Intelligent determination system and method for resistance spot welding electrode life

Abstract

The present application relates to the technical field of welding, in particular to a kind of intelligent determination system and method of resistance spot welding electrode life, including resistance spot welding adjustable operating condition test device, multi-parameter real-time monitoring module and intelligent life determination model, the resistance spot welding adjustable operating condition test device includes resistance spot welding test bench, plate positioning slider, plate fixed block, the multi-parameter real-time monitoring module is used to collect electrode hardness HV and electrode resistance R;The intelligent life determination model is based on machine learning algorithm, with historical determination data HV, R, nugget diameter d as training set, establishes the life prediction model of multi-parameter coupling, outputs life early warning threshold, carries out multi-dimensional life termination determination by model early warning or nugget quality criterion;Real-time, non-destructive, high-precision determination of resistance spot welding electrode life can be realized.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to an intelligent system and method for determining the lifespan of resistance spot welding electrodes. Background Technology

[0002] The lifespan of resistance spot welding electrodes is a key factor affecting the stability of welding quality and production costs. Currently, determining electrode lifespan faces the following challenges: First, the assessment is often delayed: It relies heavily on destructive testing of the weld joint "after the fact" (such as peel tests to measure the weld nugget diameter), failing to provide early warnings of electrode material degradation, leading to a large number of defective welds. Second, monitoring parameters are indirect: While some advanced methods monitor welding process parameters (such as temperature and dynamic resistance), these are "process phenomena" rather than the "state of the electrode itself," and their correlation with electrode lifespan is sometimes not direct or stable. Third, the adaptability to operating conditions is poor: Existing testing methods often use fixed-size plates and overlaps, failing to flexibly simulate diverse operating conditions in actual production (such as different plate thickness combinations and overlap sizes), resulting in a disconnect between test results and practical applications. Therefore, a real-time monitoring and multi-parameter coupling electrode lifespan determination scheme is urgently needed to improve measurement accuracy and practicality. Summary of the Invention

[0003] This invention provides an intelligent system and method for determining the lifespan of resistance spot welding electrodes. It is applicable to the evaluation of electrode lifespan for materials such as coated / uncoated steel and can achieve real-time, non-destructive, and high-precision determination of electrode lifespan.

[0004] To achieve the above objectives, the present invention employs the following technical solution:

[0005] An intelligent life determination system for resistance spot welding electrodes includes an adjustable resistance spot welding test device, a multi-parameter real-time monitoring module, and an intelligent life determination model.

[0006] The adjustable resistance spot welding test device includes a resistance spot welding test bench, a plate positioning slider, and a plate fixing block.

[0007] The resistance spot welding test bench is provided with a slide rail on each side. Two plate positioning sliders are respectively inserted into one end of the two slide rails. The two plate positioning sliders are L-shaped sliders. Two plate fixing blocks are respectively set on the upper platform of the two L-shaped sliders to fix the welding plate on the resistance spot welding test bench and the lower platform of the L-shaped sliders.

[0008] The multi-parameter real-time monitoring module is used to collect electrode resistance R and electrode hardness HV;

[0009] The intelligent life determination model is based on machine learning algorithms. It uses historical measurement data such as electrode hardness HV, electrode resistance R, and weld nugget diameter d as training sets to establish a multi-parameter coupled life prediction model, which is used to output life warning thresholds and realize the correlation determination between weld nugget quality and electrode life.

[0010] Furthermore, the plate positioning slider is provided with bolt holes that match the resistance spot welding test bench and the plate fixing block, and one of the plate positioning sliders is provided with a scale.

[0011] Furthermore, the plate fixing block is provided with two bolt holes, one of which corresponds to the position and size of the upper surface of the L-shaped slider and the resistance spot welding test table, and the other bolt hole has internal threads and is positioned corresponding to the lower surface of the L-shaped slider.

[0012] Furthermore, the resistance spot welding adjustable working condition test fixture is used to place welding plates with a length range of 30-500mm and a width range of 20-400mm.

[0013] The adjustable resistance spot welding test fixture is suitable for welding plates with a thickness range of 0.5mm to 3mm.

[0014] Furthermore, the electrode resistance R is measured using a DC low-resistance tester, with consistent measurement conditions each time, the electrode being cooled to room temperature before measurement each time, and the measurement position being the same each time; the electrode hardness HV is measured using an ultrasonic hardness tester, with the ultrasonic probe in contact with the electrode rod.

