A high-altitude welding robot system based on environment adaptive control

Abstract

This invention discloses a high-altitude welding robot system based on environmental adaptive control. During the welding operation, the analysis unit continuously acquires raw parameters of the external environment around the welding point and performs state analysis on these parameters to form an environmental state vector, which comprehensively characterizes the impact of environmental disturbances on the welding process. The construction unit dynamically adjusts the welding cavity structure formed in the welding area based on the environmental state vector, generating a welding cavity stabilization control quantity that characterizes the adjustment range required for the welding cavity to achieve stable gas protection conditions. After the welding cavity stabilization is completed, the generation unit generates welding process correction instructions based on the coupling relationship between the welding cavity stabilization control quantity and the environmental state vector. The execution unit receives and executes the welding process correction instructions to complete the welding operation under stable welding cavity conditions. This invention improves the stability and forming quality of welding operations in complex high-altitude environments through the coordinated control of environmental states and the welding process.

Description

Technical Field

[0001] This invention relates to the field of welding control technology, and in particular to a high-altitude welding robot system based on environmental adaptive control. Background Technology

[0002] Existing welding robot systems are widely used in manufacturing, engineering installation, and field construction. They typically control welding current, voltage, and wire feed speed by pre-setting welding process parameters or based on single sensor information to complete the weld formation. In some applications, to adapt to complex working conditions, existing technologies have incorporated environmental parameter detection methods to monitor the temperature, humidity, or gas state of the welding area. The welding process is then adjusted through empirical rules or simple feedback methods, while fixed or semi-enclosed gas protection structures are used to reduce the impact of the external environment on the welding process.

[0003] However, in high-altitude areas or complex environments such as strong winds and dust, existing welding robot systems often struggle to uniformly characterize and coordinate responses to various environmental disturbances. There is a lack of effective correlation mechanisms between environmental parameters, welding cavity conditions, and welding processes, resulting in insufficient gas shielding stability, susceptibility to interference during the welding process, and difficulty in ensuring consistent weld quality.

[0004] Therefore, it is necessary to propose a new technical solution to meet the higher requirements for stability and reliability of welding operations in complex high-altitude environments. Summary of the Invention

[0005] This application provides a high-altitude welding robot system based on environmental adaptive control to improve the stability and forming quality of welding operations in complex high-altitude environments.

[0006] This application provides a high-altitude welding robot system based on environmental adaptive control, including:

[0007] The analysis unit is used to continuously acquire the original parameters of the external environment within the spatial range formed around the welding operation point during the welding operation, and to perform state analysis processing on the original parameters of the external environment to generate an environmental state vector that characterizes the degree of instantaneous environmental disturbance during the welding operation.

[0008] A construction unit is used to dynamically adjust the welding cavity structure formed around the welding area based on the environmental state vector to generate a welding cavity stability control quantity; wherein, the welding cavity stability control quantity is used to characterize the adjustment range required for the welding cavity to achieve stable gas protection conditions under the current environmental conditions;

[0009] The generation unit is used to generate welding process correction instructions based on the coupling relationship between the welding cavity stability control quantity and the environmental state vector after the construction unit completes the stable construction of the welding cavity;

[0010] The execution unit is used to receive and execute welding process modification instructions to complete the welding operation under the conditions of a stabilized welding cavity.

[0011] The beneficial effects of this application mainly include: (1) By analyzing the original parameters of various external environments such as wind field changes, atmospheric static pressure, ambient temperature and humidity and suspended particulate matter concentration, the analysis unit can simultaneously acquire and analyze the state of these parameters, and generate an environmental state vector to uniformly describe the degree of environmental disturbance, so that environmental factors of different types and dimensions can be comprehensively expressed under the same characterization framework. (2) Through the coordinated work of environmental state analysis, welding cavity stability construction and welding process correction, the welding execution unit can complete the welding operation under relatively stable welding cavity conditions, effectively reducing the influence of factors such as low air pressure, strong wind and dust on the arc shape, molten pool stability and weld formation quality, thereby significantly improving the stability of welding operations and the consistency of weld quality in complex high-altitude environments. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of a high-altitude welding robot system based on environmental adaptive control provided in the first embodiment of this application. Detailed Implementation

[0013] Many specific details are set forth in the following description to provide a full understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of this application. Therefore, this application is not limited to the specific implementations disclosed below.

[0014] The first embodiment of this application provides a high-altitude welding robot system based on environment adaptive control. Please refer to... Figure 1 This figure is a schematic diagram of the first embodiment of this application. The following is in conjunction with... Figure 1 The first embodiment of this application provides a detailed description of a high-altitude welding robot system based on environmental adaptive control.

[0015] The high-altitude welding robot system based on environmental adaptive control includes a parsing unit 101, a construction unit 102, a generation unit 103, and an execution unit 104.

[0016] The analysis unit 101 is used to continuously acquire the original parameters of the external environment within the spatial range formed around the welding operation point during the welding operation, and to perform state analysis processing on the original parameters of the external environment to generate an environmental state vector that characterizes the degree of instantaneous environmental disturbance during the welding operation.

[0017] The analysis unit 101 is installed in the high-altitude welding robot system. As the front end of the entire environmental adaptive control link, its core function is to continuously, synchronously, and quantitatively acquire and analyze the external environmental state around the welding operation point during the welding operation. This provides a unified, stable, and physically meaningful environmental input basis for subsequent welding cavity structure adjustment and welding process correction. The so-called "spatial range formed around the welding operation point" refers to a three-dimensional perception area preset in space with the welding end of the welding torch as the center. The size of this area can be set according to the welding process type and construction scenario. For example, in the field of high-altitude steel structure welding, this spatial range can be set as a spherical or cylindrical area with a radius of 0.5 meters to 2 meters centered on the welding point to ensure that the collected environmental information can truly reflect the environmental disturbances that directly affect the welding process.

[0018] The analysis unit 101 includes at least an environmental parameter acquisition module, a parameter synchronization module, and a status analysis module. The environmental parameter acquisition module acquires raw external environmental parameters, including at least wind field variation parameters, atmospheric static pressure parameters, ambient temperature and humidity parameters, and suspended particulate matter concentration parameters. The wind field variation parameters reflect the influence of airflow within the welding area on arc stability and shielding gas distribution. These parameters are acquired through multi-point wind speed and direction sensors deployed around the welding point. The wind field variation parameters include not only instantaneous wind speed and direction but also the amplitude of wind speed fluctuations and the frequency of direction changes within a preset time window, characterizing the stability of the wind field. The atmospheric static pressure parameters reflect the influence of air density changes at high altitudes on arc combustion characteristics and gas shielding effectiveness. These parameters are acquired in real-time by a pressure sensor and output as absolute pressure values ​​or relative pressure changes. The ambient temperature and humidity parameters reflect the influence of ambient temperature and humidity on the cooling rate of the weld pool and gas diffusion behavior. These parameters are typically acquired through an integrated temperature and humidity sensor, where the temperature parameter can be a Celsius value and the humidity parameter can be a relative humidity percentage. The suspended particulate matter concentration parameter is used to reflect the impact of dust or sand in the welding area on the purity of the welding shielding gas and the quality of the weld. It can be obtained by a particulate matter sensor and expressed in the form of particulate matter mass or quantity per unit volume.

[0019] The parameter synchronization module is used to perform time alignment processing on the original parameters of the above-mentioned multi-source environment to ensure that all parameters participating in the state analysis within the same analysis cycle correspond to the environmental state at the same moment or within the same time window. For example, the working cycle of the analysis unit 101 can be set to 100 milliseconds. In each cycle, the wind field change parameters, atmospheric static pressure parameters, environmental temperature and humidity parameters, and suspended particulate matter concentration parameters are uniformly cached and synchronously output to the state analysis module to avoid distortion of the environmental state description due to inconsistent sampling times.

[0020] The state analysis module is used to perform state analysis processing on the original parameters of the synchronized external environment, thereby generating an environmental state vector. The "environmental state vector" refers to a set of parameters formed by mapping various physical quantities and environmental parameters of different dimensions to the same vector space according to predetermined analysis rules, used to uniformly characterize the degree of instantaneous environmental disturbance during welding operations. Specifically, the state analysis module can first normalize each original environmental parameter, converting it into dimensionless or dimensionless standardized parameters. For example, wind speed parameters are mapped proportionally according to a preset maximum allowable wind speed range; air pressure parameters are mapped proportionally according to the deviation ratio between standard atmospheric pressure and actual air pressure; temperature and humidity parameters are mapped according to the empirical range of their impact on welding stability; and suspended particulate matter concentration parameters are mapped proportionally according to allowable thresholds. After normalization, each environmental parameter is assigned a specific physical meaning weight. This weight reflects the relative influence of different environmental factors on welding stability. This weight can be preset according to the welding process type, welding material characteristics, or construction experience, and remains consistent during system operation.

[0021] Based on this, the state analysis module combines the normalized and weighted environmental parameters in a fixed order to form an environmental state vector. For example, in a specific embodiment, the environmental state vector can be represented as a vector set composed of wind field disturbance components, air pressure offset components, temperature and humidity coupling components, and particulate matter disturbance components.

[0022] Furthermore, the analysis unit is specifically used for: determining the spatial range centered on the welding operation point during the welding operation, and synchronously collecting wind field change parameters, atmospheric static pressure parameters, ambient temperature and humidity parameters, and suspended particulate matter concentration parameters within the spatial range at a unified sampling period to form a time-aligned set of original environmental parameters; based on the set of original environmental parameters, jointly analyzing the wind field change parameters and atmospheric static pressure parameters to obtain a shear disturbance component characterizing the lateral shearing effect of the external airflow on the welding area, and jointly analyzing the atmospheric static pressure parameters and ambient temperature and humidity parameters to obtain a diffusion disturbance component characterizing the diffusion and dilution trend of the protective gas. The parameters of wind field variation and suspended particulate matter concentration are analyzed together to obtain the dust-carrying disturbance component, which characterizes the trend of dust intrusion into the welding area with the airflow. Within a preset state evolution time window, the shear disturbance component, diffusion disturbance component, and dust-carrying disturbance component are subjected to time evolution processing to generate disturbance evolution features to characterize the degree of disturbance accumulation. The disturbance evolution features include at least the average intensity features and change stability features of each disturbance component within the time window. Based on the shear disturbance component, diffusion disturbance component, dust-carrying disturbance component, and corresponding disturbance evolution features, an environmental state vector is constructed in a preset order.

[0023] During the welding operation, the analysis unit first uses the welding operation point as the reference center for environmental perception and state analysis. The welding operation point, as referred to here, is the actual welding position where the welding torch tip forms an arc with the workpiece surface, generating a molten pool. This position continuously changes along the weld path during the welding process. Determining the spatial range centered on this welding operation point means constructing an effective sensing area around the welding operation point for collecting environmental parameters. This area covers airflow, air pressure changes, temperature and humidity conditions, and dust distribution, which directly affect welding stability. The spatial range can be set as a three-dimensional region with fixed dimensions in the radial and axial directions, centered on the welding operation point. For example, it can extend a predetermined distance in the front-to-back, left-to-right, and up-down directions of the welding operation point, thus forming a dynamic sensing area that moves synchronously with the welding operation point.

[0024] Within the defined spatial range, the analysis unit synchronously collects wind field variation parameters, atmospheric static pressure parameters, ambient temperature and humidity parameters, and suspended particulate matter concentration parameters at a unified sampling period. The term "unified sampling period" means that all the aforementioned environmental parameters are sampled under the same time reference. The sampling period can be a fixed time interval, such as 50 milliseconds, 100 milliseconds, or other time intervals suitable for welding control rhythm, to avoid state analysis deviations caused by inconsistent sampling times for different parameters. The synchronously collected environmental parameters correspond one-to-one in time, thus forming a time-aligned set of original environmental parameters. This set of original environmental parameters can be understood as a complete snapshot of the environmental state around the welding operation point at the same sampling moment, providing basic data for subsequent joint analysis.

[0025] First, the analysis unit performs joint analysis of wind field variation parameters and atmospheric static pressure parameters to obtain the shear disturbance component. The shear disturbance component here refers to the comprehensive characterization of the shear damage caused by the transverse or oblique flow of external airflow near the welding point under the action of air pressure difference on the shielding gas and arc morphology within the welding area. Wind field variation parameters reflect changes in airflow velocity and direction, while atmospheric static pressure parameters reflect air density and gas expansion characteristics; both together determine the intensity and duration of the airflow's impact on the welding area. By jointly analyzing these two parameters, a shear disturbance component can be obtained to quantify the strength of the transverse shearing effect of the external airflow on the welding area. This component can be expressed in normalized or dimensionless form for subsequent unified processing.

[0026] Simultaneously, the analysis unit performs joint analysis of atmospheric static pressure parameters and ambient temperature and humidity parameters to obtain the diffusion disturbance component. This diffusion disturbance component refers to the combined trend of outward diffusion of the protective gas and inward penetration of outside air within the welding area under high altitude, low air pressure, and specific temperature and humidity conditions. Atmospheric static pressure parameters determine the overall density level of the gas, while ambient temperature and humidity parameters affect the motion state and diffusion rate of gas molecules; both together affect the stability of the protective gas in the welding cavity or welding area. By jointly analyzing these two types of parameters, the analysis unit can obtain the diffusion disturbance component reflecting the tendency of the protective gas to be diluted or escape, thus providing targeted input information for subsequent welding cavity stability control.

