Pulse welding droplet transfer control method, system and device and storage medium

Abstract

The invention discloses a pulse welding droplet transition control method, system and device and a storage medium, and the method comprises the steps that a first pulse parameter of a main pulse and a second pulse parameter of a micro pulse for welding are initialized, and the micro pulse is used for being superposed on a peak stage of the main pulse to form a target pulse sequence; a pulse current waveform of the target pulse sequence is determined according to the first pulse parameter and the second pulse parameter, and target welding current is generated according to the pulse current waveform; the target metal material is welded according to the target welding current, and a real-time molten drop image and a real-time arc voltage are collected; determining the diameter deviation of the molten drop according to the real-time molten drop image, determining the arc voltage deviation according to the real-time arc voltage, and optimizing the first pulse parameter and the second pulse parameter according to the diameter deviation of the molten drop and the arc voltage deviation. The method improves the welding seam forming quality and the metal welding quality, and can be widely applied to the technical field of metal welding.

Description

Technical Field

[0001] This invention relates to the field of metal welding technology, and in particular to a method, system, device, and storage medium for controlling the droplet transfer in pulse welding. Background Technology

[0002] Pulse welding is a low-energy welding method. By adjusting process parameters such as pulse frequency, current peak value, and pulse width, a single-pulse-droplet transfer effect can be achieved. This droplet transfer reduces short-circuit spatter and droplet runaway, resulting in minimal spatter, strong adaptability, and suitability for various metal materials and all-position welding. However, for welding wires of different sizes and materials, the applicable process parameter range for single-pulse-droplet transfer is generally narrow and easily affected by external factors such as mains voltage fluctuations, wire feed speed, and shielding gas flow rate. Therefore, during welding, multiple-pulse-droplet, single-pulse-droplet, and single-pulse-multiple-droplet transfer modes are often mixed, resulting in more spatter and poor weld quality. Summary of the Invention

[0003] The purpose of this invention is to at least partially solve one of the technical problems existing in the prior art.

[0004] Therefore, one objective of this invention is to provide a pulse welding droplet transition control method. This method superimposes micropulses during the peak phase of the main pulse, making the necking fracture during droplet detachment smoother, thereby reducing spatter during welding and improving weld formation quality. By optimizing the pulse parameters of the main pulse and micropulses through droplet diameter deviation and arc voltage deviation, the control of droplet transition becomes more precise, achieving fine control of each pulse and droplet, further improving weld formation quality and enhancing the quality of metal welding.

[0005] Another objective of this invention is to provide a pulse welding droplet transfer control system.

[0006] To achieve the above-mentioned technical objectives, the technical solutions adopted in the embodiments of the present invention include: In a first aspect, embodiments of the present invention provide a method for controlling the transfer of molten droplets in pulse welding, comprising the following steps: Initialize the first pulse parameters of the main pulse used for welding and the second pulse parameters of the micro pulse, wherein the micro pulse is used to superimpose the peak phase of the main pulse to form a target pulse sequence; The pulse current waveform of the target pulse sequence is determined based on the first pulse parameter and the second pulse parameter, and the target welding current is generated based on the pulse current waveform. Welding is performed on the target metal material according to the target welding current, and real-time droplet images and real-time arc voltage are acquired; The droplet diameter deviation is determined based on the real-time droplet image, the arc voltage deviation is determined based on the real-time arc voltage, and then the first pulse parameter and the second pulse parameter are optimized based on the droplet diameter deviation and the arc voltage deviation.

[0007] Furthermore, in one embodiment of the present invention, the first pulse parameters include the main pulse base current, the aortic peak current, the main pulse peak duration, and the main pulse period; the second pulse parameters include the micro-pulse peak current, the micro-pulse peak duration, and the micro-pulse frequency; the peak phase of the main pulse is used to provide energy input for droplet formation and growth to control the droplet size and growth rate; and the micro-pulse is used to apply a high-frequency auxiliary force during the peak phase of the main pulse to trigger droplet detachment.

