A kind of based on welding data acquisition's group welding quality monitoring method, equipment and medium

Abstract

The application discloses a kind of based on welding data acquisition's group welding quality monitoring method, equipment and medium, it is related to industrial data acquisition technical field, including, based on group welding influence chart, abnormal source, group welding transmission range and affected object are corresponded to weld position and structure area, determine the execution stage of affected object, according to execution stage, the affected object of unfinished welding is classified into field adjustment object and generates field adjustment task, the affected object of completion welding is classified into back check object and generates back check task, forms quality disposal record;According to quality disposal record, the review result of the execution feedback of field adjustment task and back check task is collected, and is written back to corresponding weld position and structure area, verifies the disposal completion state of field adjustment object and the abnormal elimination state of back check object, generates group welding traceability account book.The application improves group welding positioning and traceability ability by structure area heat accumulation identification and group welding transmission range positioning.

Description

Technical Field

[0001] This invention relates to the field of industrial data acquisition technology, and in particular to a method, equipment and medium for monitoring the quality of welded groups based on welding data acquisition. Background Technology

[0002] With the development of automation in welding equipment, industrial data acquisition, and manufacturing process control technologies, the assembly and welding production of box-type metal components is gradually shifting from manual experience-based control to process data-driven control. This is particularly true in the manufacturing of products such as battery boxes, high-voltage boxes, and metal frame boxes. Multiple welds, multi-station connections, and multiple passes are typically involved between the base plate, side plates, reinforcing beams, and connectors. Welding quality is not only affected by process parameters such as current, voltage, speed, and temperature of individual welds, but also closely related to the structural position of the box, the weld sequence, the heat-affected zone relationship between adjacent welds, and the condition of the on-site tooling. Existing technologies have already implemented welding data acquisition, welding process parameter monitoring, weld quality inspection, and manufacturing execution management. These technologies record data such as welding current, voltage, temperature, welding time, and station status, and assist in judging weld quality after welding through visual inspection, non-destructive testing, or process alarms.

[0003] However, for production objects with structural and sequential coupling characteristics, such as box-type welded structures, existing welding quality monitoring methods still have shortcomings. Current technologies mostly rely on welding machine parameters or single weld seam inspection results as monitoring targets. The data collected lacks sufficient connection with the box structure location, weld attribution, welding sequence, and adjacent influence relationships. This results in abnormal data being recorded but difficult to accurately correspond to specific weld segments, structural areas, and affected objects. Quality judgment tends to remain at the level of single-point alarms or post-weld verification. Existing technologies are insufficient in identifying the correlation between accumulated heat input, heat response retention, heat conduction between adjacent weld seams, and process deviations during continuous welding, making it difficult to promptly distinguish the source of anomalies, the scope of transmission, and subsequently affected weld objects. At the handling level, there is also a lack of a closed-loop mechanism that forms on-site adjustment tasks and re-inspection and verification tasks according to the execution stage of the affected objects. This prevents effective coordination between advance adjustments for unwelded objects and targeted verification of welded objects, affecting the real-time performance, positioning accuracy, and traceability integrity of welding quality monitoring. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, this invention provides a welding quality monitoring method based on welding data acquisition to solve the problem that it is difficult to link welding data acquisition with the welded structure to identify quality anomalies and their transmission effects, and it is difficult to form a closed loop for phased handling.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: In a first aspect, the present invention provides a method for monitoring the quality of weld assembly based on welding data acquisition, comprising: acquiring basic welding data of a box to be welded; organizing the weld attribution, welding sequence, and adjacent influence relationships of the basic welding data; generating a welding acquisition index; acquiring welding process signals and on-site status quantities during the welding process to form welding time-series acquisition data; mapping the welding time-series acquisition data to the current weld according to the welding acquisition index, and performing weld segment processing to determine the process state and thermal response state of the weld segment, generating a weld segment state table; mapping the thermal response state of each weld segment to its corresponding structural region according to the welding sequence in the weld segment state table and the welding acquisition index, determining the thermal accumulation state of the structural region, and identifying the thermal accumulation state and thermal response state of the structural region based on the adjacent influence relationships in the welding acquisition index. The welding process status is determined by the welding transmission range. Within this range, the source of anomalies and affected objects are marked, generating a welding impact diagram. Based on this diagram, the source of anomalies, the welding transmission range, and affected objects are mapped to the weld location and structural area. The execution stage of the affected objects is determined, and affected objects that have not yet been welded are classified as on-site adjustment objects according to their execution stages, generating on-site adjustment tasks. Affected objects that have been welded are classified as re-inspection and verification objects, generating re-inspection and verification tasks, thus forming a quality handling record. Based on the quality handling record, the execution feedback of the on-site adjustment tasks and the verification results of the re-inspection and verification tasks are collected and written back to the corresponding weld location and structural area. The completion status of the on-site adjustment objects and the anomaly elimination status of the re-inspection and verification objects are verified, generating a welding traceability ledger.

[0007] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition according to the present invention, the specific steps for generating the welding acquisition index are as follows: In the basic data of assembly welding, determine the box structure position and weld position corresponding to the same box to be assembled and welded, match the weld position with the box structure position, and associate it with the work station to form weld ownership; Based on the weld attribution, the order of operations for each weld in the same box to be assembled is sorted out, and the thermal response coverage of each weld is determined by combining the extension range of the weld in the structural area, thus forming the assembly sequence, weld operation section and reference process state. Based on the welding sequence and thermal response coverage, welds that meet the conditions of structural proximity, sequential proximity, and thermal response coverage overlap are selected as adjacent influence objects to form adjacent influence relationships. Weld attribution, welding sequence, weld operation section, reference process state, and adjacent influence relationships are then organized to generate a welding acquisition index.

[0008] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition described in this invention, the specific steps for generating the weld segment status table are as follows: During the assembly welding process, welding process signals and on-site status quantities are recorded according to the acquisition time, and the welding process signals and on-site status quantities at the same acquisition time are organized to form welding time sequence acquisition data. Based on the weld seam affiliation and weld seam operation segment in the welding acquisition index, the welding timing acquisition data is mapped to the current weld seam, and the welding process change position is identified within the data range of the current weld seam. The data between adjacent welding process change positions is organized into weld segment data fragments. Based on the data fragments of the weld section, the changes in welding process signals and field status quantities in each weld section are sorted out to determine the process status and thermal response status of each weld section. The weld, weld section, process status and thermal response status are then sorted out to generate a weld section status table.

[0009] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition described in this invention, the specific steps for determining the thermal accumulation state of the structural region are as follows: Based on the correspondence between weld segments and welds in the weld segment status table, the thermal response status of each weld segment is traced back to the corresponding weld. According to the weld affiliation in the group welding acquisition index, the thermal response status of the corresponding weld is mapped to the structural region to form a structural region thermal response record. According to the welding sequence in the welding acquisition index, the thermal response records of the structural area are arranged in time sequence, and the thermal response status of adjacent welds in the same structural area is sorted out to form a thermal response sequence of the structural area. Based on the thermal response sequence of the structural region, the superposition state of thermal response and the direction of thermal response expansion generated by continuous welding in the same structural region are identified, and the thermal accumulation index of the structural region is calculated to determine the thermal accumulation state of the structural region.

[0010] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition described in this invention, the specific steps for generating the welding influence diagram are as follows: Using the thermal response expansion direction in the thermal accumulation state of the structural region as the guide, the weld association path with directional bearing relationship corresponding to the thermal accumulation state of the structural region is found in the adjacency influence relationship of the weld acquisition index, and the welds and structural regions that satisfy the directional bearing relationship in the weld association path are organized into a weld conduction chain. The weld seams in the welding transmission chain are matched with the weld segment status table. The process status of each weld seam corresponding to the weld segment is extracted. The process status is compared with the baseline process status of the corresponding weld seam in the welding acquisition index. Weld segments that deviate from the standard and are located in the welding transmission chain and are affected by the heat accumulation of the preceding sequence are marked as transmission trigger weld segments. Based on the position of the conduction-triggered weld segment in the welding conduction chain, the chain segment where conduction occurs is extracted along the welding conduction chain as the welding conduction range; the structural area corresponding to the thermal accumulation state of the structural area and the conduction-triggered weld segment are jointly marked as the source of the anomaly, and the welds and structural areas within the welding conduction range that are affected are marked as the affected objects, generating a welding influence diagram.