[0027] Furthermore, the analysis unit also performs joint analysis of wind field variation parameters and suspended particulate matter concentration parameters to obtain the dust-carrying disturbance component. This component characterizes the tendency and intensity of dust particles intruding into the welding area under the influence of airflow. The wind field variation parameters determine the movement path and kinetic energy of the dust particles, while the suspended particulate matter concentration parameter reflects the dust content per unit volume of air. The combination of these two parameters reflects the degree of risk of dust entering the welding area with the airflow and interfering with the welding process.

[0028] After obtaining the shear disturbance component, diffusion disturbance component, and dust-carrying disturbance component, the analysis unit does not only focus on the disturbance intensity at a single moment, but also performs time evolution processing on each of the above disturbance components within a preset state evolution time window. The "state evolution time window" refers to a continuous sampling interval covering the time axis backward from the current sampling moment, such as the most recent 1 second, 2 seconds, or several sampling periods, used to reflect the changing trend and cumulative effect of environmental disturbances over a short period. By statistically analyzing each disturbance component within this time window, the analysis unit can generate disturbance evolution characteristics to characterize the degree of disturbance accumulation.

[0029] The disturbance evolution characteristics include at least average intensity characteristics and change stability characteristics. The average intensity characteristic reflects the overall level of a disturbance component within the time window, and can be obtained by averaging the disturbance component values ​​at each sampling point within the time window. For example, in a time window containing ten sampling points, if the sampled values ​​of the sheared disturbance component are d1, d2 to d... 10The average intensity characteristic can be obtained by adding these ten values ​​and dividing by ten, thus reflecting the average intensity of the external airflow shearing effect within that time period. The variation stability characteristic reflects the fluctuation of the disturbance component within the time window. It can be characterized by calculating the fluctuation amplitude, variation amplitude, or dispersion of the disturbance component within the time window, for example, by the difference between the maximum and minimum values, or by the standard deviation. By simultaneously introducing the average intensity characteristic and the variation stability characteristic, the analytical unit can not only determine "how strong" the environmental disturbance is, but also "whether" the disturbance is stable, thereby avoiding distortion of environmental state judgment caused by instantaneous changes or short-term noise.

[0030] After completing the aforementioned time evolution processing, the analytical unit constructs an environmental state vector based on the shear disturbance component, diffusion disturbance component, dust-carrying disturbance component, and their corresponding disturbance evolution characteristics, according to a preset arrangement order. The "preset arrangement order" refers to determining the position and correspondence of each component and its evolution characteristics within the vector during the system design phase, ensuring structural consistency of the environmental state vector across different sampling periods and welding tasks. The environmental state vector can be understood as a multi-dimensional dataset, where each dimension has a clear physical meaning, containing both instantaneous disturbance intensity information and the characteristic information of disturbance evolution over time. This environmental state vector, as the output of the analytical unit, is directly used by subsequent construction units to dynamically adjust the welding cavity structure, thereby achieving accurate characterization and effective control of welding stability in high-altitude, low-pressure, strong-wind, and dust-coupled environments.

[0031] In practical implementation, the above joint analysis can be understood through a clear calculation example. Taking the raw environmental parameters obtained within a certain sampling period as an example, assume that at that sampling time, the average wind speed near the welding operation point is 6 m / s, the angle between the prevailing wind direction and the weld direction is 60°, the atmospheric static pressure is 68 kPa, the ambient temperature is 5℃, the relative humidity is 40%, and the suspended particulate matter concentration is 1.2 mg / m³. 3The analysis unit first calculates the component of wind speed in the transverse direction of the weld. For example, by multiplying the wind speed by the sine of the included angle, the transverse wind speed component is obtained to be approximately 5.2 m / s. This transverse wind speed component is then combined with the deviation ratio of the current static pressure relative to the standard atmospheric pressure to form a shear disturbance component, which reflects the shear damage trend of the airflow on the protective gas in the welding area under low atmospheric pressure conditions. Subsequently, the analysis unit combines the static pressure value of 68 kPa with the gas diffusion characteristic parameters corresponding to temperature and humidity. For example, by introducing a gas density correction coefficient and a diffusion coefficient correction factor, a diffusion disturbance component is obtained, which characterizes the diffusion and dilution trend of the protective gas under this low-pressure and low-temperature environment. At the same time, the analysis unit multiplies the transverse wind speed component with the suspended particulate matter concentration or maps it according to a preset ratio to obtain a dust-carrying disturbance component, which reflects the risk level of dust intruding into the welding area with the airflow under the current wind field conditions. The aforementioned shear disturbance component, diffusion disturbance component, and dust-carrying disturbance component then enter the state evolution time window, and together with the corresponding components in the previous several sampling periods, participate in the calculation of average intensity and change stability, thus forming an environmental state vector that reflects both the instantaneous disturbance level and the disturbance evolution trend.

[0032] For example, in one specific embodiment, the analysis unit acquires the following raw environmental parameters within one sampling period: the measured wind speed near the welding operation point is 6 m / s, the angle between the prevailing wind direction and the weld direction is 60°, the measured atmospheric static pressure is 68 kPa, the ambient temperature is 5 ℃, the relative humidity is 40%, and the suspended particulate matter concentration is 1.2 mg / m³. 3 After time alignment, the analytical unit first performs directional decomposition on the wind field variation parameters to obtain the transverse wind speed component that truly destructs welding stability. Since airflow along the weld direction mainly affects the molten pool surface morphology, while airflow perpendicular to the weld direction directly disrupts the shielding gas boundary and induces arc shift, the analytical unit uses the weld direction as the reference coordinate axis to perform orthogonal decomposition on the measured wind speed. This decomposition is achieved by calculating the sine of the angle between the wind direction and the weld orientation; the transverse wind speed component is defined as the product of the measured wind speed and this sine value. In this example, the angle is 60°, and its sine value is approximately 0.866, therefore the transverse wind speed component is 6 × 0.866 ≈ 5.20 m / s.

[0033] After obtaining the lateral wind speed component, the analytical unit does not directly use it as a disturbance input, but further considers the amplification effect of the current air pressure conditions on the destructive power of the airflow. In high-altitude environments, gas density decreases with decreasing air pressure, and the "shear resistance" protecting the gas boundary weakens accordingly. Therefore, the destructive effect of the same wind speed under low pressure is more significant. To this end, the analytical unit first calculates the deviation ratio of static pressure relative to the standard air pressure. Using 101 kPa as the standard air pressure reference, the analytical unit calculates the static pressure deviation ΔP = 101 - 68 = 33 kPa, and selects 41 kPa as the maximum deviation reference range (corresponding to the typical lower limit of high-altitude construction, from 101 kPa to 60 kPa). Dividing 33 kPa by 41 kPa yields a low-pressure deviation coefficient of approximately 0.805. This low-pressure deviation coefficient is used to quantitatively describe the "severity of low pressure in the current environment relative to the standard environment."

[0034] Subsequently, the analytical unit normalizes the lateral wind speed component to eliminate dimensions and facilitate subsequent combination. Assuming that 10 m / s is defined as the upper limit of the permissible lateral wind speed for the welding equipment during system design, the normalized lateral wind speed value is 5.20 / 10 = 0.52. The analytical unit combines this normalized wind speed value with the low-pressure offset coefficient to form the shear disturbance component. To reflect the combined effect of the two rather than simple superposition, the analytical unit uses a "linear superposition + coupled amplification" method for combination. For example, the shear disturbance component is defined as: 0.5 × normalized wind speed value + 0.3 × low-pressure offset coefficient + 0.2 × (normalized wind speed value × low-pressure offset coefficient). After substituting the values, the shear disturbance component is 0.5 × 0.52 + 0.3 × 0.805 + 0.2 × (0.52 × 0.805), i.e., 0.26 + 0.242 + 0.084 ≈ 0.586. The shear disturbance component is a dimensionless quantity used to directly reflect the combined intensity of the transverse shear damage caused by the external airflow to the shielding gas and electric arc in the welding area under the current low-pressure conditions.

[0035] In constructing the diffusion perturbation component, the analysis unit focuses on the diffusion and dilution trends of the protective gas under the combined effects of low pressure, temperature, and humidity. First, the analysis unit calculates the gas density correction factor based on the measured static pressure. Since gas density is approximately proportional to gas pressure, the ratio of the measured static pressure to the standard gas pressure can be used as the density correction factor. In this example, the gas density correction factor is 68 / 101≈0.673, which indicates that the number of molecules per unit volume of gas under the current environment is approximately 67.3% of that under standard conditions. Lower density means that the protective gas is more easily perturbed and diffused. Next, the analysis unit introduces the influence of temperature and humidity on the gas diffusion characteristics. Higher temperatures result in more intense molecular thermal motion and a larger diffusion coefficient; higher humidity leads to more pronounced gas mixing and convection characteristics. Therefore, the analysis unit normalizes the temperature and humidity separately. Assuming the temperature normalization range is -20℃ to 40℃, the normalized temperature value corresponding to 5℃ is (5 - (-20)) / 60≈0.417; the humidity is normalized from 0% to 100%, and the normalized humidity value corresponding to 40% is 0.40. The parsing unit combines the two according to preset weights. For example, if the temperature and humidity diffusion factor is defined as 0.6 × temperature normalization value + 0.4 × humidity normalization value, then the temperature and humidity diffusion factor is 0.6 × 0.417 + 0.4 × 0.40≈0.410.

[0036] Subsequently, the analytical unit combines the gas density correction coefficient with the temperature and humidity diffusion factor to form a diffusion perturbation component. To reflect the "amplification effect of temperature and humidity changes on diffusion under low-density environments," the analytical unit also uses a combination of linear and multiplicative terms. For example, the diffusion perturbation component is defined as 0.6 × (1 - gas density correction coefficient) + 0.25 × temperature and humidity diffusion factor + 0.15 × [(1 - gas density correction coefficient) × temperature and humidity diffusion factor]. In this example, 1 - gas density correction coefficient is 0.327. Substituting this into the equation, the diffusion perturbation component is 0.6 × 0.327 + 0.25 × 0.410 + 0.15 × (0.327 × 0.410), which is approximately 0.196 + 0.103 + 0.020 ≈ 0.319. This diffusion perturbation component is used to quantify the overall trend strength of the protective gas being diluted and the intrusion of outside air under the current environment.

[0037] In constructing the dust-carrying disturbance component, the analysis unit simultaneously considers both "whether the dust is sufficient" and "whether the airflow has the ability to carry dust into the welding area." First, the analysis unit normalizes the suspended particulate matter concentration, assuming 2 mg / m³. 3 As the upper limit for typical high-dust working conditions, it is 1.2 mg / m³. 3The corresponding normalized particulate matter value is 1.2 / 2 = 0.60. Subsequently, the analysis unit combines this normalized particulate matter value with the aforementioned normalized lateral wind speed value of 0.52. To reflect the fact that "the risk only increases significantly when both wind and dust are high," the analysis unit uses a combination method that is primarily multiplicative and secondarily linear. For example, the dust-carrying disturbance component is defined as 0.4 × normalized particulate matter value + 0.3 × normalized wind speed value + 0.3 × (normalized particulate matter value × normalized wind speed value). After substituting the values, the dust-carrying disturbance component is 0.4 × 0.60 + 0.3 × 0.52 + 0.3 × (0.60 × 0.52), which is approximately 0.24 + 0.156 + 0.094 ≈ 0.490. To further reflect the enhanced dust-carrying capacity of airflow under low-pressure conditions, the analysis unit can also introduce the low-pressure offset coefficient as a correction factor. For example, multiply the above result by (1 + 0.5 × low-pressure offset coefficient), i.e., 1 + 0.5 × 0.805 ≈ 1.403, so that the final dust-carrying disturbance component is approximately 0.490 × 1.403 ≈ 0.688.

[0038] The construction unit 102 is used to dynamically adjust the welding cavity structure formed around the welding area based on the environmental state vector to generate a welding cavity stability control quantity; wherein, the welding cavity stability control quantity is used to characterize the adjustment range required for the welding cavity to achieve stable gas protection conditions under the current environmental conditions.

[0039] The construction unit 102 is set after the analysis unit 101 and connected to its signal. It is used to convert the environmental state vector output by the analysis unit 101 into a "dynamic adjustment behavior of the welding cavity structure" that can be directly applied to the welding area. In essence, it changes the welding cavity structure formed around the welding area in real time according to the degree of high altitude, low pressure, strong wind and dust coupling disturbance represented by the environmental state vector throughout the welding operation. This enables the welding cavity to achieve stable gas protection conditions under the current external environmental conditions and further outputs a clear and usable welding cavity stability control quantity. The term "welding cavity" refers to a partially enclosed or semi-enclosed gas-protected space formed near the welding operation point. The boundary of this space is formed by adjustable structural components and gas flow field. The atmosphere inside the space, dominated by protective gas, isolates the molten pool, electric arc, and welding wire tip from the outside air, thereby reducing the intrusion and impact of oxygen, nitrogen, water vapor, and dust particles on the welding process. Under high-altitude and low-pressure conditions, due to the reduced air density and enhanced convection diffusion, the protective gas is more easily diluted or dispersed by external disturbances. Therefore, this invention emphasizes that the "welding cavity structure" must have adjustable capabilities to maintain an effective gas protection boundary even when the wind field and air pressure change.

