Manual argon arc welding simulation training method and system

Abstract

A manual argon arc welding simulation training method and system are provided. The manual argon arc welding simulation training method is performed using a simulation training system. First, the system is in a teaching mode, a first operator uses a mechanical motion system to simulate welding, and a control system collects welding data and fits a welding standard motion trajectory formula, which is a polynomial function. Then, the system is in a learning mode, a second operator uses a simulated welding torch to simulate welding, and an upper control unit records the movement data of the simulated welding torch and real-time fitting calculation of the actual movement trajectory formula of the welding torch. Finally, the actual movement trajectory formula and the constant coefficients of the standard motion trajectory formula are compared to determine whether there is a deviation in real time. The above method fits the welding trajectory into a polynomial function, automatically filters out high-frequency dithering noise using the function regression process, and makes the entire device and method have better anti-interference ability.

Description

Technical Field

[0001] This invention relates to the field of simulation training, specifically to a manual argon arc welding simulation training method and system. Background Technology

[0002] Welding is a common industrial processing method widely used in shipbuilding, nuclear power, automotive, and aerospace industries. Despite the extensive use of automated and semi-automated welding machines, manual welding remains a widely employed method. Compared to automated and semi-automated machines, manual welding is more flexible and has a wider range of applications.

[0003] Argon arc welding includes consumable electrode argon arc welding and non-consumable electrode argon arc welding. Consumable electrode argon arc welding uses a metal welding wire as the electrode, which is automatically fed in and melted. Non-consumable electrode argon arc welding uses a metal material with a relatively high melting point as the electrode to generate an electric arc. During welding, the welding wire filling the weld seam enters from one side.

[0004] Qualified welders need to master the correct operating techniques, therefore a simulation training device and method are needed to effectively improve the quality and efficiency of welder training.

[0005] Chinese patent CN104169996A discloses a welding skills education support device, including an operating unit, a display, a worktable with a 3D input / output device, and a support platform for supporting the worktable. The worktable is configured on the support platform so that the angle of the display can be changed. The 3D input / output device acquires and records the position information of the operating unit simulating a welding torch, and outputs images and sounds corresponding to the position information, thereby easily simulating the welding environment. By recording the position information and comparing it with reference data, errors can be displayed, scores can be calculated, and evaluations can be performed. This method uses the center point of the sphere of the 3D input / output device as the origin. After the front-end data obtained by the user holding and moving the operating unit is captured, the scoring is judged by comparing the position coordinate information and the weld line protrusion.

[0006] However, the inventors found in practice that this method requires recording and comparing a series of discrete three-dimensional coordinate points. In actual operation, even the slightest hand tremor will be recorded as discrete data. This discrete data will generate noise, causing frequent alarms during comparison and affecting the actual teaching process. Summary of the Invention

[0007] One object of the present invention is to provide a manual argon arc welding simulation training method that can solve the above-mentioned problems.

[0008] To achieve the above objectives, a manual TIG welding simulation training method is implemented using a simulation training system. This system includes a host control unit and a mechanical motion unit, the latter comprising a simulated welding torch. The method includes the following steps: 1) Setting the system to teaching mode, a first operator simulates welding using the simulated welding torch, and the host control unit collects welding data and fits it into a standard welding trajectory formula; 2) Setting the system to learning mode, a second operator simulates welding using the simulated welding torch, and the host control unit records the movement data of the simulated welding torch and fits the actual movement trajectory formula of the torch in real time; 3) Comparing the constant coefficients of the actual movement trajectory formula with the constant coefficients of the standard movement trajectory formula, and determining in real time whether there is a deviation. If a deviation exists and does not meet preset conditions, the trajectory of the simulated welding torch is corrected.

[0009] In one or more embodiments, the welding standard motion trajectory formula is a polynomial function, including multiple constant coefficients, with time as the independent variable and the front end position of the simulated welding torch as the dependent variable.

[0010] In one or more embodiments, both the standard motion trajectory formula and the actual movement trajectory formula include a lateral oscillation function and a welding forward direction function: the lateral oscillation function is y(t) = At. 4 +Bt 3 +Ct 2 +Dt+E, where A, B, C, D, and E are constants, t is time, and y is the position of the welding torch tip in the lateral swing direction over time; the welding forward direction function is x(t)=Gt 4 +Ht 3 +It 2 +Jt+K, where G, H, I, J, and K are constants, t is time, and x is the position of the welding torch tip in the welding forward direction over time.

