High speed wire harness welding method and system based on pulsed laser welding

Abstract

The application relates to the field of laser manufacturing technology, and relates to a high-speed wire harness welding method and system based on pulse laser welding, which comprises the following steps: receiving a wire harness welding instruction, confirming a laser welding system through the wire harness welding instruction, obtaining a welding node, starting the laser welding system, positioning the welding node in the laser welding system after starting through a positioning device, obtaining a positioned welding node, pressing and fixing the positioned welding node through a clamping tool and a welding vibration unit to obtain a fixed welding node, performing welding test on the fixed welding node through a laser, synchronously measuring the temperature during welding through a temperature sensor to obtain a welding temperature, moving a terminal bottom die to obtain a plurality of welding positions, controlling the laser to weld a plurality of welding points on the plurality of welding positions through a laser working node, and realizing the high-speed wire harness welding method based on pulse laser welding. The application can improve the precision and rate of pulse laser welding.

Description

Technical Field

[0001] This invention relates to the field of laser manufacturing technology, and in particular to a high-speed wire bundle welding method and system based on pulsed laser welding. Background Technology

[0002] High-speed wire harness welding technology based on pulsed lasers is a key path for modern automotive, aerospace, and precision electronics manufacturing industries to achieve high-efficiency and high-quality connections. Pulsed lasers can achieve micro-area precision melting at the interface between the wire harness and the terminal metal with extremely short action time and extremely high energy density, effectively overcoming the thermal damage and deformation problems of traditional welding, and improving the strength and consistency of the weld joint. It has significant strategic value for promoting the technological upgrading and reliability assurance of the entire wire harness processing industry chain.

[0003] Currently, in traditional pulsed laser wire beam welding, the workpiece is positioned and fixed by simple fixtures before welding. Under laser impact and thermal stress, it is prone to displacement, resulting in poor welding or positional deviation of the weld.

[0004] While traditional pulsed laser wire welding can perform wire welding, the lack of effective real-time monitoring and adaptive parameter adjustment during the welding process makes it unable to cope with interference from incoming material tolerances and surface condition fluctuations, resulting in unstable welding quality. Furthermore, a single laser energy input is insufficient to perfectly control the heat-affected zone, easily leading to defects such as spatter, overheating, or insufficient connection. Therefore, improving the precision and speed of pulsed laser welding has become an urgent problem to be solved. Summary of the Invention

[0005] This invention provides a high-speed wire harness welding method based on pulsed laser welding and a computer-readable storage medium, the main purpose of which is to improve the accuracy and speed of pulsed laser welding.

[0006] To achieve the above objectives, the present invention provides a high-speed wire harness welding method based on pulsed laser welding, comprising: The system receives a wire harness welding command and confirms the laser welding system based on the command. The laser welding system includes a terminal mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. Start the laser welding system, use the positioning device in the laser welding system to position the node to be welded, obtain the positioning welding node, use the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain the fixed welding node. The laser is used to perform welding tests on fixed welding nodes, and a temperature sensor is used simultaneously to measure the welding temperature to obtain the welding temperature. Based on the welding temperature, the operating frequency, pulse width and laser power of the laser are determined to obtain the laser operating node. The bottom mold of the moving terminal is used to obtain multiple welding positions. The laser working node is used to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

[0007] Optionally, placing the welding node in the terminal mold to obtain the node to be welded includes: Check the length of the wire harness and the integrity of the terminals to obtain the status of the welding nodes, which can be either normal or abnormal. When the welding node is in the normal state, insert the wire harness into the terminal to obtain the initial welding node. Place the initial welding node in the predetermined position in the terminal bottom mold to obtain the node to be welded. Otherwise, replace the wiring harness or terminals to obtain a new wiring harness or new terminals. Use the new wiring harness as the wiring harness and the new terminals as the terminals, and return to the steps of checking the wiring harness length and terminal integrity until the solder joint status is normal.

[0008] Optionally, the step of checking the wire harness length and terminal integrity to obtain the weld node status includes: The actual length of the wire harness is measured to obtain the measured length, and the measured length is compared with a preset standard length range, wherein the standard length range includes an upper limit and a lower limit of the standard length; If the measured length is within the standard length range, the wire harness is confirmed as a normal wire harness; If the measured length is less than the lower limit of the standard length corresponding to the standard length range, the wire harness will be identified as an abnormal wire harness. If the measured length is greater than the upper limit of the standard length corresponding to the standard length range, the wire harness is cut according to the preset unit length to obtain a cut wire harness. The cut wire harness is used as the wire harness, and the step of measuring the actual length of the wire harness is returned until the length difference meets the error range and a normal wire harness is obtained. Observe the defects on the terminal surface to obtain the screening terminal, test the electrical continuity of the screening terminal to obtain the terminal status, wherein the terminal status includes normal continuity or abnormal continuity; If the terminal status is normal conduction, the selected terminal is recorded as a normal terminal; otherwise, an abnormal terminal is obtained. If the wire harness is a normal wire harness and the terminal is a normal terminal, then the welding node is in a normal state; otherwise, the welding node is in an abnormal state, and the normal state or abnormal state is taken as the welding node state.

[0009] Optionally, the step of using the positioning device in the laser welding system after startup to position the node to be welded, thereby obtaining a positioned welding node, includes: In a laser welding system, the terminal mold with the node to be welded is moved to a pre-prepared welding station to obtain the initial welding position; The positioning device of the laser welding system is used to detect the deviation between the initial welding position and the preset standard welding position to obtain the position offset node, wherein the position offset node includes the position error and the offset direction; If the position error is less than or equal to the preset offset error threshold, the node to be welded at the initial welding position is taken as the positioning welding node; Otherwise, adjust the position of the terminal bottom mold according to the offset direction to obtain the target welding position; The target welding position is used as the initial welding position. The process returns to the step of detecting the deviation between the initial welding position and the preset standard welding position using the positioning device of the laser welding system, until the position error is less than or equal to the offset error threshold. The node to be welded at the target welding position is then used as the positioning welding node.

[0010] Optionally, the method of using the positioning device of the laser welding system to detect the deviation between the initial welding position and the preset standard welding position to obtain the position offset node includes: The initial position coordinates are obtained by using the positioning device to acquire the coordinates of the initial welding position; Obtain the coordinates of the standard welding position, calculate the deviation between the initial position coordinates and the standard position coordinates, and obtain the position deviation nodes, which include the X-axis deviation, Y-axis deviation and Z-axis deviation. The offset direction is determined based on the position deviation node; The position error is calculated based on the position deviation nodes, as shown in the following method: in, This indicates the position error. This indicates the X-axis deviation. This indicates the Y-axis deviation. This indicates the Z-axis deviation; By associating the offset direction with the positional deviation, the positional offset node is obtained.

[0011] Optionally, the step of acquiring the coordinates of the initial welding position using the positioning device to obtain the initial position coordinates includes: The positioning device is activated, and the initial welding position is scanned using the activated positioning device to obtain a three-dimensional point cloud, wherein the three-dimensional point cloud includes all scanned points of the initial welding position; Noise points are removed from the 3D point cloud to obtain a denoised point cloud, in which only the feature region of the initial welding position is retained. Special marker points are extracted from the noise-reduced point cloud using threshold segmentation to obtain a feature coordinate set, and the coordinate system of the positioning device is determined based on the feature coordinate set; Feature coordinates are extracted sequentially from the feature coordinate set, and the following operation is performed on each extracted feature coordinate: Obtain the preset rotation matrix, preset translation vector, and pre-constructed welding station coordinate system. Use the rotation matrix and translation vector to transform the feature coordinates from the positioning device coordinate system to the welding station coordinate system to obtain the station coordinates. The transformation method is as follows: in, This represents the value of the workstation coordinates on the X-axis. This represents the value of the workstation coordinates on the Y-axis. This represents the value of the workstation coordinates on the Z-axis. This represents the value of the feature coordinates on the X-axis. This represents the value of the feature coordinates on the Y-axis. This represents the value of the feature coordinates on the Z-axis. Represents the rotation matrix, Denotes the translation vector, This indicates that the coordinates are represented in matrix form; Summarize the workstation coordinates to obtain a workstation coordinate set. Calculate the mean values ​​of the workstation coordinate set on the X-axis, Y-axis, and Z-axis respectively to obtain the mean values ​​of the X-axis, Y-axis, and Z-axis. By correlating the mean values ​​of the X-axis, Y-axis, and Z-axis, the initial position coordinates are obtained.

