Welding dotting counting method, system and equipment and medium

Abstract

The invention provides a welding dotting counting method, system and device and a medium, and belongs to the technical field of industrial automation. The method comprises the steps that the dotting frequency of a welding gun and the use frequency of an electrode cap are updated according to an obtained welding dotting signal; comparing the dotting times of the welding gun with a welding set threshold value corresponding to a target workpiece type to obtain a first comparison result; whether a welding judgment signal is received or not is judged, and a judgment result is obtained; comparing the number of use times of the electrode cap with a set grinding threshold value to obtain a second comparison result; and triggering a corresponding state indication according to the judgment result, the first comparison result and the second comparison result. The welding quality is improved, and welding production automation and intelligence are achieved.

Description

Technical Field

[0001] This invention relates to the field of industrial automation technology, specifically to a welding dot counting method, system, equipment, and medium. Background Technology

[0002] In modern industrial manufacturing, especially in assembly line production such as automobile body manufacturing and metal component welding, resistance spot welding has become a widely used core process due to its advantages such as high efficiency, low cost, and ease of automation. This process applies pressure to the workpiece and passes a huge current through the welding torch electrode, utilizing the resistance heat at the contact point of the workpiece to locally melt and form a weld point (commonly known as "spot welding").

[0003] To ensure the stability and consistency of welding quality, it is necessary to accurately count and manage the number of welding points for each welding torch and the wear condition of the electrode cap during the production process.

[0004] Currently, on many production lines that have not yet been upgraded, solder joint counting still relies on manual recording by operators or simple mechanical counters. This method not only increases labor costs but is also highly susceptible to counting errors, data omissions, or tampering due to human negligence. Although some devices with counting functions exist on the market, their functionality is often limited to a single counting display and cannot provide multi-station status indications. Summary of the Invention

[0005] In view of this, it is necessary to provide a welding dot counting method, system, equipment and medium to solve the technical problems of existing technologies that cannot automatically realize dot counting and multi-station status indication, and have low counting accuracy and reliability.

[0006] To address the aforementioned technical problems, in a first aspect, the present invention provides a welding dot counting method, comprising: Update the number of welding torch dots and electrode cap uses based on the acquired welding dot signals; The first comparison result is obtained by comparing the number of welding torch strikes with the welding setting threshold corresponding to the target workpiece type. Determine whether a welding judgment signal has been received and obtain the judgment result; The second comparison result is obtained by comparing the number of times the electrode cap has been used with the set threshold for grinding. Based on the judgment result, the first comparison result, and the second comparison result, the corresponding status indication is triggered.

[0007] In one possible implementation, before updating the welding torch dot count and electrode cap usage count based on the acquired welding dot count signal, the following steps are included: In response to the workpiece type selection command, the current workpiece type is switched to the target workpiece type, and the welding setting threshold and grinding setting value corresponding to the target workpiece type are loaded; Based on the acquired sensor signals, it is determined whether the workpiece to be welded is located at the preset welding position of the fixture and whether the fixture is in a clamping state. If the workpiece to be welded is located at the preset welding position and the fixture is in the clamping state, a start welding command is sent to the welding gun. When a welding start signal is received, the welding torch dot count is reset to zero. The welding torch dot count and the electrode cap usage count are calculated based on the received welding dot count signals. The number of welding dot count signals is the same as the increase in the welding torch dot count and the increase in the electrode cap usage count.

[0008] In one possible implementation, the workpiece type selection instruction comes from at least one of the following methods: The target workpiece type is determined by manually input information received through a human-computer interaction touchscreen; or, The target workpiece type is determined based on remote signals sent by the assembly line scheduling system or workpiece identification sensors.

[0009] In one possible implementation, the step of statistically determining the number of welding torch strikes and the number of electrode cap uses based on the received welding strike signals includes: The process parameters for each welding process are collected; the welding process is the time interval between receiving two adjacent welding point signals; The process parameters are compared with the preset acceptable range, and the number of welding torch dots and the number of electrode cap uses are updated. If a grinding completion signal is received, the grinding calculation will be reset to zero.

[0010] In one possible implementation, comparing the process parameters with a preset acceptable range and updating the number of welding torch dots and the number of electrode cap uses includes: If any of the process parameters for this welding process is outside the preset acceptable range, the welding quality is determined to be unqualified and a quality alarm is triggered. At the same time, the number of welding torch dots is increased by zero, and the number of electrode cap uses is increased by one. The process parameters include at least welding current, energizing time, and dynamic resistance between electrodes. If all the process parameters corresponding to this welding process are within the preset qualified range, the welding quality is determined to be qualified, and the number of welding torch dots is increased by one, and the number of electrode cap uses is increased by one.

[0011] In one possible implementation, triggering the corresponding status indication based on the judgment result, the first comparison result, and the second comparison result includes: If the judgment result is that the welding judgment signal is not received, and the first comparison result is that the number of welding torch dots is less than the welding set threshold, a first welding prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding gun dots is greater than or equal to the welding set threshold, a second welding prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding torch dots is less than the welding set threshold, a welding alarm prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding gun dots is greater than or equal to the welding set threshold, a welding compliance indication is given; If the second comparison result is that the number of times the electrode cap is used is equal to the set value of the number of times the electrode cap is used, a first grinding alarm will be triggered. If the second comparison result indicates that the number of times the electrode cap has been used is greater than the set value for the number of times the electrode cap has been used, a second grinding alarm will be issued; the alarm level of the second grinding alarm is higher than the alarm level of the first grinding alarm, and the notification method of the second grinding alarm is different from that of the welding alarm.

[0012] One possible implementation also includes: A unique identifier is generated for each weld point based on the welding dot signal; The unique identifier is associated with and stored in conjunction with the corresponding workpiece information, welding torch information, welding process parameters, and quality judgment results.

[0013] Secondly, the present invention also provides a welding dot counting system, comprising: The calculation module is used to update the number of welding torch dots and the number of electrode cap uses based on the acquired welding dotting signals; The first comparison module is used to compare the number of welding torch dots with the welding setting threshold corresponding to the target workpiece type to obtain a first comparison result; The judgment module is used to determine whether a welding judgment signal has been received and to obtain the judgment result. The second comparison module is used to compare the number of times the electrode cap has been used with a grinding set threshold to obtain a second comparison result; The processing module is used to trigger the corresponding status indication based on the judgment result, the first comparison result, and the second comparison result.

[0014] Thirdly, the present invention also provides an electronic device, including a memory and a processor, wherein, The memory is used to store programs; The processor, coupled to the memory, is used to execute the program stored in the memory to implement the steps in the welding dot counting method described in any of the above implementations.