[0011] In one or more embodiments, the upper control unit further includes a trajectory display screen, which displays in real time the weld formation pattern when the second operator uses the simulated welding gun to simulate welding, and compares it with the weld formation pattern recorded when the first operator uses the simulated welding gun to simulate welding.

[0012] In one or more embodiments, the standard motion trajectory formula generated each time in the teaching mode is independent of each other and stored in association with the information of the first operator.

[0013] In one or more embodiments, welding posture correction is performed according to the following steps: comparing the constant coefficients of the actual movement trajectory formula with the constant coefficients of the standard movement trajectory formula; when the deviation of any constant coefficient exceeds a preset threshold, a welding posture correction command is triggered; the upper control unit transmits a correction command to the mechanical motion unit based on the deviation of the constant coefficients, and applies a guiding force to the simulated welding torch; the upper control unit continuously receives the movement data of the simulated welding torch; when the deviations of the constant coefficients corresponding to the actual movement trajectory formula and the constant coefficients of the standard movement trajectory formula are all less than or equal to the preset threshold, the correction command output is stopped, and the simulated welding torch returns to its follow-up state.

[0014] Another object of the present invention is to provide a manual argon arc welding simulation training system, the system comprising: The system includes: an operating platform; a mechanical motion unit comprising a simulated welding torch and a multi-dimensional connection component, the multi-dimensional connection component connecting the operating platform and the simulated welding torch and configured to adjust the posture and position of the simulated welding torch in space, the simulated welding torch simulating actual welding operations; a detection unit for collecting motion data of the simulated welding torch in space; and a host control unit disposed on the operating platform, connected to the mechanical motion unit and the detection unit respectively, for calculating the standard motion trajectory formula and the actual movement trajectory formula and performing constant comparison.

[0015] In one or more embodiments, the multi-dimensional connection assembly includes a slider and a universal support arm, the slider being movably disposed on the operating table along the main welding direction, and the two ends of the universal support arm being rotatably connected to the slider and the simulated welding torch, respectively.

[0016] In one or more embodiments, the end of the universal support arm includes a spherical connecting end, the slider includes an arc-shaped groove, the spherical connecting end is located in the arc-shaped groove, and the system further includes a magnetic induction limiting structure, the magnetic induction limiting structure includes a magnetic field generating component and a plurality of rolling balls located between the spherical connecting end and the arc-shaped groove, the plurality of rolling balls being arranged circumferentially spaced along the spherical connecting end, the magnetic field generating component being used to generate a magnetic field acting on the plurality of rolling balls to cause the rolling balls to move radially, forming a limiting structure and / or a guiding structure.

[0017] The above method fits the welding trajectory to a function and automatically filters out high-frequency jitter noise through the function regression process. The constant coefficient can reflect the overall contour and trend of the trajectory, making the evaluation results more focused on the overall skill stability and route trend, avoiding the problem of excessive alarms, and giving the whole device and method better anti-interference ability. Attached Figure Description

[0018] The above and other features, properties and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings and embodiments, wherein: Figure 1 This is a schematic diagram of a manual argon arc welding simulation training system; Figure 2 yes Figure 1 Enlarged view of point P in the middle; Figure 3 This is a schematic diagram of one embodiment of the magnetic induction limiting structure; Figure 4 yes Figure 3 Enlarged view of the middle T section; Figure 5 yes Figure 1 Enlarged view of point Q; Figure 6 It is a schematic diagram of the crescent-shaped function and its trajectory; Figure 7 This is a flowchart of a manual argon arc welding simulation training method. Detailed Implementation

[0019] The present invention will be further described below with reference to specific embodiments and accompanying drawings. More details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention can obviously be implemented in many other ways different from those described herein. Those skilled in the art can make similar extensions and derivations based on actual application situations without departing from the spirit of the present invention. Therefore, the scope of protection of the present invention should not be limited by the content of this specific embodiment.

[0020] It should be noted that these and other accompanying drawings are merely examples and are not drawn to scale, and should not be construed as limiting the scope of protection of the present invention.

