A welding apparatus

Abstract

The application provides a welding device, relates to the field of product processing, and comprises a welding device, a driving mechanism, a displacement detection device, at least one pressing assembly and a control device; the pressing assembly is provided with an elastic pressing piece and an elastic piece which are connected in an elastic mode, the driving mechanism is in transmission connection with the elastic piece so as to drive the elastic pressing piece to reciprocate towards or away from the material to be welded; the control device is electrically connected with the driving mechanism, the displacement detection device and the welding device respectively, the displacement detection device is used for acquiring displacement information of the pressing assembly in the pressing process; the control device is used for acquiring the displacement information, determining a focal point compensation parameter based on the displacement information, controlling the welding device to adjust the welding focal point based on the focal point compensation parameter and welding the material to be welded. Through the elastic piece in the pressing assembly and the displacement detection feedback, the welding device can automatically adapt to the material to be welded with different heights, realize dynamic compensation of the welding focal point, and improve the welding precision and the production yield.

Description

Technical Field

[0001] This application relates to the field of product processing, and more particularly to a welding device. Background Technology

[0002] In the assembly process of new energy battery modules, the laser welding process typically requires first pressing and positioning the welding parts such as cell tabs and busbars using a copper block pressing mechanism, and then the laser head performs the welding to ensure stable adhesion of the welding area and reduce the risk of spatter. Existing production lines often use a fixed-stroke pressing method combined with a preset laser focus, i.e., the copper block pressing distance and laser focusing position are pre-set, and welding is performed directly after the copper block completes the fixed-stroke pressing. However, in actual production, due to factors such as cell size tolerances, busbar thickness fluctuations, assembly errors, and deformation of the pressing parts, the actual pressing height of the copper block will have slight deviations. This causes changes in the distance between the laser focus and the welding surface, resulting in welding defects such as incomplete welds, spalling, and uneven welds, affecting the welding yield and long-term safety of the battery module. Summary of the Invention

[0003] The purpose of this application is to address at least one of the aforementioned existing technical problems by providing a welding device that dynamically adjusts the welding focus by acquiring displacement information of the pressing component during the pressing process and determining focus compensation parameters based on the displacement information, thereby improving the matching accuracy, welding quality, and welding consistency between the welding focus and the area to be welded.

[0004] This application provides a welding device, comprising a welding apparatus, a driving mechanism, a displacement detection device, at least one pressing assembly, and a control device. The pressing assembly has a pressing member and an elastic member that are elastically connected. The driving mechanism is pulsatorically connected to the elastic member to drive the pressing member to reciprocate toward or away from the material to be welded. The control device is electrically connected to the driving mechanism, the displacement detection device, and the welding apparatus. The displacement detection device is used to acquire displacement information of the pressing assembly during the pressing process. The control device is used to acquire the displacement information, determine a focus compensation parameter based on the displacement information, and control the welding apparatus to adjust the welding focus based on the focus compensation parameter and weld the material to be welded.

[0005] In a possible implementation, the control device is configured to: acquire the displacement information, which includes the motion displacement data of the pressing member and the deformation displacement data of the elastic member; input the displacement information into a preset compensation model to calculate the focal offset and obtain the focal compensation parameters.

[0006] In a possible implementation, the welding equipment further includes a pressure sensing device electrically connected to the control device. The pressure sensing device is used to detect the pressure data applied by the pressing assembly to the material to be welded. When the pressure data meets a preset pressure threshold condition, the control device can acquire the displacement information.

[0007] In a possible implementation, the displacement detection device includes a detection beam emitter, a detection beam receiver, and a baffle; the baffle is fixedly connected to the pressing member, and the baffle can move synchronously with the pressing member; the detection beam emitter is used to emit a detection beam to the baffle; the detection beam receiver is used to receive the beam signal reflected by the baffle; and the control device is used to determine the displacement information based on the beam signal.

[0008] In a possible implementation, the at least one pressing component includes a first pressing device and a second pressing device, the first pressing device and the second pressing device being arranged at an interval; the first pressing device is used to press a first area to be welded of the material to be welded, and the second pressing device is used to press a second area to be welded of the material to be welded.

[0009] In a possible implementation, the displacement detection device includes a first displacement detection mechanism and a second displacement detection mechanism. The first displacement detection mechanism is used to acquire first displacement data of the first pressing device, and the second displacement detection mechanism is used to acquire second displacement data of the second pressing device. The control device is used to determine the focus compensation parameter based on the average of the first displacement data and the second displacement data.

[0010] In a possible implementation, the at least one pressing component further includes a third pressing device and a fourth pressing device; the first pressing device, the second pressing device, the third pressing device, and the fourth pressing device are arranged in a rectangular array.

[0011] In a possible implementation, the control device is configured to: control the welding device to stop welding and output an abnormal prompt message when the displacement difference between the first displacement data and the second displacement data meets a preset difference threshold condition.

[0012] In a possible implementation, the welding equipment further includes an image acquisition device electrically connected to the control device. The detection area of ​​the image acquisition device can cover at least a portion of the material to be welded. The image acquisition device is used to acquire first image information of the material to be welded. The control device is used to determine the positional state of the material to be welded based on the first image information. When the material to be welded meets preset welding conditions, the control device controls the drive mechanism to drive the pressing assembly to move toward the material to be welded.

