An automated welding method and system for a dust collector steel structural frame

Abstract

The present application relates to the technical field of welding, in particular to an automatic welding method and system for a dust collector steel structure frame, the method comprising: collecting image information and ranging information of a to-be-welded component, determining structural characteristic parameters of the to-be-welded component, and generating current welding parameters corresponding to the to-be-welded component based on the structural characteristic parameters; in response to a component specification switching instruction, generating target welding parameters corresponding to a new-specification component according to the structural characteristic parameters of the new-specification component; collecting first time-series data and second time-series data; determining a collaborative mismatch evaluation parameter between welding current and wire feeding speed in a parameter switching process according to the first time-series data and the second time-series data, and pre-compensating welding current control instructions and wire feeding speed control instructions in a subsequent parameter switching process based on the collaborative mismatch evaluation parameter. The present application realizes automatic welding of rapid changeover and high-quality welding in a multi-specification small-batch production scenario.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and specifically to an automated welding method and system for the steel structure frame of a dust collector. Background Technology

[0002] As the core load-bearing component of the dust collector, the steel structure frame of the dust collector is directly related to the overall load-bearing capacity, operational safety and service life of the equipment, and plays a key role in the stable operation of industrial dust removal systems.

[0003] With the increasing environmental protection requirements of industrial production, dust collectors are being used in a wider range of applications, and the corresponding frame specifications and models are also increasing. Single batch orders are showing a trend of small batches and multiple varieties, which puts forward higher requirements for the automation, adaptability and production efficiency of frame welding.

[0004] Currently, welding of the steel structure frame of dust collectors mainly relies on manual or semi-automatic welding methods. Although some companies have introduced welding robots and achieved automated production through teaching programming, these existing technologies are mostly suitable for mass production scenarios with high standardization and single specifications. The welding parameters and paths need to be preset or determined manually. When faced with the demand for multi-specification, small-batch production with frequent model changes, existing technologies cannot quickly adapt to the structural differences of different frames. The overall production adaptability and parameter adjustment flexibility are insufficient, resulting in an inability to effectively balance production changeover efficiency and welding quality stability, making it difficult to meet the actual production requirements for efficient and reliable welding. Summary of the Invention

[0005] To address the technical problem of poor adaptability to production switching and insufficient flexibility in parameter adjustment during multi-specification, small-batch production, which makes it difficult to simultaneously achieve production efficiency and welding quality stability, the present invention aims to provide an automated welding method and system for the steel structure frame of a dust collector. The specific technical solution adopted is as follows:

[0006] In a first aspect, an automated welding method for a steel structure frame of a dust collector is provided. The method includes: acquiring image information and distance measurement information of the component to be welded; determining the structural characteristic parameters of the component to be welded based on the image information and distance measurement information, and generating current welding parameters corresponding to the component based on the structural characteristic parameters. The structural characteristic parameters include component type, wall thickness, and weld gap; the welding parameters include welding current parameters and wire feed speed parameters. In response to a component specification switching command, generating target welding parameters corresponding to the new specification component based on the structural characteristic parameters of the component to be switched to; and switching the current welding parameters to the new specification component. During the target welding parameter process, first time-series data and second time-series data are collected. The first time-series data is the time-series data of the welding current value changing over time, and the second time-series data is the time-series data of the wire feed speed value changing over time. Based on the first and second time-series data, a collaborative mismatch evaluation parameter between the welding current and the wire feed speed is determined during the parameter switching process. Based on the collaborative mismatch evaluation parameter, the welding current control command and the wire feed speed control command in the subsequent parameter switching process are pre-compensated. The collaborative mismatch evaluation parameter is used to characterize the degree of mismatch between the dynamic response of the welding current and the dynamic response of the wire feed speed in terms of amplitude and frequency.

[0007] In one possible design, the structural feature parameters of the component to be welded are determined based on image information and distance measurement information, including: extracting the contour and recognizing the shape of the image information to determine the component type of the component to be welded; and determining the wall thickness of the component to be welded and the average width of the weld gap based on the distance measurement information.

[0008] In one possible design, generating current welding parameters corresponding to the component to be welded based on structural feature parameters includes: identifying the material of the component to be welded based on image information, and determining the physical property parameters of the component to be welded based on the material, including melting point, density, and specific heat capacity; determining the theoretical welding current based on the physical property parameters and a preset target weld depth; determining a correction coefficient based on the average width of the weld gap and a preset mapping relationship between the gap width and the correction coefficient; correcting the theoretical welding current based on the correction coefficient to obtain the welding current parameter in the current welding parameters; determining the theoretical wire feed speed based on the welding current parameter in the current welding parameters; determining the cross-sectional area of ​​the weld gap based on the average width of the weld gap, and determining the wire feed speed increment based on the gap cross-sectional area and the wire cross-sectional area; and obtaining the wire feed speed parameter in the current welding parameters based on the theoretical wire feed speed and the wire feed speed increment.

[0009] In one possible design, target welding parameters corresponding to the new specification component are generated based on the structural feature parameters of the component to be switched to. This includes: acquiring image information and ranging information of the new specification component; determining the structural feature parameters of the new specification component based on the image information and ranging information; and generating target welding parameters based on the structural feature parameters of the new specification component.

[0010] In one possible design, the cooperative mismatch evaluation parameters include a first evaluation parameter and a second evaluation parameter. Determining the cooperative mismatch evaluation parameters between welding current and wire feed speed during parameter switching includes: constructing a parameter phase space, using the actual parameter values ​​as the abscissa and the parameter change rate as the ordinate; mapping the first time-series data to the phase space to form a first trajectory curve, and mapping the second time-series data to the phase space to form a second trajectory curve; determining the first evaluation parameter based on the morphological differences between the first and second trajectory curves; performing frequency domain transformation on the first time-series data to obtain a first spectrum, and performing frequency domain transformation on the second time-series data to obtain a second spectrum; and determining the second evaluation parameter based on the offset of the dominant frequency components in the first and second spectra.

[0011] In one possible design, based on cooperative mismatch evaluation parameters, pre-compensation is performed on the welding current control command and wire feed speed control command during subsequent parameter switching processes. This includes: when the first evaluation parameter is greater than a first threshold, determining the actuator to be compensated based on the envelope areas of the first trajectory curve and the second trajectory curve; when the envelope area of ​​the first trajectory curve is less than the envelope area of ​​the second trajectory curve, the actuator to be compensated is the wire feed mechanism; when the envelope area of ​​the first trajectory curve is greater than the envelope area of ​​the second trajectory curve, the actuator to be compensated is the welding power source; in response to a switching command from the specification corresponding to the component to be welded to the specification corresponding to the new specification component, sending an overshoot pulse command to the actuator to be compensated; sending a welding current parameter switching command to the welding power source and a wire feed speed parameter switching command to the wire feed mechanism; when the second evaluation parameter is greater than a second threshold, during the switching process from the specification corresponding to the component to be welded to the specification corresponding to the new specification component, increasing the proportional gain of the wire feed speed control loop and applying a digital low-pass filter to the welding current control loop.

