A production control system and method for roll welding of a pole reinforcement

Abstract

The application relates to the technical field of automatic control, and discloses a production control system and method for the roll welding forming of electric pole steel bars. The method comprises the following steps: a given control quantity sequence is calculated according to electric pole taper structure parameters; an accumulated drift correction quantity and a local geometric correction quantity are respectively calculated by combining accumulated welding counting and detected diameter deviation; an execution control quantity is obtained by weighting combination and limiting, and then output; and drift parameters and contact resistance coefficients are updated according to batch detection deviation feedback, so that an updated given control quantity sequence is obtained. The application improves the matching precision between the welding execution control quantity and actual process requirements in the roll welding forming process of electric pole steel bars.

Description

Technical Field

[0001] This application relates to the field of automatic control technology, and in particular to a production control system and method for roll welding of steel bars for utility poles. Background Technology

[0002] As a widely used supporting component in power transmission and distribution lines, the internal steel reinforcement cage of the pole is usually manufactured using a roll welding process. Specifically, several main reinforcing bars are inserted and clamped into slots along the circumference of a rotating disk. As the rotating disk drives the entire cage to rotate, the stirrups are continuously attached to and wrapped around the surface of the main reinforcing bars. Whenever the stirrups and main reinforcing bars meet on the circumference to form an intersection, a welding robot performs resistance welding at the intersection. After completing this point-by-point sequence, a steel reinforcement cage running through the entire length of the pole is obtained. Existing steel cage roll welding machines and pole reinforcement forming equipment generally use programmable logic controllers combined with touch screens for control. Before starting the equipment, the operator sets parameters such as stirrup spacing, rotation speed, and uniform welding current, welding voltage, and energizing time along the entire length through the touch screen. During the entire production process, the equipment performs welding actions point by point according to this set of pre-set fixed parameters. Some equipment also uses rotational sequential welding and utilizes the residual heat of the previous weld point to preheat the next weld point to alleviate the cage deformation caused by welding thermal stress.

[0003] The existing fixed-parameter control method for the entire length does not take into account the geometric characteristics of the pole itself, which is a tapered structure with a continuously varying diameter along the axial direction. The diameter of the pole gradually decreases from the root to the tip, and the radius of curvature formed by the stirrups attached to the surface of the main reinforcement varies at different axial positions. The resulting contact pressure and contact resistance should systematically change with position. However, the existing equipment uses the same set of welding parameters for the entire length of the pole, meaning that this set of parameters can only match a specific axial position. At other positions, there will inevitably be a deviation between the welding current and the actual energy required at that location. This deviation is not a random fluctuation but a systematic mismatch that accumulates continuously with position. Meanwhile... During the welding process, the electrodes undergo surface oxidation and wear as the number of consecutive uses increases, and the contact resistance gradually increases accordingly. The fixed parameters of existing equipment or the passive method of relying on residual heat preheating do not provide any quantitative tracking or active compensation for this systematic drift that accumulates with the total number of welding sessions. Furthermore, the main reinforcement material itself has production tolerances in diameter, and there are also deviations between the actual diameter and the design diameter of different main reinforcements and different cross-sections on the same pole. Existing technology does not distinguish between these two completely different types of deviations, one of which accumulates monotonically with the number of welding sessions and the other of which fluctuates independently with the individual main reinforcements, and lacks the means to separate, identify and process them separately. Summary of the Invention

[0004] This application provides a production control system and method for roll welding of reinforcing bars for utility poles. The system enables the welding execution control quantity to be dynamically adjusted simultaneously based on three factors: the taper change of the pole's axial position, the drift trend of the electrode's cumulative usage status, and the current tolerance of the main reinforcing bar material at the weld point. Furthermore, the system continuously calibrates the baseline parameters and drift parameters through batch inspection feedback, thereby improving the matching accuracy between the welding execution control quantity and the actual process requirements during the roll welding of reinforcing bars for utility poles.

[0005] In a first aspect, this application provides a production control method for the roll welding forming of reinforcing bars for utility poles, the production control method for the roll welding forming of reinforcing bars for utility poles comprising: Step S1: Calculate the contact resistance based on the continuously varying tapered structural parameters of the pole along the axial direction to obtain a sequence of given control quantities corresponding to each weld point position. Step S2: Calculate the monotonic drift amount based on the cumulative welding count of the current weld point to obtain the cumulative drift correction amount; and calculate the local deviation amount based on the deviation between the detection diameter of the current weld point and the design taper value of the corresponding position in the given control quantity sequence to obtain the local geometric correction amount. Step S3: Based on the cumulative welding count, the cumulative drift correction amount and the local geometric correction amount are weighted and combined to obtain the adjustment control amount of the next weld point. The adjustment control amount is then superimposed and limited with the given control amount of the next weld point in the given control amount sequence to obtain the execution control amount of the next weld point, which is then output to the execution mechanism. Step S4: Based on the deviation feedback result between the batch detection control quantity of the solder joint and the given control quantity sequence, update the drift calculation parameters corresponding to the cumulative drift correction quantity and the contact resistance coefficient in the contact resistance calculation process to obtain the updated given control quantity sequence.

