Welding quality detection method and device, terminal and readable storage medium

Abstract

This invention discloses a method, apparatus, terminal, and readable storage medium for detecting welding quality. The detection method includes the following steps: acquiring multiple welding state information of a welding machine under preset welding conditions, each welding state information containing multiple time points and multiple different working states of the welding machine corresponding to each time point; obtaining the upper and lower limits of each working state at different time points; acquiring the welding state information of the welding to be detected under the preset welding conditions; and if any working state at each time point in the welding state information of the welding to be detected is between the corresponding upper and lower limits, then the welding quality of the welding to be detected is qualified. This detection method can evaluate the welding quality of a welding machine.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a method, apparatus, terminal, and readable storage medium for detecting welding quality. Background Technology

[0002] A welding machine is an industrial device that uses heating, pressurization, or a combination of both to permanently bond metal (or some non-metal) workpieces through interatomic diffusion and bonding. As a core piece of equipment in manufacturing, it is widely used in construction, automotive, shipbuilding, aerospace, electronics, and other fields, and is a key tool for achieving metal structure forming and component assembly.

[0003] Currently, the mainstream method for evaluating the welding quality of welding machines is through destructive tensile testing. The maximum tensile force that the weldment can withstand is the core indicator for determining whether its welding quality meets standards. However, tensile testing has significant limitations: this method requires applying an extreme tensile force to the weldment to obtain data, inevitably leading to damage to the tested material. Therefore, in actual production, it is usually only possible to sample and inspect materials that have already been welded on the production line, and to indirectly infer the welding quality level of the entire batch of materials based on the test results of the samples.

[0004] In addition to the methods mentioned above, some experienced welding operators may try to make a preliminary judgment on whether there are any welding abnormalities by observing the sound characteristics emitted by the equipment during ultrasonic welding. However, this method, which relies on subjective hearing and personal experience, lacks unified standards and scientific basis, and is not a mature and reliable quality assessment solution.

[0005] Therefore, how to evaluate the welding quality of welding machines is an urgent problem to be solved. Summary of the Invention

[0006] In view of this, the main objective of the present invention is to provide a method, apparatus, terminal and readable storage medium for detecting welding quality.

[0007] To achieve the above objectives, the technical solution of the present invention is implemented as follows: a method for detecting the welding quality of a welding machine, comprising the following steps: acquiring N welding status information of the welding machine under preset welding conditions, wherein the welding quality of all N welds is qualified, and the i-th welding status information includes M time points and Num different working states of the welding machine corresponding to the j-th time point. This represents the k-th working state at the j-th time point in the i-th welding status information; the maximum value of the k-th working state at the j-th time point. The minimum value of the k-th working state at the j-th time point. Where N, M, Num, i, j, and k are all natural numbers, i = 1, 2, ..., N, j = 1, 2, ..., M, and k = 1, 2, ..., Num; Obtain the welding status information of the welding machine under preset welding conditions; if any of the j-th time points and any k-th working states in the welding status information of the welding machine under preset welding conditions... All meet If the welding quality of the weld to be inspected is deemed acceptable, then the weld quality is deemed acceptable. and All are correction factors. , .

[0008] As an improvement of this embodiment of the invention, Num=3, the first working state is the voltage frequency, the second working state is the current frequency, and the third working state is the phase difference between voltage and current.

[0009] As an improvement of this embodiment of the invention, the welding machine is an ultrasonic welding machine.

[0010] As an improvement to an embodiment of the present invention , Where a is the correction factor caused by the welding material, b is the correction factor caused by the welding parameters, and c is the correction factor caused by the welding area.

[0011] This invention also provides a welding quality detection device for a welding machine, comprising the following modules: an information processing module, used to acquire N welding status information of the welding machine under preset welding conditions, wherein the welding quality of all N welds is qualified, and the i-th welding status information includes M time points and Num different working states of the welding machine corresponding to the j-th time point. This represents the k-th working state at the j-th time point in the i-th welding status information; the maximum value of the k-th working state at the j-th time point. The minimum value of the k-th working state at the j-th time point. Where N, M, Num, i, j, and k are all natural numbers, i = 1, 2, ..., N, j = 1, 2, ..., M, and k = 1, 2, ..., Num; the detection module is used to acquire the welding status information of the welding machine under preset welding conditions, and if any of the j-th time points in the welding status information of the welding machine under preset welding conditions, the detection module is used to acquire the welding status information of the welding machine under preset welding conditions. All meet If the welding quality of the weld to be inspected is deemed acceptable, then the weld quality is deemed acceptable. and All are correction factors. , .

[0012] As an improvement of this embodiment of the invention, Num=3, the first working state is the voltage frequency, the second working state is the current frequency, and the third working state is the phase difference between voltage and current.

