Intelligent galvanometer correction method and system based on deflection error compensation

Abstract

The invention discloses an intelligent galvanometer correction method and system based on deflection error compensation, and relates to the technical field of intelligent galvanometer correction, and the method comprises the steps: obtaining calibration data of a galvanometer scanning region, dividing the calibration data into a galvanometer region library containing different deflection angle sections, and enabling the calibration data to comprise straight line, circular arc and curve calibration graphs; extracting an initial deflection error of each section according to the calibration data to obtain a deflection error parameter group; position data of a welding seam formed in the actual welding process is obtained, the forming offset and direction are extracted, a welding seam offset information set is formed, and the comprehensive correction value of each section is obtained in combination with the deflection error parameter set; a to-be-executed welding track is obtained, deflection compensation is conducted on the basis of the comprehensive correction value, and a complete welding track instruction is generated; and residual deviation is evaluated, the comprehensive correction value is updated in a self-adaptive mode, a final correction instruction is generated, high-precision welding track compensation is achieved, and the welding seam forming precision and the welding efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mirror intelligent correction, in particular to a mirror intelligent correction method and system based on deflection error compensation. BACKGROUND

[0002] The mirror intelligent correction method and system aims to improve the precision of mirror trajectory control and the quality of weld formation in welding operation. In the context of growing demand for high-precision welding and increasing requirement for production efficiency, traditional manual adjustment or fixed compensation methods cannot meet the requirements of real-time correction and high-precision welding. By analyzing and compensating the calibration data of the mirror scanning area, the weld position and the deflection error, accurate correction of each deflection angle section can be achieved, reducing weld offset and improving welding trajectory precision, and providing a reliable correction scheme for high-precision welding operation. The application of this method helps to improve welding quality and efficiency, and has important significance for stable operation of precision manufacturing and industrial production.

[0003] However, the compensation effect of the existing mirror system is inconsistent at different deflection angle sections, and traditional manual adjustment or fixed compensation methods cannot effectively cope with dynamic deflection errors in the welding process, which may result in insufficient correction or overcompensation in some sections, leading to incomplete elimination of weld trajectory errors, uneven weld formation, and unguaranteed welding precision and efficiency. Therefore, a mirror intelligent correction method and system based on deflection error compensation are needed to solve the above problems and achieve high-precision correction of each deflection angle section, improving the precision and efficiency of weld formation. SUMMARY

[0004] To solve the above technical problems, a mirror intelligent correction method and system based on deflection error compensation are provided, which solves the problem of inconsistent compensation effect of the existing mirror system at different deflection angle sections, and the problem that traditional manual adjustment or fixed compensation methods cannot effectively cope with dynamic deflection errors in the welding process, which may result in insufficient correction or overcompensation in some sections, leading to incomplete elimination of weld trajectory errors, uneven weld formation, and unguaranteed welding precision and efficiency.

[0005] To achieve the above purposes, the technical solution adopted by the present application is as follows: A mirror intelligent correction method based on deflection error compensation, comprising: Obtaining calibration data of a mirror scanning area, dividing the mirror scanning area to obtain a mirror area library containing different deflection angle sections, the calibration data including straight line calibration patterns, circular arc calibration patterns and curve calibration patterns; Extracting the initial deflection error of the mirror at each deflection angle section according to the calibration data to obtain a deflection error parameter group containing a static offset term, a dynamic response term and a curvature distortion term; Obtain the welding seam position data formed in the actual welding process by the galvanometer area library, and extract the welding seam forming offset and offset direction from the welding seam position data to obtain a welding seam offset information set, and then combine the deflection error parameter group to obtain the comprehensive correction amount of each deflection angle section; Obtain the welding trajectory of the welding process to be executed, and perform deflection compensation on the welding trajectory based on the comprehensive correction amount to generate an initial welding trajectory instruction; Based on the initial welding trajectory instruction, obtain the residual deviation, and evaluate the residual deviation, and then adaptively update the comprehensive correction amount according to the evaluation result to generate a final correction instruction for controlling the galvanometer to execute the welding operation.

[0006] In an optional embodiment, the method comprises obtaining calibration data of the galvanometer scanning area, and dividing the galvanometer scanning area to obtain a galvanometer area library containing different deflection angle sections, specifically comprising: Perform a preset scanning path by the galvanometer to obtain a scanning result; Obtain calibration data from the scanning result, wherein the calibration data includes straight line calibration patterns, circular arc calibration patterns, and curve calibration patterns; Extract the deflection angles of each scanning point based on the calibration data to form a deflection angle feature set of the galvanometer scanning area; Sort the deflection angles in the deflection angle feature set to obtain the angle difference values between adjacent deflection angles; According to the deflection angle feature set, obtain the minimum deflection angle value and the maximum deflection angle value of the galvanometer scanning area to determine the deflection angle coverage range of the galvanometer scanning area; Within the deflection angle coverage range, obtain the angle difference values between adjacent deflection angles, compare the adjacent angle difference values according to a preset angle difference threshold, and divide the scanning area into a sub-region with an angle difference value lower than the preset angle difference threshold and a sub-region with an angle difference value higher than the preset angle difference threshold; Based on the angle difference values between adjacent deflection angles in the sub-regions obtained by the division, divide the scanning area into multiple continuous secondary deflection intervals from the minimum deflection angle; Divide the galvanometer scanning area into multiple secondary division galvanometer areas using the secondary deflection intervals, and generate a unique identifier for each secondary division galvanometer area to establish a secondary division galvanometer area library; According to the angle difference values between adjacent deflection angles in each secondary division galvanometer area in the secondary division galvanometer area library, merge the secondary division galvanometer areas with continuous angle difference values between adjacent deflection angles and stable change amplitudes to obtain merged galvanometer areas; Based on the merged galvanometer areas, subdivide the secondary division galvanometer areas with sudden changes in the angle difference values between adjacent deflection angles to obtain subdivided galvanometer areas; Based on the subdivided galvanometer region, a plurality of deflection angle sections are formed, each section corresponding to a range of galvanometer deflection angles, and a galvanometer region library is established.

[0007] In an optional embodiment, the initial deflection error of the galvanometer at each deflection angle section is extracted from the calibration data to obtain a deflection error parameter group containing a static offset term, a dynamic response term and a curvature distortion term, specifically including: The straight line calibration pattern in the calibration data is fitted to obtain the spatial offset between the theoretical trajectory and the actual scanning trajectory of the straight line calibration pattern, and the spatial offset is counted within the corresponding deflection angle section to form the initial deflection error of the straight line calibration pattern as the static offset term of the corresponding deflection angle section; The arc calibration pattern in the calibration data is analyzed to extract the trajectory response deviation of the galvanometer under different scanning speeds and accelerations, and the correlation between the trajectory response deviation and the deflection angle is established within the corresponding deflection angle section to form the initial deflection error of the arc calibration pattern as the dynamic response term of the corresponding deflection angle section; The curvature of the curve calibration pattern in the calibration data is analyzed to obtain the curvature difference between the actual scanning curve and the theoretical curve, and the curvature difference is mapped to the corresponding deflection angle section to form the initial deflection error of the curve calibration pattern as the curvature distortion term of the corresponding deflection angle section; The initial deflection errors of the straight line calibration pattern, the arc calibration pattern and the curve calibration pattern are combined according to the deflection angle section to obtain the deflection error parameter group containing the static offset term, the dynamic response term and the curvature distortion term.