[0013] In a possible implementation, the image acquisition device is used to acquire second image information of the welded material; the control device is used to determine the welding quality level based on the second image information, and if the welding quality level is within the preset repair welding level range, control the welding device to re-weld the welded material.

[0014] The welding equipment provided in this application has the following beneficial effects: This application provides a welding device, comprising a welding apparatus, a driving mechanism, a displacement detection device, at least one pressing assembly, and a control device. The pressing assembly has a pressing member and an elastic member elastically connected together. The driving mechanism is driven by the elastic member to drive the pressing member to reciprocate toward or away from the material to be welded. The control device is electrically connected to the driving mechanism, the displacement detection device, and the welding apparatus. The displacement detection device is used to acquire displacement information of the pressing assembly during the pressing process. The control device is used to acquire the displacement information, determine a focus compensation parameter based on the displacement information, and control the welding apparatus to adjust the welding focus based on the focus compensation parameter and weld the material to be welded. By setting the elastic member in the pressing assembly, the pressing member can generate elastic deformation according to the height change of the material to be welded during the pressing process. Combined with the real-time displacement information acquired by the displacement detection device and the determination of the focus compensation parameter, the welding apparatus is controlled to dynamically adjust the welding focus, realizing adaptive pressing and welding of products with different heights or thicknesses, thereby improving the welding focus matching accuracy, welding consistency, and product yield. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of this application, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the welding equipment in the embodiments of this application; Figure 2 This is a schematic diagram of the welding equipment in the embodiments of this application; Figure 3 This is a schematic diagram of the welding equipment in the embodiments of this application; Figure 4 This is a schematic diagram of the welding equipment in the embodiments of this application; Figure 5 This is a schematic diagram of the welding equipment in the embodiments of this application; Figure 6 This is a schematic diagram of the welding equipment in the embodiments of this application; Figure 7 This is a schematic diagram of the welding equipment in the embodiments of this application.

[0017] The following is supplementary explanation of the attached figures: 1. Pressing assembly; 1a. First pressing device; 1b. Second pressing device; 1c. Third pressing device; 1d. Fourth pressing device; 11. Pressing component; 12. Elastic component; 2. Displacement detection device; 21. Detection beam emitting component; 22. Baffle; 3. Drive mechanism; 4. Image acquisition device. Detailed Implementation

[0018] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] As used herein, "an embodiment" or "embodiment" refers to a specific feature, structure, or characteristic that may be included in at least one implementation of this application. In the description of this application, it should be understood that the terms "upper," "lower," "top," "bottom," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this application and for simplifying the description, and 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 of this application.

[0020] Understandably, in the assembly process of new energy battery modules, it is usually necessary to first use a copper block pressing mechanism to press and position the welding parts such as cell tabs and busbars, and then complete the welding operation using a laser welding device. In existing technologies, a combination of fixed stroke pressing and preset focus welding is commonly used, that is, the pressing stroke of the copper block and the laser welding focus parameters are preset, and welding is performed directly according to the preset focus after pressing is completed.

[0021] However, in actual production, due to factors such as product size tolerance, assembly clearance of mechanism, elastic deformation of pressing components and differences in workpiece surface flatness, there is often a deviation between the actual pressing state of the pressing components and the preset state. This causes the welding focus to shift from the target welding position, which in turn easily leads to welding quality problems such as incomplete welding, incomplete penetration, blasting, and uneven weld formation, affecting the welding yield and product reliability of battery modules.

[0022] To address these issues, some solutions employ external laser displacement sensors to detect the height of the workpiece to be welded and compensate for the welding focal point based on the detection results. However, such solutions typically require additional measurement processes before welding, resulting in limited detection points, data lag, limited compensation accuracy, and low detection efficiency. They also struggle to accurately reflect the real-time deformation generated during the pressing process, thus failing to meet the requirements of new energy battery module PACK production lines for welding precision, consistency, and production efficiency.

[0023] The following describes a welding device provided in an embodiment of this application with reference to the accompanying drawings. The welding device of this application is particularly suitable for the laser welding process of new energy battery module PACK.

[0024] Please see Figures 1-7 This application provides a welding device, which includes a welding apparatus, a drive mechanism, a displacement detection device, at least one pressing component, and a control device. The pressing component has a pressing element and an elastic element that are elastically connected. The drive mechanism is driven by the elastic element to drive the pressing element to reciprocate towards or away from the material to be welded. The control device is electrically connected to the drive mechanism, the displacement detection device, and the welding apparatus. The displacement detection device is used to acquire displacement information of the pressing component during the pressing process. The control device is used to acquire the displacement information, determine the focus compensation parameters based on the displacement information, and control the welding apparatus to adjust the welding focus based on the focus compensation parameters and weld the material to be welded. By acquiring the displacement information of the pressing component and dynamically adjusting the welding focus accordingly, the control device effectively compensates for the dimensional tolerances, assembly errors, and pressing deformation of the material to be welded, achieving precise matching between the welding focus and the workpiece, thereby improving weld formation consistency, welding quality, and production yield.

[0025] In one embodiment, the welding equipment includes a welding device, a drive mechanism, a displacement detection device, at least one pressing component, and a control device.