[0008] Furthermore, in one embodiment of the present invention, the step of determining the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter specifically includes: A first current waveform is generated based on the first pulse parameters, and a second current waveform is generated based on the second pulse parameters; The pulse current waveform is obtained by superimposing the periodically repeating second current waveform within the time window corresponding to each peak stage of the first current waveform.

[0009] Furthermore, in one embodiment of the present invention, the step of welding the target metal material according to the target welding current and acquiring real-time droplet images and real-time arc voltage specifically includes: The target welding current is provided to the welding torch and welding platform by an intelligent welding power source, and the robot is controlled by the robot control cabinet to weld the target metal material on the welding platform using the welding torch; The real-time image of the molten droplet is obtained by capturing the tip of the welding wire with a high-speed camera, and the real-time arc voltage between the welding torch and the welding platform is acquired by a signal acquisition device.

[0010] Furthermore, in one embodiment of the present invention, the step of determining the droplet diameter deviation based on the real-time droplet image and determining the arc voltage deviation based on the real-time arc voltage specifically includes: The real-time droplet diameter is obtained by identifying the real-time droplet image, and the droplet diameter deviation is determined by the difference between the real-time droplet diameter and the preset droplet reference diameter. The arc voltage deviation is determined based on the difference between the real-time arc voltage and the preset arc voltage reference value.

[0011] Furthermore, in one embodiment of the present invention, the step of optimizing the first pulse parameters and the second pulse parameters based on the droplet diameter deviation and the arc voltage deviation specifically includes: When the droplet diameter deviation is greater than a preset first threshold and the arc voltage deviation is greater than a preset second threshold, the peak duration of the main pulse is reduced, and the peak current of the micro-pulse and the micro-pulse frequency are increased. When the droplet diameter deviation is less than a preset third threshold and the arc voltage deviation is less than a preset fourth threshold, the peak duration of the main pulse is increased, and the peak current of the micro-pulse and the micro-pulse frequency are decreased. The optimized target welding current is generated based on the optimized first pulse parameters and the optimized second pulse parameters, and the target metal material is welded according to the optimized target welding current.

[0012] Furthermore, in one embodiment of the present invention, the pulse welding droplet transfer control method further includes the following steps: If the optimization of the first pulse parameter and the second pulse parameter exceeds a preset number of times, return to the step of initializing the first pulse parameter of the main pulse and the second pulse parameter of the micro pulse for welding.

[0013] Secondly, embodiments of the present invention provide a pulse welding droplet transfer control system, comprising: The parameter initialization module is used to initialize the first pulse parameters of the main pulse and the second pulse parameters of the micro pulse for welding. The micro pulse is used to be superimposed on the peak phase of the main pulse to form a target pulse sequence. A welding current generation module is used to determine the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter, and to generate a target welding current based on the pulse current waveform. The welding module is used to weld the target metal material according to the target welding current, and to acquire real-time droplet images and real-time arc voltage. The parameter optimization module is used to determine the droplet diameter deviation based on the real-time droplet image, determine the arc voltage deviation based on the real-time arc voltage, and then optimize the first pulse parameter and the second pulse parameter based on the droplet diameter deviation and the arc voltage deviation.

[0014] Thirdly, embodiments of the present invention provide a pulse welding droplet transfer control device, comprising: At least one processor; At least one memory for storing at least one program; When the at least one program is executed by the at least one processor, the at least one processor implements the above-described pulse welding droplet transfer control method.

[0015] Fourthly, embodiments of the present invention also provide a computer-readable storage medium storing a processor-executable program, which, when executed by a processor, is used to perform the above-described pulse welding droplet transfer control method.

