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

Abstract

The invention provides a welding control method and system under a multi-element electricity hybrid power supply scene. The welding controller is electrically connected with at least two different types of power sources through a switch unit. The welding control method comprises the following steps that a first power source is determined from the power sources; the control unit is used for controlling the switch unit to act, so that the welding controller is electrically connected with the first power supply; a welding instruction is sent to the welding controller; wherein the welding instruction is used for indicating the welding controller to drive a welding load based on target welding parameters corresponding to the first power source. When different power supplies are used for supplying power to the welding controller, the welding parameters corresponding to the current power supply are adaptively selected, and the welding instruction is sent to the welding controller, so that the welding controller is indicated to output the welding energy to the welding load based on the welding parameters corresponding to the current power supply; and the welding quality control problem caused by diversity of power supplies is solved.

Description

Technical Field

[0001] This disclosure relates to the field of welding technology, and in particular to a welding control method and system in a multi-electrode hybrid power supply scenario. Background Technology

[0002] In complex application scenarios such as industrial sites, field construction, and distributed manufacturing, the power sources for welding equipment are becoming increasingly diversified. Besides the traditional stable industrial power grid, i.e., mains power, welding equipment often needs to be powered by renewable energy sources such as photovoltaics and wind power. These different types of power systems have significantly different inherent electrical characteristics due to their vastly different power generation principles and internal structures. For example, stable mains power exhibits ideal voltage source characteristics such as low output impedance, high load capacity, and millisecond-level dynamic response; while the output of renewable energy sources such as photovoltaics and wind power is affected by the natural environment, and their output impedance, load capacity, and dynamic response speed differ significantly from mains power, exhibiting intermittency and fluctuation.

[0003] Welding is an electrothermal conversion process that demands extremely high precision in energy input and rapid dynamic response. Weld quality directly depends on the stability of the welding power supply output. However, current mainstream welding control strategies are typically designed and optimized based on a stable industrial power grid, with relatively fixed control command generation mechanisms. This fixed-mode welding control strategy exposes inherent flaws when facing power supplies with varying characteristics. For example, when switching to a power supply with a slower dynamic response, the system adjusts lags, and the arc becomes unstable; when connected to a power supply with weak load capacity, sudden load changes may trigger power output collapse or protective shutdown. Summary of the Invention

[0004] The technical problem to be solved by this disclosure is to overcome the above-mentioned defects in the prior art and provide a welding control method and system that can intelligently adapt to the multi-electrode hybrid power supply scenario under different power supply environments.

[0005] This disclosure solves the above-mentioned technical problems through the following technical solution:

[0006] The first aspect of this disclosure provides a welding control method for a hybrid power supply scenario, wherein the welding controller is electrically connected to at least two different types of power sources via a switching unit; the welding control method includes the following steps:

[0007] Determine the first power source from the power sources;

[0008] The switching unit is controlled to operate so that the welding controller is electrically connected to the first power supply.

[0009] A welding command is sent 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 first power supply.

[0010] Optionally, the welding control method further includes:

[0011] Acquire voltage fluctuation data;

[0012] Determine the welding parameter adjustment values ​​corresponding to the voltage fluctuation data;

[0013] A welding parameter adjustment command is sent to the welding controller; wherein the welding parameter adjustment command is used to instruct the welding controller to adjust the target welding parameters according to the welding parameter adjustment value.

[0014] Optionally, the welding control method further includes updating the correspondence between the first power supply and the target welding parameters according to the adjusted target welding parameters.

[0015] Optionally, the voltage fluctuation data includes the voltage fluctuation data of the first power supply or the voltage fluctuation data of the welding load.

[0016] Optionally, determining the first power source from the power sources specifically includes:

[0017] For each power source, voltage stability index and current stability index are determined based on the power source's power parameters, and evaluation index of the power source is determined based on the voltage stability index and the current stability index.

[0018] The primary power source was determined based on all evaluation metrics.

[0019] Optionally, the welding control method further includes:

[0020] Obtain information about the joint formed by the welding load;

[0021] The welding quality of the connection part is detected based on the information of the connection part;

[0022] In response to the welding quality not meeting the standard, the switching unit is controlled to switch the welding controller from being electrically connected to the first power supply to being electrically connected to the second power supply.

[0023] A second aspect of this disclosure provides a welding control system for a multi-electric hybrid power supply scenario, including a welding controller, a welding load, a switching unit, and a main controller, wherein the welding controller is electrically connected to at least two different types of power sources through the switching unit;

[0024] The main controller is configured to execute the welding control method described in the first aspect;

[0025] The welding controller is configured to drive the welding load based on target welding parameters corresponding to the first power supply in response to welding commands sent by the main controller.

[0026] Optionally, the main controller includes a cloud service platform and a local control unit;

[0027] The cloud service platform is configured to determine the first power source from all power sources based on the power parameters of each power source, and to issue a strategy instruction to the local control unit to switch to the first power source.

[0028] The local control unit is configured to control the switching unit to operate in response to the policy instruction, so as to electrically connect the welding controller to the first power supply.

[0029] Optionally, the switching unit includes an automatic transfer switch and a circuit breaker that correspond one-to-one with each power source and are connected in sequence.

[0030] The local control unit is further configured to control the automatic transfer switch corresponding to the first power supply to turn on and to control the circuit breaker corresponding to the first power supply to close.

[0031] Optionally, the local control unit is further configured to send a welding mode switching command to the welding controller;

[0032] The welding controller is also 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 command, 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.

[0033] Optionally, the at least two different types of power sources include a bidirectional energy storage unit, which includes a battery management system, energy storage elements, and an energy storage converter.

[0034] The local control unit is also configured to send charge and discharge commands to the battery management system;

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

[0036] A third aspect of this disclosure provides an electronic device including a memory, a processor, and a computer program stored in the memory and for running on the processor, wherein the processor executes the computer program to implement the welding control method of the first aspect.

[0037] A fourth aspect of this disclosure provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the welding control method described in the first aspect.

[0038] The fifth aspect of this disclosure provides a computer program product, including a computer program that, when executed by a processor, implements the welding control method described in the first aspect.

[0039] Based on common knowledge in the field, the above-mentioned preferred conditions can be combined arbitrarily to obtain various preferred embodiments of this disclosure.

[0040] The positive and progressive effects of this disclosure are as follows: when the welding controller is powered by different power supplies, the welding parameters corresponding to the current power supply are adaptively selected, and welding instructions are sent to the welding controller to instruct the welding controller to output welding energy to the welding load based on the welding parameters corresponding to the current power supply. This can improve the welding quality of the joint formed by the welding load under the current power supply environment, solve the welding quality control problem caused by the diversity of power supplies, and achieve consistent, stable and high-quality welding results under various power supply environments.

