Welding control method and system for motor circuit board of energy-saving freezer with stator

Abstract

The invention relates to a welding control method and system for a motor circuit board of an energy-saving freezer with a stator, and relates to the field of welding technology.The method comprises the steps that a stator image is obtained in response to a preset welding signal; determining a stator category according to the stator image; searching a corresponding welding temperature and a welding scheme according to the stator category; sorting the stators corresponding to the stator categories based on the welding temperature to obtain a stator sequence; sequentially obtaining welding stator types according to the stator sequence; and controlling a stator corresponding to the welding stator category to execute a welding scheme to obtain a welding finished product. The stator welding device has the effect of improving the stator welding efficiency.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a welding control method and system for an energy-saving freezer motor circuit board with a stator. Background Technology

[0002] In the manufacturing process of energy-saving freezers, the welding quality of the motor stator and circuit board is the core key to ensuring the stability and energy efficiency of the freezer motor. Because energy-saving freezer motors need to balance low power consumption and cooling efficiency, their stators often employ a combination structure of fine-diameter, high-temperature resistant enameled wire windings, miniaturized circuit boards, and low-loss power lines. This places stringent requirements on the precision of welding, temperature control, and the amount of solder applied.

[0003] Currently, the industry has gradually adopted automated welding equipment to complete the welding of the stator and circuit board of energy-saving refrigerator motors. These devices typically integrate constant temperature soldering iron modules, vision positioning components, and basic parameter control modules, which can realize automatic alignment and basic welding of solder joints, replacing the traditional manual welding mode. This improves welding efficiency to a certain extent, reduces quality risks caused by human error, and provides technical support for the large-scale production of energy-saving refrigerator motors.

[0004] Regarding the aforementioned technologies, in the actual welding process, the parameters of different energy-saving refrigerator motor stators vary. The automatic welding system generally welds different types of stators according to the set program, without sorting them according to the welding temperature of the stators before welding. There is still room for improvement in welding efficiency. Summary of the Invention

[0005] To improve the welding efficiency of the stator, this invention provides a welding control method and system for an energy-saving freezer motor circuit board with a stator.

[0006] In a first aspect, the present invention provides a welding control method for an energy-saving freezer motor circuit board with a stator, employing the following technical solution: A method for controlling the welding of circuit boards for an energy-saving freezer motor with a stator, comprising: Step 1: In response to a preset welding signal, acquire a stator image; Step 2: Determine the stator category based on the stator image; Step 3: Find the corresponding welding temperature and welding scheme according to the stator type; Step 4: Sort the stators corresponding to the stator categories based on the welding temperature to obtain the stator sorting; Step 5: Obtain the welding stator categories according to the stator sorting; Step 6: Control the stator corresponding to the welding stator category to execute the welding scheme to obtain the welded finished product.

[0007] By adopting the above technical solution, the stators are sorted according to their categories, and different stators are welded sequentially according to the sorting. This allows the stators to be welded in an orderly manner, avoiding low welding efficiency due to different welding temperatures and other factors when welding different stators, and improving the welding efficiency between the stator and the circuit board.

[0008] Optionally, methods for controlling the stator to perform welding schemes corresponding to the welding stator category to obtain welded finished products include: Step 60: Obtain the current stator category based on the stator sorting; Step 61: Find the corresponding welding material based on the current stator category; Step 62: Determine the welding method based on the welding material and the current stator type; Step 63: Weld the welding materials to the stator corresponding to the current stator type according to the welding method to obtain the welded finished product.

[0009] By adopting the above technical solution, the welding materials and welding methods corresponding to the current stator category are matched based on the stator sorting, so as to achieve precise matching of stator category, welding materials and welding methods. This avoids weld defects caused by mismatch between materials and processes, and improves the continuity and efficiency of the overall welding process while ensuring the stability of the quality of the welded products.

[0010] Optional, also includes: Step 64: Obtain welding images; Step 65: Analyze the stator welding quality based on the welding images; Step 66: If the stator welding quality does not meet the preset standard quality, obtain the welding abnormality points based on the welding image; Step 67: Find and implement corresponding solutions based on welding anomalies.

[0011] By adopting the above technical solutions, visual quality inspection of stator welding products can be carried out, welding anomalies can be accurately identified and corresponding solutions can be matched, welding defects can be corrected in a timely manner, and unqualified products can be prevented from flowing into subsequent processes, thus ensuring the overall quality and finished product qualification rate of stator circuit board welding.

[0012] Optionally, methods for finding corresponding solutions based on welding anomalies include: Step 670: Obtain the abnormal stator category based on the welding image; Step 671: Locate the corresponding welding material based on the abnormal stator category; Step 672: Determine the abnormal situation based on the welding abnormality points; Step 673: If the abnormal situation is the preset welding material shortage, determine the material replenishment plan as the solution based on the welding material and the finished welding product, and output it.

[0013] By adopting the above technical solutions, we can accurately locate abnormal stator types and welding abnormalities caused by missing welding materials, match corresponding welding materials in a targeted manner, formulate a material replenishment plan, quickly correct welding defects caused by missing welding materials, effectively improve the efficiency of welding problem handling, and ensure the quality stability and pass rate of stator circuit board welding products.

[0014] Optionally, methods for finding corresponding solutions based on welding anomalies also include: Step 674: If the abnormal situation is a preset situation of excess welding material, locate the corresponding material suction device based on the welding material; Step 675: Control the material suction device to suction the material to obtain the finished product to be re-welded; Step 676: Determine the re-welding scheme as a solution based on the finished product to be re-welded and the welding materials, and output it.

[0015] By adopting the above technical solutions, welding abnormalities caused by excess welding materials can be accurately identified, corresponding material suction devices can be matched to remove excess welding materials, and re-welding plans can be formulated. This can efficiently solve welding defects caused by excessive welding materials, avoid material waste caused by abnormal scrapping, and improve the efficiency of welding problem handling and finished product yield.