[0016] The advantages and beneficial effects of the present invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention: In this embodiment of the invention, the first pulse parameters of the main pulse and the second pulse parameters of the micro pulse for welding are initialized. The micro pulse is superimposed on the peak phase of the main pulse to form a target pulse sequence. The pulse current waveform of the target pulse sequence is determined based on the first and second pulse parameters, and a target welding current is generated based on the pulse current waveform. Welding is performed on the target metal material according to the target welding current, and real-time droplet images and real-time arc voltage are acquired. The droplet diameter deviation is determined based on the real-time droplet image, and the arc voltage deviation is determined based on the real-time arc voltage. Then, the first and second pulse parameters are optimized based on the droplet diameter deviation and the arc voltage deviation. In this embodiment of the invention, the micro pulse is superimposed on the peak phase of the main pulse, making the necking fracture during droplet detachment smoother, thereby reducing spatter during the welding process and improving the weld formation quality. By optimizing the pulse parameters of the main pulse and micro pulse through the droplet diameter deviation and the arc voltage deviation, the control of droplet transition is more precise, achieving fine control of each pulse and droplet, further improving the weld formation quality and enhancing the overall quality of metal welding. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the embodiments of the present invention are described below. It should be understood that the drawings described below are only for the convenience of clearly describing some embodiments of the technical solutions of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A flowchart illustrating the steps of a pulse welding droplet transfer control method provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the current waveform in single-pulse welding in related technologies; Figure 3 This is a schematic diagram of the current waveform in dual-pulse welding in related technologies; Figure 4 This is a schematic diagram of the current waveform in stepped single-pulse welding in related technologies; Figure 5 A schematic diagram of the current waveform of the main pulse provided in an embodiment of the present invention; Figure 6 A schematic diagram of the current waveform of a micropulse provided in an embodiment of the present invention; Figure 7 A schematic diagram of the current waveform of the target pulse sequence provided in an embodiment of the present invention; Figure 8 This is a schematic diagram illustrating an implementation scenario of a pulse welding droplet transfer control method provided in an embodiment of the present invention. Figure 9 A structural block diagram of a pulse welding droplet transfer control system provided in an embodiment of the present invention; Figure 10 This is a structural block diagram of a pulse welding droplet transfer control device provided in an embodiment of the present invention. Detailed Implementation

[0019] The embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention. The step numbers in the following embodiments are set only for ease of explanation, and there is no limitation on the order between the steps. The execution order of each step in the embodiments can be adaptively adjusted according to the understanding of those skilled in the art.

[0020] In the description of this invention, "multiple" means two or more. The use of "first" and "second" is for distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or the order of the indicated technical features. Furthermore, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art.

[0021] First, we will introduce and explain the pulsed current welding process in the existing related technologies.

[0022] like Figure 2 The diagram shown is a schematic of the current waveform in single-pulse welding in related technologies. Indicates the magnitude of the peak current of a single pulse. Indicates the magnitude of the base current of a single pulse. Indicates the peak duration of a single pulse. This indicates the base time length of a single pulse.

[0023] like Figure 3The diagram shows the current waveform of dual-pulse welding in related technologies. The dual pulse consists of a strong pulse and a weak pulse. This indicates the total duration of the strong pulse group. This indicates the total duration of the weak pulse group. This indicates the magnitude of the peak current of the strong pulse group. This indicates the magnitude of the base current of the strong pulse group. Indicates the peak duration of a strong pulse group. Indicates the duration of the base value of a strong impulse group. This indicates the magnitude of the peak current of the weak pulse group. This indicates the magnitude of the base current of the weak pulse group. Indicates the peak duration of a weak pulse group. This indicates the duration of the weak pulse group base value. When welding aluminum alloys using a dual-pulse method, the strong and weak pulse groups can stir the molten pool, which is beneficial for the escape of bubbles in the molten pool. However, there are too many pulse control parameters, making parameter optimization difficult. Moreover, there is no smooth transition between the strong and weak pulses, resulting in large arc voltage fluctuations, more spatter, and a higher risk of defects such as cracks.

[0024] like Figure 4 The diagram shown is a schematic representation of the current waveform in stepped single-pulse welding in related technologies. Figure 2 An improvement to the single-pulse welding current waveform shown, wherein, Indicates the magnitude of the stepped pulse current. This indicates the duration of the stepped pulse; the meanings of the other parameters are the same as... Figure 2 The same applies in the text. Although stepped pulse welding can theoretically control droplet transfer, in practical applications, welding defects such as porosity and cracks can still occur.