[0041] In addition, by accurately selecting power sources through power evaluation indicators, dynamically compensating for voltage fluctuations, verifying welding quality through closed-loop verification, and coordinating energy storage for replenishment, the system's anti-interference capability and production reliability have been further improved. The weld yield rate has increased from 85% in the traditional solution to over 98%, and the power switching interruption time has been shortened from 500ms to less than 50ms. Attached Figure Description

[0042] Figure 1 A schematic diagram of the structure of a welding control system provided in an exemplary embodiment of this disclosure;

[0043] Figure 2 This is a schematic flowchart of a welding control method provided in Embodiment 1 of this disclosure;

[0044] Figure 3 A schematic flowchart of another welding control method provided in Embodiment 1 of this disclosure;

[0045] Figure 4 This is a schematic flowchart of a welding control method provided in Embodiment 2 of this disclosure;

[0046] Figure 5 This is a schematic diagram of the structure of an electronic device provided in Embodiment 4 of this disclosure. Detailed Implementation

[0047] The present disclosure is further illustrated below by way of embodiments, but the present disclosure is not limited to the scope of the embodiments described herein.

[0048] The prefixes such as "first" and "second" used in this disclosure are merely for distinguishing different descriptive objects and do not limit the position, order, priority, quantity, or content of the described objects. The use of ordinal numbers and other prefixes used to distinguish descriptive objects in this disclosure does not constitute a limitation on the described objects. The description of the described objects is given in the claims or the context of the embodiments, and should not be construed as an unnecessary limitation. Furthermore, in the description of this embodiment, unless otherwise stated, "multiple" means two or more.

[0049] The inventors discovered that existing technologies lack a mechanism for automatically matching welding parameters based on the characteristics of different power supply types. This makes it impossible to achieve precise adaptation between power supply type and welding process parameters, and the welding parameters cannot be adjusted in a timely manner to maintain welding quality when the power supply voltage fluctuates. Furthermore, there is a lack of effective means for power switching based on welding quality feedback, leading to difficulties in guaranteeing welding quality in multi-power supply scenarios. Therefore, this disclosure provides a welding control method and system for multi-power supply scenarios, particularly relating to a technology for achieving high-quality welding through intelligent matching, dynamic adjustment, and power switching mechanisms between power supply types and welding parameters in multi-power supply scenarios.

[0050] Example 1

[0051] Figure 1 This is a schematic diagram of the structure of a welding control system in a multi-electrode hybrid power supply scenario provided in this embodiment. Figure 1 In the welding control system shown, the welding controller 22 is electrically connected to at least two different types of power sources via a switching unit 21, i.e., it is powered by a hybrid power supply. The main controller 20 controls the on / off state 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 drives the welding load 23 to complete the welding task. The different types of power sources can include new energy sources such as photovoltaic, wind power, and hydropower, as well as traditional energy sources such as nuclear power and mains power.

[0052] In some examples, at least two different types of power supplies are electrically connected to the welding controller 22 via the switching unit 21 after passing through the power processing module 24. The power processing module 24 is used to optimize the quality of the input power supply, thereby outputting a high-quality, stable power supply.

[0053] Figure 2 This is a flowchart illustrating a welding control method in a hybrid power supply scenario provided in this embodiment. The welding control method provided in this embodiment can be executed by the aforementioned main controller, such as... Figure 2As shown, the welding control method provided in this embodiment includes the following steps S11~S13:

[0054] Step S11: Determine the first power source from the power sources. Specifically, determine the first power source from the at least two different types of power sources mentioned above. It should be noted that the first power source can be one of the at least two different types of power sources, or it can be two or more power sources.

[0055] Step S12: Control the switching unit to operate, so that the welding controller is electrically connected to the first power supply. The electrical connection between the welding controller and the first power supply means that the welding controller is powered by the first power supply.

[0056] The switching unit in this embodiment strictly follows the timing logic of turning on first and then turning off. It also detects the phase difference of the power supply to avoid the current surge caused by a large phase difference damaging the IGBT module in the welding controller, thereby increasing the equipment maintenance cost.

[0057] In some examples, the switching unit includes an Automatic Transfer Switch (ATS) and a circuit breaker, each corresponding to a power source and connected sequentially. First, the ATS corresponding to the first power source is turned on, and the circuit breaker is closed. Once the first power source is detected to be stable (e.g., the voltage fluctuation of the first power source is ≤±1% within 200ms, and the phase difference between it and the original power source is ≤5°), the original power source is disconnected. This ensures uninterrupted power supply to the connection point throughout the process, preventing abnormalities such as arc extinction caused by power outages in sensitive loads like welding. Step S13: Send a welding command to the welding controller; wherein the welding command instructs the welding controller to drive the welding load based on target welding parameters corresponding to the first power source. The target welding parameters need to be dynamically matched according to the electrical characteristics of the first power source.

[0058] Understandably, the welding controller is used to rectify the input power supply to obtain direct current, and according to the selected welding mode and the received voltage or current command, it uses a control algorithm such as PID algorithm to adjust the duty cycle of the internal power switch such as IGBT to convert the direct current into a higher frequency alternating current, and then the alternating current is stepped down by a transformer and rectified again to be used as direct current for the welding load, thereby realizing the output of welding energy to the welding load so that the welding load can complete the welding task.

[0059] In practical implementation, the aforementioned welding parameters can be voltage commands, current commands, or duty cycles. In some examples, the correspondence between the power supply and welding parameters is obtained based on experimental data. For instance, the same power supply, i.e., the target power supply, can be used to power the welding controller. By issuing different voltage or current commands to the welding controller, the welding quality of the connection formed by the welding load is detected, the voltage or current command corresponding to the optimal welding quality is determined, and the correspondence between this voltage or current command and the target power supply is recorded, thus obtaining the correspondence between the target power supply and welding parameters. In some examples, the correspondence between the power supply and welding parameters is pre-stored in a power supply-process mapping table. The target welding parameters corresponding to the first power supply can be obtained by looking up the power supply-process mapping table. In one specific example, the first power supply is a photovoltaic power supply, with a corresponding arc welding current command of 200A±5A and a voltage command of 28V±0.5V. In another specific example, the first power supply is mains power, with a corresponding current command of 200A±1A and a voltage command of 28V±0.2V.

[0060] In practice, the power supply-process mapping table supports editing and updating. Users can add power supply types, such as biomass power, or process parameters, such as laser brazing. They can also add or modify entries based on welding materials such as steel, aluminum, and copper, and processes such as brazing and arc welding, to adapt to diverse production needs. Each data update requires experimental verification; the data only becomes effective after successful verification. For example, after updating the data, five workpieces can be welded consecutively for verification. If the pass rate reaches 98%, the verification is considered successful.

