data. The accuracy is affected by the performance of the scanning equipment and the environment, resulting in insufficient stability. Furthermore, multiple scans lead to low efficiency and high equipment procurement and maintenance costs.

[0003] The above solutions share common problems such as low decision-making and communication efficiency, poor process consistency, difficulty in modifying calculation data and inflexibility, and high cost. They are difficult to meet the actual needs of high precision, high efficiency and flexibility in tube sheet circular hole welding, and there is an urgent need to optimize the technical solutions to break through the bottlenecks.

[0004] Therefore, a new technical solution is urgently needed to address the technical problems of low decision-making and communication efficiency, poor process consistency, difficulty in modifying calculation data, inflexibility and high cost of existing technologies. Summary of the Invention

[0005] The purpose of this invention is to overcome the problems of the prior art and provide a template-based intelligent welding decision-making and path optimization method and system for tube sheet circular holes. This aims to solve the core problems of existing tube sheet circular hole welding technology, namely, "low decision-making and communication efficiency, poor process consistency, difficulty in modifying calculated data, inflexibility, and high cost." Specifically, it includes: eliminating the need for expensive hardware such as 3D scanning, reducing equipment procurement and maintenance costs; achieving automated determination and dynamic adjustment of welding priorities, reducing the time spent on manual decision-making; supporting flexible optimization of welding paths and real-time data modification, avoiding repeated export and teaching processes; establishing real-time communication between the program and welding equipment, enabling rapid data distribution and processing status monitoring, improving overall efficiency; and ensuring that welding data is uniformly calculated and generated by the program, reducing process fluctuations caused by manual intervention and improving consistency.

[0006] The above objectives are achieved through the following technical solutions: A template-based intelligent welding decision-making and path optimization method and system for circular holes in tube sheets includes the following steps: Step (1) System initialization: Obtain the communication IP of the welding equipment according to the configuration file and initialize the distribution address. Read the file list and template list from the registry. After verifying the existence of the files, import the file module and template module and refresh the file preview display. Step (2) Import the processing file: Import the standard DXF file, perform graphic analysis on the file to filter auxiliary line primitives and retain the circular hole data, and use a weighted clustering analysis algorithm to determine the left and right parts of the imported graphic; Step (3) Apply template: The user imports a standard DXF file as a template through the template module and stores it in the template list. The matching judgment between the graphics in the template and the machining graphics imported in the CAD module is performed. If the matching judgment is passed, the priority of the round hole is set according to the template. The round hole corresponding to the template is set to priority 1, and the other round holes are set to priority 2. Step (4) Path priority sorting: The user sets the processing path start point type and path type through the functional module, sorts all the round holes according to the start point type, generates path data for the round holes with priority 1 using the shortest path algorithm, and generates path data for the round holes with priority 2 according to the set path type. The path is optimized by the double-end nearest neighbor strategy. Step (5) User interaction modification: Users can open the point overview pop-up window through the CAD module or directly click on the interface graphic to open the data pop-up window to modify the circular hole data. After modification, the path generation algorithm is called again. Step (6) Data delivery: Communicate with the welding equipment via Modbus TCP protocol, select full data delivery or segmented data delivery. When full data is delivered, clear the processing status display. When segmented data is delivered, generate segmented paths and provide sub-path previews. Supports delivery of any three points for three-point calibration of the welding equipment. Step (7) Processing status monitoring: During the processing, the host computer locks the operation, monitors the processing status in real time, and marks the processing status of each round hole with the corresponding color in the CAD module. After all processing is completed, the host computer operation is unlocked.

[0007] As an optimization of the template-based intelligent welding decision and path optimization method for circular holes in tube sheets described in this scheme, the process of judging the left and right parts of the imported graphic by the weighted clustering analysis algorithm in step (2) includes: Centroid initialization: The double centroid is initialized using the extreme values ​​of the X-axis coordinates and the average values ​​of the Y-axis coordinates of the circular hole. The calculation formula is as follows: , where x i y i Let X and Y be the coordinates of the i-th hole, respectively, and n be the total number of holes. Hole assignment: Each hole is dynamically assigned to two clusters using a weighted distance. The two clusters correspond to the left and right parts of the image, respectively. Centroid iteration: Update the centroid for each cluster iteration until the maximum movement distance of all cluster center points satisfies the convergence condition; Clustering decision: Define err as tolerance, calculate the bounding box half-width and minimum intra-group spacing of two clusters, and determine the clustering decision when the distance between the centers of the two clusters is equal to the tolerance. At that time, it was determined that the figure has two parts, left and right, where c L c R , where are the center coordinates of the left and right clusters, respectively; halfLeft and halfRight are the half-widths of the bounding boxes of the left and right clusters, respectively; and minDisL and minDisR are the minimum intra-group spacings of the left and right clusters, respectively.