[0012] Optionally, the step of using the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain a fixed welding node includes: The two sides of the positioning welding node are clamped using a clamping fixture to obtain the welding node to be fixed. The welding vibration unit is activated, and the piezoelectric ceramic is initialized using the activated welding vibration unit to obtain the initial piezoelectric ceramic. High-frequency vibration is generated by using an initial piezoelectric ceramic to obtain a high-frequency vibration signal. The high-frequency vibration signal is then amplified and transmitted using the amplitude transformer to obtain an amplified vibration signal. The tool head is controlled by an amplified vibration signal to obtain a vibrating tool head. The vibrating tool head is used to strike the node to be fixed for welding to obtain a fixed welding node.

[0013] Optionally, the step of using the laser to perform welding tests on the fixed welding joint and simultaneously using a temperature sensor to measure the welding temperature to obtain the welding temperature includes: Obtain the initial operating parameters, which include the initial laser power, initial operating frequency, and initial pulse width; The initial working parameters are configured into the laser after startup to obtain the initial laser. The initial laser is then used to irradiate the center position of the fixed welding node to obtain the irradiation position. The coordinates of the irradiation position are determined in the workstation coordinate system based on the irradiation position. Obtain the coordinates of each temperature sensor in the workstation coordinate system to obtain the temperature sensor coordinate set; Calculate the distance from each temperature sensor coordinate in the temperature sensor coordinate set to the irradiation position coordinate to obtain multiple sensor distances. Determine the weight of each temperature sensor based on the multiple sensor distances to obtain a sensor weight set. The temperature collected by each of the multiple temperature sensors is obtained to form a set of collected temperatures, where the collected temperatures correspond one-to-one with the sensor weights. The welding temperature is calculated based on the collected temperature set and the sensor weight set.

[0014] Optionally, the step of determining the laser's operating frequency, pulse width, and laser power based on the welding temperature to obtain the laser's operating node includes: The preset temperature sensor acquisition time is obtained, resulting in multiple temperature acquisition time points. These multiple acquisition time points are sorted in chronological order to obtain an acquisition time point sequence. The earliest and latest time points are identified from the acquisition time point sequence, and the acquisition time range is determined based on the earliest and latest time points. The laser is activated within the acquisition time range, and the welding temperature is monitored at each temperature acquisition time point in the acquisition time point sequence to obtain a welding temperature set, wherein the welding temperature corresponds one-to-one with the temperature acquisition time point; Based on the data acquisition time sequence and welding temperature set, the welding temperature curve is plotted in a pre-constructed Cartesian coordinate system. Obtain a preset filtering time range, wherein the filtering time range is within the collection time range; The maximum and minimum temperature values ​​are retrieved from the welding temperature curve by using the screening time range. Obtain the preset maximum temperature threshold and the preset minimum temperature threshold. If the maximum temperature value is less than the maximum temperature threshold and the minimum temperature value is greater than the minimum temperature threshold, then the initial operating parameters are used as the laser operating node. Otherwise, determine the maximum temperature value exceeding the limit based on the minimum temperature threshold, the maximum temperature threshold, the minimum temperature value, and the maximum temperature value, and calculate the average of the minimum temperature threshold and the maximum temperature threshold to obtain the target welding temperature; The temperature deviation is obtained by calculating the difference between the maximum temperature exceeding the limit and the target welding temperature. Based on the temperature deviation and the initial working parameters, the laser working node is calculated.

[0015] To achieve the above objectives, the present invention also provides a high-speed wire harness welding system based on pulsed laser welding, comprising: The welding system confirmation module is used to receive wire harness welding instructions and confirm the laser welding system through the wire harness welding instructions. The laser welding system includes a terminal bottom mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes piezoelectric ceramics, an amplitude transformer, a flange, and a tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. The welding node fixing module is used to start the laser welding system, and to position the node to be welded using the positioning device in the laser welding system after startup, thereby obtaining a positioned welding node. The clamping fixture and welding vibration unit are used to press and pre-weld the positioned welding node to fix it, thereby obtaining a fixed welding node. The welding test module is used to perform welding tests on fixed welding nodes using the laser, and simultaneously use a temperature sensor to measure the welding temperature to obtain the welding temperature. Based on the welding temperature, the operating frequency, pulse width and laser power of the laser are determined to obtain the laser operating node. The welding execution module is used to move the terminal bottom mold to obtain multiple welding positions. The laser working node is used to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

[0016] To address the above problems, the present invention also provides an electronic device, the electronic device comprising: A memory that stores at least one instruction; and a processor that executes the instructions stored in the memory to implement the high-speed wire harness welding method based on pulsed laser welding described above.

[0017] To address the aforementioned problems, the present invention also provides a computer-readable storage medium storing at least one instruction, which is executed by a processor in an electronic device to implement the high-speed wire harness welding method based on pulsed laser welding described above.

[0018] To address the problems described in the background art, this invention receives a wire harness welding command and identifies a laser welding system based on the command. The laser welding system includes a terminal mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. A welding node is obtained, comprising a wire harness and a terminal. The welding node is placed in the terminal mold to obtain the node to be welded. This invention effectively suppresses weld point displacement by utilizing vibration pre-fixation and optimizes laser parameters in real time using temperature feedback, significantly improving welding positioning accuracy, connection strength, and quality consistency. It overcomes the drawbacks of traditional methods, such as easy false welds and significant heat damage, achieving active positioning, real-time monitoring, and parameter adaptation during the welding process. The laser welding system is activated, and the positioning device within the system is used to locate the node to be welded, obtaining the positioned welding node. The clamping fixture and welding vibration unit are then used to... The positioning and welding nodes are pre-welded and fixed to obtain a fixed welding node. This invention utilizes high-precision three-dimensional visual positioning to automatically correct workpiece position deviations, combined with ultrasonic vibration pre-fixing technology, achieving precise alignment and firm clamping of the welding node. This eliminates displacement and incomplete welding problems in traditional welding, improving the accuracy, strength, and consistency of the welding process. The fixed welding node is tested using a laser, and a temperature sensor is used simultaneously to measure the welding temperature. Based on the welding temperature, the laser's operating frequency, pulse width, and laser power are determined, resulting in the laser's working node. The terminal mold is moved to obtain multiple welding positions. The laser's working node is used to control the laser to weld multiple weld points at these positions, realizing a high-speed wire harness welding method based on pulsed laser welding. This invention accurately calculates the welding temperature using multi-sensor distance weighted fusion technology, achieving precise control of welding energy and avoiding overheating or incomplete welding defects, providing intelligent process assurance for high-speed precision welding. Therefore, this invention can improve the accuracy and speed of pulsed laser welding. Attached Figure Description

[0019] Figure 1 This is a schematic flowchart of a high-speed wire harness welding method based on pulsed laser welding provided in an embodiment of the present invention; Figure 2 A functional block diagram of a high-speed wire harness welding system based on pulsed laser welding provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of an electronic device that implements the high-speed wire harness welding method based on pulsed laser welding, according to an embodiment of the present invention.

[0020] Explanation of reference numerals in the attached figures: 10. Electronic device; 11. Processor; 12. Memory; 13. Bus.

[0021] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0022] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0023] This application provides a high-speed wire harness welding method based on pulsed laser welding. The execution entity of the high-speed wire harness welding method based on pulsed laser welding includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application embodiment: a server, a terminal, etc. In other words, the high-speed wire harness welding method based on pulsed laser welding can be executed by software or hardware installed on a terminal device or a server device, and the software can be a blockchain platform. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster.

[0024] Reference Figure 1 The diagram shown is a flowchart illustrating a high-speed wire harness welding method based on pulsed laser welding according to an embodiment of the present invention. In this embodiment, the high-speed wire harness welding method based on pulsed laser welding includes: S1. Receive wire harness welding command, and confirm the laser welding system through the wire harness welding command. The laser welding system includes a terminal bottom mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head.