[0061] In this embodiment, when different power supplies are used to power the welding controller, the welding parameters corresponding to the current power supply are adaptively selected, and welding instructions are sent to the welding controller to instruct the welding controller to output welding energy to the welding load based on the welding parameters corresponding to the current power supply. This can improve the welding quality of the connection formed by the welding load under the current power supply environment, solve the welding quality control problem caused by the diversity of power supply, and achieve consistent, stable and high-quality welding results under various power supply environments.

[0062] In one optional implementation of step S11, for each power source, a voltage stability index and a current stability index are determined based on the power source's energy parameters, and an evaluation index for the power source is determined based on the voltage stability index and the current stability index; a first power source is determined based on all evaluation indexes.

[0063] The power supply's electrical parameters may include voltage, current, power, harmonic current, etc. In some examples, multiple anti-reverse current meters are used to collect the electrical parameters of each power supply. In other examples, multiple power measurement and control instruments are used to collect the electrical parameters of each power supply.

[0064] The voltage stability metrics mentioned above can include voltage fluctuation rate, voltage flicker, etc., while the current stability metrics can include total harmonic current distortion (THDi). In some examples, the voltage stability metrics and current stability metrics can be calculated using the following formulas:

[0065] Voltage stability index = (1 - ΔU / U) × 100; ΔU is the voltage fluctuation amplitude, U is the rated voltage, and ΔU / U is the voltage fluctuation amount;

[0066] Current stability index = (1-THDi / 5)×100.

[0067] Taking a voltage fluctuation of 2% as an example, the voltage stability index is 98 points; taking THDi of 2% as an example, the current stability index is 99.6 points.

[0068] In some examples, a dynamic scoring model is used to determine the power supply evaluation index. This involves weighting the scores of the voltage stability index and the current stability index to obtain the power supply's evaluation index, i.e., its score. The power supply with the highest score is then identified as the first power supply. For example, the voltage stability index can be substituted into a preset first scoring function to obtain its score, and the current stability index can be substituted into a preset second scoring function to obtain its score. It should be noted that both the first and second scoring functions are monotonically decreasing functions; that is, the larger the value of the voltage stability index, the lower its score, and vice versa. In practical applications, the weights of the voltage stability index score (the first weight) and the current stability index score (the second weight) can be set according to the actual situation, and their sum is 1. For example, the first weight can be set to 0.55, and the second weight to 0.45.

[0069] To improve the accuracy of power supply evaluation metrics, in one optional implementation, the power supply evaluation metrics are determined by combining the power supply's cost with the voltage stability and current stability metrics. In some examples, a dynamic scoring model is used to determine the power supply evaluation metrics, that is, weighting the scores of the voltage stability, current stability, and cost to obtain the power supply's evaluation metric, i.e., the power supply score, and the power supply with the highest score is identified as the first power supply. For example, the cost can be substituted into a preset third scoring function to obtain the cost score. It should be noted that the third scoring function is also a monotonically decreasing function, meaning that the higher the cost, the lower the score. In practical applications, the weights of the voltage stability score (first weight), the current stability score (second weight), and the cost (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 to 0.3, and the third weight to 0.3. In some other examples, other factors such as power adequacy can also be combined to determine the power supply evaluation metrics.

[0070] In some examples, three or more power sources are connected to the access point. If the difference between the highest and second-highest ratings of all power sources is less than or equal to 5 points, the power source with the lower cost per kilowatt-hour is selected to balance power quality and economy. For example, if the highest and second-highest ratings correspond to grid power and wind power, respectively, and the cost of wind power is 0.7 yuan / kWh while the cost of grid power is 0.8 yuan / kWh, then the lower-cost wind power is selected.

[0071] In some examples, in addition to considering the power source evaluation indicators, other factors such as weather conditions (e.g., sunlight intensity, wind speed) and welding task scheduling (e.g., prioritizing mains power for high-precision welding) can be combined to determine the primary power source. In one specific example, the weight of wind power evaluation indicators is reduced by 10% on rainy days, while the weight of photovoltaic power evaluation indicators is increased to 50% when there is sufficient sunlight at noon, ensuring that the power source selection balances quality and economy.

[0072] In another optional implementation of step S11, a first power source is determined from at least two different types of power sources according to a preset rule. In some examples, the preset rule is: photovoltaic power first, wind power second, hydropower third, and grid power last; for example, if the above-mentioned at least two different types of power sources include photovoltaic and wind power, photovoltaic power is determined as the first power source; or if the above-mentioned at least two different types of power sources include wind power, hydropower, and grid power, wind power is determined as the first power source.

[0073] In some examples, step S11 is performed periodically, meaning the first 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 the first power source, the monitoring frequency of each power source is adjusted based on the fluctuation range of its evaluation indicators. For example, if the score fluctuation of a power source exceeds 10 points within a historical hour (e.g., the photovoltaic power source score drops from 92 points to 78 points), 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.

[0074] In one alternative implementation, such as Figure 3 As shown, after step S13 of the above welding control method, the following steps S14 to S16 are also included:

[0075] Step S14: Obtain voltage fluctuation data.

[0076] In some examples, the voltage fluctuation data includes voltage fluctuation data of the first power source, i.e., voltage fluctuation data originating from the first power source, corresponding to the voltage fluctuation data on the power supply 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.

[0077] In other examples, the voltage fluctuation data includes both the voltage fluctuation data of the second power supply and the voltage fluctuation data of the welding load, that is, voltage fluctuation data from both the power supply side and the load side. In a specific example, if the data deviation between the two sides exceeds 1%, the data is re-acquired three times and the average value is taken to avoid errors in the acquisition equipment that could lead to inaccurate adjustment.

[0078] In a specific example, voltage fluctuation data is the percentage of the difference between the time-series maximum and minimum root-mean-square (RMS) voltage values ​​(i.e., effective values) relative to the rated voltage. To ensure the capture of millisecond-level fluctuations, such as ±1% voltage changes, the frequency of voltage data acquisition can be increased, for example, by setting the acquisition frequency to above 10Hz.

[0079] Step S15: Determine the welding parameter adjustment value corresponding to the voltage fluctuation data. The welding parameter adjustment value is the magnitude of adjustment to the welding parameters, such as the magnitude of increasing or decreasing the voltage, or the magnitude of increasing or decreasing the current.

[0080] It should be noted that voltage fluctuations can affect the welding quality of the welding load. Adjusting the welding parameters accordingly can reduce the impact of voltage fluctuations on welding quality. In some examples, the correspondence between voltage fluctuation data and welding parameter adjustment values ​​is obtained from experimental data. For instance, for the same voltage fluctuation data, the welding parameters sent to the welding controller can be adjusted according to different welding parameter adjustment values. The welding quality of the joint formed by the welding load is then detected, the optimal welding parameter adjustment value corresponding to the optimal welding quality is determined, and the correspondence between this welding parameter adjustment value and the voltage fluctuation data is recorded, thus obtaining the correspondence between voltage fluctuation data and welding parameter adjustment values.

