Aluminum profile multi-process automatic welding method and system

Abstract

The invention relates to the field of welding automation, and discloses an aluminum profile multi-process automatic welding method and system. The method includes: acquiring workpiece structure parameters to generate a weld recognition track and an initial welding track; scanning to obtain a weld space curve and calculating left-right deviation and height deviation; segmenting the welding seam based on the curve and the deviation, and judging full welding, intermittent welding, swing welding, spot welding and intersecting line welding to generate a welding process sequence; correcting the initial welding track according to the deviation, determining a welding parameter set by a welding data expert database, and issuing the welding parameter set to a digital arc welding power supply; and in the welding process, closed-loop correction and linkage compensation of welding parameters are carried out, and scanning data, correction, a process sequence, a parameter set and abnormal information are recorded. The system comprises a clamping and positioning module, a welding execution module, a welding power supply module, a welding seam scanning and tracking module and a welding control module.

Description

Technical Field

[0001] This invention relates to the field of welding automation, and specifically to a multi-process automatic welding method and system for aluminum profiles. Background Technology

[0002] Aluminum profiles, due to their light weight, corrosion resistance, and ease of forming, are widely used in rail transportation, automotive parts, building doors and windows, equipment frames, and photovoltaic supports. In actual production, aluminum profile workpieces are typically assembled from multiple profiles at certain intervals and angles to form frames or irregular structures. This results in a large number of welded joints, complex weld seam orientations, and the simultaneous presence of various weld seam types, including straight welds, short welds, intermittent welds, and intersecting welds, in different locations. To improve production efficiency and consistency, the industry is gradually adopting robotic arc welding combined with vision sensing and digital welding power supplies to automate the welding of aluminum profile workpieces.

[0003] Existing automated welding solutions for aluminum profiles typically generate welding trajectories through offline programming or teaching methods. Some solutions introduce laser vision to identify or track weld seams to compensate for clamping errors and workpiece dimensional deviations. However, due to factors such as clamping and positioning, profile spacing, weld seam assembly gaps, and thermal deformation, deviations can easily occur between the actual spatial position of the weld seam and the planned trajectory. Furthermore, in multi-process mixed welding scenarios, different weld seam segments have different requirements for welding current, voltage, welding speed, wire feed speed, and oscillation parameters. Relying solely on a single process parameter or manually switching processes can easily lead to inconsistent process matching during welding. While other solutions can perform weld seam tracking, they often focus on posture correction and lack a linkage compensation mechanism with welding parameters. Moreover, the segmentation judgment and scheduling rules for processes such as spot welding, intermittent welding, oscillating welding, and intersecting line welding are not uniform.

[0004] Therefore, in the application of existing technologies for automatic welding of aluminum profiles with multiple weld seams, multiple shapes, and multiple processes, there is still a core problem: how to accurately segment different weld seam segments within the same workpiece and match corresponding process parameters when there is a deviation between the actual spatial curve of the weld seam and the planned trajectory, and at the same time achieve trajectory correction and coordinated control of welding parameters during the welding process to ensure the stability and consistency of the automatic welding process of multiple processes. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an automated welding method and system for aluminum profiles using multiple processes, thereby resolving the technical problems existing in the prior art.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0007] A multi-process automated welding method for aluminum profiles includes the following steps:

[0008] S1. Establish welding task: Obtain the structural parameters of the aluminum profile workpiece to be welded. The structural parameters include at least the workpiece length, width, height, number of aluminum profiles, and aluminum profile spacing parameters. The welding control system generates weld recognition trajectory and initial welding trajectory based on the structural parameters.

[0009] S2. Workpiece clamping and initialization: The workpiece is clamped and positioned on the welding platform, and the welding control system controls the welding robot to complete the zeroing and welding torch posture initialization.

[0010] S3. Weld Scanning and Deviation Acquisition: The welding control system controls the laser vision integrated weld tracker to scan the area to be welded along the weld recognition trajectory, obtain the weld space curve, and calculate the deviation distribution of the weld space curve relative to the initial welding trajectory. The deviation distribution includes at least left and right deviations and height deviations.

[0011] S4. Multi-process discrimination and segmented scheduling: Based on the weld space curve and deviation distribution, the welding control system segments the weld and discriminates the process type of each segment, generating the corresponding welding process sequence. The process types include at least full welding, intermittent welding, oscillating welding, spot welding and intersection welding.

[0012] S5. Trajectory secondary generation and process parameter distribution: The welding control system performs segment-level correction on the initial welding trajectory based on the deviation distribution, generates the corrected welding trajectory corresponding to each weld segment, and determines the welding parameter set corresponding to each weld segment based on the welding data expert database, and distributes the welding parameter set to the digital arc welding power source.

[0013] S6. Closed-loop tracking welding and parameter linkage compensation: Under the output control of the digital arc welding power supply, the welding robot drives the push-pull wire welding torch to perform welding along the corrected welding trajectory; during the welding process, the laser vision integrated weld seam tracker outputs the weld seam deviation in real time, and the welding control system performs closed-loop correction of the welding torch posture according to the real-time weld seam deviation, and simultaneously performs linkage compensation for at least one welding parameter. The welding parameters include at least one or more of the following: welding speed, welding current, welding voltage, wire feed speed, oscillation amplitude, oscillation frequency, and oscillation center.

[0014] S7. Welding Data Recording: The welding control system records weld scanning data, deviation correction amount, welding process sequence, welding parameter set, and welding process abnormal information.

[0015] Preferably, S1 includes:

[0016] Obtain the structural parameters of the aluminum profile workpiece to be welded, including the workpiece length, width, height, number of aluminum profiles, and spacing parameters of the aluminum profiles;

[0017] The welding control system establishes a parametric geometric model of the workpiece based on the structural parameters, and determines the centerline of the weld to be welded in the parametric geometric model;

[0018] The welding control system generates multiple weld recognition target poses along the weld centerline at a preset sampling interval. The weld recognition trajectory consists of multiple weld recognition target poses, and each weld recognition target pose includes the spatial position and attitude of the laser vision integrated weld tracker.

[0019] The welding control system applies a tool center point offset corresponding to the push-pull wire welding gun to the target pose of each weld seam, generating a corresponding welding target pose. The initial welding trajectory consists of multiple welding target poses, and each welding target pose includes the spatial position and attitude of the push-pull wire welding gun.

[0020] Preferably, S2 includes:

[0021] Place the workpiece in the clamping reference area of ​​the welding platform and clamp and fix the workpiece with a fixture;

[0022] The welding control system controls the welding robot to sequentially execute the joint homing action and the tool coordinate system loading action, wherein the tool coordinate system is the tool center point coordinate system of the push-pull wire welding gun;

[0023] The welding control system controls the welding robot to move the push-pull wire welding torch to a preset initial standby position. The initial standby position corresponds to the first weld recognition target position of the weld recognition trajectory, and the spatial position and attitude of the initial standby position are used as the starting attitude for subsequent weld scanning.

