Robot tin sheet brazing method combined with real-time visual feedback regulation and control

Abstract

The invention relates to the technical field of robot brazing control, and discloses a robot tin sheet brazing method combined with real-time visual feedback regulation and control. The method is used for solving the problems that in a traditional method, closed-loop adjustment is only conducted on a track or a single energy parameter, and a multivariable coupling cooperative control mechanism for robot tin piece brazing is lacked. The method comprises the following steps: establishing an operation reference, loading a tin sheet and lap joint configuration, and generating an operation snapshot; the visual frame is aligned with the pose time sequence, image gating is carried out, and preheating is carried out after in-place deviation recognition is completed; a parameter group is locked by switching identifiers, and the motion rhythm, the path offset, the heating output and the coverage form are synchronously linked; and a wetting front and forming boundary state is constructed, switching is carried out among a normal group, a boundary protection group and a transition section, less tin, non-wetting, bridging and splashing are subjected to grading treatment according to trend grades, arc suppression, solidification and gradual retreating are carried out after recheck and recovery, key frames are archived, and it is guaranteed that forming is consistent under working condition disturbance.

Description

Technical Field

[0001] This invention relates to the field of robot brazing control technology, specifically a robot soldering method that combines real-time visual feedback control. Background Technology

[0002] Robotic brazing technology is widely used in the assembly and manufacturing of components such as electrical connectors, copper busbars, and thin metal sheets. To improve cycle time and reduce reliance on manual labor, production lines typically use industrial robots carrying heating heads to heat the solder pre-placed in the lap area. This allows the solder to melt and spread under capillary and wetting effects to form a connection. Compared to wire feeding or solder paste, solder sheets or pre-formed solder are easier to feed quantitatively, which theoretically helps reduce the risk of splashing and excessive accumulation. However, their forming quality is more sensitive to disturbances in working conditions such as solder sheet thickness tolerance, lap gap fluctuations, surface oxidation, and plating status. Moreover, the melting and spreading process is highly dynamic and irreversible. Once insufficient solder, misalignment, lack of wetting, or bridging occurs, rework often has to be carried out only after post-soldering inspection, making it difficult to meet consistency and yield requirements. In the prior art, one type of solution focuses on vision-guided weld seam tracking and online trajectory correction; for example, the published invention patent application CN107931787A discloses a vision closed-loop welding system and implementation method, which acquires the weld seam trajectory through a vision sensor and drives the actuator to realize online adjustment of the welding torch posture, thereby improving the welding adaptability to weld seam deviation; this type of solution can improve the accuracy of robot movement along the seam, but its control target is mainly focused on the trajectory or posture dimension, and lacks state quantities and control logic that can be directly constrained for the solder melting and spreading morphology and wetting quality. Especially when using pre-placed solder sheets for brazing, the spreading differences caused by solder sheet deviation, warping and lap gap changes are difficult to eliminate by trajectory closed loop alone; Another type of solution focuses on closed-loop control of heating energy or material supply. For example, the published invention patent application CN110961751B discloses a laser soldering tinning device and welding method, which uses sensor information to perform closed-loop control of laser working height, solder wire feed speed and laser following to improve the stability and applicability of tinning. This type of solution can alleviate the influence of factors such as height difference on the tinning effect to a certain extent, but its target is mostly the solder wire or local solder joint process. The control variables are concentrated on a single energy parameter or a small number of parameters related to material supply. Moreover, it lacks a multi-variable coupling and coordination mechanism for solder sheet brazing, and it is difficult to stably map the quality-related states such as melt boundary, wetting front, effective coverage and bridging trend formed by real-time visual feedback into a synchronous linkage adjustment strategy for robot motion and heating parameters. Therefore, traditional methods generally suffer from the problem of only performing closed-loop adjustment of the trajectory or a single energy parameter and lacking a multivariable coupled collaborative control mechanism for robot soldering. This makes it difficult to synchronously adjust the robot's motion and heating parameters based on real-time visual feedback under conditions of solder thickness tolerance, overlap gap and surface condition fluctuations, thus making it difficult to stably obtain consistent wetting, spreading and forming quality. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a robotic soldering method that combines real-time visual feedback control, solving the problems of traditional methods that only perform closed-loop adjustment of trajectory or single energy parameters and lack a multi-variable coupled collaborative control mechanism for robotic soldering.

[0004] To achieve the goal of consistently obtaining a consistent wetting and spreading morphology and reliable brazing quality mentioned in the background section, the present invention provides the following technical solution: A robotic soldering method incorporating real-time visual feedback control includes: S1: Establish work baseline, load solder sheet specifications, overlap structure and stage boundary constraints, generate work identifiers and start visual acquisition; S2: Identify the solder sheet offset, rotation and bonding gap, and correct the starting posture, arc point and incident direction according to the deviation type before entering preheating; S3: Switch to the melting start parameter group according to the preheating stability conditions, and adjust the movement speed, path offset, heating output and coverage range simultaneously; S4: Enter the wetting and spreading stage, load the wetting and spreading inlet parameters and establish the wetting front state and forming boundary state. Based on the wetting front state and forming boundary state, switch between the normal group, boundary protection group and transition action segment and link the parameters. S5: Monitor the trends of insufficient tin, lack of wetting, tin overflow bridging and splashing, trigger the graded treatment sequence, and after completing the recovery judgment, enter the arc termination and solidification stage and archive the key frames and treatment records.

[0005] In a preferred embodiment, a work baseline is established, solder sheet specifications, overlap structure, and stage boundary constraints are loaded, a work identifier is generated, and visual acquisition is initiated, including: Receive workstation and batch information to generate work identification, solidify and verify the conversion relationship between clamping datum, flange datum and point of action datum; Load the solder sheet and overlap configuration and threshold version according to the adaptation mode, and establish the stage parameter group mapping and switching; Align the visual frames with the pose timing and perform image gating to generate job snapshots and provide the pre-welding observation area, starting area and preheating parameter group index.

[0006] In a preferred embodiment, identifying the solder sheet's in-situ offset, rotation, and bonding gap includes: Switch the observation posture within the allowed initial posture set and keep heating off. Establish a short-term observation window in the observation area to form a reference view. After the consistency of consecutive frames is confirmed, check in the order of coverage band, alignment band and bonding conditions. The threshold is composed of visual and readback criteria and is versioned and bound to the solder sheet, overlap and adaptation modes.

[0007] In a preferred embodiment, after correcting the initial attitude, arc initiation point, and incident direction according to the deviation type, preheating is initiated, including: When offsetting or rotating, the correction parameter group is called to correct the initial posture, heating point and incident direction, and the preheating is started after pre-welding confirmation. If the fit is abnormal, it is classified as gap, warping, or suspension. The corresponding adjustment or refitting and re-sampling is performed. If the condition is not met, the user is prompted to reposition and the key frame and pose are recorded.

[0008] In a preferred embodiment, switching to the melt start-up parameter group based on preheating stability conditions includes: An observation window is established at the end of the preheating process, and a controlled rhythm and fixed incident posture are maintained. Based on the threshold set and state dictionary that have been calibrated, verified by trial welding and maintained in a versioned manner, visual criteria, heating readback criteria and motion readback criteria are graded and judged. When permitted, a preheating stability permit is generated; when warnings or restrictions are issued, continued observation is conducted and the situation is handled according to the rollback strategy.