[0008] As an optimization of the template-based intelligent welding decision and path optimization method for tube sheet circular holes described in this scheme, step (2) also includes a user intervention mechanism: after the weighted clustering analysis is completed, the user can force the graphic to be set into two parts, left and right, and manually adjust the division boundary of the left and right parts. The system sets the priority 1 for the right graphic and the priority 2 for the left graphic according to the adjusted boundary.

[0009] As an optimization of the template-based intelligent welding decision and path optimization method for tube sheet circular holes described in this solution, the specific method of matching judgment in step (3) is as follows: the program performs point matching between the graphic in the template and the processing graphic imported in the CAD module, and judges whether the distribution of circular holes in the template graphic and the processing graphic is consistent. If the distribution is consistent, the matching is judged to be successful. If the distribution is inconsistent, the system issues a prompt, allowing the user to adjust the template position or process the abnormal circular holes in the processing graphic and then re-perform the matching judgment.

[0010] As an optimization of the template-based intelligent welding decision and path optimization method for circular holes in tube sheets described in this scheme, the specific implementation of the shortest path algorithm in step (4) includes: Construct a minimum spanning tree based on the Euclidean distance between each hole; Extract the initial path from the minimum spanning tree, ensuring that the path covers all holes with priority 1; The initial path is processed to reduce the idle movement distance of the welding equipment.

[0011] As an optimization of the template-based intelligent welding decision and path optimization method for circular holes in tube sheets described in this scheme, the process of optimizing the path through the dual-end nearest neighbor strategy in step (4) includes: Path initialization: Using the user-specified starting point as the initial path start point, select the circular hole closest to the starting point as the second node of the initial path to form the initial path segment; Node insertion: Traverse all unvisited holes, calculate the distance between each unvisited hole and the first and last nodes of the current path, and insert the hole with the smaller distance into the corresponding end; Path update: After each node is inserted, the path is rotated left to adjust the node order, and the newly inserted node is set as the new beginning or end of the path. The node insertion and path update steps are repeated until all holes have been visited.

[0012] As an optimization of the template-based intelligent welding decision and path optimization method for tube sheet circular holes described in this solution, the user modification in step (5) also includes a batch operation function: the user can select multiple circular holes and batch modify their priority or batch translate coordinates. When batch translating coordinates, the X and Y direction coordinates are input, and the coordinates of all selected circular holes are moved to the specified coordinates.

[0013] As an optimization of the template-based intelligent welding decision and path optimization method for tube sheet circular holes described in this scheme, the specific process of the three-point calibration in step (6) is as follows: the user selects three non-collinear circular holes as calibration reference points in the CAD module, and the system sends the theoretical coordinates of the reference points to the welding equipment through the ModbusTCP protocol; the welding equipment moves to the actual position of each reference point and feeds back the actual coordinates, and the system calculates the deviation compensation value between the theoretical coordinates and the actual coordinates, which is used to correct the welding coordinates of all subsequent circular holes.

[0014] As an optimization of the template-based intelligent welding decision and path optimization method for tube sheet circular holes described in this solution, the color identification rules in step (7) are as follows: circular holes to be processed are displayed as white, circular holes in processing are displayed as green, circular holes that have been processed are displayed as yellow, circular holes that are not processed are displayed as gray dashed lines, and circular holes with abnormal processing are displayed as red. When a processing abnormality occurs, a pop-up window will indicate the type of abnormality.

[0015] A template-based intelligent welding decision-making and path optimization system for circular holes in tube sheets includes a CAD module, a file module, a template module, and a functional module, specifically: The CAD module is used for graphic display, user interaction, and color marking of processing status. User interaction includes opening a pop-up window for points and clicking on the graphic to modify data. The file module is used to store a file list, provide a file preview function, and read files from the registry and verify their existence during system initialization; The template module is used to store a template list, automatically determine execution priorities, and perform template matching verification. The automatic priority determination is based on weighted clustering analysis. The functional modules include a path algorithm unit, a distribution control unit, and a processing status monitoring unit. The path algorithm unit calculates the shortest path and optimizes the two-end nearest neighbor. The distribution control unit performs full distribution, segmented distribution, and three-point calibration. The processing status monitoring unit monitors the processing status in real time and locks the host computer operation. Each module interacts with other modules via an internal data bus, and the modules communicate with external welding equipment via the Modbus TCP protocol.