[0016] Optionally, the method of welding welding materials to a stator corresponding to the current stator category according to a welding method to obtain a welded finished product also includes: Step 630: Obtain the number of welded finished products and the number of defective finished products; Step 631: Calculate the defect rate based on the number of welded finished products and the number of defective finished products; Step 632: If the anomaly rate is higher than the preset standard value, obtain the welding tool image; Step 633: Obtain the welding tool status based on the welding tool image; Step 634: Find and implement the corresponding cleaning plan based on the condition of the welding tools; Step 635: If the anomaly rate is lower than the standard value, obtain the next current stator category according to the stator sorting and find the corresponding welding material and weld it according to the corresponding welding method to obtain the welded finished product.

[0017] By adopting the above technical solution, the welding defect rate is calculated by statistically analyzing the number of welded finished products and the number of abnormal finished products. Based on the defect rate threshold, the image detection and cleaning process of welding tools is triggered to promptly eliminate batch welding defects caused by abnormal welding tool conditions, reduce invalid welding operations, and improve the intelligent control level and production efficiency of the welding process while ensuring the stability of welding quality.

[0018] Optionally, methods for finding and implementing corresponding cleaning solutions based on the welding tools include: Step 6340: Obtain the welding tool number based on the welding tool image; Step 6341: If the welding tool is in a preset high-temperature condition, locate the corresponding cooling device based on the welding tool number and perform cooling. Step 6342: If the welding tool is in the preset welding material accumulation state, locate the corresponding cleaning device and cleaning fluid according to the welding tool number; Step 6343: Pour the cleaning fluid into the cleaning device and clean the welding tools corresponding to the welding tool numbers.

[0019] By adopting the above technical solution, the tool number can be accurately located based on the welding tool image. For two abnormal situations, namely tool overheating and welding material accumulation, corresponding cooling or cleaning devices and consumables can be matched to carry out targeted treatment. This can promptly eliminate welding quality hazards caused by abnormal tool conditions, ensure the stable operation of welding tools, and improve the reliability of finished product quality and welding efficiency.

[0020] Optionally, an optimization method for stator sorting is also included, which includes: Step 68: Obtain the number of stators corresponding to the stator category; Step 69: Obtain the corresponding number of welding materials based on the stator type; Step 70: When the number of welding materials is greater than or equal to the number of stators, control the stator corresponding to the welding stator category to execute the welding scheme to obtain the welded finished product; Step 71: When the number of welding materials is less than the number of stators, define the corresponding stator category as the stator category lacking welding materials; Step 72: Remove stator categories lacking welding materials from the stator sorting to obtain the final sort.

[0021] By adopting the above technical solution, and combining the number of welding materials corresponding to the stator category with the number of stators for material matching verification, priority is given to ensuring that stator categories with sufficient welding materials are used for welding operations, while stator categories lacking welding materials are eliminated to generate the final sorting. This avoids process interruptions and ineffective waiting caused by welding material shortages, improves the rationality of welding task scheduling and the continuity of the work process, and increases welding efficiency.

[0022] Optionally, it also includes a method for controlling the execution of a welding scheme when a stator category of welding material is missing, the method comprising: Step 710: Determine the temperature of the stator lacking solder and the quantity of solder already stored based on the type of stator lacking solder. Step 711: Find the corresponding compatible material and the quantity of compatible material based on the temperature of the missing stator; Step 712: Calculate the final number of welding materials based on the existing number of welding materials and the number of compatible materials; Step 713: Find the corresponding compatible welding solution based on the final number of welding materials; Step 714: If the final number of welding materials is greater than or equal to the number of stators, control the stators corresponding to the missing welding materials stator categories to execute the compatible welding scheme; Step 715: If the final number of welding materials is less than the number of stators, do not control the stators corresponding to the missing welding materials to execute the compatible welding scheme.

[0023] By adopting the above technical solution, for stator types lacking welding materials, the system combines the temperature matching of the missing stator with compatible welding materials, integrates the total number of existing welding materials and compatible welding materials, and matches the corresponding compatible welding scheme. The decision on whether to perform welding is based on the comparison between the final number of welding materials and the number of stators. This avoids production stoppages caused by welding material shortages and improves the material utilization rate and production scheduling flexibility of the welding process.

[0024] Secondly, the present invention provides a welding control system for an energy-saving freezer motor circuit board with a stator, which adopts the following technical solution: A welding control system for an energy-saving freezer motor circuit board with a stator, comprising: The acquisition module is used to acquire stator images, welding images, the number of welded finished products, the number of abnormal finished products, and the number of stators. A memory for storing a program for a welding control method of a circuit board for an energy-saving freezer motor with a stator, as described above; The processor loads and executes programs from memory.

[0025] By adopting the above technical solution, the acquisition module can accurately collect various production data such as stator images. Combined with the stable storage of welding control method programs in the memory, the processor loads and executes the preset program, and the aforementioned technical processes such as welding sorting optimization, quality inspection, anomaly handling, and welding material adaptation are systematically implemented. This realizes the automated and intelligent management and control of motor stator circuit board welding, and improves the welding operation efficiency and finished product yield of energy-saving freezer motor stators.

[0026] In summary, the present invention has at least one of the following beneficial technical effects: 1. By sorting stators of different categories according to their corresponding welding temperatures, and then welding the stators sequentially according to the sorting, different stators are welded in an orderly manner according to the temperature rise, avoiding frequent adjustments of tool temperature during welding and improving the efficiency of stator welding. 2. By finding the number of welding materials corresponding to different stators, materials that are insufficient to complete the welding of all stators in that category are classified as stators lacking welding materials and removed from the stator sorting. This ensures that all stators in the stator sorting can be welded, thus improving the stator welding efficiency. Attached Figure Description

[0027] Figure 1 This is a flowchart of a welding control method for a circuit board of an energy-saving freezer motor with a stator, according to an embodiment of this application. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0029] This invention discloses a welding control method for a circuit board of an energy-saving freezer motor with a stator.