[0025] It should be understood that the wire harness welding command is issued by the operator of the laser welding system. The laser welding system is an integrated working environment for pulsed laser welding of wire harnesses and terminals. The terminal mold is a support structure used to support and position the wire harness and terminals, providing stable support for the welding nodes during welding and cooperating with a motion mechanism to achieve multi-point movement to complete laser welding of multiple weld points. The clamping fixture is a component used to clamp and fix the welding nodes, ensuring the stability of the wire harness and terminal positions during welding, and integrates multiple temperature sensors to monitor the welding temperature in real time. The temperature sensors are used to monitor the temperature during the welding process. The welding vibration unit is an auxiliary component used to transmit energy and clamp and fix the terminals and wire harness during pulsed laser welding of the wire harness. The piezoelectric ceramic is used to generate high-frequency vibration signals. The amplitude transformer is connected to the piezoelectric ceramic to amplify or transmit vibration energy. The flange serves as a connecting workpiece, used to firmly connect the amplitude transformer and the tool head. The tool head is connected to the flange, receives and outputs vibration, and applies the vibration to the welding nodes. The positioning device is used to detect and calibrate the spatial position of the node to be welded in the terminal mold, ensuring that the node to be welded is precisely aligned with the laser welding trajectory. The laser is an energy source capable of outputting pulsed laser beams and acting on the welding node, used to perform targeted heating and melting of the terminal and wire bundle during the welding process.

[0026] For example, in order to achieve fast and accurate welding of wire harnesses and terminals, and to avoid problems such as weak welding and easy detachment, the operator of the laser welding system issues a wire harness welding command and confirms the laser welding system.

[0027] S2. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. It should be understood that the terminal is a metal component that provides a stable connection between the wire harness and other electrical components. The welding node is the association between the wire harness to be welded and the corresponding terminal, and there is no contact or assembly involved. Therefore, placing the welding node in the terminal mold to obtain the node to be welded includes: Check the length of the wire harness and the integrity of the terminals to obtain the status of the welding nodes, which can be either normal or abnormal. When the welding node is in the normal state, insert the wire harness into the terminal to obtain the initial welding node. Place the initial welding node in the predetermined position in the terminal bottom mold to obtain the node to be welded. Otherwise, replace the wiring harness or terminals to obtain a new wiring harness or new terminals. Use the new wiring harness as the wiring harness and the new terminals as the terminals, and return to the steps of checking the wiring harness length and terminal integrity until the solder joint status is normal.

[0028] It should be explained that checking the length of the wire harness and the integrity of the terminals is to ensure that the wire harness and terminals are in a proper assembly state before soldering, thereby avoiding problems such as poor soldering, soldering misalignment, or poor contact caused by the wire harness being too long or too short, or by the terminals being deformed or damaged.

[0029] Furthermore, the welding node state refers to the quality and assembly fit of the wire harness and terminals before entering the welding process. Specifically, the welding node state can be confirmed by inspecting the wire harness length and terminal integrity. The initial welding node is the assembly to be welded formed by inserting the wire harness into the terminals after confirming that the wire harness length and terminal integrity are both normal. The welding node to be welded is a welding unit formed by placing the initial welding node at a predetermined position on the terminal bottom mold. This welding unit has not yet been positioned and clamped, but it is already in the processing position of the laser welding system and is ready to enter the welding positioning step.

[0030] For example, assuming a batch of wire harnesses has a design length of 100mm ± 2mm and the terminals are tin-plated copper terminals, after obtaining the welding node, the wire harness length and terminal integrity are first inspected. Assuming the inspection result shows that the wire harness length is 99.5mm and there are no cracks on the terminal surface, the welding node is in a normal state. At this time, the wire harness is inserted into the terminal to obtain the initial welding node, and it is placed in the predetermined position of the terminal bottom mold to form the node to be welded. If the inspection finds that the wire harness length is less than 96mm or the terminal has cracks, it is determined to be an abnormal state. The wire harness or terminal needs to be replaced and the inspection repeated until the welding node is restored to a normal state before the welding process can begin.

[0031] It should be explained that the process of checking the wire harness length and terminal integrity to obtain the weld node status includes: The actual length of the wire harness is measured to obtain the measured length, and the measured length is compared with a preset standard length range, wherein the standard length range includes an upper limit and a lower limit of the standard length; If the measured length is within the standard length range, the wire harness is confirmed as a normal wire harness; If the measured length is less than the lower limit of the standard length corresponding to the standard length range, the wire harness will be identified as an abnormal wire harness. If the measured length is greater than the upper limit of the standard length corresponding to the standard length range, the wire harness is cut according to the preset unit length to obtain a cut wire harness. The cut wire harness is used as the wire harness, and the step of measuring the actual length of the wire harness is returned until the length difference meets the error range and a normal wire harness is obtained. Observe the defects on the terminal surface to obtain the screening terminal, test the electrical continuity of the screening terminal to obtain the terminal status, wherein the terminal status includes normal continuity or abnormal continuity; If the terminal status is normal conduction, the selected terminal is recorded as a normal terminal; otherwise, an abnormal terminal is obtained. If the wire harness is a normal wire harness and the terminal is a normal terminal, then the welding node is in a normal state; otherwise, the welding node is in an abnormal state, and the normal state or abnormal state is taken as the welding node state.

[0032] It should be understood that the standard length range is the allowable range of variation in the wire harness length, defined by a preset upper and lower standard length limit. The screening terminals are those that are visually inspected before soldering and are selected for soldering only after they show no abnormalities.

[0033] For example, if the preset standard length range is [98mm, 102mm], when the measured length is 100mm, it is confirmed as a normal wire harness. When the measured wire harness length is 95mm, which is less than the lower limit of the standard length of 98mm, it is determined to be an abnormal wire harness. When the measured wire harness length is 105mm, which is greater than the upper limit of the standard length of 102mm, it is cut according to the preset unit length of 1mm. After two cuts, 103mm and 102mm are obtained, and finally it is confirmed as a normal wire harness. At the same time, the terminals are visually inspected and tested for continuity. If the terminal surface has no cracks or oxidation and the continuity resistance is 0.02 ohms, it is a normal terminal; otherwise, it is an abnormal terminal. Thus, when the wire harness length is 100mm and the terminal continuity resistance is 0.02 ohms, the welding node status is normal.

[0034] S3. Start the laser welding system, use the positioning device in the laser welding system after startup to position the node to be welded, obtain the positioning welding node, use the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain the fixed welding node.

[0035] It should be understood that after completing the inspection of the wire harness length and terminal integrity, and confirming that the welding node is in a normal state, the welding preparation stage begins. The laser welding system is then started. To ensure that the laser energy is accurately applied to the contact area between the wire harness and the terminal, the positioning device in the laser welding system after startup is used to locate the node to be welded, thus obtaining the positioned welding node. This includes: In a laser welding system, the terminal mold with the node to be welded is moved to a pre-prepared welding station to obtain the initial welding position; The positioning device of the laser welding system is used to detect the deviation between the initial welding position and the preset standard welding position to obtain the position offset node, wherein the position offset node includes the position error and the offset direction; If the position error is less than or equal to the preset offset error threshold, the node to be welded at the initial welding position is taken as the positioning welding node; Otherwise, adjust the position of the terminal bottom mold according to the offset direction to obtain the target welding position; The target welding position is used as the initial welding position. The process returns to the step of detecting the deviation between the initial welding position and the preset standard welding position using the positioning device of the laser welding system, until the position error is less than or equal to the offset error threshold. The node to be welded at the target welding position is then used as the positioning welding node.

[0036] It is understood that the positioning welding node is a node to be welded whose welding position deviation is within a preset error threshold range and meets the welding accuracy requirements after being detected and adjusted by the positioning device. The initial welding position is the first position of the node to be welded after it moves to the welding station with the terminal bottom mold, serving as a reference position for deviation comparison with the standard welding position. The standard welding position is a pre-set, ideal spatial coordinate position used to ensure that the laser beam accurately acts on the welding point in the contact area between the wire bundle and the terminal. The offset error threshold is the maximum allowable deviation range between the actual position of the node to be welded and the standard welding position during the welding positioning process. The positioning welding node is a welding node that can be used for subsequent welding operations by comparing and correcting the position of the node to be welded with the preset standard welding position through the positioning device of the laser welding system. The target welding position is a welding position obtained by adjusting the position of the terminal bottom mold according to the offset direction based on the detection results of the positioning device, used to ensure that the position error meets the preset offset error threshold.