[0015] A smart method for determining the lifespan of resistance spot welding electrodes includes the following steps:

[0016] Step 1, Sample Installation and Test Preparation: Fix the plate positioning slider with scale to the resistance spot welding test bench with bolts. Adjust the other plate positioning slider to overlap two No. 1 test plates of the same size on the lower platform of the two L-shaped sliders, and align one edge of the two No. 1 test plates with the 0 mark line on the scale. Fix the adjusted plate positioning slider to the resistance spot welding test bench with bolts. Fix the plate fixing block to the upper platform of the L-shaped slider with bolts and fix the welding plate to the lower platform of the L-shaped slider.

[0017] Step 2: Take a pair of new electrodes or refurbished electrodes and measure their initial electrode hardness HV0 and initial electrode resistance R0; set the welding current to the maximum welding current value I. max ;

[0018] Step 3, Standardized Welding and Real-time Monitoring: With the preset weld point spacing and center distance of the weld points from the edge of the test plate, weld 8-12 points per row from left to right along the preset path until 46-92 weld points are completed on the two #1 test plates; the welding rate is set according to the plate thickness: 25-35 weld points / minute when the plate thickness is <1.65mm, and 15-20 weld points / minute when the plate thickness is ≥1.65mm.

[0019] After completing the welding of test plate #1, take two test plates #2 of the same size and repeat the sample installation process in step 1. Weld 4 to 8 weld points on the two test plates #2. The welding parameters are set in the same way as those of test plate #1. After setting the parameters, weld the two test plates #2. After the test is completed, perform a peel test on the weld points on the test plates #2. That is, after removing the first weld point, perform a peel test on the remaining weld points and measure the weld nugget diameter d.

[0020] The multi-parameter real-time monitoring module collects electrode hardness (HV) and electrode resistance (R) data every 100 weld points and transmits them to the intelligent life determination model.

[0021] Step 4: Multi-dimensional intelligent judgment;

[0022] Model warning: A lifetime warning will be triggered if either HV or R exceeds its corresponding threshold, or if d < 4. If there are ≥3 solder joints, the electrode is considered to have reached the end of its lifespan, where t is the thickness of the plate material;

[0023] Step 5: If the model warning is not triggered, repeat steps 1 to 4 to continue welding until the model warning is triggered or the preset maximum number of weld points is reached.

[0024] Furthermore, the lifespan warning will be triggered when either HV or R exceeds the corresponding threshold, specifically: the warning will be triggered when the electrode hardness HV ≤ 80%HV0 or the electrode resistance R ≥ 115%R0.

[0025] Furthermore, it also includes data recording and model optimization, which is performed after step S3. Specifically, it involves recording the weld nugget diameter d of the weld point on the #2 test plate, storing HV, R data, initial electrode hardness HV0, and initial electrode resistance R0, and feeding the recorded data back to the intelligent life determination model, while updating and optimizing the warning threshold.

[0026] Furthermore, the electrode resistance of the new electrode or the ground electrode is measured once, which is used as the initial electrode resistance R0. During the test, the electrode resistance is measured once every 100 weld points are completed. The electrode hardness of the new electrode or the ground electrode is measured once, which is used as the initial electrode hardness HV0. During the test, the electrode hardness is measured once every 100 weld points are completed.

[0027] Compared with the prior art, the beneficial effects of the present invention are:

[0028] 1) Determining directness and foresight: By directly monitoring the degradation of the electrode's own performance (hardness, resistance) and combining it with intelligent models, early warnings can be issued before the weld nugget diameter becomes significantly unqualified, transforming "post-event detection" into "pre-event warning," greatly reducing the generation of defective products.

[0029] 2) High precision and reliability: It integrates the dual criteria of "electrode performance early warning" and "final quality inspection". The decrease in hardness and the increase in resistance are direct physical evidence of electrode failure, avoiding misjudgments that may be caused by indirect process parameters.

[0030] 3) Standardization and reproducibility: The test procedure is based on unified specifications (plate size, number and layout of solder joints), which ensures the comparability and reproducibility of the test results.

[0031] 4) Strong adaptability to working conditions: The adjustable tooling allows the method to be applied to different actual production conditions, and has strong adaptability. Attached Figure Description

[0032] Figure 1 This is a front view of the resistance spot welding adjustable working condition test device described in this invention;

[0033] Figure 2 This is a side view of the resistance spot welding adjustable working condition test device described in this invention.

