Intelligent welding control method and system under multi-element electricity hybrid power supply scene

Abstract

The invention provides an intelligent welding control method and system under a multi-power hybrid power supply scene. The welding controller is electrically connected with at least two different types of power supplies through the switch unit, and the welding controller is used for driving a welding load; the intelligent welding control method comprises the following steps that in response to the fact that a welding controller is electrically connected with a first power source, information of a connecting part formed by a welding load is obtained; detecting the welding quality based on the information of the connecting part; and in response to the fact that the welding quality does not reach the standard, the switch unit is controlled to act, so that the welding controller is switched from being electrically connected with the first power source to being electrically connected with a second power source. The power supply is adaptively switched based on the welding quality, specifically, under the condition that the first power supply is used for supplying power to the welding controller, if the welding quality of the connecting part does not reach the standard, the second power supply is actively switched to supply power to the welding controller, and the defect rate of the welding quality is prevented from being further increased as much as possible.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of welding, in particular to an intelligent welding control method and system in a multi-element electric hybrid power supply scenario. BACKGROUND

[0002] With the rapid development of new energy, such as photovoltaic, wind power and other new energy, the proportion of new energy in the power system is gradually increasing, and the power system is facing problems such as grid voltage imbalance fluctuation out-of-limit and intermittent fluctuation of new energy. In the field of welding, these power problems have a serious impact on welding quality and stability, and traditional welding equipment and power regulation methods cannot meet the requirements of reliable welding in complex power environments.

[0003] In the prior art, the power switching logic of traditional welding equipment usually depends on the availability of the power source itself, such as switching to other available power sources after the current power supply is interrupted. If there are voltage fluctuations, harmonic distortion and other problems in the power supply before or after switching, it is very easy to occur during welding. Arc instability, insufficient penetration, welding spatter, welding cracks, and insufficient welding spread fusion area defects, at this time, if the welding equipment still uses such power supply, it will cause a significant increase in the defect rate of welding quality, not only hidden dangers to the safety of the entire welding system, but also serious losses. SUMMARY

[0004] The technical problem to be solved by the present disclosure is to overcome the above-mentioned defects in the prior art, and to provide an intelligent welding control method and system in a multi-element electric hybrid power supply scenario based on welding quality adaptive switching of power supply.

[0005] The present disclosure solves the above technical problems by the following technical solutions:

[0006] The first aspect of the present disclosure provides an intelligent welding control method in a multi-element electric hybrid power supply scenario, a welding controller is electrically connected to at least two different types of power sources through a switching unit, and the welding controller is used to drive a welding load.

[0007] The intelligent welding control method comprises the following steps:

[0008] In response to the welding controller being electrically connected to a first power source, information of a connection part formed by the welding load is obtained;

[0009] The welding quality of the connection part is detected based on the information of the connection part;

[0010] In response to the welding quality being substandard, the switching unit is controlled to act, so that the welding controller is switched from being electrically connected to the first power source to being electrically connected to a second power source.

[0011] Optionally, the intelligent welding control method further comprises:

[0012] For each power supply, a voltage stability index and a current stability index are determined based on the power parameter of the power supply, and an evaluation index of the power supply is determined according to the voltage stability index and the current stability index;

[0013] A second power supply is determined according to the evaluation index.

[0014] Optionally, the information of the connection part includes image data and temperature data of the connection part.

[0015] The welding quality of the connection part is detected based on the information of the connection part, specifically comprising:

[0016] The image data and the temperature data of the connection part are input into a detection model for welding quality detection, to obtain the welding quality of the connection part; wherein the detection model is trained based on image data, temperature data and actual welding quality of a sample connection part.

[0017] Optionally, the intelligent welding control method further comprises: sending a welding instruction to the welding controller; wherein the welding instruction is used to instruct the welding controller to drive the welding load based on the target welding parameter corresponding to the second power supply.

[0018] Optionally, the intelligent welding control method further comprises:

[0019] Obtaining voltage fluctuation data;

[0020] Determining a welding parameter adjustment value corresponding to the voltage fluctuation data;

[0021] Sending a welding parameter adjustment instruction to the welding controller; wherein the welding parameter adjustment instruction is used to instruct the welding controller to adjust the target welding parameter according to the welding parameter adjustment value.

[0022] Optionally, the intelligent welding control method further comprises: updating the correspondence between the second power supply and the target welding parameter according to the adjusted target welding parameter.

[0023] Optionally, the voltage fluctuation data includes voltage fluctuation data of the second power supply and / or voltage fluctuation data of the welding load.

[0024] A second aspect of the present disclosure provides an intelligent welding control system in a multi-element electric hybrid power supply scenario, comprising a welding controller, a welding load, a switching unit and a main controller, the welding controller being electrically connected with at least two different types of power supplies through the switching unit.

[0025] The main controller is configured to perform the intelligent welding control method of the first aspect.

[0026] The welding controller is configured to drive the welding load.

[0027] Optionally, the main controller comprises a local processor, a cloud service platform and a local control unit.

[0028] The local processor is configured to obtain information of a connection formed by the welding load, and detect a welding quality of the connection based on the information of the connection.

[0029] The cloud service platform is configured to issue a policy instruction of switching to the second power supply to the local control unit in response to the welding quality being substandard.

[0030] The local control unit is configured to control the switching unit to act in response to the policy instruction, so that the welding controller is switched from being electrically connected to the first power supply to being electrically connected to the second power supply.

[0031] Optionally, the switching unit comprises an automatic transfer switch and a circuit breaker corresponding to each power supply and connected in sequence.

[0032] The local control unit is further configured to control the automatic transfer switch corresponding to the second power supply to be turned on and control the circuit breaker corresponding to the second power supply to be closed.

[0033] Optionally, the at least two different types of power supplies comprise a bidirectional energy storage all-in-one machine, and the bidirectional energy storage all-in-one machine comprises a battery management system, an energy storage element and an energy storage converter.

[0034] The local control unit is further configured to send a charge and discharge instruction to the battery management system.

[0035] The battery management system is configured to control the energy storage converter to perform voltage conversion processing to charge and discharge the energy storage element according to the charge and discharge instruction.

[0036] A third aspect of the present disclosure provides an electronic device comprising a memory, a processor and a computer program stored on the memory and configured to run on the processor, and the processor implements the intelligent welding control method of the first aspect when executing the computer program.

[0037] A fourth aspect of the present disclosure provides a computer readable storage medium having a computer program stored thereon, and the computer program is executed by a processor to implement the intelligent welding control method of the first aspect.

[0038] The fifth aspect of the present disclosure provides a computer program product comprising a computer program which, when executed by a processor, implements the intelligent welding control method of the first aspect.

[0039] On the basis of common sense in the art, the above-mentioned preferred conditions can be combined arbitrarily, i.e. to obtain each preferred example of the present disclosure.

[0040] The positive progress effect of the present disclosure is that the present disclosure switches the power supply for the welding controller based on the welding quality, specifically, if the welding quality of the connecting part does not meet the standard, the second power supply is actively switched to supply power for the welding controller, so as to avoid further increase of the defect rate of the welding quality as much as possible.