[0008] In an optional embodiment, the galvanometer region library is obtained in the actual welding process to form the weld position data, and the weld forming offset and the offset direction are extracted from the weld position data to obtain a weld offset information set, and then combined with the deflection error parameter group to obtain the comprehensive correction amount of each deflection angle section, specifically including: The galvanometer corresponding to the galvanometer region library is obtained in the actual welding process to form the weld position data, and the weld position data includes the actual forming trajectory of the weld and the expected welding trajectory corresponding thereto; Based on the weld position data, the actual forming trajectory of the weld and the expected welding trajectory are compared in position to obtain the spatial difference value of the two at the corresponding position to form the forming offset of the weld; According to the offset direction of the actual forming position of the weld relative to the target position of the welding trajectory, the offset direction of each forming offset is determined; Based on the deflection angle of the galvanometer at each scanning point, the forming offset and its offset direction are divided into the deflection angle section determined by the deflection angle; The forming offset and its offset direction that fall into the same deflection angle segment are collected to form a weld offset information set. Based on the weld offset information set, multiple forming offsets within the same deflection angle segment are obtained; The forming offset within the same deflection angle segment is statistically processed, and the offset located at the center of the forming offset distribution in that deflection angle segment is extracted as the representative offset of that deflection angle segment. By comparing each forming offset within the same deflection angle segment with a representative offset, a set of offset differences of each forming offset relative to the overall offset trend is obtained. The representative offset is determined as the steady-state offset component, and each offset difference in the offset difference set is determined as the dynamic offset component; Based on the steady-state offset components of each deflection angle segment, the steady-state offset components are assigned to the static offset terms of the corresponding deflection angle segments to obtain the corrected static offset terms. Based on the dynamic offset components of each deflection angle segment, the dynamic offset components are assigned to the dynamic response terms of the corresponding deflection angle segments to obtain the corrected dynamic response terms. Based on the actual forming trajectory of the weld, the actual spatial curve of the weld at each scanning point is extracted, and the curvature at each scanning point is calculated to obtain a weld trajectory curvature sequence covering the entire weld trajectory. The weld trajectory curvature sequence is divided into deflection angle segments according to the deflection angle corresponding to the scanning point. For the curvature sequence in each deflection angle segment, the local least squares method is applied to fit the curvature change trend to obtain the curvature distortion correction amount for each deflection angle segment. The curvature distortion term for the corresponding deflection angle segment is numerically superimposed or subtracted based on the curvature distortion correction amount to obtain the corrected curvature distortion term. The static offset term, dynamic response term, and curvature distortion term are combined and standardized to obtain the comprehensive correction amount corresponding to each deflection angle segment. The formula for calculating the comprehensive correction amount is as follows: In the formula, For the first The comprehensive correction amount corresponding to each deflection angle segment Index of deflection error components, These are represented as static offset, dynamic response, and curvature distortion terms, respectively. For the first Within the deflection angle segment, the first The standardized values ​​of the deflection error components.

[0009] In an optional embodiment, the step of acquiring the welding trajectory of the welding process to be performed, and performing deflection compensation on the welding trajectory based on the comprehensive correction amount to generate an initial welding trajectory instruction specifically includes: Obtain the welding trajectory of the welding process to be executed, and for each trajectory point in the welding trajectory, obtain its original target position; Based on the target position coordinates of each scanning point in the welding trajectory, determine the corresponding deflection angle segment and retrieve the comprehensive correction amount corresponding to the deflection angle segment. Based on the comprehensive correction amount corresponding to the deflection angle segment, the target position coordinates of the scanning point are corrected for position offset to obtain the deflection compensation trajectory point coordinates of the scanning point. The coordinates of the trajectory points after deflection compensation are arranged sequentially according to the welding order to form a complete compensated welding trajectory. The compensated welding trajectory is smoothed and interpolated to generate an initial welding trajectory command that can be executed by the galvanometer.

[0010] In an optional embodiment, the process of obtaining residual deviations based on initial welding trajectory commands, evaluating these residual deviations, and then adaptively updating the comprehensive correction amount based on the evaluation results to generate final correction commands for controlling the galvanometer to perform welding operations specifically includes: Based on the initial welding trajectory command, the actual weld trajectory data collected during the welding operation performed by the galvanometer is obtained to obtain the actual weld trajectory; The actual weld trajectory is compared with the compensated weld trajectory to obtain the spatial deviation corresponding to each scanning point. The spatial deviation of each scanning point is used as the residual deviation to obtain the residual deviation set; The residual deviation set is classified according to the deflection angle segment to obtain the residual deviation subset corresponding to each deflection angle segment; Statistical processing is performed on the residual deviation subset of each deflection angle segment to obtain the average residual deviation, maximum residual deviation, and deviation distribution, thus forming the residual deviation characteristics of each deflection angle segment. Based on the residual deviation characteristics of each deflection angle segment, the compensation effect of the segment is evaluated, and the compensation evaluation results of each deflection angle segment are obtained. Based on the compensation assessment results, the comprehensive correction items that need to be updated are determined, and the correction item identifier to be updated is obtained; Based on the calibration value identifier to be updated, an updated comprehensive calibration value is generated; Based on the updated integrated correction values, the final correction command for the galvanometer is generated.

[0011] Furthermore, a galvanometer intelligent correction system based on deflection error compensation is proposed to implement the galvanometer intelligent correction method as described above, characterized in that it includes: The data acquisition module is used to acquire the actual deflection angle of the galvanometer and the actual weld trajectory data. The calibration data management module is used to store calibration data of the galvanometer scanning area, including straight line calibration graphics, circular arc calibration graphics and curve calibration graphics, and to provide the required calibration data to the calibration calculation module; The correction calculation module is used to extract deflection error parameters based on calibration data, generate comprehensive correction amounts for each deflection angle segment by combining weld offset information, and adaptively update the sub-correction amounts based on residual deviation. The residual deviation assessment module is used to assess the residual deviation of each deflection angle segment based on the compensation welding trajectory command and the actual weld trajectory data, and generate the compensation assessment result. The trajectory generation module is used to perform deflection compensation on the welding trajectory to be executed based on the comprehensive correction amount, and generate the compensated welding trajectory command.

[0012] In an optional embodiment, the data acquisition module includes: A deflection angle acquisition unit is used to acquire the actual deflection angle of the galvanometer during the scanning and welding process; A weld trajectory acquisition unit is used to acquire weld trajectory data formed by the galvanometer during the actual welding process, including the actual weld formation position and the corresponding expected welding trajectory.

[0013] In an optional embodiment, the correction calculation module includes: A deflection error extraction unit is used to extract the initial deflection error of each deflection angle segment based on the straight line calibration pattern, the circular arc calibration pattern and the curve calibration pattern, and to form a deflection error parameter set. A weld offset analysis unit is used to compare the actual weld trajectory data with the expected welding trajectory, extract the weld forming offset amount and offset direction, and form a weld offset information set. The comprehensive correction quantity generation unit is used to combine the deflection error parameter set and the weld offset information set to calculate the comprehensive correction quantity for each deflection angle segment, and to adaptively update the comprehensive correction quantity.