[0009] In a preferred embodiment, the synchronous adjustment of motion speed, path offset, heating output, and coverage area includes: After obtaining preheating stability permission, a switching identifier is generated and the switching is locked, so that speed, path offset, heating output and coverage pattern take effect synchronously, and the motion status, heating status and acquisition synchronization are confirmed by reading back; The melting start-up section is graded according to melting continuity, wetting directionality and boundary proximity. When the gate control is not met, the linkage is paused and the parameter group is maintained. When exiting, the data is archived and marked as switchable.

[0010] In a preferred embodiment, the process proceeds to the wetting and spreading stage, where wetting and spreading inlet parameters are loaded and wetting front state and forming boundary state are established, including: During the wetting and spreading stage, the inlet motion parameters and heating parameters are loaded, referencing the threshold set and status dictionary bound to the job configuration snapshot; Image sequences are acquired by aligning the field of view and using image gating to generate the wetting front state and the forming boundary state.

[0011] In a preferred embodiment, parameters are switched and linked between the normal group, the boundary protection group, and the transition action segment based on the wetting front state and the forming boundary state, including: The normal group, boundary protection group, and transition action segment constitute a state machine. The motion command and heating command are switched synchronously according to the switching indicator and read back. The entry and exit adopt separate thresholds. When there are no restrictions and no escalation trend, a regression review is performed; when there is an escalation trend, the process is switched to tiered handling; when the completion criteria are met, a completion permit is generated and recorded.

[0012] In a preferred embodiment, monitoring trends of insufficient solder, lack of wetting, solder overflow bridging, and splattering includes: When image gating is enabled, the threshold set and status dictionary referenced by the job configuration snapshot are used to output trend levels for low solder, unwetting, overflowing solder bridging, and splashing, respectively. Based on the upgrade and rejection conditions, determine the corresponding tiered handling entry point for the trend level.

[0013] In a preferred embodiment, a graded handling sequence is triggered, and after the recovery determination is completed, the arc termination and solidification stage is entered, and keyframes and handling records are archived, including: When the entry point is triggered, the switching and return entry points are frozen. The switching indicator is used to synchronously link the movement and heating and read back for confirmation. The review window determines and switches between regression, enhancement, and suppression calibers according to the level. After the determination is restored, the arc gradually recedes and solidifies. The keyframes, levels, switching identifiers, and review conclusions are archived.

[0014] Compared with existing technologies, this invention provides a robotic soldering method that combines real-time visual feedback control, which has the following advantages: 1. This invention uses a job identifier to integrate benchmark verification, solder sheet and overlap configuration loading, and version references for threshold sets and state dictionaries. Through visual frame and pose timing alignment and image gating, it forms inputs that can be used to determine the solder sheet's presence and molten spreading state. During preheating to melting initiation and wetting spreading, the system uses parameter groups as control units, synchronously linking motion rhythm, path offset, heating output, and coverage shape under the same switching identifier, and confirms the constraint switching closed loop through readback. In the wetting spreading stage, based on the wetting front state and forming boundary state, it switches between normal group, boundary protection group, and transition action segment according to separation thresholds, while introducing defect trend marking, graded handling, review windows, and recovery judgment. After meeting the exit conditions, the process enters a gradual exit phase of arc termination and solidification, and archives key frames and handling records. This maintains the stability and consistency of the wetting spreading and forming process under operating condition disturbances and reduces rework dependence, solving the problems of traditional methods that only perform closed-loop adjustment of trajectory or single energy parameters and lack a multi-variable coupled collaborative control mechanism for robot solder sheet brazing.