[0006] Secondly, this application provides a production control system for the roll welding and forming of reinforcing bars for utility poles, the production control system for the roll welding and forming of reinforcing bars for utility poles comprising: The calculation module is used to calculate the contact resistance based on the continuously varying tapered structural parameters of the pole along the axial direction, and to obtain a sequence of given control quantities corresponding to each weld point position. The correction module is used to perform monotonic drift calculation based on the cumulative welding count of the current weld point to obtain the cumulative drift correction amount, and to perform local deviation calculation based on the deviation between the detection diameter of the current weld point and the design taper value of the corresponding position in the given control quantity sequence to obtain the local geometric correction amount. The processing module is used to perform weighted combination processing on the cumulative drift correction amount and the local geometric correction amount according to the cumulative welding count to obtain the adjustment control amount of the next weld point, and to perform superposition and amplitude limiting operation processing on the adjustment control amount and the given control amount of the next weld point in the given control amount sequence to obtain the execution control amount of the next weld point, and output it to the execution mechanism. The update module is used to update the drift calculation parameters corresponding to the cumulative drift correction amount and the contact resistance coefficient in the contact resistance calculation process based on the deviation feedback result between the batch detection control amount of the solder joint and the given control amount sequence, so as to obtain the updated given control amount sequence.

[0007] Thirdly, a production control device for the roll welding and forming of reinforcing bars for utility poles is provided, comprising: a memory and at least one processor, wherein the memory stores instructions; the at least one processor invokes the instructions in the memory to cause the production control device for the roll welding and forming of reinforcing bars for utility poles to execute the aforementioned production control method for the roll welding and forming of reinforcing bars for utility poles.

[0008] Fourthly, a computer-readable storage medium is provided, wherein instructions are stored therein, which, when executed on a computer, cause the computer to perform the above-described production control method for the roll welding of reinforcing bars for utility poles.

[0009] The technical solution provided in this application features a key feature: calculating contact resistance based on the continuously varying tapered structural parameters of the pole along its axial direction to obtain a sequence of given control quantities corresponding to each weld point position. This ensures that the welding control quantity is no longer a fixed value uniform throughout the entire length, but rather a set of position-related baseline values ​​that continuously vary along the axial direction with the pole's tapered shape. These baseline values ​​are directly derived from the pole's own geometric structure, fundamentally avoiding the systematic parameter mismatch that occurs at different positions on the pole due to neglecting tapered variations in existing fixed parameter methods. Furthermore, based on this, a cumulative drift correction is obtained by calculating the cumulative drift based on the current weld point's cumulative weld count, and a local geometric correction is obtained by calculating the local deviation based on the deviation between the current weld point's detection diameter and the designed tapered value. These two calculation paths are independent of each other and do not borrow input variables from each other, ensuring that the electrode's resistance increases with the number of welds. The systematic change in contact resistance drift over time and the point-by-point random change in the diameter tolerance of the main rib material itself over space can be identified and quantified separately, unlike existing technologies that mix two different types of deviations together, causing them to mask or interfere with each other. The adjustment control quantity is obtained by weighting and combining the cumulative drift correction quantity and the local geometric correction quantity based on the cumulative welding count. The adjustment control quantity is then superimposed and limited with the given control quantity of the next weld point in the given control quantity sequence to obtain the execution control quantity, which is output to the actuator. This weighted combination method dynamically transitions between the two correction quantities as the cumulative welding count changes. This allows the welding execution control quantity to rely more on the measured data of the current weld point in the early stage of electrode use, and more on the systematic trend reflected by the cumulative welding count in the later stage of electrode use. This makes the generation method of the control quantity match the actual wear process of the electrode.