[0024] Preferably, S3 includes:

[0025] The welding control system controls the welding robot to carry the laser vision integrated weld seam tracker to each weld seam recognition target pose in the weld seam recognition trajectory in sequence, and collects the weld seam contour data of the area to be welded at each weld seam recognition target pose.

[0026] The welding control system extracts weld feature points based on weld contour data, transforms each weld feature point into the base coordinate system of the welding robot, and connects them in the order of the weld recognition trajectory to form a weld space curve.

[0027] The welding control system determines trajectory reference points that correspond one-to-one with the weld feature points on the initial welding trajectory, and calculates the displacement difference vector between each weld feature point and the corresponding trajectory reference point.

[0028] The welding control system converts the displacement difference vector into the tool center point coordinate system of the push-pull wire welding gun. The tool center point coordinate system includes a first axis set along the welding direction, a second axis set perpendicular to the welding direction and parallel to the workpiece surface, and a third axis set perpendicular to the workpiece surface.

[0029] The welding control system determines the left and right deviations by projecting the displacement difference vector onto the second axis and the height deviation by projecting the displacement difference vector onto the third axis, in order to obtain the deviation distribution.

[0030] Preferably, S4 includes:

[0031] The welding control system calculates the point spacing sequence and curvature sequence between adjacent weld feature points based on the weld space curve;

[0032] The welding control system uses feature points with a point spacing greater than a first distance threshold as interval breakpoints and feature points with a curvature greater than a first curvature threshold as turning breakpoints.

[0033] The welding control system divides the weld space curve into multiple continuous weld segments based on interval breakpoints and turning breakpoints.

[0034] The welding control system determines the process type of continuous weld segments according to a preset discrimination sequence, which is spot welding, intersection welding, oscillation welding, and full welding.

[0035] Among them, when the length of a continuous weld segment is not greater than the second length threshold, the continuous weld segment is determined as a spot weld segment;

[0036] When the curvature of a continuous weld segment is greater than the second curvature threshold, and the change of the weld feature point corresponding to the continuous weld segment in the three coordinate axes of the welding robot base coordinate system is greater than the second distance threshold, the continuous weld segment is determined as an intersecting line welding segment.

[0037] When the maximum absolute value of the left and right deviations of a continuous weld segment is greater than the first deviation threshold or the maximum absolute value of the height deviation is greater than the second deviation threshold, the continuous weld segment is defined as an oscillating weld segment.

[0038] When the length of a continuous weld segment is not less than the first length threshold and the curvature of the segment is not greater than the first curvature threshold, the continuous weld segment is defined as a full weld segment.

[0039] The welding control system identifies at least two consecutive weld segments whose interval length is within a preset range based on the interval length between adjacent consecutive weld segments, and combines the at least two consecutive weld segments into a discontinuous weld segment group.

[0040] The welding control system identifies the intermittent weld segment group as the intermittent weld segment and generates a welding process sequence according to the order of multiple continuous weld segments and the intermittent weld segment group in the weld space curve.

[0041] Preferably, S5 includes:

[0042] For each weld segment, the welding control system determines the corresponding trajectory segment in the initial welding trajectory and acquires multiple trajectory points of that trajectory segment.

[0043] The welding control system converts the left and right deviations and height deviations that correspond one-to-one with multiple trajectory points in the deviation distribution into correction values, and performs translation compensation on the spatial positions of multiple trajectory points based on the correction values ​​to generate the correction trajectory points corresponding to the weld segment.

[0044] The welding control system uses correction trajectory points to form the correction welding trajectory corresponding to the weld segment in sequence.

[0045] The welding control system is based on a welding data expert database. According to the process type, length and curvature of the weld segment, it retrieves the welding parameter set corresponding to the weld segment from the preset parameter table. The welding parameter set includes at least welding current, welding voltage, welding speed and wire feed speed.

[0046] The welding control system associates the welding parameter set corresponding to each weld segment with the welding process sequence and forms a process parameter release. Based on the process parameter release, the welding parameter set is sent to the digital arc welding power source.

[0047] Preferably, S6 includes:

[0048] The welding control system acquires the real-time weld deviation output by the laser vision integrated weld tracker at a preset control cycle, and converts the real-time weld deviation to the tool center point coordinate system of the push-pull wire welding gun to obtain the corresponding left and right deviations and height deviations.

[0049] The welding control system calculates the welding torch posture correction amount based on the left and right deviations and the height deviations. The welding torch posture correction amount includes at least the position correction amount. The welding control system superimposes the position correction amount onto the position parameters of the welding target posture corresponding to the current welding moment in the correction welding trajectory, generates the corrected welding target posture, and sends the corrected welding target posture to the welding robot.

[0050] Within the same control cycle of obtaining the real-time weld deviation, the welding control system calculates the welding parameter compensation amount based on the deviation amplitude of the real-time weld deviation. The welding parameter compensation amount is the product of the deviation amplitude and the preset compensation coefficient. The welding control system superimposes the welding parameter compensation amount onto at least one welding parameter in the welding parameter set corresponding to the weld segment to form a compensated welding parameter set, and sends the compensated welding parameter set to the digital arc welding power source through the collaborative control interface.

[0051] Preferably, S7 includes:

[0052] The welding control system establishes welding batch records for the workpiece and assigns weld segment identifiers to multiple weld segments.

[0053] The welding control system writes the weld scanning data into the welding batch record. The weld scanning data includes the point set data of the weld space curve and the left and right deviations and height deviations corresponding to the point set data.

[0054] The welding control system writes the deviation correction amount into the welding batch record. The deviation correction amount includes the welding torch posture correction amount and the welding parameter compensation amount corresponding to each control cycle.

[0055] The welding control system associates the welding process sequence with the weld segment identifier and writes it into the welding batch record;

[0056] The welding control system writes the welding parameter set into the welding batch record. The welding parameter set includes the welding current, welding voltage, welding speed, wire feed speed corresponding to each weld segment, as well as the oscillation amplitude, oscillation frequency and oscillation center corresponding to the oscillation welding segment.

[0057] The welding control system writes welding process abnormal information into the welding batch record. The welding process abnormal information includes arc establishment abnormality, wire feeding abnormality, weld tracker data invalidity abnormality, welding power supply overcurrent abnormality, and welding power supply overvoltage abnormality. After adding a timestamp to the welding batch record, it is stored in the storage unit of the welding control system.

[0058] Preferably, the operating modes of the laser vision integrated weld seam tracker in S3 and S6 include:

[0059] When S3 is executed, the welding control system controls the laser vision integrated weld tracker to be in laser vision mode to collect weld contour data and form weld space curve.

[0060] When S6 is executed, the welding control system controls the laser vision integrated weld seam tracker to be in laser tracking mode to output real-time weld seam deviation;

[0061] When invalid abnormality of weld seam tracker data is detected within K consecutive control cycles, the welding control system controls the welding robot to stop welding movement along the corrected welding trajectory, and controls the laser vision integrated weld seam tracker to return to laser vision mode, and re-executes S3 on the current weld seam segment to update the deviation distribution, where K is a preset positive integer;

[0062] The handling of wire feeding abnormalities in S6 includes:

[0063] The welding control system collects the wire feeding speed feedback value and wire feeding command value of the push-pull wire welding gun within the control cycle, and calculates the difference between the two.