[0015] Fourthly, the present invention also provides a computer-readable storage medium for storing a computer-readable program or instructions, which, when executed by a processor, can implement the steps of the welding dot counting method described in any of the above implementations.

[0016] The beneficial effects of this invention are as follows: The welding dot counting method provided by this invention firstly receives and counts welding dot signals and grinding signals in real time, accurately monitoring the number of welding and grinding operations to obtain the number of welding torch dots and electrode cap uses. Simultaneously, the counting results are quickly compared with set thresholds, and a status indication is triggered based on the comprehensive judgment result. Operators can promptly understand the current production progress and quality status, enabling rapid adjustments and decisions, avoiding production delays caused by information lag. Furthermore, by setting corresponding welding and grinding thresholds according to different workpiece types, and comparing the number of welding torch dots and electrode cap uses with their respective set thresholds, it ensures that each workpiece has undergone a sufficient number of welding and grinding operations. This effectively avoids product defects caused by insufficient operation counts, such as weak welds and uneven surface grinding, thereby improving the overall product quality. Furthermore, by continuously monitoring the counting results and determining in real time whether a welding judgment signal is received, abnormalities in the production process can be detected promptly, such as welding equipment malfunctions or grinding operation errors. Once an abnormality is detected, immediate measures can be taken to repair and adjust it, preventing defective products from flowing into subsequent production stages and further ensuring product quality stability. Moreover, the entire process, from signal reception, counting, comparison, judgment to status indication triggering, is automated, reducing reliance on manual labor. Operators no longer need to frequently manually record the number of welding and grinding operations, nor do they need to perform complex comparisons and judgments manually. They only need to focus on the final status indication result, greatly reducing the workload and labor intensity of manual operation. Furthermore, the fully automated operation avoids errors that may occur during manual recording and judgment, such as omissions, calculation errors, and judgment mistakes. It can complete various tasks with extremely high accuracy and reliability, improving the stability and consistency of the production process, thereby reducing the increase in production costs caused by human error to a certain extent. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic flowchart of an embodiment of the welding dot counting method provided by the present invention; Figure 2 A schematic diagram of an embodiment of the welding dot counting system provided by the present invention; Figure 3 For the present invention Figure 2 A schematic diagram of an embodiment of a counter; Figure 4 This is a schematic flowchart of another embodiment of the welding dot counting method of the present invention; Figure 5 For the present invention Figure 4 A schematic diagram of an embodiment of S040; Figure 6 This is a schematic flowchart of another embodiment of the welding dot counting method of the present invention; Figure 7 A schematic diagram of an embodiment of the welding dot counting system provided by the present invention; Figure 8 A schematic diagram of an embodiment of the electronic device provided by the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] In the description of the embodiments of the present invention, unless otherwise stated, "multiple" means two or more. "And / or" describes the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can represent three situations: A exists alone, A and B exist simultaneously, and B exists alone.

[0021] The terms "first," "second," etc., used in the embodiments of this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a technical feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature.

[0022] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0023] This invention provides a welding dot counting method, system, device, and medium, which are described below.

[0024] Figure 1 This is a schematic flowchart of an embodiment of the welding dot counting method provided by the present invention, as shown below. Figure 1 As shown, the welding dot counting method includes: S100: Update the number of welding torch dots and the number of electrode cap uses based on the acquired welding dotting signals.

[0025] It should be noted that the welding dot counting system is mainly used to count the number of welding torch dots and electrode cap uses, and compare them with a set threshold. It uses indicator lights, buzzers, and wireless transmission to provide alarm prompts and notify the PLC when dot counting is complete. Figure 2 As shown, the hardware components of the welding dot counting system mainly include a counter, a PLC controller, an industrial control server (host), wireless equipment, a fixture (with a PLC chip installed), a welding machine, and a grinding tool.

[0026] Among them, such as Figure 3As shown, the counter includes input / output interfaces (not shown), an isolated power supply (not shown), an MCU core power supply (not shown), a real-time counting information memory (not shown), a RAM random access memory (not shown), an RS485 interface (not shown), a historical data memory (not shown), a system real-time clock (not shown), a program download interface (not shown), electrostatic and instantaneous high-voltage protection circuits (not shown), an external crystal oscillator (not shown), a system reset (not shown), LED indicators and a buzzer, and a button to reset the electrode cap usage count. The PLC controller connects to the fixture PLC chip and interacts with it, and has wireless networking capabilities. The industrial control server runs WCS service software and communicates with the PLC controller and counter to achieve functions such as linkage control, parameter distribution, time synchronization, and welding data acquisition. Wireless devices enable wireless communication between the counter, PLC controller, industrial control server (host), PLC chip, welding machine, and grinding tool. Both the welding machine and grinding tool are connected to the counter, providing welding signals and grinding completion signals. The WCS service software runs on the industrial control server and is responsible for the core functions of the entire system, such as linkage control, parameter distribution, time synchronization, and welding data acquisition. It ensures that all parts of the system work together and achieves accurate statistics and management of welding point counting.

[0027] The welding torch's weld count focuses on the production progress of the "workpiece," while the electrode cap's usage count focuses on the wear and tear of the "tool." The welding torch's weld count (welding count) refers to the total number of welds performed on a specific workpiece. For example, welding a car door might require 15 weld points; these 15 weld points constitute the welding threshold. The electrode cap's usage count (re-grinding count) refers to the total number of welds performed on the electrode cap since its last re-grinding or replacement. The electrode cap is a vulnerable copper part on the welding torch that directly contacts the workpiece during welding. Operating under high temperature and pressure, the electrode cap gradually wears, deforms, and oxidizes. A severely worn electrode cap can lead to weak welds, sparks, or even incomplete welds. By setting a re-grinding count (e.g., 200 times), the system can proactively prompt the operator to re-grind (polish) or replace the electrode cap before it wears down to the point of affecting quality. After the operator finishes grinding the electrode cap, pressing the "Grinding Complete" button or receiving a completion signal from the grinder will automatically reset the grinding count to zero and restart the accumulation. The grinding count tracks the service life cycle of the electrode cap body.