[0014] In an optional embodiment, the trajectory generation module includes: A deflection compensation trajectory generation unit is used to perform deflection compensation on the welding trajectory to be executed based on a comprehensive correction amount, and generate welding trajectory points after deflection compensation. The welding trajectory smoothing and interpolation unit is used to smooth and interpolate the welding trajectory points after deflection compensation to generate a complete welding trajectory command that can be executed by the galvanometer.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This paper proposes a galvanometer intelligent correction method and system based on deflection error compensation. By acquiring calibration data of the galvanometer scanning area, extracting the initial deflection error for each deflection angle segment, and combining this with actual weld trajectory offset information, a comprehensive correction amount for each deflection angle segment is generated, achieving real-time deflection compensation for the welding trajectory to be executed. Simultaneously, the system evaluates residual deviations based on the compensated welding trajectory and adaptively updates the comprehensive correction amount. This enables high-precision welding trajectory compensation within different deflection angle segments, significantly improving weld formation accuracy and welding efficiency, reducing welding errors, and ensuring the stability and reliability of the welding process. Attached Figure Description

[0016] Figure 1 This is a flowchart of a galvanometer intelligent correction method based on deflection error compensation proposed in this invention; Figure 2 This is a flowchart of the deflection error extraction and correction calculation in this invention; Figure 3 This is a flowchart of trajectory deflection compensation and residual update in this invention; Figure 4 This is a system framework diagram of a galvanometer intelligent correction system based on deflection error compensation proposed in this invention. Detailed Implementation

[0017] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0018] Reference Figure 1 - Figure 4 As shown, an embodiment of the present invention provides a galvanometer intelligent correction method based on deflection error compensation, comprising: The calibration data of the galvanometer scanning area is obtained, and the galvanometer scanning area is divided to obtain a galvanometer area library containing different deflection angle segments. The calibration data includes straight line calibration graphics, circular arc calibration graphics and curve calibration graphics. The initial deflection error of the galvanometer in each deflection angle segment is extracted based on the calibration data, and a deflection error parameter set including static offset term, dynamic response term and curvature distortion term is obtained. The weld position data formed by the galvanometer region library during the actual welding process is obtained, and the weld forming offset and offset direction are extracted from the weld position data to obtain the weld offset information set. Then, combined with the deflection error parameter set, the comprehensive correction amount of each deflection angle segment is obtained. The welding trajectory of the welding process to be executed is obtained, and the deflection compensation of the welding trajectory is performed based on the comprehensive correction amount to generate the initial welding trajectory command; The residual deviation is obtained based on the initial welding trajectory command, and the residual deviation is evaluated. Then, the comprehensive correction amount is adaptively updated according to the evaluation results to generate the final correction command for controlling the galvanometer to perform the welding operation.

[0019] Specifically, during scanning and welding, the deflection angle of the galvanometer is acquired in real time by an angle sensor built into the galvanometer. The acquired deflection angle is recorded synchronously with the corresponding scanning point position to form deflection angle data for each scanning point. During calibration, the galvanometer sequentially scans the straight line calibration pattern, the circular arc calibration pattern, and the curve calibration pattern according to a preset calibration path. A vision inspection system or laser position detection system configured at the welding head is used to acquire the actual scanning trajectory and record the acquired actual scanning trajectory with the corresponding theoretical calibration trajectory to obtain calibration data for deflection error extraction. During actual welding, the actual forming trajectory of the weld is acquired in real time by a vision tracking system or laser tracking system in the welding area and correlated with the welding trajectory obtained from the welding process planning to extract the weld forming offset and its offset direction. The welding trajectory is generated by welding process parameters and stored in the form of a trajectory point sequence. Each trajectory point corresponds to the target spatial position and the corresponding galvanometer deflection angle, providing basic data for subsequent deflection compensation, residual deviation evaluation, and adaptive updates of the comprehensive correction amount.

[0020] Furthermore, calibration data of the galvanometer scanning area is obtained, and the galvanometer scanning area is divided to obtain a galvanometer region library containing different deflection angle segments, specifically including: The scanning results are obtained by executing a preset scanning path using a galvanometer; The calibration data is obtained based on the scanning results. The calibration data includes straight line calibration graphs, circular arc calibration graphs, and curve calibration graphs. Specifically, by controlling the galvanometer to execute a preset scanning path, different types of calibration patterns are acquired sequentially, including straight line calibration patterns, circular arc calibration patterns, and curve calibration patterns. Straight line calibration patterns are used to obtain the linear scanning accuracy of the galvanometer at various deflection angles; the actual scanning trajectory is obtained by scanning multiple straight lines of known length and direction. Circular arc calibration patterns are used to extract the dynamic response characteristics of the galvanometer under different speeds and accelerations; the deviation between the actual scanning trajectory and the theoretical trajectory is obtained by scanning circular arc trajectories of different radii. Curve calibration patterns are used to analyze the curvature distortion of the galvanometer; the curvature information of the actual scanning trajectory is obtained by scanning a free curve with continuously changing curvature.

[0021] Based on the calibration data, the deflection angle of each scanning point is extracted to form a set of deflection angle features of the galvanometer scanning area; The deflection angles in the deflection angle feature set are sorted to obtain the angle difference between adjacent deflection angles; Specifically, the deflection angles of each scanning point in the galvanometer scanning area are sorted in ascending order. First, all the deflection angles of the scanning points are arranged from smallest to largest to form an ordered sequence. In this sequence, the deflection angles of adjacent scanning points form an adjacent relationship, which is used to calculate the angle difference between each pair of adjacent deflection angles. For example, assuming the deflection angles in a certain scanning area are 5°, 2°, 8°, and 3°, the sorted result is an ordered sequence of 2°, 3°, 5°, 8°, with adjacent angle differences of 1°, 2°, and 3° respectively. These differences will be used to divide the scanning area into different deflection segments.

[0022] Based on the deflection angle feature set, the minimum and maximum deflection angle values ​​of the galvanometer scanning area are obtained, and the deflection angle coverage range of the galvanometer scanning area is determined. Within the deflection angle coverage area, the angle difference between adjacent deflection angles is obtained. The adjacent angle differences are compared according to a preset angle difference threshold, and the scanning area is divided into sub-regions with angle differences lower than the preset angle difference threshold and sub-regions with angle differences higher than the preset angle difference threshold. Based on the angle difference between adjacent deflection angles within the divided sub-regions, the scanning region is divided into multiple consecutive secondary deflection intervals starting from the minimum deflection angle. Using the secondary deflection interval, the galvanometer scanning area is divided into multiple secondary galvanometer regions, and a unique identifier is generated for each secondary galvanometer region to establish a secondary galvanometer region library. Understandably, within the deflection angle coverage area, the deflection angle difference between adjacent scan points is calculated and compared with a preset angle difference threshold. When the angle difference is less than the preset threshold, the galvanometer deflection change in that area is considered stable, and consecutive scan points are assigned to the same sub-region. When the angle difference is greater than the preset threshold, the deflection change in that area is considered abrupt, and the corresponding scan point is assigned to a new sub-region. For the deflection angle difference within each sub-region, continuous division is performed starting from the minimum deflection angle, further dividing the scan area into multiple secondary deflection intervals. Each secondary interval ensures that the internal deflection angle change is uniform and continuous. Through the secondary deflection intervals, the scan area is divided into multiple secondary galvanometer regions, each containing several consecutive scan points, and each region is assigned a unique number as an identifier. These numbers and their corresponding deflection angle ranges are recorded in the secondary galvanometer region library for easy retrieval and matching of the deflection angle segment to which each scan point belongs.

[0023] Based on the angle difference between adjacent deflection angles in each secondary division galvanometer region in the secondary division galvanometer region library, the secondary division galvanometer regions with continuous angle differences between adjacent deflection angles and stable variation amplitudes are merged to obtain the merged galvanometer region. Based on the merged galvanometer region, the secondary galvanometer region where the angle difference between adjacent deflection angles changes abruptly is further subdivided to obtain the subdivided galvanometer region. Based on the subdivided galvanometer regions, multiple deflection angle segments are formed, and each segment corresponds to a range of galvanometer deflection angles, thus establishing a galvanometer region library.