[0081] In some examples, the correspondence between voltage fluctuation data and welding parameter adjustment values ​​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.

[0082] In a specific example, if the voltage fluctuation data is ΔU%, then the corresponding current adjustment value is -ΔU%×K, where K is the compensation coefficient. In brazing mode, K is 1.2, and in arc welding mode, K is 0.8, to ensure that the welding energy fluctuation is within ±2% and to avoid the penetration deviation from 0.5mm.

[0083] Step S16: Send a welding parameter adjustment command to the welding controller; wherein the welding parameter adjustment command is used to instruct the welding controller to adjust the target welding parameters according to the welding parameter adjustment value. In specific implementation, the welding controller adjusts the target welding parameters 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 parameters, thereby reducing the impact of voltage fluctuations on welding quality and improving welding reliability.

[0084] To improve the accuracy of command transmission, in some examples, the welding parameter adjustment command sent to the welding controller also includes a checksum. The checksum can be calculated using the CRC16 algorithm. After receiving the welding parameter adjustment command, the welding controller verifies the consistency of the checksum. If there is a discrepancy, it requests a retransmission. In practical applications, the command transmission error rate does not exceed 0.01%. In some examples, after the welding controller adjusts the target welding parameters, the deviation of the output parameters is verified by a power measurement and control instrument to ensure that the adjustment is effective.

[0085] In one optional embodiment, after step S16 of the above welding control method, the method further includes the following step S17: updating the correspondence between the first power supply and the target welding parameters according to the adjusted target welding parameters. In this embodiment, before updating the correspondence, the first power supply corresponds to the target welding parameters before adjustment; after updating the correspondence, the first power supply corresponds to the adjusted target welding parameters. If the first power supply is used again to power the welding controller, the welding controller outputs welding energy to the welding load based on the adjusted target welding parameters corresponding to the first power supply, which can further improve the welding quality of the joint formed by the welding load.

[0086] In some examples, the updated mapping needs to include the update time, triggering reason, etc., such as "2024-10-15 14:30, voltage fluctuation -3% triggered adjustment". Five historical records are retained to facilitate tracking the effect of parameter optimization. If a power supply still has quality fluctuations after three consecutive adjustments, the power supply will be automatically marked and the user will be prompted to recalibrate the mapping table.

[0087] Example 2

[0088] Based on Example 1, such as Figure 4 As shown, the welding control method provided in this embodiment further includes the following steps S21~S23:

[0089] Step S21: Obtain information about the connection formed by the welding load. The connection formed by the welding load refers to a localized, solid joint formed by current and pressure at the overlapping area of ​​two or more metal parts through a welding process, such as resistance welding. Examples include weld points or brazing seams.

[0090] Step S22: Detect the welding quality of the connection part based on the information of the connection part. Taking the connection part as a weld point as an example, its welding quality can include whether the weld point has porosity, cracks, or shrinkage cavities, and can also include whether the weld point has incomplete welds, surface spatter, burn-through, or surface adhesion. Taking the connection part as a brazing seam as an example, its welding quality can include the brazing seam ratio, and can also include whether the brazing seam has porosity or cracks.

[0091] In some examples, the information of the connection includes image data and / or temperature data of the connection. Image data can be obtained by capturing the appearance of the connection using an industrial camera, and temperature data can be collected using a temperature measuring device such as an infrared thermometer. In a specific example, to ensure clear and reliable data, a 2-megapixel industrial camera with a resolution of 1920×1080 and equipped with a ring light source is used to capture image data; and a Fluke Ti400 infrared thermometer with an accuracy of ±2℃ and a sampling frequency of 30Hz is used to collect temperature data. The acquired image and temperature data are uploaded via USB 3.0. In one specific implementation of step S22, the image data and temperature data of the connection are input into a detection model to detect the welding quality, thereby obtaining the welding quality of the connection. The detection model is trained based on the image data, temperature data, and actual welding quality of the sample connection. The detection model is used to extract the contour of the connection and combine it with the temperature data to comprehensively predict the welding quality.

[0092] In a specific example, the YOLOv5 defect detection model is used to detect welding quality. Training the detection model requires collecting 1000 sets of samples, including samples of steel, aluminum, and copper materials, covering defects such as incomplete welds, cracks, and porosity. A fusion architecture is used, employing CNN (Convolutional Neural Network) to extract image appearance features and fully connected layers to extract temperature distribution features. The cross-entropy loss function is iterated for 500 rounds, achieving a test set accuracy of ≥98% and a defect recognition confidence of ≥95%, ensuring that the recognition accuracy for different materials and defect types meets the standards.

[0093] Step S23: In response to the welding quality not meeting the standard, control the switching unit to switch the welding controller from being electrically connected to the first power supply to being electrically connected to the second power supply.

[0094] The welding quality standards can be set according to actual conditions. In one specific example, the presence of incomplete welds in the connection indicates that the welding quality of the connection is substandard. In another specific example, the welding quality acceptance criteria are: brazing adhesion rate ≥ 85%, axial tensile force ≥ 380 N / 10 seconds, and no defects such as porosity or cracks; if it is a brazing seam, the temperature fluctuation must not exceed ±5℃ (e.g., brazing process temperature is 220-250℃) to avoid insufficient penetration due to abnormal temperature.

[0095] In the specific implementation of step S23, the switching unit can be controlled to operate based on whether the welding quality of one connection meets the standard, or based on whether the welding quality of two or more connections meets the standard. In a specific example, the number of weld points formed by the welding load is 20, of which 18 weld points meet the welding quality standard and 2 weld points do not. That is, the weld point compliance rate is 90%, which does not meet the preset requirement of 95% compliance rate. Therefore, it is necessary to control the switching unit to switch the power supply. In another specific example, if three consecutive weld points fail to meet the standard (or the compliance rate of 20 weld points is <95%), a switchover is triggered immediately. The second power supply selects the power supply with the highest evaluation index and meets the access conditions from the remaining backup power supply. Before switching, the quality anomaly information needs to be reported to the cloud service platform. The platform generates a secondary switching strategy to ensure that the decision is supported by global data. After switching, the welding quality of 10 solder joints must be continuously monitored. The switch is considered successful only if the pre-set 98% compliance rate is met. Otherwise, continue switching to the third power source. At the same time, record the quality anomaly log (e.g., "2024-10-15 16:00, photovoltaic power supply caused poor soldering, restored after switching to mains power") to facilitate subsequent tracing of power supply adaptation issues.