[0028] The electrode cap is a crucial consumable component on the welding torch that directly contacts the workpiece and performs the welding. Resistance spot welding works by using a large current to generate heat at the point where metals overlap, melting and connecting them. The welding torch has two electrode arms, each with an electrode cap at its end. These two electrode caps, like two "fingers," clamp the metal plate to be welded from above, below, or sides. When they clamp the workpiece, a current of thousands to tens of thousands of amperes generated by the welding transformer flows from one electrode cap through the metal plate and back to the other. The current encounters maximum resistance at the metal plate contact point, instantly generating enormous heat (Joule heating), melting the metal in that area to form a weld nugget, which, upon cooling, becomes a weld spot. The ends (working surfaces) of the electrode caps are typically designed with a specific shape (such as conical or spherical), which determines the area of ​​concentrated current and pressure on the workpiece, i.e., the size and shape of the weld spot. Simultaneously with the current applied, the welding torch applies enormous pressure to the workpiece through the electrode caps. This pressure ensures tight contact between the metal plates before welding, reducing contact resistance; prevents molten metal from splashing (sparks) during welding; and forges the weld nugget after welding, making its structure denser and stronger. Electrode caps are typically made of copper alloys (such as chromium-zirconium copper), a material with good electrical conductivity that quickly conducts heat away from the welding area, preventing overheating and burning of the workpiece surface. Because electrode caps operate in extreme environments of high temperature, high pressure, and high current, they are inherently consumable parts, inevitably experiencing wear, deformation, oxidation, and contamination. Therefore, a special tool (grinding tool) is needed to cut away the worn working surface of the electrode cap, restoring its original standard shape. After each grinding, the grinding count is reset to zero, and its service life is recalculated. When the electrode cap is ground to its shortest length and can no longer be ground, it must be replaced. A grinding count alarm (yellow / red light) indicates to the operator that grinding or replacement is necessary. Each successful welding tap increases both the welding count and the grinding count by 1. The welding count is reset to zero at the start of each new workpiece. The grinding count is reset to zero after each electrode cap grinding. Within the lifespan of a single electrode cap (i.e., from installation / grinding to the next grinding), the grinding count is always equal to the cumulative sum of all workpiece welding counts during this period.

[0029] The counter receives welding dot signals from the welding torch via its input interface. These signals can be active or passive, depending on the type and configuration of the welding torch. Based on each received welding dot signal, the counter updates its internal storage of welding torch dot counts and electrode cap usage counts. These updated counts are stored in the counter's memory and displayed to the user in real-time via a touchscreen display.

[0030] In addition, the number of times the electrode cap is used can be replaced by the cumulative wear amount of the electrode cap. The cumulative wear amount of the electrode cap can be obtained by collecting at least one life-affecting parameter of a single welding process. The life-affecting parameter includes welding current, energizing time, or electrode pressure. The at least one process parameter is input into an electrode cap wear quantification model to calculate the theoretical wear amount corresponding to the welding process. The theoretical wear amounts are then accumulated to obtain the cumulative wear amount of the electrode cap. Specifically, the secondary circuit current of the welding machine is collected in real time using a Hall current sensor or shunt, with a sampling frequency of not less than 1kHz, and the effective value or peak value of the current is recorded. The time parameters of the welding cycle, including pressurization time, welding time, and holding time, are obtained from the welding machine controller, accurate to the millisecond level. A piezoelectric or strain gauge pressure sensor is installed on the electrode arm of the welding torch to monitor the electrode pressure changes in real time. Based on the material properties of the electrode cap, welding process parameters, and historical wear data, an electrode cap wear quantification model is established. This model can be a mathematical model based on physical principles or an empirical model trained through machine learning. The collected parameters such as welding current, energizing time, and electrode pressure are input into the model. The model calculates the theoretical wear amount corresponding to the welding process based on the input parameters. For example, if the model is a simple linear model, it can be represented as: Theoretical wear amount = k1 × welding current + k2 × energizing time + k3 × electrode pressure; where k1, k2, and k3 are coefficients of the model, obtained through experiments or data analysis. The theoretical wear amount calculated each time is added to the previous cumulative wear amount to obtain the current cumulative wear amount of the electrode cap. The cumulative wear amount is stored in a database and updated after each welding operation.

[0031] Within a single welding cycle, the aforementioned lifespan-influencing parameters are collected synchronously. The collected raw data is digitally filtered (e.g., Kalman filtering) to remove noise. The wear quantification model can be established based on the physical mechanism of electrode cap wear. Electrical wear is proportional to the square of the welding current (I) and the energizing time (t); thermal wear is related to the temperature rise caused by the current and energizing time; and mechanical wear is related to the electrode pressure (F) and material properties. The theoretical wear amount ΔW = α·I²·t + β·F·t + γ·I·F·t + δ. Where I is the effective value of the welding current (kA), t is the effective energizing time (ms), F is the electrode pressure (kN), α, β, and γ are wear coefficients, calibrated experimentally, and δ is the basic wear constant. After each welding cycle, the theoretical wear amount ΔW is calculated using the formula for this cycle, and the cumulative wear amount of the electrode cap is obtained by summing these theoretical wear amounts.

[0032] Of course, welding tests can also be conducted under different combinations of process parameters, and the actual wear of the electrode cap can be measured periodically (using 3D scanning or specialized measuring tools) to establish a parameter database for different electrode cap materials and workpiece materials. The relationship between key feature values ​​in the parameter database and the actual wear of the electrode cap is used as input to train an electrode cap wear quantification model. Then, the real-time collected life-affecting parameters are filtered to extract key feature values ​​from the processed data. These key feature values ​​include the RMS value of the current, the peak pressure, and the integral value of the energizing time. The current key feature values, collected during the welding operation and extracted after data filtering, are input into the trained electrode cap wear quantification model. The model then estimates the theoretical wear amount for this operation, and the cumulative wear amount is obtained by summing these theoretical wear amounts.

[0033] S200, The number of welding torch dots is compared with the welding setting threshold corresponding to the target workpiece type to obtain the first comparison result.

[0034] It should be noted that the counter has a built-in MCU, which reads the corresponding welding setting threshold from memory based on the target tool type. The welding setting threshold can be manually set via the touchscreen or automatically issued by the PLC. The counter compares the number of welding torch strikes with the welding setting threshold to obtain the first comparison result.

[0035] S300: Determine whether a welding judgment signal has been received and obtain the judgment result.

[0036] It should be noted that the counter checks whether a welding judgment signal has been received via the input interface. The welding judgment signal is typically issued by the PLC or other control system, indicating that the welding operation has been completed. If a welding judgment signal is received, the judgment result is "received". If no welding judgment signal is received, the judgment result is "not received".

[0037] S400, The number of times the electrode cap has been used is compared with the grinding set threshold to obtain a second comparison result.

[0038] It should be noted that the counter retrieves the grinding setting threshold from memory. This threshold can be set manually via the touchscreen or automatically by the PLC. The counter compares the number of times the electrode cap has been used with the grinding setting threshold to obtain a second comparison result.

