Online monitoring system of laser welding machine

Abstract

The invention belongs to the technical field of laser welding machines, and particularly relates to a laser welding machine online monitoring system which comprises a signal acquisition module, a data transmission and preprocessing module, an analysis and decision module and a man-machine interaction and visualization module. The signal acquisition module comprises an optical signal acquisition sensor, a mechanical signal acquisition sensor, a laser parameter acquisition sensor and a weld form acquisition sensor; and a data transmission and preprocessing module. Through cooperation of the signal acquisition module, the data transmission and preprocessing module, the analysis and decision module and the man-machine interaction and visualization module, data acquisition can be performed from optical, mechanical and laser parameters and welding seam forms, so that a rich data basis is provided for accurate judgment of a welding state; and secondly, all welding process parameters and monitoring data can be recorded, so that full-life-cycle tracing of product quality is realized, and subsequent quality analysis and process optimization are facilitated.

Description

Technical Field

[0001] This invention relates to the field of laser welding machine technology, specifically to an online monitoring system for laser welding machines. Background Technology

[0002] Laser welding technology, due to its advantages such as high energy density, deep penetration welding effect, and small heat-affected zone, has been widely used in high-end industrial fields such as aerospace, automobile manufacturing, and precision electronics. However, the laser welding process is extremely rapid and the internal reaction is complex. Its quality is easily affected by the workpiece assembly accuracy, material composition, fluctuations in process parameters, and external environmental interference, which can easily lead to defects such as porosity and cracks.

[0003] Traditional laser welding quality monitoring relies heavily on manual sampling or offline testing, which suffers from significant delays and cannot detect and correct quality issues in the production process in real time, resulting in high scrap rates and low production efficiency. Although some online monitoring systems have emerged in the existing technology, their acquisition units often suffer from the following drawbacks: the core optical acquisition sensor is easily contaminated by spatter and fumes in harsh welding environments, leading to blurred images and monitoring failures; at the same time, the sensor lacks a fast and reliable installation and positioning structure, making disassembly and maintenance inconvenient. Therefore, we propose an online monitoring system for laser welding machines to solve the above problems. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an online monitoring system for laser welding machines, which solves the problems mentioned in the background section.

[0005] (II) Technical Solution To achieve the above objectives, the present invention specifically adopts the following technical solution: An online monitoring system for a laser welding machine includes a signal acquisition module, a data transmission and preprocessing module, an analysis and decision-making module, and a human-computer interaction and visualization module; The signal acquisition module includes an optical signal acquisition sensor, a mechanical signal acquisition sensor, a laser parameter acquisition sensor, and a weld morphology acquisition sensor; The data transmission and preprocessing module includes a data transmission unit connected to the signal acquisition module, and a data preprocessing unit that performs noise reduction and format conversion on the raw data output by the data transmission unit. The analysis and decision-making module includes an edge computing unit that receives the output data of the data preprocessing unit, an algorithm model library that stores welding quality analysis algorithms, and a quality and status determination unit that makes judgments based on the output results of the edge computing unit and the algorithm model library. The human-computer interaction and visualization module includes a monitoring terminal for displaying monitoring data, an alarm unit for issuing abnormal prompts, and a data storage and traceability unit for saving and retrieving historical monitoring information.

[0006] Furthermore, the optical signal acquisition sensor includes a bracket fixed to the welding head of a laser welding machine. A high-speed industrial camera is installed inside a through hole in the bracket. A limiting component for fixing the high-speed industrial camera is provided on the bracket. A protective cover is threaded to the acquisition end of the high-speed industrial camera. A transparent glass plate is fixed inside a through hole at the bottom of the protective cover. A housing is fixed to the surface of the high-speed industrial camera. Air blowers are fixed in a circular array on the housing. An annular tube is fitted onto the surface of the high-speed industrial camera. One end of each air blower is connected and fixed to the annular tube. A bellows is fixed to the top of the bracket. Two air outlet pipes of the bellows are detachably connected and fixed to the annular tube. An exhaust fan is fixed inside the bellows.