[0011] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition described in this invention, the specific steps of the execution phase for determining the affected object are as follows: The affected objects in the welding influence diagram are mapped to the weld seam attribution in the welding acquisition index along the welding transmission range, and the weld seam location and structural area corresponding to the affected objects are determined to form an influence location record. The affected objects in the location record are matched with the welding sequence in the welding acquisition index to determine the operation sequence position of the affected objects in the current box to be welded. The operation sequence position is then compared with the welds that have formed a welding segment status in the welding segment status table to form an execution stage record. Based on the execution phase record, affected objects that have not formed a complete weld segment are marked as incomplete welding phase, and affected objects that have formed a complete weld segment are marked as completed welding phase. The affected objects, weld locations, structural areas, and execution phases are retained in the execution phase record.

[0012] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition described in this invention, the specific steps for forming the quality handling record are as follows: Select the affected objects in the incomplete welding stage in the execution phase record and mark them as on-site adjustment objects. Determine the adjustment target according to the source of the anomaly of the on-site adjustment object in the weld location and structural area, and generate the on-site adjustment task. Based on the execution phase record, the affected objects that are in the completed welding stage are selected and marked as re-inspection and verification objects. The verification targets are determined according to the weld positions and structural areas covering the re-inspection and verification objects in the weld transmission range. Re-inspection and verification tasks are generated, and the re-inspection and verification objects, verification targets, and re-inspection and verification tasks are written into the quality handling record.

[0013] As a preferred embodiment of the welding quality monitoring method based on welding data acquisition described in this invention, the specific steps for generating the welding traceability ledger are as follows: Collect on-site adjustment task execution feedback, match the task object in the execution feedback with the on-site adjustment object in the quality handling record, and write the matched execution feedback into the corresponding weld position and structural area to form an adjustment feedback record; Collect the verification results of the re-inspection and review task, match the verification objects in the verification results with the re-inspection and review objects in the quality handling record, and write the matched verification results into the corresponding weld position and structural area to form a re-inspection and review record; Based on the adjustment feedback record, verify the completion status of the on-site adjustment object. Based on the return inspection and verification record, verify the anomaly elimination status of the return inspection and verification object. Write the completion status, anomaly elimination status, anomaly source, welding transmission range, weld location and structural area into the same traceability record to generate a welding traceability ledger.

[0014] In a second aspect, the present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, wherein when the computer program is executed by the processor, it implements any step of the welding quality monitoring method based on welding data acquisition as described in the first aspect of the present invention.

[0015] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program is executed by a processor, it implements any step of the welding quality monitoring method based on welding data acquisition as described in the first aspect of the present invention.

[0016] The beneficial effects of this invention are as follows: By tracing the thermal response status in the weld segment status table back to the corresponding structural area, and combining the welding sequence to identify the superposition state of thermal response, the direction of thermal response expansion, and the thermal accumulation state of the structural area, the welding transmission range is constructed and the source of anomalies and affected objects are marked. This realizes the transformation from monitoring single weld parameters to identifying quality impacts at the structural area level and sequential correlation level, so that welding anomalies no longer remain at a single-point alarm, but can reflect the continuous impact of heat input accumulation and transmission from adjacent welds on the welding quality. By mapping the affected objects in the welding impact diagram to the weld position and structural area, and combining the welding sequence and weld segment formation to determine their execution stage, on-site adjustment tasks and re-inspection and verification tasks are generated respectively. This realizes the pre-adjustment of unfinished welding objects and the targeted verification of completed welding objects, so that the quality monitoring results can directly enter the on-site handling and traceability closed loop, improving the accuracy of anomaly location, the timeliness of handling, and the traceability of welding quality. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a flowchart of a welding quality monitoring method based on welding data acquisition.

[0019] Figure 2 A schematic diagram for generating the welding acquisition index and forming the weld segment status table.

[0020] Figure 3 This is a schematic diagram for identifying the thermal accumulation state of the structural region and generating a welding effect diagram.

[0021] Figure 4 A schematic diagram illustrating the generation of quality handling records and welding traceability ledgers. Detailed Implementation

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0023] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0024] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0025] Reference Figures 1-4 This is one embodiment of the present invention, which provides a method for monitoring the quality of weld assembly based on welding data acquisition, comprising the following steps: S1. Obtain the basic data of the assembly welding of the box body to be assembled, organize the weld seam attribution, assembly welding sequence and adjacent influence relationship of the basic data of the assembly welding, and generate the assembly welding acquisition index.

[0026] S1.1 Determine the box structure position and weld position corresponding to the same box to be assembled and welded in the basic data of assembly welding, match the weld position with the box structure position, and associate it with the work station to form weld ownership.

[0027] It should be noted that before the box to be assembled enters the assembly welding station, the box identification is determined according to the production task issuance record, and the basic assembly welding data corresponding to the same box to be assembled is collected based on the box identification. The basic assembly welding data consists of box structure records, weld setting records, work station records, process reference records, and on-site confirmation records. The box structure records are derived from the box structure drawings and assembly process documents, recording the structural areas, assembly boundaries, and structural reference positions of the box to be assembled. The weld setting records are derived from the weld process annotations and welding path documents, recording the weld number, weld start and end positions, weld extension range, and the corresponding connection parts of the weld. The work station records are derived from... Production scheduling records and workstation assignment records record the execution correspondence between box identification, weld number, and workstation; process reference records are derived from welding process cards and work instruction records, recording the reference process status and process judgment conditions corresponding to each weld. The reference process status records the reference welding current, reference welding voltage, reference welding speed, and reference temperature response changes. The process judgment conditions are used to characterize the correspondence between welding process signals and reference process status, as well as the continuous maintenance requirements; on-site confirmation records are derived from box online confirmation, component arrival confirmation, and tooling fixture arrival confirmation, recording the consistency between the box to be assembled and the actual on-site work object.

[0028] To unify the positions of the box structure record and weld setting record under the same structural reference: the start and end positions and extension range of the weld in the weld setting record are converted to the structural reference position in the box structure record, and the structural regions are divided according to the structural boundaries in the box structure record; the box structure position is used to characterize the positioning basis of the box to be welded in the structural drawing, and the structural region is the welding monitoring range and thermal response mapping range divided based on the box structure position; the converted weld position falls into the corresponding structural region; if the weld is entirely located within a structural region, that structural region is determined as the structural region to which the weld belongs; if the weld crosses multiple structural regions, the main structural region is determined according to the length occupied by the weld extension range in each structural region, and the other structural regions crossed are recorded as associated structural regions, thus obtaining the correspondence between the weld position and the structural region.

[0029] After the weld location is matched with the structural area, the weld number is matched with the work station record to determine the work station that performs the weld, and the work station is associated with the structural area to which the weld belongs. In the case of multiple welds being performed at the same work station, work station associations are established separately according to the weld number. In the case of multiple work stations performing the same weld consecutively, work station associations are established separately according to the execution segments corresponding to the start and end positions of the weld.

[0030] Each weld is assigned to the structural area and work station of the box to be welded, forming a weld assignment. The weld assignment records the box identification, weld number, structural area, main structural area, associated structural area, work station, and execution section.

[0031] S1.2. Based on the weld seam assignment, the order of operations for each weld seam within the same box to be assembled is sorted out, and the thermal response coverage of each weld seam is determined by combining the extension range of the weld seam in the structural area, thus forming the assembly welding sequence, weld seam operation section and reference process state.

[0032] It should be noted that, taking the same box body to be assembled as the processing object, the weld number, structural area, work station, and execution section in the weld attribution are retrieved and matched with the work order in the work station's work record: for welds executed continuously by the same work station, they are arranged according to the work order in the work station's work record; for welds completed successively by different work stations, they are arranged according to the flow order of the box body between each work station; for cases where there are multiple welds in the same structural area, they are locally sorted according to the execution order of the welds in that structural area to determine the work order relationship between the welds in the same box body to be assembled, thus forming the assembly welding sequence.

[0033] Match the execution segment corresponding to each weld in the weld assignment with the weld extension range: if the weld extension range falls entirely within an execution segment, that execution segment is designated as the corresponding weld operation segment; if the weld extension range spans multiple execution segments, the weld extension range is divided into segments according to the execution segments, and the corresponding work station and structural area of ​​each segment are recorded to form a weld operation segment; the weld operation segment is consistent with the welding sequence, so that each weld operation segment corresponds to a specific work area and execution order.

[0034] Based on the extension range of the weld operation segment in the structural area, the coverage boundary of the welding thermal response in the corresponding structural area is determined. Specifically, the start and end positions, extension direction and structural area boundary of the weld operation segment are matched to obtain the thermal response coverage range of the weld operation segment in the box to be welded. If the coverage boundaries of adjacent weld operation segments overlap, the overlapping area is recorded under the corresponding weld operation segment.