[0041] In addition, by accurately screening the second power supply through the power supply evaluation index, guaranteeing the welding quality judgment accuracy through the multi-modal detection model, optimizing the power supply stability through the power switching module and energy storage, a full closed-loop control of quality detection, power switching, parameter adaptation and state feedback is formed, effectively solving the problem of unstable welding quality in the multi-element power supply scene. BRIEF DESCRIPTION OF DRAWINGS

[0042] Figure 1 A structural schematic diagram of an intelligent welding control system provided for an exemplary embodiment of the present disclosure is shown in the figure;

[0043] Figure 2 A flowchart of an intelligent welding control method provided for embodiment 1 of the present disclosure is shown in the figure;

[0044] Figure 3 A flowchart of an intelligent welding control method provided for embodiment 2 of the present disclosure is shown in the figure;

[0045] Figure 4 A flowchart of another intelligent welding control method provided for embodiment 2 of the present disclosure is shown in the figure;

[0046] Figure 5 A structural schematic diagram of an electronic device provided for embodiment 4 of the present disclosure is shown in the figure. DETAILED DESCRIPTION

[0047] The present disclosure will be further illustrated by way of examples below, but the present disclosure is not limited in the scope of the examples.

[0048] The prefix words such as "first", "second" in the embodiments of the present disclosure are only used to distinguish different description objects, and have no limiting effect on the position, order, priority, quantity or content of the described objects. The use of ordinal words such as "first" in the embodiments of the present disclosure does not constitute a limitation on the described objects, and the description of the described objects should be referred to the description in the context of claims or embodiments, and should not constitute redundant limitations because of the use of such prefix words. In addition, in the description of the embodiments, unless otherwise stated, the meaning of "multiple" is two or more than two.

[0049] Embodiment 1

[0050] Figure 1 A structural schematic diagram of an intelligent welding control system in a multi-element electric hybrid power supply scene is provided in the embodiments. In the intelligent welding control system as shown in Figure 1 The welding controller 22 is electrically connected with at least two different types of power sources through the switching unit 21, that is, the welding controller 22 is supplied with power by multi-element electric hybrid power supply. The main controller 20 is used to control the on-off of each switch in the switching unit 21, so that different power sources can supply power to the welding controller 22. The welding controller 22 is used to drive the welding load 23 to complete the welding task. The different types of power sources can include new energy power sources such as photovoltaic, wind power, and hydroelectric power, and can also include traditional energy power sources such as nuclear power and commercial power.

[0051] It can be understood that the welding controller is used to rectify the input power to obtain direct current. According to the selected welding mode and the received voltage instruction or current instruction, the duty cycle of the internal power switch such as IGBT is adjusted by using a control algorithm such as PID algorithm, the direct current is converted into alternating current with a higher frequency, and then the voltage is reduced by a transformer and rectified into direct current for welding load, so as to realize the output of welding energy to the welding load, so that the welding load can complete the welding task.

[0052] In some examples, the at least two different types of power sources pass through the power supply processing module 24 and are electrically connected with the welding controller 22 through the switching unit 21. The power supply processing module 24 is used to optimize the quality of the input power, so as to output high-quality and stable power supply.

[0053] Figure 2 A flowchart of an intelligent welding control method is provided in the embodiments. The intelligent welding control method provided in the embodiments can be executed by the above-mentioned main controller, as shown in Figure 2 The intelligent welding control method provided in the embodiments includes the following steps S11-S13:

[0054] In step S11, in response to the welding controller being electrically connected with the first power supply, information of a connection formed by the welding load is acquired. The welding controller being electrically connected with the first power supply means that the welding controller is powered by the first power supply. It should be noted that the first power supply can be one of the at least two different types of power supplies, or two or more power supplies.

[0055] The connection formed by the welding load refers to a local solid joint formed by using current and pressure at the overlapping position of two or more metal parts through a welding process, such as resistance welding, which can be a welding spot or a solder joint.

[0056] In step S12, the welding quality of the connection is detected based on the information of the connection. For example, when the connection is a welding spot, the welding quality can include whether the welding spot has pores, cracks, shrinkage holes, and the like, and can also include whether the welding spot has virtual welding, surface spatter, burn-through, surface adhesion, and the like. For example, when the connection is a solder joint, the welding quality can include the solder joint rate, and can also include whether the solder joint has pores, cracks, and the like.

[0057] In step S13, in response to the welding quality being substandard, the switching unit is controlled to act so as to switch the welding controller from being electrically connected with the first power supply to being electrically connected with the second power supply.

[0058] The switching unit in the embodiments of the present disclosure strictly follows the timing logic of first making contact and then breaking contact when acting, and also detects the phase difference of the power supply to avoid current impact damage to the IGBT module in the welding controller when the phase difference is large, thereby increasing the maintenance cost of the equipment.

[0059] In some examples, the switching unit includes an automatic transfer switch (ATS) and a circuit breaker corresponding to each power supply one by one and connected in sequence. First, the ATS corresponding to the second power supply is controlled to be turned on and the circuit breaker is closed, and after it is detected that the second power supply is stable, for example, the voltage fluctuation amplitude of the second power supply is ≤±1% within 200 ms, and the phase difference between the first power supply is ≤5°, the path of the first power supply is cut off, the whole process guarantees uninterrupted power supply at the access point, and avoids the generation of abnormalities such as welding arc extinguishing caused by power failure of sensitive loads such as welding.

[0060] The standard of the welding quality can be set according to actual conditions. In a specific example, if the connection part has a virtual weld, it indicates that the welding quality of the connection part is not up to standard. In another specific example, if the connection part is a welding point, the virtual weld determination standard is that the axial tension of the welding point is less than 380 N / 10 seconds; if the connection part is a brazing seam, the unqualified determination standard is that the brazing rate is less than 80%, and the temperature data needs to be comprehensively judged. When the temperature fluctuation of the brazing seam is greater than ± 5℃, even if there is no obvious defect in appearance, it is also determined that the welding quality is not up to standard.

[0061] In the implementation of step S13, the action of the switch unit can be controlled according to whether the welding quality of one connection part is up to standard, or whether the welding quality of two or more connection parts is up to standard. In a specific example, the number of welding points formed by the welding load is 20, of which the welding quality of 18 welding points is up to standard, and the welding quality of 2 welding points is not up to standard, that is, the pass rate of the welding points is 90%, which does not meet the requirement of the pre-set 95% pass rate, so the action of the switch unit needs to be controlled to switch the power supply.

[0062] It should be noted that the second power supply can be one of the at least two different types of power supplies, or two or more power supplies, and the second power supply can be determined according to factors such as the power quality of each power supply, the pre-set rule, and the weather condition. In a specific example, in step S13, the welding controller is switched from photovoltaic power connection to wind power connection by controlling the action of the switch unit. In another specific example, in step S13, the welding controller is switched from photovoltaic power connection to simultaneous photovoltaic and wind power connection by controlling the action of the switch unit.