[0024] Specifically, adjacent secondary galvanometer regions are compared sequentially. If the angular difference between adjacent deflection angles is in the same direction, and the deflection angle differences of several consecutive scan points are all positive or all negative, the trend is considered continuous. Furthermore, if the absolute change in the angular difference between adjacent angles within this continuous trend does not exceed one-tenth of the angular difference of the previous scan point, the change is considered stable. These secondary regions are then merged into a new galvanometer region, and the starting and ending deflection angles of this region are updated, while retaining a unique identifier for subsequent reference. Within the merged galvanometer region, if the absolute change in the angular difference between adjacent deflection angles at a certain scan point is significantly larger than the average change of the preceding and following points, exceeding twice the continuous trend change, a sudden change is considered. This abnormal scan point is then separately classified into a new galvanometer region, ensuring that the deflection angle direction within each region is consistent and the change is stable. After merging and subdivision, all galvanometer regions are arranged in order of deflection angle, and the starting and ending deflection angles and unique identifier of each region are recorded, ultimately forming a complete galvanometer region library, providing basic data for subsequent deflection error extraction and comprehensive correction calculation.

[0025] Furthermore, based on the calibration data, the initial deflection error of the galvanometer in each deflection angle segment is extracted, resulting in a deflection error parameter set including static offset, dynamic response, and curvature distortion terms, specifically including: Fit the straight line calibration graph in the calibration data to obtain the spatial offset between the theoretical trajectory and the actual scanning trajectory of the straight line calibration graph. Statistically calculate the spatial offset within the corresponding deflection angle segment to form the initial deflection error of the straight line calibration graph, which serves as the static offset term for the corresponding deflection angle segment. The circular arc calibration pattern in the calibration data is analyzed, the trajectory response deviation of the galvanometer under different scanning speed and acceleration conditions is extracted, and the correlation between the trajectory response deviation and the deflection angle is established in the corresponding deflection angle segment to form the initial deflection error of the circular arc calibration pattern, which serves as the dynamic response term of the corresponding deflection angle segment. Curvature analysis is performed on the curve calibration graph in the calibration data to obtain the curvature difference between the actual scan curve and the theoretical curve. The curvature difference is then mapped to the corresponding deflection angle segment to form the initial deflection error of the curve calibration graph, which serves as the curvature distortion term for the corresponding deflection angle segment. The initial deflection errors corresponding to the straight line calibration pattern, circular arc calibration pattern, and curve calibration pattern are combined according to the deflection angle segment to obtain a deflection error parameter set including static offset term, dynamic response term, and curvature distortion term.

[0026] Specifically, in this embodiment, the calibration data for straight lines, circular arcs, and curves are processed separately to extract the initial deflection error for each deflection angle segment. For the straight line calibration pattern, multiple straight lines of known length and direction are fitted, and the theoretical trajectory is compared with the actual scanning trajectory of the galvanometer to calculate the spatial offset of each scanning point. For example, when scanning a horizontal straight line 50 mm long, if the actual scanning trajectory deviates by 0.1 mm relative to the theoretical trajectory in the X direction, this offset is recorded in the corresponding deflection angle segment, and the offsets of all scanning points within the segment are statistically analyzed to obtain the initial deflection error of the straight line calibration pattern, which is used as the static offset term for that deflection angle segment.

[0027] For circular arc calibration patterns, the relationship between deflection angle and trajectory deviation is established by analyzing the trajectory response deviation of the galvanometer under different scanning speeds and acceleration conditions. For example, when scanning a circular arc with a radius of 30 mm, if the actual scanning point of the arc shifts towards the center by 0.05 mm when the angular velocity increases, and by 0.08 mm when decelerating, these trajectory response deviations are mapped to the corresponding deflection angle segments, forming the initial deflection error of the circular arc calibration pattern, which serves as the dynamic response term.

[0028] For curve calibration graphics, the curvature difference is calculated by analyzing the curvature of the actual scanned curve and the theoretical curve. For example, when scanning an S-shaped curve with continuously changing curvature, the actual curvature at a certain deflection angle is 0.02 mm. -1 The theoretical curvature is 0.018mm. -1 The curvature difference is 0.002 mm. -1 The curvature difference is mapped to the corresponding deflection angle segment to obtain the initial deflection error of the curve calibration graph, which serves as the curvature distortion term. Through the above three types of calibration graph processing, a deflection error parameter set containing static offset, dynamic response, and curvature distortion terms can be formed, providing basic data for subsequent weld offset analysis and comprehensive correction quantity generation.

[0029] Furthermore, the weld position data formed during the actual welding process is obtained from the galvanometer region library, and the weld formation offset and offset direction are extracted from the weld position data to obtain the weld offset information set. Then, combined with the deflection error parameter set, the comprehensive correction amount for each deflection angle segment is obtained, specifically including: Acquire the weld position data formed by the galvanometer corresponding to the galvanometer region library during the actual welding process. The weld position data includes the actual weld formation trajectory and its corresponding expected welding trajectory. Based on the weld position data, the actual weld formation trajectory and the expected welding trajectory are compared to obtain the spatial difference between the two at the corresponding positions, which forms the weld formation offset. The offset direction of each forming offset is determined based on the offset direction of the actual weld formation position relative to the target position of the welding trajectory; Based on the deflection angle of the galvanometer at each scanning point, the forming offset and its offset direction are classified into the deflection angle segment determined by the deflection angle. The forming offset and its offset direction that fall into the same deflection angle segment are collected to form a weld offset information set. Specifically, the process involves acquiring weld position data formed by the galvanometer during the actual welding process. This data includes both the actual weld formation trajectory and the corresponding expected welding trajectory. The actual and expected welding trajectories at corresponding positions within the same welding trajectory are aligned and compared point-by-point to determine their spatial differences. This determines the weld formation offset at each scanning point, reflecting the positional deviation of the actual weld formation position relative to the target trajectory. After obtaining the offset, the direction of each offset is determined based on the direction of the actual weld formation position relative to the expected welding trajectory, distinguishing between weld offsets to one side or the other. Combining this with the galvanometer deflection angle corresponding to each scanning point, the offset and its direction are categorized into a deflection angle segment determined by that angle. Multiple offsets and their directions categorized into the same deflection angle segment are then centrally organized to form a weld offset information set for that deflection angle segment, reflecting the overall distribution characteristics of the weld formation offset within that segment.

[0030] Based on the weld offset information set, multiple forming offsets within the same deflection angle segment are obtained; The forming offset within the same deflection angle segment is statistically processed, and the offset located at the center of the forming offset distribution in that deflection angle segment is extracted as the representative offset of that deflection angle segment. By comparing each forming offset within the same deflection angle segment with a representative offset, a set of offset differences of each forming offset relative to the overall offset trend is obtained. The representative offset is determined as the steady-state offset component, and each offset difference in the offset difference set is determined as the dynamic offset component; Based on the steady-state offset components of each deflection angle segment, the steady-state offset components are assigned to the static offset terms of the corresponding deflection angle segments to obtain the corrected static offset terms. Based on the dynamic offset components of each deflection angle segment, the dynamic offset components are assigned to the dynamic response terms of the corresponding deflection angle segments to obtain the corrected dynamic response terms. Based on the actual forming trajectory of the weld, the actual spatial curve of the weld at each scanning point is extracted, and the curvature at each scanning point is calculated to obtain a weld trajectory curvature sequence covering the entire weld trajectory. The weld trajectory curvature sequence is divided into deflection angle segments according to the deflection angle corresponding to the scanning point. For the curvature sequence in each deflection angle segment, the local least squares method is applied to fit the curvature change trend to obtain the curvature distortion correction amount for each deflection angle segment. The curvature distortion term for the corresponding deflection angle segment is numerically superimposed or subtracted based on the curvature distortion correction amount to obtain the corrected curvature distortion term. Specifically, for multiple forming offsets collected within the same deflection angle segment, these forming offsets are first statistically analyzed to determine their distribution within that segment. The offset value located at the center of the distribution is then selected as the representative offset for that segment, reflecting the overall level of weld forming offset within that segment. Subsequently, each forming offset within the segment is compared one by one with the representative offset to obtain the difference between each offset and the overall offset level. The representative offset reflects a stable overall offset trend, while the differences reflect local fluctuations around this overall trend.