[0007] Furthermore, the limiting component includes a connecting plate fixed on the bracket, a push rod slidably passing through the side wall of the connecting plate, a pushing block fixed to one end of the push rod, two springs fixed to one side wall of the pushing block, the other ends of the springs being fixedly connected to the connecting plate, two connecting rods rotatably connected to one side wall of the pushing block via pins, two locking blocks adapted to high-speed industrial cameras slidably connected on the bracket, the locking blocks being locked onto the surface of the high-speed industrial camera, and the other ends of the connecting rods being rotatably connected to the corresponding locking blocks via pins.

[0008] Furthermore, the bracket has four T-slots, and the bottom of each card block has two T-blocks that are compatible with the T-slots.

[0009] Furthermore, two through holes are opened on one side wall of the air box, and heat sinks are fixed inside each of the holes. Semiconductor cooling chips are fixed on each of the heat sinks.

[0010] Furthermore, a speed reduction plate fixed inside the air box is provided on one side of each of the two semiconductor cooling chips, and the number of speed reduction plates is four.

[0011] Furthermore, a positioning block is fixed to the bottom of the bracket, and a retaining ring adapted to the positioning block is fixed to the surface of the high-speed industrial camera.

[0012] (III) Beneficial Effects Compared with the prior art, the present invention provides an online monitoring system for laser welding machines, which has the following advantages: This invention, through the cooperation of a signal acquisition module, a data transmission and preprocessing module, an analysis and decision-making module, and a human-computer interaction and visualization module, can collect data from optical, mechanical, and laser parameters and weld morphology, thus providing a rich data foundation for accurately judging the welding status; secondly, it can record all welding process parameters and monitoring data, thereby realizing full life cycle traceability of product quality, which facilitates subsequent quality analysis and process optimization.

[0013] This invention, through the combination of a bellows and an air blower, can create a continuous and uniform clean airflow barrier in front of the lens of a high-speed industrial camera, thereby effectively dispersing welding fumes and blocking metal spatter, ensuring that the lens remains clean and that the image is clear and stable. Furthermore, the high-speed industrial camera is fixed by a limiting component, making it easy to disassemble and assemble, thus facilitating its maintenance in the future. Attached Figure Description

[0014] Figure 1 This is a flowchart of the online monitoring system of the present invention; Figure 2 This is a schematic diagram of the optical signal acquisition sensor structure of the present invention; Figure 3 This is a schematic diagram of the support structure of the present invention; Figure 4 This is a schematic diagram of the protective cover structure of the present invention; Figure 5 This is a schematic diagram of the bellows structure of the present invention; Figure 6 For the present invention Figure 2 Enlarged schematic diagram of the structure at point A in the middle; Figure 7 For the present invention Figure 3 Enlarged schematic diagram of the structure at point B.