[0015] 2. This invention solidifies the threshold set and state dictionary into a versioned judgment standard, and organizes stability judgment, separation threshold switching, upgrade conditions and rejection conditions, review window and recovery judgment into a unified closed-loop rule chain. The control action is driven by observable state and level output, forming a disposal path corresponding to regression, enhancement and suppression, reducing the reliance on experience trial and error or temporary parameter tuning of a single variable; disposal branches, switching identifiers, readback confirmation and key frame index are uniformly written into the process record for tracing the cause of abnormal triggering, disposal process and regression basis; under uncertain factors such as fitting fluctuation, reflective occlusion or thermal response abrupt change, the judgment standard can still be kept consistent and the disposal path can be repeated, improving process controllability and quality traceability. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a robotic soldering method that combines real-time visual feedback control according to the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1: Figure 1 A robotic soldering method combining real-time visual feedback control is presented, including: S1: Establish work baselines, load solder sheet specifications, overlap structures, and stage boundary constraints, generate work identifiers, and enable visual data acquisition. The specific implementation is as follows: Before the operation begins, the robot control system enters the operation initialization process, receiving the operation unit information for this brazing task through the task management interface or the host computer interface. The operation unit information is associated with the clamping station identifier, lap area identifier, weld direction identifier, and solder sheet supply batch identifier. After receiving the operation unit information, the system generates an operation identifier and establishes a unified operation benchmark. The unified operation benchmark consists of the workpiece clamping benchmark, the robot flange benchmark, and the heating head action point benchmark. The initialization phase solidifies the conversion relationship between the three, ensuring that the descriptions of position, attitude, path offset, and action area in subsequent stages use a consistent coordinate system. The system then performs benchmark consistency verification, covering fixture positioning, workpiece positioning, and heating head installation status. If the verification passes, the system enters the process configuration loading process. If the verification fails, an unavailable status and handling prompts are output, and the current operation identifier is prevented from entering subsequent stage configuration calls. The system loads solder sheet specification information and supply batch information, maps the solder sheet specifications to process configuration items and assigns them unique configuration identifiers, and then binds and registers the configuration identifiers with the supply batch identifiers, serving as a unified basis for the solder form and operational area boundaries in this operation. The solder sheet specification information is used to constrain the solder supply form and operational area boundaries, including the shape profile type, thickness level, surface treatment status, and flux medium compatibility status, enabling each stage to call the corresponding stage boundaries and linkage instruction sets under the same solder sheet diameter. The system simultaneously loads overlap structure information, which is used to constrain... The formation and spreading direction of the molten zone includes the lap form, lap boundary, sensitive boundary, weld target centerline, and target forming area. For the same lap structure, the system sets an adaptation mode to distinguish the differences in thermal response under different surface conditions and clamping conditions. The adaptation mode is triggered by the batch identifier and clamping status identifier in the work unit information, or by the operator selecting and writing the configuration record in the task interface. The adaptation mode is used to limit the range of stage boundary set and parameter group set that can be called in this operation, and is associated with the operation identifier to avoid inconsistencies in switching standards caused by mixing different modes within the same operation. After determining the solder sheet specifications, overlap structure, and adaptation mode, the system loads stage boundary constraints to form an executable staged constraint chain. These stage boundary constraints cover stages such as preheating preparation, melt initiation, and wetting and spreading, and configure entry conditions, holding constraints, and exit conditions for each stage. Entry conditions define the preconditions and permissible parameters for stage switching; holding constraints define the linkage range of robot movement and heating output within a stage; and exit conditions define the trigger parameters for entering the next stage or transitioning to abnormal handling. The system establishes a correspondence between each stage condition and observable criteria, which consist of visual state criteria, equipment readback criteria, and operational baseline criteria. The system is structured as follows: visual status criteria reflect the continuity of visibility and appearance of key areas; equipment readback criteria reflect the consistency between the working status of the execution unit and the instructions; and operation baseline criteria reflect the geometric consistency between the current pose and the target area. Various criteria thresholds are managed using interval boundaries or grade levels. The threshold set is version-maintained along with process configuration entries and bound to the adaptation mode to support different solder sheet specifications and different overlap conditions in calling matching threshold sets. During operation execution, the system uses the version referenced in the operation configuration as the basis for judgment, determines the stage conditions, and outputs the permission result. The permission result serves as the judgment criterion for stage switching and handling action entry. To ensure that the stage boundary constraints can effectively drive subsequent coordinated control, the system establishes a mapping relationship between stages and parameter groups. Each stage has a corresponding parameter group, which defines a set of linkage instructions. These instructions control the robot's motion posture, movement rhythm, path offset, heating output level, and energy coverage pattern. The internal constraints of the parameter group ensure that the robot's motion and heating output maintain a consistent coordinated rhythm within the same stage. Each stage is configured with a corresponding parameter group, and the switching relationship between stages is recorded. The switching relationship includes candidate parameter groups, switching priority order, holding constraints, and linkage range after switching. The switching conditions of parameter groups are related to the stage boundary constraints. The process control module executes the switching after obtaining stage permission. In this way, it can be ensured that the adjustment of robot motion and heating output is carried out synchronously on a parameter group basis, rather than adjusting a single parameter. After completing the process configuration and stage mapping, the system initializes the vision acquisition equipment, installing it near or coaxially with the heating head to ensure coverage of the overlapping area and the visible range of the solder sheet outline. The system establishes a synchronization relationship between vision acquisition and robot control, associating each frame of visual data with the corresponding robot pose and current stage state through unified time and frame sequence identifiers. Simultaneously, the system adjusts the reference direction of vision acquisition to align it with the weld seam direction, and uses this alignment as the visual reference standard for the operation. To cope with high reflectivity and smoke interference, the system configures different acquisition strategies for each stage: in the preheating stage, priority is given to clearly acquiring the solder sheet outline and bonding status; in the melting start-up and wetting spread stages, the focus is on observing the wetting front and forming boundary. The acquisition strategy is bound to the stage state, and the process control module automatically switches the acquisition strategy when switching stages to ensure that the visual input is consistent with the stage criteria. Image quality gating rules are established to ensure the effectiveness of visual input for in-situ solder sheet recognition. These gating rules are based on indicators such as key area visibility, image saturation ratio, contrast, and noise level, and the quality threshold is bound to the camera configuration version in the form of grade levels. When the image quality does not meet the judgment standard, the system will adjust the acquisition configuration, specifically including adjusting the exposure strategy, switching the supplementary lighting strategy, or adjusting the acquisition window. After these adjustments, the system regenerates a valid visual input permission, and can only proceed to the next step when the gating conditions are met, thereby ensuring that stable and high-quality visual input is used for in-situ solder sheet recognition and subsequent judgment stages. After configuration, the system generates a job configuration snapshot and starts process recording, recording key information such as benchmark verification, configuration version and visual input permission; then, the system outputs the pre-soldering status, which includes the observation area for solder sheet in-situ identification, the solder joint start area, the set of allowed start postures, and the index of parameter groups that can be called during the preheating stage.