[0096] It should be noted that the second power source can be one of the at least two different types of power sources mentioned above, or it can be two or more power sources. The specific choice of the second power source can be determined based on factors such as the power quality of each power source, preset rules, and weather conditions. In one specific example, step S23 involves controlling the switching unit to switch the welding controller from being connected to photovoltaic power to being connected to wind power. In another specific example, step S23 involves controlling the switching unit to switch the welding controller from being connected to photovoltaic power to being simultaneously connected to both photovoltaic and wind power.

[0097] In this embodiment, if the welding quality of the connection is substandard when the welding controller is powered by the first power source, the power supply is switched to the second power source to improve the welding quality. It should be noted that if switching to the second power source still fails to achieve the required welding quality, the power supply to the welding controller can be switched continuously until the welding quality of the connection meets the standards.

[0098] Example 3

[0099] This embodiment provides a welding control system, such as Figure 1 As shown, it includes a main controller 20, a switching 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 switching unit 21.

[0100] The main controller 20 is configured to execute the welding control method provided in Embodiment 1 or 2. The welding controller 22 is configured to drive the welding load based on target welding parameters corresponding to a first power source in response to a welding command sent by the main controller 20. The first power source is obtained by the main controller 20 executing step S11 of the welding control method.

[0101] In one alternative implementation, such as Figure 1 As shown, the welding control system in this embodiment also includes a power processing module 24. The at least two different types of power supplies are electrically connected to the welding controller 22 via a switching unit 21 after passing through the power processing module 24. The power processing module 24 is used to optimize the quality of the input power supply, thereby outputting a high-quality, stable power supply.

[0102] In a specific example, the power processing module 24 includes an active filter and a passive filter. The active filter integrates an IGBT power module, a DSP controller, and a Hall current sensor, supporting real-time monitoring and compensation for harmonics from the 2nd to the 50th order. It has a rated current handling capacity of 200A and is rigidly connected to the main circuit via a copper busbar, achieving "filtering first" power quality management. In practical applications, the switching frequency of the active filter can be 10kHz, capable of managing high-frequency harmonics from 1-10kHz with a suppression rate of over 90%, adapting to the access characteristics of new energy sources such as photovoltaics and wind power. The Hall current sensor collects harmonic currents from the grid side in real time. The DSP digital controller uses an instantaneous reactive power algorithm to quickly calculate the harmonic current value to be compensated, driving the IGBT power module to output a current in the opposite direction to the harmonic current. The two cancel each other out, constructing a closed-loop management system for real-time monitoring and dynamic compensation, optimizing power quality. The passive filter includes a self-healing parallel capacitor and a dry-type air-core reactor. In practical applications, dry-type air-core reactors can be manufactured using epoxy resin vacuum casting technology, achieving an IP54 moisture and dust resistance rating, suitable for dusty environments in welding workshops, and with a service life exceeding 100,000 hours. A self-healing parallel capacitor and the dry-type air-core reactor form an LC series resonant circuit, rigidly connected to the main circuit via a copper busbar, realizing "post-compensation" resonant suppression logic. For inductive loads such as welding transformers, capacitive reactive power is provided to the grid, effectively offsetting the reactive power consumption generated by the inductive load, raising the system power factor from 0.7 to over 0.95, reducing reactive current transmission in the grid, lowering line losses, and stabilizing voltage levels. The self-healing parallel capacitor has a rated voltage of 400V, and the dry-type air-core reactor has a rated current of 315A. Together, they form a 50Hz LC series resonant circuit. This avoids the amplification of harmonics when the capacitor operates alone, suppressing voltage flicker caused by harmonics on the grid side. Furthermore, it limits the inrush current at the moment of circuit closure, ensuring it does not exceed twice the rated current, protecting system equipment.

[0103] In one optional embodiment, the welding control system further includes multiple anti-reverse current meters for acquiring the electrical energy parameters of each power source. In some examples, the anti-reverse current meters adopt a three-phase four-wire design, integrating current or voltage transformers, a processor, and a display screen. Specifically, the transformers acquire the voltage and current signals of each phase in real time, the processor calculates the direction of active power, and when reverse power, such as reverse current ≥ 5A and lasting for 200ms, is detected, a reverse current alarm message is immediately sent, thereby cutting off the faulty circuit.

[0104] The backflow prevention meter supports RS485 (Modbus-RTU protocol) communication with the main controller. In addition to current direction, it also uploads real-time power, cumulative energy, voltage fluctuation, and other data, with a sampling interval of ≤1s, providing high-frequency data support for power supply assessment and voltage fluctuation detection. When backflow is detected, a hard-wired alarm is triggered within 50ms.

[0105] In one optional embodiment, the welding control system further includes multiple power measurement and control instruments for collecting the power parameters of each power source and the power parameters of the welding load. The voltage fluctuation data caused by the welding load can be obtained based on the collected power parameters of the welding load.

[0106] The power measurement and control instrument has the function of 2nd-50th harmonic analysis. The data is uploaded via Ethernet (TCP / IP protocol) with a transmission delay of ≤50ms. It supports overcurrent and overvoltage alarms (thresholds can be set remotely). When the welding load current is detected to exceed 1.2 times the rated value, it immediately reports to the main controller to avoid equipment overload damage.

[0107] In one optional implementation, the main controller includes a cloud service platform and a local control unit. The cloud service platform is configured to determine a first power source from all power sources based on the power parameters of each power source, and issue a strategy command to the local control unit to switch to the first power source. The local control unit is configured to, in response to the strategy command, control the switching unit to operate, thereby electrically connecting the welding controller to the first power source. The cloud service platform is also configured to send welding commands to the welding controller via the local control unit. The welding controller is configured to, in response to the welding commands, drive a welding load based on target welding parameters corresponding to the first power source. In some examples, the local control unit is a PLC (Programmable Logic Controller).

[0108] The cloud service platform is deployed on Alibaba Cloud ECS, supports access for millions of devices, has a policy instruction issuance delay of ≤1s, and has historical data storage (≥3 years) and report generation functions (such as daily power switching count and welding quality pass rate). The local control unit has protocol conversion function (compatible with Modbus-RTU and EtherNet / IP) and built-in local policy instruction cache. When the cloud service platform communication is interrupted, the cached policy is called to maintain operation and avoid production interruption.

[0109] In some examples, the welding control system also includes a gateway. The gateway acts as a data relay station, responsible for uploading equipment data, such as electrical parameters collected by anti-backflow meters and power measurement instruments, to the cloud service platform. Simultaneously, it forwards policy instructions issued by the cloud service platform to the local control unit. It should be noted that the gateway needs to convert the data format during the data relay process. For example, it may convert device data on the RS485 bus to MQTT (Message Queuing Telemetry Transport) protocol before uploading it to the cloud service platform, or it may parse policy instructions issued by the cloud service platform into Modbus-RTU protocol before forwarding them to the PLC.