[0015] In the diagram: 1. Signal acquisition module; 11. Optical signal acquisition sensor; 111. Bracket; 112. High-speed industrial camera; 113. Protective cover; 114. Transparent glass plate; 115. Housing; 116. Air blower; 117. Ring tube; 118. Air box; 119. Limiting component; 1191. Connecting plate; 1192. Push rod; 1193. Push block; 1194. Spring; 1195. Connecting rod; 1196. Locking block; 1197. T-slot; 1198. T-block; 1110. Exhaust fan; 1111. Heat sink; 1112. 1. Semiconductor cooling chip; 1113. Speed ​​reducer; 1114. Positioning block; 1115. Retaining ring; 12. Mechanical signal acquisition sensor; 13. Laser parameter acquisition sensor; 14. Weld morphology acquisition sensor; 2. Data transmission and preprocessing module; 21. Data transmission unit; 22. Data preprocessing unit; 3. Analysis and decision-making module; 31. Edge computing unit; 32. Algorithm model library; 33. Quality and status judgment unit; 4. Human-computer interaction and visualization module; 41. Monitoring terminal; 42. Alarm unit; 43. Data storage and traceability unit. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Example like Figure 1 and Figure 2 As shown, an embodiment of the present invention proposes an online monitoring system for a laser welding machine, which includes a signal acquisition module 1, a data transmission and preprocessing module 2, an analysis and decision-making module 3, and a human-computer interaction and visualization module 4. The signal acquisition module 1 includes an optical signal acquisition sensor 11, a mechanical signal acquisition sensor 12, a laser parameter acquisition sensor 13, and a weld morphology acquisition sensor 14. The data transmission and preprocessing module 2 includes a data transmission unit 21 connected to the signal acquisition module 1, and a data preprocessing unit 22 that performs noise reduction and format conversion on the raw data output by the data transmission unit 21. The analysis and decision module 3 includes an edge computing unit 31 that receives the output data of the data preprocessing unit 22, an algorithm model library 32 that stores welding quality analysis algorithms, and a quality and status determination unit 33 that makes judgments based on the output results of the edge computing unit 31 and the algorithm model library 32. The human-computer interaction and visualization module 4 includes a monitoring terminal 41 for displaying monitoring data, an alarm unit 42 for issuing abnormal prompts, and a data storage and traceability unit 43 for saving and retrieving historical monitoring information. The working principle and usage process of this invention are as follows: During use, the signal acquisition module 1 collects data on the optical, mechanical, laser parameters and weld morphology of the laser welding machine, and sends the collected data to the data transmission and preprocessing module 2. Then, the data is sent to the analysis and decision module 3 for processing through this module. Finally, the processed data is displayed through the human-computer interaction and visualization module 4. Signal acquisition module 1: Optical signal acquisition sensor 11 is used to determine problems such as molten pool stability and plasma anomalies; mechanical signal acquisition sensor 12 is a piezoelectric acoustic sensor used to identify defects such as weld cracks and equipment misalignment; laser parameter acquisition sensor 13 is a laser power meter used to monitor the deviation between the output power and the set value in real time to ensure that the core laser parameters meet the welding requirements; and weld morphology acquisition sensor 14 is a laser contour sensor used to acquire appearance data such as weld reinforcement height, width, and undercut depth in real time to directly determine weld morphology defects; Data transmission and preprocessing module 2: Data preprocessing unit 22 uses industrial Ethernet to transmit signals from fixed equipment and wireless industrial gateways to transmit signals from moving parts such as welding heads, ensuring data real-time performance; Data preprocessing unit 22 removes high-frequency noise such as power grid and mechanical vibration through signal conditioner, smooths the data with algorithms such as Kalman filtering and wavelet transform, and standardizes heterogeneous data such as images and numerical data into a unified format, clearing obstacles for subsequent analysis; Analysis and Decision Module 3: Edge computing unit 31 and algorithm model library 32, based on GPU / FPGA embedded platform, perform local rapid analysis of data with high real-time requirements such as molten pool image and laser power, avoiding cloud transmission lag; Quality and status judgment unit 33 compares "real-time data" with "standard threshold" and outputs the weld "qualified / unqualified" result; at the same time, it accumulates equipment operation data, calculates the remaining lifespan, and provides early warning of maintenance needs; Human-computer interaction and visualization module 4: The monitoring terminal 41 can adopt an industrial touch screen to display welding parameters, molten pool images, and judgment results in real time; the alarm unit 42 can promptly remind users of abnormal equipment through audible and visual alarms or other channels, and indicate the cause of the abnormality; the data storage and traceability unit 43 stores historical data through a MySQL / MongoDB database, supports retrieval by welding batch, time, and workpiece number, and facilitates quality review and problem tracing in the later stage.