[0034] In the diagram: 1. Resistance spot welding test bench; 2. Plate positioning slider; 3. Plate fixing block. Detailed Implementation

[0035] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0036] The present invention provides an intelligent life determination system for resistance spot welding electrodes, comprising an adjustable resistance spot welding test device, a multi-parameter real-time monitoring module, and an intelligent life determination model.

[0037] The adjustable resistance spot welding test device is used to install welding plates of different sizes and to conduct resistance spot welding tests. It includes a resistance spot welding test bench 1, a plate positioning slider 2, and a plate fixing block 3.

[0038] The resistance spot welding test bench 1 has a slide rail on each side. Two plate positioning sliders 2 are respectively inserted into one end of the two slide rails. The two plate positioning sliders 2 are L-shaped sliders. The plate positioning sliders are provided with bolt holes that match the resistance spot welding test bench 1 and the plate fixing block 3. One of the plate positioning sliders 2 is provided with a scale.

[0039] Two plate fixing blocks 3 are respectively set on the upper platform of the two L-shaped sliders. The plate fixing block 3 is provided with two bolt holes. One bolt hole corresponds to the position of the upper platform of the L-shaped slider, and the other bolt hole has internal threads and corresponds to the position of the lower platform of the L-shaped slider. The plate fixing block 3 is fixedly connected to the upper platform of the L-shaped slider by bolts. The welded plate is fixed to the lower platform of the L-shaped slider by bolts passing through the internal thread bolt holes of the plate fixing block 3.

[0040] The multi-parameter real-time monitoring module is used to collect electrode resistance R and electrode hardness HV during the welding process;

[0041] The intelligent lifespan determination model is based on machine learning algorithms, such as random forest. It uses historical measurement data of electrode hardness HV, electrode resistance R, and weld nugget diameter d as training sets to establish a multi-parameter coupled lifespan prediction model, which is used to output lifespan warning thresholds and realize the correlation determination between weld nugget quality and electrode lifespan.

[0042] The adjustable resistance spot welding test fixture can hold a 300×400mm test plate #1 and a 40mm×300mm test plate #2, respectively.

[0043] The adjustable resistance spot welding test fixture is suitable for welding plates with a thickness range of 0.5mm to 3mm.

[0044] The electrode resistance R is measured using a DC low-resistance tester, with consistent measurement conditions each time. To avoid temperature effects, the electrode is cooled to room temperature before measurement, and the measurement position must be the same each time. The electrode resistance is measured once for a new electrode or an electrode after grinding, which is used as the initial electrode resistance R0. During the test, the electrode resistance is measured once after every 100 weld points are completed. The electrode hardness HV is measured using an ultrasonic hardness tester. The ultrasonic probe contacts the electrode rod, and the electrode hardness is converted from the relationship between sound velocity and material hardness. The electrode hardness is measured once for a new electrode or an electrode after grinding, which is used as the initial electrode hardness HV0. During the test, the electrode hardness is measured once after every 100 weld points are completed.

[0045] A smart method for determining the lifespan of resistance spot welding electrodes includes the following steps:

[0046] Step 1, Sample Installation and Test Preparation: Fix the plate positioning slider 2 with a scale to the resistance spot welding test bench 1 with bolts. Adjust the other plate positioning slider 2 to overlap two #1 test plates with a size of 300mm×400mm on the lower platform of the two L-shaped sliders, and align one edge of the two #1 test plates with the 0 mark line on the scale. Fix the adjusted plate positioning slider 2 to the resistance spot welding test bench 1 with bolts. Fix the plate fixing block 3 to the upper platform of the L-shaped slider with bolts and fix the welding plate to the lower platform of the L-shaped slider to prevent the test plate from moving.

[0047] Step 2, Tooling Adjustment: Using a new electrode or a refurbished electrode, measure its initial electrode hardness HV0 and initial electrode resistance R0; set the welding current to the maximum welding current value I. max ;

[0048] Step 3, Standardized Welding and Real-time Monitoring: With a weld point spacing of 30mm and a weld point center distance of 15mm from the edge of the plate, weld 92 weld points from left to right on the No. 1 test plate according to the preset path; the welding rate is set according to the plate thickness: 30 weld points / minute when the plate thickness is <1.65mm, and 15 weld points / minute when the plate thickness is ≥1.65mm.