[0026] Specifically, the pressing assembly is positioned above the material to be welded and near the welding path of the welding device. The pressing assembly includes a pressing member and an elastic member. The pressing member contacts the material to be welded, and the elastic member is positioned between the pressing member and the driving mechanism to allow the pressing member to generate elastic displacement relative to the driving mechanism during the pressing process. The driving mechanism is drively connected to the elastic member and can drive the elastic member and the pressing member to move along the pressing direction. In one embodiment, the driving mechanism is a cylinder; in another embodiment, the driving mechanism is an electric actuator; and in yet another embodiment, the driving mechanism is a lead screw module or a linear motor.

[0027] Specifically, the displacement detection device is set up in correspondence with the pressing component, and the displacement detection device is used to obtain the displacement information of the pressing component during the pressing process.

[0028] In one embodiment, the displacement detection device is disposed on the drive mechanism to detect the motion displacement of the drive mechanism; in another embodiment, the displacement detection device is disposed between the pressing member and the drive mechanism to detect the displacement change of the pressing member relative to the drive mechanism; in yet another embodiment, the displacement detection device is disposed near the elastic member to detect the deformation of the elastic member.

[0029] Optionally, the displacement detection device can be one or more combinations of displacement sensors, laser rangefinders, grating rulers, encoders, and magnetostrictive displacement sensors.

[0030] In one embodiment, the welding device is disposed on one side or in the central region of the pressing assembly and is positioned corresponding to the material to be welded. In one embodiment, the welding device is a laser welding head; in another embodiment, the welding device is a laser galvanometer welding system; and in yet another embodiment, the welding device is a laser welding assembly with focus adjustment function.

[0031] Specifically, the control device is electrically connected to the drive mechanism, the displacement detection device, and the welding device. The control device receives the displacement information output by the displacement detection device and determines the focus compensation parameters according to a preset correspondence.

[0032] Specifically, the focus compensation parameter can be one or more of the following: focus offset, Z-axis compensation, and focal length compensation.

[0033] In one embodiment, the welding equipment includes multiple pressing components spaced apart in different areas of the material to be welded; correspondingly, the displacement detection device includes multiple detection units, each used to acquire displacement information of the corresponding pressing component. The control device can determine the focus compensation parameters corresponding to different welding areas based on the multiple displacement information.

[0034] In one embodiment, the pressing component is a copper block press head, and the material to be welded is a cell tab, busbar, or connecting piece in a new energy battery module; in another embodiment, the pressing component is a voltage-conducting block, and the material to be welded is a metal plate, metal terminal, or metal connector.

[0035] In one embodiment, the control device is configured to: acquire displacement information, including motion displacement data of the pressing member and deformation displacement data of the elastic member; input the displacement information into a preset compensation model to calculate the focal offset and obtain focal compensation parameters.

[0036] In one embodiment, the displacement detection device is used to acquire displacement information of the pressing assembly, wherein the displacement information includes motion displacement data of the pressing member and deformation displacement data of the elastic member. The motion displacement data of the pressing member represents the overall displacement of the pressing member relative to the driving mechanism along the pressing direction, and the motion displacement data can be measured by a linear displacement sensor, encoder, or laser rangefinder. The deformation displacement data of the elastic member represents the deformation of the elastic member during the pressing process, and the deformation displacement data can be obtained by devices such as strain gauges, fiber optic sensors, and magnetostrictive displacement sensors.

[0037] In one possible implementation, the displacement data of the pressing component and the deformation data of the elastic component can be collected separately; in another possible implementation, the displacement data of the pressing component and the deformation data of the elastic component can also be combined to form composite displacement information, which is used to describe the actual pressing state of the pressing assembly.

[0038] Specifically, the control device is configured to acquire the displacement information and input it into a preset compensation model for calculation. The preset compensation model can be a mathematical model, a lookup table model, or a machine learning model. During implementation, the control device first receives displacement data of the pressing component and deformation displacement data of the elastic component from the displacement detection device, and calculates the actual pressing height of the pressing component relative to the material to be welded based on the displacement data. Subsequently, the control device inputs the calculated pressing height and related parameters into the preset compensation model, which outputs the focal offset as a focal compensation parameter. The focal compensation parameter characterizes the displacement of the laser head in the Z-axis direction, the focal length adjustment value, or the offset of the welding focal point position. The control device controls the focal position adjustment of the welding device according to the focal compensation parameter, ensuring precise matching between the welding focal point and the actual surface of the workpiece to be welded.

[0039] In different embodiments, the control device can simultaneously process the displacement information of multiple pressing components, calculate the corresponding focus compensation parameters respectively, and synchronously adjust the multi-point welding focus to achieve dynamic compensation for multi-area welding.

[0040] In one embodiment, the displacement information includes deformation displacement data of the elastic element. The elastic element is disposed between the driving mechanism and the pressing component. During the process of the pressing component pressing the material to be welded, the elastic element is subjected to compression and undergoes elastic deformation. A displacement detection device is used to acquire the deformation displacement data of the elastic element, which characterizes the actual pressing state of the pressing assembly. The displacement detection device can be located near the elastic element or connected to it to detect the compression, elongation, or deformation of the elastic element during the pressing process. A control device is electrically connected to the displacement detection device to acquire the deformation displacement data and input it into a preset compensation model for calculation. The preset compensation model is used to establish the correspondence between the deformation of the elastic element and the offset of the welding focus.

[0041] In one embodiment, a preset compensation model determines the actual pressing position of the pressing component based on the stiffness coefficient, initial length, pre-compression amount, and deformation displacement data of the elastic component. In another embodiment, the preset compensation model is trained based on historical welding data and is used to directly output focus compensation parameters based on the deformation displacement data. After obtaining the focus compensation parameters, the control device controls the welding device to adjust the position of the welding focus.