[0039] S500: Based on the judgment result, the first comparison result, and the second comparison result, trigger the corresponding status indication.

[0040] It should be noted that: based on the above three results (judgment result, first comparison result, and second comparison result), a comprehensive decision is made according to preset logical rules. Based on the decision result, the control and indication devices (including LED indicators and buzzers, etc.) perform corresponding status indication operations to remind the staff.

[0041] In summary, the welding dot counting method provided in this invention firstly receives and counts welding dot signals and grinding signals in real time, accurately monitoring the number of welding and grinding operations to obtain the number of welding torch dots and electrode cap uses. Simultaneously, the counting results are quickly compared with set thresholds, and a status indication is triggered based on the comprehensive judgment result. Operators can promptly understand the current production progress and quality status, enabling rapid adjustments and decisions, avoiding production delays due to information lag. Furthermore, corresponding welding and grinding thresholds are set according to different workpiece types. Comparing the welding torch dot count and electrode cap uses with their respective set thresholds ensures that each workpiece undergoes a sufficient number of welding and grinding operations, effectively avoiding product defects caused by insufficient operation counts, such as weak welds and uneven surface grinding, thereby improving the overall product quality. Furthermore, by continuously monitoring the counting results and determining in real time whether a welding judgment signal is received, abnormalities in the production process can be detected promptly, such as welding equipment malfunctions or grinding operation errors. Once an abnormality is detected, immediate measures can be taken to repair and adjust it, preventing defective products from flowing into subsequent production stages and further ensuring product quality stability. Moreover, the entire process, from signal reception, counting, comparison, judgment to status indication triggering, is automated, reducing reliance on manual labor. Operators no longer need to frequently manually record the number of welding and grinding operations, nor do they need to perform complex comparisons and judgments manually. They only need to focus on the final status indication result, greatly reducing the workload and labor intensity of manual operation. Furthermore, the fully automated operation avoids errors that may occur during manual recording and judgment, such as omissions, calculation errors, and judgment mistakes. It can complete various tasks with extremely high accuracy and reliability, improving the stability and consistency of the production process, thereby reducing the increase in production costs caused by human error to a certain extent.

[0042] In some embodiments of the present invention, such as Figure 4 As shown, before updating the welding torch dot count and electrode cap usage count based on the acquired welding dot count signals, the following steps are included: S010. In response to the workpiece type selection command, switch from the current workpiece type to the target workpiece type, and load the welding setting threshold and grinding setting value corresponding to the target workpiece type.

[0043] It should be noted that the counter receives workpiece type selection instructions via its input interface or touch screen. The internal control system of the counter switches from the current workpiece type to the target workpiece type based on the received instructions. This switching process includes updating information such as the workpiece type number and name. The counter loads the welding setting threshold and grinding setting value corresponding to the target workpiece type from its memory. These settings can be preset in memory or updated via the touch screen or PLC.

[0044] S020. Based on the acquired sensor signals, determine whether the workpiece to be welded is located at the preset welding position of the fixture and whether the fixture is in a clamping state.

[0045] It should be noted that the counter receives signals from the fixture position sensor and fixture status sensor via the input interface. These sensors can be proximity switches, photoelectric switches, or other types of sensors, used to detect the position of the workpiece and the status of the fixture. By analyzing the sensor signals, it is determined whether the workpiece to be welded is located in the preset welding position of the fixture, and at the same time, whether the fixture is in a clamped state, ensuring the safety and accuracy of the welding operation.

[0046] S030. If the workpiece to be welded is located at the preset welding position and the fixture is in the clamping state, send a start welding command to the welding gun.

[0047] It should be noted that if the sensor signal indicates that the workpiece to be welded is in the preset welding position and the fixture is in a clamped state, the counter's control system determines that the welding conditions are met. The counter then sends a start welding command to the welding torch through its output interface, initiating the welding operation.

[0048] S040. Upon receiving a welding start signal, the welding torch dot count is reset to zero. The welding torch dot count and the electrode cap usage count are calculated based on the received welding dot count signals. The number of welding dot count signals is the same as the increase in the welding torch dot count and the increase in the electrode cap usage count.

[0049] It should be noted that the counter receives the welding start signal sent by the welding torch through the input interface. The welding start signal indicates that the welding operation has begun. Upon receiving the welding start signal, the counter resets the welding torch dot count to zero, preparing for a new round of welding operations. Each time a welding dot count signal is received, the welding torch dot count increases by 1, and the electrode cap usage count also increases by 1.

[0050] In this embodiment, by responding to the workpiece type selection command, the system can quickly switch workpiece types and load corresponding welding setting thresholds and grinding setting values, ensuring that welding operations for different workpiece types can be performed according to preset standards, thus improving the accuracy and consistency of welding operations. Furthermore, sensor signals are used to determine whether the workpiece is located in the preset welding position and whether the fixture is clamped, ensuring that welding operations are performed under safe and accurate conditions, avoiding welding quality problems or safety accidents caused by incorrect workpiece positioning or clamping failure. When the workpiece position and fixture status meet the conditions, the system automatically sends a start welding command to the welding torch, reducing manual intervention and improving the automation and efficiency of the welding process. Furthermore, the number of welding torch dots is reset to zero at the start of welding, and accurate statistics are performed based on the welding dot signals, avoiding counting errors and improving the accuracy and reliability of counting. Furthermore, the entire welding process, from workpiece type switching to welding command sending to counting statistics, is automated, reducing manual intervention and improving production efficiency. Furthermore, the system can quickly respond to workpiece type selection commands and sensor signals, promptly switching workpiece types, determining positions, and sending welding commands, ensuring the continuity and efficiency of welding operations.

[0051] In some embodiments of the present invention, the workpiece type selection instruction comes from at least one of the following methods: The target workpiece type is determined by manually input information received through a human-computer interaction touchscreen; or, The target workpiece type is determined based on remote signals sent by the assembly line scheduling system or workpiece identification sensors.

[0052] It should be noted that the operator manually selects the target workpiece type on the counter's human-machine interface touchscreen. The touchscreen provides a user-friendly interface displaying a list of available workpiece types, and the operator can select the target workpiece type by touching the options on the screen. The counter's control system generates manual input information based on the options entered and clicked by the operator on the touchscreen. This received manual input information from the touchscreen is used as a workpiece type selection instruction. The system then switches from the current workpiece type to the target workpiece type, and loads the welding setting threshold and grinding setting value corresponding to the target workpiece type.