[0035] Match the reference process state corresponding to the weld operation segment in the process reference record: read the reference welding current, reference welding voltage and reference welding speed in the reference process state, convert the product of the reference welding current and the reference welding voltage into the reference input energy per unit welding length according to the reference welding speed, form the reference unit heat input, and write the reference unit heat input into the reference process state of the corresponding weld operation segment.

[0036] S1.3. Based on the welding sequence and thermal response coverage, select welds that meet the conditions of structural proximity, sequential proximity and thermal response coverage overlap as adjacent influence objects, form adjacent influence relationships, and organize the weld affiliation, welding sequence, weld operation section, reference process state and adjacent influence relationships accordingly to generate a welding acquisition index.

[0037] It should be noted that, taking the same box body to be assembled as the processing object, the current weld operation segment is determined one by one according to the assembly welding sequence; for the current weld operation segment, according to the structural region to which the weld belongs, weld operation segments in the same structural region, adjacent structural region, and connecting transition region are searched to form structurally adjacent candidate welds; according to the assembly welding sequence, welds with operation inheritance relationship with the current weld operation segment are selected from the structurally adjacent candidate welds to form sequentially adjacent candidate welds.

[0038] The thermal response coverage area of ​​the current weld operation segment is compared with the thermal response coverage area of ​​the sequentially adjacent candidate welds. If the thermal response coverage areas overlap within the same structural area, or if the coverage boundary crosses the connection transition area, the corresponding sequentially adjacent candidate welds are identified as adjacent affected objects. In the case of multiple adjacent affected objects corresponding to the same current weld operation segment, the order of influence is determined according to the welding sequence, and the direction of influence is determined according to the overlapping position of the thermal response coverage areas, thus forming an adjacent influence relationship.

[0039] The weld seam affiliation, welding sequence, weld seam operation section, reference process status, and adjacent influence relationship are organized according to the weld seam number, so that each weld seam corresponds to its structural area, operation position, operation sequence, operation section, reference process status, and adjacent influence objects. After the correspondence is completed, the corresponding results of each weld seam are collected according to the box identification of the same box to be welded, and a welding acquisition index is generated.

[0040] S2. During the assembly welding process, welding process signals and on-site status quantities are collected to form welding timing data. The welding timing data is mapped to the current weld according to the assembly welding acquisition index, and weld segment processing is performed to determine the process status and thermal response status of the weld segment and generate a weld segment status table.

[0041] S2.1 During the welding process, welding process signals and field status quantities are recorded according to the acquisition time, and the welding process signals and field status quantities at the same acquisition time are organized to form welding time sequence acquisition data.

[0042] It should be noted that after the box to be assembled enters the actual assembly welding process, the weld operation segment in the assembly welding acquisition index is used as the acquisition trigger object; when the work station starts to execute the corresponding weld operation segment, the start acquisition time of the current weld operation segment is recorded, and the welding process signals and field status quantities are continuously recorded according to the acquisition time during the welding process; the welding process signals include welding current, voltage, wire feeding status, shielding gas status, welding speed, and welding torch operation status; the field status quantities include work station status, tooling fixture status, box positioning status, local temperature status, and work confirmation status; all signals and status quantities are recorded according to the box identification, work station, and acquisition time of the same box to be assembled.

[0043] During the recording process, welding process signals and field status quantities acquired at the same acquisition time are time-aligned: for data acquired simultaneously at the same acquisition time, a direct correspondence is established; for data with acquisition delays, the acquisition time of the workstation is used as the synchronization benchmark, and the acquisition time window is determined based on the sampling period of the welding process signal, the sampling period of the field status quantity, the equipment time synchronization error, and the communication delay compensation record; welding process signals and field status quantities whose acquisition time falls within the acquisition time window are mapped to the acquisition time of the same workstation; if there are multiple similar data within the same acquisition time window, the data with the smallest time difference from the acquisition time of the workstation is selected as the corresponding data, and if the time differences are the same, one data is retained according to the priority of the acquisition source or the order of acquisition time, and the remaining data is recorded as the data for reference within the window.

[0044] After time alignment is completed, the corresponding welding process signals and field status quantities are arranged sequentially according to the acquisition time to form welding timing acquisition data synchronized with the current welding process.

[0045] S2.2. Based on the weld seam affiliation and weld seam operation segment in the welding acquisition index, the welding timing acquisition data is mapped to the current weld seam, and the welding process change position is identified within the data range of the current weld seam. The data between adjacent welding process change positions is organized into weld segment data fragments.

[0046] It should be noted that the weld affiliation and weld operation segment corresponding to the current box to be welded are retrieved from the welding acquisition index. The box identifier, operation position, and acquisition time in the welding timing acquisition data are matched with the box identifier, operation position, and execution segment in the weld affiliation to determine the weld to which the current acquisition data belongs. In the case of multiple welds being executed consecutively at the same operation position, the data whose acquisition time falls into the corresponding execution segment are assigned to the current weld according to the start and end order of the weld operation segment. In the case of the same weld being completed by multiple execution segments, the data are assigned to the corresponding segment under the same weld according to the execution segment.

[0047] After completing the current weld correspondence, the location of the welding process change is identified within the data range of the current weld. Specifically, the changes in the welding process signal and the field status quantity are checked sequentially along the acquisition time. When the welding process signal changes from the non-welding state to the welding output state corresponding to the reference process state, it is determined as the starting change position, and the welding output state is recorded as the effective welding state.

[0048] When the welding process signal enters a stable welding state corresponding to the reference process state, the stable change position is determined. The stable welding state is determined with reference to the reference process state and process judgment conditions in the welding acquisition index. The correspondence between the welding current, welding voltage, and welding speed and the reference welding current, reference welding voltage, and reference welding speed meets the process judgment conditions in the process reference record. The welding torch operation status maintains continuous welding. The status of the work station, tooling fixture, and box positioning does not show any changes inconsistent with the current weld section, and all statuses remain consistent within the continuous acquisition time. The acquisition position that first meets the corresponding conditions is determined as the stable change position. If a single acquisition jump occurs within the continuous acquisition time but the adjacent acquisition time still returns to the correspondence of the reference process state, the single acquisition jump is recorded as an acquisition fluctuation, and a new welding process change position is not determined separately.

[0049] When the welding torch operating status, welding speed, local temperature status, or on-site status changes corresponding to the transition of the weld operation section, the process transition change position is determined; when the welding process signal exits from the effective welding state, the end change position is determined; if there is a rework operation for the current weld, the acquisition positions corresponding to the start and end of the rework operation are determined as the rework change positions respectively.

[0050] After determining the location of the welding process change, the data between adjacent welding process change locations are divided into a welding segment data range according to the order of acquisition time. The welding process signals, field status quantities, acquisition time, weld number, and execution section within this range are retained to form a welding segment data fragment. When determining the welding segment data fragment, the welding segment length is determined according to the start and end positions of adjacent welding process change locations in the weld operation section. The acquisition time range, the start and end positions of the welding segment, and the welding segment length are written into the welding segment data fragment.

[0051] S2.3 Based on the data fragments of the weld section, the changes in welding process signals and field status quantities in each weld section are sorted out to determine the process status and thermal response status of each weld section. The weld, weld section, process status and thermal response status are sorted out to generate a weld section status table.

[0052] It should be noted that each welding segment data fragment is taken as the processing object, and the changes in welding process signals and field status quantities are read according to the acquisition time; the continuity of the changes in welding process signals within the welding segment is sorted out to determine whether the welding process signals are maintained in the continuous state that should be in the corresponding welding segment; the status changes in the field status quantities related to the work position, fixture holding, box positioning and local temperature are correlated with the changes in welding process signals in time to obtain the correspondence between the welding execution state and the field maintenance state within the welding segment.

[0053] After completing the data correspondence within the weld segment, the changes in welding process signals in the weld segment data fragments are compared with the baseline process state and process judgment conditions in the welding acquisition index: if the correspondence between welding current, welding voltage, and welding speed and the baseline process state meets the process judgment conditions, and the work station status, tooling fixture status, and box positioning status do not show any changes inconsistent with the corresponding weld work segment, the weld segment is determined as a stable process state; if at least one of the welding current, welding voltage, welding speed, and welding torch operating status does not meet the process judgment conditions, or the work station status, tooling fixture status, and box positioning status do not show any changes inconsistent with the corresponding weld work segment, the weld segment is determined as a stable process state; If at least one of the following—position status, tooling fixture status, and box positioning status—changes inconsistent with the corresponding weld operation segment, and this inconsistent change meets the continuous confirmation requirement in the process judgment conditions, the weld segment is determined to be deviating from the process state. For cases where a single acquisition jump occurs and the relationship between the acquisition time and the baseline process state is restored at adjacent acquisition times, the jump is recorded as an acquisition fluctuation, and the weld segment is not determined to be deviating from the process state separately. For weld segments corresponding to the starting change position, process transition change position, ending change position, and rework change position, the process state markers are recorded according to the order of the corresponding change positions in the weld operation segment.