[0042] In one embodiment, the elastic element is a compression spring, and the deformation displacement data is the compression amount of the compression spring; in another embodiment, the elastic element is an elastic buffer, and the deformation displacement data is the deformation amount of the elastic buffer along the pressing direction; in yet another embodiment, the elastic element is an elastic support structure, and the deformation displacement data is the displacement amount generated by the elastic support structure under pressure.

[0043] In one embodiment, the welding equipment further includes a pressure sensor electrically connected to a control device. The pressure sensor detects the pressure data applied to the material to be welded by the pressing assembly. When the pressure data meets a preset pressure threshold, the control device acquires displacement information. By adding a pressure sensor to the welding equipment and having it work in conjunction with the control device, displacement information is acquired only when the pressing assembly reaches the preset pressure threshold. This effectively avoids displacement data errors caused by insufficient or abnormal pressing, improves the accuracy of welding focus compensation and welding quality, and enhances equipment safety and automation reliability.

[0044] In one embodiment, a pressure sensing device is used to detect pressure data applied by the pressing assembly to the material to be welded. The pressure data is used to characterize the degree of compression between the pressing assembly and the material to be welded.

[0045] In one embodiment, the pressure sensing device may be disposed between the pressing member and the material to be welded; in another embodiment, the pressure sensing device may also be disposed on the force transmission path of the pressing member, the elastic member, or the drive mechanism.

[0046] Optionally, the pressure sensing device can be a piezoresistive pressure sensor, a piezoelectric pressure sensor, a strain gauge force sensor, a thin-film pressure sensor, or a load cell.

[0047] Specifically, the preset pressure threshold is used to characterize the minimum clamping state required to meet welding requirements. The preset pressure threshold can be set according to the thickness, material, welding area, size of the pressed parts, or welding process parameters of the material to be welded. In one embodiment, the preset pressure threshold is a fixed value; in another embodiment, the preset pressure threshold is a range; and in yet another embodiment, different pressure thresholds correspond to different welding positions.

[0048] Specifically, the control device acquires pressure data in real time and compares the pressure data with a preset pressure threshold. When the pressure data meets the preset pressure threshold condition, the control device generates a displacement acquisition command to obtain the corresponding displacement information; when the pressure data does not meet the preset pressure threshold condition, the control device remains in a waiting state or continues to control the pressing component to perform the pressing action.

[0049] In one embodiment, satisfying the preset pressure threshold condition includes pressure data being greater than or equal to the preset pressure threshold; in another embodiment, satisfying the preset pressure threshold condition includes pressure data being within a preset pressure range; in yet another embodiment, satisfying the preset pressure threshold condition includes pressure data continuously reaching the preset pressure threshold for more than a preset time.

[0050] Furthermore, the control device can also determine the pressing status based on the pressure data. In one embodiment, when the pressure data exceeds the upper pressure threshold, the control device generates an abnormal signal; in another embodiment, when the pressure data remains below the lower pressure threshold, the control device generates a pressing incomplete signal.

[0051] In one embodiment, the displacement detection device includes a detection beam emitter, a detection beam receiver, and a baffle. The baffle is fixedly connected to the pressing component and can move synchronously with it. The detection beam emitter emits a detection beam to the baffle, the detection beam receiver receives the beam signal reflected by the baffle, and a control device determines displacement information based on the beam signal. Thus, the baffle can move synchronously with the pressing component, and the beam signals collected by the emitter and receiver can accurately reflect the movement and elastic deformation of the pressing component during the pressing process. This achieves high reliability in focus compensation calculation, improves welding accuracy and consistency, and avoids friction or damage caused by contact sensing.

[0052] In one embodiment, the displacement detection device includes a detection beam emitter, a detection beam receiver, and a baffle. The baffle is fixedly connected to the pressing member and can move synchronously with the pressing member along the pressing direction. The baffle can be a metal plate, a plastic plate, or a composite material plate, and its surface can be a reflective surface or coated with a reflective film to enhance the beam reflection efficiency. The detection beam emitter is used to emit a detection beam towards the baffle.

[0053] Optionally, the detection beam can be a laser beam, an infrared beam, or a visible beam, and the beam type can be selected according to accuracy requirements and environmental conditions. The detection beam receiver is used to receive the beam signal reflected by the baffle, and the receiver can be a photodiode, a photodetector, a CCD / CMOS sensor, or an optical receiving module.

[0054] Specifically, the control device is electrically connected to the beam transmitter and receiver, and is used to determine displacement information based on the received beam signal. More specifically, the control device calculates the motion displacement of the pressing component and the deformation displacement of the elastic component based on the displacement change of the beam from emission to reception, signal strength, reflection point position, or time difference. The displacement information may include single-point displacement, area-average displacement, or multi-point distributed displacement.

[0055] In one embodiment, the light beam is directed perpendicularly to the baffle along the pressing direction, and the control device calculates the movement distance of the pressing component based on the offset of the beam reflection position; in another embodiment, the light beam is directed to the baffle along an inclined angle, and the control device calculates the displacement based on the intensity change of the received signal or the spot displacement; in yet another embodiment, the beam transmitter and receiver can be the same optical module, and the transmitting and receiving functions are realized through a beam splitter.