[0012] In one possible design, the above method further includes: during the switching process from the component to be welded to the component of the new specification after performing pre-compensation, re-collecting the first time series data and the second time series data, and updating the first evaluation parameter and the second evaluation parameter; if the updated first evaluation parameter is less than the first threshold and the updated second evaluation parameter is less than the second threshold, storing the current pre-compensation strategy for use in subsequent switching processes from the specification corresponding to the component to be welded to the specification corresponding to the component of the new specification.

[0013] In one possible design, a first evaluation parameter is determined based on the morphological difference between the first trajectory curve and the second trajectory curve, including: determining the area of ​​the closed region enclosed by the first trajectory curve and the horizontal axis as the first envelope area, and determining the area of ​​the closed region enclosed by the second trajectory curve and the horizontal axis as the second envelope area; and determining the first evaluation parameter based on the first envelope area, the second envelope area, the preset target melt depth, and the wall thickness.

[0014] In one possible design, a second evaluation parameter is determined based on the offset of the dominant frequency components in the first and second spectra. This includes: determining the frequency difference corresponding to the maximum value of the cross-correlation function between the first and second spectra as the offset of the dominant frequency component; obtaining the thermal diffusivity of the material of the component to be welded and the duration of the parameter switching process; and determining the second evaluation parameter based on the offset of the dominant frequency component, the duration, the thermal diffusivity, and the wall thickness.

[0015] Secondly, an automated welding system for a dust collector steel structure frame is provided, comprising: an information acquisition unit for acquiring image information and distance measurement information of the component to be welded; a parameter processing unit for determining the structural characteristic parameters of the component to be welded based on the image information and distance measurement information, and generating current welding parameters corresponding to the component based on the structural characteristic parameters, including component type, wall thickness, and weld gap, and welding parameters including welding current parameters and wire feed speed parameters; the parameter processing unit is also used to generate target welding parameters corresponding to the new component specification based on the structural characteristic parameters of the new component specification to be switched to in response to a component specification switching command; and a switching monitoring unit for acquiring first time-series data and second time-series data during the process of switching from the current welding parameters to the target welding parameters, wherein the first time-series data is the time-series data of the welding current value changing over time, and the second time-series data is the time-series data of the wire feed speed value changing over time. The mismatch compensation unit is used to determine the collaborative mismatch evaluation parameters between welding current and wire feed speed during parameter switching based on the first timing data and the second timing data, and to pre-compensate the welding current control command and wire feed speed control command during subsequent parameter switching based on the collaborative mismatch evaluation parameters.

[0016] The present invention has the following beneficial effects:

[0017] In the automated welding method for steel structure frames of dust collectors provided by this invention, precise acquisition of component images and distance measurement information provides comprehensive data support for determining structural feature parameters. This ensures that the generated current welding parameters are deeply adapted to the actual working conditions such as component material, size, wall thickness, and weld gap, guaranteeing the quality of basic welding from the source. When switching component specifications, target welding parameters are quickly generated based on the structural feature parameters of the new specification component. Simultaneously, time-series data during the parameter switching process is acquired in real time. Through a two-dimensional collaborative mismatch evaluation parameter, the energy matching and frequency-thermal synchronization of welding current and wire feed speed are quantified, thereby enabling targeted adjustments to subsequent cutting. Pre-compensation during the switching process effectively suppresses mismatch issues such as dynamic response lag and energy imbalance caused by parameter switching, avoiding defects such as incomplete weld fusion, uneven filling, and excessive heat-affected zone. The entire process can be completed fully automatically from data acquisition to parameter optimization without manual intervention, which not only improves the accuracy of welding parameter adaptation and switching stability, but also significantly reduces human operation errors. At the same time, it lays the foundation for parameter reuse in subsequent switching scenarios of the same specifications, significantly improving welding efficiency and quality consistency in multi-specification, small-batch production modes, and fully meeting the comprehensive requirements of dust collector steel structure frame for welding strength, forming accuracy, and production efficiency. Attached Figure Description

[0018] To more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of an automated welding system for a steel frame of a dust collector, provided as an embodiment of the present invention.

[0020] Figure 2 This is a schematic flowchart of an automated welding method for a steel structure frame of a dust collector, provided as an embodiment of the present invention. Detailed Implementation

[0021] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of an automated welding method and system for a dust collector steel structure frame proposed according to the present invention. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0022] In embodiments of the present invention, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" or "for example" in embodiments of the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0023] In the description of this invention, unless otherwise stated, " / " means "or". For example, A / B can mean A or B. The term "and / or" in this document is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, and B alone. Furthermore, "at least one" and "more than one" refer to two or more. The terms "first," "second," etc., do not limit the quantity or order of execution, and "first," "second," etc., do not necessarily imply differences.

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0025] The following description, in conjunction with the accompanying drawings, details the specific solution of an automated welding method and system for a dust collector steel structure frame provided by the present invention.

[0026] Please see Figure 1 The diagram illustrates a structural schematic of an automated welding system for a dust collector steel structure frame according to an embodiment of the present invention. Figure 1 As shown, the automated welding system 10 for the steel structure frame of the dust collector includes an information acquisition unit 11, a parameter processing unit 12, a switching monitoring unit 13, and a mismatch compensation unit 14.

[0027] The information acquisition unit 11 acquires image information and distance measurement information of the components to be welded and the new specification components, providing basic data support for subsequent parameter calculations.

[0028] The information acquisition unit 11 includes a visual sensor and a laser rangefinder.

[0029] The vision sensor is used to acquire image information of the component to be welded. After contour extraction and shape recognition algorithm processing, the component type is determined, such as square tube, I-beam, etc. The pixel coordinates are converted into spatial coordinates based on the camera calibration parameters to obtain the external dimensions of the component to be welded. At the same time, the material database is linked to identify the material of the component to be welded.

[0030] The laser rangefinder directly obtains the wall thickness of the open section component by scanning the side of the component to be welded. By measuring the distance in both directions at the same position, combined with the known external dimensions, the wall thickness of the closed section component is calculated. Furthermore, the weld gap data is sampled at preset intervals along the weld length to generate the width distribution curve of the weld gap, and the average width and standard deviation are calculated.

[0031] It should be noted that the preset interval can be set to 5-15 mm, for example, an empirical value of 10 mm can be taken. This embodiment of the invention does not make a specific limitation on this.

[0032] The parameter processing unit 12 is used to receive image information and ranging information transmitted by the information acquisition unit 11, and convert the perceived information into executable welding instructions. The welding instructions include welding parameters used in the welding process, including welding current parameters and wire feeding speed parameters.

[0033] The parameter processing unit 12 is specifically used to determine the structural characteristic parameters of the component based on image information and ranging information. These structural characteristic parameters include the component type, wall thickness, and weld gap. Further, based on these structural characteristic parameters and a preset target penetration depth, the theoretical welding current is determined through heat conduction relationships, and then the welding current parameters are obtained by correcting the parameters based on the average width of the weld gap.