[0031] During the correction of the static offset term, the aforementioned representative offset is directly superimposed onto the original static offset term for that deflection angle segment. This allows the corrected static offset term to comprehensively compensate for the long-term stable offset of the weld within that deflection angle segment. In this way, the static offset term, while maintaining its original correction characteristics, further incorporates an offset correction amount based on actual welding results, thereby improving the accuracy of static compensation. For example, within a certain deflection angle segment, after statistically analyzing the forming offsets obtained from multiple welds, it was found that the weld offset in the scanning direction within this segment is mainly concentrated between 0.18 mm and 0.22 mm, exhibiting a stable unidirectional offset characteristic. Based on this forming offset distribution, 0.20 mm, located at the center of the distribution, is selected as the representative offset for that deflection angle segment. This representative offset is then superimposed onto the original static offset term for that segment, causing the overall scanning position of the galvanometer within that deflection angle segment to shift by approximately 0.20 mm in the corresponding direction, thus comprehensively compensating for the long-term stable offset of the weld.

[0032] In the process of correcting the dynamic response term, the difference between each forming offset and the representative offset is taken as the dynamic change part. According to the distribution of scanning points within the deflection angle range, this dynamic change part is allocated to the corresponding scanning point positions and superimposed on the original dynamic response term. This allows the corrected dynamic response term to reflect the offset fluctuations caused by changes in scanning position during the welding process. In this way, the dynamic response term not only considers the dynamic characteristics of the galvanometer itself but also incorporates the dynamic offset characteristics reflected in the actual welding process. For example, within the aforementioned deflection angle range, although the overall weld offset is approximately 0.20 mm, the forming offset at different scanning points still fluctuates significantly along the welding trajectory direction. Some scanning points have an offset of 0.26 mm, while others have an offset of only 0.15 mm. To address this issue, the difference between the forming offset at each scanning point and the representative offset of 0.20 mm is taken as the dynamic change part. For example, the difference of offset increments of +0.06 mm or -0.05 mm is allocated to the corresponding scanning point according to the position of the scanning point within the deflection angle range, and superimposed on the original dynamic response term, so that the corrected dynamic response term can reflect the offset fluctuation caused by the change of scanning position during the welding process.

[0033] In the process of correcting the curvature distortion term, the spatial curve of the weld at each scanning point is extracted based on the actual weld forming trajectory, and the curvature of the curve at each scanning point is calculated to form a curvature change sequence that varies with the scanning point. After dividing the curvature change sequence into deflection angle segments according to the deflection angle corresponding to the scanning point, within each deflection angle segment, multiple adjacent and continuous scanning points are selected according to the order of the scanning points in the weld trajectory to form a local fitting range. Within this local fitting range, the curvature value corresponding to each scanning point is fitted to minimize the overall deviation between the fitted curvature change result and the actual curvature value within this local range. The multiple local fitting results are continuously updated along the scanning direction to obtain the overall trend of curvature change within the deflection angle segment. Based on the difference between this overall trend and the original curvature change sequence, the curvature distortion correction amount for the deflection angle segment is determined, and the curvature distortion correction amount is superimposed or canceled into the original curvature distortion term of the deflection angle segment to obtain the corrected curvature distortion term. For example, when performing curvature analysis on the actual weld formation trajectory within a certain deflection angle range, it was found that the actual weld curvature was approximately 1.35 mm in the local scanning area. -1 The corresponding theoretical trajectory curvature is approximately 1.20 mm. -1There are significant differences between the two. To address this, multiple adjacent and consecutive scanning points within the deflection angle range are selected to form a local analysis range. The curvature values ​​corresponding to each scanning point within this local range are fitted to minimize the overall deviation between the fitted curvature change result and the actual curvature value within this local range. Subsequently, this local analysis range is gradually moved along the welding trajectory direction, and multiple local fitting results are continuously updated to obtain the overall trend of curvature change within the deflection angle range. Based on this overall trend, the difference between the original curvature change and the actual curvature change is approximately 0.15 mm. -1 The deviation is used to determine the curvature distortion correction amount for the deflection angle segment, and the original curvature distortion term is updated accordingly.

[0034] The static offset term, dynamic response term, and curvature distortion term are combined and standardized to obtain the comprehensive correction amount corresponding to each deflection angle segment. The formula for calculating the comprehensive correction amount is as follows: In the formula, For the first The comprehensive correction amount corresponding to each deflection angle segment Index of deflection error components, These are represented as static offset, dynamic response, and curvature distortion terms, respectively. For the first Within the deflection angle segment, the first The standardized values ​​of the deflection error components.

[0035] Understandably, after correcting the static offset, dynamic response, and curvature distortion terms separately, the differences in physical meaning, dimensional scale, and numerical distribution range among the three types of deflection error components mean that direct linear superposition could easily lead to one type of deflection error having an excessively high weight in the overall correction, thus weakening the contribution of other deflection error components to the overall correction effect. Therefore, standardizing the static offset, dynamic response, and curvature distortion terms within each deflection angle segment allows for the fusion of different types of deflection error components on a unified numerical scale, which improves the stability and consistency of the overall correction. Based on this, an exponential function is introduced to map the standardized deflection error components. This exponential function enhances the influence of larger deflection error components in the overall correction while maintaining the continuous contribution of smaller deflection error components, thus avoiding excessive interference from abrupt changes in a single error component on the correction result. Furthermore, the exponential mapping results of each deflection error component are summed by squares and the square root is taken, so that the comprehensive correction amount can simultaneously reflect the overall intensity level of the three types of deflection errors—static offset, dynamic response, and curvature distortion—within the deflection angle range. This calculation method not only ensures the independent contribution of each deflection error component to the comprehensive correction amount, but also characterizes the degree of comprehensive deflection error in the deflection angle range in the form of an overall amplitude. Therefore, the obtained comprehensive correction amount is more suitable for subsequent welding trajectory deflection compensation and adaptive update processes.

[0036] Furthermore, the welding trajectory of the welding process to be executed is obtained, and deflection compensation is performed on the welding trajectory based on the comprehensive correction amount to generate the initial welding trajectory command, specifically including: Obtain the welding trajectory of the welding process to be executed, and for each trajectory point in the welding trajectory, obtain its original target position; Based on the target position coordinates of each scanning point in the welding trajectory, determine the corresponding deflection angle segment and retrieve the comprehensive correction amount corresponding to the deflection angle segment. Based on the comprehensive correction amount corresponding to the deflection angle segment, the target position coordinates of the scanning point are corrected for position offset to obtain the deflection compensation trajectory point coordinates of the scanning point. The coordinates of the trajectory points after deflection compensation are arranged sequentially according to the welding order to form a complete compensated welding trajectory. The compensated welding trajectory is smoothed and interpolated to generate an initial welding trajectory command that can be executed by the galvanometer.