[0049] After completing the welding of test plate #1, remove it and take two test plates #2 with a size of 40mm×300mm. Repeat the sample installation process in step 1 and place them on top of each other on the resistance spot welding adjustable working condition test device. Weld 8 weld points on the two test plates #2. The welding parameters are the same as those of test plate #1. After the welding test is completed, the weld points on test plate #2 are peeled off. That is, after removing the first weld point, the remaining weld points are peeled off and the weld nugget diameter d is measured.

[0050] The multi-parameter real-time monitoring module collects electrode hardness (HV) and electrode resistance (R) data once for every 100 weld points and transmits them to the intelligent life determination model.

[0051] Step 4: Multi-dimensional intelligent judgment;

[0052] Model warning: A warning will be triggered when the electrode hardness HV ≤ 80%HV0 or the electrode resistance R ≥ 115%R0, or when d < 4. If there are ≥3 solder joints, the electrode is considered to have reached the end of its lifespan, where t is the thickness of the plate material;

[0053] Step 5: If the model warning is not triggered, repeat steps 1 to 4 and continue welding until the model warning is triggered or the preset maximum number of weld points is reached (e.g., the lifespan of a chromium zirconium copper electrode is usually 2000 weld points).

[0054] Step 6, Data Recording and Model Optimization: Record the weld nugget diameter d of the auxiliary weld point, and store the data of HV, R, initial electrode hardness HV0, and initial electrode resistance R0. Feed the recorded data back to the intelligent life judgment model, and update and optimize the warning threshold.

[0055] The following embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments. Unless otherwise specified, the methods used in the following embodiments are conventional methods.

[0056] Example 1: HC340LAD+Z steel plate with a thickness of 1.7mm;

[0057] Step 1, Sample preparation, installation and test preparation: Cut the HC340LAD+Z steel plate into rectangular test plates with dimensions of 300mm×400mm and strip test plates with dimensions of 40mm×300mm respectively. The rectangular test plates are numbered 1# and the strip test plates are numbered 2#.

[0058] The plate positioning slider 2 with a scale is fixed to the resistance spot welding test bench 1 with bolts. The other plate positioning slider 2 is adjusted to overlap two 300mm×400mm No.1 test plates on the lower platform of the two L-shaped sliders, and one edge of the two No.1 test plates is aligned with the 0 mark line on the scale. The plate positioning slider 2 after adjustment is fixed to the resistance spot welding test bench 1 with bolts. The plate fixing block 3 is fixed to the upper platform of the L-shaped slider with bolts and the welding plate is fixed to the lower platform of the L-shaped slider to prevent the test plate from moving.

[0059] Step 2: After the two #1 test plates are installed, a new electrode is used to ensure stable initial weld nugget formation conditions. The new electrode material is chromium zirconium copper with a diameter of 6mm. The initial hardness of the electrode is measured to be HV0=160HV, and the initial resistance is R0=45μΩ. The welding current is set to the maximum welding current value I. max =9.2kA.

[0060] Step 3, Parameter initialization: Set the welding speed to 15 pieces / minute and input the warning threshold of the intelligent life judgment model.

[0061] Step 4, Welding and Real-time Monitoring: Start the welding test machine and perform continuous spot welding on test plate #1;

[0062] After completing 92 weld points, take two #2 test plates and repeat the sample installation process in step 1. Place the two #2 test plates on top of each other on the resistance spot welding adjustable working condition test device, and weld 8 weld points on the two #2 test plates. The welding parameters are set in the same way as the welding parameters of the #1 test plate. Perform weld point peeling test on the #2 test plates and measure the weld nugget diameter d as follows: 5.64mm, 5.66mm, 5.91mm, 6.00mm, 5.77mm, 5.81mm, and 5.70mm.

[0063] After welding 100 weld points, the electrode hardness HV was measured to be 157HV, >80%HV0, and the electrode resistance R was 48μΩ, <115%R0. The monitoring module transmitted the collected HV and R data to the intelligent life determination model.

[0064] Step 5: Intelligent Dimension Determination;

[0065] Model warning: The measured weld nugget diameter d is greater than 5.22 (i.e., the minimum weld nugget diameter is 4). ≈5.22mm, t=1.7mm), and the electrode hardness HV was measured to be 157HV, >80% HV0, and the electrode resistance R was 48μΩ, <115% R0.

[0066] Step 6: No warning is triggered at this time, so repeat steps 1 to 5.