[0016] This invention provides a template-based intelligent welding decision-making and path optimization method and system for circular holes in tube sheets. By dynamically configuring priorities and optimizing path algorithms using templates, and directly transmitting data via Modbus TCP protocol, it supports user modification and processing status monitoring. This achieves high-precision, high-efficiency, flexible, and low-cost welding data planning and transmission, improving process consistency. It solves the problems of low efficiency, poor process consistency, and difficult and costly data modification in existing tube sheet circular hole welding decision-making and communication systems. Furthermore, this solution is easy to use, utilizing standard DXF files as the processing data source and template. It achieves automated identification of the welding priority of circular holes during tube sheet welding, quickly calculates the path, supports user modification, and can be easily transmitted to welding equipment, ultimately exhibiting the following specific advantages: 1. Automated decision-making using templates or graphic grouping: Easy to use, simply import files or templates to identify welding priorities, no hardware dependency such as scanners, multiple template parameters can be configured and stored, eliminating the need for manual calculation or repeated scanning, reducing costs, improving efficiency, and the interactive logic is intuitive.

[0017] 2. Dynamic path optimization: It adopts a hybrid path planning method, which is compatible with most processing processes. Compared with the traditional processing according to sequence number, it can effectively reduce invalid paths such as idle movement. It supports automatic path updates at any time during data modification, which improves the efficiency of preparing processing data compared with manual calculation.

[0018] 3. Adjustable calculation results: After importing the file, the calculation results can be modified at any time. Compared with fixed program control, specific points can be adjusted and previewed at any time, eliminating the problem of repeatedly modifying the source file. It is more flexible, does not require repeated trial and error, and is very intuitive.

[0019] 4. Flexible data delivery: Using the Modbus TCP protocol to connect with welding equipment, data can be delivered and monitored at any time, eliminating time-consuming operations of repeated copying. It can choose to deliver full data or segmented data. Before delivering processing data, three-point calibration data can be delivered to improve welding accuracy. Segmented delivery is supported, allowing for the insertion of subtasks or adjustments to subsequent processing data at any time, making it more flexible and saving time.

[0020] 5. Standardized parameter control: All data is calculated and generated by the program, and the results can be modified reasonably and legally by humans, which largely avoids the uncertainty of manually setting parameters. Attached Figure Description

[0021] Figure 1 This is an architecture diagram of a template-based intelligent welding decision and path optimization system for tube sheet circular holes according to the present invention. Figure 2 This is a core flowchart of the intelligent welding decision and path optimization method for tube sheet circular holes based on templates, as described in this invention. Figure 3 This is a flowchart of the path algorithm in the template-based intelligent welding decision and path optimization method for circular holes in tube sheets according to the present invention. Figure 4 This is a flowchart of the path optimization algorithm in the template-based intelligent welding decision and path optimization method for circular holes in tube sheets according to the present invention; Figure 5 This is a schematic diagram of the data calculation results of the template-based intelligent welding decision and path optimization method for circular holes in tube sheets according to the present invention. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. The described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0023] like Figure 1As shown, this solution provides a template-based intelligent welding decision-making and path optimization system for circular holes in tube sheets. The system uses a CAD module, imports DXF files, automatically identifies and filters out useless information such as auxiliary lines, retains the circular hole data, and automatically identifies the left and right parts of the graphic according to priority conventions (optional). The right part is set to priority 1, and the center positions of both parts are moved to the origin (0, 0) of the coordinate system for merging, followed by subsequent path planning, point calibration, and other settings. If priority identification is not selected, a priority template can be imported. When applying the template, the program automatically determines whether the template matches the overall point data and automatically sets the priority in the template for subsequent path planning. The program communicates with the welding equipment using the Modbus TCP protocol. After calculation, the data can be directly sent down, which is accurate, intuitive, fast, and low-cost.

[0024] like Figure 1 As shown, the system consists of four main modules with the following functions: CAD module: Provides user interaction functions, supports file preview, can open the point overview pop-up or click the graphic to open the data pop-up to modify the data, and uses color to indicate the status of the round holes during processing. Specifically, as the core of user interaction, it has three major functions: (1) Graphic display: Displays the round holes in the imported DXF file in a visual form and renders them according to the actual coordinate ratio; (2) User interaction: Supports users to click the "Overall Points" button to open the point overview pop-up (such as Figure 5 As shown, the pop-up window includes the hole number, X / Y coordinates, priority, and path sequence, or you can directly click on the hole graphic in the interface to open the data pop-up window to modify the priority and coordinates; (3) Status identification: During the processing, the status of each hole is identified according to the color rules to intuitively reflect the progress.