[0030] Reference Figure 1 A method for controlling the welding of circuit boards for an energy-saving freezer motor with a stator, comprising: Step 1: In response to a preset welding signal, acquire a stator image.

[0031] The welding signal refers to the signal used to weld the stator to the circuit board. The response here is that there is an electrical signal button on the workbench or production line; pressing it triggers a response.

[0032] A stator image refers to a picture of the stator placed on a workbench or production line. Here, it is obtained by using a camera on the workbench; the system captures real-time images through the camera to obtain the stator image.

[0033] Step 2: Determine the stator category based on the stator image.

[0034] Stator category refers to the type of stator present on the workbench or production line. The method of determination here is as follows: there are many types of stators. Personnel in the field search for various stators online, then input the information into the system. The system analyzes the characteristics of different stators based on these characteristics, stores them, and then, after acquiring a stator image, determines the type of stator in the image based on the stored characteristics.

[0035] Step 3: Find the corresponding welding temperature and welding scheme according to the stator type.

[0036] Soldering temperature refers to the temperature required to solder the stator onto the circuit board. The search method here is as follows: different types of stators have different soldering temperatures. Personnel skilled in the field determine the soldering temperature for each type of stator based on their experience and by searching relevant information online, and then input this information into the system. Once the system identifies the stator type, it automatically searches for the corresponding soldering temperature.

[0037] The welding scheme refers to the specific method for welding the stator to the circuit board. The search method here is based on the fact that the specific welding operations for different types of stators to the circuit board may vary. This information is obtained by professionals in the field based on their work experience or by searching for relevant information online and inputting it into the system. After the system determines the stator type, it searches for the corresponding welding scheme. For example: the welding temperature for the stator of a miniature low-power refrigerator fan is 350~380℃, and the corresponding welding scheme is laser spot welding. The welding temperature for the stator of a conventional energy-saving refrigerator compressor motor is 360~390℃, and the corresponding welding scheme is automated drag soldering with a constant temperature soldering iron. The welding temperature for the stator of a commercial large-capacity refrigerator compressor motor is 380~400℃, and the corresponding welding scheme is wave soldering.

[0038] Step 4: Sort the stators corresponding to the stator categories based on the welding temperature to obtain the stator sorting.

[0039] Stator sorting refers to the arrangement order formed by different stator categories. Here, it is obtained by sorting the stators from low to high welding temperature, with the lowest welding temperature in the first position, until all stators are arranged to obtain the stator sorting.

[0040] Step 5: Obtain the welding stator category according to the stator sorting.

[0041] The stator category refers to the type of stator that is soldered to the circuit board. This is obtained by sequentially extracting the corresponding stator categories from the stator sorting order. After completing the soldering process for each stator category, the next stator category in the sorting is automatically retrieved.

[0042] Step 6: Control the stator corresponding to the welding stator category to execute the welding scheme to obtain the welded finished product.

[0043] The execution method here is for the system to find the welding scheme (such as laser spot welding, constant temperature soldering iron automated drag soldering, etc.) and welding temperature parameters corresponding to the current welding stator type, drive the welding module, positioning fixture and other components to start, and after the fixture completes the precise positioning of the stator and the circuit board, the welding operation is performed according to the welding scheme process (such as preheating, solder feeding, heating and melting, cooling and solidification).

[0044] The finished product refers to the part after the stator has been soldered to the circuit board. Here, it is obtained by the system completing the soldering of the stator to the circuit board, resulting in a complete object, which is then considered the finished product.

[0045] The methods for controlling the stator to execute the welding scheme corresponding to the welding stator category to obtain the welded finished product include: Step 60: Obtain the current stator category based on the stator sorting.

[0046] The current stator category refers to the type of stator that is currently being soldered to the circuit board. This is obtained by the system retrieving the stator category for the current soldering task from the stator sorting queue.

[0047] Step 61: Find the corresponding welding material based on the current stator category.

[0048] Welding materials refer to the materials required for stator welding. These materials include the molten metal, welding tools, and the circuit board itself. The search method involves identifying different welding materials for different stator types. Personnel skilled in the field search relevant information online to obtain the welding materials for each stator type and input this information into the system. When the system receives the current stator type, it automatically retrieves and matches the corresponding welding materials.

[0049] Step 62: Determine the welding method based on the welding material and the current stator type.

[0050] The welding method refers to the specific operation method for welding the current stator type to the circuit board. Here, the method is determined because different stators corresponding to different current stator types have different welding methods. The welding methods for different stators are obtained by professionals in this field by combining mature industry process experience and relevant information found online, and then input into the system. After the system obtains the current stator type and the matching welding material, it automatically performs feature matching and selects the uniquely suitable welding method.

[0051] Step 63: Weld the welding materials to the stator corresponding to the current stator type according to the welding method to obtain the welded finished product.

[0052] The execution method here is that the system controls the corresponding tool to pick up the stator and welding material corresponding to the current stator type, and then follows the welding procedure to ensure that the stator can be successfully installed on the circuit board to perform welding.

[0053] This also includes: Step 64: Obtain welding images.

[0054] Welding images refer to pictures of the stator after the welding process is completed. These images are obtained in real-time via a camera device located at the workbench or end of the production line.

[0055] Step 65: Analyze the stator welding quality based on the welding images.

[0056] Stator welding quality refers to the quality of the stator after welding. The analysis here addresses various quality issues that may arise in a welded stator, such as incomplete welds, bridging, missing welding materials, and carbonization of the insulation layer. Therefore, professionals in this field pre-collect the appearance and structural characteristics of the weld points corresponding to each quality issue (e.g., uneven surface of incomplete welds, pin continuity of bridging welds, and incomplete forming of welds with missing welding materials). They then assign grading standards of acceptable, minor abnormalities, and severe abnormalities to each quality issue. These characteristic data and grading standards are entered into the system's welding quality assessment model. When the system acquires the welding image, it first sends an image preprocessing command to the image processing module to perform preprocessing operations such as noise reduction, enhancement, and edge extraction. Then, the preprocessed image features are precisely compared with the various quality features stored in the model to analyze the stator welding quality.