[0037] For example, suppose the terminal is placed on the terminal base mold and moved to the welding station to obtain an initial welding position (X=10.2mm, Y=5.0mm). The positioning device of the laser welding system is used to detect the deviation between the initial position and the standard welding position (X=10.0mm, Y=5.0mm) to obtain the position offset node. X=0.2mm With Y=0mm and the offset direction being the positive X direction, since the position error of 0.2mm is greater than the threshold of 0.1mm, the position of the terminal bottom mold is adjusted along the offset direction to the target welding position (X=10.0mm, Y=5.0mm). The deviation is re-checked and found to be 0mm, which meets the threshold condition. The target welding position is then determined as the positioning welding node.

[0038] It should be explained that the method of using the positioning device of the laser welding system to detect the deviation between the initial welding position and the preset standard welding position to obtain the position offset node includes: The initial position coordinates are obtained by using the positioning device to acquire the coordinates of the initial welding position; Obtain the coordinates of the standard welding position, calculate the deviation between the initial position coordinates and the standard position coordinates, and obtain the position deviation nodes, which include the X-axis deviation, Y-axis deviation and Z-axis deviation. The offset direction is determined based on the position deviation node; The position error is calculated based on the position deviation nodes, as shown in the following method: in, This indicates the position error. This indicates the X-axis deviation. This indicates the Y-axis deviation. This indicates the Z-axis deviation; By associating the offset direction with the positional deviation, the positional offset node is obtained.

[0039] It should be understood that special markings exist on the terminal surface for position detection and initial welding location. These initial position coordinates are three-dimensional coordinates generated by the positioning device identifying the positions of these special markings on the terminal surface. These initial position coordinates are spatial three-dimensional coordinate data collected by the positioning device after the node to be welded moves to the welding station with the terminal mold. This initial position coordinates are used for deviation comparison with standard position coordinates. The standard position coordinates are the spatial three-dimensional coordinate data of a pre-set standard welding position at the welding station, serving as the benchmark for deviation comparison of the initial position coordinates. The offset direction is the direction in three-dimensional space in which the initial welding position needs to move relative to the standard welding position.

[0040] For example, the positioning device of the laser welding system identifies the markings on the terminal surface, acquires the initial welding position coordinates (X=10.2mm, Y=5.0mm, Z=0.8mm), retrieves the standard position coordinates (X=10.0mm, Y=5.0mm, Z=0.7mm) from the laser welding system, and calculates the position deviation node. X=0.2mm Y=0mm With Z=0.1mm, the offset direction is determined to be the negative X-axis and the negative Z-axis. The position error ∆P≈0.224mm is calculated. After associating the offset direction and the position deviation, a position offset node {0.224mm, (-0.2mm, 0mm, -0.1mm)} is generated, which is used to adjust the terminal bottom mold to move to the standard welding position.

[0041] It should be explained that the step of using the positioning device to acquire the coordinates of the initial welding position to obtain the initial position coordinates includes: The positioning device is activated, and the initial welding position is scanned using the activated positioning device to obtain a three-dimensional point cloud, wherein the three-dimensional point cloud includes all scanned points of the initial welding position; Noise points are removed from the 3D point cloud to obtain a denoised point cloud, in which only the feature region of the initial welding position is retained. Special marker points are extracted from the noise-reduced point cloud using threshold segmentation to obtain a feature coordinate set, and the coordinate system of the positioning device is determined based on the feature coordinate set; Feature coordinates are extracted sequentially from the feature coordinate set, and the following operation is performed on each extracted feature coordinate: Obtain the preset rotation matrix, preset translation vector, and pre-constructed welding station coordinate system. Use the rotation matrix and translation vector to transform the feature coordinates from the positioning device coordinate system to the welding station coordinate system to obtain the station coordinates. The transformation method is as follows: in, This represents the value of the workstation coordinates on the X-axis. This represents the value of the workstation coordinates on the Y-axis. This represents the value of the workstation coordinates on the Z-axis. This represents the value of the feature coordinates on the X-axis. This represents the value of the feature coordinates on the Y-axis. This represents the value of the feature coordinates on the Z-axis. Represents the rotation matrix, Denotes the translation vector, This indicates that the coordinates are represented in matrix form; Summarize the workstation coordinates to obtain a workstation coordinate set. Calculate the mean values ​​of the workstation coordinate set on the X-axis, Y-axis, and Z-axis respectively to obtain the mean values ​​of the X-axis, Y-axis, and Z-axis. By correlating the mean values ​​of the X-axis, Y-axis, and Z-axis, the initial position coordinates are obtained.

[0042] It should be explained that in a laser welding system, the three-dimensional point cloud collected by the positioning device is in coordinates relative to the positioning device's own coordinate system, while the control of the terminal bottom mold is based on the station coordinate system. The origins and directions of the two are different, so a coordinate system transformation must be used to establish a corresponding relationship. By using a pre-obtained rotation matrix and translation vector, the feature coordinates are converted into station coordinates, so that the laser welding system can accurately map the position detected by the positioning device to the station coordinate system and achieve the positioning of the initial welding position.

[0043] Furthermore, the three-dimensional point cloud uses a large number of three-dimensional coordinate points to represent the coordinates of the surface shape of the initial welding position. The denoised point cloud is a more accurate coordinate obtained from the three-dimensional point cloud after removing erroneous or irrelevant points through a denoising algorithm. Optionally, the denoising algorithm includes, but is not limited to, Gaussian filtering, bilateral filtering, etc., which are existing technologies. The feature coordinate set is a set of coordinate points that can represent the terminal position or shape features after denoising and threshold segmentation of the three-dimensional point cloud of the initial welding position surface. The threshold segmentation is an existing technology. The positioning device coordinate system is a three-dimensional rectangular coordinate system established with the center of the positioning device as the origin and according to the scanning direction of the positioning device itself. It is used to describe the position of the feature points collected by the positioning device. The rotation matrix is ​​a square matrix used to describe the rotation transformation relationship of the coordinate system in space. It is used to transform the vector represented by the feature coordinates from one coordinate system to another rotated coordinate system while keeping the length of the vector unchanged. The translation vector is a three-dimensional vector used to represent the position difference between the origins of the two coordinate systems. The welding station coordinate system is a three-dimensional rectangular coordinate system established with the welding station as a reference, serving as the reference frame for all movements and positions in the laser welding system. The rotation matrix, translation vector, and welding station coordinate system are pre-calibrated by the laser welding system and stored in the system database.

[0044] For example, in a laser welding system, suppose the positioning device scans the initial welding position to obtain a 3D point cloud {(10.2, 5.1, 3.0), (10.4, 5.0, 3.1), (10.3, 5.2, 2.9), (12.0, 7.0, 4.0)}. After removing noise points, a denoised point cloud {(10.2, 5.1, 3.0), (10.4, 5.0, 3.1), (10.3, 5.2, 2.9)} is obtained. Threshold segmentation is used to extract the feature coordinate set {(10.2, 5.1, 3.0), (10.4, 5.0, 3.1)}, and a rotation matrix, assumed to be an identity matrix (invariant after rotation), and a translation vector (100, 200, 0) are used. Transform it to the welding station coordinate system to obtain the station coordinates (110.2, 205.1, 3.0) and (110.4, 205.0, 3.1). Calculate the average value to obtain the initial position coordinates (110.3, 205.05, 3.05).

[0045] It should be explained that the step of using the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain a fixed welding node includes: The two sides of the positioning welding node are clamped using a clamping fixture to obtain the welding node to be fixed. The welding vibration unit is activated, and the piezoelectric ceramic is initialized using the activated welding vibration unit to obtain the initial piezoelectric ceramic. High-frequency vibration is generated by using an initial piezoelectric ceramic to obtain a high-frequency vibration signal. The high-frequency vibration signal is then amplified and transmitted using the amplitude transformer to obtain an amplified vibration signal. The tool head is controlled by an amplified vibration signal to obtain a vibrating tool head. The vibrating tool head is used to strike the node to be fixed for welding to obtain a fixed welding node.

[0046] It should be understood that clamping the two sides of the positioning welding node is to fix the welding node laterally during the welding process, to prevent the positioning welding node from shifting due to the high-frequency vibration of the tool head, and to ensure the efficient transmission of vibration energy. At the same time, the high-frequency vibration of the tool head provides longitudinal fixation, further ensuring that the welding interface is fully adhered, and ultimately improving the strength of the weld and the welding quality.