[0021] Figure 1 A schematic diagram of a manual argon arc welding simulation training system is shown, including an operating console 1, a host control unit 2, a mechanical motion unit 3, a detection unit 4, and a display screen 7.

[0022] The control panel 1 serves as the overall support module, with all other components placed on top of it. A self-locking caster assembly can be installed at the bottom of the control panel 1 for easy movement.

[0023] The mechanical motion unit 3 includes a simulated welding torch 5 and a multi-dimensional connection assembly 30. The simulated welding torch 5 is held by the operator to simulate actual welding operations, and the multi-dimensional connection assembly 30 is used to connect the operating table 1 and the simulated welding torch 5. The multi-dimensional connection assembly 30 is configured to adjust the posture and position of the simulated welding torch 5 in space.

[0024] Furthermore, the multi-dimensional connection component 30 includes a slider 31 and a universal support arm 32. The two ends of the universal support arm are rotatably connected to the slider 31 and the simulated welding torch 5, respectively. The operating table 1 is provided with a slide rail 21, and the slider 31 cooperates with the slide rail 21 on the operating table 1, driving the universal support arm 32 and the simulated welding torch 5 to be movably mounted on the operating table along the main welding direction.

[0025] The main welding direction is the welding forward direction, i.e., the X direction shown in the figure, which is also the overall extension direction of weld M. Of course, the actual welding direction can be either +X or -X. In addition, welding also has an oscillation direction, i.e., the Y direction shown in the figure. The XY plane formed by the X and Y directions constitutes the plane of the operating table 1. The height direction Z is orthogonal to both the X and Y directions.

[0026] Furthermore, refer to Figure 1 and Figure 2 As shown, the universal support arm 32 includes a first universal support arm 321 and a second universal support arm 322. One end of the first universal support arm 321 is connected to the second universal support arm 322 via a first connector 33, and the other end of the first universal support arm 321 is connected to the slider 31 via a second connector 34. The second universal support arm 322 is connected to the simulated welding gun 5 via a third connector 35.

[0027] The first connector 33, the second connector 34, and the third connector 35 can be universal swivel joints or ball joints to achieve 360° rotation, ensuring flexible and unrestricted movement in the X, Y, and Z axes during practice; or they can be rotating locking blocks, allowing the two connecting parts to rotate around the fixed axis of one of the parts and be locked after reaching the ideal position.

[0028] Further reference Figure 3 and Figure 4 The second connector 34 shown forms a universal rotary joint structure. The end of the first universal support arm 321 is provided with a spherical connecting end 29, and the slider 31 is provided with a protruding shaft 310. The protruding shaft 310 has an arc-shaped groove 28 that matches the spherical connecting end 29. The spherical connecting end 29 is accommodated within the arc-shaped groove 28, thus forming a ball-and-socket rotatable connection structure.

[0029] Preferably, this ball-and-socket rotatable connection structure enables the universal support arm 32 to rotate 360°, ensuring flexible and unrestricted movement in the X, Y, and Z axes during practice.

[0030] It is understandable that the first connector 33, the second connector 34, and the third connector 35 can all be this type of ball-and-socket rotatable connection structure.

[0031] More preferably, the multi-dimensional connection component 30 enables the simulated welding torch 5 to achieve six degrees of freedom of movement, including three translational degrees of freedom (X, Y, Z) and one rotational degree of freedom (X, Y, Z) about the three axes (X, Y, Z).

[0032] In this way, the slider 31, the second connector 34, the first universal support arm 321, the first connector 33, the second universal support arm 322, the simulated welding torch 5, and other components form an integrated mechanical motion system.

[0033] The ball-and-socket rotatable connection structure also includes a probe 57, which serves as a sensor. The probe 57 is part of the detection unit 4 and is used to record the movement position of the ball-shaped connection end 29, which is then transmitted to the upper control unit 2 via the signal transmission line 58.

[0034] In some embodiments, the ball-and-socket rotatable connection structure is further provided with a magnetic limiting structure 50. The magnetic limiting structure is disposed between the spherical connection end 29 and the arc-shaped groove 28, and includes a plurality of rolling balls 55 and a magnetic field generating component 56.

[0035] The multiple rolling spheres 55 are preferably steel balls, and are spaced apart circumferentially between the spherical connecting end 29 and the arc-shaped groove 28. The magnetic field generating component 56 is disposed inside the spherical-groove rotatable connecting structure, and can be located on the periphery of the steel balls 55; of course, the magnetic field generating component can also be located outside the spherical-groove rotatable connecting structure.

