Welding control method, ultrasonic welding device, and computer-readable storage medium

Abstract

The application provides a welding control method, an ultrasonic welding device and a computer readable storage medium, the method comprising receiving a welding instruction, controlling a welding head to move in a welding direction; when the welding head is controlled to move to a welding position, a pressure sensor is used to detect a pressure value of the welding head in real time; a first pressure value detected by the pressure sensor is obtained, and a second pressure value detected by the pressure sensor is obtained after a preset time period; it is judged whether the difference between the first pressure value and the second pressure value is greater than a first preset value; if yes, the welding head is controlled to stop moving in the welding direction and move to an initial position; when the welding head is controlled to move close to a preset position, the first preset value is positively correlated with a first distance, and the first distance is the distance between the welding head and the preset position. The intelligent welding system can use the method. The application can avoid the ultrasonic welding device from stopping and resetting immediately due to the detection of pressure at the beginning, and ensure normal use during welding.

Description

Technical Field

[0001] This invention relates to the technical field of ultrasonic welding control, specifically to a welding control method, an ultrasonic welding apparatus, and a computer-readable storage medium. Background Technology

[0002] After receiving a welding command, the ultrasonic welding device drives the motor to work and pushes the welding head downward. When the welding head begins to move downward, due to the tiny gap between the welding head and the sensor and the drive end, the tiny gap between the welding head and the sensor and the drive end closes rapidly at the moment of start-up, generating an impact force, which causes the pressure sensor to detect a large pressure.

[0003] After the ultrasonic welding device begins its downward movement, it needs to continuously monitor the pressure of the welding head until it reaches the welding position. This monitoring checks for changes in pressure readings to determine if any foreign objects, such as a worker's hand, have come into contact with the welding head during the downward movement. If a pressure change is detected, the ultrasonic welding device must be stopped immediately to prevent injury to the worker's arm.

[0004] However, as explained above, when the ultrasonic welding device begins to move downwards, an impact force is generated. The pressure sensor detects a pressure value of this impact force, which is greater than the pressure value when the worker's arm touches the welding head. Therefore, when the ultrasonic welding device begins to move, the pressure sensor can also detect this pressure, causing the ultrasonic welding device to stop abruptly and reset, thus preventing the ultrasonic welding device from working properly.

[0005] A current type of fully servo ultrasonic welding machine has a safety protection function. During normal operation, if the pressure sensor reading abnormally increases as the welding head moves onto the workpiece, it indicates that a foreign object, such as the operator's hand, has entered. At this point, the control system immediately activates an emergency stop and reset, and the ultrasonic generator stops working. This effectively prevents injury to the operator's arms or other body parts. However, because this fully servo ultrasonic welding machine automatically stops and resets when it detects an abnormally high pressure sensor reading during the downward movement of the welding head, it would malfunction. Summary of the Invention

[0006] The first objective of this invention is to provide a welding control method that can detect whether a foreign object is touching the welding head when it moves downwards, and ensures that the ultrasonic welding device can work normally.

[0007] A second objective of the present invention is to provide an ultrasonic welding apparatus for implementing the above-described welding control method.

[0008] A third objective of this invention is to provide a computer-readable storage medium that applies the above-described welding control method.

[0009] To achieve the first objective of this invention, the present invention provides a welding control method, which includes: receiving a welding command and controlling a welding head to move in the welding direction; while controlling the welding head to move towards the welding position, using a pressure sensor to detect the pressure value of the welding head in real time; acquiring a first pressure value detected by the pressure sensor, and acquiring a second pressure value detected by the pressure sensor after a preset time period; determining whether the difference between the first pressure value and the second pressure value is greater than a first preset value; if the difference between the first pressure value and the second pressure value is greater than the first preset value, then controlling the welding head to stop moving in the welding direction and controlling the welding head to move towards the initial position; wherein, when controlling the welding head to move closer to the preset position, the first preset value is positively correlated with the magnitude of a first distance, the first distance being the distance between the welding head and the preset position, and the preset position being set between the welding position and the initial position.

[0010] As can be seen from the above scheme, when the welding head moves closer to the preset position, the first preset value decreases as the first distance decreases, meaning the sensitivity of the pressure sensor increases as the first distance decreases. When the ultrasonic welding device is started, the first preset value is at its maximum, and the sensitivity of the pressure sensor is at its minimum. Therefore, when the welding head moves downward, it will not cause an emergency stop due to the pressure generated when the tiny gap closes rapidly. When the welding head reaches the preset position, the first preset value is at its minimum, and the sensitivity of the pressure sensor is at its maximum. If a worker's hand is detected at this point, an emergency stop can be initiated to ensure the worker's safety. When the welding head continues to move downward beyond the preset position, the first preset value remains unchanged, and the sensitivity of the pressure sensor remains at its maximum, ensuring the worker's safety.