[0010] Based on the feedback results of the deviation between the batch detection control quantity and the given control quantity sequence, the drift calculation parameters corresponding to the cumulative drift correction quantity and the contact resistance coefficient in the contact resistance calculation are updated to obtain the updated given control quantity sequence. This allows the baseline parameters derived from the pole structure to continuously absorb on-site measured data and be continuously corrected as production batches progress, rather than remaining at the static values ​​at the beginning of equipment production. The algorithm features used in this application are not general prediction methods detached from the specific scenario of pole rebar rolling welding. The quantities involved in the calculation, such as cumulative weld count, detection diameter, and contact resistance coefficient, are all directly taken from the physical measurement and structural design parameters in this scenario. The separate calculation method of cumulative drift correction quantity and local geometric correction quantity is established only after fully considering the specific domain characteristics that the two types of deviation causes, electrode wear and incoming material tolerance, are physically independent. The weighting coefficients used in the weighted combination process directly correspond to the process law of electrode wear, rather than simply applying a certain general algorithm structure to this scenario. Attached Figure Description

[0011] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0012] Figure 1 This is a schematic diagram of an embodiment of the production control method for the roll welding of reinforcing bars for utility poles in this application. Figure 2 This is a schematic diagram illustrating how the given control quantity sequence changes with the axial position of the solder joint in an embodiment of this application. Figure 3 This is a schematic diagram illustrating how the drift growth factor and cumulative drift correction amount change with the cumulative weld count in the embodiments of this application. Detailed Implementation

[0013] This application provides a production control system and method for roll welding and forming of reinforcing bars for utility poles. The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data used can be interchanged where appropriate so that the embodiments described herein can be implemented in a sequence other than that illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0014] For ease of understanding, the specific process of the embodiments of this application is described below. Please refer to [link / reference]. Figure 1 One embodiment of the production control method for the roll welding forming of pole reinforcement bars in this application includes: Step S1: Calculate the contact resistance based on the continuously varying tapered structural parameters of the pole along the axial direction to obtain a sequence of given control quantities corresponding to each weld point position. Specifically, the taper structural parameters consist of three original design dimensions: the total length of the pole, the design diameter of the large end, and the design diameter of the small end. Taking the large end of the pole as the starting point, a coordinate system is established along the pole's length. The distance of a weld point from the starting point is divided by the total length of the pole to obtain a positional ratio between zero and one. This ratio is multiplied by the difference between the design diameters of the large and small ends, and then the product is subtracted from the design diameter of the large end to obtain the design diameter corresponding to that weld point location, i.e., the design taper value. These two are the same quantity described in different ways. The design radius is obtained by dividing the diameter by two. The contact pressure generated by the stirrups wrapped around the surface of the main reinforcement is inversely proportional to the design radius. The greater the pressure, the smaller the radius. This inverse relationship is obtained by dividing the preset stirrup winding tension setting value by the design radius, and then multiplying it by the preset contact resistance coefficient to obtain the contact resistance of the weld point. Finally, the given control quantity corresponding to the weld point is obtained by dividing the target welding heat input design value by the product of the contact resistance and the baseline energizing time and then taking the square root. This given control quantity itself is a specific value with the dimension of current. They are connected in series to form a given control quantity sequence.

[0015] Step S2: Calculate the monotonic drift amount based on the cumulative welding count of the current weld point to obtain the cumulative drift correction amount; and calculate the local deviation amount based on the deviation between the detection diameter of the current weld point and the design taper value at the corresponding position in the given control quantity sequence to obtain the local geometric correction amount. Specifically, the detection diameter is measured by the ranging device at the cross-section where the current weld point is located. The difference between this diameter and the corresponding value in the design taper value (as described in the previous paragraph) is used to obtain the diameter deviation. The diameter deviation is divided by the design taper value to obtain a dimensionless relative deviation rate. This relative deviation rate is multiplied by a preset local deviation coefficient. The local deviation coefficient itself is a proportional constant calibrated in current units. For example, each 1% of the relative deviation rate corresponds to a certain adjustment amount in amperes. After multiplication, the local geometric correction amount is itself a value in the dimension of current, no longer a pure proportion. The cumulative welding count is obtained by the counter incrementing sequentially after the equipment is powered on, representing the number of welding actions completed by the electrode. This count is substituted into the preset drift coefficient and exponentially calculated to obtain a growth factor that approaches one as the number of counts increases. This growth factor is multiplied by a preset upper limit of the drift saturation ratio. The upper limit of the drift saturation ratio is also a constant calibrated in current units, not a dimensionless proportion. After multiplication, the cumulative drift correction amount also falls in the dimension of current. In this way, the two correction amounts are consistent with the given control amount to be added later in terms of dimension.