[0054] Simultaneously, based on the local temperature state, welding duration, and welding process signal changes in the weld segment data fragments, the thermal response state of the weld segment is determined: the thermal response state is recorded according to the temperature change trend and the post-weld residual results. A continuously increasing local temperature state between the start and end of the weld segment acquisition, corresponding to the acquisition time when the welding process signal is in an effective welding state, is recorded as an enhanced thermal response state. During the observation period after the end of the weld segment acquisition, a decreasing local temperature state relative to the local temperature state corresponding to the end of the weld segment acquisition is recorded as a decaying thermal response state. During the observation period after the end of the weld segment acquisition, a local temperature state still higher than the local temperature state corresponding to the start of the weld segment acquisition is recorded as a stagnant thermal response state. The decaying and stagnant thermal response states can be recorded simultaneously to characterize situations where the post-weld temperature decreases but residual thermal response still exists. A local temperature state in a reworked weld segment higher than the local temperature state corresponding to the start of the reworked weld segment acquisition is recorded as a repetitive thermal response state.

[0055] After determining the thermal response state, the welding current and welding voltage corresponding to each acquisition time within the weld segment data segment are matched item by item. The product of welding current and welding voltage at the same acquisition time is accumulated according to the acquisition time interval to obtain the measured welding input energy of the weld segment. It is then converted into the measured input energy per unit weld length according to the weld segment length to form the measured unit heat input. The measured temperature response change is determined based on the local temperature state corresponding to the start acquisition time and end acquisition time of the weld segment.

[0056] The weld number, weld segment data fragment, weld operation section, process status, thermal response status, measured unit heat input, and measured temperature response change are organized to generate a weld segment status table.

[0057] S3. Based on the welding segment status table and the welding sequence in the welding acquisition index, the thermal response status of each welding segment is mapped to its corresponding structural region to determine the thermal accumulation status of the structural region. Based on the adjacency influence relationship in the welding acquisition index, the welding transmission range of the thermal accumulation status of the structural region and the welding process status is identified. Within the welding transmission range, the source of the anomaly and the affected objects are marked to generate the welding influence map.

[0058] S3.1 Based on the correspondence between weld segments and welds in the weld segment status table, the thermal response status of each weld segment is traced back to the corresponding weld. According to the weld affiliation in the group welding acquisition index, the thermal response status of the corresponding weld is mapped to the structural region to form a structural region thermal response record.

[0059] It should be noted that, taking the same box body to be assembled as the processing object, the weld to which each weld segment belongs is determined according to the weld number, weld segment data fragment and weld operation segment recorded in the weld segment status table; the thermal response status of each weld segment under the same weld is collected according to the acquisition time range to obtain the weld thermal response status of the corresponding weld in this assembly welding process; for the case where the same weld contains multiple weld segments, the thermal response status of each weld segment and its position in the weld operation segment are retained separately, and the thermal response status of different weld segments is not merged into a single status.

[0060] According to the weld seam attribution in the weld acquisition index, the weld seam thermal response state is mapped to the corresponding structural region. If the weld seam belongs to a single structural region, the thermal response state of each weld segment under that weld seam is recorded in that structural region. If the weld seam has both a main structural region and an associated structural region, the weld segment thermal response state is mapped to the main structural region and the associated structural region respectively according to the position of the weld segment data fragment in the weld seam operation section. For weld segments that cross the boundary of structural regions, the mapping position of the weld segment in each structural region is determined according to the execution section corresponding to the weld segment data fragment and the weld seam extension range.

[0061] After mapping is completed, the structural region, weld number, weld segment data fragment, acquisition time range, weld operation segment, thermal response status, and the coverage length of the weld segment thermal response coverage falling into the corresponding structural region are recorded to form a structural region thermal response record.

[0062] S3.2. Arrange the thermal response records of the structural area in chronological order according to the welding sequence in the welding acquisition index, and sort out the thermal response status of adjacent welds in the same structural area to form a thermal response sequence of the structural area.

[0063] It should be noted that each structural area in the same box to be assembled and welded is taken as the processing object. The weld number, weld segment data fragment, acquisition time range and thermal response status mapped to the structural area are retrieved and matched with the assembly sequence in the assembly and welding acquisition index. The thermal response status of the same structural area is arranged according to the order of operation of each weld in the assembly and welding sequence. For the case where the same weld contains multiple weld segments, the weld segment data fragments are first arranged according to the order of operation of the weld segment, and then the arranged weld segments are placed into the position of the weld in the assembly and welding sequence.

[0064] After arranging the time sequence within the same structural area, the thermal response continuity relationship between adjacent weld operations is identified. Specifically, two adjacent weld operation segments in the arrangement are taken as the continuity judgment objects. The thermal response state of the preceding weld operation segment is compared with that of the following weld operation segment. If the preceding weld operation segment has a thermal response stagnation state, and the acquisition time range of the following weld operation segment overlaps with the post-weld observation period corresponding to the thermal response stagnation state, or if the starting acquisition time of the following weld operation segment is located within the adjacent operation continuation period after the end of the post-weld observation period, the two are recorded as a time continuity relationship, and the following weld operation segment is... The segment record is the weld operation segment that receives the heat response retention state. The post-weld observation period is determined based on the heat response judgment conditions, local temperature acquisition cycle and operation continuity time of adjacent welds in the same structural area in the process reference record. The adjacent operation continuity period is determined based on the welding sequence and station operation record. If the heat response coverage of the previous weld operation segment extends along its weld extension direction, structural connection boundary or heat response expansion direction to the structural area where the next weld operation segment is located, and the two have overlapping heat response coverage in the receiving direction and have an adjacent operation relationship in the welding sequence, the two are recorded as directional receiving relationship.

[0065] After the acceptance and sorting are completed, the weld operation sections, weld segment data fragments, thermal response status, acceptance relationship, acceptance direction, and thermal response overlap length of adjacent weld segments in the same structural area are recorded according to the welding sequence, forming a structural area thermal response sequence.

[0066] S3.3. Based on the thermal response sequence of the structural region, identify the superposition state of thermal response and the direction of thermal response expansion generated by continuous welding in the same structural region, and calculate the thermal accumulation index of the structural region to determine the thermal accumulation state of the structural region.

[0067] It should be noted that, taking adjacent weld sections within the same structural area as the judgment object, the thermal response state and connection relationship of each weld section are read item by item along the thermal response sequence of the structural area. When the preceding weld section has a thermal response stagnation state and the following weld section has a thermal response enhancement state, and both satisfy the temporal continuity relationship and directional connection relationship in the thermal response sequence of the structural area, the adjacent weld sections are recorded as thermal response superposition state. When the preceding weld section has a repeated thermal response state and the following weld section is located in the same connection direction, the corresponding thermal response change is recorded as thermal response superposition state.

[0068] After identifying the superimposed state of thermal response, the direction of thermal response expansion is determined based on the bearing direction in the thermal response sequence of the structural region and the arrangement of the welded sections within the structural region. The preceding welded section that generates the superimposed state of thermal response is taken as the starting point of expansion, and the subsequent welded section that has a bearing relationship with it is taken as the direction of expansion. When multiple subsequent welded sections have a bearing relationship, the main direction of expansion is determined according to the welded section that first bears the superimposed state of thermal response in the welding sequence, and the remaining bearing welded sections are recorded as auxiliary directions of expansion, thus obtaining the direction of thermal response expansion from the welded area to other welded sections within the same structural region.

[0069] After determining the superposition state and direction of thermal response, the weld segments corresponding to the weld operation segments participating in the superposition state of thermal response are identified as the set of weld segments in the structural region. Adjacent weld segment pairs that have a connection relationship and participate in the superposition state of thermal response are identified as receiving weld segment pairs. The thermal accumulation index of the structural region is calculated based on the thermal response coverage length of the weld segment, the overlap length of the receiving weld segment pair, the measured unit heat input, and the temperature response change.

[0070] The expression for calculating the thermal accumulation index of the structural region is: in, For structural regions The thermal accumulation index of the structural region, For structural regions The corresponding set of welded sections in the structural region. For structural regions The corresponding welding section pair set, For the first The length of each weld segment For the first The length of each weld segment For the first The thermal response coverage of each weld segment falls within the structural area. Coverage length, For the first The thermal response coverage of each weld segment falls within the structural area. Coverage length, For the first The welding segment and the first The thermal response coverage of each weld segment is the overlap length in the bearing direction. For the first Measured unit heat input of each welding segment; For the first The reference unit heat input for each welding segment; For the first The measured temperature response change of each welding segment For the first The measured temperature response change of each welding segment For the first The change in the reference temperature response of each weld segment For the first The change in the reference temperature response of each welding segment.