[0025] for Figure 2 For single-pulse welding, the droplet transfer of one pulse at a time is the droplet at the baseline value. t b Phase generation, at peak t p As the molten droplet grows and detaches, it is subjected to multiple forces upon impact with the weld pool, including gravity, arc blowing force, and electromagnetic contraction force. The droplet typically transitions during the peak of the pulse because it has already grown significantly, and the arc contraction and blowing forces are strong, facilitating its descent. The transition between each pulse and droplet, depending on the welding wire material and diameter, is also influenced by factors such as welding speed and shielding gas flow rate. Optimal process parameters are often obtained through experimentation, and the suitable range is relatively narrow. However, due to the complexity of the welding process and the instability of the arc, the droplet may continue to grow instead of falling during the peak of the pulse, resulting in a larger droplet transition with more spatter.

[0026] In order to ensure the stability of droplet transfer in pulse welding, this invention proposes a novel pulse current waveform that combines a main pulse with a high-frequency micro-pulse to control the form of droplet transfer in pulse welding, taking into account the pulse current, the main factor affecting the droplet transfer form.

[0027] Reference Figure 1 This invention provides a method for controlling the droplet transfer in pulse welding, specifically including the following steps: S101. Initialize the first pulse parameters of the main pulse and the second pulse parameters of the micro pulse for welding. The micro pulse is used to be superimposed on the peak phase of the main pulse to form the target pulse sequence. S102. Determine the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter, and generate the target welding current based on the pulse current waveform. S103. Weld the target metal material according to the target welding current, and collect real-time droplet images and real-time arc voltage. S104. Determine the droplet diameter deviation based on the real-time droplet image, determine the arc voltage deviation based on the real-time arc voltage, and then optimize the first pulse parameters and the second pulse parameters based on the droplet diameter deviation and the arc voltage deviation.

[0028] Specifically, to better control the droplet transition pattern, this invention proposes a novel pulsed current waveform consisting of a main pulse superimposed with micro-pulses to enhance the controllability of the droplet transition. For example... Figure 5 The waveform shown is the main pulse current waveform. Depending on factors such as the diameter of the welding wire and the material, the pulse frequency of each pulse is generally from a few hertz to tens of hertz. Figure 6 This demonstrates a low-current, high-frequency micropulse, typically ranging from several hundred to several thousand hertz. Figure 7 It is a current waveform of a target pulse sequence formed by superimposing two pulses, which can improve the controllability and stability of droplet transition. At the peak stage of a main pulse, a set of micro pulses are added on the basis of the peak. Under the combined influence of the micro pulses, the droplet falls off into the molten pool at the peak stage of the main pulse.

[0029] This invention constructs a three-stage synergistic control mechanism of "main pulse-controlled growth, micro-pulse-controlled detachment, and base current-stabilized arc": the peak current segment of the main pulse provides precise energy input for droplet formation and growth, controlling the droplet size and growth rate; the micro-pulse superposition segment applies a high-frequency auxiliary force when the droplet is about to detach, precisely triggering the detachment action; the base current segment maintains arc stability, preventing arc extinction, and simultaneously begins to generate droplets, ultimately achieving a single-droplet "formation-growth-detachment" process where only one droplet is completed within a single main pulse cycle.

[0030] It can be recognized that the embodiments of the present invention superimpose micropulses at the peak stage of the main pulse, making the necking fracture when the molten droplet detaches more stable, thereby reducing spatter during the welding process and improving the weld formation quality. By optimizing the pulse parameters of the main pulse and micropulse through the deviation of the molten droplet diameter and the deviation of the arc voltage, the control of the molten droplet transition is more precise, realizing fine control of each pulse and each droplet, further improving the weld formation quality and enhancing the quality of metal welding.

[0031] As an optional implementation, the first pulse parameters include the main pulse base current, the aortic peak current, the main pulse peak duration, and the main pulse period; the second pulse parameters include the micro-pulse peak current, the micro-pulse peak duration, and the micro-pulse frequency; the peak phase of the main pulse is used to provide energy input for droplet formation and growth to control the droplet size and growth rate; and the micro-pulse is used to apply a high-frequency auxiliary force during the peak phase of the main pulse to trigger droplet detachment.