[0047] It should be explained that the initial piezoelectric ceramic refers to the piezoelectric ceramic in its initial state after the welding vibration unit is started, when it is excited and enters normal working condition. At this time, it already has the ability to convert external electrical signals into high-frequency mechanical vibrations. The vibration tool head refers to the end effector in the welding vibration unit that, after being amplified and transmitted by the amplitude transformer after being subjected to high-frequency vibrations generated by the piezoelectric ceramic, can perform mechanical striking or vibration actions. The weld node to be fixed refers to the weld node that has been clamped from both sides by the clamping fixture and has completed lateral positioning, but has not yet undergone final vibration curing. The fixed weld node refers to the weld node to be fixed after being struck by the high-frequency vibration of the vibration tool head, where the welding interface has fully adhered and formed a metallurgical bond. The high-frequency vibration signal is a mechanical vibration signal with a frequency usually above 20kHz, converted from the electrical signal by the initialized piezoelectric ceramic. It is the original vibration source for subsequent energy amplification and transmission. The amplified vibration signal refers to the mechanical vibration signal with stronger energy obtained after the high-frequency vibration signal is amplified by the amplitude transformer.

[0048] For example, when performing ultrasonic welding on automotive wiring harness terminals, the clamping fixture can apply a clamping force of approximately 50-80N on both sides to achieve lateral fixation, preventing the weld joint from shifting when the tool head vibrates at a high frequency of 20-40kHz and an amplitude of 10-30μm. Simultaneously, the longitudinal vibration of the tool head ensures that the welding interface fully adheres and forms a stable bond within approximately 0.1-0.3s, ultimately increasing the tensile strength of the weld joint to over 120N, an increase of approximately 25% compared to when not clamped, thus guaranteeing the strength and consistency of the weld.

[0049] S4. Use the laser to perform welding tests on the fixed welding nodes, and simultaneously use a temperature sensor to measure the welding temperature to obtain the welding temperature. Based on the welding temperature, determine the laser's operating frequency, pulse width, and laser power to obtain the laser's working node.

[0050] Understandably, welding temperature reflects the energy input of the laser to the welding node, because laser power, pulse width, and operating frequency together determine the energy output per unit time. During welding, the material absorbs energy and its temperature rises. By measuring the welding temperature and referring to the pre-established correspondence between temperature and laser power, frequency, and pulse width, the operating frequency, pulse width, and laser power of the laser can be determined, thereby ensuring that the welding energy meets the requirements and achieving stable and precise welding.

[0051] Therefore, the step of using the laser to perform welding tests on the fixed welding joint and simultaneously using a temperature sensor to measure the welding temperature to obtain the welding temperature includes: Obtain the initial operating parameters, which include the initial laser power, initial operating frequency, and initial pulse width; The initial working parameters are configured into the laser after startup to obtain the initial laser. The initial laser is then used to irradiate the center position of the fixed welding node to obtain the irradiation position. The coordinates of the irradiation position are determined in the workstation coordinate system based on the irradiation position. Obtain the coordinates of each temperature sensor in the workstation coordinate system to obtain the temperature sensor coordinate set; Calculate the distance from each temperature sensor coordinate in the temperature sensor coordinate set to the irradiation position coordinate to obtain multiple sensor distances. Determine the weight of each temperature sensor based on these multiple sensor distances to obtain a sensor weight set. The calculation method is as follows: in, Indicates the first The weights of the temperature sensors, Indicates the distance of multiple sensors. The distance between the sensors Indicates the total distance of multiple sensors The distance between the sensors; The temperature collected by each of the multiple temperature sensors is obtained to form a set of collected temperatures, where the collected temperatures correspond one-to-one with the sensor weights. The welding temperature is calculated based on the collected temperature set and the sensor weight set, and the calculation method is as follows: in, This indicates the welding temperature. Indicates the collection temperature concentration of the first Each temperature was collected.

[0052] It should be understood that the initial working parameters are a set of reference control quantities that are pre-set and configured in the laser before performing laser welding tests on the fixed welding nodes, in order to start the laser and perform the first irradiation test. The laser power is the average output power of the laser, the laser frequency is the number of pulses per second of the pulsed laser, and the laser pulse width is the duration of a single pulse.

[0053] Understandably, the initial laser power is a pre-set initial average laser output power, the initial laser frequency is a pre-set initial pulse count per second, the initial laser pulse width is a pre-set initial duration of a single pulse, and the initial laser is a laser device that has been configured with initial operating parameters (including initial laser power, initial operating frequency, and initial pulse width) and is ready for use. The irradiation position is the specific spot area formed by the laser beam emitted by the initial laser on the surface of the fixed welding node, and the irradiation position coordinates refer to the mathematical coordinate values ​​corresponding to the irradiation position in the workstation coordinate system, used to accurately locate the laser action point in space.

[0054] For example, suppose there are three temperature sensors located at distances of 10mm, 20mm, and 30mm from the laser irradiation center, respectively, and the collected temperatures are 320℃, 310℃, and 300℃. The weights calculated based on the inverse distance are approximately 0.545, 0.273, and 0.182, respectively. The welding temperature calculated based on the weights is approximately 313.6℃, ​​which shows that the closer the sensor is to the irradiation position, the greater its contribution to the welding temperature, thus more accurately reflecting the actual welding temperature of the fixed welding node.

[0055] It should be explained that the process of determining the laser's operating frequency, pulse width, and laser power based on the welding temperature to obtain the laser's operating node includes: The preset temperature sensor acquisition time is obtained, resulting in multiple temperature acquisition time points. These multiple acquisition time points are sorted in chronological order to obtain an acquisition time point sequence. The earliest and latest time points are identified from the acquisition time point sequence, and the acquisition time range is determined based on the earliest and latest time points. The laser is activated within the acquisition time range, and the welding temperature is monitored at each temperature acquisition time point in the acquisition time point sequence to obtain a welding temperature set, wherein the welding temperature corresponds one-to-one with the temperature acquisition time point; Based on the data acquisition time sequence and welding temperature set, the welding temperature curve is plotted in a pre-constructed Cartesian coordinate system. Obtain a preset filtering time range, wherein the filtering time range is within the collection time range; The maximum and minimum temperature values ​​are retrieved from the welding temperature curve by using the screening time range. Obtain the preset maximum temperature threshold and the preset minimum temperature threshold. If the maximum temperature value is less than the maximum temperature threshold and the minimum temperature value is greater than the minimum temperature threshold, then the initial operating parameters are used as the laser operating node. Otherwise, determine the maximum temperature value exceeding the limit based on the minimum temperature threshold, the maximum temperature threshold, the minimum temperature value, and the maximum temperature value, and calculate the average of the minimum temperature threshold and the maximum temperature threshold to obtain the target welding temperature; The temperature deviation is obtained by calculating the difference between the maximum temperature exceeding the limit and the target welding temperature. Based on the temperature deviation and the initial operating parameters, the laser operating node is calculated as follows: in, This indicates the laser power at the working node of the laser. This represents the initial laser power in the initial operating parameters. This represents the preset power correction factor. This indicates the temperature difference value. This indicates the pulse width at the operating node of the laser. This represents the initial pulse width in the initial working node. This represents the preset pulse width correction coefficient. This indicates the operating frequency in the laser's operating node. This represents the initial operating frequency in the initial working node. This represents the preset frequency correction factor. This represents the initial identifier.

[0056] It should be understood that the acquisition time range is a continuous time interval determined by the earliest and latest time points, i.e., the time range covered by the entire welding temperature data acquisition. The earliest time point is the first time point in the acquisition time point sequence, i.e., the time point at the start of the temperature acquisition process, and the latest time point is the last time point in the acquisition time point sequence, i.e., the time point at the end of the temperature acquisition process. The filtering time range is a time interval selected for focused analysis within the acquisition time range based on preset conditions, used to extract the welding temperature curve and extract key temperature features. The maximum temperature threshold is a preset upper limit of temperature during the welding process to avoid overmelting, material ablation, or spatter. When the actual welding temperature exceeds this threshold, it is determined that there is a risk of overheating in the welding process. The minimum temperature threshold is a preset lower limit of temperature during the welding process to avoid insufficient fusion or incomplete welding. When the actual welding temperature is lower than this threshold, it is determined that there is a risk of insufficient fusion in the welding process.