[0064] When the absolute value of the difference is greater than the first wire feeding deviation threshold and the duration reaches the first duration threshold, the welding control system determines that a wire feeding abnormality has occurred and controls the digital arc welding power supply to execute an arc stop command.

[0065] After the welding control system executes the arc stop command, it controls the push-pull wire welding torch to perform a reverse wire retraction action. The retraction length of the reverse wire retraction action is the preset retraction length.

[0066] After completing the reverse wire retraction action, the welding control system controls the push-pull wire welding torch to resume forward wire feeding and controls the digital arc welding power supply to restart the arc, continuing to perform welding along the corrected welding target posture.

[0067] An automated welding system for aluminum profiles with multiple processes includes: a clamping and positioning module for clamping and positioning the aluminum profile workpiece to be welded;

[0068] The welding execution module is used to drive the push-pull wire welding gun to perform welding according to the welding trajectory;

[0069] Welding power supply module, used to output welding voltage and welding current;

[0070] The weld scanning and tracking module is used to scan the area to be welded and output the weld deviation;

[0071] The welding control module includes a processor, a memory, and a welding data expert library, preset parameter tables, and control instructions stored in the memory. The welding control module is used for:

[0072] Obtain the structural parameters of the aluminum profile workpiece to be welded. The structural parameters include at least the workpiece length, width, height, number of aluminum profiles, and spacing parameters of the aluminum profiles.

[0073] Generate weld identification trajectory and initial welding trajectory based on structural parameters;

[0074] The control weld scanning and tracking module scans the area to be welded along the weld identification trajectory to obtain the weld space curve, and calculates the deviation distribution of the weld space curve relative to the initial welding trajectory. The deviation distribution includes at least left and right deviations and height deviations.

[0075] Based on the weld space curve and deviation distribution, the weld is segmented and the process type of each segment is determined to generate a welding process sequence. The process types include at least full welding, intermittent welding, oscillating welding, spot welding and intersection welding.

[0076] Based on the deviation distribution, the initial welding trajectory is corrected at the segment level to generate the corrected welding trajectory corresponding to each segment of the weld, and the welding parameter set corresponding to each segment of the weld is determined based on the welding data expert database.

[0077] The control welding execution module performs welding along the corrected welding trajectory, and during the welding process, it performs closed-loop correction of the welding torch posture based on the real-time weld deviation output by the weld scanning and tracking module, while simultaneously performing linkage compensation for at least one welding parameter.

[0078] Record weld scan data, deviation correction amount, welding process sequence, welding parameter set, and welding process abnormal information.

[0079] In summary, the present invention has the following main beneficial effects:

[0080] This invention establishes a parametric geometric model based on workpiece structural parameters and generates a weld identification trajectory and an initial welding trajectory, thereby achieving the goal of uniformly constraining the weld position and trajectory point sequence during the welding task establishment stage. By scanning the weld under the weld identification trajectory and forming a weld space curve, the actual weld geometry of the area to be welded is converted into spatial data that can be used for trajectory correction. By calculating the left and right deviations and height deviations of the weld space curve relative to the initial welding trajectory, the weld deviation is introduced into subsequent segmented discrimination and secondary trajectory generation in a quantifiable distribution form, thus establishing a one-to-one correspondence between weld identification, deviation acquisition, and trajectory planning, reducing the risk of trajectory deviation caused by clamping errors and the accumulation of profile dimensions.

[0081] This invention achieves the purpose of dividing the weld into continuous weld segments by calculating the point spacing sequence and curvature sequence based on the weld space curve and setting interval breakpoints and turning breakpoints. By determining the process type of spot welding, intersection welding, oscillating welding and full welding according to the preset discrimination order of the continuous weld segments, and identifying the discontinuous weld segment group based on the interval length between adjacent continuous weld segments, the invention achieves the purpose of multi-process segmented scheduling in the weld of the same workpiece. By associating the segmentation results with the welding process sequence and outputting the process parameter output table, the invention achieves the purpose of consistent scheduling of process types and parameter sets of different weld segments, thereby reducing the process matching deviation that occurs during the switching process of multi-process mixed welds and improving the stability and consistency of the welding process.

[0082] The present invention achieves the purpose of directly mapping the scanning deviation into the welding execution trajectory by performing segment-level correction on the initial welding trajectory according to the deviation distribution and generating a corrected welding trajectory; by real-time outputting the weld deviation during the welding process and performing closed-loop deviation correction on the torch pose, and simultaneously performing linkage compensation on at least one welding parameter among the welding speed, welding current, welding voltage, wire feeding speed, swing amplitude, swing frequency, and swing center, it achieves the purpose of establishing a synchronous control relationship between trajectory deviation correction and welding output; by recording the weld scan data, deviation correction amount, welding process sequence, welding parameter set, and abnormal information during the welding process, it achieves the purpose of forming a data closed-loop record corresponding to the welding batch, thereby facilitating the traceability of the parameter consistency during the welding process and supporting the iterative update of the subsequent process parameter table. BRIEF DESCRIPTION OF THE DRAWINGS

[0083] Figure 1 is a flowchart of the method of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0084] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0085] Embodiment 1

[0086] Refer to Figure 1 , a multi-process automatic welding method for aluminum profiles, including the following steps: S1. Establish a welding task: Obtain the structural parameters of the aluminum profile workpiece to be welded, and the structural parameters at least include the workpiece length dimension, width dimension, height dimension, number of aluminum profiles, and aluminum profile spacing parameter; the welding control system generates a weld recognition trajectory and an initial welding trajectory based on the structural parameters;

[0087] S2. Workpiece clamping and initialization: Clamp and position the workpiece on the welding platform, and the welding control system controls the welding robot to complete zero return and torch pose initialization;

[0088] S3. Weld scan and deviation acquisition: The welding control system controls the laser vision integrated weld tracker to scan the to-be-welded area along the weld recognition trajectory, obtain the weld space curve, and calculate the deviation distribution of the weld space curve relative to the initial welding trajectory. The deviation distribution at least includes left-right deviation and height deviation;

[0089] S4. Multi-process discrimination and segmented scheduling: Based on the weld space curve and deviation distribution, the welding control system segments the weld and discriminates the process type of each segment, generating the corresponding welding process sequence. The process types include at least full welding, intermittent welding, oscillating welding, spot welding and intersection welding.

[0090] S5. Trajectory secondary generation and process parameter distribution: The welding control system performs segment-level correction on the initial welding trajectory based on the deviation distribution, generates the corrected welding trajectory corresponding to each weld segment, and determines the welding parameter set corresponding to each weld segment based on the welding data expert database, and distributes the welding parameter set to the digital arc welding power source.