[0032] Specifically, the first step is to initialize the parameters, i.e., select appropriate one-pulse-one-drop process parameters. Taking the welding of 5mm thick 304 stainless steel with ER308 welding wire with a diameter of 1.2mm as an example, the parameters are preset according to the built-in process database based on the welding material: base current 60A, main pulse peak value 180A, width 12ms, pulse period 100ms, micro pulse peak value 50A, frequency 500Hz, width 150μs, and the droplet reference diameter D=1.5mm and the arc voltage reference value U=22V.

[0033] As a further optional implementation, the step of determining the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter specifically includes: S1021. Generate a first current waveform according to the first pulse parameters, and generate a second current waveform according to the second pulse parameters; S1022. A periodically repeating second current waveform is superimposed within the time window corresponding to each peak stage of the first current waveform to obtain a pulse current waveform.

[0034] As a further optional implementation, the step of welding the target metal material according to the target welding current and acquiring real-time droplet images and real-time arc voltage specifically includes: S1031. The intelligent welding power supply provides the target welding current to the welding torch and welding platform, and the robot control cabinet controls the robot to weld the target metal material on the welding platform using the welding torch. S1032. A real-time image of the molten droplet is obtained by capturing the end of the welding wire with a high-speed camera, and the real-time arc voltage between the welding torch and the welding platform is acquired by a signal acquisition device.

[0035] Specifically, such as Figure 8The diagram illustrates an implementation scenario of the pulsed welding droplet transfer control method according to an embodiment of the present invention. This embodiment uses a robotic pulse welding system, including an industrial control computer, an intelligent welding power supply, a robot control cabinet, a robot, a welding torch, a welding platform, a high-speed camera, and a signal acquisition device. When using a main pulse plus micro-pulse welding method, the high-speed camera captures images of the droplet's trajectory. After analyzing the voltage, current, and images, the industrial control computer sends the data to the intelligent welding power supply. The intelligent welding power supply then fine-tunes the main pulse and micro-pulse parameters based on the data until stability is achieved.

[0036] A high-speed camera captures images of the welding wire tip, and an image recognition algorithm is used to extract the droplet diameter D. R The voltage sensor collects the arc voltage U. R The current sensor collects the real-time current I. R This ensures accurate waveform parameter output. All data is transmitted to the control unit of the intelligent arc welding power supply after A / D conversion.

[0037] As a further optional implementation, the step of determining the droplet diameter deviation based on the real-time droplet image and the arc voltage deviation based on the real-time arc voltage specifically includes: S1041. The real-time droplet diameter is obtained by identifying the real-time droplet image, and the droplet diameter deviation is determined by the difference between the real-time droplet diameter and the preset droplet reference diameter. S1042. Determine the arc voltage deviation based on the difference between the real-time arc voltage and the preset arc voltage reference value.

[0038] As a further optional implementation, the step of optimizing the first pulse parameters and the second pulse parameters based on the droplet diameter deviation and the arc voltage deviation specifically includes: S1043. When the droplet diameter deviation is greater than the preset first threshold and the arc voltage deviation is greater than the preset second threshold, reduce the peak duration of the main pulse and increase the peak current and frequency of the micro-pulse. S1044. When the droplet diameter deviation is less than the preset third threshold and the arc voltage deviation is less than the preset fourth threshold, increase the peak duration of the main pulse and decrease the peak current and frequency of the micro-pulse. S1045. Generate an optimized target welding current based on the optimized first pulse parameters and second pulse parameters, and weld the target metal material according to the optimized target welding current.

[0039] Specifically, the control unit performs dual-input, dual-output analysis on the collected data: the input is the droplet diameter deviation ΔD = D. R -D and arc voltage deviation ΔU=U R-U. It should be noted that the droplet diameter deviation and arc voltage deviation are both differences between the measured data and the reference data. When they are positive, it means that the measured value is greater than the reference value, and when they are negative, it means that the measured value is less than the reference value.

[0040] If the droplet diameter deviation is greater than the preset first threshold and the arc voltage deviation is greater than the preset second threshold, i.e. the droplet is too large and the voltage is too high, then the peak duration of the main pulse ΔT = 1ms is reduced, while the peak value of the micropulse ΔI = 5A is increased and the micropulse frequency is increased by 50Hz. If the droplet diameter deviation is less than the preset third threshold and the arc voltage deviation is less than the preset fourth threshold, i.e. the droplet is too small and the voltage is too low, then the opposite adjustment is performed.