[0016] Step S3: Based on the cumulative welding count, the cumulative drift correction amount and the local geometric correction amount are weighted and combined to obtain the adjustment control amount of the next weld point. The adjustment control amount is then superimposed and limited with the given control amount of the next weld point in the given control amount sequence to obtain the execution control amount of the next weld point, which is then output to the execution mechanism. Specifically, the cumulative welding count is substituted into a preset weighting function to obtain the current drift weighting coefficient. This weighting coefficient increases with the increase of the cumulative welding count, indicating that the more times the electrode is used, the higher the proportion of the drift component in the final adjustment. Subtracting this coefficient from one yields the current geometric weighting coefficient. The two weighting coefficients are multiplied by the cumulative drift correction amount and the local geometric correction amount, which have been converted to the dimension of current, respectively. The products are added together to obtain the adjustment control amount. The adjustment control amount is also a value in the dimension of current, belonging to the same dimension as the given control amount at the corresponding position of the weld point. The two are added together to obtain the superimposed control amount, which is then compared with the preset upper limit value and lower limit value of the control amount in sequence. If it exceeds the upper limit, it is output according to the upper limit value; if it is lower than the lower limit, it is output according to the lower limit value; if it falls within the range, it is output according to the original value. The obtained execution control amount is sent to the welding robot that completes the actual welding action. The execution mechanism here refers to the robot component that undertakes the action. After receiving the execution control amount, it drives the actual output of the welding current according to the value.

[0017] Step S4: Based on the deviation feedback result between the batch detection control quantity of the solder joint and the given control quantity sequence, update the drift calculation parameters corresponding to the cumulative drift correction quantity and the contact resistance coefficient in the contact resistance calculation process to obtain the updated given control quantity sequence.

[0018] Specifically, the batch inspection control quantity of weld points comes from sampling several weld points that have been welded at fixed intervals. The actual control quantity values ​​of the sampled weld points are measured using non-destructive resistance detection methods. These detection values ​​are subtracted one by one from the given control quantity at their respective positions, and the difference is taken as an arithmetic mean to obtain the deviation feedback result. The drift calculation parameter specifically refers to the drift coefficient mentioned above used for exponential calculation. The deviation feedback result is added to the current drift coefficient according to the set adjustment step size to obtain the updated drift coefficient. Similarly, the deviation feedback result is added to the current contact resistance coefficient according to another set step size to obtain the updated contact resistance coefficient. This updated contact resistance coefficient is then substituted back into the entire calculation chain from the design radius to the given control quantity described earlier to recalculate a set of given control quantity sequences, which replace the original sequence for the production of the next pole. To address the issue raised in the background section regarding the systematic deviation in welding quality caused by fixed parameters along the entire length of existing roll welding equipment, which varies with position and electrode usage frequency, the aforementioned entire link—which obtains a position-related baseline through structural parameter analysis, then corrects it using two independently induced components, and transmits the calibration back in batches—enables the execution control quantity to dynamically follow the pole taper position and the cumulative electrode usage status, thus solving the problem that fixed parameters cannot cover the aforementioned two types of systematic deviations.

[0019] In one specific embodiment, step S1 includes: Based on the total length of the pole, the design diameter of the large end and the design diameter of the small end in the tapered structure parameters, the design diameter of each weld point is calculated to obtain the design diameter sequence corresponding to each weld point position. The design diameter sequence is processed by design radius calculation to obtain the design radius sequence corresponding to each weld point position; Based on the preset stirrup winding tension setting value and the preset contact resistance coefficient, the contact resistance is calculated on the design radius sequence to obtain the contact resistance sequence corresponding to each weld point position. Based on the preset target welding heat input design value and the preset baseline energizing time, the contact resistance sequence is processed by a given control quantity calculation to obtain a given control quantity sequence corresponding to each weld point position.

[0020] Specifically, the coordinates of the weld point location are established along the axial direction starting from the end face of the large end of the pole. Each weld point corresponds to a weld point number that is incremented starting from zero. The number is multiplied by the axial pitch of the stirrup winding and divided by the number of main reinforcement bars to obtain a fixed axial increment, which gives the axial distance of the weld point from the starting point. This axial distance is divided by the total length of the pole to obtain a position ratio between zero and one. The position ratio is multiplied by the difference between the design diameter of the large end and the design diameter of the small end, and then the product is subtracted from the design diameter of the large end to obtain the design diameter corresponding to the weld point location. The design diameter sequence is this series of values ​​arranged in order of weld point number. The design diameter is divided by two to obtain the design radius. The design radius sequence corresponds one-to-one with the design diameter sequence, and the dimensions of both are length units. During the winding process, the stirrups are attached to the surface of the main reinforcement with a constant tension. The tension setting value is divided by the design radius of the corresponding position to obtain the contact pressure distribution per unit length at that location. This is then multiplied by a preset contact resistance coefficient. The contact resistance coefficient itself is derived from the ratio of the measured contact resistance to the pressure distribution in the calibration test of the same batch of steel bars and stirrups. After this multiplication, the dimension of the coefficient is made to fall into the resistance unit, thus obtaining the contact resistance corresponding to the weld point position. The contact resistance is arranged in the order of the weld point number to form a contact resistance sequence. If the design radius of a certain weld point position is zero or negative after calculation, the data of that weld point position is determined to be invalid, the contact resistance calculation of that weld point is skipped, and the contact resistance value of the adjacent previous weld point position is used.