[0057] It should be explained that the preset maximum and minimum temperature thresholds can ensure that multiple welding temperatures in the selected temperature curve do not both exceed the maximum temperature threshold and fall below the minimum temperature threshold, thereby further reducing the complexity of the algorithm and improving the running efficiency of the program.

[0058] For example, during a laser welding process, the temperature sensor obtained multiple sampling time points from 0.0s to 2.0s with a sampling period of 0.1s: {0.0s, 0.1s, 0.2s, ...}. The time range is defined as [0.0s, 2.0s], where 0.0s is the earliest time point and 2.0s is the latest time point. Assuming the welding temperature curve acquired within this range shows the temperature gradually increasing from 25℃ and reaching a peak of 460℃ at 1.5s, then decreasing to 380℃ at 2.0s, the screening temperature curve is intercepted within the preset screening time range [0.5s, 1.8s], with a maximum temperature of 460℃ and a minimum temperature of 250℃. Assuming the maximum temperature threshold is 500℃ and the minimum temperature threshold is 200℃, since the maximum temperature... The initial operating parameters are directly used as the laser operating node because the maximum temperature value is less than the pre-maximum temperature threshold of 500℃ and the minimum temperature value is greater than the minimum temperature threshold of 200℃. If an over-limit situation occurs, assuming the maximum temperature reaches 520℃, the average of the maximum and minimum temperature thresholds, 350℃, is used as the target welding temperature. The difference between the over-limit temperature of 520℃ and the target welding temperature is calculated, yielding a temperature deviation of 170℃. Assuming the initial laser power is 30W, the initial pulse width is 2ms, and the initial operating frequency is 100Hz, the initial temperature parameters are corrected using a correction formula, ultimately obtaining the laser operating node { =21.5W, =1.66ms, =83Hz}, thus ensuring that the laser welding process remains stable within a reasonable temperature range.

[0059] S5. Move the terminal bottom mold to obtain multiple welding positions. Use the laser working node to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

[0060] It should be understood that, since the contact surface between the wire harness and the terminal is usually large and irregular in shape, a single solder joint is difficult to guarantee firmness and conductivity. Therefore, moving the terminal bottom mold to complete multi-point welding can make the solder joints evenly distributed on the terminal and increase the effective fusion area.

[0061] To address the problems described in the background art, this invention receives a wire harness welding command and identifies a laser welding system based on the command. The laser welding system includes a terminal mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. A welding node is obtained, comprising a wire harness and a terminal. The welding node is placed in the terminal mold to obtain the node to be welded. This invention effectively suppresses weld point displacement by utilizing vibration pre-fixation and optimizes laser parameters in real time using temperature feedback, significantly improving welding positioning accuracy, connection strength, and quality consistency. It overcomes the drawbacks of traditional methods, such as easy false welds and significant heat damage, achieving active positioning, real-time monitoring, and parameter adaptation during the welding process. The laser welding system is activated, and the positioning device within the system is used to locate the node to be welded, obtaining the positioned welding node. The clamping fixture and welding vibration unit are then used to... The positioning and welding nodes are pre-welded and fixed to obtain a fixed welding node. This invention utilizes high-precision three-dimensional visual positioning to automatically correct workpiece position deviations, combined with ultrasonic vibration pre-fixing technology, achieving precise alignment and firm clamping of the welding node. This eliminates displacement and incomplete welding problems in traditional welding, improving the accuracy, strength, and consistency of the welding process. The fixed welding node is tested using a laser, and a temperature sensor is used simultaneously to measure the welding temperature. Based on the welding temperature, the laser's operating frequency, pulse width, and laser power are determined, resulting in the laser's working node. The terminal mold is moved to obtain multiple welding positions. The laser's working node is used to control the laser to weld multiple weld points at these positions, realizing a high-speed wire harness welding method based on pulsed laser welding. This invention accurately calculates the welding temperature using multi-sensor distance weighted fusion technology, achieving precise control of welding energy and avoiding overheating or incomplete welding defects, providing intelligent process assurance for high-speed precision welding. Therefore, this invention can improve the accuracy and speed of pulsed laser welding.

[0062] like Figure 2 The diagram shown is a functional block diagram of a high-speed wire harness welding system based on pulsed laser welding provided in an embodiment of the present invention.

[0063] The high-speed wire harness welding system 100 based on pulsed laser welding described in this invention can be installed in electronic devices. Depending on the functions implemented, the high-speed wire harness welding system 100 based on pulsed laser welding may include a welding system verification module 101, a welding node fixing module 102, a welding test module 103, and a welding execution module 104. The module described in this invention can also be called a unit, referring to a series of computer program segments that can be executed by the processor of an electronic device and can perform a fixed function, stored in the memory of the electronic device.

[0064] The welding system confirmation module 101 is used to receive wire harness welding instructions and confirm the laser welding system through the wire harness welding instructions. The laser welding system includes a terminal bottom mold, a clamping fixture, a welding vibration unit, a positioning device and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes piezoelectric ceramics, an amplitude transformer, a flange and a tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. The welding node fixing module 102 is used to start the laser welding system, use the positioning device in the laser welding system after startup to position the node to be welded, obtain the positioning welding node, and use the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to fix it, thus obtaining the fixed welding node. The welding test module 103 is used to perform welding tests on fixed welding nodes using the laser, and simultaneously use a temperature sensor to measure the welding temperature to obtain the welding temperature. Based on the welding temperature, the operating frequency, pulse width and laser power of the laser are determined to obtain the laser operating node. The welding execution module 104 is used to move the terminal bottom mold to obtain multiple welding positions, and uses the laser working node to control the laser to weld multiple weld points at multiple welding positions, thereby realizing a high-speed wire harness welding method based on pulsed laser welding.

[0065] In detail, the modules in the high-speed wire harness welding system 100 based on pulsed laser welding described in this embodiment of the invention employ the same methods as described above during use. Figure 1 The high-speed wire harness welding method based on pulsed laser welding described herein uses the same technical means and can produce the same technical effect, so it will not be repeated here.

[0066] like Figure 3The diagram shown is a structural schematic of an electronic device that implements a high-speed wire harness welding method based on pulsed laser welding, according to an embodiment of the present invention.

[0067] The electronic device 1 may include a processor 10, a memory 11 and a bus 12, and may also include a computer program stored in the memory 11 and executable on the processor 10, such as a high-speed wire harness welding method program based on pulsed laser welding.

[0068] The memory 11 includes at least one type of readable storage medium, such as flash memory, portable hard drive, multimedia card, card-type memory (e.g., SD or DX memory), magnetic memory, magnetic disk, optical disk, etc. In some embodiments, the memory 11 can be an internal storage unit of the electronic device 1, such as a portable hard drive. In other embodiments, the memory 11 can be an external storage device of the electronic device 1, such as a plug-in portable hard drive, smart media card (SMC), secure digital card (SD), flash card, etc., equipped on the electronic device 1. Furthermore, the memory 11 includes both internal storage units and external storage devices of the electronic device 1. The memory 11 can be used not only to store application software and various types of data installed on the electronic device 1, such as the code of a high-speed wire harness welding method program based on pulsed laser welding, but also to temporarily store data that has been output or will be output.

[0069] In some embodiments, the processor 10 may be composed of integrated circuits, such as a single packaged integrated circuit or multiple integrated circuits with the same or different functions, including combinations of one or more central processing units (CPUs), microprocessors, digital processing chips, graphics processors, and various control chips. The processor 10 is the control unit of the electronic device, connecting various components of the entire electronic device through various interfaces and lines. It executes programs or modules stored in the memory 11 (e.g., a high-speed wire harness welding method program based on pulsed laser welding) and calls data stored in the memory 11 to perform various functions of the electronic device 1 and process data.

[0070] The bus 12 can be a peripheral component interconnect (PCI) bus or an extended industry standard architecture (EISA) bus, etc. The bus 12 can be divided into an address bus, a data bus, a control bus, etc. The bus 12 is configured to realize the connection and communication between the memory 11 and at least one processor 10, etc.

[0071] Figure 3 Only electronic devices with components are shown; it will be understood by those skilled in the art that... Figure 3 The structure shown does not constitute a limitation on the electronic device 1, and may include fewer or more components than shown, or combine certain components, or have different component arrangements.