[0019] S2: Identify solder sheet misalignment, rotation, and bonding gap; correct the initial posture, arc initiation point, and incident direction according to the deviation type before proceeding to preheating. The specific implementation is as follows: Receive a snapshot of the pre-soldering state and work configuration. The system controls the robot to switch to the observation posture within the allowed set of starting postures, aligning the heating head with the observation area specified in the pre-soldering state and keeping the heating off. The vision acquisition module establishes a short-term observation window within the observation area, continuously acquires the outline of the solder sheet and the overlap boundary to generate a reference view, and completes stability confirmation based on the consistency criterion of continuous frames. After the stability confirmation is passed, the deviation judgment is entered, and the start and end marks of the observation window are recorded at the same time. Using the lap area markers and weld direction markers fixed in the work reference as references, the relative relationships between the lap boundary, the weld target centerline, and the solder sheet boundary are extracted to generate the solder sheet's in-situ status. Consistency verification is then performed in a general-to-local order. Positional relationships are used to determine the coverage status of the solder sheet outline relative to the weld target forming area. This coverage status is characterized by geometric overlap and boundary allowance levels to confirm whether the solder sheet is within the target coverage zone where melting can be initiated. Attitude relationships are used to determine the directional consistency and end alignment status of the solder sheet relative to the weld direction. End alignment status is determined by the deviation of the end relative to the weld start area. The system is characterized by a setting level to confirm that the starting heating point and incident direction have feasible geometric conditions; the bonding relationship is used to determine the bonding condition between the solder sheet and the overlapping surface. The bonding condition is characterized by the continuity level of the edge shadow band, the local warping feature level, and the end suspension feature level to identify bonding anomalies such as continuous gaps, local warping, or end suspension; the system completes the verification in the order of target coverage band determination, end alignment band determination, and bonding determination. When any of the preceding determinations is not met, it directly switches to the corresponding pre-soldering correction or bonding treatment process, thereby avoiding repeated movement caused by performing local corrections when the overall conditions are not met. The target coverage area, end alignment area, bonding allowance, and preheating entry permission all correspond to a threshold set composed of visual criteria and equipment readback criteria. The threshold set is incorporated into the process configuration items for version management in the form of interval boundaries or level levels, and is bound to the solder sheet specification items, overlap structure items, and adaptation mode. When the job is executed, the system uses the job configuration snapshot to reference the current version of the threshold set to complete the judgment, so that the judgment criteria under the same job identifier remain consistent. Visual criteria are used to define the allowable range of coverage relationships, directional consistency, end alignment status, and bonding characteristics; equipment readback criteria are used to define process prerequisites such as robot pose reachability, posture maintenance capability, command readback consistency, and acquisition synchronization effectiveness; the threshold set is formed by equipment calibration and typical working condition test verification, whereby equipment calibration is used to determine the visual field alignment aperture, scale consistency aperture, and available illumination aperture, and typical working condition test soldering verification is used to confirm the acceptable range of coverage level, alignment level, bonding level, and abnormal classification characteristic level under different solder sheet levels and different overlap conditions; changes to the threshold set are recorded through version updates, and the job configuration snapshot is fixed to reference the corresponding version for traceability, avoiding inconsistencies in judgment criteria caused by temporary changes on site; When a misalignment or rotation of the solder sheet is detected, the heating process is not initiated. Instead, the pre-soldering calibration parameter group is invoked for geometric correction. This parameter group coordinates the correction of the initial posture, the initial heating point, and the incident direction. Initial posture correction ensures the heating head's posture aligns with the weld bead direction and aligns the heating head with the corrected weld bead initiation area, preventing thermal bias caused by a fixed orientation. Initial heating point correction adjusts the heating initiation position to a safe starting zone between the solder sheet end and the overlap boundary, ensuring melt initiation is achieved within a controllable area. The heating head is positioned to avoid sensitive boundaries and unfavorable edge areas. The incident direction correction is used to simultaneously adjust the lateral offset and direction of the heating head relative to the center line of the weld target when the solder sheet shifts or rotates, causing changes in the target coverage area. This ensures that the heat effect preferentially falls on the area used to establish wetting initiation. The robot control module generates a corrected set of starting poses based on the parameter set of the pre-welding correction stage, and selects a starting pose consistent with the clamping state from the set of allowed starting poses to complete the transition to the correct position. During the transition to the correct position, the heating output is kept off, while the visual acquisition remains continuous and effective so that the pre-welding confirmation process can be directly entered after the position is reached. When an abnormal bonding condition is detected, the abnormality is first classified, and then pre-welding response actions are generated based on the classification results. The classification label and response label are written into the process record as a reference for subsequent stage boundary and parameter group selection. The bonding abnormalities are classified into continuous gap type, local warping type, and end suspension type. For continuous gap type, the system adjusts the incident direction and starting heating point to avoid the maximum gap area when establishing melt initiation, so that the heating initiation falls on the area with better bonding, and the gap change area is marked as the over-concern area during the wetting and spreading stage, so that a smoother linkage rhythm and a more conservative boundary diameter can be adopted when crossing the gap change. For local warping type, the system restricts the warped area from participating in the initiation. The system marks the boundary of the warped area and includes it in the boundary protection caliber, prohibiting the warped area from being selected as the starting heating point. Simultaneously, the boundary protection parameter group is set to a priority switchable state to suppress warped areas from crossing boundaries during the spreading process. For end-suspended types, the system follows the principle of guiding re-bonding before determining permission, executing a re-bonding guidance action and re-collecting the bonding status. The re-bonding guidance action invokes the attitude and incident direction linkage strategy in the pre-welding correction stage parameter group, making the thermal effect more conducive to the controllable initial trend of end formation. If the re-collection result meets the bonding permission conditions and preheating entry permission is obtained, the process continues; if the re-collection result still does not meet the permission, a reset or rework prompt is output, terminating the current process. To ensure consistency between the pre-soldering calibration and preheating stages, a pre-soldering confirmation action is performed after pre-soldering calibration or bonding is completed to generate a preheating entry permit. During pre-soldering confirmation, the robot maintains its initial calibrated posture, and the vision acquisition module re-acquires the status of the solder sheet and overlapping area within the observation area, forming a calibrated reference view based on the same criteria as before calibration. The system establishes a link between the pre-calibrated and post-calibrated reference views and stores them as a record of the pre-soldering calibration effect. When the post-calibrated reference view meets the target coverage area, end alignment area, and bonding allowance conditions, the system generates a preheating entry permit. The preheating entry permit is only used to allow entry into the preheating stage, and the preheating stage entry configuration is inherited from the initial pose, initial heating point, and incident direction configuration obtained from the pre-soldering calibration, so that the preheating stage uses the same set of initial conditions to enter the subsequent process. After entering the preheating stage, a controlled heat input rhythm is established according to the preheating stage parameter set to ensure that the overlapping area and the solder sheet are in a stable heat response state that can be collected. During the preheating process, the vision acquisition module continuously outputs key frames and records them synchronously with the robot's pose and timing. The key frames correspond to the neighborhood of the starting heating point, the neighborhood of the solder sheet end, and the neighborhood of the overlapping boundary. The key frames and pose and timing are used as the input basis for preheating stability determination and melting start parameter set switching.