[0040] The building unit 102 includes at least a welding cavity structure actuator, a welding cavity state acquisition mechanism, and a stability control calculation mechanism. The welding cavity structure actuator is used to dynamically adjust the welding cavity boundary, and it can be composed of a deployable flexible boundary component, a variable opening guide component, and a gas supply and recovery component working together. The deployable flexible boundary component can be made of materials that are resistant to high temperatures and sparks, and possess certain rigid-flexible coupling characteristics, such as aluminum-coated fiberglass cloth, silicone-coated heat-resistant cloth, or multi-layer composite films. It forms an approximate dome or skirt structure around the welding operation point through a ring-shaped skeleton, telescopic support rod, or folding frame. The degree of deployment, contact distance, and opening direction of this flexible boundary component can be controlled by a servo motor, lead screw slide, pneumatic push rod, or shape memory alloy drive mechanism, allowing the effective enclosure range of the welding cavity to contract or expand according to changes in environmental disturbances. The variable-opening flow guide assembly is used to control the "venting path" of the welding chamber to the outside world without complete sealing. It can be manifested as an adjustable air inlet gap, an exhaust slit, or a directional flow guide. The opening area and orientation of the flow guide are adjusted by electric louvers, rotating baffles, or variable cross-section nozzles, thereby creating a controllable flow direction and velocity distribution of the protective gas within the chamber. The gas supply and recovery assembly is used to supply protective gas to the welding chamber and create backflow or local negative pressure when needed to suppress dust entry. It may include a mass flow controller, solenoid valve group, pressure regulating valve, cyclone stabilizer, gas recovery pipeline, and filter device. The cyclone stabilizer is used to create a certain swirling flow of the protective gas entering the welding chamber, thereby establishing a relatively stable gas core area within the chamber and reducing the cutting effect of external lateral winds on the gas boundary. The recovery pipeline and filter device can be used to extract and filter the dust-laden gas within the chamber when the dust concentration is high, preventing dust from accumulating within the chamber or entering the weld area.

[0041] The welding cavity status acquisition mechanism is used to acquire status information inside and near the boundary of the welding cavity, so that the construction unit 102 can determine whether the welding cavity has reached the stable gas protection condition. This status information may include at least the pressure difference inside and outside the welding cavity, the concentration or dilution degree of the protective gas inside the welding cavity, the airflow shear intensity at the boundary of the welding cavity, and the degree of particulate matter intrusion inside the cavity. To achieve the above acquisition, a differential pressure sensor can be used to sample the pressure inside the welding cavity and the external pressure, and calculate the pressure difference; an oxygen concentration sensor or a thermal conductivity gas concentration sensor can be used to assess the degree of dilution of the protective gas by air, for example, using oxygen volume fraction as a dilution index; a miniature hot-wire anemometer or ultrasonic anemometer can be placed at the boundary of the welding cavity to measure the tangential wind speed at the boundary to reflect the disturbance of the external wind on the gas boundary of the welding cavity; a particulate matter sensor can be placed inside the welding cavity near the molten pool area, or light scattering can be used to estimate the dust concentration to determine whether dust has significantly intruded into the welding cavity. The output of the aforementioned acquisition mechanism will enter the stability control calculation mechanism, enabling the construction unit 102 to not only "predict how much adjustment is needed based on the environmental state vector", but also "verify whether the adjustment meets the standard based on the actual state of the welding cavity", thereby improving feasibility and stability.

[0042] The stability control calculation mechanism is used to map the environmental state vector into welding cavity structure adjustment quantities, and further form welding cavity stability control quantities. Here, it is first necessary to clearly define the "stable gas protection conditions." Stable gas protection conditions do not require the welding cavity to be completely sealed, but rather require the formation of a protective atmosphere near the welding operation point that meets the allowable range of the welding process, so that the intrusion of outside air, dust intrusion, and gas boundary fluctuations are all limited within controllable thresholds. An operational definition method is to define stable gas protection conditions as follows: within a preset continuous stability judgment time period, the oxygen volume fraction inside the welding chamber is not higher than threshold A, the pressure difference between the inside and outside of the welding chamber is not lower than threshold B, the particulate matter concentration inside the welding chamber is not higher than threshold C, and the boundary shear velocity of the welding chamber is not higher than threshold D. Thresholds A, B, C, and D can be set according to the welding method and material system. For example, for common gas-shielded arc welding scenarios, threshold A can be set to an oxygen volume fraction not higher than 1% or a more stringent value; threshold B can be set to a minimum pressure difference that maintains positive pressure relative to the outside environment inside the welding chamber; threshold C can be set to a particulate matter mass concentration not exceeding a certain allowable upper limit; and threshold D can be set to a boundary shear velocity not exceeding the critical value that causes the gas boundary to rupture. Those skilled in the art can determine these thresholds through construction standards or welding procedure qualification results, or recommended parameter sets can be provided at the time of equipment delivery.

[0043] After meeting the aforementioned stability criteria, the welding cavity stability control quantity output by the construction unit 102 needs to possess the characteristics of being calculable, executable, and feedback-enabled. The welding cavity stability control quantity characterizes the adjustment range required for the welding cavity to achieve stable gas protection conditions under the current environmental state. Here, "adjustment range" can be defined as a combination of structural and gas parameters, including at least the adjustment range of the protective gas supply flow rate, the adjustment range of the welding cavity opening area, and the adjustment range of the welding cavity boundary contact distance or enclosure range. To facilitate subsequent use by the generation unit 103, the welding cavity stability control quantity can be output in a unified vector form. For example, the output can be a control vector containing three or more elements, each element corresponding to a directly executable adjustment command. For instance, the first element corresponds to the set increment of the mass flow controller, the second element corresponds to the change in the opening angle or cross-section of the flow guide component, and the third element corresponds to the change in the unfolded length of the flexible boundary component or the effective height of the welding cavity. In this way, the generation unit 103 can explicitly use each part of the welding cavity stability control quantity as a constraint or input when subsequently generating welding process correction commands.

[0044] The construction unit 102 can adopt the following feasible calculation logic: First, extract the wind field disturbance component, air pressure offset component, temperature and humidity coupling component, and particulate matter interference component from the environmental state vector, and map them respectively to the incremental demand for the welding cavity structure. For example, the larger the wind field disturbance component, the more necessary it is to improve the boundary fit of the welding cavity and reduce the opening area on the windward side, while increasing the supply flow rate of protective gas to counteract the blown gas; the larger the air pressure offset component, the more necessary it is to increase the target value of the pressure difference inside and outside the welding cavity and adjust the gas supply pressure stabilization strategy; the larger the particulate matter interference component, the more necessary it is to improve the recovery and extraction capacity and optimize the flow path to form an airflow barrier from the inside out. In a specific, directly reproducible example, the environmental state vector output by the analysis unit 101 can be set as a four-dimensional vector, with the four components being the normalized value of the wind field disturbance, the normalized value of the air pressure offset, the normalized value of the temperature and humidity coupling, and the normalized value of the particulate matter interference, all ranging from 0 to 1. Assuming the environmental state vector at a certain moment is [0.8, 0.6, 0.3, 0.7], it indicates that the current wind field disturbance is strong, the air pressure shift is significant, the influence of temperature and humidity is weak, but the dust interference is strong. The building unit 102 can pre-set the reference protective gas flow rate to 20 L / min, the reference welding cavity opening area corresponding to the guide port opening to 30%, and the reference welding cavity boundary contact distance to maintain a 30 mm gap with the workpiece surface. At this time, the adjustment range can be calculated according to the preset mapping rules. For example, the protective gas flow rate increment can be set as the reference flow rate multiplied by the weighted sum of the wind field disturbance component and the air pressure shift component, and then superimposed with the positive pressure barrier requirement corresponding to the particulate matter interference component; the guide port opening can be adjusted to the reference opening minus the opening contraction proportional to the wind field disturbance component, and when the dust interference is strong, the opening on the windward side can be further reduced, and the opening on the leeward side can be moderately increased to form directional venting; the boundary contact distance can be adjusted to the reference distance minus the contact contraction proportional to the wind field disturbance component, making the cavity enclosure tighter. For example, if the incremental protective gas flow rate is calculated as 20 × (0.5 × 0.8 + 0.3 × 0.6 + 0.2 × 0.7) = 20 × (0.4 + 0.18 + 0.14) = 14.4 L / min, then the new flow rate setting is 34.4 L / min. If the guide opening is adjusted to 30% - (15% × 0.8) = 18%, and the opening on the windward side is further reduced to 12% while the leeward side remains at 18% when the dust component is 0.7, and the boundary contact distance is adjusted to 30 mm - (10 mm × 0.8) = 22 mm, then the welding cavity will be closer to the welding area. In the above examples, the weights and proportional coefficients can be given at the factory according to typical operating conditions, or they can be determined by trial welding at the construction site.

[0045] After outputting the welding cavity stability control quantity, the construction unit 102 also needs to confirm the "welding cavity stability construction". Otherwise, the generation unit 103 cannot determine when to start generating welding process correction instructions. To this end, the construction unit 102 can adopt a continuous stability judgment mechanism. That is, when the oxygen volume fraction, pressure difference, particulate matter concentration, and boundary shear velocity output by the welding cavity status acquisition mechanism all meet the aforementioned stable gas protection conditions within a continuous judgment time period, the welding cavity stability construction is determined to be complete, and a stability completion flag signal is output to the generation unit 103 or a stable state field is attached to the welding cavity stability control quantity. The continuous judgment time period can be set according to the tolerance of the welding process to short-term disturbances, for example, set to 0.5 seconds to 2 seconds. If any indicator exceeds the limit within this time period, the timing is restarted, thereby ensuring that the generation unit 103 starts process correction based on real stability conditions, avoiding fine adjustment of welding energy, arc space, and welding material delivery before the welding cavity is stable.

[0046] Furthermore, the construction unit is specifically used for: determining a target set of stable gas protection conditions based on an environmental state vector, wherein the target set includes at least a target for the pressure difference inside and outside the welding cavity, a target for the upper limit of oxygen volume fraction inside the welding cavity, and a target for the upper limit of suspended particulate matter concentration inside the welding cavity, and outputting a corresponding stable target parameter set; driving the welding cavity state acquisition process based on the stable target parameter set to acquire the pressure inside the welding cavity, the pressure outside the welding cavity, the oxygen volume fraction inside the welding cavity, and the suspended particulate matter concentration inside the welding cavity, forming a welding cavity state parameter set that is time-aligned with the stable target parameter set; calculating a welding cavity stability deviation vector based on the stable target parameter set and the welding cavity state parameter set, wherein the welding cavity stability deviation vector includes at least a pressure difference deviation, an oxygen volume fraction deviation, and a particulate matter concentration deviation; and generating a welding cavity stability control quantity based on the correspondence between the welding cavity stability deviation vector and the environmental state vector, wherein the welding cavity stability control quantity includes at least a protective gas supply adjustment range, a welding cavity opening adjustment range, and a welding cavity boundary fitting adjustment range.

[0047] In this invention, the input to the construction unit is the environmental state vector output by the analysis unit, and the output of the construction unit is the welding cavity stability control quantity. Here, "welding cavity" refers to a local gas protection space formed around the welding area. This space is formed by an adjustable boundary structure and a protective gas flow field. The atmosphere inside the space is mainly composed of protective gas, isolating the arc, molten pool, and welding wire tip from the outside air, thereby inhibiting the intrusion of oxygen, nitrogen, water vapor, and dust particles. The "stable gas protection condition" is not an abstract "protection effective" or "protection stable," but rather a set of measurable, comparable, and quantifiable physical state constraints used to ensure that the atmosphere boundary inside the welding cavity can maintain the required welding quality even under high altitude, low pressure, strong wind, and dust coupling environments. The "welding cavity stability control quantity" is a set of adjustment ranges calculated by the construction unit to achieve stable gas protection conditions in the welding cavity. Its implementation corresponds to executable control quantities in three directions: protective gas supply adjustment, welding cavity opening adjustment, and welding cavity boundary fit adjustment, for use by subsequent generation and execution units.

[0048] The construction unit first determines the target set of stable gas protection conditions based on the environmental state vector and outputs a set of stable target parameters. Here, the "target set" refers to the set of target constraint values ​​that the welding cavity must achieve under the current environmental disturbance level, used to guide subsequent state acquisition and deviation calculation. The target set includes at least the target pressure difference between inside and outside the welding cavity, the upper limit target for oxygen volume fraction inside the welding cavity, and the upper limit target for suspended particulate matter concentration inside the welding cavity. The target pressure difference between inside and outside the welding cavity refers to the target difference between the static pressure inside the welding cavity and the static pressure of the environment outside the welding cavity. Its purpose is to maintain positive pressure inside the cavity, making it difficult for outside air to backflow into the welding cavity, thereby reducing oxygen and dust intrusion. This pressure difference target is not fixed but matches the intensity of shear disturbance, diffusion disturbance, and dust-carrying disturbance represented by the environmental state vector. When the environmental state vector indicates increased wind field shear disturbance, the pressure difference target needs to be increased to enhance the boundary shear resistance; when the environmental state vector indicates increased diffusion disturbance, the pressure difference target also needs to be appropriately increased to suppress dilution and mixing. The upper limit target for oxygen volume fraction in the welding chamber refers to the maximum allowable oxygen concentration within the welding chamber. This upper limit can be determined based on the welding process type, welding materials, and base metal system. For example, in common gas-shielded arc welding, to avoid porosity and oxidation, the oxygen volume fraction near the welding area is typically controlled to be significantly lower than the oxygen volume fraction in air. The building unit can preset a basic upper limit and adjust it according to the degree of diffusion disturbance. The upper limit target for suspended particulate matter concentration in the welding chamber refers to the maximum allowable dust concentration within the welding chamber. This upper limit is used to suppress the risk of decreased arc stability, slag inclusions, and weld contamination caused by dust entering the arc zone. This upper limit target can be set according to the welding process tolerance and dynamically tightened or relaxed based on the degree of dust-carrying disturbance.