[0053] Of course, the counter can also be directly connected to the assembly line scheduling system or a workpiece identification sensor. The assembly line scheduling system can send workpiece type information as a remote signal to the counter, and the fixture workpiece identification sensor can identify the workpiece type of the workpiece to be welded mounted on the fixture and send the identification information, including the target workpiece type, as a remote signal to the counter. The counter parses the received workpiece type information or identification information to obtain the target workpiece type, generates a corresponding workpiece type selection instruction, and then switches from the current workpiece type to the target workpiece type. The system loads the welding setting threshold and grinding setting value corresponding to the target workpiece type.

[0054] Of course, the counter is connected to the PLC controller, and the controller is connected to the assembly line scheduling system or workpiece identification sensor. The assembly line scheduling system can send workpiece type information as a remote signal to the controller, and the fixture workpiece identification sensor can identify the workpiece type of the workpiece to be welded mounted on the fixture and send the identification information, including the target workpiece type, as a remote signal to the controller. The controller parses the received workpiece type information or identification information to obtain the target workpiece type and generates a corresponding workpiece type selection instruction. The controller sends the workpiece type selection instruction to the counter through a network or communication interface. After receiving the workpiece type selection instruction sent by the controller, the counter verifies the validity of the instruction, then switches from the current workpiece type to the target workpiece type, and the system loads the welding setting threshold and grinding setting value corresponding to the target workpiece type.

[0055] In this embodiment, the operator can manually select the workpiece type via a touchscreen. This method is suitable for scenarios requiring temporary changes to the workpiece type or manual adjustments, improving operational convenience and user-friendliness. The counter can also automatically select the workpiece type based on signals from the assembly line scheduling system or fixture identification sensors. This method is suitable for scenarios with high levels of production line automation and frequent changes in workpiece types, improving automation levels and reducing the steps required for manual input by the operator. This reduces errors caused by human error and improves the accuracy of workpiece type switching.

[0056] In some embodiments of the present invention, such as Figure 5 As shown, the step of statistically determining the number of welding torch strikes and the number of times the electrode cap is used based on the received welding strike signals includes: S041. Collect process parameters for each welding process; the welding process is the time interval between receiving two adjacent welding point signals.

[0057] It should be noted that the system receives welding dot signals through an input interface, identifying the start and end of each welding process. A welding process is defined as the time interval between the receipt of two adjacent welding dot signals. Relevant process parameters are collected within each welding time interval. These collected process parameters are stored in the system memory and associated with the corresponding welding dot signals.

[0058] S042. Compare the process parameters with the preset acceptable range, and update the number of welding torch dots and the number of electrode cap uses.

[0059] It should be noted that the counter's memory stores preset acceptable ranges for various process parameters. The preset acceptable ranges for different process parameters can be set and adjusted according to welding process requirements and quality standards. The counter compares the collected process parameters with their corresponding preset acceptable ranges; that is, for each process parameter, it determines whether it falls within its corresponding preset acceptable range. Based on the comparison result, the number of welding torch dots and the number of electrode cap uses are updated.

[0060] S043. If a grinding completion signal is received, the grinding calculation is reset to zero.

[0061] It should be noted that the system receives the grinding completion signal via the input interface. This signal is emitted by the grinding machine after completing the electrode cap grinding operation. Upon receiving the grinding completion signal, the system resets the electrode cap's usage count to zero, preparing for the next grinding cycle.

[0062] In this embodiment, by collecting process parameters during each welding process and comparing them with the acceptable range, the counter can monitor welding quality in real time, promptly detect unqualified welding processes, thereby improving the stability and consistency of welding quality. Furthermore, based on the collected process parameters and comparison results, it can provide feedback to the operator, helping them optimize welding process parameters and further improve welding quality. Moreover, the counter automatically updates the number of welding torch dots and electrode cap uses, and automatically resets the electrode cap usage count to zero upon receiving a grinding completion signal, reducing manual intervention and improving production efficiency. Furthermore, by accurately recording the electrode cap usage count and automatically resetting it after grinding, the counter helps operators better manage the electrode cap's lifespan, enabling timely grinding or replacement and reducing equipment downtime.

[0063] In some embodiments of the present invention, comparing the process parameters with a preset acceptable range and updating the number of welding torch dots and the number of electrode cap uses includes: If any of the process parameters for this welding process is outside the preset acceptable range, the welding quality is determined to be unqualified and a quality alarm is triggered. At the same time, the number of welding torch dots is increased by zero, and the number of electrode cap uses is increased by one. The process parameters include at least welding current, energizing time, and dynamic resistance between electrodes. If all the process parameters corresponding to this welding process are within the preset qualified range, the welding quality is determined to be qualified, and the number of welding torch dots is increased by one, and the number of electrode cap uses is increased by one.

[0064] It should be noted that during each welding process, the counter collects process parameters such as welding current, energizing time, and dynamic resistance between electrodes via sensors. These sensors can be current sensors, timers, and resistance meters, used to measure the current, energizing time, and dynamic resistance between electrodes, respectively. The collected process parameters are stored in the counter's memory for further processing. The counter's memory has preset acceptable ranges for each of the welding current, energizing time, and dynamic resistance between electrodes. These ranges can be set and adjusted according to welding process requirements and quality standards. For example, the acceptable range for welding current might be 200A to 300A, the acceptable range for energizing time might be 0.1 seconds to 0.5 seconds, and the acceptable range for dynamic resistance between electrodes might be 0.01Ω to 0.1Ω. The counter compares the collected welding current, energizing time, and dynamic resistance between electrodes with the corresponding preset acceptable ranges.

[0065] If any process parameter exceeds the corresponding preset acceptable range, the counter determines that the welding quality is unacceptable. The number of welding torch dots does not increase (increases by zero), but the electrode cap usage count increases by one because the welding process was unsuccessful, yet electrode cap wear still occurs. If all process parameters are within the corresponding preset acceptable range, the counter determines that the welding quality is acceptable. The welding torch dot count increases by one, recording a successful welding operation. Additionally, the electrode cap usage count increases by one, and the electrode cap wear status is recorded.

[0066] In this embodiment, by collecting and comparing key process parameters during the welding process, the counter can monitor welding quality in real time and promptly detect unqualified welding processes, thereby improving the stability and consistency of welding quality. Furthermore, the counter can promptly detect and alarm for unqualified welding operations during the welding process, preventing unqualified welded parts from entering subsequent processes and reducing rework and scrap rates. Further, the counter automatically updates the number of welding torch dots and electrode cap uses, triggering an alarm when welding quality is unqualified, reducing the workload of manual inspection and recording, and improving production efficiency. Furthermore, by accurately recording the number of electrode cap uses, the counter helps operators better manage the lifespan of electrode caps, allowing for timely grinding or replacement, reducing equipment downtime. Furthermore, the counter's built-in touchscreen display intuitively shows the real-time status of the welding torch dots, electrode cap uses, and process parameters, allowing operators to easily view and adjust relevant parameters, improving operational convenience and user-friendliness.