[0020] S3: Based on the preheating stability conditions, switch to the melting start-up parameter group and simultaneously adjust the motion speed, path offset, heating output, and coverage area. Specifically, the implementation is as follows: After the preheating entry permit is generated, the preheating stage parameter group remains valid, and a preheating stability determination is performed at the end of the preheating stage to generate a stage switching permit. The preheating entry permit is used to enter the preheating stage, and the preheating stability permit is used to switch from the preheating stage to the melt start-up stage. Both types of permits reference the threshold set of the job configuration snapshot and correspond to the determination criteria for preheating entry and stage switching, respectively. Near the end of the preheating phase, the switching is not based on a preset duration, but on the preheating stability condition. An observation window is established at the end of the preheating phase. The robot maintains a controlled movement rhythm and a fixed incident posture within the observation window, ensuring that the thermal response of the overlapping area and solder sheet is not disturbed by additional posture changes, thus making the stability judgment repeatable. The preheating stability condition is given by a threshold set, which is fixed in the version of the process configuration item in the form of interval boundaries or level levels, and referenced by the job configuration snapshot. The threshold set is accompanied by a state dictionary, which normalizes the criterion output into allow, warning, restriction, and prohibition states, enabling phase switching permission, linkage action triggering, and rollback strategies to be executed directly based on the state output. The input criteria for the threshold set include visual criteria, additive... Thermal readback criteria and motion readback criteria are used. Visual criteria are used to characterize the consistency of the heat-affected zone morphology, the stability of hotspot distribution, the continuity of surface condition, and the visibility of key areas. Thermal readback criteria are used to characterize the output level status, coverage morphology status, and protection status. Motion readback criteria are used to characterize the position status, attitude maintenance status, and speed mode switching status. The threshold set is formed by equipment calibration and typical working condition test soldering verification and is maintained in a versioned manner. Equipment calibration is used to determine the field of view alignment, scale consistency, and available acquisition range. Test soldering verification is used to confirm the acceptable range and level boundary of the heat-affected morphology, surface condition, and execution side readback under different solder sheet specifications and overlap conditions. Threshold changes are recorded through version updates to ensure that the judgment criteria are consistent and traceable within the same operation identifier. The preheating stability determination is performed in the order of overall stability first, then local stability, and the output of the state dictionary is used as the basis for the determination. Within the observation window, it is first determined whether the morphology of the heat-affected zone is in an acceptable state. An acceptable state corresponds to no abnormal expansion, abrupt change, or drift in the boundary and hot spot distribution of the heat-affected zone. Then, it is determined whether the surface state of the target coverage area of ​​the tin sheet is in an acceptable state. An acceptable state corresponds to continuous surface state changes and no abnormal accumulation, abnormal curling, or local loss. At the same time, it is determined whether the visibility of the key area is in an acceptable state. The visibility of the key area is constrained by the image quality gating rule set, which is bound to the stage acquisition strategy in the job configuration snapshot. The system is used to eliminate situations where critical areas are undeterminable due to obstruction, reflective saturation, or smoke. It then determines whether heating readback and motion readback are in an allowed state, excluding restrictions and prohibitions such as localized overheating, sudden changes in thermal response, protection intervention, or inconsistencies on the execution side. When all determinations are in an allowed state, the control module generates a preheating stability permit and writes it to the process record, sets the melt start-up stage parameter group to a switchable state, and enters the switching lock process. When any determination enters a warning or restriction state, the control module keeps the preheating stage parameter group unchanged and continues to confirm through the observation window. If necessary, it triggers a rollback strategy to restore the determineable input and allowed state before performing the switch. After obtaining preheating stability permission, the melting start-up switching process begins. Melting start-up is a multi-variable collaborative stage transition. The switching adopts a one-time linkage method, so that the motion speed, path offset, heating output and coverage range take effect synchronously under the same stage switching identifier, so as to avoid the risk of asynchrony caused by multiple adjustments. When switching, the control module locks the current state of the preheating stage and generates a stage switching identifier. The robot execution component and the heating execution component use the stage switching identifier as the basis for the command to take effect. The system reads back to confirm the position status and mode switching status of the coverage motion side, the output level status and coverage mode switching status of the heating side, and the effective status of data acquisition synchronization. When the stage switching identifier is consistent and the readback confirmation is satisfied, the system enters the melting start-up stage. After locking is completed, the control module records the key frame and corresponding pose identifier before the switch and saves it in association with the operation identifier, which is used to trace the input basis and switching consistency at the melting start-up moment. Subsequently, synchronization commands are issued according to the parameter group of the melting start-up stage. The synchronization commands are divided into motion-side commands and heating-side commands, and are bound to the same stage switching identifier as the basis for effectiveness. The motion-side commands limit the motion rhythm and path shape of the melting start-up stage, which is manifested in the speed switching relative to the preheating stage, the fine adjustment of the incident attitude, and the activation of the path offset, so that the heating area and the melting start-up starting area maintain a stable correspondence. The heating-side commands limit the output rhythm and coverage shape of the melting start-up stage, which is manifested in the output level switching relative to the preheating stage, the convergence of the coverage area, or the directional offset, so that the energy effect falls first on the target area in the vicinity of the starting heating point. After the synchronization commands take effect, the control module updates the stage marker to melting start-up and enables observation gating to maintain the decisionability of visual input. When the observation gating determines that the key area is not visible or the image quality does not meet the judgment criteria, the control module pauses the linkage action and maintains the current stage parameter group, and continues to execute after the gating is restored to the allowed state. If the gating cannot be restored, the rollback strategy is used to ensure that subsequent judgments and action triggers are based on traceable and valid input. During the melt start-up phase, the control module uses the threshold set and state dictionary to classify the process state and integrates visual event markers and execution-side protection event markers into trend marker management to form a comprehensive state input that can be used for process adjustment. The process judgment is based on melt continuity, wetting initiation directionality, and forming boundary proximity. Melt continuity is used to determine whether the initial melt zone is continuous and stable to eliminate discontinuous spreading caused by intermittent melting. Wetting initiation directionality is used to determine whether the initial spreading direction of the molten metal deviates from the target boundary to suppress the tendency of tin overflow caused by flow towards non-target boundaries. Forming boundary proximity is used to determine the degree of proximity of the melt zone to the boundary protection zone to suppress out-of-bounds expansion during the start-up phase. To enable the judgment results to directly drive coordinated adjustment, the control module establishes linkage adjustment rules. The linkage adjustment rules use combined actions to make the process state return to the allowable range, and the triggering frequency, holding window, and repeated triggering conditions of the linkage actions are constrained by the stage boundary threshold to reduce process fluctuations caused by frequent switching. When the status output indicates insufficient melt initiation or insufficient melt continuity, the control module triggers a compensation action. This compensation action simultaneously executes motion rhythm convergence and heating coverage directional enhancement at the same adjustment node to ensure consistency between heat input and dwell strategy. When the status output indicates a tendency towards overmelting, splashing, or a protective event, the control module triggers a suppression action. This suppression action simultaneously executes motion rhythm relaxation and heating output convergence at the same adjustment node to reduce heat load per unit time and shorten heat dwell time. When the status output indicates that wetting initiation is biased to one side or the proximity of the forming boundary is increased, the control module triggers a correction action. This correction action simultaneously executes path offset adjustment and coverage offset at the same adjustment node to maintain consistency between geometric guidance direction and thermal guidance direction. When the status output returns to the allowable state and remains stable within the observation window, the control module exits the linkage action, restores the basic linkage aperture of the melt initiation stage parameter group, and maintains the current effective parameters as the entry configuration for the subsequent wetting and spreading stage. When the melt start-up phase meets the exit conditions, the control module generates a start-up completion permit. This permit is determined based on the continuous and stable wetting start state within the observation window. After the start-up completion permit is generated, the control module solidifies the currently valid motion parameters and heating parameters as the entry parameters for the wetting and spreading stage, and marks the normal group, boundary protection group, and transition action segment of the wetting and spreading stage as switchable. The control module also archives the key frames of the melt start-up phase, the stage switching identifier, the readback confirmation results, and the linkage action records, so that the process enters the switching preparation state of the wetting and spreading stage.