[0034] It should be noted that the preset target penetration depth can be set according to a specific proportion of the wall thickness of the component to be welded, such as 60%-80% of the wall thickness. For example, an empirical value of 70% can be taken. This embodiment of the invention does not make a specific limitation on this.

[0035] Meanwhile, the theoretical wire feeding speed is calculated based on the energy balance relationship of the welding wire, and the wire feeding speed increment is determined by combining the cross-sectional area of ​​the weld gap and the cross-sectional area of ​​the welding wire, so as to obtain the wire feeding speed parameters and form the current welding parameters.

[0036] After receiving the component specification switching instruction, the parameter processing unit 12 repeats the above steps, generates target welding parameters based on the structural characteristic parameters of the new specification component, and transmits the current welding parameters and target welding parameters to the switching monitoring unit 13 and the mismatch compensation unit 14 respectively, providing parameter benchmarks for parameter switching monitoring and pre-compensation.

[0037] The switching monitoring unit 13 is used to collect the operating data of the welding system in real time during the process of switching the current welding parameters output by the parameter processing unit 12 to the target welding parameters.

[0038] The switching monitoring unit 13 is specifically used to collect first-time-series data of welding current value changing over time and second-time-series data of wire feeding speed value changing over time at preset time intervals through signal interfaces linked with the welding power source and wire feeding mechanism. The parameter switching progress is synchronized throughout the data acquisition process to ensure data continuity and timeliness.

[0039] It should be noted that the process of switching the current welding parameters to the target welding parameters can be selected to be 200 milliseconds. Correspondingly, the preset time interval can be set to 2 milliseconds, so as to obtain the welding current value and wire feed speed value at 100 sampling moments respectively, and construct the first time series data and the second time series data.

[0040] The switching monitoring unit 13 is used to transmit the collected first time-series data and second time-series data to the mismatch compensation unit 14 as a data source for judging the degree of mismatch between welding current and wire feeding speed.

[0041] The mismatch compensation unit 14 is used to receive the first timing data and the second timing data transmitted by the switching monitoring unit 13, and at the same time associate the structural characteristic parameters output by the parameter processing unit 12 to determine the cooperative mismatch evaluation parameters between welding current and wire feeding speed during the parameter switching process. Based on the cooperative mismatch evaluation parameters, the welding current control command and wire feeding speed control command in the subsequent parameter switching process are pre-compensated.

[0042] The mismatch compensation unit 14 includes an evaluation parameter determination module and a compensation control module.

[0043] The evaluation parameter determination module first constructs a parameter phase space with the actual parameter values ​​on the x-axis and the parameter change rate (the ratio of the parameter difference between adjacent sampling times to a preset time interval) on the y-axis. The first and second time-series data are mapped to this phase space to form a first trajectory curve and a second trajectory curve, respectively. The envelope area enclosed by the two trajectory curves and the x-axis is calculated for each. Combined with the preset target melt depth and wall thickness, a first evaluation parameter characterizing energy mismatch is determined. Next, the first and second time-series data are frequency-domain transformed to obtain a first spectrum and a second spectrum. The frequency difference at which the cross-correlation function of the two reaches its maximum value is calculated as the dominant frequency offset. Combined with the material's thermal diffusivity, wall thickness, and parameter switching duration, a second evaluation parameter characterizing the degree of frequency mismatch is determined.

[0044] The compensation control module is used to compare the first evaluation parameter and the second evaluation parameter with the first threshold and the second threshold, respectively. If the first evaluation parameter exceeds the first threshold, the actuator to be compensated (welding power source or wire feeding mechanism) is determined according to the size of the envelope area, and an overshoot pulse command is sent to the actuator to be compensated in response to the switching command. If the second evaluation parameter exceeds the second threshold, the proportional gain of the wire feeding speed control loop is adjusted and a low-pass filter is applied to the welding current control loop.

[0045] The pre-compensation control command generated by the mismatch compensation unit 13 will directly act on the welding power source and wire feeding mechanism, and at the same time store the effective pre-compensation strategy in the system parameter library. It can be directly called when encountering the same specification switching scenario, thereby realizing the continuous optimization and improvement of the welding system's performance during frequent model changes.

[0046] Please see Figure 2 The diagram illustrates a flow chart of an automated welding method for a steel structure frame of a dust collector, provided by an embodiment of the present invention, including steps S201-S206.

[0047] S201. Collect image information and distance measurement information of the component to be welded.

[0048] As one possible approach, a high-definition industrial camera positioned vertically to the weld seam is used to capture continuous image information of the weldable node area of ​​the component to be welded. After removing noise interference through image preprocessing, a contour extraction algorithm is used to extract the straight line segments and corner features of the component to be welded. Combined with the structural characteristics of typical components such as square tubes and I-beams, the component type is determined. Then, based on preset camera calibration parameters, the pixel coordinates in the image are converted into three-dimensional spatial coordinates, thereby measuring the external dimensions of the component to be welded. At the same time, by comparing the image features with the sample features in the material database, the material of the component to be welded is identified and the corresponding physical property parameters are obtained.

[0049] By uniformly arranging laser rangefinders along the length of the component to be welded, the wall thickness of the component is first measured. For open-section components, the laser beam is perpendicularly irradiated on the side of the component, and the distance difference between the outer surface and the inner surface is directly collected as the wall thickness. For closed-section components, laser beams are emitted from two opposite sides of the component to be welded at the same measurement position (the bidirectional measurement paths of the laser rangefinders are coaxially aligned), and the first and second distance values ​​are collected. Combined with the external dimensions of the component to be welded obtained by the vision sensor, the wall thickness of the component to be welded is calculated.

[0050] In some embodiments, when the component to be welded is a closed-section component, the formula for calculating the wall thickness is as follows:

[0051]

[0052] In the formula, Let the wall thickness of the component to be welded be denoted as . The first distance measurement value, This is the second distance measurement value. The installation spacing between the two laser rangefinders. The dimensions are the external dimensions of the component to be welded.

[0053] It should be noted that before using a laser rangefinder for distance measurement, the laser rangefinder should be focused and its optical path designed so that the reflection path of the laser energy covers the wall thickness range from the outer surface to the inner surface of the component to be welded. At this time, the distance measured by the laser rangefinder includes the distance from the sensor to the outer surface on the same side and the distance from the outer surface on the same side to the inner surface.

[0054] Based on this , , , The distance from the sensor to the outer surface on the same side. ; Let be the installation distance between the two laser rangefinders. , Correspondingly, Therefore, by dividing the numerator by 2, the wall thickness of the component to be welded can be obtained. .

[0055] It should be noted that if the wall thickness calculated using the above formula is negative or zero when the component to be welded is a closed section component, the ranging data is considered abnormal, and the ranging information is re-acquired to calculate the wall thickness.