[0067] When 1100 weld points were reached, the intelligent model detected that the electrode hardness had dropped to 125 HV (125 / 160≈78% HV0), triggering the threshold condition.

[0068] Judgment result: Due to the triggering of the model warning, the electrode life was determined to have ended, and the experiment was terminated early.

[0069] Step 7: Data recording and optimization: Record relevant data and feed it back to the intelligent model, and update the threshold to improve the accuracy of subsequent judgments.

[0070] Example 2: CR3 steel plate with a thickness of 0.7 mm;

[0071] Step 1, Sample preparation, installation and test preparation: Cut the CR3 steel plate into rectangular test plates with dimensions of 300mm×400mm and strip test plates with dimensions of 40mm×300mm respectively. The rectangular test plates are numbered 1# and the strip test plates are numbered 2#.

[0072] The plate positioning slider 2 with a scale is fixed to the resistance spot welding test bench 1 with bolts. The other plate positioning slider 2 is adjusted to overlap two 300mm×400mm No.1 test plates on the lower platform of the two L-shaped sliders, and one edge of the two No.1 test plates is aligned with the 0 mark line on the scale. The plate positioning slider 2 after adjustment is fixed to the resistance spot welding test bench 1 with bolts. The plate fixing block 3 is fixed to the upper platform of the L-shaped slider with bolts and the welding plate is fixed to the lower platform of the L-shaped slider to prevent the test plate from moving.

[0073] Step 2: After the two #1 test plates are installed, use the ground electrodes. The electrode material is chromium zirconium copper, with a diameter of 6mm. Measure the initial electrode hardness H0 = 155HV and the initial electrode resistance R0 = 48μΩ. Set the welding current to the maximum welding current value I. max =11.2kA.

[0074] Step 3, Parameter Initialization: Set the welding speed to 30 pieces / minute and input the warning threshold of the intelligent life judgment model.

[0075] Step 4, Welding and Real-time Monitoring: Start the welding test machine and perform continuous spot welding on test plate #1;

[0076] After every 92 weld points are completed, two #2 test plates are taken, and the sample installation process in step 1 is repeated. The two #2 test plates are overlapped and placed on the adjustable resistance spot welding test device. Eight weld points are welded on the two #2 test plates, and the welding parameters are set to be consistent with those of the #1 test plate. The electrode hardness HV and electrode resistance R are measured after every 100 weld points are welded, until the 1600th weld point. At this time, the measured weld nugget diameters d are 3.64mm, 3.21mm, 3.03mm, 3.55mm, 3.40mm, 3.51mm, and 3.11mm, respectively. The monitoring module transmits the collected HV and R data to the intelligent life determination model.

[0077] Step 5: Intelligent Dimension Determination;

[0078] Model warning: Real-time monitoring parameters did not trigger the threshold; however, 3 out of 7 auxiliary solder joints had weld nugget diameters d < 3.35 mm (i.e., the minimum weld nugget diameter was 4 mm). ≈3.35mm, t=0.7mm).

[0079] Judgment result: Due to the failure of the solder joint inspection, the electrode life is deemed to have ended.

[0080] Step 6: Data recording and optimization: Record relevant data and feed it back to the intelligent model to optimize threshold settings.

[0081] This invention provides a scientific, accurate, and efficient solution for determining electrode tip lifespan by combining standardized testing procedures with intelligent monitoring of the electrode's performance, and has significant industrial application value.