[0021] S4: Enter the wetting and spreading stage, load the wetting and spreading inlet parameters, and establish the wetting front state and forming boundary state. Based on the wetting front state and forming boundary state, switch between the normal group, boundary protection group, and transition action segment and link the parameters. The specific implementation is as follows: Upon entering the wetting and spreading stage, the control module loads the stage entry parameters. These entry parameters are pre-defined motion and heating parameters, and reference the process configuration entry version bound to the job configuration snapshot as the configuration source for this stage. The process configuration entry version outputs a threshold set and a state dictionary to limit the judgment criteria for the wetting and spreading stage. The threshold set and state dictionary are formed based on equipment calibration and typical working condition trial welding verification and are maintained in a versioned manner. The wetting and spreading stage uses the version referenced by the job configuration snapshot as the sole judgment criterion. The vision acquisition device outputs an image sequence based on the field alignment relationship and image gating rules fixed in the job configuration snapshot. The control module uses the target forming area, overlap boundary, and sensitive boundary as references to construct the wetting front state and forming boundary state, and uses the subsequent stability judgment results for the selection and switching of control objects. The wetting front state is characterized by the boundary of the molten spreading area within the target forming area. The control module consistently locates the boundary of the molten spreading area in a continuous image sequence, extracts the leading edge line along the weld direction as the front position, and forms the state variables of skewness and continuity of advancement based on the consistency of direction and amplitude of boundary displacement in adjacent frames. The forming boundary state is characterized by the envelope relationship between the outer edge of the molten spreading area and the boundary of the target forming area. The control module uniformly calculates the relative distance relationship between the outer edge of the spreading area and the boundary of the target forming area and the sensitive boundary under the working reference coordinates, forming state variables such as boundary line position, outward expansion trend and boundary proximity relationship, and forms the state variables of edge continuity and abrupt change risk based on the edge morphology abrupt change and fracture characteristics of continuous frames. Stability determination is performed on an observation window basis. Within the observation window, the control module verifies the consistency between the wetting front state and the forming boundary state, and simultaneously verifies the consistency between the state dictionary level output corresponding to the trend marker and the motion readback criteria and heating readback criteria. When the state dictionary level remains unchanged within the observation window, or evolves continuously according to the allowed level sequence without triggering the upgrade condition, it is determined to be stable. When the state dictionary level jumps across levels, repeatedly goes back and forth, or is inconsistent with the motion readback criteria and heating readback criteria, it is determined to be unstable. When it is determined to be unstable, the control module freezes the control object switching entry, limiting it to retaining only the regression action entry and hierarchical handling entry within the current control object, in order to avoid frequent switching under unstable input or inconsistent execution conditions. The wetting and spreading stage employs a state machine to organize the control logic. The control object includes at least a normal group, a boundary protection group, and a transition action segment. The normal group drives the wetting front advancement within the target forming area and imposes constraints on the convergence of the forming boundary. Under the normal group, the motion rhythm, path offset, heating output, and coverage shape are adjusted in a coordinated manner according to the linkage caliber. Priority is given to suppressing front-end skew and edge fluctuations through the refinement of path offset and coverage shape, and then the uneven advancement and local accumulation trend are suppressed through the coordination of motion rhythm and heating output. The boundary protection group is used to switch the control caliber to boundary priority when the forming boundary approaches the sensitive boundary or shows a tendency to cross the boundary, and converges the wetting front and forming boundary under the boundary constraints. The transition action segment is used to maintain the continuity of trajectory and heat input when switching between the normal group and the boundary protection group, reducing the risk of front-end instability or edge abrupt changes caused by sudden changes in speed, attitude, path offset, or coverage shape. The switching of the controlled object adopts a unified switching identifier. The motion-side command and the heating-side command take effect synchronously under the same switching identifier, and the switching loop is completed by readback confirmation. The readback confirmation at least verifies the motion position and mode status, heating level and coverage mode status, and the effectiveness of data acquisition synchronization. The switching of the controlled object is completed when the switching identifier is consistent and the readback confirmation is satisfied. When the image gating is determined to be unavailable or the critical area is undeterminable, the control module freezes the control object switching entry and return entry, maintains the current control object and its linkage caliber unchanged, and retains the forced switching entry of the boundary protection caliber; after the gating is restored to allowed, the control module checks the status dictionary output and the effectiveness of the acquisition synchronization in the continuous observation window, and after confirming that it is in a determinate state, it unfreezes and restores the control object switching and return entry determination. When the status output is within the allowable range and the wetting front advances and approaches the forming boundary steadily, the control module maintains normal organization and executes inter-stage linkage adjustment. When the status output enters the warning range or the approach to the forming boundary increases, the control module initiates a transition action segment. Through trajectory continuity and thermal input continuity, the control aperture is switched, allowing the motion rhythm and thermal input to smoothly transition from the normal group linkage aperture to the boundary protection aperture. After the transition action segment is completed and confirmed by readback, the control module switches to the boundary protection group. To reduce the risk of frequent back-and-forth switching, the control module adopts separate threshold logic for entry and exit. Entering the boundary protection group and exiting the boundary protection group respectively reference different levels of output from the threshold set, and the corresponding switch is only allowed to be triggered when the stability judgment is satisfied, thereby keeping the boundary protection action stable and repeatable. After the boundary protection group takes effect, the control module performs linkage adjustment based on the proximity relationship between the forming boundary and the sensitive boundary, the boundary expansion trend, and the edge abrupt change characteristics. The control focus is to constrain the out-of-boundary expansion and reduce the risk of local over-melting. The linkage adjustment first converges the coverage area or applies a coverage orientation offset to reduce the heat input to non-target areas. Then, it performs path offset retraction to bring the wetting front back to the target forming area and weaken the deflection towards the sensitive boundary. At the same time, it adjusts the movement rhythm to reduce local heat retention and keeps the heating output and coverage shape at the protection aperture, so that the forming boundary gradually converges within the target forming area and maintains a safe distance from the sensitive boundary. The boundary protection group exits based on the state output returning to allow and the stability judgment being met. After the exit conditions are met, the control module triggers a transition action segment and returns to the normal group, so that wetting and spreading are restored to the control state of forming advancement priority. The regression action caliber is used to handle regressible deviations within the wetting and spreading stage. Regression actions are applicable to uneven spreading, localized accumulation, leading edge deviation, and edge continuity fluctuations, but not to risk types requiring escalation, such as insufficient solder, lack of wetting, bridging, or splashing. Trend markers are formed by visual event markers and execution-side protection event markers, mapped to escalation and rejection conditions based on a threshold set. When the status output enters a restricted state but not a prohibited state, and the trend marker does not trigger an escalation condition, the control module triggers a regression action within the current controlled object and verifies the regression effect within a stable observation window. The linkage sequence of regression actions prioritizes path offset and coverage pattern adjustments, followed by motion rhythm and heating output adjustments. All adjustments are constrained by the stage boundary threshold set to maintain the linkage range within the allowable range. When the status remains restricted or the trend marker triggers an escalation condition, the control module terminates the regression action and solidifies the current state, records the trend marker and keyframe index, writes the escalation entry into the process record, and hands it over to the hierarchical handling sequence to maintain clear stage boundaries and avoid overlapping action responsibilities. When the threshold set output meets the completion criteria, the control module generates a spreading completion permit. The completion criteria must simultaneously meet the following conditions: the wetting front advance remains stable, the forming boundary is within the allowable range, the weld edge continuity meets the judgment criteria, and the trend marker is within the allowable range. If the completion criteria are not met but the state is still within the regressible range, the control module performs a regression action and performs a review. If the regression conditions are not met, the control module maintains the current controlled object and reconfirms it in the next observation window. After the spreading completion permit is generated, the control module solidifies the currently valid motion parameters and heating parameters into candidate inlet parameters for the arc termination and solidification segment, and writes the state trajectory, controlled object switching record, transition action record, and keyframe index within the stage into the process record as the input basis for the next step.