[0036] The magnetic field generating components include, but are not limited to, electromagnet components.

[0037] When the magnetic field generating component is not in operation, the rolling ball 55 is not subjected to radial clamping force and can roll freely between the spherical connecting end 29 and the arc-shaped groove 28 without rolling out of the arc-shaped groove 28. At this time, the spherical connecting end 29 and the arc-shaped groove 28 mainly form rolling contact, and the universal support arm can rotate relatively smoothly relative to the slider, thereby reducing operating resistance and improving movement flexibility.

[0038] When the magnetic field generating component is energized, the magnetic field acts on multiple rolling balls 55, causing them to move radially. For example, the rolling balls 55 move radially toward the spherical connecting end 29 to press against its surface, thereby increasing the contact pressure and friction between the spherical connecting end 29 and the arc-shaped groove 28. This increases the swing resistance of the universal support arm, forming a limiting structure. When the excitation current of the electromagnet component is further increased, the rolling balls 55 generate a greater pressing force on the spherical connecting end, keeping the universal support arm in a set posture and preventing it from shifting. Alternatively, multiple rolling balls 55 acting together on the spherical connecting end 29 cause it to move in a specific direction, forming a guiding structure. A guiding effect can also be achieved by applying differentiated magnetic field strengths to the rolling balls in different directions to create directional damping.

[0039] Therefore, when the deviation of the practice trajectory parameters exceeds the threshold, this magnetic induction limiting structure triggers the force control function, applies a restrictive force to the simulated welding torch and universal support arm, guides and corrects the trainee's operation, and constrains the welding torch posture back to the standard trajectory range.

[0040] Continue to refer to Figure 5 As shown, the simulated welding torch 5 can be equipped with a simulation practice control switch 51, which is used to start or stop the welding torch.

[0041] The detection unit 4 is used to collect motion data of the simulated welding torch 5 in space, including but not limited to the laser tracker 41, the trajectory acquisition module 42, and the vision component.

[0042] For example, the laser tracker 41 emits an infrared laser beam that shines on the end of the simulated welding torch or the operator's hand. It obtains the distance from the target to the tracker host through laser interferometry and then converts the data into the target's precise spatial position through coordinate transformation.

[0043] For example, the trajectory acquisition module 42 includes, but is not limited to, an X-axis acquisition module, a Y-axis acquisition module, and a Z-axis acquisition module. Figure 1 The settings shown are for illustrative purposes only. The X-axis acquisition module can use a linear encoder or grating ruler to record the step distance in the welding direction. The Y-axis acquisition module can directly use a linear encoder or grating ruler to record lateral data, or it can use a rotary encoder to record the rotation angle and convert it into lateral displacement.

[0044] Alternatively, vision components such as cameras can be used to capture the specific movement position of the welding torch tip to calculate the trajectory and pose.

[0045] A trajectory display screen 6 can be set below the simulated welding torch 5. The trajectory display screen 6 can display the welding graphic trajectory according to the simulated output of welding current and voltage, realizing the visualization of analog digital practice.

[0046] As mentioned above, if tens of thousands of coordinate points need to be stored and compared each time the welding process is judged, this method requires a large amount of data storage and is easily affected by noisy data, which is not conducive to teaching.

[0047] Based on this, the manual argon arc welding simulation training method described in this disclosure can fit the welding trajectory into a concise mathematical formula to characterize the trajectory. Compared with simple physical coordinate alignment or single parameter comparison, this method has better anti-interference ability and better evaluation efficiency.

[0048] Specifically, the method includes the following steps: S1. Put the system into teaching mode, have the first operator simulate welding using the simulated welding torch 5, and use the upper control unit 2 to collect welding data and fit it into a standard welding trajectory formula. The welding data includes at least real-time two-dimensional data of the movement of the simulated welding torch 5. The standard welding trajectory formula is a polynomial function, including multiple constant coefficients, with time as the independent variable and the position of the simulated welding torch tip as the dependent variable. The first operator is generally the instructor. Specifically, it includes a lateral oscillation function and a welding forward direction function, which will be described in detail later.