[0056] In addition, the laser rangefinder is also used to sample weld gaps at preset intervals along the length of the weld. During the acquisition process, the laser beam is ensured to be perpendicular to the plane where the weld gap is located. The gap width of each sampling point is calculated based on the laser triangulation principle. The gap width data of all sampling points are integrated to generate a gap distribution curve. The average width and standard deviation of the weld gap are then calculated through statistical analysis. The average width reflects the overall width of the weld gap, and the standard deviation reflects the degree of fluctuation of the weld gap along the length direction.

[0057] S202. Based on the image information and ranging information, determine the structural feature parameters of the component to be welded, and generate the current welding parameters corresponding to the component to be welded based on the structural feature parameters.

[0058] The structural characteristic parameters include component type, wall thickness, and weld gap, while the welding parameters include welding current parameters and wire feed speed parameters.

[0059] As one possible implementation, as described in step S201 above, for the obtained image information, the straight line features and corner features of the outline of the component to be welded are extracted through edge detection and Hough transform algorithms. These features are then matched with standard component models (such as the four right-angle features of a square tube, the perpendicular features of the web and flange of an I-beam) pre-stored in the database to determine the component type of the component to be welded, such as "100mm×100mm square tube" or "200mm×100mm I-beam". Simultaneously, by comparing the image features with sample features in a pre-set material database, the material of the component to be welded (such as Q235 steel or Q355 steel) is identified, and the corresponding physical property parameters are obtained from the database. These physical property parameters include the melting point, density, and specific heat capacity of the component to be welded.

[0060] In addition, the wall thickness of the component to be welded can be determined as described in step S201 above. When the component to be welded is an open section component (such as channel steel), the distance difference between the outer surface and the inner surface collected by the laser range sensor is directly extracted as the wall thickness of the component to be welded. When the component to be welded is a closed section component (such as square tube), the wall thickness of the component to be welded is determined based on the above formula for calculating the wall thickness.

[0061] For the weld gap of the component to be welded, the average width of the weld gap is determined based on multiple width values ​​sampled at preset intervals.

[0062] For the cross-sectional area of ​​the component, it can be calculated using the corresponding geometric formula based on the component type to be welded, combined with the external dimensions and wall thickness measured by the sensor.

[0063] If the component to be welded is a square tube, the calculation formula is as follows:

[0064]

[0065] In the formula, Let be the cross-sectional area of ​​the component to be welded. , These are the side lengths of the square tube. That is, the cross-sectional area of ​​the outer contour of the square tube. For wall thickness, , These are the side lengths of the inner contour of the square tube, respectively. This is the cross-sectional area of ​​the hollow region corresponding to the inner contour. Subtracting the two gives the cross-sectional area corresponding to the wall thickness region, which is also the cross-sectional area of ​​the area of ​​the component to be welded. .

[0066] If the component to be welded is an I-beam, the calculation formula is as follows:

[0067]

[0068] In the formula, Let be the cross-sectional area of ​​the component to be welded. The web height of the I-beam. This refers to the flange width of the I-beam. Given the wall thickness, the cross-sectional area of ​​the web of the I-beam is... The cross-sectional area of ​​the two flanges connected to the web is Based on this, the cross-sectional area of ​​the area to be welded in the component to be welded can be obtained.

[0069] Furthermore, determine the welding current parameter in the current welding parameters, including:

[0070] First, based on the preset target melt depth (e.g., 70% of the wall thickness), physical property parameters, and wall thickness, the theoretical linear energy density required to heat the base material to the melting point at the target melt depth is calculated. The formula for calculating the linear energy density is as follows: ,in, To preset the target melting depth, The melting point of the component to be welded (since the melting point of the base material has a large temperature difference compared to the initial temperature, the melting point temperature can be used to replace the temperature difference of the base material as it rises from the initial temperature to the melting point temperature). The density of the component to be welded, The specific heat capacity of the component to be welded. For arc thermal efficiency, the base material at the target melt depth must reach its melting point temperature. This temperature is directly related to the melting point, density, specific heat capacity, and temperature rise of the material at that melt depth. (Preset target melt depth × melting point × density × specific heat capacity) represents the basic heat required to melt the base material, and the arc thermal efficiency. This refers to the proportion of arc energy converted into heat in the base material. In gas shielded welding scenarios, it is usually taken as 0.7-0.85, but the specific value is affected by process conditions such as shielding gas composition and flow rate. For example, an empirical value of 0.8 can be taken.

[0071] Secondly, given the preset welding speed and arc voltage, the relationship can be established through the formula. , The theoretical welding current that satisfies the target penetration depth is derived, and its calculation formula is as follows: ,in, Linear energy density, Arc voltage For welding speed, This represents the arc power.

[0072] It should be noted that the theoretical welding current is the reference value for welding under the ideal working condition of "zero gap and no assembly deviation", that is, there is no gap between the components to be welded and they are in good contact. However, in actual welding, the existence of assembly gap will change the boundary conditions for the transfer of arc heat to the base material: when the gap is zero, the arc heat is concentrated at the intersection of the two base materials, the heat flux density is the maximum and the heat conduction path is the shortest; when the gap increases, the arc coverage area expands, the heat flux density obtained per unit area decreases, and at the same time, the heat needs to cross the gap space to reach the base material on the other side, and the conduction path is lengthened, resulting in increased heat loss.

[0073] Based on this, finite element thermal analysis was used to simulate the temperature field distribution under different gap conditions. The gap region was set as an air domain, as air has a much lower thermal conductivity than metal, forming a thermal barrier layer. The actual current value required to reach the target melting depth was then extracted, and the ratio of this value to the baseline current value at zero gap was used as a correction coefficient. The correction coefficient increased rapidly as the gap increased from zero to a certain value, but its growth slowed down as the gap continued to increase. This is because when the gap is small, heat can still cross the gap through radiation and convection; as the gap increases to a certain extent, the heat transfer mode tends to stabilize, and the two exhibit a nonlinear relationship. Therefore, multiple sets of correction coefficients and corresponding datasets of gap widths were nonlinearly fitted to obtain a curve mapping the gap width to the correction coefficient.

[0074] Subsequently, based on the average width of the weld gap, the mapping relationship between the gap width and the correction factor is looked up to obtain the correction factor corresponding to the component to be welded. Then, the theoretical welding current is corrected according to the correction factor to obtain the welding current parameter in the current welding parameters.

[0075]

[0076] In the formula, This refers to the welding current parameter in the current welding parameters. The theoretical welding current, This is a correction factor obtained from a query based on the average width of the weld gap.

[0077] In some embodiments, a correction coefficient can be determined for each sampled width based on the width of multiple weld gaps obtained by sampling at preset intervals, thereby obtaining the welding current parameter corresponding to each sampling position. This allows for dynamic adjustment of the welding current parameter when welding to the corresponding sampling position, ensuring that the actual penetration depth meets the design requirements.