Claims

1. An intelligent system for determining the lifespan of resistance spot welding electrodes, characterized in that, This includes an adjustable resistance spot welding test device, a multi-parameter real-time monitoring module, and an intelligent life determination model. The adjustable resistance spot welding test device includes a resistance spot welding test bench, a plate positioning slider, and a plate fixing block. The resistance spot welding test bench is provided with a slide rail on each side. Two plate positioning sliders are respectively inserted into one end of the two slide rails. The two plate positioning sliders are L-shaped sliders. Two plate fixing blocks are respectively set on the upper platform of the two L-shaped sliders to fix the welding plate on the resistance spot welding test bench and the lower platform of the L-shaped sliders. The multi-parameter real-time monitoring module is used to collect electrode resistance R and electrode hardness HV; The intelligent life determination model is based on machine learning algorithms. It uses historical measurement data of electrode hardness HV, electrode resistance R, and weld nugget diameter d as training sets to establish a multi-parameter coupled life prediction model, which is used to output life warning thresholds and realize the correlation determination between weld nugget quality and electrode life. The determination method using the aforementioned intelligent determination system includes the following steps: Step 1, Sample Installation and Test Preparation: Fix the plate positioning slider with scale to the resistance spot welding test bench with bolts. Adjust the other plate positioning slider to overlap two No. 1 test plates of the same size on the lower platform of the two L-shaped sliders, and align one edge of the two No. 1 test plates with the 0 mark line on the scale. Fix the adjusted plate positioning slider to the resistance spot welding test bench with bolts. Fix the plate fixing block to the upper platform of the L-shaped slider with bolts and fix the welding plate to the lower platform of the L-shaped slider. Step 2: Take a pair of new electrodes or refurbished electrodes and measure their initial electrode hardness HV0 and initial electrode resistance R0; set the welding current to the maximum welding current value I. max ; Step 3, Standardized Welding and Real-time Monitoring: With the preset weld point spacing and center distance of the weld points from the edge of the test plate, weld 8-12 points per row from left to right along the preset path until 46-92 weld points are completed on the two #1 test plates; the welding rate is set according to the plate thickness: 25-35 weld points / minute when the plate thickness is <1.65mm, and 15-20 weld points / minute when the plate thickness is ≥1.65mm. After completing the welding of test plate #1, take two test plates #2 of the same size and repeat the sample installation process in step 1. Weld 4 to 8 weld points on the two test plates #2. The welding parameters are set in the same way as those of test plate #1. After setting the parameters, weld the two test plates #2. After the test is completed, perform a peel test on the weld points on the test plates #2. That is, after removing the first weld point, perform a peel test on the remaining weld points and measure the weld nugget diameter d. The multi-parameter real-time monitoring module collects electrode hardness (HV) and electrode resistance (R) data every 100 weld points and transmits them to the intelligent life determination model. Step 4: Multi-dimensional intelligent judgment; Model warning: A lifespan warning will be triggered if either electrode hardness HV or electrode resistance R exceeds its corresponding threshold, or if the weld nugget diameter d < 4. If there are ≥3 solder joints, the electrode is considered to have reached the end of its lifespan, where t is the thickness of the plate material; Step 5: If the model warning is not triggered, repeat steps 1 to 4 to continue welding until the model warning is triggered or the preset maximum number of weld points is reached.

2. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, The plate positioning slider is provided with bolt holes that match the resistance spot welding test bench and the plate fixing block, and one of the plate positioning sliders is provided with a scale.

3. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, The plate fixing block is provided with two bolt holes. One bolt hole corresponds to the position and size of the upper platform of the L-shaped slider and the resistance spot welding test table. The other bolt hole has internal threads and its position corresponds to the lower platform of the L-shaped slider.

4. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, The adjustable resistance spot welding test fixture can be placed on welding plates with a length range of 30-500 mm and a width range of 20-400 mm. The adjustable resistance spot welding test fixture is suitable for welding plates with a thickness range of 0.5mm to 3mm.

5. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, The electrode resistance R is measured using a DC low-resistance tester, with consistent measurement conditions each time. The electrode is cooled to room temperature before each measurement, and the measurement position must be the same each time. The electrode hardness HV is measured using an ultrasonic hardness tester, with the ultrasonic probe in contact with the electrode rod.

6. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, The lifespan warning will be triggered when either the electrode hardness HV or the electrode resistance R exceeds the corresponding threshold. Specifically, the warning will be triggered when the electrode hardness HV ≤ 80% of the initial electrode hardness HV0 or the electrode resistance R ≥ 115% of the initial electrode resistance R0.

7. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, It also includes data recording and model optimization, which is performed after step S3. Specifically, it involves recording the weld nugget diameter d of the weld point on the #2 test plate, storing the electrode hardness HV, electrode resistance R data, and the initial electrode hardness HV0 and initial electrode resistance R0, and feeding the recorded data back to the intelligent life judgment model, while updating and optimizing the warning threshold.

8. The intelligent system for determining the lifespan of a resistance spot welding electrode according to claim 1, characterized in that, The electrode resistance R of the new electrode or the ground electrode is measured once, which is used as the initial electrode resistance R0. During the test, the electrode resistance R is measured once after every 100 weld points are completed. The electrode hardness HV of the new electrode or the ground electrode is measured once, which is used as the initial electrode hardness HV0. During the test, the electrode hardness HV is measured once after every 100 weld points are completed.

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