[0091] S6. Closed-loop tracking welding and parameter linkage compensation: Under the output control of the digital arc welding power supply, the welding robot drives the push-pull wire welding torch to perform welding along the corrected welding trajectory; during the welding process, the laser vision integrated weld seam tracker outputs the weld seam deviation in real time, and the welding control system performs closed-loop correction of the welding torch posture according to the real-time weld seam deviation, and simultaneously performs linkage compensation for at least one welding parameter. The welding parameters include at least one or more of the following: welding speed, welding current, welding voltage, wire feed speed, oscillation amplitude, oscillation frequency, and oscillation center.

[0092] S7. Welding Data Recording: The welding control system records weld scanning data, deviation correction amount, welding process sequence, welding parameter set, and welding process abnormal information.

[0093] The welding control system acquires the structural parameters of the aluminum profile workpiece to be welded, including the workpiece length dimension. Workpiece width dimensions Workpiece height dimensions Quantity of aluminum profiles and aluminum profile spacing parameters .in, This refers to the center-to-center distance or edge distance between adjacent aluminum profiles in the clamping reference direction, used to determine the relative arrangement of the aluminum profiles.

[0094] The welding control system establishes a parametric geometric model of the workpiece based on the structural parameters, and determines the centerline of the weld seam within this model. The weld centerline is expressed as an arc length parameter.

[0095] ;

[0096] in, Let be the spatial position vector of the weld centerline. For arc length parameters, This is the total arc length of the centerline of the weld.

[0097] Welding control system set preset sampling interval And perform equal arc length sampling on the weld centerline:

[0098] ;

[0099] in, For sampling sequence number, This is the sampling termination number. The sampling point is obtained from this.

[0100] ;

[0101] The welding control system uses each sampling point Constructing weld seam identification target pose Each weld seam identification target pose includes the spatial position and orientation of the integrated laser vision weld seam tracker, and the weld seam identification trajectory is determined by... Composed in sequence.

[0102] Preset tool center point offset vector in welding control system The A fixed geometric offset is provided for the measurement coordinate origin of the laser vision integrated weld seam tracker to the center point of the push-pull wire welding gun tool.

[0103] For each weld seam, identify the target pose. The welding control system applies the bias vector to obtain the welding target pose. and with The initial welding trajectory is formed sequentially. At this point, the generation of the weld identification trajectory and the initial welding trajectory is complete.

[0104] The workpiece is placed within the clamping reference area of ​​the welding platform and clamped and fixed using fixtures. The clamping reference area is defined by the reference edge and reference positioning surface of the welding platform, so that the workpiece forms a defined clamping reference position within the reachable space of the welding robot.

[0105] The welding control system controls the welding robot to sequentially perform joint homing actions, returning each joint of the welding robot to a preset zero position. Subsequently, the welding control system loads the tool coordinate system of the push-pull wire welding torch, which is the coordinate system of the tool center point of the push-pull wire welding torch, for subsequent trajectory planning, deviation calculation, and posture correction.

[0106] The welding control system controls the welding robot to move the push-pull wire welding torch to a preset initial standby position. The initial standby position corresponds to the first weld recognition target position of the weld recognition trajectory and serves as the starting position for subsequent weld scanning.

[0107] The welding control system controls the welding robot, carrying an integrated laser vision weld tracker, to sequentially reach each weld recognition target pose on the weld recognition trajectory. At each weld recognition target pose, it collects weld contour data of the area to be welded. This contour data is denoted as... .

[0108] The welding control system uses weld contour data Extracting weld feature points The extraction of weld feature points is achieved using any of the following determination rules:

[0109] a) Identify the two edge points in the weld contour data, and take the midpoint of the two edge points as the weld feature point;

[0110] b) Identify the lowest point of the bevel in the weld profile data and use the lowest point of the bevel as the weld feature point.

[0111] Connect the feature points of each weld in the order of the weld identification trajectory to form a set of spatial curve points of the weld:

[0112] ;

[0113] in, This represents the number of weld feature points.

[0114] To standardize the deviation calculation benchmark, the welding control system adopts the welding robot's base coordinate system. As a global reference coordinate system; the coordinate system of the center point of the push-pull wire welding gun tool is adopted. As a deviation projection coordinate system The origin is the center point of the push-pull wire welding gun tool.

[0115] exist The three axes are defined as follows: First axis Set along the welding direction; second axis The third axis is positioned perpendicular to the welding direction and parallel to the workpiece surface. It is set perpendicular to the workpiece surface.

[0116] The welding control system determines trajectory reference points on the initial welding trajectory that correspond one-to-one with the characteristic points of the weld. And calculate the displacement difference vector:

[0117] ;

[0118] in, For weld feature points at coordinates in For the corresponding trajectory reference point in coordinates in For the displacement difference vector in The representation in [the text]. Transform the displacement difference vector to [the appropriate value]. get:

[0119] ;

[0120] in, for relatively The rotation matrix, For the displacement difference vector in The representation in the text. The welding control system will... Second axis The directional component is determined as the left and right deviation. On the third axis The directional component is determined as the height deviation:

[0121] ;

[0122] in, For the first The left and right deviation of each position For the first Height deviation at each location for exist Components of the axis, for exist The components of the axis. This yields the deviation distribution. .

[0123] Welding control system based on weld space curve point set Calculate the spacing between characteristic points of adjacent welds:

[0124] ;

[0125] in, The distance between adjacent feature points. The Euclidean norm is used. Simultaneously, the discrete curvature sequence is calculated, using the three-point method for curvature:

[0126] ;

[0127] in, For discrete curvature values, This refers to the vector cross product operation.

[0128] The welding control system stores the first distance threshold. With the first curvature threshold .

[0129] when When, the corresponding position is used as an interval breakpoint; when When the time is right, the corresponding position will be taken as the turning point.

[0130] The welding control system divides the weld space curve into multiple continuous weld segments based on the aforementioned interval breakpoints and turning breakpoints. Each continuous weld segment consists of a sequence of continuous points, and adjacent continuous weld segments are separated by interval breakpoints or turning breakpoints. The segment length is calculated for each continuous weld segment.

[0131]

[0132] in, This is the length of the segment.

[0133] Calculate the maximum curvature of this segment. .

[0134] Calculate the deviation statistic for this segment:

[0135] ;

[0136] The welding control system stores the first length threshold. Second length threshold Second curvature threshold Second distance threshold First deviation threshold With the second deviation threshold And determine the process type of the continuous weld segment according to a preset discrimination order, wherein the preset discrimination order is spot welding, intersection welding, oscillating welding, and full welding: a) When At that time, it was determined to be a spot welding section;

[0137] b) When Furthermore, the weld feature points corresponding to this continuous weld segment are in the welding robot's base coordinate system. The changes in the directions of the three coordinate axes are respectively greater than When the intersection line is welded, it is determined to be the segment; the change amount is the difference between the maximum and minimum values ​​of the point set of the segment in each coordinate axis direction;

[0138] c) When or At that time, it was determined to be an oscillating welding segment;

[0139] d) When and At that time, it is determined to be a full weld section. The interval length is calculated for adjacent continuous weld sections:

[0140] ;

[0141] in, For the first Segment end feature points, For the first Segment starting feature point, This refers to the interval length between the two segments. The welding control system stores a preset interval range. .