[0011] In a further proposed solution, when determining whether the difference between the first pressure value and the second pressure value is greater than the first preset value, the following steps are also performed: determining whether the welding head has reached the preset position; if the welding head has not reached the preset position, the first preset value is adjusted; if the welding head has reached the preset position, the first preset value is not adjusted.

[0012] In a further proposed scheme, the first preset value decreases linearly with the first distance between the welding head and the preset position.

[0013] Therefore, by setting a preset position, the sensitivity of the pressure sensor can be adjusted to the maximum when the welding head reaches the preset position. Since the welding head is closer to the workpiece when it continues to move downward after reaching the preset position, it is more dangerous when the worker touches it. Therefore, the pressure value needs to be detected with the maximum sensitivity to ensure the safety of the worker.

[0014] In a further proposed solution, while acquiring the first pressure value of the welding head, the encoder information of the motor is also acquired, and the third pressure value is calculated. It is then determined whether the third pressure value is equal to the first pressure value. If so, the welding head is controlled to continue moving towards the welding position.

[0015] Therefore, by comparing the encoder information of the motor with the pressure information detected by the pressure sensor, it can be determined whether the pressure sensor is faulty. If an error is found, an alarm needs to be issued to notify the staff to check the ultrasonic welding device to ensure its normal operation.

[0016] In a further embodiment, the step of controlling the welding head to move in the welding direction includes: controlling the welding head to move in the welding direction at a preset speed.

[0017] In a further proposed solution, while controlling the welding head to move towards the welding position, the moving speed of the welding head is obtained; it is determined whether the moving speed is less than the preset speed. If so, the welding head is controlled to stop moving in the welding direction and is then controlled to move back to the initial position.

[0018] Therefore, by determining whether the actual moving speed of the welding head is less than the preset speed, it is possible to ensure that no foreign objects come into contact with the welding head, thereby further ensuring the safety of the workers.

[0019] To achieve the second objective, the ultrasonic welding apparatus provided by the present invention includes a controller, a pressure sensor, a driver, a motor, and a stroke sensor. The controller is connected to the pressure sensor, the driver, and the stroke sensor. The motor is connected to the driver and the stroke sensor. The controller includes a processor and a memory. The memory stores a computer program, and when the computer program is executed by the processor, it implements the above-mentioned welding control method.

[0020] To achieve the third objective, the present invention provides a computer-readable storage medium characterized in that it stores a computer program thereon, which, when executed, implements the above-described welding control method. Attached Figure Description

[0021] Figure 1 This is a system structure block diagram of an embodiment of the ultrasonic welding device of the present invention.

[0022] Figure 2 This is a flowchart of an embodiment of the welding control method of the present invention.

[0023] Figure 3 This is a graph of the first preset value in an embodiment of the welding control method of the present invention.

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0025] The welding control method provided by this invention, upon receiving a welding command, controls the welding head of the ultrasonic welding device to move in the welding direction. It then determines whether the pressure difference detected by the pressure sensor is less than a first preset value. As the welding head moves closer to the preset position, the first preset value becomes smaller and smaller. That is, as the welding head moves closer to the preset position, the sensitivity of the pressure sensor becomes larger and larger. This avoids the impact force generated by the rapid closure of the tiny gap at the moment of startup when the pressure sensor detects the initial movement of the welding head. This ensures the safety of the workers while ensuring the normal operation of ultrasonic welding.

[0026] Example of an ultrasonic welding device:

[0027] See Figure 1 The ultrasonic welding device in this embodiment includes a controller 1, a pressure sensor 2, a driver 3, a motor 5, and a stroke sensor 4. The controller 1 is connected to the pressure sensor 2, the driver 3, and the stroke sensor 4. The motor 5 is connected to both the driver 3 and the stroke sensor 4. The controller 1 outputs commands to control the driver and detects the pressure value of the pressure sensor 2. The driver 3 drives the motor 5, and the stroke sensor 4 detects the stroke and speed of the motor 5 and feeds this information back to the driver 3.

[0028] Controller 1 includes a processor and a memory. The memory stores a computer program, which, when executed by the processor, implements the welding control method of the welding control method embodiment.