[0021] The target welding heat input design value represents the energy required to form a qualified weld nugget at the contact point during a single weld. Its value is derived from peel tests performed on main reinforcement bars and stirrups of the same specification after multiple welds, deducing the lower limit of energy required to form a stable weld nugget and allowing for a margin. The baseline energizing time is the fixed energizing duration allowed by the mechanical action of the welding controller at the current rotation speed. The target welding heat input design value is divided by the product of the contact resistance at the weld point location and the baseline energizing time. The square root of the quotient is then taken to obtain the given control quantity corresponding to that weld point location. The sequence of given control quantities is this series of square root results arranged in order of weld point number. If the calculated contact resistance at a weld point location is zero, or the baseline energizing time is set to zero, it is determined that the denominator is zero and the square root operation cannot be performed. In this case, the given control quantity calculation is not performed, and the given control quantity already calculated for the adjacent previous weld point location is directly used as the value for that weld point. The given control sequence is ultimately expressed in units of current and arranged in complete order of solder joint number. The value of each solder joint continuously rises and falls with the change of position ratio. The larger end has a smaller radius and lower contact resistance, resulting in a lower corresponding current value, while the smaller end has a smaller radius and higher contact resistance, resulting in a higher corresponding current value.

[0022] Figure 2 This is a schematic diagram illustrating how the given control quantity sequence changes with the axial position of the solder joint in an embodiment of this application. Figure 2 The curves show the changes of the given control quantity sequence, calculated point by point based on the pole's tapered structural parameters, with the axial position of the weld point along the entire length of the pole. The horizontal axis represents the axial position of the weld point from the large end of the pole, and the vertical axis represents the given control quantity value corresponding to that position. The curves show a continuous upward trend as the position increases, corresponding to the structural feature that the diameter of the pole gradually decreases from the large end to the small end, and the contact resistance increases accordingly.

[0023] In one specific embodiment, step S2 includes: The counter is incremented based on the number of welding actions completed to obtain the cumulative welding count; The cumulative welding count is processed exponentially based on a preset drift coefficient to obtain a drift growth factor. The drift growth factor is then proportionally calculated based on a preset upper limit for drift saturation ratio to obtain the cumulative drift correction amount. The difference between the detected diameter and the designed taper value is calculated to obtain the diameter deviation. The diameter deviation is then normalized according to the designed taper value to obtain the relative deviation rate. The relative deviation rate is proportionally calculated based on a preset local deviation coefficient to obtain the local geometric correction amount.

[0024] Specifically, the counter increments by one for each welding operation, resulting in a cumulative welding count. If the counter reaches a preset storage limit, it stops incrementing and remains at that limit to prevent overflow caused by continuous production. The cumulative welding count and drift coefficient are used together in an exponential calculation. Specifically, the natural constant is used as the base, and the negative value of the product of the drift coefficient and the cumulative welding count is used as the exponent. The result is then subtracted from one to obtain the drift growth factor. This calculation method ensures that the drift growth factor is zero when the cumulative welding count is zero, and gradually approaches one as the cumulative welding count increases, but never exceeds one. The drift coefficient is derived from the curve of the change in contact resistance with the number of welding operations recorded at fixed intervals for continuous welding of the same electrode from its initial installation state until replacement. The growth rate of this curve is then fitted and inversely deduced. The cumulative drift correction is obtained by multiplying the drift growth factor by the preset upper limit of the drift saturation ratio. Although the upper limit of the drift saturation ratio has the word "ratio" in its name, its actual value is determined by the deviation of the measured contact resistance value of the electrode when it reaches the replacement cycle from the state of the new electrode, and the value of the current required to increase the current under the target welding heat input design value. Therefore, this constant itself is a value in the unit of current. The cumulative drift correction is also zero when the drift growth factor is zero, and it approaches the upper limit of the drift saturation ratio itself when the drift growth factor approaches one. The direction is consistent with the physical process that the degree of electrode wear increases with the number of welding cycles.