[0071] All parameters of the structural region thermal accumulation index are taken from the weld segment status table, structural region thermal response sequence, process reference record, and local temperature acquisition record. Before calculation, the validity of the structural region weld segment set and the receiving weld segment pair set is checked: if the structural region weld segment set is empty, or there is no receiving weld segment pair participating in the thermal response superposition state, no thermal accumulation term is added, and the corresponding structural region is recorded as not forming a thermal response superposition state; if the weld segment length, reference unit heat input, or reference temperature response change is lower than the valid acquisition conditions corresponding to the equipment acquisition accuracy record and process reference record, the corresponding weld segment does not participate in the structural region thermal accumulation index calculation and is marked as an invalid thermal accumulation term in the structural region thermal response record; if the measured temperature response change is negative and used to characterize the post-weld cooling process, it is only recorded as a thermal response decay state and is not considered as a positive thermal accumulation contribution.

[0072] The thermal accumulation index of the structural area is correlated with the baseline thermal accumulation judgment boundary in the process reference record, historical qualified welding records, and thermal response records of similar boxes to determine the thermal accumulation state of the structural area: if no thermal response superposition state is identified, or if the effective calculation conditions are not met, the structural area is recorded as having no thermal accumulation state; if a thermal response superposition state has been identified, and the thermal accumulation index of the structural area matches the baseline thermal accumulation judgment boundary, the structural area is recorded as having a thermal accumulation observation state; if a thermal response superposition state has been identified, and the thermal accumulation index of the structural area does not match the baseline thermal accumulation judgment boundary during the continuous acquisition and judgment period, or between adjacent welded sections within the same structural area, the structural area is recorded as having an abnormal thermal accumulation state, and the corresponding expansion start point, main expansion direction, and auxiliary expansion direction are retained as the abnormal influence direction; the continuous acquisition and judgment period is determined based on the local temperature acquisition cycle, the continuity time of adjacent weld operations, and the thermal response judgment conditions in the process reference record.

[0073] The thermal response superposition state, structural region thermal accumulation index, thermal accumulation state, expansion start point, main expansion direction, auxiliary expansion direction, corresponding weld operation segment and acquisition time range are written into the state record of the same structural region to determine the thermal accumulation state of the structural region.

[0074] S3.4. Using the thermal response expansion direction in the thermal accumulation state of the structural region as the guide, find the weld association path in the adjacent influence relationship of the weld acquisition index that has a directional bearing relationship with the structural region corresponding to the thermal accumulation state of the structural region, and organize the welds and structural regions that satisfy the directional bearing relationship in the weld association path into a weld conduction chain.

[0075] It should be noted that the corresponding structural region, expansion start point, main expansion direction, auxiliary expansion direction, and weld operation segment generating the superimposed state of thermal response are extracted from the thermal accumulation state of the structural region. The corresponding structural region is taken as the conduction start region, and the main expansion direction and auxiliary expansion direction are taken as the conduction direction reference. The adjacent welds and adjacent structural regions associated with the start region are searched in the adjacent influence relationship of the welding acquisition index. During the search, the influence direction in the adjacent influence relationship is compared with the conduction direction reference. The adjacent relationship with the influence direction consistent with the main expansion direction is determined as the main direction bearing relationship, and the adjacent relationship with the influence direction consistent with the auxiliary expansion direction is determined as the auxiliary direction bearing relationship.

[0076] After determining the directional connection relationship, the weld section that generates the superimposed thermal response state is taken as the starting point of the path. Adjacent welds and adjacent structural areas are sequentially connected along the main directional connection relationship to form the main weld connection path. Similarly, adjacent welds and adjacent structural areas are connected along the auxiliary directional connection relationship to form the auxiliary weld connection path. During the connection process, welds that simultaneously possess structural proximity, sequential proximity, and thermal response overlap with the path starting point are prioritized for retention. For welds that only possess structural proximity but do not meet the thermal response overlap requirement, the thermal accumulation state, structural connection relationship, and welding sequence of the structural area where the weld is located are further analyzed. If the weld is located on the main or auxiliary expansion direction corresponding to the abnormal thermal accumulation state, and forms a continuous connection with the conduction initiation region through the structural connection boundary, then the weld is retained as an observation and acceptance weld. If the weld only exists in the structural vicinity, and is not located in the thermal response expansion direction, nor forms a continuous connection through the structural connection boundary, then it is not written into the weld association path. In the case of multiple acceptable welds in the same adjacent structural area, the acceptance order is determined according to the order in which the welds are accepted with the path start point in the welding sequence, and the corresponding acceptance order is written into the weld association path.

[0077] The welds, structural areas, receiving order, and influence direction in the main weld association path and auxiliary weld association path are uniformly numbered. The path start point, conduction start area, receiving weld, receiving structural area, main direction receiving relationship, and auxiliary direction receiving relationship are recorded accordingly to form a weld assembly conduction chain.

[0078] S3.5 Match the weld seams in the welding transmission chain with the weld segment status table, extract the process status of each weld seam corresponding to the weld segment, and compare the process status with the baseline process status of the corresponding weld seam in the welding acquisition index. Mark the weld segments that deviate from the standard process status, are located in the welding transmission chain, and are affected by the heat accumulation of the preceding sequence as transmission trigger weld segments.

[0079] It should be noted that each receiving weld is read in the order of nodes in the welding transmission chain, and the weld number of the receiving weld is matched with the weld segment status table to extract the process status of each weld segment under that weld. In the case where the same receiving weld corresponds to multiple weld segments, the process status is extracted according to the position of the weld segment in the weld operation section and the time range of the acquisition, so as to maintain the correspondence between the weld segment and the receiving weld in the welding transmission chain.

[0080] The process status of each welding segment is compared with the reference process status of the same weld in the welding acquisition index: if the process status of the welding segment is consistent with the reference process status, the welding segment is retained as a normal acceptance welding segment; if the process status of the welding segment deviates from the reference process status, the welding segment is retained as a deviation candidate welding segment, wherein the deviation is based on the reference process status of the same weld in the welding acquisition index.

[0081] In the welding transmission chain, it is determined whether the deviation candidate weld segment inherits the influence of the preceding heat accumulation. Specifically, the node position of the weld where the deviation candidate weld segment is located in the welding transmission chain is read. If the node is located after the expansion start point corresponding to the heat accumulation state of the structural area, and there is a directional inheritance relationship between the node and the previous node, then it is determined that the deviation candidate weld segment inherits the influence of the preceding heat accumulation. Weld segments that simultaneously satisfy the process state deviation and the inheritance of the preceding heat accumulation influence are marked as transmission trigger weld segments. For weld segments where the process state has not deviated, but the weld is located on the main expansion direction or auxiliary expansion direction corresponding to the abnormal heat accumulation state of the structural area, and the weld segment corresponding to the weld has a heat response stagnation state, a repeated heat response state, or an inheritance of the preceding heat response superposition state, the weld segment is marked as a heat accumulation observation weld segment. The transmission trigger weld segment is used to determine the source of the anomaly, and the heat accumulation observation weld segment is used to determine the observational transmission object, and is not used as an anomaly source alone.

[0082] S3.6. Based on the position of the conduction-triggered weld segment in the welding conduction chain, the chain segment where conduction occurs is extracted along the welding conduction chain as the welding conduction range; the structural area corresponding to the thermal accumulation state of the structural area and the conduction-triggered weld segment are jointly marked as the source of the anomaly, and the welds and structural areas within the welding conduction range that are affected are marked as the affected objects, generating a welding influence diagram.

[0083] It should be noted that, in the case of forming a conductive trigger weld segment, the chain node corresponding to the weld to which the conductive trigger weld segment belongs is located in the weld conduction chain, and the receiving sequence, receiving direction, preceding chain node and the structural region to which the chain node belongs are read; taking the structural region corresponding to the thermal accumulation state of the structural region as the conduction starting point, and the chain node where the conductive trigger weld segment is located as the trigger node, the chain segment is cut along the receiving relationship in the direction consistent with the thermal response expansion direction in the weld conduction chain, and the trigger receiving chain segment extending from the conduction starting point to the trigger node is obtained; the trigger receiving chain segment records the path of the thermal accumulation state of the structural region to the conductive trigger weld segment.