[0049] S2. Put the system into learning mode, allowing the second operator to simulate welding using the simulated welding torch 5. The upper control unit records the movement data of the simulated welding torch and calculates the actual movement trajectory formula of the welding torch in real time. The second operator is usually a trainee.

[0050] S3. Compare the constant coefficients of the actual movement trajectory formula with those of the standard movement trajectory formula to determine in real time whether there is a deviation. If a deviation exists and does not meet the preset conditions, the mechanical motion system actively corrects the trajectory of the simulated welding torch, for example, by using a magnetic limiting structure to limit the movement of the universal support arm. The preset conditions can take various forms depending on the actual working conditions, such as the deviation of a certain constant coefficient exceeding a set threshold, or the deviation of at least two constant coefficients exceeding a set threshold.

[0051] This method enables the upper control unit 2 to have two built-in modes: "teaching mode" and "learning mode".

[0052] The "teaching mode" refers to a system where the instructor demonstrates on-site, dynamically generates weld seams, and writes them into the system in real time to obtain a standard motion trajectory formula for teaching. Because different instructors may have different teaching styles, this method allows the standard motion trajectory formula to be generated independently for each teaching mode and matched with the information from the first operator. The standard motion trajectory formula in the "teaching mode" serves as a guide and correction benchmark in subsequent "learning modes."

[0053] In "learning mode," trainees hold a simulated welding torch and press the simulation practice control switch to perform simulated practice. The detection unit 4 collects the trainee's welding torch trajectory in real time, and the upper control unit 2 compares the practice trajectory parameters with the constant coefficients in the standard motion trajectory formula stored in S1. When a deviation is detected, the mechanical motion unit 3 actively corrects the trajectory of the simulated welding torch 5.

[0054] Specifically, welding posture correction should be performed according to the following steps.

[0055] First, the upper control unit 2 receives and fits the student practice trajectory data collected by the detection unit 4 in real time to obtain the actual movement trajectory formula. The constant coefficient of the actual movement trajectory formula corresponding to the current trajectory is compared with the parameters in the standard motion trajectory formula stored in the teaching mode. When the deviation of any parameter exceeds the preset threshold, the welding posture correction command is triggered.

[0056] Subsequently, the upper control unit 2 transmits a correction command to the mechanical motion unit based on the deviation of the constant coefficient, and applies a guiding force to the simulated welding torch. The guiding force has a higher priority than the force applied to the simulated welding torch by the second operator. That is, the magnitude of the guiding force is set to be able to overcome the operating deviation force of the second operator, so as to forcibly constrain the simulated welding torch to return to the standard trajectory.

[0057] Specifically, the upper control unit 2 outputs correction data to the multi-dimensional connection component 30 in the mechanical motion unit 3 according to the deviation amount.

[0058] In one specific embodiment, the upper control unit 2 decomposes the deviation of each constant coefficient and distinguishes between the deviation in the lateral swing direction (Y direction) and the deviation in the welding forward direction (X direction).

[0059] For the deviation of the constant coefficient in the lateral swing function y(t), the upper control unit 2 sends an excitation command to the magnetic induction limiting structure 50 at the corresponding universal support arm connection end, and linearly adjusts the excitation current of the magnetic field generating component 56 according to the magnitude of the deviation: the larger the deviation, the stronger the excitation current, the greater the radial clamping force applied by the rolling ball 55 to the spherical connection end 29, and the swing resistance of the universal support arm 32 in the corresponding direction increases accordingly, thereby constraining the lateral movement range of the simulated welding torch 5 to the interval corresponding to the standard trajectory.

[0060] For the welding forward direction function, the upper control unit 2 can synchronously output the displacement correction amount to the actuator of the drive slider 31, so that the slider 31 can actively compensate along the slide rail 21 in the X direction to correct the overall offset trend of the welding torch forward speed or position.

[0061] When there is a combined deviation between the lateral direction and the forward direction, the upper control unit 2 can output the two correction commands superimposed. The direction and magnitude of the guiding force are determined by the synthesis of each deviation component, so that the simulated welding torch 5 approaches the spatial posture described by the standard motion trajectory formula.

[0062] The corrective guiding force has a higher priority than the force applied by the second operator to the simulated welding torch, and its magnitude is set to be sufficient to overcome the continuous force applied by the operator in the deviating direction, thereby achieving forced guidance of the simulated welding torch 5's posture.