[0057] Step 66: If the stator welding quality does not meet the preset standard quality, welding abnormality points are obtained based on the welding image.

[0058] Standard quality refers to the minimum quality threshold of the stator and circuit board welded products that ensure the stable operation of the energy-saving refrigerator motor and meet the requirements of electrical safety and mechanical strength. The standard quality is obtained by those skilled in the art first identifying the appearance, electrical, and mechanical performance indicators that the welded products must meet based on industry technical standards for energy-saving refrigerator motors (such as welding process specifications for refrigeration equipment motors), overall machine operational reliability requirements, and environmental adaptation needs of actual application scenarios. Then, multiple sets of process tests are used to verify the reasonable threshold range of each indicator. These quantitative indicators are integrated with the corresponding appearance characteristics into a standard quality judgment system, which is then entered into the system.

[0059] Welding anomalies are specific locations where the stator and circuit board fail to meet standard quality after welding. The method used here is as follows: after the system completes welding quality analysis and determines that the weld is substandard, it first locates the defective areas in the pre-processed welding image. Using an image segmentation algorithm, it precisely divides the solder joint area, stator winding area, and circuit board pad area. Then, it calls up stored welding defect feature templates and compares them region by region with the pixel and contour features of each area in the image, marking defective areas with a matching degree exceeding a threshold. Simultaneously, it assigns an anomaly label to this area based on the defect type. Finally, it uses coordinate positioning technology to determine the precise spatial location of each anomaly on the finished welded product.

[0060] If the stator welding quality does not meet the standard quality, it indicates that there is an abnormality in the welding process, which will affect normal use and create safety hazards. Therefore, welding abnormality points are obtained based on the welding images.

[0061] Step 67: Find and implement corresponding solutions based on welding anomalies.

[0062] A solution refers to the method of resolving the welding problem corresponding to the welding anomaly, enabling the abnormal welded product to be used normally. The search method here involves mapping different welding problems to welding anomalies, where skilled personnel search for relevant information online to obtain solutions for different problems, which are then input into the system. The system automatically matches and outputs the corresponding solution after identifying the welding anomaly. The execution method involves the system controlling the corresponding tools to clean or re-weld the abnormal welded product to achieve the desired result.

[0063] The methods for finding corresponding solutions based on welding anomalies include: Step 670: Obtain the abnormal stator category based on the welding image.

[0064] The abnormal stator category refers to the type of stator containing welding anomalies. This is achieved by the system extracting the core structural features of the stator from a welding image containing the anomalies. The extracted feature data is then compared one by one with a pre-stored feature library of various stator categories. A feature matching algorithm is used to calculate the similarity between the image features and the features of each category. The stator category with the highest similarity is then selected and identified as the abnormal stator category.

[0065] Step 671: Find the corresponding welding material based on the abnormal stator category.

[0066] The search method here is the same as that in step 61, except that it is for different types of stator welding materials.

[0067] Step 672: Determine the abnormal situation based on the welding abnormality points.

[0068] Anomalies refer to the specific defect type and severity corresponding to welding anomalies on the finished weld. The determination method involves the system retrieving feature data such as the location and shape of the welding anomalies, performing feature matching, and simultaneously determining the severity of the defect based on its area and distribution range. Finally, the defect type and severity are integrated to determine the specific anomaly.

[0069] Step 673: If the abnormal situation is the preset welding material shortage, determine the material replenishment plan as the solution based on the welding material and the finished welding product, and output it.

[0070] Solder deficiency refers to a welding defect in which the amount of solder used in the solder joint area does not meet the standard during the soldering process between the stator and the circuit board, resulting in an incomplete and reliable solder joint. The method for obtaining information on solder deficiency is as follows: Those skilled in the art conduct multiple sets of welding process experiments for different stator types, artificially setting different degrees of solder usage deviation. The appearance characteristics, electrical performance, and mechanical strength data of the solder joints under each set of experiments are recorded. Critical states where solder usage is below the standard value and leads to substandard solder joint performance, along with their corresponding appearances, are identified. The specific parameters and judgment criteria of these critical states are then categorized and organized to obtain different levels of solder deficiency, which are then input into the system.

[0071] A material replenishment plan refers to a specific welding repair operation plan developed to address solder joint defects and ensure the finished product meets standard quality requirements when solder materials are missing in the stator and circuit board welded products. The system determines this plan by retrieving the recorded solder material deficiency level and corresponding stator category welding material information, then combining this with the location and extent of the solder material deficiency anomalies on the welded product to clarify the required solder specifications and quantity, welding temperature and time, operating tools, and action path. This information is then integrated to form a complete material replenishment plan and output it. The output method involves the system simultaneously outputting the integrated material replenishment plan in both digital instruction and visual document formats. On one hand, it issues control instructions containing welding parameters and operation steps to the welding equipment, directly driving the equipment to perform the welding operation according to the plan. On the other hand, it outputs the detailed text and graphical flowchart of the material replenishment plan to the production management terminal and quality traceability system for technical personnel to view and verify.

[0072] If the abnormality is due to a lack of welding material, it indicates that the welding material used in the finished product was insufficient, resulting in an unstable weld and potentially causing the stator to detach. Therefore, a material replenishment plan should be determined based on the welding material and the finished product as a solution and output.

[0073] The methods for finding corresponding solutions based on welding anomalies also include: Step 674: If the abnormal situation is a preset situation of excess welding material, find the corresponding material suction device based on the welding material.