[0037] Specifically, before actually performing the welding operation, the welding trajectory corresponding to the welding process to be performed is first obtained. This welding trajectory consists of multiple trajectory points arranged in the welding sequence, with each trajectory point corresponding to a predetermined scanning target position. For each trajectory point in the welding trajectory, based on the spatial positional relationship of its target position in the galvanometer scanning plane, the galvanometer deflection angle corresponding to that trajectory point is determined, and the deflection angle segment into which the deflection angle falls is further determined, thereby retrieving the comprehensive correction amount corresponding to that deflection angle segment. Since the comprehensive correction amount has integrated multiple deflection error characteristics such as static offset, dynamic response, and curvature distortion, it can characterize the overall deflection error level of the galvanometer within that deflection angle segment. After obtaining the corresponding comprehensive correction amount, the original target position of the current trajectory point is corrected by position offset based on the comprehensive correction amount, so that the corrected trajectory point coordinates spatially pre-cancel the deflection error that the galvanometer may generate within that deflection angle segment, thereby obtaining the deflection-compensated position of the trajectory point. By sequentially performing the above deflection compensation process on all trajectory points in the welding trajectory and arranging them according to the original welding sequence, a complete compensated welding trajectory is formed. Furthermore, to avoid abrupt changes or discontinuities in the position of trajectory points due to the compensation process, the compensated welding trajectory is smoothed and interpolated to maintain spatial continuity and smoothness, ultimately generating an initial welding trajectory command that can be directly used by the galvanometer to perform welding operations.

[0038] Furthermore, residual deviations are obtained based on the initial welding trajectory commands, and these residual deviations are evaluated. Then, the comprehensive correction amount is adaptively updated based on the evaluation results to generate the final correction command for controlling the galvanometer to perform the welding operation. Specifically, this includes: Based on the initial welding trajectory command, the actual weld trajectory data collected during the welding operation performed by the galvanometer is obtained to obtain the actual weld trajectory; The actual weld trajectory is compared with the compensated weld trajectory to obtain the spatial deviation corresponding to each scanning point. The spatial deviation of each scanning point is used as the residual deviation to obtain the residual deviation set; The residual deviation set is classified according to the deflection angle segment to obtain the residual deviation subset corresponding to each deflection angle segment; Statistical processing is performed on the residual deviation subset of each deflection angle segment to obtain the average residual deviation, maximum residual deviation, and deviation distribution, thus forming the residual deviation characteristics of each deflection angle segment. Specifically, during the welding operation performed by the galvanometer, the actual weld formation trajectory data is simultaneously acquired through the weld trajectory acquisition device, resulting in an actual weld trajectory that corresponds one-to-one with the compensated welding trajectory. By comparing the actual weld trajectory with the compensated welding trajectory point by point at the same scanning point position, the spatial difference between the two is obtained, and this spatial difference is used as the residual deviation of the corresponding scanning point, thus forming a set of residual deviations covering the entire welding process. For example, for a certain scanning point, the target position of the compensated trajectory is X=50.00 mm, Y=25.00 mm, Z=1.00 mm, while the actual weld position is X=50.05 mm, Y=24.97 mm, Z=0.98 mm. Then the spatial deviation of this point is ΔX=0.05 mm, ΔY=-0.03 mm, ΔZ=-0.02 mm, and the spatial deviation modulus is approximately 0.061 mm. Based on the galvanometer deflection angle corresponding to each scanning point, the residual deviation set is divided into different deflection angle segments, so that each deflection angle segment corresponds to a set of residual deviation data reflecting the compensation effect of that segment. For example, if a certain deflection angle segment covers a deflection angle range of 10°~15°, then the residual deviations of all scanning points with deflection angles falling within this range are all classified into the residual deviation subset of that segment. For each residual deviation subset within a deflection angle segment, statistical analysis is performed to obtain the average level, extreme values, and overall distribution characteristics of the residual deviations within that segment. For example, if the residual deviation moduli collected in this segment are 0.05 mm, 0.06 mm, 0.04 mm, 0.07 mm, and 0.05 mm, then the average residual deviation is 0.054 mm, and the maximum residual deviation is 0.07 mm. Simultaneously, a deviation distribution histogram can be plotted to observe the concentrated intervals of residual deviations, thus forming residual deviation characteristics used to characterize the compensation effect of that deflection angle segment. This method can intuitively reflect the error level and changes that still exist in different deflection angle sections during the compensated welding process, providing a basis for subsequent judgment on whether the comprehensive correction amount needs further adjustment.

[0039] Based on the residual deviation characteristics of each deflection angle segment, the compensation effect of the segment is evaluated, and the compensation evaluation results of each deflection angle segment are obtained. Based on the compensation assessment results, the comprehensive correction items that need to be updated are determined, and the correction item identifier to be updated is obtained; Based on the calibration value identifier to be updated, an updated comprehensive calibration value is generated; Based on the updated integrated correction values, the final correction command for the galvanometer is generated.

[0040] Understandably, the compensation effect of each deflection angle segment is evaluated based on the residual deviation characteristics of each segment. The evaluation method includes a comprehensive analysis of the average, maximum, and distribution of the residual deviation to determine the accuracy of the compensation trajectory within that deflection angle segment. For example, if the average residual deviation of a deflection angle segment is less than a preset threshold of 0.05 mm and the maximum residual deviation is less than 0.08 mm, the compensation effect of that segment is considered good; if the average or maximum residual deviation exceeds the threshold, the segment is considered to have insufficient compensation and requires further adjustment. Based on the evaluation results, the comprehensive correction items that need to be updated are determined. The static offset item, dynamic response item, and curvature distortion item corresponding to the segment with an evaluation result of "substandard" are marked as items to be updated, thus generating a correction item identifier to be updated. For example, in a certain deflection angle segment, if the residual deviation of the static offset item reaches 0.06 mm and the residual deviation of the dynamic response item fluctuates more than ±0.05 mm, then the static offset item and dynamic response item of that segment are marked as items to be updated. Based on this, adjustments are made to the correction terms to be updated. Insufficiently compensated static offsets are superimposed or corrected, dynamic response terms are increased or decreased, and curvature distortion terms are increased or decreased to better match the actual welding trajectory. For example, the original value of the static offset term (0.20 mm) is adjusted to 0.25 mm, and the dynamic response term is increased or decreased by ±0.03 mm according to the distribution of scan point deviations, thus generating an updated comprehensive correction. Based on the updated comprehensive correction, the updated comprehensive correction for each scan point is applied to the original welding trajectory coordinates to calculate the final compensation position. A complete welding trajectory instruction is then formed according to the welding sequence. This final correction instruction guides the galvanometer to scan in real-time according to the optimized compensation trajectory during welding operations, thereby minimizing residual deviations and achieving high-precision welding.

[0041] Furthermore, a galvanometer intelligent correction system based on deflection error compensation is proposed to implement the galvanometer intelligent correction method as described above, characterized in that it includes: The data acquisition module is used to acquire the actual deflection angle of the galvanometer and the actual weld trajectory data. The calibration data management module stores calibration data for the galvanometer scanning area, including straight line calibration graphics, circular arc calibration graphics, and curve calibration graphics, and provides the required calibration data to the calibration calculation module. The calibration calculation module is used to extract deflection error parameters based on calibration data, generate comprehensive correction amounts for each deflection angle segment by combining weld offset information, and adaptively update the sub-correction amounts based on residual deviation. The residual deviation assessment module is used to assess the residual deviation of each deflection angle segment based on the compensated welding trajectory command and the actual weld trajectory data, and generate the compensation assessment results. The trajectory generation module is used to perform deflection compensation on the welding trajectory to be executed based on the comprehensive correction amount, and generate the compensated welding trajectory command.