[0013] As an improvement of this embodiment of the invention, the welding machine is an ultrasonic welding machine.

[0014] As an improvement to an embodiment of the present invention , Where a is the correction factor caused by the welding material, b is the correction factor caused by the welding parameters, and c is the correction factor caused by the welding area.

[0015] This invention also provides a terminal, comprising: a memory for storing a computer program; and a processor for executing the computer program to implement the steps of the detection method described above.

[0016] This invention also provides a readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the detection method described above.

[0017] The welding quality detection method, apparatus, terminal, and readable storage medium provided in this invention have the following advantages: This invention discloses a welding quality detection method, apparatus, terminal, and readable storage medium. The detection method includes the following steps: acquiring multiple welding state information of a welding machine in a preset welding condition, each welding state information containing multiple time points and multiple different working states of the welding machine corresponding to each time point; obtaining the upper and lower limits of each working state at different time points; acquiring the welding state information of the welding to be detected in the preset welding condition; if any working state at each time point in the welding state information of the welding to be detected is between the corresponding upper and lower limits, then the welding quality of the welding to be detected is qualified. This detection method can evaluate the welding quality of a welding machine. Attached Figure Description

[0018] Figure 1 This is a schematic flowchart of the detection method provided in an embodiment of the present invention. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings. However, these embodiments do not limit the present invention, and any structural, methodological, or functional modifications made by those skilled in the art based on these embodiments are included within the scope of protection of the present invention.

[0020] The following description and accompanying drawings fully illustrate specific embodiments described herein to enable those skilled in the art to practice them. Some embodiments may include or substitute parts and features of other embodiments. The scope of the embodiments herein encompasses the entire scope of the claims and all available equivalents thereof. Throughout this document, the terms “first,” “second,” etc., are used only to distinguish one element from another without requiring or implying any actual relationship or order between the elements. Indeed, a first element can also be referred to as a second element, and vice versa. Furthermore, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a structure, apparatus, or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a structure, apparatus, or device. Without further limitation, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the structure, apparatus, or device that includes said element. The various embodiments described herein are presented in a progressive manner, with each embodiment focusing on its differences from other embodiments; similar or identical parts between embodiments can be referred to interchangeably.

[0021] The terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer" used in this document to indicate orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings and are used only for the convenience of describing this document and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention. In the description herein, unless otherwise specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two elements, or direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0022] Embodiment 1 of the present invention provides a method for detecting the welding quality of a welding machine, such as... Figure 1 As shown, it includes the following steps:

[0023] Step 101: Obtain N welding status information of the welding machine under preset welding conditions. The welding quality of all N welds is qualified. The i-th welding status information contains M time points and Num different working states of the welding machine corresponding to the j-th time point. This represents the k-th working state at the j-th time point in the i-th welding status information; the maximum value of the k-th working state at the j-th time point. The minimum value of the k-th working state at the j-th time point. Where N, M, Num, i, j, and k are all natural numbers, i = 1, 2, ..., N, j = 1, 2, ..., M, and k = 1, 2, ..., Num; In actual industrial production lines, accurate judgment of welding quality is a key link in ensuring product quality. Before formally carrying out large-scale welding production and conducting comprehensive welding quality assessment, a crucial preliminary task is required—small-batch welding tests.

[0024] This experiment requires the use of the exact same pre-set welding conditions as actual production, meaning the same materials. The specifications, materials, and performance of these materials must be consistent with those used in subsequent large-scale production to ensure the experiment results accurately reflect actual production conditions. Simultaneously, welding parameters proven to produce good welding results must be used. These parameters have been repeatedly verified and optimized and are crucial for ensuring welding quality. Furthermore, a corresponding welding electrical box is required. The performance and operation of this welding electrical box must be stable and reliable, as it provides the necessary power support for the welding process, and its performance directly affects the welding outcome.

[0025] When small-batch welding is carried out, it is necessary to accurately record key data during the welding process. Specifically, the frequency and phase difference data during welding should be recorded. Frequency data reflects the rate of change of current or voltage during welding, while phase difference data reflects the relative positional relationship between different electrical signals. These two data are important for analyzing the stability and accuracy of the welding process. Simultaneously, after welding is completed, a tensile test should be performed on the welded material. The tensile test is an important means of measuring welding quality, as it can directly reflect the bonding strength of the welded joint. The data obtained from the tensile test should be comprehensively statistically analyzed with the previously recorded frequency and phase difference data. Next, the statistical data should be carefully distinguished. Based on the results of the tensile test, the data should be clearly divided into acceptable and unacceptable data. Acceptable data means that the welding quality meets the pre-set standards, and the bonding strength of the welded joint meets the requirements of actual use; unacceptable data indicates that there are problems with the welding quality, which may be due to unreasonable welding parameter settings or other abnormalities during the welding process. In other words, the welding quality of N welds is considered acceptable.