[0025] The measured diameter is obtained by measuring the cross-section of the current weld point using a ranging device. This diameter is then subtracted from the design taper value corresponding to that weld point. If the measured diameter is greater than the design taper value, the difference is positive, indicating that the actual cross-section of the main rib at that location is too thick, resulting in a larger contact area and lower contact resistance. In this case, the current needs to be increased based on the given control value to maintain the same target welding heat input. If the measured diameter is less than the design taper value, the difference is negative, indicating that the actual cross-section of the main rib is too thin, resulting in higher contact resistance. In this case, the current needs to be reduced. This difference is the diameter deviation. The diameter deviation is divided by the design taper value to obtain the relative deviation rate. If the calculated design taper value for a weld point falls within the range of a pre-set minimum effective diameter, the coordinate calculation result for that location is deemed invalid, and no normalization is performed. The relative deviation rate already calculated for the adjacent previous weld point is directly used as the value for that weld point. The relative deviation rate is multiplied by a preset local deviation coefficient. The value of the local deviation coefficient is obtained by conducting welding tests on the main reinforcement bars of the same batch within different diameter tolerance ranges, recording the current adjustment required for qualified weld points corresponding to different diameter deviations, and averaging the ratio of this adjustment to the relative deviation rate. Its dimension is the unit of current divided by the relative deviation rate. The local geometric correction amount obtained by multiplying the two also falls in the current unit, and the positive and negative directions are consistent with the positive and negative of the diameter deviation amount. The main reinforcement bar is thicker, which corresponds to a positive correction value, and thinner, which corresponds to a negative correction value. This result, together with the aforementioned cumulative drift correction amount, participates in the subsequent weighted combination calculation in the current unit.

[0026] Figure 3 This is a schematic diagram illustrating how the drift growth factor and cumulative drift correction amount change with the cumulative weld count in the embodiments of this application. Figure 3 The curves show how the drift growth factor and the cumulative drift correction change with the number of welds within the same cumulative weld count range. The left vertical axis represents the dimensionless drift growth factor value, the right vertical axis represents the cumulative drift correction value converted to current units, and the horizontal axis represents the cumulative weld count. Both curves show that they increase with the cumulative weld count, and the growth rate gradually slows down and eventually tends to saturate, corresponding to the contact resistance drift trend of the electrode as the number of consecutive uses increases.

[0027] In one specific embodiment, step S3 involves weighting and combining the cumulative drift correction amount and the local geometry correction amount based on the cumulative weld count to obtain the adjustment control amount for the next weld point, including: The current drift weight coefficient is obtained by assigning values ​​to the preset weight function based on the cumulative welding count. The current drift weight coefficients are subjected to complementary calculation processing to obtain the current geometric weight coefficients; The cumulative drift correction is weighted according to the current drift weight coefficient to obtain the weighted drift correction, and the local geometric correction is weighted according to the current geometric weight coefficient to obtain the weighted geometric correction. The weighted drift correction amount and the weighted geometric correction amount are summed to obtain the adjustment control amount for the next solder joint.

[0028] Specifically, the cumulative welding count is substituted into a preset weighting function for evaluation. This function takes the cumulative welding count as its independent variable, and its value is limited to the range of zero to one. It increases monotonically as the cumulative welding count increases. When the cumulative welding count is zero, the function value is zero. When the cumulative welding count reaches the preset upper limit number corresponding to the electrode replacement cycle, the function value is one. Intermediate values ​​are obtained by linear interpolation based on the ratio of the cumulative welding count to the upper limit number. If the cumulative welding count exceeds the upper limit number but the electrode replacement signal is not triggered, the function value remains one and does not continue to increase. This value is the current drift weight coefficient. Subtracting the current drift weight coefficient from one yields the current geometric weight coefficient. Since the current drift weight coefficient itself is limited to the range of zero to one, the resulting geometric weight coefficient also falls within the range of zero to one. The sum of the two is always one, and no negative value will occur. Substituting the two endpoints to verify the direction, when the cumulative welding count is zero, the current drift weight coefficient is zero and the current geometric weight coefficient is one, which means that when the electrode has just been replaced, it relies entirely on the local geometric correction amount and does not accept the drift correction amount. When the cumulative welding count reaches the upper limit, the current drift weight coefficient is one and the current geometric weight coefficient is zero, which means that when the electrode is close to the replacement cycle, it relies entirely on the cumulative drift correction amount. The direction is consistent with the physical process that the degree of electrode wear increases with the number of weldings and the reference value of local detection data decreases relatively with electrode aging.

[0029] The current drift weight coefficient is multiplied by the cumulative drift correction to obtain the weighted drift correction. The cumulative drift correction itself is in current units, while the weight coefficient is a dimensionless proportionality. After multiplication, the weighted drift correction is still in current units. The current geometric weight coefficient is multiplied by the local geometric correction to obtain the weighted geometric correction. The local geometric correction is also in current units. After multiplication, the weighted geometric correction is still in current units, and both have the same dimensions. The weighted drift correction and the weighted geometric correction are added together to obtain the adjustment control value for the next weld point. The adjustment control value also falls in current units, and its value continuously transitions between the two correction values ​​as the cumulative weld count changes. When the cumulative weld count is small, the value of the adjustment control value is closer to the local geometric correction value itself; when the cumulative weld count is large, the value of the adjustment control value is closer to the cumulative drift correction value itself. This result is then added to the given control value at the corresponding position of the weld point in the same current unit.