[0025] File Module: Stores a list of files. During initialization, it reads the file list from the registry and verifies the existence of the files. After importing the files, it refreshes the preview. Specifically, the file module is responsible for the management of the processed files, including: (1) File storage: Reads and stores the historical processed file list from the registry, and supports users to filter files by file name and creation time; (2) File preview: Displays the distribution of circular holes in the DXF file in a thumbnail on the module interface, and can quickly determine whether the file matches the current tube sheet without opening the CAD module; (3) File verification: When the system is initialized, it automatically checks the integrity of the file, such as whether the DXF file is damaged or whether the circular hole data is missing. If the verification fails, it will prompt "The file is damaged, please re-import".

[0026] Template Module: Stores a list of templates and can import standard DXF files as templates. The program automatically determines whether the template matches the processing graphic point data; if they match, the priority is set according to the template. Specifically, the template module is used to implement the template-based configuration of priorities, including: Template storage: Import standard DXF files as templates, such as "Tube Sheet A Standard Template" and "Tube Sheet B Standard Template", store them in the template list and support renaming and deletion; Automatic priority determination: A weighted clustering analysis algorithm is invoked to automatically identify the left and right parts of the graphic and assign priority 1 to the right side; ③ Template matching verification: The distribution of circular holes in the template and the processed graphic is compared to determine whether the priority should be set according to the template. Functional modules include a path algorithm unit (implementing shortest path calculation and dual-end nearest neighbor strategy path optimization), a data distribution control unit (supporting full / segmented data distribution and three-point calibration), and a processing status monitoring unit (real-time monitoring of processing status and locking the host computer during processing).

[0027] The modules work together and communicate with the welding equipment via the Modbus TCP protocol.

[0028] like Figure 2 As shown, this solution also provides a template-based intelligent welding decision and path optimization method for circular holes in tube sheets, including the following steps: Step (1) System Initialization: Before starting the system, obtain the welding equipment communication IP according to the configuration file and initialize the distribution address. Read the file list and template list from the registry, verify the existence of the files and import them into the file module and template module, and refresh the preview display. Specifically, this includes: 1. Communication Configuration: Read the welding equipment communication parameters from the configuration file, such as IP address, port number, and initial data transmission address, to ensure a smooth communication link with the welding equipment; 2. File / Template Loading: Read the historical file list and template list from the registry, verify the existence of the physical path of each file and template, import the corresponding module if the verification is successful, remove it from the list and record it in the log; 3. Preview Refresh: After the file module and template module are loaded, the preview interface will be refreshed automatically. The distribution of the holes in each DXF file will be displayed in the file preview area, and the template name and the corresponding number of holes will be displayed in the template list area, such as "Tube Sheet A Template: 80 holes".

[0029] Step (2) Import the processing file: Import the standard DXF file, perform graphic analysis, automatically filter out other primitives used for auxiliary lines, retain only circles, and use a weighted clustering analysis algorithm to determine the left and right parts of the imported graphic: (1) Initialization: Initialize the two centroids with the x-axis extrema; (2) Dynamically allocate the circular holes to the two parts using weighted distance; (3) For each cluster, iteratively update the centroid until the maximum movement distance of all centroids satisfies the convergence condition; (4) Define err as tolerance. The judgment is made by calculating the bounding box features and the minimum spacing within the group. When the center distance between two clusters is greater than the following values, the image is considered to have two parts. The user decides whether to apply the automatically recognized part. The user can also force the program to recognize both parts. The program will merge the graphics according to the priority set for the segmented parts. The user can also manually set the priority and finally automatically import it into the CAD module for display.