[0078] Furthermore, determine the wire feed speed parameter in the current welding parameters, including:

[0079] First, the theoretical wire feed rate is calculated based on the welding current parameter and the wire energy balance equation in the current welding parameters. This equation considers that the energy required for wire fusion comes from resistance heat (the power value is calculated by substituting the current value indicated by the welding current parameter into the resistance power formula, which is welding current parameter² × wire resistance) and arc heat (the power value is calculated by substituting the current value indicated by the welding current parameter into the arc power formula). Summing the two yields the mass melting rate, which is then divided by the wire density to obtain the volume melting rate. Finally, dividing by the wire cross-sectional area yields the theoretical wire feed rate.

[0080] Secondly, based on the average width of the weld gap, the cross-sectional area of ​​the weld gap is determined, and the wire feed speed increment is determined based on the cross-sectional area of ​​the gap and the cross-sectional area of ​​the welding wire.

[0081] In some embodiments, the presence of a weld gap means that more filler metal needs to be filled into the weld cross section. The filler cross section of the weld gap should be triangular or trapezoidal. The cross-sectional area of ​​the weld gap is calculated based on the average width of the weld gap and the preset weld leg height (base times height divided by 2). The preset weld leg height is set according to the standard of the welding process and can be 0.5-0.7 times the wall thickness.

[0082] Based on this, the wire feed speed increment can be calculated using (weld gap cross-sectional area × welding speed) / welding wire cross-sectional area.

[0083] Finally, the theoretical wire feed speed is superimposed with the wire feed speed increment to obtain the wire feed speed parameter in the current welding parameters.

[0084] It should be noted that the wire feed speed parameter was determined based on the welding current parameter, which was specifically increased according to the weld gap. This ensures that for larger weld gaps, the increased wire feed speed has sufficient arc heat input to match, thereby ensuring that the filler metal can fully melt and fuse well with the base metal, maintaining the mechanical properties of the weld.

[0085] Understandably, in this embodiment of the invention, firstly, by automatically associating material databases through image recognition, precise physical property parameters are directly obtained, fundamentally avoiding errors that may arise from manual querying or estimation of material parameters, thus laying an accurate data foundation for subsequent thermodynamic calculations. Secondly, a "gap width-correction coefficient mapping relationship" is established and applied to calculate the welding current. This essentially involves pre-modeling the complex physical process of welding heat conduction (especially the thermal barrier and heat loss effects caused by the gap) digitally through finite element analysis. Therefore, when facing the ever-changing assembly gaps in actual production, the system can perform nonlinear, adaptive current compensation, rather than simple linear adjustment. This effectively solves the industry problem of unstable penetration depth and the tendency for incomplete fusion or burn-through defects caused by fluctuations in assembly precision. Finally, by introducing incremental calculations of wire feed speed based on gap geometry, precise matching of the filler metal amount is achieved, ensuring the fullness and mechanical properties of the weld formation. Overall, this solution enables the welding system to "sense" the specific conditions of the current operation (material, wall thickness, weld gap) and "think" out the optimal combination of parameters to match them, thereby significantly improving the welding success rate, weld quality consistency, and process adaptability to components of different specifications without human intervention.

[0086] S203. In response to the component specification switching command, generate target welding parameters corresponding to the new specification component based on the structural characteristic parameters of the component to be switched to.

[0087] As one possible implementation, after receiving the component specification switching instruction, image information and distance measurement information of the component to be switched to the new specification are collected, and based on the image information and distance measurement information, the structural characteristic parameters of the new specification component are determined in the manner described in step S202 above, and target welding parameters are generated based on the structural characteristic parameters of the new specification component.

[0088] In some embodiments, receiving a component specification switching instruction is exemplified by: the welding system establishing a communication connection with the factory's Manufacturing Execution System (MES) or a host control computer. After completing the welding task for the current component to be welded, the MES sends a structured digital instruction to the welding system according to the production order schedule. This instruction contains at least one "specification identifier code" to uniquely identify the next frame specification to be welded, such as "FRAME_TYPE_B" or "PNO-2024-015". The control unit within the system parses this instruction to confirm that the production task has been switched. Receiving this "component specification switching instruction" signifies that the system has officially transitioned from the state of "executing the current welding parameters" to the state of "preparing welding parameters for the next specification component," thereby automatically triggering a complete adaptive process for subsequent image and distance measurement information acquisition, structural feature parameter determination, and target welding parameter generation for the new specification component.

[0089] Optionally, for example, when the conveyor line delivers a new batch of components to the welding station, if the visual sensor of the information acquisition unit first detects that the component outline is "H"-shaped (a characteristic of I-beams), which differs from the currently being welded "rectangular outline square tubes," the system automatically determines and triggers a specification switching command without manual intervention. It then performs complete structural feature parameter acquisition and target welding parameter calculation for the I-beam component. Another example is switching between different sizes of the same type: if the original welding specification is "small-sized square tube," and after completing this batch of welding, the production management system issues an order switching command, changing the new specification to "large-sized square tube." After receiving the component specification switching command, the system immediately performs complete structural feature parameter acquisition and target welding parameter calculation for the I-beam component.

[0090] It should be noted that the acquisition of image information and distance measurement information of the new specification components can be referred to the description of step S201 in the above embodiment of the present invention, and the determination of structural feature parameters and target welding parameters of the new specification components can be referred to the description of step S202 in the above embodiment of the present invention, which will not be repeated here.

[0091] S204. During the process of switching from the current welding parameters to the target welding parameters, first time series data and second time series data are collected.

[0092] The first time series data is the time series data of the welding current value changing with time, and the second time series data is the time series data of the wire feed speed value changing with time.

[0093] As one possible implementation, after determining the target welding parameters for the new specification component, the system control unit will generate and issue specific parameter switching instructions. These instructions will switch the welding current parameter in the currently effective welding parameters to the welding current parameter in the target welding parameters, and switch the wire feed speed parameter in the currently effective welding parameters to the wire feed speed parameter in the target welding parameters.

[0094] In this process, the moment when the parameter switching command is issued is taken as the absolute time zero point. Data acquisition continues for a preset response time window, such as from From the moment it begins, data collection continues. Milliseconds. Within this time window, the welding current value and wire feed speed value are synchronously sampled at constant preset time intervals to obtain the welding current value and wire feed speed value at each sampling moment, thereby obtaining the time series data of the welding current value changing with time (first time series data) and the time series data of the wire feed speed value changing with time (second time series data).

[0095] In some embodiments, a high-precision Hall sensor connected to the welding power output circuit can be used to measure and record the instantaneous value of the actual welding current in real time; and an encoder installed on the wire feeding mechanism can be used to measure and record the instantaneous value of the actual wire feeding speed in real time.

[0096] In some embodiments, after the acquisition of the first and second time-series data is completed, outlier removal is performed respectively. The positions of the removed outliers are supplemented by linear interpolation to ensure the continuity of the data sequence. Outlier removal can be performed by comparing the absolute value of the difference between each time-series data point and the mean with three times the standard deviation; if the difference is greater than three times the standard deviation, the outlier is removed.

[0097] S205. Based on the first time series data and the second time series data, determine the evaluation parameters for the coordinated mismatch between welding current and wire feed speed during parameter switching.