[0042] Furthermore, the data acquisition module includes: The deflection angle acquisition unit is used to acquire the actual deflection angle of the galvanometer during the scanning and welding process. The weld trajectory acquisition unit is used to acquire weld trajectory data formed by the galvanometer during the actual welding process, including the actual weld formation position and the corresponding expected welding trajectory.

[0043] Furthermore, the correction calculation module includes: The deflection error extraction unit is used to extract the initial deflection error of each deflection angle segment based on the straight line calibration graph, the circular arc calibration graph, and the curve calibration graph, and to form a deflection error parameter set. The weld offset analysis unit is used to compare the actual weld trajectory data with the expected welding trajectory, extract the weld forming offset amount and offset direction, and form a weld offset information set. The comprehensive correction quantity generation unit is used to combine the deflection error parameter set and the weld offset information set to calculate the comprehensive correction quantity for each deflection angle segment, and to adaptively update the comprehensive correction quantity.

[0044] Furthermore, the trajectory generation module includes: The deflection compensation trajectory generation unit is used to perform deflection compensation on the welding trajectory to be executed based on the comprehensive correction amount, and generate the welding trajectory points after deflection compensation. The welding trajectory smoothing and interpolation unit is used to smooth and interpolate the welding trajectory points after deflection compensation, generating a complete welding trajectory command that can be executed by the galvanometer.

[0045] In summary, the advantages of this invention are as follows: by acquiring the calibration data of the galvanometer scanning area, extracting the initial deflection error of each deflection angle segment, and combining it with the actual weld trajectory offset information to generate a comprehensive correction amount, real-time deflection compensation of the welding trajectory is achieved; based on the compensated welding trajectory, residual deviation is evaluated and adaptively updated, significantly improving the accuracy of the welding trajectory in each deflection angle segment; at the same time, the weld formation accuracy and welding efficiency are improved, welding errors are reduced, and the stability and reliability of the welding process are guaranteed, providing an effective technical means for high-precision welding operations.

[0046] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A galvanometer intelligent correction method based on deflection error compensation, characterized in that, include: The calibration data of the galvanometer scanning area is obtained, and the galvanometer scanning area is divided to obtain a galvanometer area library containing different deflection angle segments. The calibration data includes straight line calibration graphics, circular arc calibration graphics and curve calibration graphics. The initial deflection error of the galvanometer in each deflection angle segment is extracted based on the calibration data, and a deflection error parameter set including static offset term, dynamic response term and curvature distortion term is obtained. The weld position data formed by the galvanometer region library during the actual welding process is obtained, and the weld forming offset and offset direction are extracted from the weld position data to obtain the weld offset information set. Then, combined with the deflection error parameter set, the comprehensive correction amount of each deflection angle segment is obtained. The welding trajectory of the welding process to be executed is obtained, and the deflection compensation of the welding trajectory is performed based on the comprehensive correction amount to generate the initial welding trajectory command; The residual deviation is obtained based on the initial welding trajectory command, and the residual deviation is evaluated. Then, the comprehensive correction amount is adaptively updated according to the evaluation results to generate the final correction command for controlling the galvanometer to perform the welding operation.

2. The intelligent galvanometer correction method based on deflection error compensation according to claim 1, characterized in that, The process of acquiring calibration data for the galvanometer scanning area, dividing the galvanometer scanning area, and obtaining a galvanometer region library containing segments with different deflection angles specifically includes: The scanning results are obtained by executing a preset scanning path using a galvanometer. The calibration data is obtained based on the scanning results, and the calibration data includes straight line calibration patterns, circular arc calibration patterns, and curve calibration patterns; Based on the calibration data, the deflection angle of each scanning point is extracted to form a set of deflection angle features of the galvanometer scanning area; The deflection angles in the deflection angle feature set are sorted to obtain the angle difference between adjacent deflection angles; Based on the deflection angle feature set, the minimum and maximum deflection angle values ​​of the galvanometer scanning area are obtained, and the deflection angle coverage range of the galvanometer scanning area is determined. Within the deflection angle coverage area, the angle difference between adjacent deflection angles is obtained. The adjacent angle differences are compared according to a preset angle difference threshold, and the scanning area is divided into sub-regions with angle differences lower than the preset angle difference threshold and sub-regions with angle differences higher than the preset angle difference threshold. Based on the angle difference between adjacent deflection angles within the divided sub-regions, the scanning region is divided into multiple consecutive secondary deflection intervals starting from the minimum deflection angle. Using the secondary deflection interval, the galvanometer scanning area is divided into multiple secondary galvanometer regions, and a unique identifier is generated for each secondary galvanometer region to establish a secondary galvanometer region library. Based on the angle difference between adjacent deflection angles in each secondary division galvanometer region in the secondary division galvanometer region library, the secondary division galvanometer regions with continuous angle differences between adjacent deflection angles and stable variation amplitudes are merged to obtain the merged galvanometer region. Based on the merged galvanometer region, the secondary galvanometer region where the angle difference between adjacent deflection angles changes abruptly is further subdivided to obtain the subdivided galvanometer region. Based on the subdivided galvanometer regions, multiple deflection angle segments are formed, and each segment corresponds to a range of galvanometer deflection angles, thus establishing a galvanometer region library.

3. The intelligent galvanometer correction method based on deflection error compensation according to claim 2, characterized in that, The initial deflection error of the galvanometer in each deflection angle segment is extracted based on the calibration data, resulting in a deflection error parameter set including static offset, dynamic response, and curvature distortion terms, specifically including: Fit the straight line calibration graph in the calibration data to obtain the spatial offset between the theoretical trajectory and the actual scanning trajectory of the straight line calibration graph. Statistically calculate the spatial offset within the corresponding deflection angle segment to form the initial deflection error of the straight line calibration graph, which serves as the static offset term for the corresponding deflection angle segment. The circular arc calibration pattern in the calibration data is analyzed, the trajectory response deviation of the galvanometer under different scanning speed and acceleration conditions is extracted, and the correlation between the trajectory response deviation and the deflection angle is established in the corresponding deflection angle segment to form the initial deflection error of the circular arc calibration pattern, which serves as the dynamic response term of the corresponding deflection angle segment. Curvature analysis is performed on the curve calibration graph in the calibration data to obtain the curvature difference between the actual scan curve and the theoretical curve. The curvature difference is then mapped to the corresponding deflection angle segment to form the initial deflection error of the curve calibration graph, which serves as the curvature distortion term for the corresponding deflection angle segment. The initial deflection errors corresponding to the straight line calibration pattern, circular arc calibration pattern, and curve calibration pattern are combined according to the deflection angle segment to obtain a deflection error parameter set including static offset term, dynamic response term, and curvature distortion term.