[0142] When at least two adjacent consecutive weld segments meet their interval length When, the at least two continuous weld segments are combined into an intermittent weld segment group, and the intermittent weld segment group is defined as an intermittent weld segment.

[0143] The welding control system writes continuous weld segments and intermittent weld segments into the welding process sequence according to the order of the weld space curve. Each item in the welding process sequence corresponds one-to-one with the process type of the corresponding weld segment. The process types include full welding, intermittent welding, oscillating welding, spot welding and intersecting line welding.

[0144] For each weld segment, the welding control system determines the corresponding trajectory segment in the initial welding trajectory and obtains the trajectory point sequence of that segment. Each trajectory point contains both spatial position and orientation.

[0145] The welding control system identifies the left and right deviations in the deviation distribution and assigns them one-to-one correspondences to each trajectory point. and height deviation Converted to Correction vector in:

[0146] ;

[0147] in, This is the position correction amount for the trajectory points in the tool coordinate system. Switch to get:

[0148] ;

[0149] Perform translation compensation on the initial trajectory point position:

[0150] ;

[0151] in, For the initial trajectory point at The position in the middle, To correct the trajectory points at The position within the weld seam. The welding control system maintains the trajectory point attitude matrix consistent with the initial trajectory, and sequentially assembles the corrected welding trajectory for that weld segment.

[0152] The welding control system has a built-in welding data expert database, which stores welding parameter tables corresponding to process type, segment length, and segment curvature. Based on the process type, segment length, and segment curvature of the weld segment, the welding control system retrieves the corresponding welding parameter set from the preset parameter tables.

[0153] ;

[0154] in, For welding current, For welding voltage, For welding speed, This refers to the wire feeding speed.

[0155] When the weld segment is determined to be a swing weld segment, the welding parameter set is expanded as follows:

[0156] ;

[0157] in, The amplitude of the swing. The oscillation frequency, This represents the offset of the swing center.

[0158] The welding control system associates the welding parameter set corresponding to each weld segment with the welding process sequence to form a process parameter release, and sends the welding parameter set to the digital arc welding power source according to the process parameter release.

[0159] Under the output control of the digital arc welding power source, the welding robot drives the push-pull wire welding torch to perform welding along the corrected welding trajectory. The welding control system executes the corresponding process for each weld segment in sequence according to the welding process sequence.

[0160] Welding control system setting control cycle The real-time weld deviation output by the integrated laser vision weld tracker is acquired within each control cycle. And construct the deviation vector:

[0161] ;

[0162] in, For the first The real-time deviation vector for each control cycle. The welding control system calculates the welding torch pose correction based on the real-time deviation vector. The pose correction includes at least the position correction, which is compensated proportionally.

[0163] ;

[0164] in, This is the position correction amount in the tool coordinate system. The preset position compensation coefficient will be used. The welding control system will... Switch to The position parameters are then superimposed onto the current welding target pose to generate a corrected welding target pose, which is then sent to the welding robot to perform closed-loop correction.

[0165] The welding control system calculates the deviation amplitude:

[0166] ;

[0167] in, For the first The deviation amplitude for each control cycle. The welding control system calculates the welding parameter compensation based on the deviation amplitude:

[0168] ;

[0169] in, The welding parameters to be compensated, To correspond to the preset compensation coefficient, This is the compensation amount for welding parameters.

[0170] The welding control system superimposes the welding parameter compensation amount onto at least one parameter in the welding parameter set for the weld segment to form a compensated welding parameter set, and sends it to the digital arc welding power source through a collaborative control interface. The compensated welding parameters can be any one or more of the following: welding speed, welding current, welding voltage, wire feed speed, oscillation amplitude, oscillation frequency, or oscillation center.

[0171] The weld seam tracker is in laser vision mode to acquire weld seam contour data and form weld seam spatial curves; the weld seam tracker is in laser tracking mode to output real-time weld seam deviation.

[0172] Welding control system setting judgment parameters As a preset positive integer, when consecutive When the weld tracker detects an invalid or abnormal weld data during a control cycle, the welding control system controls the welding robot to stop welding along the corrected welding trajectory, and controls the weld tracker to switch to laser vision mode. The system then re-scans and acquires the weld for the current weld segment to update the deviation distribution, and regenerates the corrected welding trajectory for the current weld segment based on the updated deviation distribution before resuming the welding motion.

[0173] The welding control system acquires the wire feeding speed command value of the push-pull wire welding torch within the control cycle. Feedback value of wire feeding speed And calculate the difference:

[0174] ;

[0175] in, This represents the difference in wire feeding speed.

[0176] The welding control system is set with a first wire feed deviation threshold. With the first duration threshold .when And the duration reached At that time, the welding control system determines that an abnormal wire feeding has occurred and controls the digital arc welding power supply to execute an arc stop command.

[0177] After the welding control system stops the arc, it controls the push-pull wire welding torch to perform a reverse wire retraction action, with the retraction length set to the preset retraction length. After completing the reverse wire retraction action, the welding control system controls the push-pull wire welding torch to resume forward wire feeding and controls the digital arc welding power supply to reignite the arc, continuing to perform welding along the corrected welding target posture.

[0178] The welding control system establishes welding batch records for the workpiece and assigns weld segment identifiers to multiple weld segments. The welding control system records the following data and writes it into the welding batch record:

[0179] a) Weld scan data, including point set data of weld space curves. and the left and right deviations corresponding to the point set data. and height deviation ;

[0180] b) Deviation correction amount, including welding torch posture correction amount and welding parameter compensation amount corresponding to each control cycle;

[0181] c) The welding process sequence and its correspondence with the weld segment identification;

[0182] d) Welding parameter set, including welding current, welding voltage, welding speed, wire feed speed, and the oscillation amplitude, oscillation frequency and oscillation center corresponding to the oscillation welding section;

[0183] e) Abnormal information in the welding process, including abnormal arc establishment, abnormal wire feeding, abnormal invalid weld tracker data, abnormal welding power supply overcurrent, and abnormal welding power supply overvoltage.

[0184] The welding control system adds a timestamp to the above data in the welding batch record and stores it in the storage unit of the welding control system.

[0185] Example 2

[0186] This embodiment provides an automatic welding system for aluminum profiles with multiple processes, used to perform the method described in Embodiment 1. The system includes: a clamping and positioning module, a welding execution module, a welding power supply module, a weld scanning and tracking module, and a welding control module.

[0187] The welding control module includes a processor, a memory, a welding data expert library, a preset parameter table, and control instructions stored in the memory. When executing control instructions, the welding control module completes the acquisition of structural parameters, generation of weld identification trajectory and initial welding trajectory, generation of weld space curve, calculation of deviation distribution, multi-process discrimination and segmented scheduling, generation of corrected welding trajectory, retrieval and distribution of welding parameter set, closed-loop correction and parameter linkage compensation, and recording of welding data.

[0188] The clamping and positioning module is used for clamping and positioning the aluminum profile workpiece to be welded.