[0049] The target set can be determined using a "base target value + environmental disturbance correction" approach. The base target values ​​are obtained from process evaluation or equipment factory calibration; for example, the base differential pressure target might be set to a fixed value, the base oxygen volume fraction upper limit might be set to a fixed value, and the base particulate matter concentration upper limit might be set to a fixed value. The building unit then reads the disturbance intensity components and their evolution characteristics from the environmental state vector, calculates the correction amount, and adds it to the base target values ​​to obtain the stable target parameter set. For example, suppose the base differential pressure target for a welding task is set to 150 Pa, the base oxygen volume fraction upper limit target is set to 1.0%, and the base particulate matter concentration upper limit target is set to 0.5 mg / m³. 3 . If the environmental state vector output by the analytical unit shows a shear disturbance component of 0.58, a diffusion disturbance component of 0.32, and a dust-carrying disturbance component of 0.69, then the building unit can correct the pressure difference target to 150 Pa plus the increments related to shear and diffusion disturbances. For example, pressure difference target = 150 + 200 × shear disturbance component + 100 × diffusion disturbance component, i.e., 150 + 200 × 0.58 + 100 × 0.32 = 150 + 116 + 32 = 298 Pa; correct the upper limit target for oxygen volume fraction to the base value minus the tightening amount related to diffusion disturbances. For example, oxygen upper limit = 1.0% - 0.3% × diffusion disturbance component = 1.0% - 0.096% = 0.904%; correct the upper limit target for particulate matter concentration to the base value minus the tightening amount related to dust-carrying disturbances. For example, dust upper limit = 0.5 - 0.2 × dust-carrying disturbance component = 0.5 - 0.138 = 0.362 mg / m³. 3 The coefficients in the above examples are determined by factory calibration or field trial welding. Those skilled in the art can solidify these mapping relationships in the controller, thereby forming a reproducible method for generating target sets. The resulting stable target parameter set contains three types of target values, each with a clear physical meaning and measurability.

[0050] After outputting a stable target parameter set, the construction unit drives the welding cavity state acquisition process based on this stable target parameter set, acquiring the pressure inside the welding cavity, the pressure outside the welding cavity, the oxygen volume fraction inside the welding cavity, and the concentration of suspended particulate matter inside the welding cavity, forming a welding cavity state parameter set that is time-aligned with the stable target parameter set. This "driving state acquisition" does not require the construction unit to control the sensor hardware itself, but it at least requires the construction unit to trigger or schedule sensor sampling so that the acquisition time is consistent with the effective time of the target parameter set, thereby ensuring that subsequent deviation calculations correspond to the same control cycle. The pressure inside the welding cavity can be measured by arranging a miniature pressure sampling port inside the welding cavity and connecting it to a pressure sensor. The pressure outside the welding cavity can be measured by arranging a sampling port outside the welding cavity, close to the welding area but not directly affected by the airflow inside the cavity, thus obtaining synchronous readings of the internal and external pressures. The oxygen volume fraction can be measured by an oxygen concentration sensor. The sensor location should be close to the core area of ​​the shielding gas inside the welding cavity or a representative location near the welding operation point to avoid overestimating values ​​near the boundary vent, which could lead to misjudgment. The concentration of suspended particulate matter can be measured using a light-scattering dust sensor or other particulate matter sensors that can operate in the welding environment. The sensors can be placed along the main airflow path within the welding chamber or near the welding point, but anti-spatter and high-temperature resistance measures must be taken. The building unit aligns the outputs of the above four types of sensors within the same sampling period to form a welding chamber state parameter set, including four elements: internal chamber pressure, external chamber pressure, internal chamber oxygen volume fraction, and internal chamber dust concentration, which serve as inputs for subsequent deviation vector calculations.

[0051] After obtaining the welding cavity state parameter set, the construction unit calculates the welding cavity stability deviation vector based on the stability target parameter set and the welding cavity state parameter set. The "welding cavity stability deviation vector" refers to a vector used to uniformly characterize the difference between the current state of the welding cavity and the target set, which includes at least pressure difference deviation, oxygen volume fraction deviation, and particulate matter concentration deviation. Pressure difference deviation requires first calculating the actual pressure difference and then comparing it with the pressure difference target. The actual pressure difference is defined as the pressure inside the welding cavity minus the pressure outside the welding cavity. Pressure difference deviation can be defined as the target pressure difference minus the actual pressure difference; a positive value indicates insufficient pressure difference, requiring an increase in the positive pressure inside the cavity or a reduction in venting; a negative value indicates excessive pressure difference, requiring a reduction in gas supply or an increase in venting to avoid excessive disturbance. Oxygen volume fraction deviation can be defined as the actual oxygen volume fraction minus the upper limit target oxygen volume fraction; a positive value indicates exceeding the limit, requiring enhanced protective gas purity, increased positive pressure, or optimized boundary fit; a negative value indicates not exceeding the limit, with a margin of safety. Particulate matter concentration deviation can be defined as the actual particulate matter concentration minus the upper limit target for particulate matter concentration. A positive value indicates that the standard is exceeded, and dust removal needs to be strengthened or airflow barriers need to be improved; a negative value indicates that the standard is not exceeded.

[0052] The following is a specific calculation example. Based on this example, assume that within a certain control period, the stable target parameter set is: differential pressure target 298 Pa, oxygen upper limit 0.904%, and dust upper limit 0.362 mg / m³. 3 The measured parameters for the welding cavity state were: internal pressure 68.40 kPa, external pressure 68.20 kPa, oxygen volume fraction 1.10%, and dust concentration 0.50 mg / m³. 3 The actual pressure difference is 68.40 - 68.20 = 0.20 kPa, or 200 Pa. The pressure difference deviation is 298 - 200 = 98 Pa, indicating that the pressure difference is less than 98 Pa. The oxygen volume fraction deviation is 1.10% - 0.904% = 0.196%, indicating that the oxygen concentration exceeds the standard by 0.196 percentage points. The particulate matter concentration deviation is 0.50 - 0.362 = 0.138 mg / m³. 3 This indicates that the dust concentration exceeds the standard by 0.138 mg / m³. 3 The construction unit arranges these three deviations into a stable deviation vector for the welding cavity in a preset order. Furthermore, the deviations can be normalized to dimensionless quantities during implementation for unified mapping to the control quantity generation stage. For example, the pressure difference deviation can be divided by 500 Pa as the normalization upper limit, the oxygen deviation by 1% as the normalization upper limit, and the dust deviation by 1 mg / m³. 3 As a normalization upper limit, a bias scale that is easy to control for mapping is obtained.

[0053] After obtaining the welding cavity stability deviation vector, the building unit generates welding cavity stability control quantities based on the correspondence between the welding cavity stability deviation vector and the environmental state vector. This "correspondence" must be an implementable mapping. The core idea is that the stability deviation vector reflects "how far the current state is from the target," while the environmental state vector reflects "what type of external disturbance it is, its intensity, and whether it is continuous." Together, they determine "what should be adjusted, how much should be adjusted, and with what priority." The welding cavity stability control quantities include at least the shielding gas supply adjustment range, the welding cavity opening adjustment range, and the welding cavity boundary fit adjustment range. The shielding gas supply adjustment range is used to change the positive pressure inside the cavity and enhance the gas barrier by increasing or decreasing the gas flow rate and pressure. The welding cavity opening adjustment range is used to change the flow field and venting path inside the cavity by adjusting the opening of the inlet / outlet or vent, thereby ensuring gas renewal while suppressing external backflow. The welding cavity boundary fit adjustment range is used to adjust the gap between the flexible or deformable boundary and the workpiece, making the welding cavity more tightly surround the welding area, improving wind resistance and reducing air mixing.

[0054] The following executable mapping method can be adopted. The adjustment range of the protective gas supply can be determined by both the pressure difference deviation and the oxygen deviation, because insufficient pressure difference and excessive oxygen often require increased gas supply; at the same time, when the dust-carrying disturbance is strong, increasing the gas supply can also form an outward airflow barrier to suppress dust intrusion. The adjustment range of the welding chamber opening can be determined by both the pressure difference deviation and the dust-carrying deviation. When the pressure difference is insufficient, the opening should be contracted to reduce venting; when the dust exceeds the standard, the opening can be optimized in a specific direction to form directional dust discharge. The adjustment range of the welding chamber boundary fit depends more on the shear disturbance component, because a closer boundary is needed to improve shear resistance stability during strong wind shearing. Continuing with the above deviation example, assume that the building unit defines the protective gas supply adjustment range as ΔQ = Qmax × (0.5 × normalized differential pressure deviation + 0.3 × normalized oxygen deviation + 0.2 × dust-carrying disturbance component), where Qmax is the maximum allowable flow rate increment; the welding chamber opening adjustment range is defined as ΔA = Amax × (0.6 × normalized differential pressure deviation + 0.4 × normalized dust deviation), where Amax is the maximum allowable opening shrinkage; and the welding chamber boundary bonding adjustment range is defined as ΔG = Gmax × (0.7 × shear disturbance component + 0.3 × normalized differential pressure deviation), where Gmax is the maximum allowable bonding shrinkage. Those skilled in the art can solidify the above mapping relationships into a calculation module in the controller, or achieve the same effect using a lookup table, thereby converting the deviation vector and environmental state vector into executable control quantities.

[0055] Furthermore, the construction unit is specifically used for: determining the length of the stability determination time window and the stability determination threshold group based on the environmental state vector. The stability determination threshold group includes at least the lower limit threshold of the pressure difference inside and outside the welding cavity, the upper limit threshold of the oxygen volume fraction inside the welding cavity, and the upper limit threshold of the suspended particulate matter concentration inside the welding cavity, and outputting the corresponding determination configuration parameter group; driving continuous sampling of the welding cavity state based on the determination configuration parameter group, acquiring at least multiple sets of welding cavity pressure, welding cavity external pressure, welding cavity oxygen volume fraction, and welding cavity suspended particulate matter concentration within the stability determination time window to form a time-seriesd welding cavity state sequence; calculating a stability determination index group based on the welding cavity state sequence. The stability determination index group includes at least the pressure difference satisfaction rate index, the oxygen volume fraction exceedance rate index, and the particulate matter concentration exceedance rate index; generating a stable gas protection determination result based on the stability determination index group and the determination configuration parameter group. When the pressure difference satisfaction rate index is not less than a preset satisfaction rate threshold and the oxygen volume fraction exceedance rate index and the particulate matter concentration exceedance rate index are respectively not greater than preset exceedance rate thresholds, the welding cavity is determined to have reached the stable gas protection condition.

[0056] In this invention, the construction unit receives the environmental state vector output by the parsing unit and determines the stability determination time window length and stability determination threshold group accordingly. Here, the "stability determination time window length" refers to the continuous time span used for stability statistical determination. It should cover at least one typical fluctuation cycle of an external disturbance, enabling the determination to reflect the persistence of the disturbance rather than transient values. This time window length is not a fixed constant but is jointly determined by the disturbance intensity and evolution characteristics represented by the environmental state vector. For example, when the environmental state vector shows high intensity and poor stability of shear disturbances and dust-carrying disturbances, the construction unit can select a longer determination window to avoid short-term "pseudo-stability" caused by sudden strong wind changes; when the environmental disturbance is weak and the stability is good, the construction unit can select a shorter determination window to improve the system response speed. For feasibility, the time window length can be preset into several discrete increments in the system, such as 0.5 seconds, 1 second, 2 seconds, etc. The construction unit selects the corresponding increment based on the disturbance level into which the environmental state vector falls, or converts the disturbance intensity into a window length through a simple mapping.

[0057] The "stability judgment threshold group" includes at least the lower limit threshold for the pressure difference between the inside and outside of the welding cavity, the upper limit threshold for the oxygen volume fraction inside the welding cavity, and the upper limit threshold for the concentration of suspended particulate matter inside the welding cavity. It is necessary to first clarify the physical meaning and measurement object of each threshold. The lower limit threshold for the pressure difference between the inside and outside of the welding cavity refers to the minimum actual pressure difference that must not be lower than the actual pressure difference obtained by subtracting the pressure outside the welding cavity from the pressure inside the welding cavity. The purpose of setting this lower limit is to ensure that the welding cavity is continuously under sufficient positive pressure, making it difficult for outside air and dust to backflow. The upper limit threshold for the oxygen volume fraction inside the welding cavity refers to the maximum allowable oxygen volume fraction in the atmosphere inside the welding cavity. Exceeding this upper limit means that the shielding gas has been mixed with outside air or there is a leak, which will significantly increase the risk of weld oxidation, porosity, etc. The upper limit threshold for the concentration of suspended particulate matter inside the welding cavity refers to the maximum allowable dust particle concentration in the air inside the welding cavity. Exceeding this upper limit means that dust intrusion is significant, which may lead to increased risk of arc instability, molten pool contamination, and inclusion defects. The aforementioned thresholds can be set to basic values ​​and adaptively adjusted based on the environmental state vector. For example, the stronger the shear disturbance, the higher the lower limit threshold for differential pressure; the stronger the diffusion disturbance, the more stringent the upper limit threshold for oxygen volume fraction; and the stronger the dust-carrying disturbance, the more stringent the upper limit threshold for particulate matter concentration. The construction unit combines the selected time window length with the three types of thresholds to form a judgment configuration parameter group and outputs it. This judgment configuration parameter group provides a unified judgment benchmark for subsequent continuous sampling and index calculation.