[0029] Example of welding control method:

[0030] When workers need to weld parts, they output a welding command to controller 1. (See also...) Figure 2 Controller 1 executes step S1, receiving a welding command and controlling the welding head of the ultrasonic welding device to move in the welding direction. After receiving the welding command, controller 1 can output a welding command to the driver, which controls the motor to rotate, thereby moving the welding head in the welding direction. The initial position is the position of the welding head before startup, and the welding position is the position where the welding head welds the workpiece. The welding head moves from the initial position to the welding position.

[0031] When controlling the welding head to move towards the welding position, step S2 is executed, where a pressure sensor is used to detect the pressure value of the welding head in real time. Specifically, a preset time interval is set, and the pressure value detected by the pressure sensor is acquired every preset time interval while controlling the welding head to move towards the welding position; that is, the first pressure value detected by the pressure sensor is acquired. A second pressure value is acquired after the preset time interval.

[0032] After obtaining the second pressure value detected by the pressure sensor, step S3 is executed to determine whether the difference between the first pressure value and the second pressure value is greater than a first preset value. By determining whether the difference between the first pressure value and the second pressure value is greater than the first preset value, it is determined whether the welding head has come into contact with a foreign object, such as a worker's hand, thereby ensuring the safety of the worker.

[0033] A preset position is set between the welding position and the initial position. When the welding head is controlled to move towards the welding position, it is determined whether the welding head has reached the preset position. If the welding head has not reached the preset position, the first preset value is adjusted. That is, the first preset value is adjusted when the welding head is controlled to move closer to the preset position.

[0034] See Figure 3 When the controller moves the welding head to a preset position, the first preset value is positively correlated with the magnitude of the first distance, which is the distance between the welding head and the preset position. The first preset value decreases as the first distance decreases, meaning the sensitivity of the pressure sensor increases as the first distance decreases. The first preset value decreases linearly with the first distance between the welding head and the preset position.

[0035] When the welding head reaches the preset position, i.e., when the controller determines that the welding head has reached the preset position, the first preset value is not adjusted, i.e., it is not decreased. At this time, the sensitivity of the pressure sensor is adjusted to the maximum. For example, the first preset value at the initial position can be set to 100 N, and after linear reduction, when the welding head reaches the preset position, the first preset value can be 1 N. The preset position can be one-third of the distance from the initial position to the welding position; that is, if the distance from the initial position to the welding position is 10 mm, the preset position is 3 mm away from the initial position. Setting the preset position ensures that the controller maintains maximum sensitivity during the process from the preset position to the welding position, ensuring the safety of the operator.

[0036] As the welding head continues to move in the welding direction, the first preset value at the preset position is used as the judgment criterion for step S3. When the welding head reaches the preset position, the first preset value is at its minimum, and the pressure sensor is at its maximum sensitivity. If a worker's hand is detected at this point, the sensor can be stopped immediately to ensure worker safety. When the welding head moves downward beyond the preset position, the first preset value remains unchanged, and the pressure sensor's sensitivity remains at its maximum, ensuring worker safety.

[0037] In step S3, if the difference between the first pressure value and the second pressure value is greater than the first preset value, it indicates that the welding head has come into contact with a foreign object, such as a worker's hand. Step S5 is executed, controlling the welding head to stop moving in the welding direction and moving it back to its initial position to prevent the welding head from pressing on the worker's hand and ensure worker safety. If the difference between the first pressure value and the second pressure value in step S3 is less than the first preset value, step S4 is executed, controlling the welding head to continue moving towards the welding position until the welding head contacts the workpiece.

[0038] While acquiring the first pressure value of the welding head, the encoder information of the motor is obtained through the driver to calculate the third pressure value. It is then determined whether the third pressure value equals the first pressure value; if so, the welding head continues to move towards the welding position. The encoder information of the motor is compared with the pressure information detected by the pressure sensor to determine if the pressure sensor is malfunctioning, thus ensuring the normal operation of the ultrasonic welding device.

[0039] When controlling the welding head to move towards the welding position, the movement speed of the welding head is obtained through a stroke sensor. It is then determined whether the movement speed is less than a preset speed. If the movement speed is less than the preset speed, it indicates that the welding head has come into contact with a foreign object. The welding head is then stopped moving in the welding direction and moved back to the initial position to ensure operator safety. By comparing the movement speed with the initial speed, it is ensured whether a foreign object has come into contact with the welding head. This, combined with the pressure value detected by the pressure sensor, further ensures the safety of the operator.