[0030] This step is specifically as follows: 1. When the user selects the "Import Processing File" function and imports a standard DXF file, the system performs the following operations: Graphics parsing and filtering: The DXF parsing engine is called to read the graphic data in the file, including lines, circles, polygons, etc. The auxiliary lines, such as lines and polygons, are filtered out by the "graphic type recognition algorithm". Only the circular hole data corresponding to the "circle" graphic element is retained, including the X / Y coordinates and radius. 2. Weighted Cluster Analysis (Determining Left and Right Parts): Perform clustering in the following four steps: (1) Centroid initialization: Traverse the X coordinates of all circular holes and take the minimum value x. min Maximum value x max Calculate the average value of the Y coordinates of all circular holes. The coordinates of the two centroids are obtained. (Left initial centroid) and (Right initial centroid); (2) Dynamic allocation of circular holes: Each circular hole is assigned to the cluster corresponding to the centroid with the smaller weighted distance by weighted distance; (3) Centroid Iterative Update: For each cluster, recalculate the centroid coordinates and repeat the “assign-update” process until the maximum centroid movement distance between the two iterations satisfies the convergence condition; (4) Clustering determination: Calculate the half-width of the bounding box of the left cluster (halfLeft) and the half-width of the bounding box of the right cluster (halfRight). Calculate the minimum spacing (minDisL) of all holes in the left cluster and the minimum spacing (minDisR) of the right cluster. Define err as the tolerance, which can be adjusted in the system settings. If the left and right sides are both present, the figure is considered to have two parts; otherwise, it is considered to have a single part.

[0031] 3. User Intervention and Initial Priority Setting: After clustering is completed, the system pops up a "Confirm Priority" window, displaying the determination result of "whether there are left and right parts": If the user approves the result, the system will automatically set the priority of the round holes in the right cluster to 1 and the priority of the left cluster to 2. If the user selects "force division of left and right parts", then regardless of whether the left and right parts are recognized, the system will divide the circular hole into two parts according to the overall center line as the boundary line, and set the left circular hole as priority 2 and the right hole as priority 1. 4. Importing graphics into CAD: After the initial priority setting is completed, the system imports all circular holes into the CAD module according to the actual coordinate scale, renders and displays them in the interface, and displays priority 1 in bold.

[0032] Step (3) Apply template: Using templates, users can quickly configure the processing priority for round holes. Users can use the import template function to import standard dxf files as templates and store them in the list. When users use templates, the matching judgment between the graphics in the template and the graphics imported in the CAD module is performed. If the judgment is successful, the corresponding round hole in the template is set to priority 1, and other graphics are set to priority 2. This step specifically involves: If the user selects "Import Template" instead of "Import Processing Files," or needs to adjust the priority after importing processing files, they can perform the "Apply Template" operation: 1. Template Selection and Loading: The user selects the target template from the template list, such as "Tube Sheet A Standard Template". The system loads the corresponding circular hole data of the template, including X / Y coordinates and priority. 2. Fitting Determination: Determine whether the distribution of circular holes in the template and the machining drawing in the current CAD module are consistent. If the distribution is consistent, the fitting is considered successful; if the distribution is inconsistent, the system will display a "fitting failed" message, suggesting that the user adjust the template position or handle the abnormal circular holes in the machining drawing. After the user makes the adjustment, the fitting determination will be re-executed. 3. Priority Configuration: After a successful match, the system sets the round holes in the processing drawing that match the template as priority 1, and the remaining unmatched round holes as priority 2.

[0033] Step (4) Path priority sorting: In order to conform to the common processing technology of tube sheet welding, the user can set the starting point and path type of the processing path through the function list. Among them, the graphics with priority 1 always use the shortest path to generate data, and the graphics with priority 2 are processed according to the path type. To optimize time efficiency, an approximate solution algorithm is used to calculate the shortest path, and a two-terminal nearest neighbor strategy is employed to further refine the results. The algorithm implementation steps are as follows: (1) Sort: Sort all the graphics according to the starting point type specified by the user, ensuring that the first graphic is the starting point specified by the user. Use this sorting method to optimize the generated results.

[0034] (2) Construct the minimum spanning tree using Euclidean distance and obtain the path according to the minimum spanning tree.

[0035] (3) Use the dual-end nearest neighbor strategy to optimize the path.