[0074] Excess solder refers to a welding defect where the amount of solder used in the solder joint area exceeds the preset standard amount during the soldering process between the stator and the circuit board. The method for obtaining information on excess solder is to follow the same experimental logic as for insufficient solder. Personnel skilled in the art conduct multiple sets of excessive soldering tests for different stator types, recording the appearance of the solder joints, electrical short-circuit risk, and insulation damage under different degrees of excess. The critical state and corresponding appearance characteristics where solder usage exceeds the standard and affects the quality of the finished product are identified. This data is then categorized into mild, moderate, and severe excess solder levels and entered into the system.

[0075] A material suction device is a device that removes excess welding material from the finished weld. The search method here is that different welding materials correspond to different material suction devices. Those skilled in the art first filter out the types of devices that can efficiently absorb the corresponding welding materials based on the melting point, viscosity, and other characteristics of different welding materials, and input this information into the system. When the system identifies excess welding material and retrieves the welding material corresponding to the current stator category, it automatically searches the database for a matching material suction device.

[0076] If the abnormal situation is due to excess welding material, it indicates that the welded product used too much material during welding, which may result in high resistance and indirectly cause a fire hazard. Therefore, the corresponding material suction device should be found based on the welding material.

[0077] Step 675: Control the material suction device to suction the material to obtain the finished product to be re-welded.

[0078] The finished product to be re-soldered refers to the product after all the soldering material between the stator and the circuit board has been removed. The process involves the system first issuing precise operating instructions to the material suction device based on the grade and location of the excess solder. This controls the suction device to adjust its operating parameters to match the current soldering material. Then, the system drives the suction device's actuator to the abnormal location of the excess solder, precisely suctioning and removing it. After removal, the system re-acquires an image of the area and performs solder residue detection. Once it confirms that there is no excess solder and that the stator insulation layer and circuit board substrate have not been damaged, the finished product to be re-soldered is obtained.

[0079] Step 676: Determine the re-welding scheme as a solution based on the finished product to be re-welded and the welding materials, and output it.

[0080] A re-welding plan refers to a scheme for re-welding the finished product. The method for determining this plan involves the system retrieving information on the abnormal stator category, original welding material specifications, and previous defect levels and removal records of excess welding materials. Combined with the actual condition of the finished product, the precise amount of solder required for re-welding, the re-welding temperature and holding time, the welding method, and the operation path are determined. Finally, a complete re-welding plan is integrated and output. The output method here is consistent with the method described in step 673 and will not be described further.

[0081] The method of welding welding materials to the stator corresponding to the current stator category according to the welding method to obtain the welded product also includes: Step 630: Obtain the number of welded finished products and the number of defective finished products.

[0082] The quantity of welded finished products refers to the total number of stator and circuit board integrated assemblies formed after all welding processes are completed on the same batch and type of energy-saving refrigerator motor stators. The quantity of abnormal finished products refers to the number of welded finished products that, according to quality inspection, have welding abnormalities and do not meet standard quality requirements. This is obtained by assigning a unique batch code to each batch of stators of the same type. After the welding process is completed, the production line counting sensor automatically counts the total number of welded stators of the same type in that batch, generating welded finished product quantity data and storing it in association with the batch code. Simultaneously, the system connects to the welding quality inspection module to summarize the number of finished products in that batch that have welding abnormalities as determined by image analysis. After removing the repaired and qualified finished products, the final quantity of abnormal finished products in that batch is determined.

[0083] Step 631: Calculate the abnormality rate based on the number of welded finished products and the number of abnormal finished products.

[0084] The defect rate refers to the proportion of defective stator welded products in a single batch of the same type to the total number of welded products. It is calculated by dividing the number of defective products by the total number of welded products.

[0085] Step 632: If the anomaly rate is higher than the preset standard value, obtain the welding tool image.

[0086] The standard value refers to the acceptable threshold for the abnormality rate of welding processes. The standard value is obtained by those skilled in the art by combining historical welding production data, industry quality control standards, and the actual application quality requirements of energy-saving refrigerator motor stators. Through multiple batches of process verification, a reasonable abnormality rate range is determined. Then, considering production efficiency and quality costs, the standard value for the abnormality rate under different scenarios is defined and entered into the system.

[0087] Welding tool images refer to visualized images obtained by capturing images of various core equipment involved in stator and circuit board welding operations (such as solder supply modules, constant temperature soldering irons, laser spot welding heads, wave soldering nozzles, positioning fixtures, etc.). The acquisition method here involves the system automatically sending a shooting command to the production line image acquisition device when the system determines that the anomaly rate exceeds a preset standard value. This commands the camera to capture images of key working components of each welding tool (such as the oxidation level of the soldering iron tip, the solder outlet channel of the solder nozzle, and the cleanliness of the laser head lens) from multiple angles with high precision.

[0088] If the anomaly rate is higher than the standard value, it indicates that most of the stator welding products in this batch are unqualified, which may be due to the welding tools being used for too long. Therefore, images of the welding tools are obtained.

[0089] Step 633: Obtain the welding tool status based on the welding tool image.

[0090] The condition of welding tools refers to the comprehensive status information of key components of various welding equipment, including their working status, wear level, cleanliness, and assembly accuracy, obtained through image analysis of welding tools. This information is obtained by first preprocessing the acquired welding tool images (denoising, enhancement, and component region segmentation), and then comparing the processed image features with the standard conditions of the welding tools one by one (e.g., no oxidation on the soldering iron tip, unobstructed solder delivery channel on the solder nozzle, clean laser head lens, and no offset of the fixture positioning reference). This identifies whether the tools have abnormalities such as component oxidation, blockage, wear, looseness, or positioning deviation.

[0091] Step 634: Find the corresponding cleaning solution based on the condition of the welding tools and execute it.