[0063] In this embodiment, if the welding quality of the connection part is not up to standard when the first power supply is used to supply power to the welding controller, the second power supply is actively switched to supply power to the welding controller, so as to avoid further increase of the welding quality defect rate as much as possible. It should be noted that if the welding quality of the connection part cannot be up to standard even after the second power supply is switched to supply power to the welding controller, the power supply can be further switched until the welding quality of the connection part is up to standard.

[0064] In an optional implementation, the intelligent welding control method further includes: for each power supply, determining a voltage stability index and a current stability index based on the power energy parameters of the power supply, and determining an evaluation index of the power supply according to the voltage stability index and the current stability index; and determining the second power supply according to the evaluation index.

[0065] The power parameters of the power supply can include voltage, current, power, harmonic current, etc. In some examples, multiple anti-reverse flow ammeters are arranged to collect the power parameters of each power supply. In other examples, multiple power measurement and control instruments are arranged to collect the power parameters of each power supply.

[0066] The voltage stability index can include voltage fluctuation rate and voltage flicker value, and the current stability index can include total harmonic current distortion (THDi). In some examples, the voltage stability index and the current stability index can be calculated using the following formulas:

[0067] The voltage stability index = (1-ΔU / U) x 100, where ΔU is the voltage fluctuation amplitude, U is the rated voltage, and ΔU / U is the voltage fluctuation amount.

[0068] The current stability index = (1-THDi / 5) x 100.

[0069] For example, if the voltage fluctuation amount is 2%, the voltage stability index is 98 points, and if THDi is 2%, the current stability index is 99.6 points.

[0070] In some examples, a dynamic scoring model is used to determine the power supply evaluation index, i.e., the scores of the voltage stability index and the current stability index are weighted to obtain the evaluation index of the power supply, i.e., the score of the power supply. The power supply with the highest score is determined as the second power supply. For example, the voltage stability index can be substituted into a preset first scoring function to obtain the score of the voltage stability index, and the current stability index can be substituted into a preset second scoring function to obtain the score of the current stability index. It should be noted that the first scoring function and the second scoring function are both monotonically decreasing functions, i.e., the larger the value of the voltage stability index, the lower the score, and the larger the value of the current stability index, the lower the score. In actual applications, the weight of the score of the voltage stability index, i.e., the first weight, and the weight of the score of the current stability index, i.e., the second weight, can be set according to actual conditions, and the sum of the two is 1, for example, the first weight can be set to 0.55, and the second weight can be set to 0.45.

[0071] To improve the accuracy of the power evaluation index, in an optional embodiment, the evaluation index of the power is determined based on the voltage stability index and the current stability index in combination with the cost of the power. In some examples, the scores of the voltage stability index, the current stability index and the cost are weighted to obtain the score of the power, and the power with the highest score is determined as the second power. For example, the cost can be substituted into a preset third scoring function to obtain the score of the cost. It should be noted that the third scoring function is also a monotonically decreasing function, that is, the higher the cost, the lower the score. In actual applications, the weight of the score of the voltage stability index, i.e., the first weight, the weight of the score of the current stability index, i.e., the second weight, and the weight of the cost, i.e., the third weight, can be set according to actual conditions, and the sum of the three is 1. For example, the first weight can be set to 0.4, the second weight can be set to 0.3, and the third weight can be set to 0.3. In some other examples, the evaluation index of the power can also be determined in combination with other factors such as power adequacy and the like.

[0072] In some examples, in addition to considering the evaluation index of the power, the second power can also be determined in combination with other factors such as weather conditions, welding task scheduling conditions and the like. For example, if the meteorological forecast predicts that the light intensity will decrease by 30% in the next 1 hour, even if the evaluation index of the current photovoltaic power is higher than that of the wind power, the wind power is still determined as the second power. For another example, if the welding task is high-precision chip packaging with extremely high voltage stability requirements, the weight of the nuclear power evaluation index is increased, for example, to 60%, and the nuclear power is preferentially selected as the second power.

[0073] In another optional embodiment, the second power is determined from at least two different types of power according to a preset rule. In some examples, the preset rule is photovoltaic first, wind power second, hydroelectric power third, and commercial power last. For example, the above-mentioned at least two different types of power include photovoltaic and wind power, and the first power is photovoltaic, so the wind power is determined as the second power. For another example, the above-mentioned at least two different types of power include wind power, hydroelectric power and commercial power, and the first power is hydroelectric power, so the commercial power is determined as the second power.

[0074] In some examples, step S11 is performed periodically, meaning a second power source is determined periodically, for example, 13 times per day at a frequency of once every 1.8 hours. In other examples, before each determination of a second power source, the monitoring frequency of each power source is adjusted based on the fluctuation range of its evaluation metrics. For example, if the score fluctuation of a power source exceeds 10 points within a historical hour (e.g., a photovoltaic power source drops from 92 points to 78 points due to cloud cover), the monitoring frequency of that power source is increased, for example, from once every 1.8 hours to once every 30 minutes, to avoid switching decision errors due to sudden changes in power source characteristics.

[0075] In one optional embodiment, the information of the connection includes image data and / or temperature data of the connection. The image data can be obtained by capturing the appearance of the connection using an industrial camera, or the temperature data can be collected using a temperature measuring device such as an infrared thermometer. In this embodiment, step S12 specifically includes: inputting the image data and temperature data of the connection into a detection model to detect the welding quality, thereby obtaining the welding quality of the connection; wherein the detection model is trained based on the image data, temperature data, and actual welding quality of a sample connection, and the detection model is used to extract the contour of the connection and comprehensively predict the welding quality by combining the temperature data.

[0076] In a specific example, the YOLOv5 defect detection model is used to detect welding quality. Training this model requires collecting at least 1000 sets of sample data, including samples of different welding materials such as steel, aluminum, and copper, with at least 200 defect samples (e.g., porosity, cracks, and incomplete welds) for each material. A fusion architecture is used, employing a CNN (Convolutional Neural Network) to extract image appearance features and a fully connected layer to extract temperature distribution features. After feature fusion, a classifier outputs a qualified or unqualified welding quality level. Training uses a cross-entropy loss function, with at least 500 iterations, until the detection model achieves a defect recognition accuracy of ≥98% and a temperature correlation judgment error of ≤3℃ on the test set before being put into practical use.

[0077] Example 2

[0078] Based on Example 1, such as Figure 3 As shown, the intelligent welding control method provided in this embodiment further includes step S21: sending a welding command to the welding controller; wherein the welding command is used to instruct the welding controller to drive the welding load based on target welding parameters corresponding to the second power supply. The target welding parameters need to be dynamically matched according to the electrical characteristics of the second power supply.