[0018] like Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 7 As shown, in some embodiments, the optical signal acquisition sensor 11 includes a bracket 111 fixed to the welding head of a laser welding machine. A high-speed industrial camera 112 is disposed inside a through hole in the bracket 111. Two slots adapted to the locking blocks 1196 are provided on the surface of the high-speed industrial camera 112. When the locking blocks 1196 are engaged in the slots, the high-speed industrial camera 112 can be fixed and positioned. A positioning block 1114 is fixed to the bottom of the bracket 111, and a retaining ring 1115 adapted to the positioning block 1114 is fixed to the surface of the high-speed industrial camera 112 to position and limit the high-speed industrial camera 112. The function of the device is to facilitate subsequent operation by fixing it with the limiting component 119 after it is inserted into the socket of the bracket 111. The bracket 111 is provided with the limiting component 119 for fixing the high-speed industrial camera 112. The acquisition end of the high-speed industrial camera 112 is threadedly connected to the protective cover 113. A transparent glass plate 114 is fixed inside the through hole at the bottom of the protective cover 113. A housing 115 is fixed to the surface of the high-speed industrial camera 112. Air blowers 116 are fixed in a ring array on the housing 115. A ring tube 117 is sleeved on the surface of the high-speed industrial camera 112. One end of each air blower 116 is connected to the ring tube. The support 111 is fixedly connected to the ring pipe 117. A bellows 118 is fixed to the top of the support 111. A filter is installed at the air inlet of the bellows 118 to filter the air entering the bellows 118. Both air outlets of the bellows 118 are detachably connected and fixed to the ring pipe 117. An exhaust fan 1110 is fixed inside the bellows 118. In use, the support 111 serves as the basic load-bearing structure fixed to the welding head of the laser welding machine. The high-speed industrial camera 112 is stably fixed by the limiting component 119 to ensure accurate shooting position. Its acquisition end is protected by a threaded protective cover 113. The bottom of the protective cover 113 has a transparent glass... The glass plate 114 can block interference from spatter and fumes during the welding process without affecting the acquisition of optical signals. During operation, the exhaust fan 1110 inside the bellows 118 is activated, which draws in external air into the bellows 118 and sends it to the annular tube 117 on the surface of the high-speed industrial camera 112. Then, the annular tube 117 evenly distributes the airflow to the air blowers 116 fixed in a ring array on the housing 115 and blows it out. At this time, the airflow ejected by the air blowers 116 directly acts on the surface of the transparent glass plate 114 and forms an air curtain barrier, thereby preventing fumes and spatter from obstructing the shooting field of the high-speed industrial camera 112.

[0019] like Figure 1 and Figure 6As shown, in some embodiments, the limiting component 119 includes a connecting plate 1191 fixed to the bracket 111. A push rod 1192 slides through the side wall of the connecting plate 1191. A pushing block 1193 is fixed to one end of the push rod 1192. Two springs 1194 are fixed to one side wall of the pushing block 1193. The other ends of the springs 1194 are fixedly connected to the connecting plate 1191. Two connecting rods 1195 are rotatably connected to one side wall of the pushing block 1193 via pins. Two clips adapted to the high-speed industrial camera 112 are slidably connected to the bracket 111. Block 1196 and bracket 111 have four T-slots 1197. Two T-blocks 1198, which fit into the T-slots 1197, are fixed to the bottom of each block 1196, providing auxiliary support and guidance for the block 1196, thus making it more stable during sliding. The blocks 1196 are all engaged with the surface of the high-speed industrial camera 112. The other end of the connecting rod 1195 is rotatably connected to the corresponding block 1196 via pins. When the high-speed industrial camera 112 needs to be removed for maintenance, the bellows 118 and... The annular tube 117 is separated, and its connecting wires can be disconnected. Then, the push rod 1192 can be moved. The movement of the push rod 1192 will cause the push block 1193 to move. The movement of the push block 1193 will cause the two springs 1194 to be stretched. When the push block 1193 moves, the two connecting rods 1195 will cause the two locking blocks 1196 to move away from each other. Once the locking blocks 1196 are no longer restricting the high-speed industrial camera 112, they can be removed. During installation, the above operation is repeated. After the high-speed industrial camera 112 is inserted into the through hole of the bracket 111, the push rod 1192 can be released. When the push rod 1192 is released, the restriction on the push block 1193 will be released. At this time, the push block 1193 can be reset under the reset force of the tension spring 1194. After the push block 1193 is reset, the two locking blocks 1196 can be driven to move closer to each other with the cooperation of the two connecting rods 1195. Then the two locking blocks 1196 will be locked into the locking grooves provided on the surface of the high-speed industrial camera 112, thereby realizing the limiting and fixing of it.

[0020] like Figure 5As shown, in some embodiments, two through holes are opened on one side wall of the air box 118, and heat sinks 1111 are fixed inside each hole. Semiconductor cooling chips 1112 are fixed on each heat sink 1111. A speed reduction plate 1113 fixed inside the air box 118 is provided on one side of the two semiconductor cooling chips 1112. There are four speed reduction plates 1113. The speed reduction plates 1113 can extend the air flow time inside the air box 118 so that the gas is cooled more thoroughly. The semiconductor cooling chips 1112 can cool the air entering the air box 118, so that the air blown out by the air blower 116 can become cold air, so as to cool the transparent glass plate 114 on the protective cover 113.