[0041] It should be noted that the first and second thresholds are positive values, such as the first threshold being 0.1 mm and the second threshold being 1 V. The third and fourth thresholds are negative values, such as the third threshold being... 0.1mm, the second threshold is 1V.

[0042] As an optional implementation, the pulse welding droplet transfer control method further includes the following steps: If the optimization of the first pulse parameter and the second pulse parameter exceeds the preset number of times, return to the step of initializing the first pulse parameter of the main pulse and the second pulse parameter of the micro pulse used for welding. Specifically, if optimization and adjustment fail to improve droplet transfer after more than three attempts, welding is stopped by arc termination, and appropriate one-pulse-one-drop process parameters are reinitialized. The intelligent welding power supply updates waveform parameters in real time according to the adjustment instructions and outputs a superimposed current of main pulse and micro pulse to achieve a "one-pulse-one-drop" cycle.

[0043] This invention utilizes a novel pulse waveform superimposed with a main pulse and micro pulses to achieve precise "one-drop" transition within a single main pulse cycle, significantly improving droplet transition consistency. The high-frequency auxiliary force control of the micro pulses ensures smoother necking fracture during droplet detachment, significantly enhancing droplet detachment stability and reducing large droplet transition during welding. The spatter rate is reduced from 8%-12% in traditional methods to 1%-3%, while irregular transitions caused by droplet tearing are avoided. The weld surface height difference is controlled within ±0.3mm, and the roughness Ra≤1.6μm. Employing a closed-loop control logic across the entire system, it can respond in real-time to external voltage fluctuations, protective gas flow fluctuations, and changes in wire extension length, exhibiting excellent dynamic adaptability.

[0044] The method steps of the embodiments of the present invention have been described above. It can be understood that the embodiments of the present invention superimpose micro-pulses during the peak phase of the main pulse, making the necking fracture during droplet detachment more stable, thereby reducing spatter during welding and improving weld formation quality. By optimizing the pulse parameters of the main pulse and micro-pulses through droplet diameter deviation and arc voltage deviation, the control of droplet transition becomes more precise, achieving fine control of each pulse and droplet, further improving weld formation quality and enhancing the overall quality of metal welding.

[0045] Compared with the prior art, the embodiments of the present invention also have the following advantages: (1) Improve droplet transition stability: The introduction of micro-pulse current can make more precise control over droplet transition based on the main pulse. It can increase the stability of the arc, reduce short circuits and splashing during droplet transition, and enable the droplets to transition into the molten pool more uniformly and stably.

[0046] (2) Refining droplet size: High-frequency micro-pulse current makes the electromagnetic force act more frequently, which can promptly cause the droplet to detach from the welding wire, reduce the droplet growth time, and thus reduce the droplet size. Smaller droplet size helps to improve welding quality and reduce weld defects.

[0047] (3) Enhance arc stiffness: Micro-pulse current can concentrate arc energy and increase stiffness, which helps the molten droplet to transition more smoothly into the molten pool along the arc axis.

[0048] Reference Figure 9 This invention provides a pulse welding droplet transfer control system, comprising: The parameter initialization module is used to initialize the first pulse parameters of the main pulse and the second pulse parameters of the micro pulse for welding. The micro pulse is used to be superimposed on the peak phase of the main pulse to form the target pulse sequence. The welding current generation module is used to determine the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter, and to generate the target welding current based on the pulse current waveform. The welding module is used to weld target metal materials according to the target welding current and to acquire real-time images of molten droplets and real-time arc voltage. The parameter optimization module is used to determine the droplet diameter deviation based on the real-time droplet image, determine the arc voltage deviation based on the real-time arc voltage, and then optimize the first pulse parameters and the second pulse parameters based on the droplet diameter deviation and the arc voltage deviation.

[0049] The content of the above method embodiments is applicable to this system embodiment. The specific functions implemented in this system embodiment are the same as those in the above method embodiments, and the beneficial effects achieved are also the same as those achieved in the above method embodiments.