[0079] In specific implementations, the welding parameter can be a voltage command or a current command. In some examples, the correspondence between the power source and the welding parameter is obtained based on experimental data. For example, the welding controller can be powered by the same power source, i.e., the target power source, and different voltage commands or current commands can be issued to the welding controller to detect the welding quality of the joint formed by the welding load, respectively, to determine the voltage command or the current command corresponding to the optimal welding quality, and to record the correspondence between the voltage command or the current command and the target power source, thereby obtaining the correspondence between the target power source and the welding parameter. In some examples, the correspondence between the power source and the welding parameter is pre-stored in the power source-process mapping table, and the target welding parameter corresponding to the second power source can be obtained by looking up the power source-process mapping table. In one specific example, the second power source is a photovoltaic power source, and the corresponding arc welding current command is 200A±5A and the voltage command is 28V±0.5V. In another specific example, the second power source is a mains power supply, and the corresponding current command is 200A±1A and the voltage command is 28V±0.2V.

[0080] In specific implementations, the power source-process mapping table is stored in a non-volatile memory in an editable format, and users can supplement parameter entries according to newly added power source types (such as biomass power sources) or newly added welding processes (such as laser brazing), and each time after updating, at least 5 groups of tests are required to verify the effectiveness of the parameters, and after passing the verification, the parameters can take effect.

[0081] In this embodiment, when the second power source is used to power the welding controller, the target welding parameter corresponding to the current power source, i.e., the second power source, is adaptively selected, and a welding command is sent to the welding controller to instruct the welding controller to output welding energy to the welding load based on the target welding parameter, thereby improving the welding quality of the joint formed by the welding load under the current power supply environment, solving the welding quality control problem caused by the diversity of power supply sources, and achieving consistent, stable, and high-quality welding results under various power supply environments.

[0082] In an optional implementation, as shown in Figure 4 After step S21 of the above intelligent welding control method, the following steps S22-S24 are further included:

[0083] Step S22, acquiring voltage fluctuation data.

[0084] In some examples, the voltage fluctuation data includes voltage fluctuation data of the second power source, i.e., voltage fluctuation data from the second power source, corresponding to the voltage fluctuation data on the power source side. In other examples, the voltage fluctuation data includes voltage fluctuation data of the welding load, i.e., voltage fluctuation data caused by the welding load, corresponding to the voltage fluctuation data on the load side.

[0085] In some examples, the voltage fluctuation data comprises voltage fluctuation data of the second power supply and voltage fluctuation data of the welding load, i.e. voltage fluctuation data of the power supply side and the load side. In a specific example, if the deviation of the two-side data exceeds 1%, the data is collected for 3 times and averaged to avoid errors of the collection device leading to inaccurate adjustment.

[0086] In a specific example, the voltage fluctuation data is the difference between the square root of the maximum and minimum voltage values adjacent in time (i.e. the effective value) and the rated voltage, and the percentage of the difference.

[0087] Step S23, determining a welding parameter adjustment value corresponding to the voltage fluctuation data. The welding parameter adjustment value is the magnitude of adjusting the welding parameter, for example, the magnitude of increasing or decreasing the voltage, or the magnitude of increasing or decreasing the current.

[0088] It should be noted that the voltage fluctuation will affect the welding quality of the welding load, and the welding quality can be improved by adjusting the welding parameter. In some examples, the corresponding relationship between the voltage fluctuation data and the welding parameter adjustment value is obtained according to experimental data. For example, the welding parameters issued to the welding controller can be adjusted according to different welding parameter adjustment values for the same voltage fluctuation data, the welding quality of the connection part formed by the welding load is detected, the welding parameter adjustment value corresponding to the optimal welding quality is determined, and the corresponding relationship between the welding parameter adjustment value and the voltage fluctuation data is recorded, so as to obtain the corresponding relationship between the voltage fluctuation data and the welding parameter adjustment value.

[0089] In some examples, the corresponding relationship between the voltage fluctuation data and the welding parameter adjustment value can be pre-stored in a mapping table, and the welding parameter adjustment value corresponding to the voltage fluctuation data can be obtained by looking up the mapping table.

[0090] In a specific example, if the voltage fluctuation data is ΔU%, the corresponding current adjustment value is -ΔU%×K, wherein K is a compensation coefficient, K is 1.2 in the brazing mode, and K is 0.8 in the arc welding mode, so as to ensure that the welding energy fluctuation is within ±2% and the deviation of the penetration depth is less than 0.5 mm.

[0091] Step S24, sending a welding parameter adjustment instruction to the welding controller; wherein the welding parameter adjustment instruction is used to instruct the welding controller to adjust the target welding parameter according to the welding parameter adjustment value. In a specific implementation, the welding controller adjusts the target welding parameter according to the welding parameter adjustment value corresponding to the voltage fluctuation data, and outputs welding energy to the welding load based on the adjusted target welding parameter, so as to reduce the influence of the voltage fluctuation on the welding quality and improve the welding reliability.

[0092] In order to improve the accuracy of instruction transmission, in some examples, a check code is also included in the welding parameter adjustment instruction sent to the welding controller, the check code can be calculated by the CRC16 algorithm, and the welding controller needs to verify the consistency of the check code after receiving the welding parameter adjustment instruction. If it is inconsistent, it will request retransmission, ensuring that the instruction transmission error rate does not exceed 0.01%.

[0093] In an optional embodiment, after step S24 of the above-mentioned intelligent welding control method, the following step is further included: updating the correspondence between the second power supply and the target welding parameter according to the adjusted target welding parameter. In this embodiment, before updating the correspondence, the second power supply corresponds to the target welding parameter before adjustment, and after updating the correspondence, the second power supply corresponds to the adjusted target welding parameter. If the second power supply is used again to power the welding controller in the future, the welding controller outputs welding energy to the welding load based on the adjusted target welding parameter corresponding to the second power supply, which can further improve the welding quality of the connection formed by the welding load.

[0094] In some examples, the updated correspondence needs to be marked with the update time, the trigger reason, etc., such as "2024-10-13 16:20, triggered adjustment due to voltage fluctuation-4%", and the history of 5 adjustment records is retained, which facilitates subsequent tracing of parameter optimization effect. If there is still quality fluctuation after 3 consecutive adjustments of a power supply, the adaptability of the power supply needs to be re-evaluated.

[0095] Embodiment 3

[0096] This embodiment provides an intelligent welding control system in a multi-element electric hybrid power supply scenario, as shown in Figure 1 The intelligent welding control system includes a main controller 20, a switch unit 21, a welding controller 22, and a welding load 23. The welding controller 22 is electrically connected to at least two different types of power supplies through the switch unit 21.

[0097] The main controller 20 is configured to perform the intelligent welding control method provided in Embodiment 1 or 2. The welding controller 22 is configured to drive the welding load.

[0098] In an optional embodiment, as shown in Figure 1 The intelligent welding control system in this embodiment further includes a power supply processing module 24. The at least two different types of power supplies are electrically connected to the welding controller 22 through the switch unit 21 after passing through the power supply processing module 24. The power supply processing module 24 is used to optimize the quality of the input power supply, thereby outputting high-quality and stable power supply.