[0030] In one specific embodiment, the adjustment control quantity is superimposed and limited by the given control quantity of the next solder joint in the given control quantity sequence to obtain the execution control quantity of the next solder joint, which is then output to the execution mechanism, including: The superimposed control quantity is calculated by superimposing the adjustment control quantity with the given control quantity of the next weld point in the given control quantity sequence to obtain the superimposed control quantity. The superimposed control quantity is compared with the preset upper limit value of the control quantity to obtain the upper limit correction control quantity. The upper limit correction control quantity is compared with the preset lower limit value to obtain the execution control quantity of the next welding point, and the execution control quantity is output to the execution mechanism.

[0031] Specifically, the superimposed control quantity is obtained by directly adding the adjusted control quantity to the given control quantity at the corresponding position of the weld point. A positive value of the adjusted control quantity represents an increase in current based on the given control quantity, while a negative value represents a decrease in current. The addition process does not involve sign conversion, and both are expressed in current units. The result of the addition is also expressed in current units. The superimposed control quantity is compared with the preset upper limit value of the control quantity. If the value of the superimposed control quantity exceeds the upper limit value, the value is replaced with the upper limit value itself to obtain the upper limit correction control quantity. If the value of the superimposed control quantity does not exceed the upper limit value, the upper limit correction control quantity remains unchanged. The upper limit value of the control quantity is derived from the maximum current value that the welding electrode can withstand under continuous energizing conditions without electrode tip burn-out. This value is determined by leaving a margin downward after measuring the critical current value at which obvious signs of electrode tip burn-out appear in continuous energizing tests on electrodes of the same model.

[0032] The upper limit correction control quantity is compared with the preset lower limit control quantity value. If the upper limit correction control quantity value is lower than the lower limit control quantity value, the value is replaced with the lower limit control quantity value itself to obtain the execution control quantity for the next weld point. If the upper limit correction control quantity value is not lower than the lower limit control quantity value, the execution control quantity takes the original value of the upper limit correction control quantity. The lower limit control quantity value is derived from the minimum current value required to form a qualified weld nugget under the contact resistance conditions at the weld point location. If this value is lower than this limit, the weld nugget cannot be fully formed, which is within the risk range of poor weld. The lower limit control quantity value is set to be less than the upper limit control quantity value to avoid the contradictory situation where the upper limit value is corrected first and then replaced by the lower limit value, resulting in the final output being neither the original superposition result nor falling within the reasonable range. The obtained execution control quantity is output to the welding robot that completes the actual spot welding action. After receiving the execution control quantity, the robot drives the welding circuit to output the corresponding current at the next weld point location to complete the energizing action.

[0033] In one specific embodiment, the adjustment control quantity is superimposed with the given control quantity of the next solder joint in the given control quantity sequence to obtain the superimposed control quantity, including: The solder joint number of the next solder joint is obtained by incrementing the solder joint number of the current solder joint. The given control quantity sequence is indexed according to the solder joint number of the next solder joint to obtain the given control quantity of the next solder joint. Based on the actual rotation position of the rotary disk, the given control quantity of the next welding point is subjected to timing verification processing to obtain the given control quantity after verification. The superimposed control quantity is obtained by summing the adjustment control quantity and the given control quantity after verification.

[0034] Specifically, the weld point number is counted from zero starting with the first weld point at the large end of the pole. Each completed welding operation increments this number by one to obtain the weld point number for the next weld point. If the weld point number for the next weld point reaches the total length of the given control quantity sequence, it indicates that the pole has been welded to the end weld point. At this point, indexing is no longer performed, and the control flow transitions to the final actions of stopping rotation and cutting the stirrups. If the weld point number for the next weld point does not exceed the sequence length, it is used as an array index to retrieve the value from the given control quantity sequence. The specific value stored at that index position is taken as the given control quantity for the next weld point. This value is the original value at the corresponding position in the sequence, calculated point by point based on the pole's tapered structural parameters and stored in order of weld point number.

[0035] The actual rotational position of the rotary disk is represented by the cumulative angle value measured by the rotary encoder. This angle value is divided by the angle corresponding to a complete rotation, multiplied by the number of solder joints per rotation, rounded, and then incremented by one to obtain the current solder joint number actually reached by the rotary disk. This value is subtracted from the solder joint number of the next solder joint, and the absolute value is taken. If the difference does not exceed the preset tolerance number of solder joints, the verification is considered successful, and the given control quantity obtained from the aforementioned index is used as the given control quantity after verification. If the difference exceeds the tolerance number of solder joints, the actual position reached by the rotary disk is determined to be inconsistent with the theoretical solder joint number. In this case, the index result is not used, and instead, the given control quantity component corresponding to the execution control quantity already used for the adjacent previous solder joint is used as the given control quantity after verification, until the difference falls back within the tolerance range in the next verification. The given control quantity after verification is added to the adjustment control quantity to obtain the superimposed control quantity. This addition method is consistent with that described in the previous section and will not be repeated.