[0063] Throughout the correction process, the upper control unit continuously receives and fits the movement data of the simulated welding torch, dynamically updates the constant coefficients of the actual movement trajectory formula, and re-compares each constant coefficient with the corresponding coefficients of the standard movement trajectory formula. When the deviations of each constant coefficient corresponding to the actual movement trajectory formula from each constant coefficient corresponding to the standard movement trajectory formula are all less than or equal to the preset threshold, the correction command output stops, the system withdraws the forced guiding force, and the simulated welding torch returns to its follow-up state.

[0064] The upper control unit will score the data based on the correction. The number of times the magnetic limit lever is triggered is used as the scoring criterion; the fewer the triggers, the smaller the deviation of the trainee and the more standardized the operation.

[0065] For example, if the number of triggers is ≤3 and the constant deviation rate is within 10% throughout the entire learning process, it can be rated as full marks. If the number of triggers is greater than or equal to 10 throughout the entire learning process, it is judged as failing.

[0066] Display screen 7 can perform dual-track comparison assessment and training profiles, overlaying the trainee's practice trajectory with the standard trajectory stored in S1 on the trajectory display screen, providing direct feedback through the overlap of the dual tracks. If the curves do not overlap, the trainee can immediately visually perceive the error in their posture.

[0067] In this way, the device can "force" the trainee's hand movements back to the correct path, thereby achieving posture correction at the level of muscle memory.

[0068] Both the standard motion trajectory formula and the actual movement trajectory formula include a lateral swing function and a welding forward direction function.

[0069] Specifically, in argon arc welding, the oscillation of the welding torch tip involves two types of "crescent moons"—one convex and one concave—to weld forward, such as... Figure 6 As shown.

[0070] The lateral oscillation function is y(t) = At 4 +Bt 3 +Ct 2 +Dt+E, where A, B, C, D, and E are constants, t is time, and y is the position of the welding torch tip in the lateral swing direction over time.

[0071] The welding forward direction function is x(t) = Gt 4 +Ht 3 +It 2 +Jt+K, where G, H, I, J, and K are constants, t is time, and x is the position of the welding torch tip in the welding forward direction over time.

[0072] Here, x(t) refers to the position of the welding torch in the welding forward direction over time, and y(t) refers to the position of the welding torch in the lateral swing direction over time. The combination of the two describes the trajectory of the welding torch tip in a two-dimensional plane. t is a time parameter. As t increases from 0, the curve formed by x(t) and y(t) is the actual movement path of the welding torch.

[0073] A, B, C, D, and E are five coefficients that control the Y-direction (lateral swing), and G, H, I, J, and K are five coefficients that control the X-direction (forward direction).

[0074] The two sets of coefficients are independent of each other, determining the amplitude, frequency, rhythm of the lateral swing, as well as the speed and variation of the forward movement. During the coach's demonstration, the upper control unit uses the collected motion data to calculate the specific values ​​of these ten parameters and stores them as standard constant coefficients.

[0075] This formula uses a fourth-order polynomial to characterize the welding trajectory, providing sufficient bending degrees of freedom to fit the asymmetric, accelerated / decelerated curve of the "crescent moon" shape. Simultaneously, the number of parameters A, B, C, D, E or G, H, I, J, K is not excessive, facilitating real-time calculation and storage by the system. Reducing the number of parameters, for example, by using only a second-order parabola, fails to describe the acceleration and deceleration changes during the oscillation process; using higher-order polynomials results in too many parameters, leading to excessive computation and a high risk of overfitting.

[0076] Furthermore, the oscillation of the welding torch tip creates two "crescent" shapes for forward welding, one convex and one concave, such as... Figure 6 As shown, both the standard motion trajectory formula and the actual motion trajectory formula include upper convex curve functions and lower convex curve functions.

[0077] For example in Figure 6 In the embodiment shown, the horizontal axis x represents the welding direction, and the vertical axis y represents the transverse swing offset.

[0078] For the upwardly convex "crescent" region, t is within [0.2, 0.5], and y increases from a negative peak value to 0, that is, to a positive peak value. For the downwardly convex "crescent" region, t is roughly within [0, 0.2], and y changes from 0 to a negative peak value.