[0092] A cleaning plan refers to a scheme for cleaning or rinsing welding tools to remove impurities. The search method here involves those skilled in the art pre-planning common anomalies (such as soldering tip oxidation, solder nozzle clogging, laser lens contamination, and fixture solder residue) for different types of welding tools (e.g., constant temperature soldering irons, laser spot welding tips, solder supply nozzles). This is done in conjunction with the tool's material characteristics and working principle. Corresponding cleaning process parameters, operating steps, and a list of dedicated consumables are then entered into the system. Once the system obtains information about the welding tool and identifies the specific anomaly type, it automatically retrieves a matching cleaning plan from the mapping library. The execution method involves the system first converting the matched cleaning plan into executable equipment control instructions and manual operation guidelines. For automated cleaning equipment, control instructions containing cleaning duration, pressure and temperature parameters, and action paths are directly issued to drive the equipment to autonomously complete the cleaning plan.

[0093] Step 635: If the anomaly rate is lower than the standard value, obtain the next current stator category according to the stator sorting and find the corresponding welding material and weld it according to the corresponding welding method to obtain the welded finished product.

[0094] If the anomaly rate is lower than the standard value, it means that there are only a few anomalies in the batch of welded products, which may be minor errors during welding. Therefore, the next current stator category is obtained according to the stator sorting, and the corresponding welding material is found and welded according to the corresponding welding method to obtain the welded product.

[0095] The methods for finding and implementing corresponding cleaning solutions based on the condition of the welding tools include: Step 6340: Obtain the welding tool number based on the welding tool image.

[0096] The welding tool number refers to a unique identifier for the tool used to weld the stator. This is obtained by assigning a unique identifier to each welding tool and storing the corresponding tool appearance features. When an image of the welding tool is acquired, the system first extracts features from the image, identifying the tool's identifier or unique appearance features. Then, it matches the extracted features with data in the tool identification feature database. If a match is successful, the unique welding tool number corresponding to that tool can be obtained.

[0097] Step 6341: If the welding tool is in the preset high temperature condition, locate the corresponding cooling device based on the welding tool number and perform cooling.

[0098] High-temperature conditions refer to abnormal operating conditions in which the temperature of the core working components of a welding tool exceeds the normal operating temperature range or remains in an overheated state for an extended period during continuous operation. The method for obtaining information on high-temperature conditions involves those skilled in the art first determining the normal operating temperature range and overheating critical duration of the core components of each tool through multiple sets of durability tests, based on the working characteristics of different types of welding tools. The corresponding temperature and duration thresholds are then categorized and entered into the system according to tool model.

[0099] A cooling device is a specialized device used to reduce the temperature of overheated core components of welding tools, restoring them to their normal operating temperature range. The method for finding this device involves technicians pre-binding the serial numbers of various welding tools with the corresponding cooling device models (such as air-cooled heat sinks for soldering iron tips, water-cooled circulation modules for laser spot welding heads, and constant-temperature heat dissipation jackets for solder nozzles) and cooling parameters, and entering this information into the system's mapping library. When the system determines that a tool is overheating, it will retrieve the matching cooling device by tool serial number and then issue a start command to execute the cooling operation to complete the cooling process.

[0100] If the welding tool is in a high-temperature condition, it means that the welding tool temperature is too high. Continuing to weld may cause subsequent stator damage or substandard welding quality. Therefore, the corresponding cooling device should be located based on the welding tool number and the temperature should be reduced.

[0101] Step 6342: If the welding tool is in the preset welding material accumulation state, find the corresponding cleaning device and cleaning fluid according to the welding tool number.

[0102] Solder deposit accumulation refers to an abnormal condition where, during prolonged high-temperature operation, the core working components of a welding tool (such as the welding rod and soldering tip) undergo an oxidation reaction, forming an oxide layer on their surface due to prolonged exposure to high temperatures after the solder melts. This is accompanied by some solidified solder and oxides adhering to the component surface. The method for obtaining information on solder deposit accumulation involves technicians conducting multiple high-temperature durability tests on different welding tools and solder types (such as tin-lead solder and lead-free solder). Critical data such as the thickness of the oxidized solder adherence and the area of ​​agglomerates on the component surface are recorded for different operating durations. Typical visual characteristics of oxide adhesion are also identified (e.g., a dark brown oxide layer on the soldering tip and raised lumps at the end of the welding rod). These criteria are then categorized by tool model and entered into the system.

[0103] A cleaning device is a specialized piece of equipment used to precisely remove oxidized solder and solidified residue adhering to the surface of the core components of welding tools. A cleaning fluid is a specialized chemical agent used to dissolve and soften oxidized solder residue and oxide layers adhering to the surface of the core components of welding tools, assisting the cleaning device in improving cleaning effectiveness without damaging the tool substrate. The search method here involves those skilled in the art entering the model of the specialized cleaning device corresponding to various tools (such as an ultrasonic cleaner for soldering iron tips, a rotating wire brush for welding rods, or a high-pressure slag remover for nozzles), the type of compatible cleaning fluid (such as a weakly acidic cleaner for tin-lead solder, a chelating cleaning fluid for lead-free solder, or a weakly alkaline cleaning fluid for silver solder), and process parameters (such as cleaning time and cleaning fluid concentration) into the system. When the system determines that the welding tool is in a state of solder buildup, it searches for and matches a cleaning device suitable for the tool's structure and buildup level, and then determines the corresponding specialized cleaning fluid based on the type of solder currently compatible with the tool.

[0104] If the welding tool is in a state of welding material accumulation, it means that the welding tool has been used too many times and needs to be cleaned. Otherwise, the welding efficiency will be greatly reduced. Therefore, find the corresponding cleaning device and cleaning fluid according to the welding tool number.

[0105] Step 6343: Pour the cleaning fluid into the cleaning device and clean the welding tools corresponding to the welding tool numbers.

[0106] The system issues a quantitative dosing command based on the matched cleaning device model and cleaning fluid type, controls the automatic liquid injection module to mix the cleaning fluid precisely into the cleaning device, and then the system retrieves the corresponding tool fixing fixture parameters according to the welding tool number, drives the robotic arm to move the welding tool to be cleaned (such as soldering iron tip, welding rod) to the working position of the cleaning device. Then the cleaning device starts the operation according to the process parameters. When the indicators reach the preset threshold, the operation stops automatically, and the robotic arm moves the tool to the rinsing station for rinsing with clean water. After the hot air drying module removes the residual liquid, the tool is moved back to the original working position.