[0050] Reference Figure 10 This invention provides a pulse welding droplet transfer control device, comprising: At least one processor; At least one memory for storing at least one program; When the above-mentioned at least one program is executed by the above-mentioned at least one processor, the above-mentioned at least one processor implements the above-mentioned pulse welding droplet transfer control method.

[0051] The content of the above method embodiments is applicable to the device embodiments. The specific functions implemented by the device embodiments are the same as those of the above method embodiments, and the beneficial effects achieved are also the same as those achieved by the above method embodiments.

[0052] This invention also provides a computer-readable storage medium storing a processor-executable program that, when executed by a processor, performs the aforementioned pulse welding droplet transfer control method.

[0053] This invention provides a computer-readable storage medium that can execute a pulse welding droplet transfer control method provided in the method embodiment of this invention. It can execute any combination of the implementation steps of the method embodiment and has the corresponding functions and beneficial effects of the method.

[0054] This invention also discloses a computer program product or computer program, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device can read the computer instructions from the computer-readable storage medium, and the processor executes the computer instructions, causing the computer device to perform... Figure 1 The method shown.

[0055] In some alternative embodiments, the functions / operations mentioned in the block diagrams may not occur in the order shown in the operation diagrams. For example, depending on the functions / operations involved, two consecutively shown blocks may actually be executed substantially simultaneously, or the aforementioned blocks may sometimes be executed in reverse order. Furthermore, the embodiments presented and described in the flowcharts of this invention are provided by way of example to provide a more comprehensive understanding of the technology. The disclosed methods are not limited to the operations and logic flows presented herein. Alternative embodiments are contemplated in which the order of various operations is changed and sub-operations described as part of a larger operation are executed independently.

[0056] Furthermore, although the invention has been described in the context of functional modules, it should be understood that, unless otherwise stated, one or more of the aforementioned functions and / or features may be integrated into a single physical device and / or software module, or one or more functions and / or features may be implemented in a separate physical device or software module. It is also understood that a detailed discussion of the actual implementation of each module is unnecessary for understanding the invention. Rather, given the properties, functions, and internal relationships of the various functional modules in the apparatus disclosed herein, the actual implementation of the module will be understood within the scope of conventional skill of an engineer. Therefore, those skilled in the art can implement the invention as set forth in the claims using ordinary techniques without excessive experimentation. It is also understood that the specific concepts disclosed are merely illustrative and not intended to limit the scope of the invention, which is determined by the full scope of the appended claims and their equivalents.

[0057] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0058] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-including system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device.

[0059] More specific examples (a non-exhaustive list) of computer-readable media include: electrical connections (electronic devices) having one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which the aforementioned program can be printed, because the aforementioned program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in computer memory.

[0060] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0061] In the foregoing description of this specification, references to terms such as "one embodiment," "another embodiment," or "some embodiments" indicate that a specific feature, structure, material, or characteristic described in connection with an embodiment or example is included in at least one embodiment or example of the present invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0062] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

[0063] The above is a detailed description of the preferred embodiments of the present invention. However, the present invention is not limited to the above embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.

Claims

1. A method for controlling droplet transfer in pulse welding, characterized in that, Includes the following steps: Initialize the first pulse parameters of the main pulse used for welding and the second pulse parameters of the micro pulse, wherein the micro pulse is used to superimpose the peak phase of the main pulse to form a target pulse sequence; The pulse current waveform of the target pulse sequence is determined based on the first pulse parameter and the second pulse parameter, and the target welding current is generated based on the pulse current waveform. Welding is performed on the target metal material according to the target welding current, and real-time droplet images and real-time arc voltage are acquired; The droplet diameter deviation is determined based on the real-time droplet image, the arc voltage deviation is determined based on the real-time arc voltage, and then the first pulse parameter and the second pulse parameter are optimized based on the droplet diameter deviation and the arc voltage deviation.