[0058] After obtaining the set of configuration parameters, the construction unit continuously samples the welding cavity state based on these parameters. Within a stable determination time window, it acquires at least multiple sets of data on the welding cavity pressure, external pressure, oxygen volume fraction, and suspended particulate matter concentration, forming a time-series-based welding cavity state sequence. "Continuous sampling" here does not require physically continuous sensor output, but rather refers to acquiring a series of discrete sampling points at a fixed sampling period within the stable determination time window, thus forming a statistically significant time series. The sampling period can be uniformly set by the system, such as 50 milliseconds or 100 milliseconds. The construction unit collects a sufficient number of sample points within this sampling period within the window length; the number of sample points must be at least multiple to ensure that the percentage-based indicators are statistically significant. Each sampling point contains four quantities at the same moment: internal pressure, external pressure, oxygen volume fraction, and dust concentration. These quantities are time-aligned, thus forming the welding cavity state sequence. The purpose of alignment is to avoid erroneous judgments caused by inconsistent sampling times of different sensors. For example, if the oxygen concentration reading lags when the pressure difference fluctuates, it may lead to a misjudgment of the leakage state.

[0059] After obtaining the welding cavity state sequence, the construction unit calculates a stability judgment index group based on this state sequence. The stability judgment index group includes at least the differential pressure satisfaction rate index, the oxygen volume fraction exceedance rate index, and the particulate matter concentration exceedance rate index. Here, each index is first strictly defined. The differential pressure satisfaction rate index refers to the percentage of sampling points where the actual differential pressure is not lower than the lower differential pressure threshold within the stability judgment time window. The actual differential pressure is obtained by subtracting the external pressure from the internal pressure at each sampling point. If the difference is greater than or equal to the lower differential pressure threshold, the sampling point is counted as a "satisfied point"; otherwise, it is counted as a "non-satisfied point." The differential pressure satisfaction rate index equals the number of satisfied points divided by the total number of sampling points within the window, and its value ranges from 0 to 1. The oxygen volume fraction exceedance rate index refers to the percentage of sampling points where the oxygen volume fraction exceeds the upper oxygen volume fraction threshold within the stability judgment time window. Sampling points exceeding the threshold are recorded as "exceedance points," and the exceedance rate equals the number of exceedance points divided by the total number of sampling points. Similarly, the particulate matter concentration exceedance rate index refers to the percentage of sampling points where the dust concentration exceeds the upper limit threshold for particulate matter concentration within the stability judgment time window. Using the percentage of "satisfaction rate / exceedance rate" instead of a single instantaneous value or a single average value is to accurately reflect the continuity of the protection status under conditions of strong wind pulsations and dust agglomeration intrusion; for example, a short-term dust peak should not immediately negate the overall stable state, but frequently occurring peaks should be judged as unstable.

[0060] The following is a specific example of index calculation. Assume the building unit selects a stability determination time window of 1 second based on the environmental state vector, with a sampling period of 100 milliseconds, resulting in 10 sampling points within the window. Assume the thresholds given by the determination configuration parameter group are: lower limit of differential pressure 250 Pa, upper limit of oxygen volume fraction 0.90%, and upper limit of particulate matter concentration 0.40 mg / m³. 3 The actual pressure differences at the 10 sampling points collected within the 1-second window were calculated as follows: 260, 240, 255, 270, 265, 230, 260, 258, 252, and 248 Pa. The pressure difference satisfaction points are those with an actual pressure difference of not less than 250 Pa, specifically the 1st, 3rd, 4th, 5th, 7th, 8th, and 9th sampling points, resulting in a pressure difference satisfaction rate of 7 / 10 = 0.70. The oxygen volume fraction at the 10 sampling points within the same window were: 0.85%, 0.92%, 0.88%, 0.86%, 0.91%, 0.89%, 0.87%, 0.95%, 0.84%, and 0.86%. The exceedance points exceeding 0.90% were the 2nd, 5th, and 8th sampling points, resulting in an oxygen volume fraction exceedance rate of 3 / 10 = 0.30. The dust concentrations within the same window were: 0.35, 0.38, 0.42, 0.37, 0.39, 0.41, 0.36, 0.45, 0.34, and 0.38 mg / m³. 3 Exceeding 0.40 mg / m 3 The exceedance points were the 3rd, 6th, and 8th sampling points, with a particulate matter concentration exceedance rate of 3 / 10 = 0.30. The construction unit combines these three indicators into a stability determination index group and outputs it.

[0061] After obtaining the stability assessment index set, the construction unit generates a stable gas protection assessment result based on the stability assessment index set and the assessment configuration parameter set. The construction unit presets a satisfaction rate threshold and an exceedance rate threshold to convert statistical indicators into a "stable / unstable" assessment. The satisfaction rate threshold is the minimum requirement for the differential pressure satisfaction rate index, for example, it can be set to 0.90 or 0.95, indicating that the differential pressure must meet the lower limit requirement for the vast majority of the time within the window; the exceedance rate threshold is the maximum allowable value for the oxygen and dust exceedance rates, for example, it can be set to 0.05 or 0.10, indicating that oxygen and dust can only exceed the limit a very small number of times within the window, and the exceedance must be a short-term phenomenon. Taking the above example again, if the satisfaction rate threshold is set to 0.90 and the exceedance rate threshold is set to 0.10, then the differential pressure satisfaction rate 0.70 is less than 0.90, and the oxygen exceedance rate 0.30 is greater than 0.10, and the dust exceedance rate 0.30 is also greater than 0.10. Therefore, the construction unit determines that the welding cavity has not met the stable gas protection conditions. If the calculation results in another window are a differential pressure satisfaction rate of 0.95, an oxygen exceedance rate of 0.00, and a dust exceedance rate of 0.05, then the differential pressure satisfaction rate meets the condition of not less than 0.90, and the oxygen and dust exceedance rates are not greater than 0.10 respectively. The building unit can then determine that the welding cavity has reached the stable gas protection condition. When the building unit determines that stability has been achieved, it can output a stability completion flag, which serves as the trigger condition for the subsequent generation unit to generate welding process correction instructions. When stability has not been achieved, the building unit continues to update the welding cavity stability control quantity based on the environmental state vector and the welding cavity state, and continues to perform the determination in the next window until the stability condition is met.

[0062] The generation unit 103 is used to generate welding process correction instructions based on the coupling relationship between the welding cavity stability control quantity and the environmental state vector after the construction unit completes the stable construction of the welding cavity; wherein, the welding process correction instructions include at least welding energy distribution instructions, arc space control instructions and welding material delivery control instructions.

[0063] The generation unit 103 is located after and signal-connected to the construction unit 102. Its operation presupposes that the construction unit 102 has completed the stable construction of the welding cavity and output stable control quantities for the welding cavity, ensuring that the welding operation point is within a repeatable and controllable gas shielding boundary. Based on this, the generation unit 103 no longer uses the "original external environmental parameters" as the direct basis for parameter adjustment. Instead, it uses the environmental state vector output by the analysis unit 101 and the stable control quantities for the welding cavity output by the construction unit 102 as joint inputs. Through the coupling relationship between these two, it generates welding process correction instructions and outputs them to the execution unit 104, which completes the welding operation under the stabilized welding cavity conditions. The "welding process correction instructions" referred to here are a set of executable correction quantities or corrected target settings relative to the baseline welding process settings, including at least welding energy distribution instructions, arc space control instructions, and welding material delivery control instructions.

[0064] The generation unit 103 internally includes at least a reference process library, a coupling parsing module, and an instruction forming module. The reference process library stores a set of reference welding process settings that match the current welding task. This set of settings can be determined during startup configuration, task issuance, or process invocation, and its source can be process evaluation results, standard process cards, or stable parameters obtained from on-site trial welding. For example, for common gas-shielded welding, the set of reference welding process settings can include reference welding current, reference welding voltage, reference welding speed, reference wire feed speed, reference arc length settings, reference oscillation amplitude, and reference oscillation frequency. Here, "reference" does not mean that no changes are needed in high-altitude environments, but rather refers to reference settings that can achieve the target weld formation under ideal or standard conditions. The generation unit 103 generates correction instructions based on this, ensuring that the final executed settings can adapt to high-altitude, low-pressure, strong wind, and dust coupling conditions.

[0065] The coupling analysis module is used to establish the joint influence of the environmental state vector and the welding cavity stability control quantity on the welding process, and to convert this joint influence into calculable correction requirements. The term "coupling relationship" in this invention has a clear, operational meaning: the environmental state vector represents the intensity and type of external disturbance, while the welding cavity stability control quantity represents the adjustment range taken to counteract this disturbance to the welding cavity structure and gas flow field. Together, they determine the effective gas shielding intensity, heat dissipation conditions, and arc morphology stability near the welding point. For example, under conditions of strong wind disturbance, the building unit 102 typically increases the shielding gas supply and changes the opening and fit of the welding cavity, thereby altering the velocity distribution of the flow field inside the welding cavity. This change may enhance convective heat transfer, leading to faster cooling of the molten pool, or it may alter the gas density distribution around the arc, causing a shift in arc stiffness and arc pressure characteristics. For example, under high-altitude and low-pressure conditions, even if the welding cavity is stably constructed, the absolute gas pressure and gas density inside the welding cavity are still different from those in the plain environment. The arc combustion voltage window, the stable range of droplet transfer, and the response of the welding wire melting rate to the current will all undergo systematic shifts.

[0066] The generation unit 103 can employ a calibration table-driven coupling rule. A "calibration table" refers to the collection of welding quality indicators under different combinations of environmental state vector intervals and welding cavity stability control intervals during equipment delivery or field deployment, achieved through trial welding. The correction parameters that meet the target weld formation are then fixed in a table or multi-dimensional lookup table format. Welding quality indicators can be selected from those directly measurable by those skilled in the art and highly correlated with weld formation stability, such as weld reinforcement height, penetration depth, undercut tendency, spatter rate, porosity trend, or arc voltage fluctuation amplitude. The input dimension of the calibration table must at least include the intervals of each component of the environmental state vector and the key component intervals of the welding cavity stability control quantity, while the output dimension must at least include the correction values ​​for welding energy distribution commands, arc space control commands, and welding material delivery control commands. Thus, those skilled in the art can implement the coupling analysis module through table lookup and interpolation.

[0067] The instruction forming module combines the correction requirements output by the coupling analysis module with the set of reference welding process settings to form welding process correction instructions that can be directly issued to the execution unit 104, ensuring the consistency of the instructions in terms of timing and parameters. "Timing consistency" means that the welding energy distribution instructions, arc space control instructions, and welding material delivery control instructions must belong to the same control cycle, the same welding position, or the same welding state segment, avoiding instability caused by increased energy but asynchronous wire feeding, or arc length contraction but asynchronous voltage. "Parameter consistency" means that the settings of the same type of physical object must follow the inherent constraints of the welding process, such as the matching relationship between wire feed speed and welding current, the correspondence between welding voltage and arc length settings, and the correspondence between oscillation frequency and welding speed for weld bead coverage. When outputting instructions, the instruction forming module should simultaneously check and correct combinations that violate constraints to ensure stable execution by the execution unit 104.

[0068] The welding energy distribution command is used to determine the effective energy input required per unit weld length or per unit weld volume under the current coupling environment conditions, and its distribution over time. Specifically, it can modify one or more of the following: target welding current, target welding voltage, pulse duty cycle, peak current to base current ratio, and target welding speed, and provide the modified target setting or the modification amount relative to the reference value. The generation unit 103 can employ a strategy of maintaining equivalent line energy or equivalent melting rate as one of the constraints. That is, when the stable control of the welding cavity leads to enhanced convection and increased heat loss, sufficient heat in the molten pool is maintained by increasing the welding current or decreasing the welding speed; when the arc voltage window changes due to high altitude and low pressure, the arc combustion is maintained within a stable range by simultaneously adjusting the voltage target and the arc length setting. Arc space control commands are used to control the geometric relationship and stable state of the arc in space. These commands can include at least the arc length setting, the attitude parameters of the welding torch to the workpiece, the oscillation amplitude and frequency, and the spatial transition strategy for arc initiation and termination. This ensures that the arc remains aligned with the weld bevel or weld center even under strong winds and density variations, reducing the risk of undercut and incomplete fusion caused by arc deviation and drift. Conduit delivery control commands are used to control the feeding rhythm of the welding wire melting and droplet transfer. These commands can include at least the target wire feed speed, wire feed acceleration limit, short-term retraction amount, burn-off time, or anti-sticking strategies. This ensures that the wire feed matches the energy input, preventing droplet transfer instability, increased spatter, or abnormal backburning of the welding wire tip under low pressure or flow field disturbances.