[0079] T within [0.5-1] belongs to the next cycle, further including an upper convex "half-moon" region and a lower convex "half-moon" region. At this time, the welding trajectory is... At this point, g=192, h=-192, i=40, j=-4, k=0, ensuring a single direction of travel. , where a, b, c, d are 1 and e is 0.

[0080] Therefore, this method specifically establishes a fourth-order polynomial trajectory model for the kinematic characteristics of the "crescent" oscillation in manual argon arc welding. The two oscillation modes are precisely quantified and characterized by parameters A to K, which is the core technology that enables the system to accurately compare and reproduce the oscillation.

[0081] This method automatically filters out high-frequency jitter noise by fitting the welding trajectory to a polynomial function and using the function regression process. The constant coefficients can reflect the overall contour and trend of the trajectory, making the evaluation results more focused on the overall skill stability and route trend, avoiding the problem of excessive alarms, and giving the whole device and method better anti-interference ability.

[0082] Furthermore, the quality of welding essentially depends on the trajectory of the welding torch relative to the weld seam, rather than the absolute position of the torch in space. Compared to a scheme that uses the center point of a sphere on the device as the origin, changing the origin to the starting point of the welding torch movement more accurately reflects the weld seam trajectory and the essence of welding.

[0083] Furthermore, this method allows for interruption and restart of the teaching process. Even if the trainee stops during the current welding process for any reason, it will not change the system's fitting result of the polynomial function of the collected segments. When restarting welding learning, the trainee can still move to the current position, the detection unit continues to collect information, and the upper control unit continues to fit the welding trajectory without any changes, thus exhibiting better applicability.

[0084] The method will be briefly described below through a specific embodiment.

[0085] The first step is to power on the upper control unit, mechanical motion unit, etc., to ensure the stability of the overall operation. The upper control unit is then set to "teaching mode" and the parameters for simulated welding are set, including welding current, voltage, and welding speed.

[0086] In the second step, the instructor, acting as the first operator, holds the simulated welding torch 5 and presses the simulation practice control switch 51 to perform simulated welding. The weld formation will be displayed on the trajectory display screen 6. At this time, the laser tracker and trajectory acquisition module work simultaneously to record the running trajectory of the simulated welding torch tip and store it in the upper control unit. Simultaneously, the universal support arm and each universal connector record the spatial position during the overall operation and feed it back to the upper control unit. This process uses the welding start point (0, 0) as the starting coordinate.

[0087] Based on the recorded data and the oscillation of the welding torch tip, the upper control unit fits the trajectory into a polynomial and calculates the constants A, B, C, D, E, G, H, I, J, and K, which are then stored in the control system as standard values ​​to guide subsequent trajectory welding.

[0088] Subsequently, when the trainee begins practicing as the second operator, the system is switched to "learning mode" via the upper control unit.

[0089] The trainee holds the simulated welding torch 5 and presses the simulation practice control switch 51 to conduct a simulated practice. At this time, the laser tracker and the trajectory acquisition module work simultaneously to record the trajectory of the simulated welding torch's front end.

[0090] After receiving the welding torch motion trajectory parameters, the upper control unit calculates the actual constant coefficient values ​​according to the above fitting steps and calibrates them against the standard values. If there is a deviation, it is corrected by the mechanical motion unit, which applies a restrictive force to the simulated welding torch 5 to constrain the welding torch posture back to the standard trajectory range. By correcting the operator's welding technique, muscle memory is formed, accelerating training efficiency.

[0091] By comparing the weld seams produced during practice with those input by the instructor, the difference in forming is visually displayed, allowing for targeted solutions to operational technique issues and ultimately forming a closed-loop training system.

[0092] Finally, the total practice time can be recorded according to name or unique attribute of the trainee, forming a trainee training profile. Furthermore, the obtained standard motion trajectory formulas can be stored one-to-one with the instructor for easy future use.

[0093] It should be noted that the use of terms such as "first" and "second" to define the components in the above content is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application.

[0094] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms 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 a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0095] Furthermore, this application uses specific terms to describe embodiments of the application. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic related to at least one embodiment of the application. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0096] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the invention, fall within the protection scope defined by the claims of the present invention.