[0067] In some embodiments of the present invention, triggering a corresponding status indication based on the judgment result, the first comparison result, and the second comparison result includes: If the judgment result is that the welding judgment signal is not received, and the first comparison result is that the number of welding torch dots is less than the welding set threshold, a first welding prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding gun dots is greater than or equal to the welding set threshold, a second welding prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding torch dots is less than the welding set threshold, a welding alarm prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding gun dots is greater than or equal to the welding set threshold, a welding compliance indication is given; If the second comparison result is that the number of times the electrode cap is used is equal to the set value of the number of times the electrode cap is used, a first grinding alarm will be triggered. If the second comparison result indicates that the number of times the electrode cap has been used is greater than the set value for the number of times the electrode cap has been used, a second grinding alarm will be issued; the alarm level of the second grinding alarm is higher than the alarm level of the first grinding alarm, and the notification method of the second grinding alarm is different from that of the welding alarm.

[0068] It should be noted that the counter receives a welding judgment signal via an input interface. This signal, issued by the PLC or other control system, indicates whether the welding operation has been completed. The counter compares the current number of welding torch strikes with a preset welding threshold to obtain the first comparison result. The welding threshold is preset according to the welding process requirements. The counter compares the current number of electrode cap uses with a preset grinding setting value to obtain the second comparison result. The grinding setting value is preset according to the electrode cap's lifespan. In summary, the period from receiving the first welding strike signal for the current workpiece to be welded until receiving the welding judgment signal is the welding torch strike count period. Once the welding judgment signal is received, the period until the first welding strike signal for the next workpiece to be welded is the welding end judgment period.

[0069] If the judgment result indicates that no welding judgment signal has been received and the first comparison result shows that the number of welding points is less than the welding set threshold, a first welding prompt will be issued. For example, the green indicator light will stay on while the buzzer remains silent. This notifies the operator that the system is operating normally and counting is in progress. The clear, continuous green light indicates that the current number of welding points has not yet reached the target, and the work still needs to continue. It is a calm prompt that says "Everything is normal, please continue," avoiding interference with the ongoing operation.

[0070] If the judgment result indicates that no welding judgment signal has been received and the first comparison result shows that the number of welding torch dots is greater than or equal to the welding setting threshold, a second welding prompt will be issued. For example, the green indicator light will flash, while the buzzer remains silent or emits a soft intermittent sound, prompting the operator that "the number of welding dots on this workpiece is sufficient, please prepare to end welding." This effectively prevents over-welding (wasting time and potentially damaging the workpiece) or continued welding due to operator negligence.

[0071] If the judgment result is that a welding judgment signal has been received and the first comparison result is that the number of welding points is less than the welding set threshold, a welding alarm is triggered. For example, the red indicator light will stay on and the buzzer will sound continuously. Receiving the welding judgment signal indicates that the final quality judgment stage has been entered, and the workpiece is clearly determined to be unqualified (insufficient number of weld points). The strong secondary audible and visual alarm (red indicator light stays on and buzzer sounds continuously) can immediately attract the operator's attention. At the same time, the counter will prevent the "welding completed" signal from being sent to the PLC, thereby locking the fixture and preventing the workpiece from flowing into the next process, thus avoiding the outflow of unqualified products and forming a quality closed-loop control.

[0072] If the judgment result indicates that a welding judgment signal has been received and the first comparison result shows that the number of welding torch dots is greater than or equal to the welding set threshold, a welding compliance indication is issued. For example, the green indicator light is driven to flash, and a "welding complete" signal is sent to the PLC, controlling the fixture to open. A clear flashing green indicator light can notify the operator that the number of welds on the workpiece has met the standard, allowing it to be released. The flashing green light is the same as the "welding in progress" prompt (point 2), but because it is associated with the "welding judgment signal" and triggers the fixture opening action, a closed loop is formed in the state chain, realizing automated production flow.

[0073] At any stage (including the welding torch application count period and the welding end determination period), if the second comparison result shows that the electrode cap usage count equals the regrinding threshold, a first regrinding alarm will be triggered. For example, a yellow indicator light will remain on, and a buzzer will sound continuously. This informs the operator that the electrode cap has reached its standard lifespan and regrinding needs to be scheduled. This is a planned reminder designed to intervene before quality issues arise, ensuring welding stability.

[0074] At any stage (including the welding torch application count period and the welding end determination period), if the second comparison result shows that the electrode cap usage count exceeds the regrinding threshold, a second regrinding alarm will be triggered. For example, a red indicator light will flash, and a buzzer will sound intermittently. The alarm level of the second regrinding alarm is higher than that of the first regrinding alarm (red > yellow, intermittent sound > continuous sound, stronger visual and auditory impact), clearly indicating that the equipment has been used beyond its limits and the welding quality risk is extremely high. This forces the operator to immediately stop the machine and perform regrinding, avoiding situations where the alarm is ignored even after it has been escalated.

[0075] In this embodiment, the accuracy of the welding operation is ensured by real-time monitoring of the number of welding torch dots and providing different prompt signals during the welding process. Based on different judgment results, corresponding status indications are automatically executed, reducing the workload of manual inspection and recording. Furthermore, it can quickly respond to welding judgment signals and count changes, updating status indications promptly to ensure the continuity and efficiency of the production process. Further, the number of times the electrode cap is used is monitored in real time. With precise grinding prompts, operators can promptly grind or replace electrode caps, reducing downtime caused by equipment malfunctions or quality issues and improving equipment utilization and production efficiency. Different indicator light colors and flashing patterns, along with buzzer sounds, visually display the number of welding torch strikes, electrode cap usage counts, and alarm information. Operators can easily view and understand the system status, improving operational convenience and user-friendliness. This enhances welding quality, production efficiency, equipment maintenance efficiency, and operational convenience, providing strong support for the automation and intelligentization of welding production lines. It ensures efficient, safe, and reliable welding operations, helping enterprises improve production efficiency and product quality, and enhance market competitiveness.

[0076] In some embodiments of the present invention, it further includes: A unique identifier is generated for each weld point based on the welding dot signal; The unique identifier is associated with and stored in conjunction with the corresponding workpiece information, welding torch information, welding process parameters, and quality judgment results.