[0069] To illustrate the calculation process of the above instructions, a directly implementable example can be used. Assume the baseline welding process settings for a certain welding task are: baseline welding current 220 A, baseline welding voltage 24 V, baseline welding speed 5 mm / s, baseline wire feed speed 6.5 m / min, baseline arc length setting 3.0 mm, baseline oscillation amplitude 2.0 mm, and baseline oscillation frequency 2.5 Hz. The environmental state vector output by the analytical unit 101 in a certain control cycle represents strong wind disturbance, significant air pressure deviation, and moderate dust interference. The welding cavity stability control quantity output by the construction unit 102 represents a significant increase in shielding gas flow, narrowing of the welding cavity opening, and enhanced boundary contact. This means that although the welding cavity has reached stable gas protection conditions, the convection and airflow velocity distribution within the cavity are stronger than in the baseline environment, heat dissipation from the molten pool is enhanced, and the gas density distribution around the arc changes more significantly. The coupling analysis module retrieves the entry in the calibration table that is closest to the environmental state vector range and the welding cavity stability control range, and performs interpolation to obtain the correction requirements, such as increasing the welding current by 10% to 15%, decreasing the welding speed by 5%, shortening the arc length setting by 0.2 mm to 0.5 mm, reducing the oscillation amplitude by 0.3 mm to reduce the amplified offset of the oscillation endpoint by the lateral wind, and increasing the wire feed speed in proportion to the increase in current. The instruction forming module outputs welding process correction instructions accordingly. For example, the welding energy distribution instruction corrects the target value of the welding current to 242 A, the target value of the welding speed to 4.75 mm / s, and maintains or fine-tunes the target value of the welding voltage to 24.5 V to match the stable combustion zone after the arc length is shortened. The arc space control instruction corrects the arc length setting to 2.6 mm, the oscillation amplitude to 1.7 mm, and maintains the oscillation frequency at 2.5 Hz to maintain consistent weld coverage. The welding material delivery control instruction corrects the target value of the wire feed speed to 7.2 m / min and sets an upper limit for the wire feed acceleration to avoid spatter caused by a sudden increase in wire feed when the arc fluctuates due to transient disturbances in the wind field. After receiving the welding process correction instructions, the execution unit 104 performs welding under the stabilized welding cavity conditions, thereby matching the molten pool heat, arc length stability, and droplet transfer rhythm with the current environmental conditions.

[0070] The generation unit 103 can also be configured with an instruction update and freeze mechanism, enabling it to initiate instruction generation after the welding cavity has been stably constructed, but avoiding frequent and significant jumps when the welding cavity's stable state fluctuates in a short period. Specifically, when the stability completion flag output by the construction unit 102 remains valid, the generation unit 103 updates the welding process correction instructions according to a preset cycle; when the stability completion flag fails or the welding cavity status acquisition index exceeds the limit, the generation unit 103 freezes the welding process correction instructions to the most recent valid value or switches to a conservative value set, and waits for the welding cavity to stabilize before continuing to update. This ensures fine-grained correction under stable welding cavity conditions while preventing further amplification of risks from erroneous corrections when external disturbances cause short-term instability in the welding cavity.

[0071] In this embodiment, several key concepts are first clarified. The stability completion flag is a logical quantity output by the building unit based on the stability determination mechanism, used to indicate whether the welding cavity has reached stable gas protection conditions. Specifically, it can be a Boolean flag or a status word with a timestamp, as long as it can be reliably read and its validity determined by the generation unit. The welding cavity stability permission signal is an internal permission signal generated by the generation unit after detecting the validity of the stability completion flag. Its function is to transform the fact that "the welding cavity is stable" into a prerequisite trigger condition for "allowing the generation of process correction instructions." This signal can be understood as an enable gating signal within the generation unit. The so-called process constraint input set is a set of constraint parameters jointly constructed by the generation unit based on the welding cavity stability control quantity and the environmental state vector. It is used to limit the range of allowable changes in welding process parameters under the current stable cavity conditions, to prevent excessive changes in process parameters from causing abrupt changes in the internal flow field, heat source distribution, or arc column morphology of the welding cavity, thereby destroying the gas protection boundary. The restricted process generation parameter set is a parameter set formed on the basis of the process constraint input set, which can be directly used to generate three types of instructions. It includes the allowable change range of each type of instruction and coupling restriction parameters related to synchronization consistency constraints.

[0072] In practical implementation, the generation unit first receives the stability completion flag output by the construction unit and determines whether the stability completion flag is valid. Here, "valid state" is not an abstract term, but rather a judgment condition that can be implemented in engineering. For example, the stability completion flag must be true and its timestamp must fall within the current control cycle, or the stability completion flag must be true and remain true for at least several sampling cycles to avoid triggering process generation due to a single misjudgment. After confirming the stability completion flag is valid, the generation unit generates a welding cavity stability permission signal, enabling the generation unit to enter a working state that allows the generation of process correction instructions. If the stability completion flag is invalid, the welding cavity stability permission signal remains invalid, and the generation unit does not generate new welding process correction instructions or output a process generation suppression signal, ensuring that process adjustment does not occur when the welding cavity is unstable.

[0073] Provided the welding cavity stability permit signal is valid, the generation unit constructs a set of process constraint inputs based on the welding cavity stability control variables and the environmental state vector, and outputs a set of restricted process generation parameters. To ensure feasibility, it is necessary to clarify how the allowable variation range is jointly determined by the stability control variables and the environmental state vector. The welding cavity stability control variables include at least the shielding gas supply adjustment range, the welding cavity opening adjustment range, and the welding cavity boundary contact adjustment range. These adjustment ranges reflect the "control tension" of the welding cavity in order to maintain stability. When the shielding gas supply adjustment range, the welding cavity opening adjustment range, or the welding cavity boundary contact adjustment range are large, it indicates that the current environmental disturbance is strong or the welding cavity boundary stability margin is small. In this case, the allowable variation range of the process parameters should be tightened to avoid the process disturbance being superimposed on the environmental disturbance. Conversely, when the stability control variables are small and the environmental state vector shows weak disturbance, the allowable variation range can be appropriately widened to improve welding efficiency and adaptive response capability. The environmental state vector is used to provide information on the type and intensity of disturbances. For example, when shear disturbances are strong, the arc space offset is more sensitive to the damage to the protective boundary, and the arc space offset range should be further tightened. When diffusion disturbances are strong, the thermal plume and convection enhancement caused by changes in energy input may lead to the dilution of the protective gas, and the energy change range should be tightened. When dust-carrying disturbances are strong, the suction effect caused by changes in welding material delivery and arc morphology may increase the risk of dust intrusion, and the welding material delivery change range should be tightened.

[0074] One directly implementable approach is for the generation unit to first obtain the set of reference parameters for the current process, such as the reference welding current I0, reference arc length L0, or reference welding torch-workpiece distance and reference wire feed speed F0. Then, the generation unit calculates the "stability margin coefficient" based on the welding cavity stability control quantity, and further calculates the "disturbance sensitivity coefficient" in conjunction with the environmental state vector, ultimately obtaining the allowable variation range for each type of instruction. For example, assuming that at a certain moment the ratio of the shielding gas supply adjustment amplitude to the maximum allowable adjustment amplitude corresponding to the stability control quantity is 0.6, the welding cavity opening adjustment amplitude ratio is 0.4, and the welding cavity boundary contact adjustment amplitude ratio is 0.5, then the generation unit can define the stability margin coefficient as 1 minus the weighted sum of the above ratios. For example, stability margin coefficient = 1 - (0.4 × 0.6 + 0.3 × 0.4 + 0.3 × 0.5) = 1 - (0.24 + 0.12 + 0.15) = 0.49. The smaller this coefficient, the more "stressful" the situation, and the smaller the allowable variation range. Assuming the environmental state vector represents a shear disturbance component of 0.58, a diffusion disturbance component of 0.32, and a dust-carrying disturbance component of 0.69, the generation unit can obtain sensitivity coefficients corresponding to the three types of process control. For example, the energy sensitivity coefficient = 1 - diffusion disturbance component = 0.68, the arc offset sensitivity coefficient = 1 - shear disturbance component = 0.42, and the wire feeding sensitivity coefficient = 1 - dust-carrying disturbance component = 0.31. The generation unit then multiplies the preset maximum allowable variation range by a stability margin coefficient and the corresponding sensitivity coefficient to obtain the half-width of the allowable variation range. For example, based on the maximum allowable variation range of welding current being ±30 A, the allowable energy variation range can be mapped to the current variation range, with a half-width of 30 × 0.49 × 0.68 ≈ 10 A, meaning the allowable current variation is within I0 ± 10 A. If the maximum allowable variation range of arc length is ±2 mm, then the half-width of the allowable arc space offset range is 2 × 0.49 × 0.42 ≈ 0.41 mm. If the maximum allowable variation range of wire feed speed is ±1.0 m / min, then the half-width of the allowable welding material delivery variation range is 1.0 × 0.49 × 0.31 ≈ 0.15 m / min. The generation unit combines the above allowable variation ranges with the baseline process parameters to form a constrained process generation parameter set, which serves as the input for generating the three types of instructions in the next step.

[0075] After obtaining the constrained process generation parameter set, the generation unit generates welding energy distribution commands, arc space control commands, and welding material delivery control commands within the allowable variation range, ensuring that the three types of commands meet the preset synchronous consistency constraints. These "synchronous consistency constraints" must have a clear meaning and be implementable in engineering. Their core purpose is to avoid transient coupling impacts caused by independent changes in the three types of commands. For example, an increase in current without a synchronous increase in wire feed can lead to abnormal droplet transition and increased spatter; spatter and thermal convection disturbances may damage the welding cavity boundary. An increase in wire feed without a synchronous increase in current can lead to abnormal short-circuit frequency at the wire end, decreased arc stability, and pulsations that easily draw in outside air. Excessive arc space offset can alter the mainstream shielding gas flow, making it difficult for boundary fit adjustment to keep up in time. Therefore, synchronous consistency constraints can be implemented by binding the change rate and timing of the three types of commands, ensuring that they take effect with a consistent timestamp within the same control cycle, and limiting the proportional relationship between their change rates. For example, the rate of change of welding energy distribution command and the rate of change of welding material delivery control command can be required to meet a preset ratio range, and the rate of change of arc space control command must not exceed the maximum following rate of change corresponding to the boundary fit adjustment capability. The generation unit can use a "common timestamp + unified ramp" method to achieve synchronization, that is, first generate the target values ​​of the three types of commands, and then configure the same ramp time or the same number of step times for the three types of commands, so that they reach the target values ​​synchronously within a few control cycles, thereby avoiding transient impacts.

[0076] For example, assuming the reference welding current I0 is 180 A, the reference arc length L0 is 3.0 mm, and the reference wire feed speed F0 is 6.0 m / min, the previous state evolution window detected a relatively cold molten pool requiring increased energy input. However, due to the high dust-carrying disturbance component, the allowable variation range is small. The generation unit determines the allowable current range as 170 A to 190 A, the allowable arc length range as 2.6 mm to 3.4 mm, and the allowable wire feed speed range as 5.85 m / min to 6.15 m / min based on the constrained process generation parameter set. The generation unit decides to set the target current value to 188 A (not exceeding the upper limit). Simultaneously, to meet the constraints of energy and wire feed synchronization, the wire feed speed is required to be slightly increased in the same direction, for example, set to 6.10 m / min, and the target arc length is set to justify 3.1 mm to maintain arc column stability and concentrated heat input. The generation unit then sets the same ramp time (e.g., 200 ms) for all three types of commands. During this period, the current is linearly increased from 180 A to 188 A, the wire feed speed is increased from 6.0 to 6.10, and the arc length is adjusted from 3.0 to 3.1, ensuring that the three commands take effect synchronously and their rate of change is controlled. The welding energy distribution command output by the generation unit can be "set the current to 188 A and ramp up at 200 ms", the arc space control command can be "set the arc length to 3.1 mm and ramp up at 200 ms", and the welding material delivery control command can be "set the wire feed speed to 6.10 m / min and ramp up at 200 ms". This example shows that the generation of the three types of commands is not independent, but is constrained by the same set of limited parameters and satisfies synchronous consistency constraints, thus ensuring that, given a stable welding cavity, process changes will not adversely disrupt the gas shielding boundary.

[0077] After generating welding process correction instructions, the generation unit continuously monitors the status of the stable completion flag. Upon detecting a failure of the stable completion flag, it immediately freezes or rolls back the current welding process correction instruction and outputs a process generation suppression signal. Here, "failure" refers to the generation unit determining that the welding cavity no longer meets the stable gas protection conditions, such as a decrease in differential pressure satisfaction rate or an increase in oxygen or dust exceedance rates, causing the stable completion flag to change from valid to invalid. The generation unit's response to failure must be rapid and implementable. "Freezing" means preventing the final output value of the current process correction instruction from continuing to change towards the new target value, avoiding further process disturbance when the welding cavity is unstable. "Rollback" means restoring the process parameters to a preset safety benchmark or the parameter set of the previous stable state, such as rolling back the current to I0, the wire feed speed to F0, the arc length to L0, or rolling back according to a preset ramp to prevent transient impacts. The process generation suppression signal is used to prevent the generation unit from generating new welding process correction instructions during the period when the stable completion flag fails, until the stable completion flag becomes valid again. This suppression signal can be used as a gating signal by the execution unit or the upper-level control logic to ensure that the system prioritizes the construction and stabilization control of the welding cavity before the welding cavity stability is restored, rather than continuing to adjust the welding process.