4. The intelligent galvanometer correction method based on deflection error compensation according to claim 3, characterized in that, The process involves acquiring weld position data from the galvanometer region library during actual welding, extracting weld formation offset and offset direction from the weld position data to obtain a weld offset information set, and then combining this with the deflection error parameter set to obtain the comprehensive correction amount for each deflection angle segment. Specifically, this includes: Acquire weld position data formed by the galvanometer corresponding to the galvanometer region library during the actual welding process. The weld position data includes the actual weld formation trajectory and the corresponding expected welding trajectory. Based on the weld position data, the actual weld formation trajectory and the expected welding trajectory are compared to obtain the spatial difference between the two at the corresponding positions, which forms the weld formation offset. The offset direction of each forming offset is determined based on the offset direction of the actual weld formation position relative to the target position of the welding trajectory; Based on the deflection angle of the galvanometer at each scanning point, the forming offset and its offset direction are classified into the deflection angle segment determined by the deflection angle. The forming offset and its offset direction that fall into the same deflection angle segment are collected to form a weld offset information set. Based on the weld offset information set, multiple forming offsets within the same deflection angle segment are obtained; The forming offset within the same deflection angle segment is statistically processed, and the offset located at the center of the forming offset distribution in that deflection angle segment is extracted as the representative offset of that deflection angle segment. By comparing each forming offset within the same deflection angle segment with a representative offset, a set of offset differences of each forming offset relative to the overall offset trend is obtained. The representative offset is determined as the steady-state offset component, and each offset difference in the offset difference set is determined as the dynamic offset component; Based on the steady-state offset components of each deflection angle segment, the steady-state offset components are assigned to the static offset terms of the corresponding deflection angle segments to obtain the corrected static offset terms. Based on the dynamic offset components of each deflection angle segment, the dynamic offset components are assigned to the dynamic response terms of the corresponding deflection angle segment to obtain the corrected dynamic response terms. Based on the actual forming trajectory of the weld, the actual spatial curve of the weld at each scanning point is extracted, and the curvature at each scanning point is calculated to obtain a weld trajectory curvature sequence covering the entire weld trajectory. The weld trajectory curvature sequence is divided into deflection angle segments according to the deflection angle corresponding to the scanning point. For the curvature sequence in each deflection angle segment, the local least squares method is applied to fit the curvature change trend to obtain the curvature distortion correction amount for each deflection angle segment. The curvature distortion term for the corresponding deflection angle segment is numerically superimposed or subtracted based on the curvature distortion correction amount to obtain the corrected curvature distortion term. The static offset term, dynamic response term, and curvature distortion term are combined and standardized to obtain the comprehensive correction amount corresponding to each deflection angle segment. The formula for calculating the comprehensive correction amount is as follows: In the formula, For the first The comprehensive correction amount corresponding to each deflection angle segment Index of deflection error components, These are represented as static offset, dynamic response, and curvature distortion terms, respectively. For the first Within the deflection angle segment, the first The standardized values ​​of the deflection error components.

5. The intelligent galvanometer correction method based on deflection error compensation according to claim 4, characterized in that, The process of acquiring the welding trajectory of the welding process to be executed, and performing deflection compensation on the welding trajectory based on the comprehensive correction amount to generate an initial welding trajectory command, specifically includes: Obtain the welding trajectory of the welding process to be executed, and extract the original target position coordinates for each trajectory point in the welding trajectory; Based on the target position coordinates of each scanning point in the welding trajectory, determine the corresponding deflection angle segment and retrieve the comprehensive correction amount corresponding to the deflection angle segment. Based on the comprehensive correction amount corresponding to the deflection angle segment, the target position coordinates of the scanning point are corrected for position offset to obtain the deflection compensation trajectory point coordinates of the scanning point. The coordinates of the trajectory points after deflection compensation are arranged sequentially according to the welding order to form a complete compensated welding trajectory. The compensated welding trajectory is smoothed and interpolated to generate an initial welding trajectory command that can be executed by the galvanometer.

6. The intelligent galvanometer correction method based on deflection error compensation according to claim 5, characterized in that, The process involves obtaining residual deviations based on initial welding trajectory commands, evaluating these residual deviations, and then adaptively updating the comprehensive correction amount based on the evaluation results to generate the final correction command for controlling the galvanometer to perform the welding operation. Specifically, this includes: Based on the initial welding trajectory command, the actual weld trajectory data collected during the welding operation performed by the galvanometer is obtained to obtain the actual weld trajectory; The actual weld trajectory is compared with the compensated weld trajectory to obtain the spatial deviation corresponding to each scanning point. The spatial deviation of each scanning point is used as the residual deviation to obtain the residual deviation set; The residual deviation set is classified according to the deflection angle segment to obtain the residual deviation subset corresponding to each deflection angle segment; Statistical processing is performed on the residual deviation subset of each deflection angle segment to obtain the average residual deviation, maximum residual deviation, and deviation distribution, thus forming the residual deviation characteristics of each deflection angle segment. Based on the residual deviation characteristics of each deflection angle segment, the compensation effect of the segment is evaluated, and the compensation evaluation results of each deflection angle segment are obtained. Based on the compensation assessment results, the comprehensive correction items that need to be updated are determined, and the correction item identifier to be updated is obtained; Based on the calibration value identifier to be updated, an updated comprehensive calibration value is generated; Based on the updated integrated correction values, the final correction command for the galvanometer is generated.

7. A galvanometer intelligent correction system based on deflection error compensation, used to implement the galvanometer intelligent correction method as described in any one of claims 1-6, characterized in that, include: The data acquisition module is used to acquire the actual deflection angle of the galvanometer and the actual weld trajectory data. The calibration data management module is used to store calibration data of the galvanometer scanning area, including straight line calibration graphics, circular arc calibration graphics and curve calibration graphics, and to provide the required calibration data to the calibration calculation module; The correction calculation module is used to extract deflection error parameters based on calibration data, generate comprehensive correction amounts for each deflection angle segment by combining weld offset information, and adaptively update the sub-correction amounts based on residual deviation. The residual deviation assessment module is used to assess the residual deviation of each deflection angle segment based on the compensation welding trajectory command and the actual weld trajectory data, and generate the compensation assessment result. The trajectory generation module is used to perform deflection compensation on the welding trajectory to be executed based on the comprehensive correction amount, and generate the compensated welding trajectory command.

8. The intelligent galvanometer correction system based on deflection error compensation according to claim 7, characterized in that, The data acquisition module includes: A deflection angle acquisition unit is used to acquire the actual deflection angle of the galvanometer during the scanning and welding process. A weld trajectory acquisition unit is used to acquire weld trajectory data formed by the galvanometer during the actual welding process, including the actual weld formation position and the corresponding expected welding trajectory.

9. The intelligent galvanometer correction system based on deflection error compensation according to claim 7, characterized in that, The correction calculation module includes: A deflection error extraction unit is used to extract the initial deflection error of each deflection angle segment based on the straight line calibration pattern, the circular arc calibration pattern and the curve calibration pattern, and to form a deflection error parameter set. A weld offset analysis unit is used to compare the actual weld trajectory data with the expected welding trajectory, extract the weld forming offset amount and offset direction, and form a weld offset information set. The comprehensive correction quantity generation unit is used to combine the deflection error parameter set and the weld offset information set to calculate the comprehensive correction quantity for each deflection angle segment, and to adaptively update the comprehensive correction quantity.

10. A galvanometer intelligent correction system based on deflection error compensation according to claim 7, characterized in that, The trajectory generation module includes: A deflection compensation trajectory generation unit is used to perform deflection compensation on the welding trajectory to be executed based on a comprehensive correction amount, and generate welding trajectory points after deflection compensation. The welding trajectory smoothing and interpolation unit is used to smooth and interpolate the welding trajectory points after deflection compensation to generate a complete welding trajectory command that can be executed by the galvanometer.

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