[0107] This also includes an optimization method for stator sorting, which includes: Step 68: Obtain the number of stators corresponding to the stator category.

[0108] The stator quantity refers to the total number of stators with the same category code determined by the system's image recognition. This quantity is obtained by the system automatically collecting and accumulating the number of stators entering the welding process under the same category code, using the code as a unique statistical identifier after determining the stator category code through image feature matching. This is done via counting sensors, barcode scanners, or material management modules at the front end of the production line.

[0109] Step 69: Obtain the corresponding number of welding materials based on the stator type.

[0110] The number of welding material units refers to a quantitative indicator, based on the amount of welding material required to complete the circuit board welding process for a single stator of a specific type. This is obtained by those skilled in the art through pre-determining the standard material usage required for welding a single stator of each type based on the number of solder joints, winding structure, and welding process requirements for different stator types, through process experiments. This standard amount is defined as the corresponding number of units and input into the system. When the system obtains the stator type, it automatically queries and retrieves the corresponding number of welding material units from the database.

[0111] Step 70: When the number of welding materials is greater than or equal to the number of stators, control the stator corresponding to the welding stator category to execute the welding scheme to obtain the welded finished product.

[0112] When the number of welding materials is greater than or equal to the number of stators, it means that the remaining welding materials are sufficient to weld stators of that category. Therefore, the welding scheme is executed for the stators corresponding to the welding stator category to obtain the welded finished product.

[0113] Step 71: When the number of welding materials is less than the number of stators, define the corresponding stator category as the stator category lacking welding materials.

[0114] The lack of welding material stator category means that the number of welding materials required for a single welding unit cannot cover the production quantity of the corresponding category of stator.

[0115] When the number of welding materials is less than the number of stators, it means that the remaining welding materials are insufficient to weld stators of this category. Therefore, the corresponding stator category is defined as the stator category lacking welding materials.

[0116] Step 72: Remove stator categories lacking welding materials from the stator sorting to obtain the final sort.

[0117] The final sort refers to the ordered queue formed by stator categories with sufficient soldering materials and capable of completing the circuit board soldering process, after removing stator categories lacking soldering materials. This is achieved by the system retrieving the stator sorting, then searching for the marked stator categories lacking soldering materials, removing these stators in batches from the sorting, and then retaining the relative order of the remaining stator categories with sufficient soldering materials and capable of completing the circuit board soldering process, thus generating a continuous ordered queue.

[0118] This also includes a method for controlling the execution of welding schemes when there is a lack of welding material stator categories, the method comprising: Step 710: Determine the temperature of the stator with missing solder and the quantity of solder already stored based on the type of stator lacking solder.

[0119] The stator temperature lacking welding material refers to the welding temperature of the stator lacking welding material. Here, the system directly matches and extracts the standard welding process temperature corresponding to the marked stator category lacking welding material. The number of existing welding material units refers to the total number of existing welding material units currently available for welding operations. The method for obtaining this is the same as that described in step 69, only the object being retrieved is different.

[0120] Step 711: Find the corresponding compatible material and the number of compatible materials based on the temperature of the missing stator.

[0121] Compatible materials refer to standard welding materials with similar physical and chemical properties to those of stators lacking solder, capable of performing welding operations at the missing stator temperature for that type of stator, and ensuring the quality and performance of stator circuit board solder joints. The search method here involves those skilled in the art identifying and selecting suitable alternative welding materials that meet the compatibility requirements based on standard welding materials and corresponding welding temperatures for different stator types through process experiments. These materials are then input into the system. Once the system obtains the missing stator temperature, it automatically searches the database to find and match usable alternative compatible material models and related information.

[0122] The number of compatible materials refers to the total number of alternative welding materials that match the stator temperature and performance of the standard welding materials for welding operations lacking welding materials, currently available in real-time inventory to replenish welding operations for stator categories lacking welding materials. The search method here is that after the system matches the corresponding compatible material model, it simultaneously retrieves the real-time stored data of that model of compatible material from the welding material inventory management module as the number of compatible materials.

[0123] Step 712: Calculate the final number of welding materials based on the existing number of welding materials and the number of compatible materials.

[0124] The final number of welding materials refers to the total number of existing standard welding materials for the stator category, combined with the number of matched compatible materials, which can be used for welding operations of this type of stator. This is calculated by adding the existing number of welding materials to the number of compatible materials.

[0125] Step 713: Find the corresponding compatible welding solution based on the final number of welding materials.

[0126] A compatible soldering scheme refers to an alternative soldering operation plan that ensures the soldering quality of the stator circuit board, based on the lack of solder materials for different stator types, the final number of solder materials, and the temperature of the missing stator. The search method here involves those skilled in the art developing multiple alternative compatible soldering schemes in advance, based on different stator types, solder material combinations, and temperature parameters, through process verification experiments. These schemes are then input into the system. Once the system calculates the final number of solder materials, it automatically searches the database, matches, and outputs the optimal scheme that best suits the current material conditions and process requirements.

[0127] Step 714: If the final number of welding materials is greater than or equal to the number of stators, control the stators corresponding to the missing welding materials stator categories to execute the compatible welding scheme.

[0128] If the final number of welding materials is greater than or equal to the number of stators, it means that adding the number of compatible materials is enough to complete the welding of this type of stator. Therefore, the stator corresponding to the stator type that lacks welding materials is controlled to perform a compatible welding scheme.

[0129] Step 715: If the final number of welding materials is less than the number of stators, do not control the stators corresponding to the missing welding materials to execute the compatible welding scheme.