[0078] The execution unit 104 is used to receive and execute welding process modification instructions to complete the welding operation under the conditions of a stabilized welding cavity.

[0079] The execution unit 104 is configured as the end-stage execution link in this system that directly completes the welding operation. It is signal-connected to the generation unit 103 and is used to receive the welding process correction command output by the generation unit 103. It then converts the welding process correction command into actual control actions for the welding process, thereby completing the welding operation under the stable welding cavity conditions formed and maintained by the construction unit 102. The "completion of welding operation" mentioned here does not simply mean the ignition of the electric arc or the melting of the welding wire. Rather, it means that throughout the entire welding operation, the welding energy input, the arc spatial shape, and the welding material delivery rhythm are consistent with the correction command, and a continuous, stable, and consistent weld formation is achieved within the stable boundary of the gas protection in the welding cavity.

[0080] The execution unit 104 includes at least a welding power supply control module, an arc space execution module, a welding material delivery execution module, and a welding motion execution module, and may further include an execution status monitoring module and a safety interlock module. The welding power supply control module is used to perform closed-loop regulation of the welding power supply output according to the welding energy distribution command. It can be connected to an inverter welding power supply or a digital welding power supply, and can set target current, target voltage, pulse parameters, or other equivalent energy control parameters within the control cycle. It obtains the actual output value through a current sensor and a voltage sampling module, forming a closed-loop control at the power supply level. Here, the "welding energy distribution command" must be interpreted by the execution unit 104 as a directly implementable setpoint or incremental setpoint, such as target welding current, target welding voltage, pulse peak current, pulse base current, pulse frequency, duty cycle, or linkage correction amount for welding speed. The execution unit 104 should convert these setpoints into control parameters for the welding power supply and ensure stable output, preventing uncontrollable deviations due to external power grid fluctuations or load changes.

[0081] The arc space execution module controls the spatial geometry of the arc and the welding torch posture according to arc space control commands, ensuring that the arc maintains a suitable arc length, direction, and coverage area during welding. The "arc space control commands" mentioned here include at least an arc length setpoint, and may also include parameters such as the height control target of the welding torch tip relative to the workpiece surface, the welding torch angle control target, the oscillation amplitude, and the oscillation frequency. In practice, the arc length setpoint is typically achieved indirectly through the actual distance from the welding torch tip to the workpiece surface, as the arc length is related to the welding torch height, welding voltage, and welding method. To ensure feasibility, the execution unit 104 can employ arc voltage-height linkage control or distance sensor-height closed-loop control to achieve arc space control. Arc voltage-height linkage control refers to maintaining the voltage control mode or hybrid control mode of the welding power supply, and driving the welding torch to finely adjust its height along the normal direction by real-time detection of the deviation between the actual voltage and the target voltage, so that the actual voltage returns to the target voltage window, thereby stabilizing the arc length. Distance sensor-height closed-loop control refers to using a laser displacement sensor, capacitive distance sensor, or structured light ranging module to measure the distance between the welding torch tip and the workpiece surface, and comparing it with the target distance to drive the Z-axis servo actuator to adjust the height, thereby directly realizing the spatial distance corresponding to the arc length set value. For oscillation control, the execution unit 104 can achieve it through a welding torch oscillation mechanism or robot trajectory superposition, that is, superimposing a lateral oscillation displacement on the main welding trajectory, so that the welding torch tip reciprocates on both sides of the weld centerline at a preset amplitude and frequency, and coordinates with the welding speed to ensure uniform weld coverage. Here, "amplitude" refers to half of the peak-to-peak range of the swing displacement or the maximum offset. For example, with the weld centerline as the zero point, the maximum distance offset to the left and right is the swing amplitude. "Frequency" refers to the number of reciprocations completed per unit time. Based on this, those skilled in the art can set the corresponding sine, triangular, or trapezoidal swing curve parameters in the controller.

[0082] The welding material feeding execution module controls the wire feeding mechanism according to the welding material feeding control command, ensuring that the wire melting rate matches the welding energy input and maintaining stable droplet transfer and deposition. The "welding material feeding control command" mentioned here includes at least a target wire feeding speed value, and may also include auxiliary parameters such as the upper limit of wire feeding acceleration, short-time retraction amount, anti-sticking and burn-out time, or wire feeding waveform. The execution unit 104 can use a wire feeding motor driver with encoder feedback to achieve closed-loop control. It calculates the actual wire feeding speed by reading encoder pulses and adjusts it by comparing it with the target wire feeding speed. The wire feeding speed can be defined as the linear velocity of the welding wire fed into the welding torch per unit time, in m / min or mm / s. The conversion method for encoder feedback can be clearly defined as: the linear velocity is obtained by multiplying the circumference of the wire feeding wheel per revolution by the rotational speed. If the encoder outputs N pulses per revolution, and the count per unit time is C, then the rotational speed is C / N, and the linear velocity is (C / N) × circumference. For example, if the diameter of the wire feed roller is 30 mm, then the circumference is approximately 94.2 mm; if the encoder pulses 1024 times per revolution, and the measured rotational speed within a certain control cycle is 60 revolutions per minute, then the linear velocity is approximately 60 × 94.2 = 5652 mm / min, or approximately 5.65 m / min. The execution unit 104 can then convert the target wire feed speed into the motor control target based on this and maintain stability through closed-loop regulation.

[0083] The welding motion execution module drives the welding robot or welding actuator to move along the weld path, enabling the welding torch to complete the welding according to a predetermined welding speed, posture, and path. The welding speed can be defined as the linear velocity of the welding torch tip along the weld centerline, and its unit can be mm / s. The execution unit 104 can convert the welding speed correction amount in the welding energy distribution command of the generation unit 103 into the speed setting of the robot controller, and superimpose it with the swing trajectory to maintain synchronization, thereby avoiding deviation of the energy input per unit length due to speed changes, which would affect the forming.

[0084] The execution unit 104 preferably also includes an execution status monitoring module and a safety interlock module. The execution status monitoring module monitors status information such as whether the power output is stable, whether the arc is maintained normally, whether the wire feeding is continuous, and whether the welding torch height exceeds limits, and feeds the monitoring results back to the system controller for recording or triggering protection strategies. The safety interlock module restricts or suspends welding operations when the welding cavity stability state of the building unit 102 fails. Specifically, when the stable completion flag output by the building unit 102 is invalid or the welding cavity status index exceeds the limit, the execution unit 104 reduces the welding power supply to a safe current or cuts off the output, simultaneously stops wire feeding, and maintains the welding torch raised to a safe height. After the stable completion flag is restored, the arc is restarted according to the preset restart procedure, and welding continues. This type of interlock enables the system to avoid continuing welding under conditions of gas shield failure during sudden changes in strong winds or dust at high altitudes, thereby further ensuring weld quality and equipment safety.

[0085] In terms of specific execution procedures, the execution unit 104 should follow a timing sequence consistent with the physical constraints of the welding process when executing welding process modification commands to avoid transient instability caused by command mismatch. One feasible approach is that, within each control cycle, the execution unit 104 first updates the target output of the welding power supply control module to ensure a stable energy input, then updates the target wire feed speed of the welding material delivery execution module to match the melting material supply with the energy input, subsequently updates the height and attitude control targets of the arc space execution module to ensure the arc length is consistent with the voltage and current control strategy, and finally updates the speed setting and oscillation superposition parameters of the welding motion execution module to ensure the weld bead formation coverage meets the target. If the controller uses a higher frequency inner loop control, such as a shorter cycle for the power supply inner loop and wire feed inner loop, the execution unit 104 should hold or interpolate the external cycle commands to ensure continuous inner loop control.

[0086] The following is an example of its execution. Assume that the welding process correction command received by the execution unit 104 is as follows: target welding current 242 A, target welding voltage 24.5 V, target welding speed 4.75 mm / s, target wire feed speed 7.2 m / min, arc length setting 2.6 mm, oscillation amplitude 1.7 mm, and oscillation frequency 2.5 Hz. The execution unit 104 first sends 242A and 24.5V to the welding power control module. The power control module confirms that the output is stable within the allowable error range by sampling the current and voltage, for example, the current error does not exceed ±3A and the voltage error does not exceed ±0.3V. Then, it sends 7.2 m / min to the wire feeding execution module. The wire feeding execution module adjusts the motor PWM according to the encoder feedback closed loop to stabilize the actual wire feeding speed within the range of 7.2 m / min ± 0.1 m / min. At the same time, the arc space execution module converts 2.6 mm into the target value of welding torch height or voltage deviation and drives the Z-axis servo to make fine adjustments in the initial section of the weld to reduce arc voltage fluctuations. Finally, the welding motion execution module sets the welding speed to 4.75 mm / s and superimposes an oscillation trajectory with an amplitude of 1.7 mm and a frequency of 2.5 Hz to ensure that the welding torch stably covers both sides of the weld centerline. Throughout the process, if the welding cavity stability output by the construction unit 102 remains effective, the execution unit 104 will continue to execute the above-mentioned correction instructions and advance along the weld. If the stability suddenly fails, the safety interlock module will trigger actions such as reducing current, stopping wire feeding, and lifting the torch. Welding will resume according to the settings after the stability is restored, ensuring that welding always occurs within the stable gas protection boundary.

[0087] Furthermore, in this invention, the execution unit communicates at least with the welding power supply control interface, the welding torch posture control interface, and the wire feeding mechanism control interface, and receives welding process correction instructions and welding cavity stability permission signals from the generation unit, while continuously receiving stability completion flags from the construction unit. Several concepts that first appear or are easily ambiguous during the execution phase need clarification. The welding cavity stability permission signal is an enable signal generated by the generation unit based on the stability completion flag, used to indicate the state gating condition of "allowing entry into the process execution phase." The execution enable flag is an execution permission flag internally generated by the execution unit after receiving a valid welding cavity stability permission signal; it can be understood as an execution gating bit within the execution unit. Only when the execution enable flag is valid can the execution unit allow the welding process correction instructions to be converted into actual driving quantities and sent to each execution interface. The emergency interlock signal is a hard interlock signal generated by the execution unit when it detects the failure of the stability completion flag. This signal is not a simple alarm, but is used to directly trigger a forced action sequence of welding power supply de-energization, wire feeding stoppage, and welding torch retraction. The preset energy reduction mode, preset stop mode, and preset evacuation trajectory correspond to the safety handling strategies for the welding power source, wire feeding mechanism, and welding torch position, respectively. Their specific contents are fixed during system factory calibration or on-site process settings and can be directly called by the execution unit in the form of defined parameters.

[0088] The execution unit first receives welding process correction instructions and a welding cavity stability permission signal output by the generation unit. The welding process correction instructions include at least welding energy distribution instructions, arc space control instructions, and welding material delivery control instructions, corresponding to energy, space, and material control objects, respectively. The welding cavity stability permission signal has a clear logical meaning: when valid, it indicates that the welding cavity has reached stable gas protection conditions and the process can begin or continue; when invalid, it indicates that the welding cavity is unstable or its stability has been lost, and the execution unit must not enter the execution flow. The execution unit generates an execution enable flag when it detects that the welding cavity stability permission signal is valid. To avoid frequent start-stop cycles caused by edge jitter, the execution unit can define "valid" as the permission signal remaining valid for several consecutive control cycles, for example, setting the execution enable flag only after three consecutive valid cycles; similarly, when the permission signal is invalid, the execution enable flag can be immediately revoked to ensure safety priority.

[0089] When the execution enable flag is valid, the execution unit generates welding energy execution quantities, arc space execution quantities, and welding material delivery execution quantities based on the welding process correction instructions, and outputs these execution quantities to the corresponding interfaces to drive the welding operation. Here, "execution quantity" refers to the target value or control quantity that the execution unit can directly issue to the hardware interface and be executed by the hardware. The welding energy execution quantity can be one or more of the following: target current, target voltage, pulse duty cycle, pulse frequency, or equivalent heat input setting value of the welding power source, depending on the type of welding power source used. To ensure feasibility, the execution unit must at least map the welding energy distribution instructions to a set of parameters supported by the welding power source control interface. For example, for a constant current power source, it can be mapped to the target current I_set; for a pulsed power source, it can be mapped to the peak current, base current, and pulse frequency. The arc space execution quantity can be the target distance between the welding torch tip and the workpiece surface, the welding torch posture angle, or the fine-tuning offset on the welding torch trajectory. The execution unit converts the arc space control instructions into target pose or incremental pose commands that the pose control interface can recognize. The welding material feeding execution quantity can be the target speed of the wire feeding motor, the target wire feeding speed, or the wire feeding acceleration set value. The execution unit converts the welding material feeding control command into a speed setting or pulse count setting that can be recognized by the wire feeding mechanism control interface.

[0090] The aforementioned process of "generating execution quantities" can employ deterministic mapping. For example, assuming the welding process correction instruction specifies a welding current target of 188 A, an arc length target of 3.1 mm, and a wire feed speed target of 6.10 m / min, when the execution enable flag is valid, the execution unit writes 188 A as the welding energy execution quantity into the welding power control interface, converts the arc length of 3.1 mm into the target displacement offset of the welding torch tip in the normal direction and writes it into the welding torch posture control interface, and converts 6.10 m / min into the wire feed motor speed setting value and writes it into the wire feed mechanism control interface. If the interface uses ramp control, the execution unit simultaneously issues a ramp time parameter, such as 200 ms, to ensure a smooth transition between execution quantities and avoid transient impacts. Each item in this example is a register write or bus command issuance action that can be directly implemented in the controller or PLC.