[0099] In a specific example, the power processing module 24 includes an active filter and a passive filter. The active filter is built-in with an IGBT power module, a DSP controller, and a Hall current sensor, supports real-time monitoring and compensation of 2-50 harmonics, has a 200A rated current processing capacity, is connected to the main circuit through a copper bar hard connection, and realizes the power quality management of "filtering first". In actual application, the switching frequency of the active filter can be 10 kHz, the high-frequency harmonics of 1-10 kHz can be managed, the suppression rate can be as high as 90% or more, and the active filter can be compatible with high-frequency interference generated by the access of new energy such as photovoltaic and wind power. The Hall current sensor collects the harmonic current of the power grid side in real time, and the DSP digital controller uses the instantaneous reactive power algorithm to quickly calculate the harmonic current value that needs to be compensated, drives the IGBT power module to output a current opposite to the harmonic current, and the two currents cancel each other out, thereby constructing a closed-loop management system for real-time monitoring and dynamic compensation, and optimizing the power quality. The passive filter includes a self-healing shunt capacitor and a dry-type air-core reactor. In actual application, the dry-type air-core reactor can adopt an epoxy resin vacuum casting process, and has an IP54 moisture-proof and dust-proof level, which is suitable for the multi-dust environment of a welding workshop and has a service life of more than 100,000 hours. The self-healing shunt capacitor and the dry-type air-core reactor form an LC series resonant circuit, which is connected to the main circuit through a copper bar hard connection, and realizes the resonant suppression logic of "compensation later". For inductive loads such as welding transformers, the system provides capacitive reactive power to the power grid, effectively offsets the reactive power consumption generated by the inductive load, increases the power factor of the system from 0.7 to more than 0.95, reduces the transmission of reactive current in the power grid, reduces line loss, and stabilizes voltage level. The rated voltage of the self-healing shunt capacitor is 400V, and the rated current of the dry-type air-core reactor is 315A. The two can form a 50Hz LC series resonant circuit, which can avoid the amplification of harmonics when the capacitor works alone, suppress the voltage flicker caused by harmonics on the power grid side, and limit the inrush current at the moment of circuit closing to not more than 2 times the rated current, thereby protecting system equipment.

[0100] In an optional embodiment, the intelligent welding control system further includes a plurality of reverse flow ammeters for collecting electric energy parameters of each power supply. In some examples, the reverse flow ammeter adopts a three-phase four-wire design, integrates a current or voltage transformer, a processor, and a display screen. Specifically, the transformer collects real-time voltage and current signals of each phase, the processor calculates active power direction, and when reverse power such as reverse current ≥ 5A and lasts for 200ms is detected, reverse flow alarm information is immediately sent, and then the fault circuit is cut off.

[0101] The anti-backflow ammeter has a current measurement accuracy of 0.5 S level, a voltage measurement accuracy of 0.2 level, a data uploading period of ≤10 s, and supports RS485 (Modbus-RTU protocol) communication with the main controller, and the uploaded data includes real-time power, current direction, cumulative electric energy and the like, so as to facilitate the main controller to comprehensively evaluate the power supply state.

[0102] In an optional embodiment, the intelligent welding control system further includes a plurality of electric quantity measurement and control instruments for collecting electric energy parameters of each power supply and electric energy parameters of the welding load. The voltage fluctuation data caused by the welding load can be obtained according to the collected electric energy parameters of the welding load.

[0103] The electric quantity measurement and control instrument needs to collect 12 electric energy parameters including voltage, current, power, THDi and the like, has a sampling rate of ≥2 kHz, and has a harmonic analysis function (2-50 harmonics can be analyzed), the collected data is uploaded to the main controller through Ethernet (TCP / IP protocol), and the transmission delay is ≤50 ms, which provides high-precision data support for power evaluation index calculation and voltage fluctuation compensation.

[0104] In an optional embodiment, the main controller includes a local processor, a cloud service platform and a local control unit. The local processor is configured to obtain information of a connection part formed by the welding load, and detect welding quality of the connection part based on the information of the connection part. The cloud service platform is configured to issue a policy instruction of switching to the second power supply to the local control unit in response to the welding quality being substandard. The local control unit is configured to control the switching unit to act in response to the policy instruction, so that the welding controller is switched from electrical connection with the first power supply to electrical connection with the second power supply. In some examples, the local control unit is a PLC (Programmable Logic Controller).

[0105] The local processor can adopt an industrial-grade CPU (such as Intel i5-10500E) and has an image processing acceleration module, and can realize real-time analysis of 30fps welding spot images; the cloud service platform is deployed based on Ali Cloud ECS, supports access of millions of devices, has a policy instruction issuing delay of ≤1 s, and has a historical data storage function (storage period ≥3 years), and can generate daily and monthly power switching and welding quality statistical reports.

[0106] In some examples, the cloud service platform is further configured to send a welding instruction to the welding controller through the local control unit. The welding controller is configured to drive the welding load based on target welding parameters corresponding to the first power supply in response to the welding instruction.

[0107] In some examples, the local processor is configured to perform steps S22-S24 in Embodiment 2. Wherein, in performing step S24, the local processor sends welding parameter adjustment instructions to the welding controller through the local control unit, finally achieving dynamic adaptation of power quality and welding process.

[0108] In some examples, the intelligent welding control system further comprises a gateway, which serves as a data relay station, responsible for uploading device data such as anti-backflow ammeter, power parameter collected by power measurement and control instrument to the cloud service platform, and forwarding policy instructions issued by the cloud service platform to the local control unit. It should be noted that the gateway needs to convert the format of these data during data relay, for example, converting device data on RS485 bus into MQTT (Message Queuing Telemetry Transport) protocol and uploading to the cloud service platform, and for example, parsing policy instructions issued by the cloud service platform into Modbus-RTU protocol and forwarding to PLC.

[0109] Wherein, the gateway supports 2-way Ethernet, 4-way RS485 and 4G communication, has edge computing function, can filter out invalid data (such as not uploading when voltage fluctuation is ≤±1%) locally, reduce cloud bandwidth occupation by 30%; at the same time, the dual-link redundancy design of Ethernet and 4G is adopted, when wired network is interrupted, it automatically switches to 4G communication, ensures uninterrupted data transmission, and the communication reliability is as high as 99.9% or more.

[0110] In an optional implementation, the switch unit comprises an automatic transfer switch (ATS) and a circuit breaker connected in sequence corresponding to each power supply. The local control unit is further configured to control the automatic transfer switch corresponding to the first power supply to be turned on and control the circuit breaker corresponding to the first power supply to be closed. In this embodiment, one end of the automatic transfer switch is connected with the power supply, and the other end is connected with the circuit breaker, and the power supply switching is realized by cooperative control of the ATS and the circuit breaker.