[0036] This step is specifically as follows: like Figure 3 As shown, after the priority configuration is completed, the path planning phase begins, and the process is as follows: 1. Starting point type selection: Users can select the starting point type in the "Path Settings" interface of the function module, including "Top left round hole", "Bottom right round hole" and "Custom starting point". The custom starting point is to directly click on a round hole in the CAD module; 2. Path type selection: Users select the path type for the circular holes with priority 2, including "shortest path", "X-axis priority", and "Y-axis priority". X-axis priority means traversing by X coordinate from smallest to largest, and if X is the same, sorting by Y coordinate. Y-axis priority means traversing by Y coordinate from smallest to largest, and if Y is the same, sorting by X coordinate. 3. Hole Sorting: Based on the user-selected starting point type, all holes are initially sorted in the order of "starting point → other holes", ensuring that the first hole is the specified starting point; 4. Shortest path solution (priority 1): For the circular holes with priority 1, the following algorithm is used to generate the path: (1) Construct the Euclidean distance matrix: Calculate the Euclidean distance between all priority 1 circular holes and form a matrix; (2) Generate the minimum spanning tree: Construct the minimum spanning tree from the distance matrix; (3) Extract the initial path: Extract the path from the minimum spanning tree to ensure that all holes of priority 1 are covered; 5. Double-ended nearest neighbor optimization, such as... Figure 4 As shown: Optimize the initial path and the path with priority 2 as described above: (1) Path initialization: Take the sorted starting point as the initial path starting point, select the circular hole closest to the starting point as the second node, and form the initial path segment; (2) Node insertion: Traverse all unvisited holes, calculate the distance between each hole and the first and last nodes of the current path, and insert the hole with the smaller distance into the corresponding end; (3) Path update: After each node is inserted, the path is rotated to the left to adjust the node order to reduce the number of device turns. The newly inserted node is set as the new beginning or end of the path. The node insertion and path update steps are repeated until all holes are visited. 6. Path Preview: After optimization, the path sequence is marked with green lines in the CAD module, allowing users to visually check for issues such as path intersections or excessively long empty shifts.

[0037] like Figure 5As shown, the calculation results of the circular holes are displayed in a table format, including columns for "serial number, X coordinate, Y coordinate, priority, path order, and processing status". The processing status is marked with a color block, which intuitively presents the key data and current status of each circular hole.

[0038] Step (5) User Interaction Modification: All data can be legally modified by users. Users can open the pop-up window of the overall point overview by clicking on the overall point location, and modify the data of the graphic according to the serial number and location. Users can also directly click on the graphic on the interface to obtain the graphic data pop-up window and modify its priority or coordinates. Any modification will trigger a re-invocation of the path generation algorithm. The system supports users in making legitimate modifications to all data. Specific operation methods include: 1. Modify the Point Overview pop-up: When a user clicks the "Point Overview" button in the CAD module, the following pop-up will appear: Figure 5 The data table shown includes serial number, X coordinate, Y coordinate, priority, and path order. You can directly edit the values ​​in the table and click the "Save" button after editing. 2. Graphic pop-up modification: When a user clicks on a circular hole in the CAD module, a "Circular Hole Data Editing" pop-up window will appear, displaying detailed information about the circular hole, including X / Y coordinates, radius, priority, and path order. The priority or coordinates can be modified, and then "Apply" can be clicked. 3. Batch operation modification: Users can hold down the Ctrl key to select multiple holes, or select a region of holes using the "selection box" function, and click the "Batch Modify" button to perform batch priority changes, batch coordinate shifts, and batch deletion operations. When shifting coordinates in batch, users can input the X and Y offset values, and the coordinates of all selected holes will shift synchronously. Batch deletion is used to delete selected abnormal holes. 4. Path Regeneration: After any modification operation is completed, the system automatically triggers the "Path Regeneration" command, calls the path algorithm in step 4, and recalculates the path based on the modified data to ensure that the path matches the latest data.

[0039] Step (6) Data Distribution: The program communicates with the welding equipment using the Modbus TCP protocol. Users can choose to distribute all data or distribute data in segments. If all data is distributed, the processing status display will be cleared; if data is distributed in segments, the status will not be cleared. Users can use the segmented data distribution function by clicking the two circular holes to automatically generate segmented paths, with a preview of the sub-paths provided. Users can distribute any three points for three-point calibration of the welding equipment.