[0040] When the welding head reaches the welding position, it no longer checks whether the difference between the first pressure value and the second pressure value is greater than the first preset value, thus avoiding emergency stop and reset during welding.

[0041] As the welding head moves closer to the preset position, the first preset value decreases as the first distance decreases, meaning the sensitivity of the pressure sensor increases as the first distance decreases. When the ultrasonic welding device is started, the first preset value is at its maximum, and the pressure sensor's sensitivity is at its minimum. Therefore, when the welding head moves downwards, it will not cause an emergency stop due to the pressure generated by the rapid closing of the tiny gap. When the welding head reaches the preset position, the first preset value is at its minimum, and the pressure sensor's sensitivity is at its maximum. If a worker's hand is detected at this point, an emergency stop can be initiated to ensure worker safety. When the welding head continues to move downwards beyond the preset position, the first preset value remains unchanged, and the pressure sensor's sensitivity remains at its maximum, ensuring worker safety.

[0042] If the ultrasonic welding device is installed in the intelligent welding system, the intelligent welding system can use the welding control method of this embodiment.

[0043] Examples of computer-readable storage media:

[0044] The welding control method in the computer device described in the above embodiments can be stored as a computer program in a computer-readable storage medium. When the computer program is executed by a processor, it can complete the steps of the welding control method embodiments in the ultrasonic welding apparatus described above. The computer-readable medium can be a computer-readable signal medium or a computer-readable storage medium. The computer-readable storage medium can be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples of computer-readable storage media (a non-exhaustive list) include: an electrical connection having one or more wires, a portable computer disk, a hard disk, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage device, magnetic storage device, or any suitable combination thereof.

[0045] The above are merely preferred embodiments of the present invention, but the design concept of the invention is not limited thereto. Without departing from the concept of the present invention, many other equivalent embodiments may be included. Those skilled in the art can make various obvious changes, readjustments and substitutions without departing from the protection scope of the present invention.

Claims

1. A welding control method, which includes: Receive welding instructions and control the welding head to move in the welding direction; When controlling the welding head to move downwards towards the welding position, a pressure sensor is used to detect the pressure value of the welding head in real time; Its features are: Acquire a first pressure value detected by the pressure sensor, and acquire a second pressure value detected by the pressure sensor after a preset time period; Determine whether the difference between the first pressure value and the second pressure value is greater than a first preset value. If the difference between the first pressure value and the second pressure value is greater than the first preset value, control the welding head to stop moving in the welding direction and control the welding head to move in the initial position direction. Wherein, when controlling the welding head to move closer to the preset position, the first preset value is positively correlated with the magnitude of the first distance, and the first distance is the distance between the welding head and the preset position; The preset position is set between the welding position and the initial position; When determining whether the difference between the first pressure value and the second pressure value is greater than a first preset value, the following is also executed: Determine whether the welding head has reached the preset position; if the welding head has not reached the preset position, adjust the first preset value. If the welding head reaches the preset position, the first preset value will not be adjusted. The first preset value decreases linearly with the first distance between the welding head and the preset position.

2. The welding control method according to claim 1, characterized in that: While acquiring the first pressure value of the welding head, the encoder information of the motor is also acquired, and the third pressure value is calculated. Determine whether the third pressure value is equal to the first pressure value. If so, continue to control the welding head to move towards the welding position.

3. The welding control method according to claim 1, characterized in that: The steps of controlling the movement of the welding head in the welding direction include: The welding head is controlled to move in the welding direction at a preset speed.

4. The welding control method according to claim 3, characterized in that: The moving speed of the welding head is obtained when the welding head is controlled to move towards the welding position; Determine whether the moving speed is less than the preset speed. If so, control the welding head to stop moving in the welding direction and control the welding head to move back to the initial position.

5. An ultrasonic welding apparatus, comprising a controller, a pressure sensor, a driver, a motor, and a stroke sensor, wherein the controller is connected to the pressure sensor, the driver is connected to the driver, the driver is connected to the stroke sensor, the motor is connected to the driver, and the motor is connected to the stroke sensor; Its features are, The controller includes a processor and a memory, the memory storing a computer program that, when executed by the processor, implements the welding control method according to any one of claims 1 to 4.

6. A computer-readable storage medium, characterized in that, It stores a computer program, which, when executed, implements the welding control method according to any one of claims 1 to 4.

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