[0072] For example, although not shown, the electronic device 1 may also include a power supply (such as a battery) to power the various components. Preferably, the power supply can be logically connected to the at least one processor 10 through a power management device, thereby enabling functions such as charging management, discharging management, and power consumption management. The power supply may also include one or more DC or AC power supplies, recharging devices, power fault detection circuits, power converters or inverters, power status indicators, and other arbitrary components. The electronic device 1 may also include various sensors, Bluetooth modules, Wi-Fi modules, etc., which will not be described in detail here.

[0073] Furthermore, the electronic device 1 may also include a network interface. Optionally, the network interface may include a wired interface and / or a wireless interface (such as a Wi-Fi interface, a Bluetooth interface, etc.), which is typically used to establish communication connections between the electronic device 1 and other electronic devices.

[0074] Optionally, the electronic device 1 may further include a user interface, which may be a display, an input unit (such as a keyboard), and optionally, a standard wired interface or a wireless interface. Optionally, in some embodiments, the display may be an LED display, a liquid crystal display, a touch-sensitive liquid crystal display, or an OLED (Organic Light-Emitting Diode) touchscreen, etc. The display may also be appropriately referred to as a screen or display unit, used to display information processed in the electronic device 1 and to display a visual user interface.

[0075] The high-speed wire harness welding method program based on pulsed laser welding stored in the memory 11 of the electronic device 1 is a combination of multiple instructions. When run in the processor 10, it can achieve the following: The system receives a wire harness welding command and confirms the laser welding system based on the command. The laser welding system includes a terminal mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. Start the laser welding system, use the positioning device in the laser welding system to position the node to be welded, obtain the positioning welding node, use the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain the fixed welding node. The laser is used to perform welding tests on fixed welding nodes, and a temperature sensor is used simultaneously to measure the welding temperature to obtain the welding temperature. Based on the welding temperature, the operating frequency, pulse width and laser power of the laser are determined to obtain the laser operating node. The bottom mold of the moving terminal is used to obtain multiple welding positions. The laser working node is used to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

[0076] Specifically, the processor 10's implementation method for the above instructions can be found in [reference needed]. Figures 1 to 3 The descriptions of the relevant steps in the corresponding embodiments are not repeated here.

[0077] Furthermore, if the modules / units integrated in the electronic device 1 are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. The computer-readable storage medium can be volatile or non-volatile. For example, the computer-readable medium may include: any entity or device capable of carrying the computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, or a read-only memory (ROM).

[0078] The present invention also provides a computer-readable storage medium storing a computer program, which, when executed by a processor of an electronic device, can perform the following: The system receives a wire harness welding command and confirms the laser welding system based on the command. The laser welding system includes a terminal mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. Start the laser welding system, use the positioning device in the laser welding system to position the node to be welded, obtain the positioning welding node, use the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain the fixed welding node. The laser is used to perform welding tests on fixed welding nodes, and a temperature sensor is used simultaneously to measure the welding temperature to obtain the welding temperature. Based on the welding temperature, the operating frequency, pulse width and laser power of the laser are determined to obtain the laser operating node. The bottom mold of the moving terminal is used to obtain multiple welding positions. The laser working node is used to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

[0079] In the embodiments provided by this invention, it should be understood that the disclosed devices, systems, and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative, and actual implementations may have other classification methods.

[0080] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0081] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or in the form of hardware plus software functional modules.

[0082] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-speed wire harness welding method based on pulsed laser welding, characterized in that, The method includes: The system receives a wire harness welding command and confirms the laser welding system through the wire harness welding command. The laser welding system includes a terminal mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. The flange serves as a connecting component to firmly connect the amplitude transformer and the tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. Start the laser welding system, use the positioning device in the laser welding system to position the node to be welded, obtain the positioning welding node, use the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain the fixed welding node. The laser is used to perform welding tests on the fixed welding joint, and a temperature sensor is used simultaneously to measure the welding temperature to obtain the welding temperature. Specifically, this includes: Obtain the initial operating parameters, which include the initial laser power, initial operating frequency, and initial pulse width; The initial working parameters are configured into the laser after startup to obtain the initial laser. The initial laser is then used to irradiate the center position of the fixed welding node to obtain the irradiation position. The irradiation position coordinates are determined in a pre-constructed welding station coordinate system based on the irradiation position. Obtain the coordinates of each temperature sensor in the welding station coordinate system from multiple temperature sensors to obtain the temperature sensor coordinate set; Calculate the distance from each temperature sensor coordinate in the temperature sensor coordinate set to the irradiation position coordinate to obtain multiple sensor distances. Determine the weight of each temperature sensor based on the multiple sensor distances to obtain a sensor weight set. The temperature collected by each of the multiple temperature sensors is obtained to form a set of collected temperatures, where the collected temperatures correspond one-to-one with the sensor weights. The welding temperature is calculated based on the collected temperature set and the sensor weight set. Based on the welding temperature, the laser's operating frequency, pulse width, and laser power are determined, thus obtaining the laser's operating nodes, specifically including: The preset temperature sensor acquisition time is obtained, resulting in multiple temperature acquisition time points. These multiple acquisition time points are sorted in chronological order to obtain an acquisition time point sequence. The earliest and latest time points are identified from the acquisition time point sequence, and the acquisition time range is determined based on the earliest and latest time points. The laser is activated within the acquisition time range, and the welding temperature is monitored at each temperature acquisition time point in the acquisition time point sequence to obtain a welding temperature set, wherein the welding temperature corresponds one-to-one with the temperature acquisition time point; Based on the data acquisition time sequence and welding temperature set, the welding temperature curve is plotted in a pre-constructed Cartesian coordinate system. Obtain a preset filtering time range, wherein the filtering time range is within the collection time range; The maximum and minimum temperature values ​​are retrieved from the welding temperature curve by using the screening time range. Obtain the preset maximum temperature threshold and the preset minimum temperature threshold. If the maximum temperature value is less than the maximum temperature threshold and the minimum temperature value is greater than the minimum temperature threshold, then the initial operating parameters are used as the laser operating node. Otherwise, determine the maximum temperature value exceeding the limit based on the minimum temperature threshold, maximum temperature threshold, minimum temperature value, and maximum temperature value, and calculate the average of the minimum temperature threshold and the maximum temperature threshold to obtain the target welding temperature; The temperature deviation is obtained by calculating the difference between the maximum temperature exceeding the limit and the target welding temperature. Based on the temperature deviation and the initial working parameters, the laser working node is calculated. The bottom mold of the moving terminal is used to obtain multiple welding positions. The laser working node is used to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

2. The high-speed wire harness welding method based on pulsed laser welding as described in claim 1, characterized in that, The step of placing the welding node in the terminal bottom mold to obtain the node to be welded includes: Check the length of the wire harness and the integrity of the terminals to obtain the status of the welding nodes, which can be either normal or abnormal. When the welding node is in the normal state, insert the wire harness into the terminal to obtain the initial welding node. Place the initial welding node in the predetermined position in the terminal bottom mold to obtain the node to be welded. Otherwise, replace the wiring harness or terminals to obtain a new wiring harness or new terminals. Use the new wiring harness as the wiring harness and the new terminals as the terminals, and return to the steps of checking the wiring harness length and terminal integrity until the solder joint status is normal.

3. The high-speed wire harness welding method based on pulsed laser welding as described in claim 2, characterized in that, The process of checking the wire harness length and terminal integrity to obtain the weld node status includes: The actual length of the wire harness is measured to obtain the measured length, and the measured length is compared with a preset standard length range, wherein the standard length range includes an upper limit and a lower limit of the standard length; If the measured length is within the standard length range, the wire harness is confirmed as a normal wire harness; If the measured length is less than the lower limit of the standard length corresponding to the standard length range, the wire harness will be identified as an abnormal wire harness. If the measured length is greater than the upper limit of the standard length corresponding to the standard length range, the wire harness is cut according to the preset unit length to obtain a cut wire harness. The cut wire harness is used as the wire harness, and the step of measuring the actual length of the wire harness is returned until the length difference meets the error range and a normal wire harness is obtained. Observe the defects on the terminal surface to obtain the screening terminal, test the electrical continuity of the screening terminal to obtain the terminal status, wherein the terminal status includes normal continuity or abnormal continuity; If the terminal status is normal conduction, the selected terminal is recorded as a normal terminal; otherwise, an abnormal terminal is obtained. If the wire harness is a normal wire harness and the terminal is a normal terminal, then the welding node is in a normal state; otherwise, the welding node is in an abnormal state, and the normal state or abnormal state is taken as the welding node state.