[0084] If no conductive trigger weld segment is formed, but the thermal accumulation state of the structural area is in an abnormal state, the starting point of the expansion in the thermal accumulation state of the structural area is taken as the observation starting point, and the main expansion direction and auxiliary expansion direction are taken as the observation direction. The chain segment containing the observation receiving weld and the thermal accumulation observation weld segment is intercepted along the weld assembly transmission chain to form the observation transmission range. The weld and structural area within the observation transmission range are marked as the objects affected by the observation and are not regarded as the source of the anomaly alone.

[0085] After forming the conductive trigger weld segment and determining the trigger node, the chain node where the conductive trigger weld segment is located is used as the starting point for expansion. Along the same receiving direction in the weld transmission chain, the directional receiving relationship, thermal response coverage overlap relationship, and observation receiving relationship between adjacent chain nodes are checked: If adjacent chain nodes simultaneously satisfy both the directional receiving relationship and the thermal response coverage overlap relationship, the adjacent chain node is included in the receiving chain segment; if adjacent chain nodes do not form a thermal response coverage overlap but belong to the observation receiving weld or contain a heat accumulation observation weld segment, the adjacent chain node is included in the observation receiving chain segment; if adjacent chain nodes neither simultaneously satisfy the directional receiving relationship and the thermal response coverage overlap relationship, nor belong to the observation receiving weld and do not contain a heat accumulation observation weld segment, the preceding chain node of the adjacent chain node is taken as the end node of the receiving chain segment. The weld transmission range is formed by the trigger receiving chain segment, the chain node where the conductive trigger weld segment is located, the receiving chain segment extending from the trigger node to the end node, and the observation receiving chain segment.

[0086] The structural region corresponding to the thermal accumulation state is marked as the source of the regional anomaly, and the conduction-triggered weld segment is marked as the source of the weld segment anomaly. The regional anomaly source and the weld segment anomaly source are both used as the source of anomalies. Within the weld conduction range, weld nodes and structural region nodes located after the anomaly source are read according to the receiving order. Welds and structural regions located within the receiving chain segment and receiving the same conduction direction are marked as affected objects. Welds and structural regions located within the observation receiving chain segment are marked as observed affected objects. If the weld to which the conduction-triggered weld segment belongs participates in both the anomaly source marking and the affected object marking, the conduction-triggered weld segment is used as the anomaly source, and the remaining weld segments received along the conduction direction in that weld segment are used as affected objects. The thermal accumulation observation weld segment is not used as an anomaly source, and its weld and structural region are recorded as observed affected objects.

[0087] After marking is completed, the source of the anomaly, the range of weld transmission, the range of observational transmission, the affected object, the observed affected object, the direction of acceptance, the order of acceptance, the location of the weld and the structural area are recorded accordingly, and a weld influence diagram is generated.

[0088] S4. Based on the welding impact diagram, the source of the anomaly, the range of welding transmission, and the affected objects are mapped to the weld location and structural area. The execution stage of the affected objects is determined. According to the execution stage, the affected objects that have not been welded are classified as on-site adjustment objects and on-site adjustment tasks are generated. The affected objects that have been welded are classified as re-inspection and verification objects and re-inspection and verification tasks are generated, forming a quality handling record.

[0089] S4.1. Map the affected objects in the welding influence diagram along the welding transmission range to the weld seam attribution in the welding acquisition index, determine the weld seam location and structural area corresponding to the affected objects, and form an influence location record.

[0090] It should be noted that the affected objects marked in the weld impact diagram are the processing objects. The weld transmission range, bearing direction and bearing sequence of the affected object are read. If the affected object is a weld node, the weld number corresponding to the weld node is extracted. If the affected object is a structural area node, the structural area identifier corresponding to the structural area node is extracted, and weld nodes with directional bearing relationship with the structural area node are found along the weld transmission range to determine the associated welds corresponding to the structural area node.

[0091] Match the weld number with the weld attribution in the welding acquisition index to obtain the weld position, main structural area, associated structural area, and work station of the weld in the box to be welded; for cases where the affected object is formed by multiple weld nodes, match each weld node according to the acceptance order in the welding transmission range, and retain the weld position and structural area corresponding to each weld node; for cases where the affected object is a structural area node and corresponds to multiple associated welds, select the welds that are directly connected to the structural area node as positioning welds according to the directional acceptance relationship.

[0092] Record the affected objects, welding transmission range, receiving direction, receiving sequence, weld location, structural area and work station accordingly to form an impact positioning record.

[0093] S4.2 Match the affected objects in the location record with the welding sequence in the welding acquisition index to determine the operation sequence position of the affected objects in the current box to be welded, and compare the operation sequence position with the welds that have formed a welding segment status in the welding segment status table to form an execution stage record.

[0094] It should be noted that each affected object in the impact positioning record is taken as the processing object. The weld position, structural area and work station corresponding to the affected object are read, and the corresponding weld position is matched with the assembly welding sequence in the assembly welding acquisition index. During the matching, the operation sequence position of the weld corresponding to the affected object in the current box to be assembled is determined according to the weld number, weld operation section and operation sequence recorded in the assembly welding sequence. For the case where one affected object corresponds to multiple welds, the operation sequence position of each weld in the assembly welding sequence is determined separately, and its receiving order in the assembly welding transmission range is retained.

[0095] Compare the weld seam corresponding to the work sequence position with the weld segment status table: if the weld segment status table already contains a complete weld segment record corresponding to the weld seam, it means that the welding process data acquisition for the weld seam has been completed; if the weld segment status table does not contain a weld segment record corresponding to the weld seam, or only contains a weld segment record that has not reached the end change position, it means that the welding process data acquisition for the weld seam has not been completed; for the case where the same weld seam consists of multiple weld seam work segments, check one by one whether each weld seam work segment has formed a complete weld segment record in the weld segment status table.

[0096] Record the affected object, weld location, structural area, work sequence location, acceptance order, and weld segment formation status in the weld segment status table to form the execution phase record; for the case where the same affected object corresponds to multiple welds or multiple weld operation segments, record the weld segment formation status separately according to the weld operation segment, and write the complete weld segment record, incomplete weld segment record, and unstarted weld segment record corresponding to each weld operation segment into the execution phase record respectively.

[0097] S4.3. Based on the execution phase record, affected objects that have not formed a complete weld segment are marked as incomplete welding phase, and affected objects that have formed a complete weld segment are marked as completed welding phase. The affected objects, weld positions, structural areas and execution phases are retained in the execution phase record.

[0098] It should be noted that the formation status of the weld segments corresponding to the affected objects is read item by item, and the execution stage is determined according to the weld operation segment: when the weld operation segment corresponding to the affected object has not formed a weld segment data fragment in the weld segment status table, or has only formed a weld segment data fragment after the starting change position but has not yet reached the ending change position, the weld operation segment is marked as an incomplete welding stage; when the weld operation segment corresponding to the affected object has formed a complete weld segment data fragment from the starting change position to the ending change position in the weld segment status table, the weld operation segment is marked as a completed welding stage; when the same affected object contains both weld operation segments with incomplete welding stages and weld operation segments with completed welding stages, the affected object is marked as a mixed execution stage, and the incomplete part and the completed part are retained separately in the execution stage record.

[0099] After completing the stage marking, the affected object, weld location, structural area, undertaking order, weld operation section, and execution stage are all retained in the execution stage record. The execution stage in the execution stage record is consistent with the corresponding weld location and structural area to avoid unclear stage affiliation for the same affected object in subsequent task assignments.

[0100] S4.4 Select the affected objects in the incomplete welding stage in the execution stage record and mark them as on-site adjustment objects. Determine the adjustment target according to the direction of the abnormal source of the on-site adjustment object in the weld position and structural area, and generate the on-site adjustment task.

[0101] It should be noted that affected objects in the incomplete welding stage are screened from the execution phase record and marked as on-site adjustment objects. For affected objects in mixed execution phases, the incomplete parts in the execution phase record are read and the weld operation segments corresponding to the incomplete parts are marked as on-site adjustment objects. For on-site adjustment objects, their corresponding weld positions, structural areas, weld operation segments and connection sequences are read, and the anomaly sources corresponding to the on-site adjustment objects are found in the welding influence diagram. When the anomaly source is the structural area corresponding to the thermal accumulation state of the structural area, the weld operation segment in the on-site adjustment object located in the thermal response expansion direction of the structural area is determined as the adjustment target. When the anomaly source is a conduction-triggered weld segment, the weld operation segment that has a directional connection with the conduction-triggered weld segment and has not yet been welded is determined as the adjustment target.

[0102] The adjustment targets are matched with the work stations and welding sequences in the execution phase records to determine the weld operation sections and execution positions that need to be adjusted in the current welding process. In the case of multiple adjustment targets corresponding to the same on-site adjustment object, the adjustment targets are arranged according to the acceptance order in the welding transmission range, and the adjustment targets are arranged from the source of the anomaly to the affected object according to the acceptance order in the welding transmission range.