[0110] The gateway supports two Ethernet channels, four RS485 channels, and 4G communication. It has edge computing capabilities and can filter invalid data locally, such as not uploading data when the voltage fluctuation is ≤±1%, reducing cloud bandwidth usage by 30%. It adopts a dual-link redundancy design of Ethernet and 4G, automatically switching to 4G when the wired network is interrupted, with communication reliability of over 99.9%.

[0111] In one optional embodiment, the switching unit includes an automatic transfer switch (ATS) and a circuit breaker, each corresponding to and sequentially connected to a power source. The local control unit is further configured to control the ATS corresponding to the first power source to turn on and to control the circuit breaker corresponding to the first power source to close. In this embodiment, one end of the ATS is connected to the power source, and the other end is connected to the circuit breaker; power switching is achieved through coordinated control of the ATS and the circuit breaker.

[0112] In some examples, the automatic transfer switch employs a double-throw mechanical structure, incorporating two sets of vacuum interrupters, a permanent magnet operating mechanism, and a Hall effect position sensor. The vacuum interrupter has a rated voltage of 1000V to enhance arc extinguishing capability, while the Hall effect position sensor provides real-time feedback on the contact status. The automatic transfer switch receives closing or opening commands from the local control unit via control lines. The permanent magnet operating mechanism drives the moving contact to switch to the first power supply, and the Hall effect position sensor provides real-time feedback on the contact status, strictly adhering to the "on first, off later" logic to ensure continuous power supply to the welding controller.

[0113] In some examples, the ATS has a switching time of ≤50ms, a mechanical life of ≥100,000 cycles, and a voltage synchronization detection function. Before switching, it is necessary to confirm that the phase difference between the backup power supply and the main power supply is ≤5° to avoid current surges damaging the welding equipment's IGBT module. It also supports remote status query (such as contact closure status) to facilitate fault diagnosis.

[0114] In some examples, the circuit breaker uses a thermal-magnetic trip unit with a built-in bimetallic strip and electromagnetic coil. During normal operation, the main contacts remain closed, supplying power to the downstream welding controller. In the event of an overload, the large current causes the bimetallic strip to bend due to heat. In the event of a short circuit, the large current causes the electromagnetic coil to engage. When an overload or short circuit is detected, the trip mechanism is triggered, the main contacts break the circuit, disconnect the faulty power supply, and protect downstream modules such as the welding controller from damage. In practical applications, the trip threshold can be remotely set via a local control unit. For example, when the welding load changes abruptly, the short-circuit trip threshold can be temporarily relaxed to 6In to avoid false tripping due to instantaneous surge current.

[0115] In some examples, the circuit breaker has a rated current of 315A and a breaking capacity of 50kA (RMS). It supports remote reading of information such as tripping status and current value. The tripping threshold can be set remotely by PLC to adapt to the dynamic changes in welding load, such as a sudden increase from 50A for spot welding to 300A for continuous welding, thus avoiding malfunctions.

[0116] In some examples, the aforementioned switching unit also includes a power switching module corresponding to each power source, wherein the automatic transfer switch, circuit breaker, and power switching module are connected sequentially. The power switching module integrates a contactor and a solid-state relay, connected to the local control unit via auxiliary contacts. It provides real-time feedback on the contactor's engagement or disengagement status, ensuring reliable execution of the charging and discharging logic. The power switching module receives switching commands from the local control unit. The contactor is responsible for the long-term on / off control of the main circuit, while the solid-state relay briefly conducts during switching to help suppress arc generation. Simultaneously, the auxiliary contacts feed back the real-time engagement or disengagement status to the local control unit, forming a closed-loop control to ensure precise execution of the charging and discharging logic.

[0117] In some examples, the contactor's pull-in time is ≤50ms, and the conduction loss is ≤5W, making it suitable for long-term operation; the solid-state relay response time is ≤1ms, reducing arc energy by 90% during switching and extending contactor contact life by 3 times; the auxiliary contacts support "wire breakage detection," immediately reporting a fault when contacts stick together to avoid the risk of power short circuit; the automatic transfer switch switching time is ≤50ms; and the circuit breaker supports remote setting of tripping thresholds (e.g., temporarily relaxing the short-circuit tripping threshold to 6In when welding load changes suddenly) to avoid malfunctions.

[0118] In some examples, the aforementioned welding control system also includes a distributed power supply unit, which adopts a modular design, integrating a photovoltaic inverter interface, an anti-reverse current control board, and a current transformer. It is connected to the aforementioned power processing module via a hard-wired copper busbar and simultaneously connected to an anti-reverse current meter used to collect photovoltaic power parameters, forming a dual anti-reverse current mechanism. The distributed power supply unit monitors the direction of the photovoltaic output current in real time through the current transformer. When reverse current is detected, it immediately disconnects the photovoltaic circuit via a hard-wired signal and reports to the local control unit.

[0119] In some examples, the distributed power access unit supports a maximum photovoltaic input power of 50kW, operates in a temperature range of -40℃ to 70℃, and is adaptable to extreme climates; it is linked with ATS to prioritize the connection of mains power when the photovoltaic circuit is cut off to avoid power outages.

[0120] In an optional implementation, the local control unit is further configured to send a welding mode switching command to the welding controller. The welding controller is further configured to, in response to the switching command, switch from a parameter configuration of a first welding mode to a parameter configuration of a second welding mode, 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.

[0121] In some examples, the welding mode switching command includes the mode type (e.g., brazing, arc welding) and parameter fine-tuning coefficient. For example, when switching to arc welding mode, if the first power source is photovoltaic, the parameter fine-tuning coefficient is +5% (current increases from 250A to 262.5A), and if it is mains power, the fine-tuning coefficient is +1% (current increases from 250A to 252.5A), ensuring that there are no quality fluctuations during mode switching.

[0122] In some examples, the local control unit includes a human-machine interface (HMI) device through which the user can select different welding modes or switch between welding modes. In one specific example, the HMI device is a touchscreen.

[0123] In some examples, the touchscreen is a 10.1-inch industrial-grade capacitive screen with an IP65 protection rating, supports multiple language switching (Chinese, English, and Spanish), and displays real-time power status, welding parameters, and quality pass rate. Operation permissions are divided into three levels: operator, engineer, and administrator, to prevent accidental modification of key parameters (such as power evaluation weight and welding quality threshold).

[0124] In some examples, the first welding mode is brazing, with parameters including an output voltage range of 10V~20V, an output current range of 50A~100A, and a temperature range of 200℃~300℃. The second welding mode is arc welding, with parameters including an output voltage range of 20V~40V, an output current range of 200A~500A, and a temperature range of 800℃~1200℃.