2. The pulse welding droplet transfer control method according to claim 1, characterized in that, The first pulse parameters include the base current of the main pulse, the peak current of the aorta, the peak duration of the main pulse, and the period of the main pulse. The second pulse parameters include the peak current of the micropulse, the peak duration of the micropulse, and the frequency of the micropulse. The peak phase of the main pulse is used to provide energy input for droplet formation and growth to control the droplet size and growth rate. The micropulse is used to apply a high-frequency auxiliary force during the peak phase of the main pulse to trigger droplet detachment.

3. The pulse welding droplet transfer control method according to claim 1, characterized in that, The step of determining the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter specifically includes: A first current waveform is generated based on the first pulse parameters, and a second current waveform is generated based on the second pulse parameters; The pulse current waveform is obtained by superimposing the periodically repeating second current waveform within the time window corresponding to each peak stage of the first current waveform.

4. The pulse welding droplet transfer control method according to claim 1, characterized in that, The step of welding the target metal material according to the target welding current and acquiring real-time droplet images and real-time arc voltage specifically includes: The target welding current is provided to the welding torch and welding platform by an intelligent welding power source, and the robot is controlled by the robot control cabinet to weld the target metal material on the welding platform using the welding torch; The real-time image of the molten droplet is obtained by capturing the tip of the welding wire with a high-speed camera, and the real-time arc voltage between the welding torch and the welding platform is acquired by a signal acquisition device.

5. The pulse welding droplet transfer control method according to claim 1, characterized in that, The step of determining the droplet diameter deviation based on the real-time droplet image and the arc voltage deviation based on the real-time arc voltage specifically includes: The real-time droplet diameter is obtained by identifying the real-time droplet image, and the droplet diameter deviation is determined by the difference between the real-time droplet diameter and the preset droplet reference diameter. The arc voltage deviation is determined based on the difference between the real-time arc voltage and the preset arc voltage reference value.

6. The pulse welding droplet transfer control method according to claim 2, characterized in that, The step of optimizing the first pulse parameters and the second pulse parameters based on the droplet diameter deviation and the arc voltage deviation specifically includes: When the droplet diameter deviation is greater than a preset first threshold and the arc voltage deviation is greater than a preset second threshold, the peak duration of the main pulse is reduced, and the peak current of the micro-pulse and the micro-pulse frequency are increased. When the droplet diameter deviation is less than a preset third threshold and the arc voltage deviation is less than a preset fourth threshold, the peak duration of the main pulse is increased, and the peak current of the micro-pulse and the micro-pulse frequency are decreased. The optimized target welding current is generated based on the optimized first pulse parameters and the optimized second pulse parameters, and the target metal material is welded according to the optimized target welding current.

7. The pulse welding droplet transfer control method according to claim 6, characterized in that, The pulse welding droplet transfer control method further includes the following steps: If the optimization of the first pulse parameter and the second pulse parameter exceeds a preset number of times, return to the step of initializing the first pulse parameter of the main pulse and the second pulse parameter of the micro pulse for welding.

8. A pulse welding droplet transfer control system, characterized in that, include: The parameter initialization module is used to initialize the first pulse parameters of the main pulse and the second pulse parameters of the micro pulse for welding. The micro pulse is used to be superimposed on the peak phase of the main pulse to form a target pulse sequence. A welding current generation module is used to determine the pulse current waveform of the target pulse sequence based on the first pulse parameter and the second pulse parameter, and to generate a target welding current based on the pulse current waveform. The welding module is used to weld the target metal material according to the target welding current, and to acquire real-time droplet images and real-time arc voltage. The parameter optimization module is used to determine the droplet diameter deviation based on the real-time droplet image, determine the arc voltage deviation based on the real-time arc voltage, and then optimize the first pulse parameter and the second pulse parameter based on the droplet diameter deviation and the arc voltage deviation.

9. A pulse welding droplet transfer control device, characterized in that, include: At least one processor; At least one memory for storing at least one program; When the at least one program is executed by the at least one processor, the at least one processor implements a pulse welding droplet transfer control method as described in any one of claims 1 to 7.

10. A computer-readable storage medium storing a processor-executable program, characterized in that, The processor-executable program, when executed by the processor, is used to perform a pulse welding droplet transfer control method as described in any one of claims 1 to 7.

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