[0077] It should be noted that the unique identifier generation process is initiated immediately upon capturing a welding point signal. This ensures a one-to-one correspondence between the identifier and the physical weld point. To ensure global uniqueness and include a traceability path, the most reliable solution is to generate a composite unique identifier, whose components include the workpiece unique code, the timestamp of the welding point signal generation, the welding torch / station ID (the welding torch number performing the welding operation, or the station number it belongs to), and the welding sequence number (which number of this weld point on that specific workpiece, which can be obtained from the number of welding points on that workpiece). Among these, the workpiece unique code is the unique identification information of the currently welded workpiece. For example, the Vehicle Identification Number (VIN) in the automotive industry, or the internal serial number obtained by a barcode scanner. The above elements are encoded according to predetermined rules and concatenated into a string as a unique identifier. In a record in the database, using the unique identifier as the primary key, the workpiece information, welding torch information, welding process parameters, and quality judgment results are structured and packaged into a structured data packet. The name of the structured data packet includes the unique identifier. Structured data packets are uploaded to the industrial control server in real time via Wi-Fi and stored in a time-series database or relational database. Meanwhile, to prevent network interruption, the counter can be temporarily cached locally and transmitted again after the network is restored.

[0078] The workpiece information includes workpiece number, workpiece name, and workpiece type. Welding torch information includes torch ID, torch type, and torch status. Welding process parameters include the actual welding current, energizing time, and electrode pressure for this weld. The quality assessment result includes an evaluation of the welding process parameters based on a preset acceptable range, resulting in a quality assessment result (if all parameters are within the acceptable range, the result is "acceptable"; otherwise, it is "unacceptable"), and a final quality report from subsequent inspection processes (such as ultrasonic testing and visual inspection).

[0079] In this embodiment, by generating a unique identifier for each weld point and storing this identifier in association with detailed welding information, the system can accurately trace the welding process of each weld point. This helps to quickly locate problematic weld points, analyze the causes of problems, and take targeted improvement measures when quality issues are discovered. Furthermore, by integrating and associating various information from the welding process with the unique identifier, subsequent data analysis and statistics are facilitated. Managers can analyze this data to optimize welding process parameters, improve production efficiency, and reduce production costs. Moreover, operators can quickly query the corresponding associated information, including workpiece information, welding torch information, welding process parameters, and quality judgment results, through the unique identifier, improving operational convenience and efficiency.

[0080] For example, such as Figure 6 As shown, an example of a welding dot-counting process is as follows: The counter receives the welding dot-counting signal, welding judgment signal, and grinding completion signal from the welding machine and the grinding tool. Through active / passive input signal switching and corresponding interface processing, the signals (including the welding dot-counting signal, welding judgment signal, and grinding completion signal) are transmitted to the counter for updating the welding count (i.e., the number of times the welding torch dots) and the grinding count (the number of times the electrode cap is used). The counter counts the welding dot-counting signal in real time and compares the welding count with the set value, while simultaneously performing statistical analysis and judgment on the grinding count. Based on the counting results and the set alarm rules, different levels of alarm prompts are issued through a three-color indicator light and a buzzer. Furthermore, the counting data and prompt information can be sent to the PLC controller and industrial control server via RS485 interface or WiFi wireless transmission, while simultaneously receiving commands such as welding count reset or welding start signals from the PLC controller, realizing system linkage control and data interaction. The system utilizes a 10.1-inch resistive touchscreen display to show information such as welding count setting value (i.e., welding setting threshold), welding count, grinding count setting value (i.e., grinding setting threshold), and grinding count. It also provides operation interfaces for vehicle model settings, welding torch settings, alarm clearing, count zeroing, and system settings, making it convenient for users to set parameters and manage the system.

[0081] To better implement the welding dot counting method in the embodiments of the present invention, based on the welding dot counting method, correspondingly, as follows: Figure 7 As shown, this embodiment of the invention also provides a welding spot counting system, the welding spot counting system 700 including: The calculation module 701 is used to update the number of welding torch dots and the number of electrode cap uses based on the acquired welding dotting signals; The first comparison module 702 is used to compare the number of welding torch dots with the welding setting threshold corresponding to the target workpiece type to obtain a first comparison result; The judgment module 703 is used to determine whether a welding judgment signal has been received and to obtain a judgment result; The second comparison module 704 is used to compare the number of times the electrode cap is used with the grinding set threshold to obtain a second comparison result; The processing module 705 is used to trigger the corresponding status indication based on the judgment result, the first comparison result and the second comparison result.

[0082] like Figure 8 As shown, the present invention also provides an electronic device 800. The electronic device 800 includes a processor 801, a memory 802, and a display 803. Figure 8 Only some components of the electronic device 800 are shown, but it should be understood that it is not required to implement all the components shown, and more or fewer components may be implemented instead.

[0083] In some embodiments, processor 801 may be a central processing unit (CPU), microprocessor, or other data processing chip, used to run program code stored in memory 802 or process data, such as the welding dot counting method of the present invention.

[0084] In some embodiments, processor 801 may be a single server or a group of servers. The server group may be centralized or distributed. In some embodiments, processor 801 may be local or remote. In some embodiments, processor 801 may be implemented on a cloud platform. In one embodiment, the cloud platform may include a private cloud, public cloud, hybrid cloud, community cloud, distributed cloud, intranet, multi-cloud, etc., or any combination thereof.

[0085] In some embodiments, memory 802 may be an internal storage unit of electronic device 800, such as a hard disk or memory of electronic device 800. In other embodiments, memory 802 may also be an external storage device of electronic device 800, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc. equipped on electronic device 800.

[0086] Furthermore, the memory 802 may include both internal storage units of the electronic device 800 and external storage devices. The memory 802 is used to store application software and various types of data installed on the electronic device 800.

[0087] In some embodiments, display 803 may be an LED display, a liquid crystal display, a touch-sensitive liquid crystal display, or an OLED (Organic Light-Emitting Diode) touchscreen. Display 803 is used to display information from electronic device 800 and to display a visual user interface. Components 801-803 of electronic device 800 communicate with each other via a system bus.

[0088] In one embodiment, when the processor 801 executes the welding dot counting program in the memory 802, the following steps can be implemented: Update the number of welding torch dots and electrode cap uses based on the acquired welding dot signals; The first comparison result is obtained by comparing the number of welding torch strikes with the welding setting threshold corresponding to the target workpiece type. Determine whether a welding judgment signal has been received and obtain the judgment result; The second comparison result is obtained by comparing the number of times the electrode cap has been used with the set threshold for grinding. Based on the judgment result, the first comparison result, and the second comparison result, the corresponding status indication is triggered.