[0111] In some examples, the automatic transfer switch adopts a double-throw mechanical structure, and is internally provided with 2 groups of vacuum interrupters, a permanent magnet operating mechanism and a Hall position sensor. The rated voltage of the vacuum interrupter is 1000V, which is used to enhance the arc extinguishing capability, and the Hall position sensor is used to feedback the contact state in real time. The automatic transfer switch receives the on-off switching quantity instruction issued by the local control unit through the control circuit, the permanent magnet operating mechanism drives the moving contact to switch to the first power supply, and the Hall position sensor feedbacks the contact state in real time, strictly follows the logic of first on and then off, and ensures continuous power supply of the welding controller.

[0112] In some examples, the ATS has a switching time of ≤ 50 ms, a mechanical life of ≥ 100,000 times, and a voltage synchronization detection function. Before switching, the phase difference between the standby power supply and the main power supply needs to be detected to be ≤ 5° to avoid current impact caused by a large phase difference and protect the internal power devices of the welding controller.

[0113] In some examples, the circuit breaker uses a thermal magnetic tripping device with a built-in bimetallic strip and an electromagnetic coil. When the circuit breaker is working normally, the main contact remains closed to supply power to the downstream welding controller. When an overload occurs, the bimetallic strip will bend due to the heat generated by the large current. When a short circuit occurs, the electromagnetic coil will be attracted due to the large current. When an overload or short circuit is detected, the tripping mechanism triggers the main contact to break the circuit and cut off the faulty power supply, protecting the downstream modules such as the welding controller from damage. In actual use, the tripping threshold can be remotely set by the local control unit, for example, when the welding load suddenly changes, the short circuit tripping threshold can be temporarily widened to 6 In, thereby avoiding false tripping caused by instantaneous impact current.

[0114] In some examples, the rated current of the circuit breaker is 315 A, the breaking capacity is up to 50 kA (effective value), and the Modbus-RTU protocol is supported for communication with the local control unit. The tripping state, current value, and other information can be remotely read for fault diagnosis and remote maintenance.

[0115] In some examples, the above-mentioned switching unit further includes a power switching module corresponding to each power supply. The automatic transfer switch, the circuit breaker, and the power switching module are connected in sequence. The power switching module integrates a contactor and a solid-state relay, which are connected to the local control unit through auxiliary contacts to real-time feedback the switching state of the contactor being attracted or being disconnected, ensuring the reliable execution of the charging and discharging logic. The power switching module receives the switching instructions issued by the local control unit. The contactor is responsible for the long-term on-off control of the main circuit, and the solid-state relay is turned on for a short time during switching to assist in suppressing arc generation and avoid current impact damage to the welding controller during the switching process. At the same time, the auxiliary contacts feed back the real-time state of being attracted or being disconnected to the local control unit, forming a closed-loop control to ensure the accurate execution of the charging and discharging logic.

[0116] In some examples, the contactor has an attraction time of ≤ 50 ms, and the solid-state relay has a response time of ≤ 1 ms. The combination of the two can reduce the arc energy during switching by 90%. The contactor has a conduction loss of ≤ 5 W, which is suitable for long-term work. The auxiliary contact supports a broken line detection function, which immediately reports a fault when the contact is stuck to avoid the risk of power supply short circuit.

[0117] In some examples, the intelligent welding control system described above further comprises a distributed power access unit, which adopts a modular design, integrates a photovoltaic inverter interface, an anti-backflow control board and a current transformer, is connected to the power processing module through a copper hard connection, and is connected with an anti-backflow ammeter for collecting photovoltaic power parameters to form a double anti-backflow mechanism. The distributed power access unit monitors the output current direction of the photovoltaic in real time through the current transformer, and when detecting reverse current, i.e., when the current is reversed, immediately cuts off the photovoltaic loop through a hard-wire signal and reports to the local control unit.

[0118] In some examples, the anti-backflow response time of the distributed power access unit is ≤50 ms, the maximum supported photovoltaic input power is 50 kW, the working temperature range is -40°C to 70°C, and it can adapt to extreme weather conditions; at the same time, it is linked with the ATS, and when the photovoltaic loop is cut off, the power supply interruption is avoided by preferentially triggering the mains access.

[0119] In an optional implementation, the local control unit is further configured to send a welding mode switching instruction to the welding controller. The welding controller is further configured to switch from the parameter configuration of the first welding mode to the parameter configuration of the second welding mode in response to the switching instruction, and drive the welding load according to the parameter configuration of the second welding mode and the target welding parameters corresponding to the first power supply.

[0120] In some examples, the local control unit comprises a human-computer interaction device, and a user can select different welding modes or switch welding modes through the human-computer interaction device. In a specific example, the human-computer interaction device is a touch screen.

[0121] In some examples, the touch screen adopts a 10.1-inch industrial-grade capacitive screen with an IP65 protection level, supports Chinese, English and Spanish language switching, can display real-time power supply status, welding parameters, welding quality pass rate and other information, and supports manual intervention (such as emergency switching of power supply and modification of welding parameters). The operation authority is divided into three levels of operator, engineer and administrator to prevent misoperation.

[0122] In some examples, the first welding mode is brazing, and the parameter configuration of brazing includes an output voltage range of 10V-20V, an output current range of 50A-100A, and a temperature range of 200°C-300°C. The second welding mode is arc welding, and the parameter configuration of arc welding includes an output voltage range of 20V-40V, an output current range of 200A-500A, and a temperature range of 800°C-1200°C.

[0123] In some examples, 100 sets of process parameters corresponding to different materials and thicknesses can be stored in each welding mode, such as current-time curves. The switching time is less than or equal to 10 ms, and the output parameter deviation is less than or equal to ± 2% after switching, which ensures the reliability of process switching.

[0124] In the embodiment, the welding controller dynamically adjusts the output welding energy according to the second welding mode after switching and the target welding parameter, so as to realize accurate switching from the first welding mode to the second welding mode.

[0125] In an optional embodiment, the at least two different types of power sources include a bidirectional energy storage all-in-one machine for realizing rapid energy compensation when the power source fluctuates or power is insufficient. The bidirectional energy storage all-in-one machine includes a battery management system, an energy storage element, and an energy storage converter. The local control unit is further configured to send a charging and discharging instruction to the battery management system. The battery management system is configured to control the energy storage converter to perform voltage conversion processing according to the charging and discharging instruction, so as to charge and discharge the energy storage element. In a specific example, the energy storage element includes a lithium iron phosphate battery pack.

[0126] In some examples, the rated power of the bidirectional energy storage all-in-one machine is 30 kW, the energy storage capacity is 50 kWh, the charging and discharging efficiency is greater than or equal to 90% (10%-100% SOC interval), and the cycle life is greater than or equal to 3000 times (80% DOD). The energy storage converter adopts an IGBT full-bridge topology and supports four-quadrant operation, can realize seamless switching of charging and discharging, and the response time is less than or equal to 10 ms.

[0127] In some examples, the battery management system is used to monitor the voltage, temperature, SOC (State of Charge), and other information of the energy storage element in real time, and feeds back the monitored information to the local control unit. The local control unit can send a charging instruction to the battery management system when the SOC is lower than a first threshold or the power of other power sources is excessive, and the battery management system controls the energy storage converter to switch to a boost mode to charge the energy storage element using other power sources. The local control unit can also send a discharging instruction to the battery management system when the SOC is higher than a second threshold or the power of other power sources is insufficient, and the battery management system controls the energy storage converter to switch to a buck mode to compensate for the power of other power sources using the energy storage element.