[0056] Specifically, after receiving displacement information, the control device can input it into a preset compensation model to calculate the compensation parameters for the welding focus, thereby achieving dynamic focus adjustment. In the case of multi-pressed components or large-area pressed parts, the displacement detection device includes multiple detection beam emitters, multiple detection beam receivers, and multiple baffles. The control device acquires displacement information for each region and calculates the focus compensation parameters for each point, thereby achieving dynamic focus compensation for multiple regions.

[0057] In one embodiment, at least one pressing component includes a first pressing device and a second pressing device, which are spaced apart. The first pressing device is used to press a first area to be welded of the material to be welded, and the second pressing device is used to press a second area to be welded of the material to be welded. By setting at least two pressing devices arranged at intervals, independent pressing control of different areas of the same material to be welded is achieved. The multi-pressing area design improves the uniformity and stability of pressing during the welding process, reduces the risk of insufficient or excessive pressing at a single point, provides more accurate displacement information for dynamic focus compensation, and thus improves weld quality and welding consistency.

[0058] In one embodiment, at least one pressing assembly includes a first pressing device and a second pressing device, which are spaced apart along the welding direction or on the surface of the workpiece to be welded, so as to act on different welding areas of the material to be welded respectively.

[0059] Specifically, the first pressing device applies a clamping force to the first area to be welded, and the second pressing device applies a clamping force to the second area to be welded. The first pressing device includes a first pressing component, a first elastic component, and a first driving mechanism; the second pressing device includes a second pressing component, a second elastic component, and a second driving mechanism. The first and second pressing devices can share the driving mechanism, but their pressing areas are independent to ensure that the clamping state of each area can be individually controlled. The control device is electrically connected to the first and second pressing devices and can acquire displacement information and pressure data from each pressing device.

[0060] In one embodiment, the control device calculates the focus compensation parameters for the first area to be welded based on the displacement information and pressure data of the first pressing device; and calculates the focus compensation parameters for the second area to be welded based on the displacement information and pressure data of the second pressing device. The control device can process data from multiple pressing devices simultaneously to achieve dynamic focus compensation for multi-area welding.

[0061] In one embodiment, both the first pressing device and the second pressing device are compression spring pressing mechanisms with elastic elements; in another embodiment, the first pressing device is a cylinder pressing mechanism and the second pressing device is an electric screw pressing mechanism, to adapt to the pressing force requirements or spatial arrangement constraints of different areas; in yet another embodiment, the pressing force, displacement threshold and triggering conditions of multiple pressing devices are set independently to adapt to the needs of complex welded workpieces or different material areas.

[0062] In one embodiment, the displacement detection device includes a first displacement detection mechanism and a second displacement detection mechanism. The first displacement detection mechanism is used to acquire first displacement data of the first pressing device, and the second displacement detection mechanism is used to acquire second displacement data of the second pressing device. The control device is used to determine the focus compensation parameters based on the average of the first and second displacement data. By acquiring displacement data corresponding to multiple pressing devices respectively and determining the focus compensation parameters based on the average of multiple displacement data, the influence of local pressing errors, local warping of the workpiece, and measurement fluctuations of a single detection mechanism on the compensation results can be reduced, improving the representativeness and stability of displacement information, thereby improving the focus compensation accuracy and welding consistency.

[0063] In one embodiment, the displacement detection device includes a first displacement detection mechanism and a second displacement detection mechanism. The first displacement detection mechanism is correspondingly configured with the first pressing device and is used to acquire first displacement data of the first pressing device during the pressing process; the second displacement detection mechanism is correspondingly configured with the second pressing device and is used to acquire second displacement data of the second pressing device during the pressing process.

[0064] The first displacement data is used to characterize the pressing state corresponding to the first area to be welded, and the second displacement data is used to characterize the pressing state corresponding to the second area to be welded. In one possible implementation, the first and second displacement data are the motion displacement data of the first and second pressing components; in another possible implementation, the first and second displacement data are the deformation displacement data of the first and second elastic components; in yet another possible implementation, the first displacement data is the combined displacement data formed by the first pressing component and the first elastic component, and the second displacement data is the combined displacement data formed by the second pressing component and the second elastic component.

[0065] In one embodiment, both the first displacement detection mechanism and the second displacement detection mechanism are optical detection mechanisms; in another embodiment, the first displacement detection mechanism is a laser displacement sensor and the second displacement detection mechanism is an encoder detection mechanism; in yet another embodiment, both the first displacement detection mechanism and the second displacement detection mechanism are contact displacement sensors.

[0066] Specifically, the control device acquires first displacement data and second displacement data respectively, and performs an average calculation on the first displacement data and second displacement data to obtain the target displacement value. The target displacement value is used to characterize the overall pressing state of multiple areas to be welded.

[0067] In one embodiment, the target displacement value = (first displacement data + second displacement data) / 2. The control device inputs the target displacement value into a preset compensation model to determine the focus compensation parameters. The preset compensation model is used to establish the correspondence between the displacement amount and the focus offset, thereby outputting the focus compensation parameters corresponding to the target displacement value.

[0068] In one embodiment, the first area to be welded and the second area to be welded are located on both sides of the same welding path; in another embodiment, the first area to be welded and the second area to be welded are spaced apart along the welding direction.