[0189] The welding execution module is used to drive the push-pull wire welding gun to perform welding according to the welding trajectory;

[0190] Welding power supply module, used to output welding voltage and welding current;

[0191] The weld scanning and tracking module is used to scan the area to be welded and output the weld deviation;

[0192] The welding control module includes a processor, a memory, and a welding data expert library, preset parameter tables, and control instructions stored in the memory. The welding control module is used for:

[0193] Obtain the structural parameters of the aluminum profile workpiece to be welded. The structural parameters include at least the workpiece length, width, height, number of aluminum profiles, and spacing parameters of the aluminum profiles.

[0194] Generate weld identification trajectory and initial welding trajectory based on structural parameters;

[0195] The control weld scanning and tracking module scans the area to be welded along the weld identification trajectory to obtain the weld space curve, and calculates the deviation distribution of the weld space curve relative to the initial welding trajectory. The deviation distribution includes at least left and right deviations and height deviations.

[0196] Based on the weld space curve and deviation distribution, the weld is segmented and the process type of each segment is determined to generate a welding process sequence. The process types include at least full welding, intermittent welding, oscillating welding, spot welding and intersection welding.

[0197] Based on the deviation distribution, the initial welding trajectory is corrected at the segment level to generate the corrected welding trajectory corresponding to each segment of the weld, and the welding parameter set corresponding to each segment of the weld is determined based on the welding data expert database.

[0198] The control welding execution module performs welding along the corrected welding trajectory, and during the welding process, it performs closed-loop correction of the welding torch posture based on the real-time weld deviation output by the weld scanning and tracking module, while simultaneously performing linkage compensation for at least one welding parameter.

[0199] Record weld scan data, deviation correction amount, welding process sequence, welding parameter set, and welding process abnormal information.

[0200] This invention uses a welding control system as the core control unit, and completes the automatic welding of aluminum profiles through multiple processes in the order of task modeling, weld identification, deviation calculation, multi-process discrimination, trajectory secondary generation, closed-loop correction and parameter linkage, and data recording.

[0201] During the welding task setup phase, the welding control system acquires the structural parameters of the aluminum profile workpiece to be welded and establishes a parametric geometric model based on these parameters. The centerline of the weld seam is then determined within this model. The welding control system generates the weld seam identification target pose along the weld seam centerline at preset sampling intervals, forming a weld seam identification trajectory. Simultaneously, an offset of the tool center point corresponding to the push-pull wire welding torch is applied to the weld seam identification target pose, generating the welding target pose and forming an initial welding trajectory. This establishes a one-to-one correspondence between the weld seam identification trajectory and the initial welding trajectory in terms of sampling sequence numbers.

[0202] During the workpiece clamping and initialization stage, the workpiece is clamped and positioned on the welding platform and fixed by the fixture. The welding control system controls the welding robot to complete the zeroing and welding gun posture initialization, loads the tool center point coordinate system of the push-pull wire welding gun, and moves the push-pull wire welding gun to the initial standby position, providing a unified motion reference and coordinate reference for weld scanning.

[0203] During the weld scanning and deviation acquisition stage, the welding control system controls the integrated laser vision weld tracker to scan the area to be welded along the weld recognition trajectory and collect weld contour data. Weld feature points are extracted from the weld contour data and connected in the sampling order to form a weld space curve. The welding control system determines trajectory reference points on the initial welding trajectory that correspond one-to-one with the weld feature points, calculates the displacement difference vector between the weld feature points and the trajectory reference points, and transforms the displacement difference vector to the tool center point coordinate system of the push-pull wire welding torch. The projection of the displacement difference vector onto the second axis of the tool center point coordinate system is taken as the left-right deviation, and the projection onto the third axis is taken as the height deviation, thus obtaining the deviation distribution of the weld space curve relative to the initial welding trajectory.

[0204] In the multi-process discrimination and segmented scheduling stage, the welding control system calculates the point spacing sequence and curvature sequence between adjacent weld feature points based on the weld space curve. It uses feature points with point spacing greater than a first distance threshold as interval breakpoints and feature points with curvature greater than a first curvature threshold as turning breakpoints, dividing the weld space curve into multiple continuous weld segments. For each continuous weld segment, the welding control system calculates the segment length, segment curvature, and corresponding deviation distribution statistics. Following a preset discrimination order, it sequentially determines the process type: spot welding, intersection welding, oscillating welding, and full welding. Based on the interval length between adjacent continuous weld segments, it identifies combinations of continuous weld segments that meet a preset interval range, designating these combinations as discontinuous weld segments, and ultimately generating a welding process sequence consistent with the weld segment sequence.

[0205] In the secondary trajectory generation and process parameter distribution stage, the welding control system extracts the corresponding trajectory segment from the initial welding trajectory for each weld segment. It then converts the left-right and height deviations corresponding to the trajectory points in the deviation distribution into correction values, performs translational compensation on the spatial positions of the trajectory points, and generates the corrected trajectory points corresponding to the weld segment, thus forming the corrected welding trajectory for that weld segment. Simultaneously, based on the welding data expert database, the welding control system retrieves the corresponding welding parameter set according to the process type, segment length, and segment curvature of the weld segment. The welding parameter set includes at least welding current, welding voltage, welding speed, and wire feed speed; when the weld segment is an oscillating weld segment, the welding parameter set further includes oscillation amplitude, oscillation frequency, and oscillation center. The welding control system associates the welding parameter set of each weld segment with the welding process sequence to form a process parameter distribution list, and then distributes the process parameter distribution list to the digital arc welding power source.

[0206] In the closed-loop tracking welding and parameter linkage compensation stage, the welding robot, under the output control of the digital arc welding power supply, drives the push-pull wire welding torch to perform welding along the corrected welding trajectory. During the welding process, the laser vision integrated weld seam tracker outputs real-time weld seam deviation at a preset control cycle. The welding control system converts the real-time weld seam deviation to the tool center point coordinate system of the push-pull wire welding torch, calculates the welding torch pose correction amount, and updates the position parameters of the current welding target pose, realizing closed-loop correction of the welding torch pose. Within the same control cycle, the welding control system calculates the welding parameter compensation amount based on the real-time weld seam deviation, superimposes the welding parameter compensation amount onto at least one welding parameter in the corresponding welding parameter set of the weld seam segment, forms a compensated welding parameter set, and sends it to the digital arc welding power supply, realizing synchronous control of welding torch pose correction and welding parameter compensation. When the weld seam tracker data invalidation is detected for consecutive preset control cycles, the welding control system controls the welding robot to stop welding movement along the corrected welding trajectory and controls the laser vision integrated weld seam tracker to return to laser vision mode, re-scan the weld seam segment to update the deviation distribution, and then updates the corrected welding trajectory accordingly before resuming welding movement. During the welding process, the welding control system collects the wire feeding speed command value and the wire feeding speed feedback value of the push-pull wire welding torch and calculates the difference. When the difference meets the preset threshold and duration conditions, it determines that the wire feeding is abnormal and controls the digital arc welding power supply to execute the arc stop command. At the same time, it controls the push-pull wire welding torch to execute the reverse wire retraction action. After the wire retraction is completed, it controls the push-pull wire welding torch to resume the forward wire feeding and controls the digital arc welding power supply to restart the arc so as to continue welding along the corrected welding target posture.