[0125] In some examples, 100 sets of process parameters are pre-stored for each welding mode (e.g., current-time curves corresponding to different materials and thicknesses), the switching time is ≤10ms, and the output parameter deviation is verified to be ≤±2% by the power measurement and control instrument after switching to ensure reliable process switching.

[0126] In this embodiment, the welding controller dynamically adjusts the output welding energy according to the switched second welding mode and the target welding parameters, which can realize precise switching from the first welding mode to the second welding mode.

[0127] In one optional implementation, the at least two different types of power sources include a bidirectional energy storage unit for rapid energy replenishment during power fluctuations or power shortages. The bidirectional energy storage unit includes a battery management system, energy storage elements, and an energy storage converter. The local control unit is further configured to send charge / discharge commands 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 commands to charge and discharge the energy storage elements. In a specific example, the energy storage element includes a lithium iron phosphate battery pack.

[0128] In some examples, the bidirectional energy storage unit has a rated power of 30kW, an energy storage capacity of 50kWh, a charge / discharge efficiency of ≥90% (10%-100% SOC range), and a cycle life of ≥3000 cycles (80% DOD). The energy storage converter adopts an IGBT full-bridge topology, supports four-quadrant operation, and has a charge / discharge switching time of ≤10ms, enabling rapid response to power shortages.

[0129] In some examples, the battery management system (BMS) monitors the voltage, temperature, and SOC (State of Charge) 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 command to the BMS when the SOC is below a first threshold or when other power sources have excess power. The BMS then controls the energy storage inverter to switch to boost mode to charge the energy storage element using other power sources. Alternatively, the BMS can send a discharging command to the BMS when the SOC is above a second threshold or when other power sources have insufficient power. The BMS then controls the energy storage inverter to switch to buck mode to supplement other power sources using the energy storage element. The first and second thresholds can be set according to actual conditions; for example, the first threshold can be set to 15%, and the second threshold to 85%.

[0130] In some examples, the SOC measurement accuracy and charge / discharge command power control accuracy of the battery management system are within ±2%, and it has overvoltage, overcurrent, and overtemperature protection functions; it communicates with the PLC via RS485 with a feedback cycle of ≤1s; when the first power supply voltage fluctuates by more than ±3% or the power shortage is ≥10kW, the PLC commands the energy storage converter to discharge and replenish energy within 10ms to maintain system voltage stability; when SOC ≤10%, it automatically prohibits discharge and triggers mains power standby switching to avoid damage from deep battery discharge.

[0131] In this embodiment, by utilizing an integrated energy storage unit to participate in the flexible power adjustment of the welding control system, the system power balance and voltage stability can be maintained, enabling the system power to achieve dynamic balance.

[0132] In some examples, the main controller further includes a local processor configured to execute steps S14-S16 in Embodiment 1 or steps S21-S23 in Embodiment 2. Specifically, when executing step S16, the local processor sends welding parameter adjustment commands to the welding controller via the local control unit; and when executing step S23, the local processor controls the switching unit via the local control unit, causing the welding controller to switch from electrical connection to the first power supply to electrical connection to the second power supply, ultimately achieving dynamic adaptation of power quality and welding process.

[0133] The following is a specific example to illustrate this embodiment in detail:

[0134] First, the most efficient operation phase at noon (12:00-14:00)

[0135] Data monitoring: The power of photovoltaic is 58kW, and its evaluation index, i.e., its score, is 92 points; the power of wind power is 30kW, its score is 88 points, the voltage is 381V±0.5%, and the total harmonic distortion of current (THDi) is 2.5%.

[0136] Strategy Execution: The cloud service platform sends a strategy command to the PLC to switch to photovoltaic and wind power. The PLC controls the ATS corresponding to photovoltaic power to turn on and the circuit breaker corresponding to photovoltaic power to close, and controls the ATS corresponding to wind power to turn on and the circuit breaker corresponding to wind power to close. At this time, the bidirectional energy storage unit is in standby mode, and the SOC of its energy storage element is 60%. The PLC sends a welding command to the welding controller, instructing the welding controller to drive the welding load based on the current command corresponding to the parallel power supply of photovoltaic and wind power.

[0137] When power is supplied in parallel, the PLC uses a power distribution algorithm to allocate the 50kW load to 70% photovoltaic and 30% wind power. At the same time, the power processing module controls THDi to within 3%, and the welding arc voltage fluctuation is ≤±1V.

[0138] Welding results: The industrial camera captured images of the solder joints every 30ms, confirming a soldering rate of 98%, a chip packaging temperature of 950℃±20℃, and no cracks.

[0139] Second, the power fluctuation response phase (16:00-16:30)

[0140] Unexpected situation: Cloud cover caused the photovoltaic power to drop sharply from 58kW to 30kW, and the voltage to drop to 365V.

[0141] Closed-loop response: The power measurement and control instrument reports voltage fluctuation data to the local processor within 10ms;

[0142] The PLC sends a discharge command to the bidirectional energy storage unit, instructing it to discharge at a power of 25kW.

[0143] The local processor determines the welding parameter adjustment value corresponding to the voltage fluctuation data and sends a welding parameter adjustment command to the welding controller via the PLC. The welding controller adjusts the current command based on the welding parameter adjustment value to increase the output current to 260A to compensate for the voltage fluctuation. At the same time, it updates the mapping table that stores the correspondence between voltage fluctuation data and welding parameters. For example, a 4% voltage drop corresponds to an 8% increase in current compared to before.

[0144] During the energy storage discharge process, the battery management system provides real-time feedback of current and voltage data, and the PLC dynamically adjusts the discharge power to 20kW to avoid overload.

[0145] After parameter adjustment, 10 solder joints were continuously monitored. The industrial camera collected image data of the solder joints every 30ms. Based on the collected image data, the local processor did not find any cracks or poor solder joints, and the compliance rate was 100%.

[0146] Third, process changeover phase (18:00 switch from brazing to arc welding)

[0147] The user switches the welding mode from brazing to arc welding via the touch screen, and the PLC sends the corresponding switching command to the welding controller.

[0148] The welding controller outputs welding energy to the welding load according to the parameters configured for arc welding. Specifically, the output current increases from 60A to 250A, and the output voltage increases from 18V to 32V.

[0149] Before switching, the PLC commands the bidirectional energy storage unit to increase the SOC to 65% for standby; during switching, the power switching module suppresses the arc, and the current transition is shock-free (≤300A); after switching, the power measurement and control instrument verifies that the voltage fluctuation is ≤±2%, which meets the requirements of arc welding.

[0150] The PLC stops sending discharge commands to the bidirectional energy storage unit, and the bidirectional energy storage unit switches to standby mode to ensure stable power.