[0098] Among them, the collaborative mismatch evaluation parameter is used to characterize the degree of mismatch between the dynamic response of welding current and the dynamic response of wire feed speed in terms of amplitude and frequency.

[0099] As one possible implementation, the collaborative mismatch evaluation parameters include a first evaluation parameter for characterizing the degree of energy mismatch between welding current and wire feed speed, and a second evaluation parameter for characterizing the dynamic response synchronization between welding current and wire feed speed.

[0100] To determine the first evaluation parameter, including:

[0101] First, a parameter phase space is constructed, where the actual value of the parameter is used as the horizontal axis and the rate of change of the parameter is used as the vertical axis. The first time series data is mapped to the phase space to form the first trajectory curve, and the second time series data is mapped to the phase space to form the second trajectory curve.

[0102] It should be noted that, ideally, the trajectory curve should exhibit monotonically converging characteristics, rapidly approaching the target value from the starting point and then becoming smooth and stable. However, in reality, due to factors such as control loop delay and power device switching characteristics, the trajectory may exhibit non-ideal forms such as overshooting, oscillation, or crawling stagnation.

[0103] Based on this, to quantify the deviation between the actual response and the ideal path, the system uses numerical integration methods (such as applying Green's theorem) to calculate the area of ​​the closed region enclosed by the first trajectory curve and the horizontal axis, denoted as the first envelope area, and calculates the area of ​​the closed region enclosed by the second trajectory curve and the horizontal axis, denoted as the second envelope area. The size of the area directly reflects the "excess" dynamic energy accumulated by the actuator during the adjustment process, and directly reflects the overall deviation of the actual dynamic response trajectory of the actuator from the ideal adjustment path. The larger the area, the more significant the non-ideal dynamic phenomena such as oscillation, overshoot, or delay in the response process, and the lower the efficiency and stability of the dynamic adjustment.

[0104] To further eliminate dimensions and focus on relative mismatch, the first and second envelope areas are normalized. The maximum-minimum normalization method can be used, which uses the maximum and minimum values ​​of the envelope area in the historical processing as a benchmark to normalize the first and second envelope areas, mapping the values ​​of the first and second envelope areas to the 0-1 interval.

[0105] Finally, the first evaluation parameter is determined based on the first envelope area, the second envelope area, the preset target melt depth, and the wall thickness.

[0106] In some embodiments, the formula for determining the first evaluation parameter is as follows:

[0107]

[0108] In the formula, As the first evaluation parameter, The normalized area is the first envelope area. The normalized area is the second envelope area. To preset the target melting depth, Let the wall thickness of the component to be welded be denoted as . To take the absolute value.

[0109] in, Indicates the intensity of energy mismatch. This represents the unit weld volume, and before calculation using the above formula, it is normalized based on the maximum unit weld volume in the historical processing. The ratio of the actual value to the maximum unit weld volume, if If the actual value is greater than the maximum unit welding volume in the historical processing, then the value is taken as 1), and both the numerator and denominator have been dimensionless. Therefore, the first evaluation parameter is the degree of energy mismatch accumulated within a unit welding volume; the larger the value, the stronger the potential destructive effect of the parameter switching process on the weld quality.

[0110] To determine the second evaluation parameter, including:

[0111] First, the first time-series data is transformed into the frequency domain to obtain the first spectrum, and the second time-series data is transformed into the frequency domain to obtain the second spectrum.

[0112] In some embodiments, a Fast Fourier Transform (FFT) can be used to convert the time-series data from the time domain to the frequency domain, yielding the corresponding first and second spectra. The two spectra reveal the energy distribution of different frequency components in their respective response signals, typically showing a main peak at the fundamental frequency position representing the system's primary response dynamics.

[0113] It should be noted that the welding current spectrum (first spectrum) usually has a main peak in the low-frequency band corresponding to the fundamental frequency response of the system, while the secondary peak in the high-frequency band reflects the switching frequency of the power regulation circuit; the main peak position of the wire feed speed spectrum (second spectrum) is often different from that of the current, because the mechanical inertia of the wire feed mechanism makes its natural frequency lower than that of the electrical system.

[0114] Furthermore, the cross-correlation function between the first and second spectra is calculated. The values ​​of the cross-correlation function at different frequency offsets reflect the similarity between the two signals at that frequency. The frequency difference corresponding to the maximum value of the cross-correlation function between the first and second spectra is determined as the offset of the dominant frequency component, denoted as . This offset represents the degree of misalignment between the dominant frequency components of the welding current and the wire feed speed. The larger the offset, the greater the difference in their dynamic rhythms.

[0115] Further obtain the thermal diffusivity of the material of the component to be welded and the duration of the parameter switching process, and determine the second evaluation parameter based on the offset of the dominant frequency component, the duration, the thermal diffusivity, and the wall thickness.

[0116] In some embodiments, the formula for determining the second evaluation parameter is as follows:

[0117]

[0118] In the formula, This is the second evaluation parameter. This represents the offset of the dominant frequency components between the first and second spectra. The duration of the parameter switching process (as described above), =200 milliseconds), The thermal diffusivity is calculated as the thermal conductivity of the component divided by its density and specific heat capacity. The wall thickness is [not specified].

[0119] in, The product of the offset of the dominant frequency component and its duration represents the equivalent phase difference due to the mismatch between current and wire feed speed. According to Fourier's law of heat conduction, the time constant for heat diffusion in the component is... The ratio of the equivalent phase difference to the diffusion time constant characterizes the effect of transient mismatch. When the numerator is much larger than the denominator, that is... The larger ( The larger the value, the more the phase difference caused by the frequency misalignment exceeds the allowable range of the thermal diffusion time constant, and the more severe the impact.

[0120] It should be noted that before using the above formula for calculation, a reference value is set for each parameter, and the parameters are normalized by calculating the ratio of each parameter value to the reference value to eliminate the influence of the dimensions of each parameter. Finally, based on the normalized parameters, a dimensionless second evaluation parameter is calculated using the above formula.

[0121] S206. Based on the collaborative mismatch evaluation parameters, pre-compensate the welding current control command and wire feed speed control command during the subsequent parameter switching process.

[0122] As one possible implementation, the first evaluation parameter is compared with the first threshold, and the second evaluation parameter is compared with the second threshold. If the first evaluation parameter is less than or equal to the first threshold and the second evaluation parameter is less than or equal to the second threshold, it means that there is no coordination mismatch in the handover process and no additional compensation is required.

[0123] It should be noted that the value range of the first threshold is 0.1-0.2, and an empirical value of 0.15 can be taken. The value range of the second threshold is 2-3, and an empirical value of 2.5 can be taken. This embodiment of the invention does not make specific limitations on these values.

[0124] If the first evaluation parameter is greater than the first threshold, it indicates that the energy fluctuation mismatch between the welding current and the wire feeding speed exceeds the allowable range. It is necessary to compensate for the dynamic response lag of the actuator to be compensated by overshoot pulse command. Then, the actuator to be compensated is determined according to the envelope area of ​​the first trajectory curve and the second trajectory curve.