[0022] S5: Monitor trends of insufficient tin, lack of wetting, tin overflow bridging, and splashing; trigger a graded treatment sequence; after completing the recovery judgment, enter the arc termination and solidification stage and archive key frames and treatment records. Specific implementation is as follows: During the wetting and spreading stage, when the image quality gating is in the allowed state, the control module generates defect trend markers and outputs levels based on the threshold set and status dictionary referenced by the job configuration snapshot; the control module uses the level as the entry judgment basis for the graded treatment sequence, and limits the treatment entry range and process advancement conditions through upgrade conditions and rejection conditions; When the status dictionary output enters a restricted or prohibited state, or when the trend marker triggers an escalation condition, the control module freezes the regular automatic switching entry and regression overlay entry during the wetting and spreading phase, and enters a tiered handling sequence. The tiered handling sequence determines the handling entry based on the level output: allow and warning entries enter regression-type handling, restriction entries enter enhanced handling, and prohibition or escalation entries enter suppression-type handling. Freezing only restricts the automatic switching and regression overlay of regular spreading, and does not restrict the protection switching triggered within the handling branch for risk convergence, ensuring that boundary constraints remain effective throughout the handling process. Tiered handling uses combined linkage as the basic action unit, and combined linkage binds the movement rhythm, path offset, heating output, and coverage pattern to the same switching identifier. The lower-level synchronization is used to avoid lag, overshoot, or inconsistency in direction caused by a single variable changing first. The control module generates a switching identifier each time the treatment is switched and simultaneously issues motion-side and heating-side commands, followed by readback confirmation. The readback confirmation covers the motion-side arrival and mode switching status, the heating-side output level and coverage mode switching status, and the effective status of data acquisition synchronization. After the readback confirmation is satisfied, the review window is entered. The review window only makes judgments and does not add new actions. It is used to verify the return to the state after treatment and suppress repeated switching caused by the superposition of actions. During the effective period of the suppression treatment entry, the local backsweep action segment is disabled to avoid the re-aggregation of molten solder, cross-gap connection, or increased splashing caused by back-and-forth sweeping in high-risk states. The observable characteristics of the tin deficiency trend include: a persistent insufficient coverage zone appears in the target forming area; after the wetting front advances, an uncovered area or edge retraction zone forms locally, accompanied by a sluggish advancement of the forming boundary or local edge thinning; after identifying the tin deficiency trend, the control module enters a directional compensation branch. Under the premise that the boundary constraints remain effective, it first adjusts the path offset and coverage morphology to align the energy action area with the insufficient area and limit the action boundary. Then, it adjusts the motion rhythm and heating output in a coordinated manner to match the compensation heat input with the residence change, thereby concentrating the compensation effect on the target forming area and suppressing its expansion outward to the sensitive boundary; coverage morphology Prioritize using convergent or directional bias apertures, with path bias constrained by retracement boundaries to ensure consistency between geometric and thermal guidance. If the tin deficiency trend does not revert to allow or trigger a warning within the review window, the control module introduces a local retracement action segment within that branch. The local retracement organizes motion-side commands using a controlled reciprocating path and follows heating-side commands in a covering pattern, ensuring continuous trajectory and heat input during the retracement process. After the retracement is completed, re-enter the review window. If the review still fails and the upgrade condition is triggered, the control module elevates the handling entry to the suppression category to avoid repeated deepening of compensation within the same level, which could lead to accumulation or expansion risks. Observable characteristics of the unwetting trend include: the wetting front remains stagnant within the observation window; the front fracture is multi-segmented and appears intermittently; the front advancement direction continuously deviates from the weld centerline; and there is continuous edge deterioration or repeated local surface conditions. Upon detecting the unwetting trend, the control module enters the wetting reconstruction branch. Wetting reconstruction aims to re-establish a continuous wetting initiation zone and stabilize the advancement direction. First, it adjusts the path offset and coverage orientation offset related to the incident direction to prioritize wetting initiation in areas with more stable adhesion and surface conditions. The continuous advancement process is formed by coordinating the convergence of the motion rhythm and the segmented changes in heating output. During wetting and reconstruction, the forming boundary proximity constraint is continuously applied. When the proximity increases or an outward expansion trend appears, the control module switches to the protection aperture and continues to perform wetting and reconstruction, so that the reconstruction action converges under the boundary constraint, avoiding over-boundary spreading or end accumulation caused by enhanced wetting. After wetting and reconstruction is completed, the system enters the review window. If the review is passed, the system is unfrozen and returns to the normal spreading aperture. If the review fails and the upgrade condition is triggered, the treatment level is upgraded to the suppression entry to prioritize convergence risk. The observable characteristics of solder overflow bridging include: the forming boundary crossing the target forming area boundary and extending towards the sensitive boundary; the appearance of continuous connecting bands or signs of connection between the molten areas on both sides at the overlap gap; abrupt changes in the continuity of the weld edge accompanied by an outward expansion trend or rapid growth of local accumulation bands; after the control module detects this trend, it enters the solder overflow suppression branch and switches the control constraint to the boundary priority caliber; the suppression branch reduces solder accumulation and suppresses the risk of bridging by organizing the following actions: releasing the movement rhythm to shorten the local heat dwell time, converging the heating output to reduce energy density, converging the coverage area or applying a directional bias to reduce heat input to non-target areas, while withdrawing the path bias to keep the wetting front away from the sensitive boundary and bridging-prone area, so that geometric guidance and heat input work together in the convergence direction; after the action is executed, it enters the review window; if the review still shows signs of bridging or the upgrade conditions are not resolved, the control module maintains the suppression caliber and records the upgrade mark, and if necessary, upgrades the treatment level to enter a stronger suppression entry point to avoid releasing the suppression before the risk of bridging subsides and triggering bridging again; The observable characteristics of the splashing trend include: transient jet points or bright spots appearing at the edge of the molten zone and accompanied by discontinuous jumps in the wetting front; sudden, fracture-like changes in the wetting front and edge morphology within the observation window; the execution side generating a protective event marker corresponding to the jetting phenomenon; after detecting the splashing trend, the control module enters the splashing suppression branch; splashing suppression is executed in a priority order of suppression, first converging the heating output and the coverage morphology to reduce transient energy input, then releasing the movement rhythm to reduce local dwell time, while adjusting the path offset to ensure that the energy action area avoids the edge abrupt change region and sensitive boundary, thereby prompting the process to return to a determinable and convergent state; the exit of splashing suppression is constrained by a threshold set. The control module confirms in the review window that the state dictionary regression is allowed or a warning is issued and that the stability judgment is met, and only after confirming that the upgrade condition is lifted and the rejection condition is not met, is it allowed to exit the suppression aperture, to avoid prematurely restoring the normal spreading aperture before the risk is eliminated, which could lead to jetting or jump recurrence; After the graded treatment is completed, the control module performs a recovery judgment. The recovery judgment is based on the return of the status dictionary output to allow or warn and pass the stability judgment. At the same time, it meets the requirements of removing the trend marker from the upgrade status, the rejection condition not being met, and the image quality gate remaining allowed. For bridging and spatter risks, the recovery judgment also requires the forming boundary proximity relationship to return to the threshold set allowable range, and the weld edge continuity to return to the established judgment caliber. When the recovery judgment passes, the control module generates a treatment completion permission, unfreezes, and solidifies the currently effective motion parameters and heating parameters as candidate parameters for the arc-closing solidification section entrance, and enters the arc-closing solidification section. The arc-closing solidification section organizes the action according to the principle of heat input gradual withdrawal and trajectory exit continuity. Under the condition that the forming boundary constraint continues to be effective, the heating output and coverage shape converge according to the gradual withdrawal caliber, while the motion rhythm smoothly transitions according to the exit caliber, so as to reduce the risk of edge abrupt change, local thermal shock or uneven solidification in the exit stage, and retain the end shape that can be used for subsequent quality verification. During the graded handling and arc-end solidification process, the control module writes evidence into the process log and archives it. The process log is bound and saved with the operation identifier and operation configuration snapshot. The archived content includes three categories: trigger evidence, handling evidence, and closing evidence. Trigger evidence includes the keyframe index before triggering and the status dictionary output and trend markers at the triggering time. Handling evidence includes the handling branch type and level, switching identifier, linkage action record, readback confirmation result and review window judgment result, and records the handling completion permission identifier. Closing evidence includes the candidate inlet parameters and exit keyframe index of the arc-end solidification section.