[0040] Specifically, after the user confirms that the path is correct, the "data delivery" operation is executed, and the specific process is as follows: 1. Communication connection verification: The system sends a "heartbeat packet" to the welding equipment via the Modbus TCP protocol. If a "response packet" is received from the equipment within the specified time, the communication is considered normal. Otherwise, a communication failure message will pop up, and it is recommended to check the device IP or network cable. 2. Three-point calibration (optional): If the user selects the "calibration" function, they can click on three non-collinear circular holes in the CAD module. The system will then send the theoretical coordinates of these three circular holes to the welding equipment via the Modbus TCP protocol. The welding equipment will move to the actual positions of these three circular holes, acquire the actual coordinates through its own position sensors, and feed them back to the system. The system will calculate the deviation compensation value between the theoretical and actual coordinates, which will be used to correct the welding coordinates of all subsequent circular holes, thus completing the calibration. 3. Data delivery options: (1) Full data download: When the user selects "Full data download", the system packages all the welding data of the round holes in the ModbusTCP protocol format and downloads it to the designated register area of ​​the welding equipment; after the download is completed, the system clears the processing status indicator in the CAD module and all round holes are restored to white for processing. (2) Segmented distribution: When the user selects “Segmented distribution” and clicks on the two circular holes in the CAD module, the system automatically generates the segmented path between the two circular holes. The order and length of the segmented path are displayed in the “Sub-path Preview” interface. After the user confirms, the system only distributes the welding data of the segment and does not clear the historical processing status. The circular holes that have been processed are still displayed in yellow. Multiple segmented distributions are supported, which makes it easy to insert urgent sub-tasks. 4. Feedback on transmission results: After receiving the data, the device sends a "Data reception complete" message to the system, and the system displays a "Transmission successful, processing can begin" message. If packet loss occurs during data transmission, the device sends a "Data incomplete" message, and the system automatically retransmits the lost data segments to ensure data integrity.

[0041] Step (7) Processing status monitoring: The host computer cannot be operated during the processing status. The processing status is monitored in real time, and the corresponding color is set for the corresponding status of the corresponding round hole in the CAD module. Other operations can be performed after all processing is completed.

[0042] Specifically, after the data is distributed, the processing status monitoring phase begins: 1. Host computer lock: The system automatically locks the operation buttons of the CAD module, file module, and template module. For example, the "Import File" and "Modify Data" buttons will be grayed out and cannot be clicked to prevent accidental data modification during the processing. 2. Real-time status reception: The system periodically sends a "status query" command to the welding equipment via the Modbus TCP protocol. The equipment then reports the current processing status, such as "Processing, current round hole number 25" or "Fault, fault code E03". 3. Status Visualization Indicator: Based on the status feedback from the device, the system updates the color of the corresponding circular hole in the CAD module. If the current processing step number is 25, then the round hole with step number 25 will be displayed in green; If the equipment reports that the round hole with serial number 24 has been processed, the round hole with serial number 24 will be displayed in yellow. If the equipment reports a fault, the round hole of the current processing step number will be displayed in red, and a fault prompt pop-up window will appear, indicating the fault type and handling suggestions; 4. Processing Completion: When the equipment sends a "All round holes have been processed" instruction, the system unlocks the host computer operation button and pops up a processing completion statistics pop-up window, displaying the total number of round holes processed this time and the pass rate. The pass rate is calculated based on the "number of qualified round holes" fed back by the equipment, and the processing data for this time is automatically saved to the historical log.

[0043] The above description is merely illustrative of the embodiments of the present invention and is not intended to limit the present invention. For those skilled in the art, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A template-based tube sheet round hole intelligent welding decision and path optimization method, characterized in that, Comprise: Step (1) system initialization: according to the configuration file gets welding equipment communication IP and initialization issued address, read file list and template list from the registry, verify file existence after importing file module and template module, refresh file preview display; Step (2) import processing file: import standard DXF file, the file is analyzed to filter auxiliary line graphics and keep the hole data, the left and right parts of the imported graphics are determined by weighted clustering analysis algorithm; Step (3) application template: user imports standard DXF file as template through template module and stores it to template list, the graphics in the template and the processing graphics imported in CAD module are judged, if the graphics match, the template setting hole priority is determined, the template corresponding hole is set as priority 1, and the rest of the hole is set as priority 2; Step (4) path priority sorting: user sets the starting point type and path type through the function module, sorts all the holes according to the starting point type, the shortest path algorithm is used to generate path data for the hole with priority 1, and the path data is generated for the hole with priority 2 according to the set path type, and the path is optimized by double-end nearest neighbor strategy; Step (5) user interactive modification: user opens the point overview pop-up window or directly clicks the interface graphics to open the data pop-up window, modifies the hole data, and re-calls the path generation algorithm after modification; Step (6) data issuing: communicate with the welding equipment through Modbus TCP protocol, select full data issuing or segmented data issuing, clear the processing state display when full data issuing, generate segmented path and provide sub-path preview when segmented data issuing, support issuing any three points for welding equipment three-point calibration; Step (7) processing state monitoring: lock the operation of host computer during processing, monitor the processing state in real time, and mark the processing state of each hole with corresponding color in CAD module, and unlock the operation of host computer after all processing is completed.