[0103] Write the on-site adjustment object, the source of the abnormality, the adjustment target, the corresponding weld location, the structural area, the work station, and the order of acceptance into the on-site adjustment task.

[0104] S4.5. Based on the execution phase record, select the affected objects that are in the completed welding stage and mark them as re-inspection and verification objects. Determine the verification targets according to the weld positions and structural areas covering the re-inspection and verification objects in the welding transmission range. Generate re-inspection and verification tasks and write the re-inspection and verification objects, verification targets and re-inspection and verification tasks into the quality handling record.

[0105] It should be noted that affected objects in the completed welding stage are selected from the execution stage records, and the selected affected objects are marked as re-inspection and verification objects. For affected objects in mixed execution stages, the completed part in the execution stage records is read, and the weld operation segment corresponding to the completed part is marked as a re-inspection and verification object. The weld position, structural area, weld operation segment, acceptance sequence and execution stage corresponding to the re-inspection and verification object are read, and the welding transmission range covering the re-inspection and verification object is retrieved in the welding influence diagram. If there is a weld node corresponding to the re-inspection and verification object in the welding transmission range, the weld position corresponding to the weld node is determined as the verification target. If there is a structural area node corresponding to the re-inspection and verification object in the welding transmission range, the structural area covered by the structural area node and the weld operation segment that has formed a complete weld segment in the structural area are determined as the verification target.

[0106] Match the verification targets with the sources of anomalies in the welding influence diagram: if the verification target is located in the receiving direction of the regional anomaly source, record the verification target as a heat accumulation verification target; if the verification target is located in the receiving direction of the conduction trigger welding section, record the verification target as a process conduction verification target; if the same re-inspection object corresponds to multiple verification targets, record each verification target according to the receiving order in the welding conduction range, so that each verification target and the source of anomaly maintain a correspondence.

[0107] Write the re-inspection and review object, review target, source of anomaly, weld transmission range, weld location, structural area, and order of acceptance into the re-inspection and review task; after the re-inspection and review task is formed, write the re-inspection and review object, review target, and re-inspection and review task into the quality handling record, and maintain the correspondence with the already written on-site adjustment object and on-site adjustment task under the same source of anomaly.

[0108] S5. Collect the execution feedback of on-site adjustment tasks and the verification results of re-inspection and review tasks based on the quality handling records, and write them back to the corresponding weld positions and structural areas. Verify the completion status of on-site adjustment objects and the elimination status of abnormalities of re-inspection and review objects, and generate a welding traceability ledger.

[0109] S5.1 Collect execution feedback of on-site adjustment tasks, match the task objects in the execution feedback with the on-site adjustment objects in the quality handling record, and write the matched execution feedback into the corresponding weld position and structural area to form an adjustment feedback record.

[0110] It should be noted that after the on-site adjustment task is issued to the corresponding work station, the work station will return the execution feedback of the on-site adjustment task. The execution feedback records the task object, the work station, the adjustment target, the execution time, the execution completion mark, the execution obstruction mark, and the confirmation result after the adjustment.

[0111] After obtaining the execution feedback, the task object in the execution feedback is matched with the on-site adjustment object in the quality handling record. The matching is based on the weld position, structural area, work station and adjustment target corresponding to the on-site adjustment object. If the task object in the execution feedback is consistent with the weld position and structural area corresponding to the on-site adjustment object, and the execution station is consistent with the work station recorded in the quality handling record, the execution feedback is determined as the feedback data of the corresponding on-site adjustment object.

[0112] The feedback data is written into the corresponding weld location and structural area in the quality handling record. If one on-site adjustment object corresponds to multiple adjustment targets, the execution feedback is written separately according to the adjustment targets. If multiple on-site adjustment objects are located in the same structural area, the execution feedback is distinguished according to the weld location. When writing, the task object, adjustment target, execution position, execution time, execution completion mark, execution obstruction mark, and post-adjustment confirmation result are retained, and they are associated with the corresponding abnormality source and welding propagation range to form an adjustment feedback record.

[0113] S5.2 Collect the verification results of the re-inspection and review task, match the verification objects in the verification results with the re-inspection and review objects in the quality handling record, and write the matched verification results into the corresponding weld position and structural area to form a re-inspection and review record.

[0114] It should be noted that after the verification task is executed, the corresponding verification station will return the verification results. The verification results record the verification object, verification station, verification target, verification time, verification completion mark, exception retention mark and verification conclusion.

[0115] After obtaining the review results, the review objects in the review results are matched with the re-inspection review objects in the quality handling record. The matching is based on the weld position, structural area, review target, and weld transmission range corresponding to the re-inspection review object. If the review object in the review results is consistent with the weld position and structural area corresponding to the re-inspection review object, and the review target falls within the corresponding weld transmission range in the quality handling record, the review result is determined as the review data of the corresponding re-inspection review object.

[0116] Write the verification data into the corresponding weld location and structural area in the quality handling record. If one re-inspection verification object corresponds to multiple verification targets, write the verification results separately according to the verification targets. If multiple re-inspection verification objects are located in the same structural area, distinguish the verification results according to the weld location. When writing, retain the verification object, verification target, verification station, verification time, verification completion mark, anomaly retention mark and verification conclusion, and keep them associated with the corresponding anomaly source and welding propagation range to form a re-inspection verification record.

[0117] S5.3. Verify the completion status of the on-site adjustment object based on the adjustment feedback record, verify the anomaly elimination status of the re-inspection object based on the re-inspection and verification record, and write the completion status, anomaly elimination status, anomaly source, welding transmission range, weld location and structural area into the same traceability record to generate a welding traceability ledger.

[0118] It should be noted that, using the same source of anomaly in the quality handling record as the verification object, the corresponding on-site adjustment object, re-inspection and verification object, welding transmission range, weld location, and structural area should be retrieved. For on-site adjustment objects, the execution completion mark, execution obstruction mark, and post-adjustment confirmation result in the adjustment feedback record should be read. If the execution completion mark exists, the execution obstruction mark does not exist, and the post-adjustment confirmation result corresponds to the adjustment target in the on-site adjustment task, the on-site adjustment object should be recorded as handling completed. If the execution completion mark does not exist, or the execution obstruction mark exists, the on-site adjustment object should be recorded as handling incomplete, and the corresponding execution obstruction location and execution obstruction reason should be retained.

[0119] For the re-inspection and review object, read the review completion mark, anomaly retention mark, and review conclusion from the re-inspection and review record; if the review completion mark exists, the anomaly retention mark does not exist, and the review conclusion corresponds to the review target in the re-inspection and review task, record the re-inspection and review object as an anomaly eliminated; if the review completion mark does not exist, record the re-inspection and review object as an incomplete review; if the anomaly retention mark exists, record the re-inspection and review object as an anomaly not eliminated, and retain the anomaly retention location, the corresponding weld location, and the corresponding structural area.

[0120] In the same traceability record, the closed-loop status is determined based on the status of completed handling, incomplete handling, anomaly elimination, incomplete review, and anomaly not eliminated. If all on-site adjustment objects are in the completed handling status and all re-verification objects are in the anomaly elimination status, the closed-loop status is recorded as closed-loop completed. If there is an incomplete handling status but no incomplete review status or anomaly not eliminated status, the closed-loop status is recorded as adjustment not closed. If there is an incomplete review status or anomaly not eliminated status but no incomplete handling status, the closed-loop status is recorded as review not closed. If there are both incomplete handling status and incomplete review status or anomaly not eliminated status, the closed-loop status is recorded as mixed not closed.

[0121] Write the closed-loop status, reasons for incompleteness, locations to be further processed, locations to be reviewed, directions for re-review, status of completed processing, status of anomaly elimination, source of anomaly, range of weld transmission, weld location, and structural area into the same traceability record to generate a weld traceability ledger.

[0122] This embodiment also provides a computer device applicable to the welding quality monitoring method based on welding data acquisition, comprising: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to implement the welding quality monitoring method based on welding data acquisition as proposed in the above embodiment.