[0091] During the execution of welding process modification instructions, the execution unit continuously receives stable completion flags output by the building unit and performs interlock determination. "Continuous reception" here means that the execution unit reads the current state of the stable completion flag in each control cycle and uses it as a hard interlock condition in the decision-making process. The interlock determination rules must be clearly defined: when the stable completion flag fails, the execution unit must generate an emergency interlock signal and immediately execute a safety procedure sequence. "Failure" means that the building unit determines, based on the stability determination index set, that the welding cavity no longer meets the stable gas protection conditions, such as a decrease in differential pressure satisfaction rate or an oxygen / dust exceedance rate exceeding the threshold, causing the stable completion flag to change from valid to invalid. Once the execution unit detects a stable completion flag failure, it does not need to wait for the building unit to recalculate the process constraints, nor does it rely on manual confirmation; instead, it directly triggers the emergency interlock signal to ensure rapid response at the execution level.

[0092] The actions triggered by an emergency interlock signal include at least three parts: the welding power source enters a preset energy reduction mode, the wire feed mechanism enters a preset stop mode, and the welding torch position enters a preset withdrawal trajectory. To ensure "implementability and clarity," these three preset modes and trajectories need to be defined in an executable manner. The preset energy reduction mode can be defined as linearly or piecewise reducing the welding current from its current value to a safe current value within a preset energy reduction time, or directly switching to a low-energy arc sustaining mode before further extinguishing the arc. The safe current value can be a specific numerical value or a specific proportion, such as reducing it to 20% of the current current, with a minimum requirement not less than a certain sustaining value to prevent wire sticking. Alternatively, the current can be directly reduced to 0 and the power output cut off, depending on the arc extinguishing strategy allowed by the welding process. The preset stop mode can be defined as reducing the wire feed speed to 0 within a preset stop time, or immediately stopping the feed and performing a retraction to prevent wire tip sticking. The retraction distance or retraction time can be preset to a fixed value, such as a retraction of 2 mm or 50 ms. The preset withdrawal trajectory can be defined as the welding torch tip rapidly rising from the current welding position along the workpiece normal to a safe height and offsetting to a safe standby point. The safe height is, for example, rising 10 mm, and the offset distance is, for example, retreating 5 mm in the opposite direction of the weld seam, to avoid the welding torch remaining in the arc zone or high dust concentration zone when the molten pool splashes and strong winds carry dust.

[0093] Assuming welding is currently underway at 188 A and a wire feed rate of 6.10 m / min, the execution unit detects a failure of the stable completion flag at time t0. Within the same control cycle, the execution unit generates an emergency interlock signal and issues a power reduction command to the welding power source: linearly reducing the current from 188 A to 30 A within 100 ms, maintaining 30 A for 50 ms before cutting off the output; simultaneously, it issues a stop command to the wire feed mechanism: reducing the wire feed speed to 0 within 50 ms and retracting 1.5 mm; and simultaneously, it issues a withdrawal command to the welding torch posture control interface: raising the torch 10 mm along the normal direction within 150 ms and retracting 5 mm to a safe standby point using a preset S-shaped speed curve. This avoids the risk of severe weld oxidation or inclusions caused by continuing high-energy welding in situations where the welding cavity is unstable and oxygen and dust may rapidly intrude, while also preventing wire adhesion and spatter risks, and allowing the welding torch to quickly leave the danger zone.

[0094] After outputting the emergency interlock signal, the execution unit generates a stable recovery waiting flag. The purpose of this flag is to switch the execution unit to a "waiting for the welding cavity to stabilize" state. In this state, the execution unit rejects new welding process correction commands from entering the execution flow, even if the generation unit continues to output new commands. This prevents repeated attempts at arcing or continued wire feeding while the welding cavity is still unstable. The execution unit only releases the emergency interlock signal and regenerates the execution enable flag after detecting that the stable completion flag has become valid again and continuously meets the preset recovery time threshold. The "preset recovery time threshold" is a defined time length used to ensure that the stable completion flag is not an instantaneous jump but a continuous stabilization. For example, it may require the stable completion flag to be continuously valid for 500 ms or 1 s. This threshold can be set according to the high-altitude wind field fluctuation characteristics and should be adjustable in the system configuration. When the recovery conditions are met, the execution unit releases the emergency interlock signal and regenerates the execution enable flag, only then allowing welding process correction commands to re-enter the execution flow, thus forming a strict "stabilize first, then execute; interlock upon instability; continue only after stabilization" mandatory interlock closed loop.

[0095] Although this application discloses preferred embodiments as described above, it is not intended to limit this application. Any person skilled in the art can make possible changes and modifications without departing from the spirit and scope of this application. Therefore, the scope of protection of this application should be determined by the scope defined in the claims of this application.

Claims

1. A high-altitude welding robot system based on environmental adaptive control, characterized in that, include: The analysis unit is used to continuously acquire raw external environmental parameters within the spatial range formed around the welding point during the welding operation, and to perform state analysis processing on the raw external environmental parameters to generate an environmental state vector characterizing the degree of instantaneous environmental disturbance during the welding operation. The raw external environmental parameters include at least wind field variation parameters, atmospheric static pressure parameters, ambient temperature and humidity parameters, and suspended particulate matter concentration parameters. The environmental state vector is used to uniformly characterize the comprehensive environmental state affecting welding stability under conditions of high altitude, low pressure, strong wind, and dust coupling. A construction unit is used to dynamically adjust the welding cavity structure formed around the welding area based on the environmental state vector to generate a welding cavity stability control quantity; wherein, the welding cavity stability control quantity is used to characterize the adjustment range required for the welding cavity to achieve stable gas protection conditions under the current environmental conditions; The generation unit is used to generate welding process correction instructions based on the coupling relationship between the welding cavity stability control quantity and the environmental state vector after the construction unit completes the stable construction of the welding cavity; wherein, the welding process correction instructions include at least welding energy distribution instructions, arc space control instructions and welding material delivery control instructions. The execution unit is used to receive and execute welding process modification instructions to complete the welding operation under the conditions of a stabilized welding cavity.

2. The high-altitude welding robot system based on environmental adaptive control according to claim 1, characterized in that, The parsing unit is specifically used for: During the welding operation, the spatial range is determined with the welding operation point as the center, and wind field change parameters, atmospheric static pressure parameters, environmental temperature and humidity parameters, and suspended particulate matter concentration parameters are collected synchronously within the spatial range at a uniform sampling period to form a time-aligned set of original environmental parameters. Based on the original set of environmental parameters, the wind field variation parameters and atmospheric static pressure parameters are jointly analyzed to obtain the shear disturbance component that characterizes the lateral shearing effect of the external airflow on the welding area. The atmospheric static pressure parameters and environmental temperature and humidity parameters are jointly analyzed to obtain the diffusion disturbance component that characterizes the diffusion and dilution trend of the protective gas. The wind field variation parameters and suspended particulate matter concentration parameters are jointly analyzed to obtain the dust-carrying disturbance component that characterizes the trend of dust entering the welding area with the airflow. Within a preset state evolution time window, the shear disturbance component, diffusion disturbance component, and dust-carrying disturbance component are subjected to time evolution processing to generate disturbance evolution features that characterize the degree of disturbance accumulation. The disturbance evolution features include at least the average intensity features and change stability features of each disturbance component within the time window. An environmental state vector is constructed based on the shear disturbance component, diffusion disturbance component, dust-carrying disturbance component, and their corresponding disturbance evolution characteristics, arranged in a preset order.

3. The high-altitude welding robot system based on environmental adaptive control according to claim 1, characterized in that, The building unit is specifically used for: The target set of stable gas protection conditions is determined based on the environmental state vector. The target set includes at least the pressure difference target inside and outside the welding cavity, the upper limit target of oxygen volume fraction inside the welding cavity, and the upper limit target of suspended particulate matter concentration inside the welding cavity, and the corresponding stable target parameter set is output. The welding cavity state acquisition process is driven by a stable target parameter set to obtain the pressure inside the welding cavity, the pressure outside the welding cavity, the oxygen volume fraction inside the welding cavity, and the concentration of suspended particulate matter inside the welding cavity, forming a welding cavity state parameter set that is time-aligned with the stable target parameter set. The stability deviation vector of the welding cavity is calculated based on the stable target parameter set and the welding cavity state parameter set. The stability deviation vector of the welding cavity includes at least the pressure difference deviation, oxygen volume fraction deviation and particulate matter concentration deviation. The welding cavity stability control quantity is generated based on the correspondence between the welding cavity stability deviation vector and the environmental state vector. The welding cavity stability control quantity includes at least the protective gas supply adjustment range, the welding cavity opening adjustment range, and the welding cavity boundary fitting adjustment range.

4. The high-altitude welding robot system based on environmental adaptive control according to claim 1, characterized in that, The building unit is specifically used for: The stability determination time window length and stability determination threshold group are determined based on the environmental state vector. The stability determination threshold group includes at least the lower limit threshold of the pressure difference inside and outside the welding cavity, the upper limit threshold of the oxygen volume fraction inside the welding cavity, and the upper limit threshold of the suspended particulate matter concentration inside the welding cavity, and the corresponding determination configuration parameter group is output. Based on the continuous sampling of the welding cavity state driven by the determination configuration parameter group, at least multiple sets of welding cavity pressure, welding cavity external pressure, welding cavity oxygen volume fraction and welding cavity suspended particulate matter concentration are obtained within the stable determination time window to form a time-seriesd welding cavity state sequence. A stability assessment index set is calculated based on the welding cavity state sequence. The stability assessment index set includes at least a pressure difference satisfaction rate index, an oxygen volume fraction exceedance rate index, and a particulate matter concentration exceedance rate index. The pressure difference satisfaction rate index is the percentage of sampling points where the actual pressure difference is not lower than the lower pressure difference threshold within the stability assessment time window. The oxygen volume fraction exceedance rate index is the percentage of sampling points where the oxygen volume fraction exceeds the upper oxygen volume fraction threshold within the stability assessment time window. The particulate matter concentration exceedance rate index is the percentage of sampling points where the suspended particulate matter concentration exceeds the upper particulate matter concentration threshold within the stability assessment time window. The stability assessment index set is then output. Based on the stability judgment index group and the judgment configuration parameter group, a stable gas protection judgment result is generated. When the pressure difference satisfaction rate index is not less than the preset satisfaction rate threshold and the oxygen volume fraction exceedance rate index and the particulate matter concentration exceedance rate index are not greater than the preset exceedance rate threshold respectively, the welding cavity is judged to have reached the stable gas protection condition.

5. The high-altitude welding robot system based on environment adaptive control according to claim 1, characterized in that, The generation unit is specifically used for: Receive the stability completion flag output by the building unit, and generate a welding cavity stability permission signal when the stability completion flag is detected to be in a valid state; Under the premise that the welding cavity stability state permit signal is valid, a process constraint input set is constructed based on the welding cavity stability control quantity and the environmental state vector. The process constraint input set includes at least the allowable energy change range, the allowable arc space offset range, and the allowable welding material delivery change range corresponding to the welding cavity stability control quantity, and outputs a set of restricted process generation parameters. Based on the constrained process parameter set, welding energy distribution instructions, arc space control instructions, and welding material delivery control instructions are generated within the allowable variation range. The welding energy distribution instructions, arc space control instructions, and welding material delivery control instructions satisfy the preset synchronization and consistency constraints to ensure that the coordinated changes of each process parameter in the stable state of the welding cavity will not damage the gas protection boundary. After generating the welding process correction command, the status of the stable completion flag is continuously monitored. When the stable completion flag is detected to be invalid, the current welding process correction command is immediately frozen or rolled back, and a process generation suppression signal is output to prevent the generation of new welding process correction commands in an unstable state of the welding cavity.

6. The high-altitude welding robot system based on environment adaptive control according to claim 5, characterized in that, The execution unit is specifically used for: The system receives welding process correction instructions and welding cavity stability permission signals output by the generation unit, and generates an execution enable flag when the welding cavity stability permission signal is valid. The execution enable flag is used to allow the welding process correction instructions to enter the execution process. Provided that the enable flag is valid, the welding energy execution quantity, arc space execution quantity, and welding material delivery execution quantity are generated based on the welding process modification command, and the welding energy execution quantity is output to the welding power control interface, the arc space execution quantity is output to the welding torch posture control interface, and the welding material delivery execution quantity is output to the wire feeding mechanism control interface to drive the welding operation. During the execution of welding process correction instructions, the stable completion flag output by the construction unit is continuously received and interlock judgment is performed. When the stable completion flag is detected to be invalid, an emergency interlock signal is generated. The emergency interlock signal is used to trigger the welding power supply to enter the preset energy reduction mode and trigger the wire feeding mechanism to enter the preset stop feeding mode, while driving the welding torch posture to enter the preset withdrawal trajectory. After outputting the emergency interlock signal, a stable recovery waiting flag is generated, and new welding process modification instructions are rejected from entering the execution process during the period when the stable recovery waiting flag is valid, until the stable completion flag becomes valid again and the preset recovery time threshold is continuously met. Then, the emergency interlock signal is released and the execution enable flag is regenerated.

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