[0023] In this embodiment, the technical solution for solder sheet soldering operations involves the control module loading the solder sheet specifications, overlap structure, and stage boundary constraints at the start of the operation, generating an operation identifier, and completing visual acquisition and time synchronization configuration to form a traceable operation configuration snapshot. Subsequently, the module identifies the solder sheet's in-situ offset, rotation, and bonding gap within the pre-soldering observation field, and adjusts the starting posture, arc initiation point, and incident direction in conjunction with the deviation type. After confirming that the entry conditions are met, preheating is initiated to ensure that the overlap area is in a stable thermal response state that can be acquired. When the preheating stabilization conditions are met, the module synchronously switches to the melt start parameter group under the same switching identifier. The system adjusts the motion rhythm, path offset, heating output, and coverage shape in a coordinated manner, and performs necessary combination regressions based on the continuity of wetting initiation. After entering the wetting and spreading stage, the system organizes the normal group, boundary protection group, and transition action segment using the state machine of the controlled object. Based on the real-time status of the wetting front and forming boundary, the system synchronously switches between each controlled object and completes readback confirmation. During the spreading process, trend markers for insufficient solder, unwetting, solder overflow bridging, and splashing are continuously generated, triggering a graded treatment sequence and completing the recovery judgment through the review window. Subsequently, the system switches to the arc termination and solidification segment, exits according to the gradual withdrawal caliber, and archives key frames, switching indicators, and treatment records.

[0024] It should be noted that this invention can be deployed on the device itself to realize embedded applications, or it can run on a PC or other terminal with a user interface, thereby meeting various hardware environments and usage requirements.

[0025] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wireless or wired transmission; wired transmission methods include optical fiber, twisted pair, coaxial cable, etc.; wireless transmission includes infrared, microwave, etc. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center containing one or more sets of available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. A semiconductor medium can be a solid-state drive.

[0026] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and modules described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0027] In the embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or modules may be electrical, mechanical, or other forms.

[0028] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical modules; they may be located in one place or distributed across multiple network modules. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0029] In addition, the functional modules in the embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0030] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0031] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0032] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for soldering of a tin sheet with a robot in combination with a real-time visual feedback control, characterized in that, Comprise: S1: Establish job reference, load tin sheet specifications, lap joint structure and stage boundary constraints, generate job identification and start visual acquisition; S2: Identify tin sheet in-place deviation, rotation and fit gap, correct starting posture, starting arc point and incident direction according to deviation type, and enter preheating after entering preheating; S3: Switch to melting start parameter group according to preheating stable condition, adjust motion speed, path offset, heating output and coverage range synchronously; S4: Enter the wet spreading stage, load wet spreading entry parameters and establish wet front state and forming boundary state, switch between normal group, boundary protection group and transition action segment according to wet front state and forming boundary state, and link parameters; S5: Monitor tin shortage, unwet, tin overflow, bridge and spatter trend, trigger hierarchical disposal sequence, complete recovery determination, enter arc closing and solidification segment, and archive key frames and disposal records.

2. The method of claim 1, wherein the method further comprises: providing a real-time visual feedback to the user. Establish job reference, load tin sheet specifications, lap joint structure and stage boundary constraints, generate job identification and start visual acquisition, comprising: Receive station and batch information to generate job identification, solidify the conversion relationship of clamping reference, flange reference and action point reference and verify; Load tin sheet and lap joint configuration and threshold version according to adaptive mode, establish stage parameter group mapping and switching; Align visual frame and pose time sequence and perform image gating, generate job snapshot and give pre-welding observation area, starting area and preheating parameter group index.

3. The method of claim 1, wherein the method further comprises: providing a real-time visual feedback to the user. Identify tin sheet in-place deviation, rotation and fit gap, comprising: Switch observation posture within the allowed starting posture set and keep heating off, establish a short observation window in the observation area to form a reference view, after consistent confirmation of consecutive frames, verify in order of coverage band, alignment band and fit condition; Thresholds are composed of visual and readback criteria and are versioned and bound to tin sheet, lap joint and adaptive mode.

4. The method of claim 1, wherein the method further comprises: Correct starting posture, starting arc point and incident direction according to deviation type, and enter preheating, comprising: When offset or rotation, call correction parameter group to link and correct starting posture, heating point and incident direction, and enter preheating after pre-welding confirmation; For fit abnormalities, according to gap, warping and suspension type, perform corresponding adjustment or re-fit, if not satisfied, prompt re-placement, and record key frames and poses.

5. The method of claim 1, wherein the method further comprises: providing real-time visual feedback to a user during the soldering process. Switch to melting start parameter group according to preheating stable condition, comprising: Establish an observation window at the end of preheating and maintain a controlled pace and fixed incident posture, according to the threshold set and state dictionary verified and versioned by calibration and trial welding, make hierarchical determination on visual criteria, heating readback criteria and motion readback criteria; Generate preheating stable permission when allowed, continue observation when warned or limited, and handle according to rollback strategy.

6. The method of claim 1, wherein the method further comprises: providing real-time visual feedback to a user during the soldering process. Synchronize adjustment of motion speed, path offset, heating output and coverage range, comprising: After obtaining preheating stable permission, generate switching identification and lock switching, make speed, path offset, heating output and coverage form synchronous effective, readback confirm motion state, heating state and acquisition synchronization; The melting start segment is graded according to melting continuity, wetting directionality and boundary proximity, and the parameters are linked and kept when the gating is not satisfied, and the archives are marked when the switching is available.

7. The method of claim 1, wherein the method further comprises: providing real-time visual feedback to a user during the soldering process. Enter the wet spreading stage, load wet spreading entry parameters and establish wet front state and forming boundary state, comprising: Load the motion parameters and heating parameters of the wetting spreading stage, reference the threshold set and state dictionary of the job configuration snapshot binding; Collect the image sequence according to the field of view alignment and image gating, generate the wetting front state and the forming boundary state.

8. The method of claim 1, wherein the method further comprises: providing real-time visual feedback to a user during the soldering process. According to the wetting front state and the forming boundary state, switch and link the parallel parameters between the normal group, the boundary protection group and the transition action segment, including: The normal group, the boundary protection group and the transition action segment constitute a state machine, and the motion instruction and the heating instruction are switched synchronously according to the switching identifier and read back, and the entry and exit use separate thresholds; When the limit is executed without escalation trend, the regression review is performed, when the escalation trend is turned into hierarchical treatment, the completion permission is generated and recorded when the completion criterion is met.

9. The method of claim 1, wherein the method further comprises: providing real-time visual feedback to a user during the soldering process. Monitor the less tin, unwet, overflow tin bridging and spatter trends, including: When the image gating is allowed, according to the threshold set and state dictionary referenced by the job configuration snapshot, the trend level of less tin, unwet, overflow tin bridging and spatter is output respectively; According to the escalation condition and the veto condition, determine the hierarchical treatment entrance corresponding to the trend level.

10. The method of claim 1, wherein the method further comprises: providing real-time visual feedback to a user during the soldering process. Trigger the hierarchical treatment sequence, enter the arc collection solidification segment and archive the key frame and treatment record after the recovery determination, including: Freeze the switching and regression entrance when the treatment entrance is triggered, and link the motion and heating synchronously according to the switching identifier and read back to confirm; Determine the review window and switch the regression, reinforcement and inhibition caliber according to the level, gradually retreat the arc collection solidification after the recovery determination, and archive the key frame, level, switching identifier and review conclusion.

Images