[0130] If the final number of welding materials is less than the number of stators, it means that even with compatible materials, it is impossible to weld all stators of this category. Therefore, the compatible welding scheme is not controlled for stators corresponding to the category lacking welding materials.

[0131] Based on the same inventive concept, embodiments of the present invention provide a welding control system for an energy-saving freezer motor circuit board with a stator.

[0132] One example is a welding control system for an energy-saving freezer motor circuit board with a stator, comprising: The acquisition module is used to acquire stator images, welding images, the number of welded finished products, the number of abnormal finished products, and the number of stators.

[0133] A memory for storing a program for a welding control method of a circuit board for an energy-saving freezer motor with a stator.

[0134] The processor loads and executes programs from memory.

[0135] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0136] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A welding control method for a circuit board of an energy-saving freezer motor with a stator, characterized in that, include: Step 1: In response to a preset welding signal, acquire a stator image; Step 2: Determine the stator category based on the stator image; Step 3: Find the corresponding welding temperature and welding scheme according to the stator type; Step 4: Sort the stators corresponding to the stator categories based on the welding temperature to obtain the stator sorting; Step 5: Obtain the welding stator categories according to the stator sorting; Step 6: Control the stator corresponding to the welding stator category to execute the welding scheme to obtain the welded finished product.

2. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 1, characterized in that, Methods for controlling the stator to execute welding schemes corresponding to different stator categories to obtain welded finished products include: Step 60: Obtain the current stator category based on the stator sorting; Step 61: Find the corresponding welding material based on the current stator category; Step 62: Determine the welding method based on the welding material and the current stator type; Step 63: Weld the welding materials to the stator corresponding to the current stator type according to the welding method to obtain the welded finished product.

3. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 2, characterized in that, Also includes: Step 64: Obtain welding images; Step 65: Analyze the stator welding quality based on the welding images; Step 66: If the stator welding quality does not meet the preset standard quality, obtain the welding abnormality points based on the welding image; Step 67: Find and implement corresponding solutions based on welding anomalies.

4. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 3, characterized in that, Methods for finding corresponding solutions based on welding anomalies include: Step 670: Obtain the abnormal stator category based on the welding image; Step 671: Locate the corresponding welding material based on the abnormal stator category; Step 672: Determine the abnormal situation based on the welding abnormality points; Step 673: If the abnormal situation is the preset welding material shortage, determine the material replenishment plan as the solution based on the welding material and the finished welding product, and output it.

5. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 4, characterized in that, The method for finding corresponding solutions based on welding anomalies also includes: Step 674: If the abnormal situation is a preset situation of excess welding material, locate the corresponding material suction device based on the welding material; Step 675: Control the material suction device to suction the material to obtain the finished product to be re-welded; Step 676: Determine the re-welding scheme as a solution based on the finished product to be re-welded and the welding materials, and output it.

6. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 2, characterized in that, The method of welding welding materials to a stator corresponding to the current stator type according to the welding method to obtain a welded finished product also includes: Step 630: Obtain the number of welded finished products and the number of defective finished products; Step 631: Calculate the defect rate based on the number of welded finished products and the number of defective finished products; Step 632: If the anomaly rate is higher than the preset standard value, obtain the welding tool image; Step 633: Obtain the welding tool status based on the welding tool image; Step 634: Find and implement the corresponding cleaning plan based on the condition of the welding tools; Step 635: If the anomaly rate is lower than the standard value, obtain the next current stator category according to the stator sorting and find the corresponding welding material and weld it according to the corresponding welding method to obtain the welded finished product.

7. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 6, characterized in that, The methods for finding and implementing corresponding cleaning solutions based on the condition of the welding tools include: Step 6340: Obtain the welding tool number based on the welding tool image; Step 6341: If the welding tool is in a preset high-temperature condition, locate the corresponding cooling device based on the welding tool number and perform cooling. Step 6342: If the welding tool is in the preset welding material accumulation state, locate the corresponding cleaning device and cleaning fluid according to the welding tool number; Step 6343: Pour the cleaning fluid into the cleaning device and clean the welding tools corresponding to the welding tool numbers.

8. The welding control method for an energy-saving freezer motor circuit board with a stator according to claim 2, characterized in that, It also includes an optimization method for stator sorting, which includes: Step 68: Obtain the number of stators corresponding to the stator category; Step 69: Obtain the corresponding number of welding materials based on the stator type; Step 70: When the number of welding materials is greater than or equal to the number of stators, control the stator corresponding to the welding stator category to execute the welding scheme to obtain the welded finished product; Step 71: When the number of welding materials is less than the number of stators, define the corresponding stator category as the stator category lacking welding materials; Step 72: Remove stator categories lacking welding materials from the stator sorting to obtain the final sort.

9. A welding control method for a circuit board of an energy-saving freezer motor with a stator according to claim 8, characterized in that, It also includes a method for controlling the execution of welding schemes when there is a lack of welding material stator categories, the method comprising: Step 710: Determine the temperature of the stator with missing welding material and the quantity of welding material already stored based on the type of stator lacking welding material; Step 711: Find the corresponding compatible material and the quantity of compatible material based on the temperature of the missing stator; Step 712: Calculate the final number of welding materials based on the existing number of welding materials and the number of compatible materials; Step 713: Find the corresponding compatible welding solution based on the final number of welding materials; Step 714: If the final number of welding materials is greater than or equal to the number of stators, control the stators corresponding to the missing welding materials stator categories to execute the compatible welding scheme; Step 715: If the final number of welding materials is less than the number of stators, do not control the stators corresponding to the missing welding materials to execute the compatible welding scheme.

10. A welding control system for an energy-saving freezer motor circuit board with a stator, characterized in that, include: The acquisition module is used to acquire stator images, welding images, the number of welded finished products, the number of abnormal finished products, and the number of stators. A memory for storing a program for a welding control method for a circuit board of an energy-saving freezer motor with a stator as described in any one of claims 1 to 9; The processor loads and executes programs from memory.

Images