[0128] In some examples, the SOC measurement accuracy and the charge-discharge instruction power control accuracy of the battery management system are within ±2%, and the battery management system has overvoltage, overcurrent, and overtemperature protection functions. When the battery cell voltage is detected to be greater than 3.65V or the temperature is detected to be greater than 60°C, the charge-discharge circuit is immediately cut off. Meanwhile, the battery management system supports RS485 communication with the local control unit, the feedback period is less than or equal to 1s, and the local control unit can ensure real-time monitoring of the energy storage state and dynamic adjustment of the charge-discharge strategy.

[0129] In this embodiment, the power flexibility adjustment of the energy storage all-in-one machine participating in the welding control system can maintain system power balance and voltage stability, so that the system power reaches dynamic balance.

[0130] The following will take a specific example to explain this embodiment in detail:

[0131] First, the noon high-efficiency operation stage (12:00-14:00)

[0132] Data monitoring: The power of photovoltaic is 58kW, and its evaluation index is 92 points; the power of wind power is 30kW, and its score is 88 points, the voltage is 381V±0.5%, and the total harmonic distortion rate THDi of the current is 2.5%.

[0133] Strategy execution: the cloud service platform issues a strategy instruction to switch to photovoltaic and wind power to the PLC, the PLC controls the ATS corresponding to the photovoltaic to be turned on, the circuit breaker corresponding to the photovoltaic to be closed, and controls the ATS corresponding to the wind power to be turned on, and the circuit breaker corresponding to the wind power to be closed; at this time, the bidirectional energy storage all-in-one machine is in standby state, and the SOC of the energy storage element is 60%. The PLC sends a welding instruction to the welding controller to instruct the welding controller to drive the welding load based on the current instruction corresponding to the parallel power supply of photovoltaic and wind power.

[0134] When parallel power supply, the PLC distributes the welding load of 50kW to photovoltaic and wind power in the proportion of 70% and 30% respectively through a power distribution algorithm, and instructs the power supply processing module to control the THDi within 3% to ensure the stability of the welding arc, for example, the arc voltage fluctuation is less than or equal to ±1V.

[0135] Welding effect: the brazing rate is 98%, the packaging temperature of the chip is 950℃±20℃, and there is no crack.

[0136] Second, the power fluctuation response stage (16:00-16:30)

[0137] Sudden situation: the power of photovoltaic is suddenly reduced from 58kW to 30kW due to cloud cover, and the voltage drops to 365V.

[0138] Closed-loop response: the power meter reports voltage fluctuation data to the local processor within 10ms;

[0139] The PLC sends a discharging instruction to the bidirectional energy storage all-in-one machine, instructing it to discharge at a power of 25 kW;

[0140] The local processor determines a welding parameter adjustment value corresponding to the voltage fluctuation data, and sends a welding parameter adjustment instruction to the welding controller through the PLC. The welding controller adjusts the current instruction based on the welding parameter adjustment value to increase the output current to 260 A to compensate for the voltage fluctuation. At the same time, the mapping table storing the corresponding relationship between the voltage fluctuation data and the welding parameters is updated, for example, the current corresponding to a 4% voltage drop is increased by 8% compared to before;

[0141] During discharging, the battery management system feeds back energy storage current and voltage data to the PLC in real time, and the PLC dynamically adjusts the discharging power (from 25 kW to 20 kW gradually to avoid energy storage overload; after parameter adjustment, the local processor continuously monitors 10 welding points to confirm that the brazing rate is all ≥85% and there are no false welding defects.

[0142] The industrial camera collects image data of the brazing seam every 30 ms, and the local processor does not find any cracks based on the collected image data.

[0143] Third, process switching stage (18:00 from brazing to arc welding)

[0144] The user switches the welding mode from brazing to arc welding through the touch screen, and the PLC sends a corresponding switching instruction to the welding controller;

[0145] The welding controller outputs welding energy to the welding load according to the parameter configuration of arc welding, specifically, the output current is increased from 60 A to 250 A, and the output voltage is increased from 18 V to 32 V;

[0146] Before switching, the PLC first instructs the bidirectional energy storage all-in-one machine to increase the SOC to 65% for standby, and during the switching process, the power switching module suppresses the arc to ensure smooth transition of the welding current (no impact current > 300 A); After switching, the power meter verifies that the output voltage fluctuation is ≤±2%, meeting the requirements of the arc welding process.

[0147] The PLC stops sending discharging instructions to the bidirectional energy storage all-in-one machine, and the bidirectional energy storage all-in-one machine switches to standby mode to ensure stable power.

[0148] In actual application, the intelligent welding control system provided by the present disclosure has improved in multiple index categories compared to the prior art solution, as shown in Table 1:

[0149] Table 1

[0150]

[0151] Example 3

[0152] Figure 5 A structural schematic diagram of an electronic device is provided for an exemplary embodiment of the present disclosure. The electronic device includes at least one processor and a memory communicatively connected to the at least one processor. The memory stores a computer program executable by the at least one processor, and the computer program is executed by the at least one processor to enable the at least one processor to perform the steps of the intelligent welding control method provided in Embodiment 1 or 2. Figure 5 The electronic device 3 shown is merely an example and should not impose any limitation on the functions and use range of the embodiments of the present disclosure.

[0153] The components of the electronic device 3 can include, but are not limited to, the at least one processor 4, the at least one memory 5, and a bus 6 connecting different system components, including the memory 5 and the processor 4.

[0154] The bus 6 includes a data bus, an address bus, and a control bus.

[0155] The memory 5 can include volatile memory, such as random access memory (RAM) 51 and / or cache memory 52, and can further include read-only memory (ROM) 53.

[0156] The memory 5 can further include a program tool 55 having a set of (at least one) program modules 54, and such program modules 54 can include, but are not limited to, an operating system, one or more application programs, other program modules, and program data, each of which or a combination of which can include implementation of a network environment.

[0157] The program modules 54 further integrate a welding control algorithm module, which integrates core algorithms such as power supply evaluation, parameter adjustment, and quality detection, supports modular calling, and can load corresponding algorithm submodules according to different welding scenarios (such as power batteries and smart meters) to improve the versatility of the device.

[0158] The processor 4 performs various functional applications and data processing by running the computer program stored in the memory 5, such as the intelligent welding control method provided in Embodiment 1 or 2.

[0159] In some examples, the processor 4 is an industrial-grade quad-core processor, such as an ARM Cortex-A53, with a main frequency ≥ 1.5 GHz and supporting AES-256 hardware encryption to ensure the storage security of sensitive data such as welding process parameters and power supply strategies. At the same time, the processor has a temperature self-adaptive adjustment function and can stably operate in an environment of -20℃ to 60℃, meeting the requirements of harsh working conditions in industrial workshops.