[0069] Furthermore, in other embodiments, the number of displacement detection mechanisms may be three, four or more, and the control device is used to average multiple displacement data to obtain a target displacement value for focus compensation.

[0070] In one embodiment, at least one pressing assembly further includes a third pressing device and a fourth pressing device; the first pressing device, the second pressing device, the third pressing device, and the fourth pressing device are arranged in a rectangular array. By setting four pressing devices in the pressing assembly and arranging them in a rectangular array, uniform pressing and multi-point force control of large-area materials to be welded can be achieved, reducing the risk of insufficient or excessive local pressing, enhancing the representativeness of multi-region displacement information, providing a high-precision overall displacement reference for focal compensation, and improving welding consistency and weld quality.

[0071] In one embodiment, at least one pressing component includes a first pressing device, a second pressing device, a third pressing device, and a fourth pressing device, the four pressing devices being arranged in a rectangular array along two directions. The first and second pressing devices are spaced apart along the X direction, and the third and fourth pressing devices are spaced apart from the first and second pressing devices along the Y direction, forming a four-corner arrangement.

[0072] Specifically, each pressing device is used to press the corresponding area of ​​the material to be welded. The rectangular array arrangement can cover a large welding area and maintain uniform pressing. Each pressing device may include a pressing component, an elastic component, and a drive mechanism, and the control device can acquire the displacement information or pressure data of each pressing device.

[0073] In one embodiment, the control device can calculate the average displacement based on the displacement data of the four pressing devices to generate overall focus compensation parameters; in another embodiment, the control device can calculate the local focus compensation parameters corresponding to each pressing device separately to achieve multi-point dynamic focus adjustment.

[0074] Specifically, the spacing of the rectangular array can be determined based on the size of the material to be welded, the size of the pressed part, and the layout of the welding area. In one embodiment, the spacing in the X direction is equal to the spacing in the Y direction; in another embodiment, the spacing in the X direction is different from the spacing in the Y direction to accommodate rectangular or irregularly shaped welding areas.

[0075] In other embodiments, the rectangular array can be expanded to more pressing devices, such as 2×3, 3×3 or 4×4 arrays, to accommodate larger workpieces to be welded, enabling multi-point pressing and focus compensation.

[0076] In one embodiment, the control device is configured to stop welding and output an abnormality warning message when the displacement difference between the first displacement data and the second displacement data meets a preset difference threshold. By comparing the displacement difference between the first displacement data and the second displacement data, the consistency of the pressing state of multiple areas to be welded can be detected. When the displacement difference exceeds the allowable range, conditions such as workpiece warping, partial suspension, incomplete pressing, or mechanical abnormalities are promptly identified, and welding is stopped, thereby avoiding continued welding under abnormal pressing conditions, improving welding quality and equipment operational reliability.

[0077] In one embodiment, the control device is used to acquire first displacement data output by a first displacement detection mechanism and second displacement data output by a second displacement detection mechanism. The first displacement data characterizes the pressing state corresponding to a first area to be welded, and the second displacement data characterizes the pressing state corresponding to a second area to be welded. The control device is used to determine a displacement difference based on the first and second displacement data. The displacement difference characterizes the difference in pressing state between different areas to be welded. A preset difference threshold characterizes the maximum allowable displacement deviation range, and its value can be set according to the size specifications of the material to be welded, flatness requirements, spacing of the pressing devices, stiffness of the elastic element, and welding process requirements.

[0078] In one embodiment, the control device obtains the displacement difference by performing a difference calculation on the first displacement data and the second displacement data; in another embodiment, the control device can determine the displacement difference by statistically processing the displacement data corresponding to multiple sampling times, thereby reducing the impact of instantaneous fluctuations on the detection results. When the displacement difference meets a preset difference threshold condition, the control device determines that the pressing state is abnormal. Meeting the preset difference threshold condition can be either a displacement difference greater than a preset difference threshold or a displacement difference exceeding a preset difference range. An abnormal pressing state may correspond to warping or deformation of the material to be welded, incomplete pressing in certain areas, misalignment of the pressing components, or abnormal stress on the pressing parts.

[0079] Specifically, upon determining an abnormality in the pressing state, the control device sends a stop command to the welding device, causing the welding device to suspend the current welding task or terminate subsequent welding processes. Simultaneously, the control device generates an abnormality alert. This alert may include at least one of the following: an abnormal alarm signal, abnormal area information, displacement difference information, and fault code information. This alert is output through a display interface, an audible and visual alarm device, or a host computer system to prompt the operator to inspect and handle the issue.

[0080] In one embodiment, the welding equipment further includes an image acquisition device electrically connected to a control device. The detection area of ​​the image acquisition device can cover at least a portion of the material to be welded. The image acquisition device is used to acquire first image information of the material to be welded. The control device is used to determine the position and state of the material to be welded based on the first image information. When the material to be welded meets preset welding conditions, the control device drives the pressing assembly to move toward the material to be welded. By adding an image acquisition device to the welding equipment and acquiring first image information of the material to be welded, real-time detection and determination of the position of the material to be welded are achieved. This enables the pressing assembly to initiate the pressing action when the material is in a suitable position and state, thereby improving welding positioning accuracy, automation level, and the consistency and reliability of welding operations.