[0123] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0124] This embodiment also provides a storage medium storing a computer program. When executed by a processor, the program implements the welding quality monitoring method based on welding data acquisition as proposed in the above embodiments. The storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0125] In summary, this invention achieves a transformation from monitoring single weld parameters to identifying structural regions by tracing the thermal response status in the weld segment status table back to its corresponding structural region, and by combining the welding sequence to identify the superposition state of thermal response, the direction of thermal response expansion, and the thermal accumulation state of the structural region. This constructs the weld transmission range and marks the source of anomalies and affected objects, enabling a shift from monitoring single weld parameters to identifying quality impacts at the structural region and sequential correlation levels. This ensures that welding anomalies no longer remain at a single-point alarm but reflect the continuous impact of accumulated heat input and transmission from adjacent welds on weld quality. By mapping affected objects in the weld impact diagram to weld locations and structural regions, and by determining their execution stages based on the welding sequence and weld segment formation, on-site adjustment tasks and re-inspection and verification tasks are generated. This enables pre-adjustment of incomplete welded objects and targeted verification of completed welded objects, allowing quality monitoring results to directly enter on-site handling and traceability loops, improving the accuracy of anomaly location, the timeliness of handling, and the traceability of weld quality.

[0126] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for monitoring the quality of welded assemblies based on welding data acquisition, characterized in that, include: Acquire the basic data of the box to be assembled, organize the weld seam attribution, assembly sequence and adjacent influence relationship of the basic data, and generate the assembly welding acquisition index; During the assembly welding process, welding process signals and on-site status quantities are collected to form welding timing data. The welding timing data is mapped to the current weld according to the assembly welding acquisition index, and weld segment processing is performed to determine the process status and thermal response status of the weld segment and generate a weld segment status table. Based on the welding segment status table and the welding sequence in the welding acquisition index, the thermal response status of each welding segment is mapped to its corresponding structural region to determine the thermal accumulation status of the structural region. Based on the adjacency influence relationship in the welding acquisition index, the welding transmission range of the thermal accumulation status of the structural region and the welding process status is identified. Within the welding transmission range, the source of anomalies and the affected objects are marked to generate a welding influence map. Based on the welding impact diagram, the source of the anomaly, the range of welding transmission, and the affected objects are mapped to the weld location and structural area. The execution stage of the affected objects is determined. According to the execution stage, the affected objects that have not been welded are classified as on-site adjustment objects and on-site adjustment tasks are generated. The affected objects that have been welded are classified as re-inspection and verification objects and re-inspection and verification tasks are generated, forming a quality handling record. Based on the quality handling records, the execution feedback of on-site adjustment tasks and the review results of re-inspection and verification tasks are collected and written back to the corresponding weld positions and structural areas. The completion status of on-site adjustment objects and the elimination status of abnormalities of re-inspection and verification objects are verified, and a welding traceability ledger is generated.

2. The method for monitoring assembly welding quality based on welding data acquisition as described in claim 1, characterized in that, The specific steps for generating the welding acquisition index are as follows: In the basic data of assembly welding, determine the box structure position and weld position corresponding to the same box to be assembled and welded, match the weld position with the box structure position, and associate it with the work station to form weld ownership; Based on the weld attribution, the order of operations for each weld in the same box to be assembled is sorted out, and the thermal response coverage of each weld is determined by combining the extension range of the weld in the structural area, thus forming the assembly sequence, weld operation section and reference process state. Based on the welding sequence and thermal response coverage, welds that meet the conditions of structural proximity, sequential proximity, and thermal response coverage overlap are selected as adjacent influence objects to form adjacent influence relationships. Weld attribution, welding sequence, weld operation section, reference process state, and adjacent influence relationships are then organized to generate a welding acquisition index.

3. The method for monitoring the quality of weld assembly based on welding data acquisition as described in claim 2, characterized in that, The specific steps for generating the weld segment status table are as follows: During the assembly welding process, welding process signals and on-site status quantities are recorded according to the acquisition time, and the welding process signals and on-site status quantities at the same acquisition time are organized to form welding time sequence acquisition data. Based on the weld seam affiliation and weld seam operation segment in the welding acquisition index, the welding timing acquisition data is mapped to the current weld seam, and the welding process change position is identified within the data range of the current weld seam. The data between adjacent welding process change positions is organized into weld segment data fragments. Based on the data fragments of the weld section, the changes in welding process signals and field status quantities in each weld section are sorted out to determine the process status and thermal response status of each weld section. The weld, weld section, process status and thermal response status are then sorted out to generate a weld section status table.

4. The method for monitoring the quality of weld assembly based on welding data acquisition as described in claim 1 or 3, characterized in that, The specific steps for determining the thermal accumulation state of the structural region are as follows: Based on the correspondence between weld segments and welds in the weld segment status table, the thermal response status of each weld segment is traced back to the corresponding weld. According to the weld affiliation in the group welding acquisition index, the thermal response status of the corresponding weld is mapped to the structural region to form a structural region thermal response record. According to the welding sequence in the welding acquisition index, the thermal response records of the structural area are arranged in time sequence, and the thermal response status of adjacent welds in the same structural area is sorted out to form a thermal response sequence of the structural area. Based on the thermal response sequence of the structural region, the superposition state of thermal response and the direction of thermal response expansion generated by continuous welding in the same structural region are identified, and the thermal accumulation index of the structural region is calculated to determine the thermal accumulation state of the structural region.

5. The method for monitoring assembly welding quality based on welding data acquisition as described in claim 4, characterized in that, The specific steps for generating the weld impact diagram are as follows: Using the thermal response expansion direction in the thermal accumulation state of the structural region as the guide, the weld association path with directional bearing relationship corresponding to the thermal accumulation state of the structural region is found in the adjacency influence relationship of the weld acquisition index, and the welds and structural regions that satisfy the directional bearing relationship in the weld association path are organized into a weld conduction chain. The weld seams in the welding transmission chain are matched with the weld segment status table. The process status of each weld seam corresponding to the weld segment is extracted. The process status is compared with the baseline process status of the corresponding weld seam in the welding acquisition index. Weld segments that deviate from the standard and are located in the welding transmission chain and are affected by the heat accumulation of the preceding sequence are marked as transmission trigger weld segments. Based on the position of the conduction-triggered weld segment in the welding conduction chain, the chain segment where conduction occurs is extracted along the welding conduction chain as the welding conduction range; the structural area corresponding to the thermal accumulation state of the structural area and the conduction-triggered weld segment are jointly marked as the source of the anomaly, and the welds and structural areas within the welding conduction range that are affected are marked as the affected objects, generating a welding influence diagram.

6. The method for monitoring assembly welding quality based on welding data acquisition as described in claim 5, characterized in that, The specific steps for determining the affected objects during the execution phase are as follows: The affected objects in the welding influence diagram are mapped to the weld seam attribution in the welding acquisition index along the welding transmission range, and the weld seam location and structural area corresponding to the affected objects are determined to form an influence location record. The affected objects in the location record are matched with the welding sequence in the welding acquisition index to determine the operation sequence position of the affected objects in the current box to be welded. The operation sequence position is then compared with the welds that have formed a welding segment status in the welding segment status table to form an execution stage record. Based on the execution phase record, affected objects that have not formed a complete weld segment are marked as incomplete welding phase, and affected objects that have formed a complete weld segment are marked as completed welding phase. The affected objects, weld locations, structural areas, and execution phases are retained in the execution phase record.

7. The method for monitoring the quality of weld assembly based on welding data acquisition as described in claim 6, characterized in that, The specific steps for creating the quality handling record are as follows: Select the affected objects in the incomplete welding stage in the execution phase record and mark them as on-site adjustment objects. Determine the adjustment target according to the source of the anomaly of the on-site adjustment object in the weld location and structural area, and generate the on-site adjustment task. Based on the execution phase record, the affected objects that are in the completed welding stage are selected and marked as re-inspection and verification objects. The verification targets are determined according to the weld positions and structural areas covering the re-inspection and verification objects in the weld transmission range. Re-inspection and verification tasks are generated, and the re-inspection and verification objects, verification targets, and re-inspection and verification tasks are written into the quality handling record.

8. The method for monitoring the quality of weld assembly based on welding data acquisition as described in claim 7, characterized in that, The specific steps for generating the welding traceability ledger are as follows: Collect on-site adjustment task execution feedback, match the task object in the execution feedback with the on-site adjustment object in the quality handling record, and write the matched execution feedback into the corresponding weld position and structural area to form an adjustment feedback record; Collect the verification results of the re-inspection and review task, match the verification objects in the verification results with the re-inspection and review objects in the quality handling record, and write the matched verification results into the corresponding weld position and structural area to form a re-inspection and review record; Based on the adjustment feedback record, verify the completion status of the on-site adjustment object. Based on the return inspection and verification record, verify the anomaly elimination status of the return inspection and verification object. Write the completion status, anomaly elimination status, anomaly source, welding transmission range, weld location and structural area into the same traceability record to generate a welding traceability ledger.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that: When the processor executes the computer program, it implements the steps of the welding quality monitoring method based on welding data acquisition as described in any one of claims 1 to 8.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by the processor, it implements the steps of the welding quality monitoring method based on welding data acquisition as described in any one of claims 1 to 8.

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