[0160] Electronic device 3 can also communicate with one or more external devices 7 (e.g., keyboard, pointing device, etc.). This communication can be performed through input / output (I / O) interface 8. Furthermore, electronic device 3 can also communicate with one or more networks (e.g., local area network (LAN), wide area network (WAN), and / or public networks, such as the Internet) via network adapter 9. Figure 5 As shown, network adapter 9 communicates with other modules of electronic device 3 via bus 6. It should be understood that, although... Figure 5 Not shown, it can be combined with electronic device 3 to use other hardware and / or software modules, including but not limited to: microcode, device drivers, redundant processors, external disk drive arrays, RAID (disk array) systems, tape drives, and data backup storage systems.

[0161] Network adapter 9 supports Gigabit Ethernet and integrates a 4G full network module, enabling dual-link redundant communication; I / O interface 8 includes 4 USB 3.0 ports and 2 RS232 ports, which can connect to peripherals such as industrial cameras and infrared thermometers, with a data transmission rate of ≥500Mbps, meeting the needs of real-time acquisition of multimodal data.

[0162] It should be noted that although several units / modules or sub-units / modules of the electronic device have been mentioned in the detailed description above, this division is merely exemplary and not mandatory. In fact, according to embodiments of this disclosure, the features and functions of two or more units / modules described above can be embodied in one unit / module. Conversely, the features and functions of one unit / module described above can be further divided and embodied by multiple units / modules.

[0163] An exemplary embodiment of this disclosure provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the intelligent welding control method provided in embodiment 1 or 2.

[0164] In some examples, the computer program is stored using AES-256 encryption to prevent unauthorized access or tampering, ensuring the security of the intelligent welding control method.

[0165] The readable storage medium is a non-volatile storage medium, which may include, but is not limited to: portable disks, hard disks, random access memory, read-only memory, erasable programmable read-only memory, optical storage devices, magnetic storage devices, solid-state drives, USB flash drives, or any suitable combination thereof.

[0166] In possible implementations, this disclosure can also be implemented as a computer program product comprising a computer program that, when executed by a processor, implements the steps of the intelligent welding control method provided in Embodiment 1 or 2.

[0167] The computer program product further comprises a configuration file storing weight parameters of the power supply evaluation indexes, threshold parameters (such as welding quality qualification threshold) of the detection model, and mapping relationship data of the voltage fluctuation and the welding parameter adjustment value. A user can modify the configuration file to adapt to the requirements of different welding scenes (such as power battery tab welding and smart meter terminal post brazing), thereby improving the generality of the method.

[0168] Wherein, the computer program for executing the present disclosure can be written in any combination of one or more programming languages, and can be executed entirely on an electronic device, partially on an electronic device, as an independent software package, partially on an electronic device and partially on a remote device, or entirely on a remote device.

[0169] Although the specific embodiments of the present disclosure are described above, those skilled in the art should understand that this is only an example, and the protection scope of the present disclosure is defined by the appended claims. Those skilled in the art can make various changes or modifications to these embodiments without departing from the principles and essence of the present disclosure, and these changes and modifications all fall within the protection scope of the present disclosure.

Claims

1. A smart welding control method in a multi-element electric hybrid power supply scene, characterized in that, A welding controller is electrically connected with at least two different types of power sources through a switching unit, and the welding controller is configured to drive a welding load; The intelligent welding control method comprises the following steps: In response to the welding controller being electrically connected with a first power source, information of a connection part formed by the welding load is acquired; Based on the information of the connection part, the welding quality of the connection part is detected; In response to the welding quality being substandard, the switching unit is controlled to act so as to switch the welding controller from being electrically connected with the first power source to being electrically connected with a second power source.

2. The intelligent welding control method of claim 1, wherein, The intelligent welding control method further comprises: For each power source, based on the electrical energy parameter of the power source, a voltage stability index and a current stability index are determined, and based on the voltage stability index and the current stability index, an evaluation index of the power source is determined; The second power source is determined according to the evaluation index.

3. The intelligent welding control method of claim 1, wherein, The information of the connection part comprises image data and temperature data of the connection part; The welding quality of the connection part is detected based on the information of the connection part, specifically comprising: The image data and the temperature data of the connection part are input into a detection model for welding quality detection, so as to obtain the welding quality of the connection part; wherein the detection model is trained based on image data, temperature data and actual welding quality of a sample connection part.

4. The intelligent welding control method of claim 1, wherein, The intelligent welding control method further comprises: A welding instruction is sent to the welding controller; wherein the welding instruction is used to instruct the welding controller to drive the welding load based on a target welding parameter corresponding to the second power source.

5. The intelligent welding control method of claim 4, wherein, The intelligent welding control method further comprises: Voltage fluctuation data is acquired; A welding parameter adjustment value corresponding to the voltage fluctuation data is determined; A welding parameter adjustment instruction is sent to the welding controller; wherein the welding parameter adjustment instruction is used to instruct the welding controller to adjust the target welding parameter according to the welding parameter adjustment value.

6. The intelligent welding control method of claim 5, wherein, The intelligent welding control method further comprises: updating the correspondence between the second power source and the target welding parameter according to the adjusted target welding parameter.

7. The intelligent welding control method of claim 5, wherein, The voltage fluctuation data comprises voltage fluctuation data of the second power source and / or voltage fluctuation data of the welding load.

8. An intelligent welding control system in a multi-element electric hybrid power supply scenario, characterized in that, A welding controller, a welding load, a switching unit and a main controller are comprised, and the welding controller is electrically connected with at least two different types of power sources through the switching unit; The main controller is configured to perform the intelligent welding control method of any one of claims 1-7; The welding controller is configured to drive the welding load.

9. The intelligent welding control system of claim 8, wherein, The main controller comprises a local processor, a cloud service platform and a local control unit; The local processor is configured to acquire information of a connection part formed by the welding load, and detect the welding quality of the connection part based on the information of the connection part; The cloud service platform is configured to, in response to the welding quality being substandard, issue a policy instruction of switching to the second power source to the local control unit; The local control unit is configured to, in response to the policy instruction, control the switching unit to act so as to switch the welding controller from being electrically connected with the first power source to being electrically connected with the second power source.

10. The intelligent welding control system of claim 9, wherein, The switch unit comprises an automatic transfer switch and a circuit breaker connected in sequence corresponding to each power supply; The local control unit is further configured to control the automatic transfer switch corresponding to the second power supply to be turned on and control the circuit breaker corresponding to the second power supply to be closed.

11. The intelligent welding control system of claim 9 or 10, wherein, The at least two different types of power supplies comprise a bidirectional energy storage all-in-one machine, and the bidirectional energy storage all-in-one machine comprises a battery management system, an energy storage element and an energy storage converter; The local control unit is further configured to send a charge-discharge instruction to the battery management system; The battery management system is configured to control the energy storage converter to perform voltage conversion processing according to the charge-discharge instruction, so as to charge and discharge the energy storage element.

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