[0081] In one embodiment, the welding equipment includes an image acquisition device electrically connected to a control device, used to acquire first image information of the material to be welded. The first image information may include the two-dimensional or three-dimensional position, orientation, appearance contour, and reference feature points of the material to be welded. The detection area of ​​the image acquisition device can cover at least a portion of the material to be welded, and its type can be an industrial camera, color camera, line scan camera, or depth camera, and can be used in conjunction with a light source, lens adjustment device, or filter device to ensure image clarity and recognizability.

[0082] Specifically, after receiving the first image information, the control device identifies the position and state of the material to be welded using image processing algorithms, machine vision methods, or a trained image recognition model. This includes the material's position and orientation on the worktable, as well as its alignment with the welding path. The control device then determines whether the material is in a weldable state based on preset welding conditions. These preset welding conditions may include the range of positional deviation, the range of angular error, and the degree of matching of identification marks or feature points on the material's surface.

[0083] Specifically, when the materials to be welded meet the preset welding conditions, the control device generates a drive command, which controls the drive mechanism to drive the pressing assembly toward the materials to be welded, thereby achieving pressing and positioning. The drive mechanism can be a cylinder, an electric lead screw, a linear motor, or other suitable linear drive device.

[0084] In one embodiment, the control device can update the position of the pressing component in real time to align it with the center of the material to be welded; in another embodiment, the control device can further fine-tune the pressing position by combining pressure data or displacement information to achieve precise pressing.

[0085] In one embodiment, the image acquisition device is used to acquire second image information of the welded material; the control device is used to determine the welding quality level based on the second image information, and if the welding quality level is within the preset repair welding level range, control the welding device to re-weld the welded material. By acquiring images of the welded material and evaluating the welding quality, the welding equipment can promptly detect welding defects and re-weld designated areas, avoiding rework of the entire part, improving welding consistency, product yield, and production efficiency, while reducing manual inspection costs and the risk of misjudgment.

[0086] In one embodiment, the image acquisition device is used to acquire second image information of the welded material. The second image information may include the weld surface morphology, color, gloss, weld depth characteristics, or local defect information in the weld area. The image acquisition device can be an industrial camera, color camera, line scan camera, or depth camera, and can be used with a light source, filter, or lens adjustment device to ensure the clarity and contrast of the acquired image.

[0087] Specifically, the control device is electrically connected to the image acquisition device, which receives, processes, and analyzes the second image information. The control device can identify weld defects using image processing algorithms, machine vision methods, or trained deep learning models, and determine the welding quality level accordingly. A preset repair weld level range characterizes the range of welding quality levels for which repair welding will be performed. The parameters of the preset repair weld level range can be set according to weld size, tolerance requirements, material type, and process standards.

[0088] Specifically, when the control device determines that the welding quality level is within the preset repair welding level range, the control device sends a re-welding command to the welding device. The welding device locates the defective area of ​​the already welded material according to the command and performs the re-welding operation. In one embodiment, the control device generates a welding path or focus compensation parameters using location information to ensure that the re-welding accurately covers the defective area. In another embodiment, the control device can combine multiple image data or multi-view image information to perform three-dimensional positioning of the defect location, achieving a more precise repair welding operation.

[0089] Furthermore, after the repair welding is completed, the control device can call the image acquisition device again for re-inspection to verify that the defect has been repaired and update the welding quality level information. At the same time, the control device can record the second image information, analysis results, and repair welding parameters in the storage unit.

[0090] The following describes the working process of the welding equipment in a preferred embodiment of this application, with reference to a specific application scenario: S1, the drive mechanism drives the pressing component to move toward the material to be welded, and presses and positions the first area to be welded, the second area to be welded and other areas to be welded. S2, The pressure sensing device detects the pressure data applied to the workpiece by the pressing assembly. When the pressure data meets the preset pressure threshold condition, the control device obtains the displacement information corresponding to each pressing device. S3, the control device processes the displacement information collected by multiple pressing devices, calculates the displacement difference or average value of each region, and generates welding focus compensation parameters according to the preset compensation model to adjust the focus position of the welding device and realize dynamic focus compensation for each region to be welded.

[0091] S4. When the displacement difference exceeds the preset difference threshold, the control device determines that there is a pressing abnormality, sends a stop signal to the welding device, and outputs an abnormality prompt message. S5, when the pressing state is normal and the focus compensation is completed, the control device controls the welding device to perform welding operation on the area to be welded along the preset path, and can simultaneously or sequentially weld multiple areas.

[0092] The following describes specific embodiments of this application based on the above technical solution.

[0093] Example 1 See Figures 1-7 This embodiment provides a welding device, which includes a welding apparatus, a driving mechanism, a displacement detection device, at least one pressing component, and a control device. The pressing component has a pressing element and an elastic element that are elastically connected. The driving mechanism is driven by the elastic element to drive the pressing element to reciprocate toward or away from the material to be welded. The control device is electrically connected to the driving mechanism, the displacement detection device, and the welding apparatus. The displacement detection device is used to acquire displacement information of the pressing component during the pressing process. The control device is used to acquire the displacement information, determine the focus compensation parameters based on the displacement information, and control the welding apparatus to adjust the welding focus based on the focus compensation parameters and weld the material to be welded.

[0094] The control device is configured to: acquire displacement information, including the motion displacement data of the pressing component and the deformation displacement data of the elastic component; input the displacement information into a preset compensation model to calculate the focal offset and obtain the focal compensation parameters.