Claims

1. A manual argon arc welding simulation training method, using a simulation training system, the system comprising a host control unit and a mechanical motion unit, wherein the mechanical motion unit includes a simulated welding torch, characterized in that... The method includes the following steps: The system is put into teaching mode, and the first operator uses a simulated welding gun to simulate welding. The upper control unit collects welding data and fits it into a standard welding motion trajectory formula. The system is put into learning mode, and the second operator uses a simulated welding torch to simulate welding. The upper control unit records the movement data of the simulated welding torch and fits the actual movement trajectory formula of the welding torch in real time. The constant coefficients of the actual movement trajectory formula are compared with the constant coefficients of the standard movement trajectory formula to determine in real time whether there is a deviation. If there is a deviation and the deviation does not meet the preset conditions, the running trajectory of the simulated welding torch is corrected.

2. The manual argon arc welding simulation training method as described in claim 1, characterized in that, The welding standard motion trajectory formula is a polynomial function, including multiple constant coefficients, with time as the independent variable and the end position of the simulated welding torch as the dependent variable.

3. The manual argon arc welding simulation training method as claimed in claim 2, wherein, Both the standard motion trajectory formula and the actual movement trajectory formula include a lateral oscillation function and a welding forward direction function: The lateral oscillation function is y(t) = At. 4 +Bt 3 +Ct 2 +Dt+E, where A, B, C, D, and E are constants, t is time, and y is the position of the welding torch tip in the lateral swing direction over time; The welding forward direction function is x(t) = Gt 4 +Ht 3 +It 2 +Jt+K, where G, H, I, J, and K are constants, t is time, and x is the position of the welding torch tip in the welding forward direction over time.

4. The manual argon arc welding simulation training method as claimed in claim 1, wherein, The upper control unit also includes a trajectory display screen, which displays the weld formation pattern when the second operator uses the simulated welding gun to simulate welding in real time, and compares it with the weld formation pattern recorded when the first operator uses the simulated welding gun to simulate welding.

5. The manual argon arc welding simulation training method as claimed in claim 1, wherein, The standard motion trajectory formula generated each time in the teaching mode is independent of each other and stored in association with the information of the first operator.

6. The manual argon arc welding simulation training method as claimed in claim 2, wherein, Follow these steps to correct the welding posture: The constant coefficients of the actual movement trajectory formula are compared with the constant coefficients of the standard movement trajectory formula. When the deviation of any constant coefficient exceeds a preset threshold, a welding posture correction command is triggered. The upper control unit transmits a correction command to the mechanical motion unit based on the deviation of the constant coefficient, thereby applying a guiding force to the simulated welding torch; The upper control unit continuously receives the movement data of the simulated welding torch. When the deviations of each constant coefficient corresponding to the actual movement trajectory formula from each constant coefficient of the standard movement trajectory formula are all less than or equal to the preset threshold, the correction command output is stopped, and the simulated welding torch returns to the follow-up state.

7. A manual argon arc welding simulation training system characterized by, For implementing the manual argon arc welding simulation training method as described in any one of claims 1-6, the system comprises: Control panel; The mechanical motion unit includes a simulated welding torch and a multi-dimensional connection component. The multi-dimensional connection component is used to connect the operating table and the simulated welding torch, and is configured to adjust the posture and position of the simulated welding torch in space. The simulated welding torch is used to simulate actual welding operations. A detection unit is used to collect motion data of the simulated welding torch in space; and The upper control unit is set on the operating table and is connected to the mechanical motion unit and the detection unit respectively. It is used to calculate the standard motion trajectory formula and the actual movement trajectory formula and to compare the constants.

8. The manual argon arc welding simulation training system as defined in claim 7 wherein, The multi-dimensional connection component includes a slider and a universal support arm. The slider is movably mounted on the operating table along the main welding direction, and the two ends of the universal support arm are rotatably connected to the slider and the simulated welding torch, respectively.

9. The manual argon arc welding simulation training system as defined in claim 8 wherein, The end of the universal support arm includes a spherical connecting end, and the slider includes an arc-shaped groove, with the spherical connecting end located within the arc-shaped groove. The system also includes a magnetic limiting structure, which includes a magnetic field generating component and a plurality of rolling balls located between the spherical connecting end and the arc-shaped groove. The plurality of rolling balls are arranged circumferentially at intervals along the spherical connecting end. The magnetic field generating component is used to generate a magnetic field acting on the plurality of rolling balls to make the rolling balls move radially, forming a limiting structure and / or a guiding structure.

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