[0021] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An online monitoring system for a laser welding machine, characterized in that: It includes a signal acquisition module (1), a data transmission and preprocessing module (2), an analysis and decision-making module (3), and a human-computer interaction and visualization module (4). The signal acquisition module (1) includes an optical signal acquisition sensor (11), a mechanical signal acquisition sensor (12), a laser parameter acquisition sensor (13), and a weld morphology acquisition sensor (14). The data transmission and preprocessing module (2) includes a data transmission unit (21) connected to the signal acquisition module (1) and a data preprocessing unit (22) that performs noise reduction and format conversion on the raw data output by the data transmission unit (21). The analysis and decision module (3) includes an edge computing unit (31) that receives the output data of the data preprocessing unit (22), an algorithm model library (32) that stores welding quality analysis algorithms, and a quality and status determination unit (33) that makes judgments based on the output results of the edge computing unit (31) and the algorithm model library (32). The human-computer interaction and visualization module (4) includes a monitoring terminal (41) for displaying monitoring data, an alarm unit (42) for issuing abnormal prompts, and a data storage and traceability unit (43) for saving and retrieving historical monitoring information.

2. The online monitoring system for a laser welding machine according to claim 1, characterized in that: The optical signal acquisition sensor (11) includes a bracket (111) fixed to the welding head of a laser welding machine. A high-speed industrial camera (112) is installed inside a through hole in the bracket (111). A limiting component (119) for fixing the high-speed industrial camera (112) is provided on the bracket (111). A protective cover (113) is threaded to the acquisition end of the high-speed industrial camera (112). A transparent glass plate (114) is fixed inside a through hole at the bottom of the protective cover (113). A housing (115) is fixed to the surface of (112). Air blowers (116) are fixed in a ring array on the housing (115). A ring tube (117) is sleeved on the surface of the high-speed industrial camera (112). One end of each air blower (116) is connected and fixed to the ring tube (117). A bellows (118) is fixed to the top of the bracket (111). The two air outlet pipes of the bellows (118) are detachably connected and fixed to the ring tube (117). An exhaust fan (1110) is fixed inside the bellows (118).

3. The online monitoring system for a laser welding machine according to claim 2, characterized in that: The limiting component (119) includes a connecting plate (1191) fixed on a bracket (111). A push rod (1192) slides through the side wall of the connecting plate (1191). A push block (1193) is fixed to one end of the push rod (1192). Two springs (1194) are fixed to one side wall of the push block (1193). The other end of each spring (1194) is fixedly connected to the connecting plate (1191). Two connecting rods (1195) are rotatably connected to one side wall of the push block (1193) via pins. Two locking blocks (1196) adapted to the high-speed industrial camera (112) are slidably connected on the bracket (111). The locking blocks (1196) are locked onto the surface of the high-speed industrial camera (112). The other end of each connecting rod (1195) is rotatably connected to the corresponding locking block (1196) via pins.

4. The online monitoring system for a laser welding machine according to claim 3, characterized in that: The bracket (111) has four T-slots (1197), and the bottom of each of the card blocks (1196) has two T-blocks (1198) that are compatible with the T-slots (1197).

5. The online monitoring system for a laser welding machine according to claim 2, characterized in that: The wind box (118) has two through holes on one side wall, each with a heat sink (1111) fixed inside. Each heat sink (1111) has a semiconductor cooling chip (1112) fixed on it.

6. The online monitoring system for a laser welding machine according to claim 5, characterized in that: Two semiconductor cooling chips (1112) are provided with a speed reduction plate (1113) fixed inside the air box (118) on one side, and the number of speed reduction plates (1113) is four.

7. The online monitoring system for a laser welding machine according to claim 2, characterized in that: The bottom of the bracket (111) is fixed with a positioning block (1114), and the surface of the high-speed industrial camera (112) is fixed with a retaining ring (1115) that is compatible with the positioning block (1114).

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