[0026] Then, for the data that passed the tensile test, they should be sorted and organized according to the specific values ​​of the tensile test results. This can be done by arranging the tensile values ​​from largest to smallest or smallest to largest. This helps to further analyze the intrinsic relationship between different welding conditions and the final welding quality, providing strong data support for subsequent optimization of welding parameters and improvement of welding quality. This results in N welding status information points, where the i-th welding status information contains M time points and Num different working states of the welding machine corresponding to the j-th time point.

[0027] Step 102: Obtain the welding status information of the welding machine under preset welding conditions. If any of the j-th time points and any k-th working states in the welding status information of the welding machine to be inspected... All meet If the welding quality of the weld to be inspected is deemed acceptable, then the weld quality is deemed acceptable. and All are correction factors. , .

[0028] Here, the specific conditions of the preset welding working conditions can be considered. and The specific values ​​are adjusted, for example, based on the different welding materials, welding parameters, and welding area. and To make corrections, let the correction factor be 'a' for the welding material, 'b' for the welding parameters, and 'c' for the welding area. , .

[0029] Here, for any k-th working state, , ... Forming an envelope, , ... This also forms an envelope. When welding (i.e., welding to be tested in the preset welding conditions), the working state obtained is compared with the overall envelope. When all working states during the welding process are within the qualified envelope range, the welding process is considered normal and the welding quality reaches the expected range.

[0030] In this embodiment, Num=3, the first operating state is the voltage frequency, the second operating state is the current frequency, and the third operating state is the phase difference between voltage and current.

[0031] The welding machine has two electrical signal output interfaces, which can output analog signals representing the voltage and current amplitudes of the actual welding high-voltage signal. The welding machine's monitoring instrument can collect these two analog signals and analyze them to calculate the voltage, current, frequency, and phase difference data of the high-voltage signal during the welding process.

[0032] The working principle of this dedicated monitoring instrument is as follows: The welding machine's two electrical signal output interfaces output analog signals representing the actual high-voltage and current amplitudes of the welding signal. The dedicated monitoring instrument connects to these two interfaces through a matching signal input port, using sensor technology to acquire the analog signals. These sensors can detect changes in the electrical signals and accurately transmit them to the monitoring instrument for subsequent processing. The newly acquired analog signals often contain noise interference, and the signal amplitude may not be suitable for subsequent processing. Therefore, the monitoring instrument has a signal conditioning circuit. This circuit mainly consists of a filter and an amplifier. The filter removes high-frequency noise and clutter from the signal, making the signal cleaner; the amplifier amplifies the signal to a suitable amplitude to meet the requirements of subsequent analog-to-digital conversion, ensuring the accuracy and stability of the signal. The conditioned analog signal is still a continuously changing analog quantity, while the monitoring instrument's internal microprocessor can only process digital signals. Therefore, an analog-to-digital converter (ADC) is needed to convert the analog signal into a digital signal. The ADC samples the analog signal at a certain sampling frequency and quantizes the sampled values ​​into binary digits, thus discretizing the continuous analog signal into a digital sequence that a computer can recognize and process. The microprocessor employs the Fast Fourier Transform (FFT) algorithm to perform spectral analysis on the digital signal. The FFT algorithm converts a signal from the time domain to the frequency domain. By analyzing the signal distribution in the frequency domain, the frequency components of the high-voltage signal can be determined, thus deriving the frequencies of the voltage and current signals during the welding process. The microprocessor processes the voltage and current digital signals separately, comparing the zero-crossing times or the time difference at specific phase points of the two signals, and then combining this with the signal period to calculate the phase difference between the voltage and current signals.

[0033] In this embodiment, the welding machine is an ultrasonic welding machine.

[0034] In this embodiment, , Where a is the correction factor caused by the welding material, b is the correction factor caused by the welding parameters, and c is the correction factor caused by the welding area.

[0035] This second embodiment provides a welding quality detection device for a welding machine, comprising the following modules: The information processing module is used to acquire N welding status information of the welding machine under preset welding conditions. The welding quality of all N welds is qualified. The i-th welding status information includes M time points and Num different working states of the welding machine corresponding to the j-th time point. This represents the k-th working state at the j-th time point in the i-th welding status information; the maximum value of the k-th working state at the j-th time point. The minimum value of the k-th working state at the j-th time point. Where N, M, Num, i, j and k are all natural numbers, i=1, 2, ..., N, j=1, 2, ..., M, k=1, 2, ..., Num.

[0036] The detection module is used to acquire the welding status information of the welding machine under preset welding conditions. If any of the j-th time points and any k-th working states in the welding status information of the welding machine to be detected are... All meet If the welding quality of the weld to be inspected is deemed acceptable, then the weld quality is deemed acceptable. and All are correction factors. , .