2. The method of claim 1, wherein, The process of determining the left and right parts of the imported graphics in step (2) includes: Centroid initialization: the double centroid is initialized by the X-axis coordinate extreme value and the Y-axis coordinate average value of the circular hole, and the calculation formula is: where x i and y i are the X and Y coordinates of the i-th circular hole, and n is the total number of circular holes; Hole distribution: dynamically distribute each hole to two clusters by weighted distance, and the two clusters correspond to the left and right parts of the graphics respectively; Centroid iteration: update the centroid of each cluster iteratively until the maximum movement distance of all cluster center points meets the convergence condition; Cluster decision: define err as tolerance, calculate the half-width of bounding box of two clusters and the minimum distance within the group, when the distance between the centers of two clusters is less than err, it is determined that the figure has left and right two parts, where c , c L , c R are the center coordinates of left and right clusters respectively, halfLeft and halfRight are the half-width of bounding box of left and right clusters respectively, and minDisL and minDisR are the minimum distance within the left and right clusters respectively.

3. The template-based tube sheet hole intelligent welding decision and path optimization method according to claim 1 or 2, characterized in that, Step (2) further includes user intervention mechanism: after the weighted clustering analysis is completed, the user can forcibly set the graphics as left and right two parts, manually adjust the division boundary of left and right parts, and the system sets the right graphics as priority 1 and the left graphics as priority 2 according to the adjusted boundary.

4. The method of claim 1, wherein, The specific way of matching in step (3) is that the program matches the points of the graphics in the template with the processing graphics imported in the CAD module, judges whether the hole distribution of the template graphics and the processing graphics is consistent, if consistent, the matching is passed, if not, the system prompts the user to adjust the template position or handle the abnormal hole in the processing graphics and then re-perform the matching.

5. The method of claim 1, wherein, The specific implementation of the shortest path algorithm in step (4) includes: Construct the minimum spanning tree based on the Euclidean distance between each hole; Extract the initial path from the minimum spanning tree, ensure that the path covers all priority 1 round holes; Process the initial path to reduce the welding equipment empty moving distance.

6. The method of claim 1 or 5, wherein, The process of optimizing the path by the double-end nearest neighbor strategy in step (4) includes: Path initialization: take the user-specified starting point as the starting point of the initial path, select the round hole closest to the starting point as the second node of the initial path, and form an initial path segment; Node insertion: traverse all unvisited round holes, calculate the distance between each unvisited round hole and the head node and tail node of the current path, and insert the round hole with smaller distance into the corresponding end; Path update: after each node insertion, perform a left rotation operation to adjust the node order, set the newly inserted node as the new head or tail of the path, and repeat the node insertion and path update steps until all round holes are visited.

7. The method of claim 1, wherein, The user modification in step (5) further includes batch operation function: the user can select multiple round holes, batch modify their priority or batch translate coordinates, input X and Y direction coordinates when batch translating coordinates, and move all selected round hole coordinates to the specified coordinates.

8. The method of claim 1, wherein, The specific process of three-point calibration in step (6) is: the user selects three non-collinear round holes as calibration reference points in the CAD module, and the system sends the theoretical coordinates of the reference points to the welding equipment through the Modbus TCP protocol; the welding equipment moves to the actual position of each reference point and feeds back the actual coordinates, and the system calculates the deviation compensation value of the theoretical coordinates and the actual coordinates, which is used to correct the welding coordinates of all subsequent round holes.

9. The method of claim 1, wherein, The color identification rule in step (7) is: the round hole to be processed is displayed in white, the round hole in processing is displayed in green, the round hole after processing is displayed in yellow, the round hole not to be processed is displayed in gray dotted line, and the round hole with processing exception is displayed in red. When there is a processing exception, a pop-up window will prompt the type of the exception.

10. The template-based tube sheet hole intelligent welding decision and path optimization system of claim 1, wherein, It includes CAD module, file module, template module and function module, wherein: The CAD module is used for graphic display, user interaction and processing state color identification, and user interaction includes opening point position pop-up window and clicking graphic to modify data; The file module is used for storing file list and providing file preview function, and reads files from the registry and verifies existence during system initialization; The template module is used for storing template list, performing priority automatic judgment and template matching verification, and the priority automatic judgment is realized based on weighted clustering analysis; The function module includes path algorithm unit, downlink control unit and processing state monitoring unit, the path algorithm unit realizes shortest path calculation and double-end nearest neighbor optimization, the downlink control unit performs full downlink, segmented downlink and three-point calibration, and the processing state monitoring unit monitors the processing state in real time and locks the host computer operation; Each module realizes data interaction through internal data bus, and the modules communicate with external welding equipment through Modbus TCP protocol.

Images