[0125] When the envelope area of ​​the first trajectory curve is smaller than that of the second trajectory curve, it indicates that the response trajectory of the welding power source is more compact and the energy accumulation is less, meaning that the welding power source responds faster than the wire feeding mechanism. Therefore, the actuator to be compensated is the wire feeding mechanism. When the envelope area of ​​the first trajectory curve is larger than that of the second trajectory curve, it indicates that the response trajectory of the wire feeding mechanism is more compact and the energy accumulation is less, meaning that the wire feeding mechanism responds faster than the welding power source. Therefore, the actuator to be compensated is the welding power source.

[0126] When the first evaluation parameter is greater than the first threshold, in response to the switching command of the next same specification switch, an overpulse command (such as a pulse command with a change of 1.2 times) is sent to the actuator to be compensated. After the overpulse command is sent, such as 50 milliseconds later, a parameter switching command is sent (a welding current parameter switching command is sent to the welding power source, and a wire feeding speed parameter switching command is sent to the wire feeding mechanism). The system inertia is used to start the actual response curve of the actuator to be compensated in advance, so that the response trajectory of the actuator is aligned with that of the other actuator on the time axis at the moment of formal switching, and the energy mismatch intensity between the two is compressed to below the threshold.

[0127] If the second evaluation parameter is greater than the second threshold, it indicates that the dominant frequency deviation of the welding current and wire feed speed exceeds the adaptability range of material thermal diffusion, and the dynamic response synchronization needs to be optimized by adjusting the control loop parameters.

[0128] For the wire feed speed control loop, the proportional gain of the proportional-integral-derivative (PID) controller is increased by a preset percentage (e.g., 15%) to increase the response bandwidth, causing the main peak of the wire feed speed spectrum to shift towards higher frequencies. For the welding current control loop, a digital low-pass filter is applied to its control command output, with its cutoff frequency set to a low value (e.g., 8Hz) to suppress high-frequency oscillations in the current response, causing the main peak of the current spectrum to contract towards lower frequencies. Through this adjustment, the dominant frequency components of the current and wire feed speed are brought closer together, thereby improving dynamic synchronization.

[0129] If the first evaluation parameter is greater than the first threshold and the second evaluation parameter is greater than the second threshold, the two compensation methods mentioned above are executed simultaneously.

[0130] In some embodiments, during the switching process from the component to be welded to the component of the new specification after pre-compensation, the first time-series data and the second time-series data are re-acquired, and the first evaluation parameter and the second evaluation parameter are updated. If the updated first evaluation parameter is less than the first threshold and the updated second evaluation parameter is less than the second threshold, the current pre-compensation strategy is stored for subsequent execution during the switching process from the specification corresponding to the component to be welded to the specification corresponding to the component of the new specification, thereby realizing adaptive optimization of welding quality during the specification switching process.

[0131] It should be noted that by establishing a mapping relationship between specification switching paths and pre-compensation strategies, whenever a switching instruction pointing to the same path (current specification identifier, new specification identifier) ​​is received again, the pre-compensation strategy associated with this path will be automatically retrieved from the database and directly applied to the upcoming switching process. This mechanism enables the system to intelligently optimize based on historical successful experience when dealing with repetitive production tasks, thereby continuously improving the switching efficiency and process stability of multi-variety, small-batch production while ensuring consistent welding quality.

[0132] Understandably, in the automated welding method for the steel structure frame of a dust collector provided in this embodiment of the invention, precise acquisition of component images and distance measurement information provides comprehensive data support for determining structural feature parameters, ensuring that the generated current welding parameters are deeply adapted to the actual working conditions such as component material, size, wall thickness, and weld gap, thus guaranteeing the quality of basic welding from the source. When switching component specifications, target welding parameters are quickly generated based on the structural feature parameters of the new specification component. At the same time, time-series data during the parameter switching process is acquired in real time. The energy matching and frequency-thermal synchronization of welding current and wire feed speed are quantified through dual-dimensional collaborative mismatch evaluation parameters, thereby enabling targeted welding. The system pre-compensates for subsequent switching processes, effectively suppressing mismatch issues such as dynamic response lag and energy imbalance caused by parameter switching, and avoiding defects such as incomplete weld fusion, uneven filling, and excessive heat-affected zone. The entire process can be completed automatically from data acquisition to parameter optimization without manual intervention, which not only improves the accuracy of welding parameter adaptation and switching stability, but also significantly reduces human operation errors. At the same time, it lays the foundation for parameter reuse in subsequent switching scenarios of the same specifications, significantly improving welding efficiency and quality consistency in multi-specification, small-batch production modes, and fully meeting the comprehensive requirements of dust collector steel structure frame for welding strength, forming accuracy, and production efficiency.

[0133] It should be noted that the order of the above embodiments of the present invention is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. The processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0134] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

Claims

1. An automated welding method for the steel structure frame of a dust collector, characterized in that, The method includes: Acquire image and distance information of the component to be welded; Based on the image information and the ranging information, the structural feature parameters of the component to be welded are determined, and the current welding parameters corresponding to the component to be welded are generated based on the structural feature parameters. The structural feature parameters include component type, wall thickness and weld gap, and the welding parameters include welding current parameters and wire feed speed parameters. In response to a component specification switching command, target welding parameters corresponding to the new specification component are generated based on the structural feature parameters of the component to be switched to. During the process of switching from the current welding parameters to the target welding parameters, first time-series data and second time-series data are collected. The first time-series data is the time-series data of the welding current value changing over time, and the second time-series data is the time-series data of the wire feed speed value changing over time. Based on the first time series data and the second time series data, a collaborative mismatch evaluation parameter between welding current and wire feed speed is determined during the parameter switching process. Based on the collaborative mismatch evaluation parameter, the welding current control command and wire feed speed control command in the subsequent parameter switching process are pre-compensated. The collaborative mismatch evaluation parameter is used to characterize the degree of mismatch between the dynamic response of welding current and the dynamic response of wire feed speed in amplitude and frequency. The cooperative mismatch evaluation parameters include a first evaluation parameter and a second evaluation parameter. Determining the cooperative mismatch evaluation parameters between welding current and wire feed speed during parameter switching includes: Construct a parameter phase space, with the actual value of the parameter on the x-axis and the rate of change of the parameter on the y-axis. Map the first time series data to the phase space to form a first trajectory curve, and map the second time series data to the phase space to form a second trajectory curve. The first evaluation parameter is determined based on the morphological differences between the first trajectory curve and the second trajectory curve. The first time-series data is transformed into a frequency domain to obtain a first spectrum, and the second time-series data is transformed into a frequency domain to obtain a second spectrum; The second evaluation parameter is determined based on the offset of the dominant frequency components in the first spectrum and the second spectrum; Based on the aforementioned collaborative mismatch evaluation parameters, pre-compensation is performed on the welding current control command and wire feed speed control command during subsequent parameter switching processes, including: When the first evaluation parameter is greater than the first threshold, the actuator to be compensated is determined based on the envelope area of ​​the first trajectory curve and the second trajectory curve. When the envelope area of ​​the first trajectory curve is less than the envelope area of ​​the second trajectory curve, the actuator to be compensated is a wire feeding mechanism. When the envelope area of ​​the first trajectory curve is greater than the envelope area of ​​the second trajectory curve, the actuator to be compensated is a welding power source. In response to a switching command that changes the specification of the component to be welded to the specification of the new specification component, an overshoot pulse command is sent to the actuator to be compensated. Send a welding current parameter switching command to the welding power source and a wire feeding speed parameter switching command to the wire feeding mechanism; When the second evaluation parameter is greater than the second threshold, during the switching process from the specification corresponding to the component to be welded to the specification corresponding to the new specification component, the proportional gain of the wire feed speed control loop is increased, and a digital low-pass filter is applied to the welding current control loop.