[0037] In this embodiment, Num=3, the first operating state is the voltage frequency, the second operating state is the current frequency, and the third operating state is the phase difference between voltage and current.

[0038] In this embodiment, the welding machine is an ultrasonic welding machine.

[0039] In this embodiment, , Where a is the correction factor caused by the welding material, b is the correction factor caused by the welding parameters, and c is the correction factor caused by the welding area.

[0040] This embodiment three provides a terminal, including: a memory for storing a computer program; and a processor for executing the computer program to implement the steps of the detection method as described in embodiment one.

[0041] This embodiment four provides a readable storage medium on which a computer program is stored. When the computer program is executed by a processor, it implements the steps of the detection method as described in embodiment one.

[0042] It should be noted that although the steps are described in a specific order above, it does not mean that the steps must be executed in the above specific order. In fact, some of these steps can be executed concurrently, or even in a different order, as long as the required function can be achieved.

[0043] This invention can be a system, method, and / or computer program product. A computer program product may include a readable storage medium having computer-readable program instructions loaded thereon for causing a processor to implement various aspects of the invention.

[0044] A readable storage medium can be a tangible device that holds and stores instructions for use by an instruction execution device. Readable storage media can include, for example, but not limited to, electrical storage devices, magnetic storage devices, optical storage devices, electromagnetic storage devices, semiconductor storage devices, or any suitable combination thereof. More specific examples (a non-exhaustive list) of readable storage media include: portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), static random access memory (SRAM), portable compact disc read-only memory (CD-ROM), digital multifunction disc (DVD), memory sticks, floppy disks, mechanical encoding devices, such as punch cards or recessed protrusions storing instructions thereon, and any suitable combination thereof.

[0045] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or technical improvements to the embodiments in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A method for detecting the welding quality of a welding machine, characterized in that, Includes the following steps: Obtain N welding status information points of the welding machine under preset welding conditions. The welding quality of all N welds is qualified. The i-th welding status information point contains M time points and Num different working states of the welding machine corresponding to the j-th time point. This represents the k-th working state at the j-th time point in the i-th welding status information; the maximum value of the k-th working state at the j-th time point. The minimum value of the k-th working state at the j-th time point. Where N, M, Num, i, j, and k are all natural numbers, i = 1, 2, ..., N, j = 1, 2, ..., M, and k = 1, 2, ..., Num; Obtain the welding status information of the welding machine under preset welding conditions. If any working state at any j-th time point in the welding status information of the welding machine to be inspected is... All meet If the welding quality of the weld to be inspected is deemed acceptable, then the weld quality is deemed acceptable. and All are correction factors. , .

2. The detection method according to claim 1, characterized in that, Num=3, the first operating state is the voltage frequency, the second operating state is the current frequency, and the third operating state is the phase difference between voltage and current.

3. The detection method according to claim 1, characterized in that, The welding machine is an ultrasonic welding machine.

4. The detection method according to claim 1, characterized in that, , Where a is the correction factor caused by the welding material, b is the correction factor caused by the welding parameters, and c is the correction factor caused by the welding area.

5. A welding quality detection device for a welding machine, characterized in that, Includes the following modules: The information processing module is used to acquire N welding status information of the welding machine under preset welding conditions. The welding quality of all N welds is qualified. The i-th welding status information includes M time points and Num different working states of the welding machine corresponding to the j-th time point. This represents the k-th working state at the j-th time point in the i-th welding status information; the maximum value of the k-th working state at the j-th time point. The minimum value of the k-th working state at the j-th time point. Where N, M, Num, i, j, and k are all natural numbers, i = 1, 2, ..., N, j = 1, 2, ..., M, and k = 1, 2, ..., Num; The detection module is used to acquire the welding status information of the welding machine under preset welding conditions. If any of the j-th time points and any k-th working states in the welding status information of the welding machine to be detected are... All meet If the welding quality of the weld to be inspected is deemed acceptable, then the weld quality is deemed acceptable. and All are correction factors. , .

6. The detection device according to claim 5, characterized in that, Num=3, the first operating state is the voltage frequency, the second operating state is the current frequency, and the third operating state is the phase difference between voltage and current.

7. The detection device according to claim 5, characterized in that, The welding machine is an ultrasonic welding machine.

8. The detection device according to claim 5, characterized in that, , Where a is the correction factor caused by the welding material, b is the correction factor caused by the welding parameters, and c is the correction factor caused by the welding area.

9. A terminal, characterized in that, include: Memory, used to store computer programs; A processor for executing the computer program to implement the steps of the detection method as described in any one of claims 1 to 4.

10. A readable storage medium, characterized in that, The readable storage medium stores a computer program that, when executed by a processor, implements the steps of the detection method as described in any one of claims 1 to 4.

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