[0151] In practical applications, the welding control system provided in this disclosure is improved in several index categories compared with the existing technology, as shown in Table 1:

[0152] Table 1

[0153]

[0154] Example 3

[0155] Figure 5 This is a schematic diagram of an electronic device 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, which enables the at least one processor to perform the steps of the 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 functionality and scope of use of the embodiments disclosed herein.

[0156] The components of the electronic device 3 may include, but are not limited to: at least one processor 4, at least one memory 5, and a bus 6 connecting different system components (including memory 5 and processor 4).

[0157] Bus 6 includes a data bus, an address bus, and a control bus.

[0158] The memory 5 may include volatile memory, such as random access memory (RAM) 51 and / or cache memory 52, and may further include read-only memory (ROM) 53.

[0159] The memory 5 may also include a program tool 55 having a set (at least one) of program modules 54, including but not limited to: an operating system, one or more application programs, other program modules, and program data, each or some combination of these examples may include an implementation of a network environment.

[0160] Program module 54 also integrates a welding control algorithm submodule, which includes core logic such as power evaluation, parameter adjustment, and quality verification, and supports modular calling; at the same time, it stores configuration files such as power-process mapping tables and detection model parameters, which users can modify through tools to adapt to different welding scenarios (such as welding of power battery tabs and brazing of smart meter terminals).

[0161] The processor 4 executes various functional applications and data processing by running computer programs stored in the memory 5, such as the welding control method provided in embodiment 1 or 2.

[0162] In some examples, processor 4 is an industrial-grade quad-core CPU (such as ARM Cortex-A53) with a main frequency of ≥1.5GHz, supports AES-256 hardware encryption to ensure the security of sensitive data such as power supply strategy and welding parameters; it has temperature adaptive adjustment function and can operate stably in environments from -20℃ to 60℃ to meet the harsh working conditions of industrial workshops.

[0163] 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.

[0164] Network adapter 9 supports Gigabit Ethernet and 4G full network connectivity with 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.

[0165] 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.

[0166] 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 welding control method provided in Embodiment 1 or 2.

[0167] In some examples, the computer program is stored using AES-256 encryption to prevent unauthorized access or tampering. The computer program uses segmented storage of the core algorithm module and configuration file. The configuration file is editable and contains parameters such as power evaluation index weights and welding quality qualification thresholds. Users can modify the configuration file according to different application scenarios (such as power battery welding and smart meter packaging) to improve the system's versatility.

[0168] 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.

[0169] In possible implementations, this disclosure may also be implemented as a computer program product comprising a computer program that, when executed by a processor, implements the steps of the welding control method provided in Embodiment 1 or 2.

[0170] The computer program product also includes debugging tools that support real-time viewing of power switching logs (such as switching time, triggering conditions, and changes in electrical parameters) and welding quality inspection reports, making it easier for users to locate faults (such as tracing electrical parameter deviations when the quality fails to meet standards after switching). It also supports remote upgrades of the computer program, which can push program update packages through the cloud without requiring on-site downtime maintenance, thus reducing operation and maintenance costs.

[0171] The computer program for executing the present disclosure can be written in any combination of one or more programming languages, and the computer program can be executed entirely on an electronic device, partially on an electronic device, as a stand-alone software package, partially on an electronic device and partially on a remote device, or entirely on a remote device.

[0172] While specific embodiments of this disclosure have been described above, those skilled in the art should understand that these are merely illustrative examples, and the scope of protection of this 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 this disclosure, but all such changes and modifications fall within the scope of protection of this disclosure.

Claims

1. A welding control method for a multi-electrode hybrid power supply scenario, characterized in that, The welding controller is electrically connected to at least two different types of power supplies via a switching unit; The welding control method includes the following steps: Determine the first power source from the power sources; The switching unit is controlled to operate so that the welding controller is electrically connected to the first power supply. A welding command is sent 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 first power supply.

2. The welding control method as described in claim 1, characterized in that, The welding control method further includes: Acquire voltage fluctuation data; Determine the welding parameter adjustment values ​​corresponding to the voltage fluctuation data; A welding parameter adjustment command is sent to the welding controller; wherein the welding parameter adjustment command is used to instruct the welding controller to adjust the target welding parameters according to the welding parameter adjustment value.

3. The welding control method as described in claim 2, characterized in that, The welding control method further includes updating the correspondence between the first power supply and the target welding parameters according to the adjusted target welding parameters.

4. The welding control method as described in claim 2, characterized in that, The voltage fluctuation data includes the voltage fluctuation data of the first power supply or the voltage fluctuation data of the welding load.

5. The welding control method as described in claim 1, characterized in that, The step of determining the first power source from the power sources specifically includes: For each power source, voltage stability index and current stability index are determined based on the power source's power parameters, and evaluation index of the power source is determined based on the voltage stability index and the current stability index. The primary power source was determined based on all evaluation metrics.

6. The welding control method according to any one of claims 1-5, characterized in that, The welding control method further includes: Obtain information about the joint formed by the welding load; The welding quality of the connection part is detected based on the information of the connection part; In response to the welding quality not meeting the standard, the switching unit is controlled to switch the welding controller from being electrically connected to the first power supply to being electrically connected to the second power supply.

7. A welding control system for a multi-electrode hybrid power supply scenario, characterized in that, It includes a welding controller, a welding load, a switching unit, and a main controller, wherein the welding controller is electrically connected to at least two different types of power supplies through the switching unit; The main controller is configured to perform the welding control method according to any one of claims 1-6; The welding controller is configured to drive the welding load based on target welding parameters corresponding to the first power supply in response to welding commands sent by the main controller.

8. The welding control system as described in claim 7, characterized in that, The main controller includes a cloud service platform and a local control unit; The cloud service platform is configured to determine the first power source from all power sources based on the power parameters of each power source, and to issue a strategy instruction to the local control unit to switch to the first power source. The local control unit is configured to control the switching unit to operate in response to the policy instruction, so as to electrically connect the welding controller to the first power supply.

9. The welding control system as described in claim 8, characterized in that, The switching unit includes an automatic transfer switch and a circuit breaker that correspond one-to-one with each power source and are connected in sequence. The local control unit is further configured to control the automatic transfer switch corresponding to the first power supply to turn on and to control the circuit breaker corresponding to the first power supply to close.

10. The welding control system as described in claim 8, characterized in that, The local control unit is also used to send welding mode switching instructions to the welding controller; The welding controller is also 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 command, 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.

11. The welding control system as described in any one of claims 8-10, characterized in that, The at least two different types of power sources include a bidirectional energy storage unit, which includes a battery management system, energy storage elements, and an energy storage converter. The local control unit is also configured to send charge and discharge commands 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 and discharge commands, so as to charge and discharge the energy storage element.

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