4. The high-speed wire harness welding method based on pulsed laser welding as described in claim 3, characterized in that, The step of using the positioning device in the laser welding system after startup to position the node to be welded, thereby obtaining the positioned welding node, includes: In a laser welding system, the terminal mold with the node to be welded is moved to a pre-prepared welding station to obtain the initial welding position; The positioning device of the laser welding system is used to detect the deviation between the initial welding position and the preset standard welding position to obtain the position offset node, wherein the position offset node includes the position error and the offset direction; If the position error is less than or equal to the preset offset error threshold, the node to be welded at the initial welding position is taken as the positioning welding node; Otherwise, adjust the position of the terminal bottom mold according to the offset direction to obtain the target welding position; The target welding position is used as the initial welding position. The process returns to the step of detecting the deviation between the initial welding position and the preset standard welding position using the positioning device of the laser welding system, until the position error is less than or equal to the offset error threshold. The node to be welded at the target welding position is then used as the positioning welding node.

5. The high-speed wire harness welding method based on pulsed laser welding as described in claim 4, characterized in that, The method of using the positioning device of the laser welding system to detect the deviation between the initial welding position and the preset standard welding position to obtain the position offset node includes: The initial position coordinates are obtained by using the positioning device to acquire the coordinates of the initial welding position; Obtain the coordinates of the standard welding position, calculate the deviation between the initial position coordinates and the standard position coordinates, and obtain the position deviation nodes, which include the X-axis deviation, Y-axis deviation and Z-axis deviation. The offset direction is determined based on the position deviation node; The position error is calculated based on the position deviation nodes, as shown in the following method: in, This indicates the position error. This indicates the X-axis deviation. This indicates the Y-axis deviation. This indicates the Z-axis deviation; By associating the offset direction with the positional deviation, the positional offset node is obtained.

6. The high-speed wire harness welding method based on pulsed laser welding as described in claim 5, characterized in that, The step of acquiring the coordinates of the initial welding position using the positioning device to obtain the initial position coordinates includes: The positioning device is activated, and the initial welding position is scanned using the activated positioning device to obtain a three-dimensional point cloud, wherein the three-dimensional point cloud includes all scanned points of the initial welding position; Noise points are removed from the 3D point cloud to obtain a denoised point cloud, in which only the feature region of the initial welding position is retained. Special marker points are extracted from the noise-reduced point cloud using threshold segmentation to obtain a feature coordinate set, and the coordinate system of the positioning device is determined based on the feature coordinate set; Feature coordinates are extracted sequentially from the feature coordinate set, and the following operation is performed on each extracted feature coordinate: Obtain the preset rotation matrix, preset translation vector, and pre-constructed welding station coordinate system. Use the rotation matrix and translation vector to transform the feature coordinates from the positioning device coordinate system to the welding station coordinate system to obtain the station coordinates. The transformation method is as follows: in, This represents the value of the workstation coordinates on the X-axis. This represents the value of the workstation coordinates on the Y-axis. This represents the value of the workstation coordinates on the Z-axis. This represents the value of the feature coordinates on the X-axis. This represents the value of the feature coordinates on the Y-axis. This represents the value of the feature coordinates on the Z-axis. Represents the rotation matrix, Denotes the translation vector. This indicates that the coordinates are represented in matrix form; Summarize the workstation coordinates to obtain a workstation coordinate set. Calculate the mean values ​​of the workstation coordinate set on the X-axis, Y-axis, and Z-axis respectively to obtain the mean values ​​of the X-axis, Y-axis, and Z-axis. By correlating the mean values ​​of the X-axis, Y-axis, and Z-axis, the initial position coordinates are obtained.

7. The high-speed wire harness welding method based on pulsed laser welding as described in claim 6, characterized in that, The step of using the clamping fixture and welding vibration unit to press and pre-weld the positioning welding node to obtain a fixed welding node includes: The two sides of the positioning welding node are clamped using a clamping fixture to obtain the welding node to be fixed. The welding vibration unit is activated, and the piezoelectric ceramic is initialized using the activated welding vibration unit to obtain the initial piezoelectric ceramic. High-frequency vibration is generated by using an initial piezoelectric ceramic to obtain a high-frequency vibration signal. The high-frequency vibration signal is then amplified and transmitted using the amplitude transformer to obtain an amplified vibration signal. The tool head is controlled by an amplified vibration signal to obtain a vibrating tool head. The vibrating tool head is used to strike the node to be fixed for welding to obtain a fixed welding node.

8. A high-speed wire harness welding system based on pulsed laser welding, characterized in that, The system includes: The welding system confirmation module is used to receive wire harness welding instructions and confirm the laser welding system through the wire harness welding instructions. The laser welding system includes a terminal bottom mold, a clamping fixture, a welding vibration unit, a positioning device, and a laser. The clamping fixture is equipped with multiple temperature sensors. The welding vibration unit includes a piezoelectric ceramic, an amplitude transformer, a flange, and a tool head. The flange serves as a connecting component to firmly connect the amplitude transformer and the tool head. Obtain the welding node, which includes wire harness and terminal. Place the welding node in the terminal bottom mold to obtain the node to be welded. The welding node fixing module is used to start the laser welding system, and to position the node to be welded using the positioning device in the laser welding system after startup, thereby obtaining a positioned welding node. The clamping fixture and welding vibration unit are used to press and pre-weld the positioned welding node to fix it, thereby obtaining a fixed welding node. The welding test module is used to perform welding tests on fixed welding nodes using the laser, and simultaneously uses a temperature sensor to measure the welding temperature to obtain the welding temperature. Specifically, it includes: Obtain the initial operating parameters, which include the initial laser power, initial operating frequency, and initial pulse width; The initial working parameters are configured into the laser after startup to obtain the initial laser. The initial laser is then used to irradiate the center position of the fixed welding node to obtain the irradiation position. The irradiation position coordinates are determined in a pre-constructed welding station coordinate system based on the irradiation position. Obtain the coordinates of each temperature sensor in the welding station coordinate system from multiple temperature sensors to obtain the temperature sensor coordinate set; Calculate the distance from each temperature sensor coordinate in the temperature sensor coordinate set to the irradiation position coordinate to obtain multiple sensor distances. Determine the weight of each temperature sensor based on the multiple sensor distances to obtain a sensor weight set. The temperature collected by each of the multiple temperature sensors is obtained to form a set of collected temperatures, where the collected temperatures correspond one-to-one with the sensor weights. The welding temperature is calculated based on the collected temperature set and the sensor weight set. Based on the welding temperature, the laser's operating frequency, pulse width, and laser power are determined, thus obtaining the laser's operating nodes, specifically including: The preset temperature sensor acquisition time is obtained, resulting in multiple temperature acquisition time points. These multiple acquisition time points are sorted in chronological order to obtain an acquisition time point sequence. The earliest and latest time points are identified from the acquisition time point sequence, and the acquisition time range is determined based on the earliest and latest time points. The laser is activated within the acquisition time range, and the welding temperature is monitored at each temperature acquisition time point in the acquisition time point sequence to obtain a welding temperature set, wherein the welding temperature corresponds one-to-one with the temperature acquisition time point; Based on the data acquisition time sequence and welding temperature set, the welding temperature curve is plotted in a pre-constructed Cartesian coordinate system. Obtain a preset filtering time range, wherein the filtering time range is within the collection time range; The maximum and minimum temperature values ​​are retrieved from the welding temperature curve by using the screening time range. Obtain the preset maximum temperature threshold and the preset minimum temperature threshold. If the maximum temperature value is less than the maximum temperature threshold and the minimum temperature value is greater than the minimum temperature threshold, then the initial operating parameters are used as the laser operating node. Otherwise, determine the maximum temperature value exceeding the limit based on the minimum temperature threshold, maximum temperature threshold, minimum temperature value, and maximum temperature value, and calculate the average of the minimum temperature threshold and the maximum temperature threshold to obtain the target welding temperature; The temperature deviation is obtained by calculating the difference between the maximum temperature exceeding the limit and the target welding temperature. Based on the temperature deviation and the initial working parameters, the laser working node is calculated. The welding execution module is used to move the terminal bottom mold to obtain multiple welding positions. The laser working node is used to control the laser to weld multiple weld points at multiple welding positions, realizing a high-speed wire harness welding method based on pulsed laser welding.

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