[0207] During the welding data recording stage, the welding control system establishes welding batch records for the workpiece and assigns weld segment identifiers to the weld segments. It writes weld scanning data, deviation correction amounts, welding process sequences, welding parameter sets, and welding process anomaly information into the welding batch records and adds timestamps to the welding batch records before storing them, thus forming a data recording link consistent with the welding task.

[0208] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art 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 appended claims and their equivalents.

Claims

1. A multi-process automatic welding method for aluminum profiles, characterized in that, Includes the following steps: S1. Establish welding task: Obtain the structural parameters of the aluminum profile workpiece to be welded. The structural parameters include at least the workpiece length, width, height, number of aluminum profiles, and aluminum profile spacing parameters. The welding control system generates weld identification trajectories and initial welding trajectories based on structural parameters; S2. Workpiece clamping and initialization: The workpiece is clamped and positioned on the welding platform, and the welding control system controls the welding robot to complete the zeroing and welding torch posture initialization. S3. Weld Scanning and Deviation Acquisition: The welding control system controls the laser vision integrated weld tracker to scan the area to be welded along the weld recognition trajectory, obtain the weld space curve, and calculate the deviation distribution of the weld space curve relative to the initial welding trajectory. The deviation distribution includes at least left and right deviations and height deviations. S4. Multi-process discrimination and segmented scheduling: Based on the weld space curve and deviation distribution, the welding control system segments the weld and discriminates the process type of each segment, generating the corresponding welding process sequence. The process types include at least full welding, intermittent welding, oscillating welding, spot welding and intersection welding. S5. Trajectory secondary generation and process parameter distribution: The welding control system performs segment-level correction on the initial welding trajectory based on the deviation distribution, generates the corrected welding trajectory corresponding to each weld segment, and determines the welding parameter set corresponding to each weld segment based on the welding data expert database, and distributes the welding parameter set to the digital arc welding power source. S6. Closed-loop tracking welding and parameter linkage compensation: Under the output control of the digital arc welding power supply, the welding robot drives the push-pull wire welding torch to perform welding along the corrected welding trajectory; during the welding process, the laser vision integrated weld seam tracker outputs the weld seam deviation in real time, and the welding control system performs closed-loop correction of the welding torch posture according to the real-time weld seam deviation, and simultaneously performs linkage compensation for at least one welding parameter. The welding parameters include at least one or more of the following: welding speed, welding current, welding voltage, wire feed speed, oscillation amplitude, oscillation frequency, and oscillation center. S7. Welding Data Recording: The welding control system records weld scanning data, deviation correction amount, welding process sequence, welding parameter set, and welding process abnormal information.

2. The automatic welding method for aluminum profiles using multiple processes according to claim 1, characterized in that, S1 includes: Obtain the structural parameters of the aluminum profile workpiece to be welded, including the workpiece length, width, height, number of aluminum profiles, and spacing parameters of the aluminum profiles; The welding control system establishes a parametric geometric model of the workpiece based on the structural parameters, and determines the centerline of the weld to be welded in the parametric geometric model; The welding control system generates multiple weld recognition target poses along the weld centerline at a preset sampling interval. The weld recognition trajectory consists of multiple weld recognition target poses, and each weld recognition target pose includes the spatial position and attitude of the laser vision integrated weld tracker. The welding control system applies a tool center point offset corresponding to the push-pull wire welding gun to the target pose of each weld seam, generating a corresponding welding target pose. The initial welding trajectory consists of multiple welding target poses, and each welding target pose includes the spatial position and attitude of the push-pull wire welding gun.

3. The automatic welding method for aluminum profiles using multiple processes according to claim 2, characterized in that, S2 includes: Place the workpiece in the clamping reference area of ​​the welding platform and clamp and fix the workpiece with a fixture; The welding control system controls the welding robot to sequentially execute the joint homing action and the tool coordinate system loading action, wherein the tool coordinate system is the tool center point coordinate system of the push-pull wire welding gun; The welding control system controls the welding robot to move the push-pull wire welding torch to a preset initial standby position. The initial standby position corresponds to the first weld recognition target position of the weld recognition trajectory, and the spatial position and attitude of the initial standby position are used as the starting attitude for subsequent weld scanning.

4. The automatic welding method for aluminum profiles using multiple processes according to claim 3, characterized in that, S3 includes: The welding control system controls the welding robot to carry the laser vision integrated weld seam tracker to each weld seam recognition target pose in the weld seam recognition trajectory in sequence, and collects the weld seam contour data of the area to be welded at each weld seam recognition target pose. The welding control system extracts weld feature points based on weld contour data, transforms each weld feature point into the base coordinate system of the welding robot, and connects them in the order of the weld recognition trajectory to form a weld space curve. The welding control system determines trajectory reference points that correspond one-to-one with the weld feature points on the initial welding trajectory, and calculates the displacement difference vector between each weld feature point and the corresponding trajectory reference point. The welding control system converts the displacement difference vector into the tool center point coordinate system of the push-pull wire welding gun. The tool center point coordinate system includes a first axis set along the welding direction, a second axis set perpendicular to the welding direction and parallel to the workpiece surface, and a third axis set perpendicular to the workpiece surface. The welding control system determines the left and right deviations by projecting the displacement difference vector onto the second axis and the height deviation by projecting the displacement difference vector onto the third axis, in order to obtain the deviation distribution.

5. The automatic welding method for aluminum profiles using multiple processes according to claim 4, characterized in that, S4 includes: The welding control system calculates the point spacing sequence and curvature sequence between adjacent weld feature points based on the weld space curve; The welding control system uses feature points with a point spacing greater than a first distance threshold as interval breakpoints and feature points with a curvature greater than a first curvature threshold as turning breakpoints. The welding control system divides the weld space curve into multiple continuous weld segments based on interval breakpoints and turning breakpoints. The welding control system determines the process type of continuous weld segments according to a preset discrimination sequence, which is spot welding, intersection welding, oscillation welding, and full welding. Among them, when the length of a continuous weld segment is not greater than the second length threshold, the continuous weld segment is determined as a spot weld segment; When the curvature of a continuous weld segment is greater than the second curvature threshold, and the change of the weld feature point corresponding to the continuous weld segment in the three coordinate axes of the welding robot base coordinate system is greater than the second distance threshold, the continuous weld segment is determined as an intersecting line welding segment. When the maximum absolute value of the left and right deviations of a continuous weld segment is greater than the first deviation threshold or the maximum absolute value of the height deviation is greater than the second deviation threshold, the continuous weld segment is defined as an oscillating weld segment. When the length of a continuous weld segment is not less than the first length threshold and the curvature of the segment is not greater than the first curvature threshold, the continuous weld segment is defined as a full weld segment. The welding control system identifies at least two consecutive weld segments whose interval length is within a preset range based on the interval length between adjacent consecutive weld segments, and combines the at least two consecutive weld segments into a discontinuous weld segment group. The welding control system identifies the intermittent weld segment group as the intermittent weld segment and generates a welding process sequence according to the order of multiple continuous weld segments and the intermittent weld segment group in the weld space curve.