2. The automated welding method for the steel structure frame of a dust collector according to claim 1, characterized in that, Based on the image information and the ranging information, the structural characteristic parameters of the component to be welded are determined, including: Contour extraction and shape recognition are performed on the image information to determine the component type of the component to be welded; Based on the distance measurement information, the wall thickness of the component to be welded and the average width of the weld gap are determined.

3. The automated welding method for the steel structure frame of a dust collector according to claim 2, characterized in that, Based on the structural feature parameters, current welding parameters corresponding to the component to be welded are generated, including: The material of the component to be welded is identified based on the image information, and the physical property parameters of the component to be welded are determined based on the material. The physical property parameters include melting point, density, and specific heat capacity. The theoretical welding current is determined based on the physical property parameters and the preset target penetration depth; Based on the average width of the weld gap, the correction coefficient is determined according to the preset mapping relationship between the gap width and the correction coefficient; The theoretical welding current is corrected according to the correction coefficient to obtain the welding current parameter in the current welding parameters; The theoretical wire feed speed is determined based on the welding current parameter in the current welding parameters. Based on the average width of the weld gap, the cross-sectional area of ​​the weld gap is determined, and the wire feed speed increment is determined based on the cross-sectional area of ​​the gap and the cross-sectional area of ​​the welding wire. The wire feed speed parameter in the current welding parameters is obtained based on the theoretical wire feed speed and the wire feed speed increment.

4. The automated welding method for the steel structure frame of a dust collector according to claim 1, characterized in that, Based on the structural feature parameters of the new specification component to be switched to, target welding parameters corresponding to the new specification component are generated, including: Collect image and distance measurement information of the new specification components; Based on the image information and ranging information of the new specification component, the structural feature parameters of the new specification component are determined; The target welding parameters are generated based on the structural feature parameters of the new specification component.

5. The automated welding method for the steel structure frame of a dust collector according to claim 1, characterized in that, The method further includes: During the switching process from the component to be welded to the component of the new specification after pre-compensation, the first time series data and the second time series data are re-acquired, and the first evaluation parameter and the second evaluation parameter are updated. If the updated first evaluation parameter is less than the first threshold and the updated second evaluation parameter is less than the second threshold, the current pre-compensation strategy is stored for execution during the subsequent switching process from the specification corresponding to the component to be welded to the specification corresponding to the new specification component.

6. The automated welding method for the steel structure frame of a dust collector according to claim 1, characterized in that, The first evaluation parameter is determined based on the morphological differences between the first trajectory curve and the second trajectory curve, including: The area of ​​the closed region enclosed by the first trajectory curve and the horizontal axis is defined as the first envelope area, and the area of ​​the closed region enclosed by the second trajectory curve and the horizontal axis is defined as the second envelope area. The first evaluation parameter is determined based on the first envelope area, the second envelope area, the preset target melt depth, and the wall thickness.

7. The automated welding method for the steel structure frame of a dust collector according to claim 1, characterized in that, The second evaluation parameter is determined based on the offset of the dominant frequency components in the first and second spectra, including: The frequency difference corresponding to the maximum value of the cross-correlation function between the first spectrum and the second spectrum is determined as the offset of the dominant frequency component; Obtain the thermal diffusivity of the material of the component to be welded and the duration of the parameter switching process; The second evaluation parameter is determined based on the offset of the dominant frequency component, the duration, the thermal diffusivity, and the wall thickness.

8. An automated welding system for the steel structure frame of a dust collector, characterized in that, include: The information acquisition unit is used to acquire image information and distance measurement information of the component to be welded. The parameter processing unit is used to determine the structural feature parameters of the component to be welded based on the image information and the ranging information, and to generate the current welding parameters corresponding to the component to be welded based on the structural feature parameters. The structural feature parameters include component type, wall thickness and weld gap, and the welding parameters include welding current parameters and wire feed speed parameters. The parameter processing unit is also used to generate target welding parameters corresponding to the new specification component in response to the component specification switching command. The switching monitoring unit is used to collect first time-series data and second time-series data during the process of switching from the current welding parameters to the target welding parameters. The first time-series data is the time-series data of the welding current value changing over time, and the second time-series data is the time-series data of the wire feed speed value changing over time. The mismatch compensation unit is used to determine the collaborative mismatch evaluation parameters between welding current and wire feed speed during parameter switching based on the first timing data and the second timing data, and to pre-compensate the welding current control command and wire feed speed control command during subsequent parameter switching based on the collaborative mismatch evaluation parameters. The cooperative mismatch evaluation parameters include a first evaluation parameter and a second evaluation parameter. The mismatch compensation unit is specifically used for: Construct a parameter phase space, with the actual value of the parameter on the x-axis and the rate of change of the parameter on the y-axis. Map the first time series data to the phase space to form a first trajectory curve, and map the second time series data to the phase space to form a second trajectory curve. The first evaluation parameter is determined based on the morphological differences between the first trajectory curve and the second trajectory curve. The first time-series data is transformed into a frequency domain to obtain a first spectrum, and the second time-series data is transformed into a frequency domain to obtain a second spectrum; The second evaluation parameter is determined based on the offset of the dominant frequency components in the first spectrum and the second spectrum; When the first evaluation parameter is greater than the first threshold, the actuator to be compensated is determined based on the envelope area of ​​the first trajectory curve and the second trajectory curve. When the envelope area of ​​the first trajectory curve is less than the envelope area of ​​the second trajectory curve, the actuator to be compensated is a wire feeding mechanism. When the envelope area of ​​the first trajectory curve is greater than the envelope area of ​​the second trajectory curve, the actuator to be compensated is a welding power source. In response to a switching command that changes the specification of the component to be welded to the specification of the new specification component, an overshoot pulse command is sent to the actuator to be compensated. Send a welding current parameter switching command to the welding power source and a wire feeding speed parameter switching command to the wire feeding mechanism; When the second evaluation parameter is greater than the second threshold, during the switching process from the specification corresponding to the component to be welded to the specification corresponding to the new specification component, the proportional gain of the wire feed speed control loop is increased, and a digital low-pass filter is applied to the welding current control loop.

Images