[0089] It should be understood that when the processor 801 executes the welding dot counting program in the memory 802, in addition to the functions mentioned above, it can also perform other functions, as can be found in the description of the corresponding method embodiments above.

[0090] Furthermore, this embodiment of the invention does not specifically limit the type of electronic device 800 mentioned. Electronic device 800 can be a mobile phone, tablet computer, personal digital assistant (PDA), wearable device, laptop computer, or other portable electronic device. Exemplary embodiments of portable electronic devices include, but are not limited to, portable electronic devices running iOS, Android, Microsoft, or other operating systems. The aforementioned portable electronic device can also be other portable electronic devices, such as a laptop computer with a touch-sensitive surface (e.g., a touch panel). It should also be understood that in some other embodiments of the invention, electronic device 800 may not be a portable electronic device, but rather a desktop computer with a touch-sensitive surface (e.g., a touch panel).

[0091] Accordingly, this application also provides a computer-readable storage medium for storing a computer-readable program or instruction. When the program or instruction is executed by a processor, it can implement the steps or functions of the welding dot counting method provided in the above-described method embodiments.

[0092] Those skilled in the art will understand that all or part of the processes of the methods described in the above embodiments can be implemented by a computer program instructing related hardware (such as a processor, controller, etc.), and the computer program can be stored in a computer-readable storage medium. The computer-readable storage medium may be a disk, optical disk, read-only memory, or random access memory, etc.

[0093] The welding dot counting method, apparatus, equipment, and medium provided by the present invention have been described in detail above. Specific examples have been used to illustrate the principle and implementation of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A method for counting welding dots, characterized in that, include: Update the number of welding torch dots and electrode cap uses based on the acquired welding dot signals; The first comparison result is obtained by comparing the number of welding torch strikes with the welding setting threshold corresponding to the target workpiece type. Determine whether a welding judgment signal has been received and obtain the judgment result; The second comparison result is obtained by comparing the number of times the electrode cap has been used with the set threshold for grinding. Based on the judgment result, the first comparison result, and the second comparison result, the corresponding status indication is triggered.

2. The welding dot counting method according to claim 1, characterized in that, Before updating the welding torch dot count and electrode cap usage count based on the acquired welding dot count signals, the following steps are included: In response to the workpiece type selection command, the current workpiece type is switched to the target workpiece type, and the welding setting threshold and grinding setting value corresponding to the target workpiece type are loaded; Based on the acquired sensor signals, it is determined whether the workpiece to be welded is located at the preset welding position of the fixture and whether the fixture is in a clamping state. If the workpiece to be welded is located at the preset welding position and the fixture is in the clamping state, a start welding command is sent to the welding gun. When a welding start signal is received, the welding torch dot count is reset to zero. The welding torch dot count and the electrode cap usage count are calculated based on the received welding dot count signals. The number of welding dot count signals is the same as the increase in the welding torch dot count and the increase in the electrode cap usage count.

3. The welding dot counting method according to claim 2, characterized in that, The workpiece type selection instruction comes from at least one of the following methods: The target workpiece type is determined by manually input information received through a human-computer interaction touchscreen; or, The target workpiece type is determined based on remote signals sent by the assembly line scheduling system or workpiece identification sensors.

4. The welding dot counting method according to claim 2, characterized in that, The step of calculating the number of welding torch strikes and the number of times the electrode cap is used based on the received welding strike signals includes: The process parameters for each welding process are collected; the welding process is the time interval between receiving two adjacent welding point signals; The process parameters are compared with the preset acceptable range, and the number of welding torch dots and the number of electrode cap uses are updated. If a grinding completion signal is received, the grinding calculation will be reset to zero.

5. The welding dot counting method according to claim 4, characterized in that, The step of comparing the process parameters with a preset acceptable range and updating the number of welding torch dots and the number of electrode cap uses includes: If any of the process parameters for this welding process is outside the preset acceptable range, the welding quality is determined to be unqualified and a quality alarm is triggered. At the same time, the number of welding torch dots is increased by zero, and the number of electrode cap uses is increased by one. The process parameters include at least welding current, energizing time, and dynamic resistance between electrodes. If all the process parameters corresponding to this welding process are within the preset qualified range, the welding quality is determined to be qualified, and the number of welding torch dots is increased by one, and the number of electrode cap uses is increased by one.

6. The welding dot counting method according to claim 1, characterized in that, The step of triggering a corresponding status indication based on the judgment result, the first comparison result, and the second comparison result includes: If the judgment result is that the welding judgment signal is not received, and the first comparison result is that the number of welding torch dots is less than the welding set threshold, a first welding prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding gun dots is greater than or equal to the welding set threshold, a second welding prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding torch dots is less than the welding set threshold, a welding alarm prompt is issued; If the judgment result is that the welding judgment signal is received, and the first comparison result is that the number of welding gun dots is greater than or equal to the welding set threshold, a welding compliance indication is given; If the second comparison result is that the number of times the electrode cap is used is equal to the set value of the number of times the electrode cap is used, a first grinding alarm will be triggered. If the second comparison result indicates that the number of times the electrode cap has been used is greater than the set value for the number of times the electrode cap has been used, a second grinding alarm will be issued; the alarm level of the second grinding alarm is higher than the alarm level of the first grinding alarm, and the notification method of the second grinding alarm is different from that of the welding alarm.

7. The welding dot counting method according to claim 1, characterized in that, Also includes: A unique identifier is generated for each weld point based on the welding dot signal; The unique identifier is associated with and stored in conjunction with the corresponding workpiece information, welding torch information, welding process parameters, and quality judgment results.

8. A welding dot counting system, characterized in that, include: The calculation module is used to update the number of welding torch dots and the number of electrode cap uses based on the acquired welding dotting signals; The first comparison module is used to compare the number of welding torch dots with the welding setting threshold corresponding to the target workpiece type to obtain a first comparison result; The judgment module is used to determine whether a welding judgment signal has been received and to obtain the judgment result. The second comparison module is used to compare the number of times the electrode cap has been used with a grinding set threshold to obtain a second comparison result; The processing module is used to trigger the corresponding status indication based on the judgment result, the first comparison result, and the second comparison result.

9. An electronic device, characterized in that, Including memory and processor, among which, The memory is used to store programs; The processor, coupled to the memory, is used to execute the program stored in the memory to implement the steps in the welding dot counting method according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, Used to store computer-readable programs or instructions, which, when executed by a processor, can implement the steps in the welding dot counting method according to any one of claims 1 to 7.

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