6. The automatic welding method for aluminum profiles using multiple processes according to claim 5, characterized in that, S5 includes: For each weld segment, the welding control system determines the corresponding trajectory segment in the initial welding trajectory and acquires multiple trajectory points of that trajectory segment. The welding control system converts the left and right deviations and height deviations that correspond one-to-one with multiple trajectory points in the deviation distribution into correction values, and performs translation compensation on the spatial positions of multiple trajectory points based on the correction values ​​to generate the correction trajectory points corresponding to the weld segment. The welding control system uses correction trajectory points to form the correction welding trajectory corresponding to the weld segment in sequence. The welding control system is based on a welding data expert database. According to the process type, length and curvature of the weld segment, it retrieves the welding parameter set corresponding to the weld segment from the preset parameter table. The welding parameter set includes at least welding current, welding voltage, welding speed and wire feed speed. The welding control system associates the welding parameter set corresponding to each weld segment with the welding process sequence and forms a process parameter release. Based on the process parameter release, the welding parameter set is sent to the digital arc welding power source.

7. The multi-process automatic welding method for aluminum profiles according to claim 6, characterized in that, S6 includes: The welding control system acquires the real-time weld deviation output by the laser vision integrated weld tracker at a preset control cycle, and converts the real-time weld deviation to the tool center point coordinate system of the push-pull wire welding gun to obtain the corresponding left and right deviations and height deviations. The welding control system calculates the welding torch posture correction amount based on the left and right deviations and the height deviations. The welding torch posture correction amount includes at least the position correction amount. The welding control system superimposes the position correction amount onto the position parameters of the welding target posture corresponding to the current welding moment in the correction welding trajectory, generates the corrected welding target posture, and sends the corrected welding target posture to the welding robot. Within the same control cycle of obtaining the real-time weld deviation, the welding control system calculates the welding parameter compensation amount based on the deviation amplitude of the real-time weld deviation. The welding parameter compensation amount is the product of the deviation amplitude and the preset compensation coefficient. The welding control system superimposes the welding parameter compensation amount onto at least one welding parameter in the welding parameter set corresponding to the weld segment to form a compensated welding parameter set, and sends the compensated welding parameter set to the digital arc welding power source through the collaborative control interface.

8. The automatic welding method for aluminum profiles using multiple processes according to claim 7, characterized in that, S7 includes: The welding control system establishes welding batch records for the workpiece and assigns weld segment identifiers to multiple weld segments. The welding control system writes the weld scanning data into the welding batch record. The weld scanning data includes the point set data of the weld space curve and the left and right deviations and height deviations corresponding to the point set data. The welding control system writes the deviation correction amount into the welding batch record. The deviation correction amount includes the welding torch posture correction amount and the welding parameter compensation amount corresponding to each control cycle. The welding control system associates the welding process sequence with the weld segment identifier and writes it into the welding batch record; The welding control system writes the welding parameter set into the welding batch record. The welding parameter set includes the welding current, welding voltage, welding speed, wire feed speed corresponding to each weld segment, as well as the oscillation amplitude, oscillation frequency and oscillation center corresponding to the oscillation welding segment. The welding control system writes welding process abnormal information into the welding batch record. The welding process abnormal information includes arc establishment abnormality, wire feeding abnormality, weld tracker data invalidity abnormality, welding power supply overcurrent abnormality, and welding power supply overvoltage abnormality. After adding a timestamp to the welding batch record, it is stored in the storage unit of the welding control system.

9. The multi-process automatic welding method for aluminum profiles according to claim 8, characterized in that, The operating modes of the laser vision integrated weld seam tracker in S3 and S6 include: When S3 is executed, the welding control system controls the laser vision integrated weld tracker to be in laser vision mode to collect weld contour data and form weld space curve. When S6 is executed, the welding control system controls the laser vision integrated weld seam tracker to be in laser tracking mode to output real-time weld seam deviation; When invalid abnormality of weld seam tracker data is detected within K consecutive control cycles, the welding control system controls the welding robot to stop welding movement along the corrected welding trajectory, and controls the laser vision integrated weld seam tracker to return to laser vision mode, and re-executes S3 on the current weld seam segment to update the deviation distribution, where K is a preset positive integer; The handling of wire feeding abnormalities in S6 includes: The welding control system collects the wire feeding speed feedback value and wire feeding command value of the push-pull wire welding gun within the control cycle, and calculates the difference between the two. When the absolute value of the difference is greater than the first wire feeding deviation threshold and the duration reaches the first duration threshold, the welding control system determines that a wire feeding abnormality has occurred and controls the digital arc welding power supply to execute an arc stop command. After the welding control system executes the arc stop command, it controls the push-pull wire welding torch to perform a reverse wire retraction action. The retraction length of the reverse wire retraction action is the preset retraction length. After completing the reverse wire retraction action, the welding control system controls the push-pull wire welding torch to resume forward wire feeding and controls the digital arc welding power supply to restart the arc, continuing to perform welding along the corrected welding target posture.

10. An automatic welding system for aluminum profiles with multiple processes, applicable to the automatic welding method for aluminum profiles with multiple processes as described in any one of claims 1-9, characterized in that, include: The clamping and positioning module is used for clamping and positioning the aluminum profile workpiece to be welded. The welding execution module is used to drive the push-pull wire welding gun to perform welding according to the welding trajectory; Welding power supply module, used to output welding voltage and welding current; The weld scanning and tracking module is used to scan the area to be welded and output the weld deviation; The welding control module includes a processor, a memory, and a welding data expert library, preset parameter tables, and control instructions stored in the memory. The welding control module is used for: Obtain the structural parameters of the aluminum profile workpiece to be welded. The structural parameters include at least the workpiece length, width, height, number of aluminum profiles, and spacing parameters of the aluminum profiles. Generate weld identification trajectory and initial welding trajectory based on structural parameters; The control weld scanning and tracking module scans the area to be welded along the weld identification trajectory to obtain the weld space curve, and calculates the deviation distribution of the weld space curve relative to the initial welding trajectory. The deviation distribution includes at least left and right deviations and height deviations. Based on the weld space curve and deviation distribution, the weld is segmented and the process type of each segment is determined to generate a welding process sequence. The process types include at least full welding, intermittent welding, oscillating welding, spot welding and intersection welding. Based on the deviation distribution, the initial welding trajectory is corrected at the segment level to generate the corrected welding trajectory corresponding to each segment of the weld, and the welding parameter set corresponding to each segment of the weld is determined based on the welding data expert database. The control welding execution module performs welding along the corrected welding trajectory, and during the welding process, it performs closed-loop correction of the welding torch posture based on the real-time weld deviation output by the weld scanning and tracking module, while simultaneously performing linkage compensation for at least one welding parameter. Record weld scan data, deviation correction amount, welding process sequence, welding parameter set, and welding process abnormal information.

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