[0095] The welding equipment also includes a pressure sensor, which is electrically connected to the control device. The pressure sensor is used to detect the pressure data applied to the material to be welded by the pressing component. When the pressure data meets the preset pressure threshold condition, the control device can obtain displacement information.

[0096] The displacement detection device includes a detection beam emitter, a detection beam receiver, and a baffle. The baffle is fixedly connected to the pressing component and can move synchronously with the pressing component. The detection beam emitter emits a detection beam to the baffle, the detection beam receiver receives the beam signal reflected by the baffle, and the control device determines the displacement information based on the beam signal.

[0097] Example 2 The similarities between Example 2 and Example 1 will not be repeated here. The difference in this example is that at least one pressing component includes a first pressing device and a second pressing device, which are spaced apart. The first pressing device is used to press a first area to be welded of the material to be welded, and the second pressing device is used to press a second area to be welded of the material to be welded. The displacement detection device includes a first displacement detection mechanism and a second displacement detection mechanism. The first displacement detection mechanism is used to acquire first displacement data of the first pressing device, and the second displacement detection mechanism is used to acquire second displacement data of the second pressing device. The control device is used to determine the focus compensation parameters based on the average of the first and second displacement data. At least one pressing component also includes a third pressing device and a fourth pressing device. The first, second, third, and fourth pressing devices are arranged in a rectangular array.

[0098] The above-disclosed embodiments are merely several preferred embodiments of this application and should not be construed as limiting the scope of this application. Therefore, any equivalent variations made in accordance with the claims of this application shall still fall within the scope of this application.

Claims

1. A welding device, characterized in that, The welding equipment includes a welding device, a drive mechanism (3), a displacement detection device (2), at least one pressing component (1), and a control device; The pressing assembly (1) has a pressing member (11) and an elastic member (12) that are elastically connected. The driving mechanism (3) is connected to the elastic member (12) to drive the pressing member (11) to reciprocate toward or away from the material to be welded. The control device is electrically connected to the drive mechanism (3), the displacement detection device (2) and the welding device respectively. The displacement detection device (2) is used to obtain the displacement information of the pressing assembly (1) during the pressing process. The control device is used to acquire the displacement information, determine the focus compensation parameter based on the displacement information, and control the welding device to adjust the welding focus based on the focus compensation parameter and weld the material to be welded.

2. The welding equipment according to claim 1, characterized in that, The control device is configured to: The displacement information is obtained, which includes the motion displacement data of the pressing member (11) and the deformation displacement data of the elastic member (12); The displacement information is input into a preset compensation model to calculate the focal offset, thereby obtaining the focal compensation parameters.

3. The welding equipment according to claim 1, characterized in that, The welding equipment also includes a pressure sensing device, which is electrically connected to the control device. The pressure sensing device is used to detect the pressure data applied by the pressing assembly (1) to the material to be welded. When the pressure data meets the preset pressure threshold condition, the control device can acquire the displacement information.

4. The welding equipment according to any one of claims 1-3, characterized in that, The displacement detection device (2) includes a detection beam emitter (21), a detection beam receiver, and a baffle (22). The baffle (22) is fixedly connected to the pressing member (11), the baffle (22) can move synchronously with the pressing member (11), the detection beam emitter (21) is used to emit a detection beam to the baffle (22), the detection beam receiver is used to receive the beam signal reflected by the baffle (22), and the control device is used to determine the displacement information based on the beam signal.

5. The welding equipment according to any one of claims 1-3, characterized in that, The at least one pressing component (1) includes a first pressing device (1a) and a second pressing device (1b), wherein the first pressing device (1a) and the second pressing device (1b) are arranged at intervals; The first pressing device (1a) is used to press the first area to be welded of the material to be welded, and the second pressing device (1b) is used to press the second area to be welded of the material to be welded.

6. The welding equipment according to claim 5, characterized in that, The displacement detection device (2) includes a first displacement detection mechanism and a second displacement detection mechanism. The first displacement detection mechanism is used to acquire the first displacement data of the first pressing device (1a), and the second displacement detection mechanism is used to acquire the second displacement data of the second pressing device (1b). The control device is used to determine the focus compensation parameters based on the average of the first displacement data and the second displacement data.

7. The welding equipment according to claim 5, characterized in that, The at least one pressing component (1) further includes a third pressing device (1c) and a fourth pressing device (1d). The first pressing device (1a), the second pressing device (1b), the third pressing device (1c), and the fourth pressing device (1d) are arranged in a rectangular array.

8. The welding equipment according to claim 6, characterized in that, The control device is configured to: If the displacement difference between the first displacement data and the second displacement data meets the preset difference threshold condition, the welding device is controlled to stop welding and output an abnormal prompt message.

9. The welding equipment according to any one of claims 1-3, characterized in that, The welding equipment also includes an image acquisition device (4), which is electrically connected to the control device. The detection area of ​​the image acquisition device (4) can cover at least part of the material to be welded. The image acquisition device (4) is used to acquire the first image information of the material to be welded. The control device is used to determine the position state of the material to be welded based on the first image information, and when the material to be welded meets the preset welding conditions, it controls the driving mechanism (3) to drive the pressing component (1) to move toward the material to be welded.

10. The welding equipment according to claim 9, characterized in that, The image acquisition device (4) is used to acquire second image information of the welded material; The control device is used to determine the welding quality level based on the second image information, and when the welding quality level is within the preset repair welding level range, control the welding device to re-weld the already welded material.

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