[0036] In one specific embodiment, step S4 includes: The difference between the batch detection control quantity of the solder joint and the given control quantity at the corresponding position in the given control quantity sequence is calculated to obtain the batch deviation set; The mean value of the batch deviation set is calculated to obtain the deviation feedback result. Based on the deviation feedback result, the drift calculation parameters are updated by gradient processing to obtain the updated drift calculation parameters. The contact resistance coefficient is corrected based on the deviation feedback result to obtain an updated contact resistance coefficient. The contact resistance calculation process is then re-executed based on the updated contact resistance coefficient to obtain the updated given control quantity sequence.

[0037] Specifically, the batch inspection control quantity for weld joints is obtained by sampling completed weld joints at fixed intervals using an online resistance detection device. The sampling method involves selecting one weld joint for inspection after each pre-set number of weld joints is completed. If the total number of weld joints corresponding to the entire length of a batch of poles is insufficient to meet the pre-set sampling interval, all completed weld joints within that batch are included in the sampling scope to avoid a zero sample size. The inspection control quantity for each sampled weld joint is subtracted from the original given control quantity stored in the given control quantity sequence for that weld joint's corresponding position to obtain the deviation value for that weld joint. The deviation values ​​of all sampled weld joints constitute the batch deviation set. The arithmetic mean of all deviation values ​​in the batch deviation set is used to obtain the deviation feedback result. If the number of deviation values ​​in the batch deviation set is zero, the deviation feedback result uses the deviation feedback result already calculated for the previous batch and is not updated in this instance.

[0038] The deviation feedback result is added to the current drift coefficient according to a pre-set update step size to obtain the updated drift calculation parameters. If the deviation feedback result is positive, it means that the measured control quantity is generally higher than the given control quantity, indicating that the electrode wear degree has exceeded the level reflected by the current drift coefficient. The updated drift coefficient is increased accordingly, making the drift growth factor in the production of the next pole higher under the same cumulative welding count. If the deviation feedback result is negative, it means that the measured control quantity is generally lower than the given control quantity. The updated drift coefficient is decreased accordingly, making the drift growth factor lower under the same cumulative welding count. In both cases, the update direction is consistent with the sign of the deviation feedback result. The same deviation feedback result is added to the current contact resistance coefficient according to another pre-set update step size to obtain the updated contact resistance coefficient. The update direction is also consistent with the sign of the deviation feedback result. When the measured control quantity is too high, the contact resistance coefficient is adjusted lower accordingly, and when the measured control quantity is too low, the contact resistance coefficient is adjusted higher accordingly.

[0039] The updated contact resistance coefficient is re-substituted into the complete calculation path of calculating the contact resistance sequence based on the design radius sequence and then calculating the given control quantity sequence. The contact resistance and given control quantity are recalculated for each of the weld points on the pole. The other values ​​involved in the calculation path, such as the stirrup winding tension setting value, the target welding heat input design value, and the baseline energizing time, remain unchanged. Only the contact resistance coefficient is replaced with the updated value. The resulting updated given control quantity sequence is used as the initial given control quantity for the corresponding position of the next pole during production.

[0040] The above describes the production control method for the roll welding of reinforcing bars in utility poles according to the embodiments of this application. The following describes the production control system for the roll welding of reinforcing bars in utility poles according to the embodiments of this application. One embodiment of the production control system for the roll welding of reinforcing bars in utility poles according to the embodiments of this application includes: The calculation module is used to calculate the contact resistance based on the continuously varying tapered structural parameters of the pole along the axial direction, and to obtain a sequence of given control quantities corresponding to each weld point position. The correction module is used to perform monotonic drift calculation based on the cumulative welding count of the current weld point to obtain the cumulative drift correction amount, and to perform local deviation calculation based on the deviation between the detection diameter of the current weld point and the design taper value of the corresponding position in the given control quantity sequence to obtain the local geometric correction amount. The processing module is used to perform weighted combination processing on the cumulative drift correction amount and the local geometric correction amount according to the cumulative welding count to obtain the adjustment control amount of the next weld point, and to perform superposition and amplitude limiting operation processing on the adjustment control amount and the given control amount of the next weld point in the given control amount sequence to obtain the execution control amount of the next weld point, and output it to the execution mechanism. The update module is used to update the drift calculation parameters corresponding to the cumulative drift correction amount and the contact resistance coefficient in the contact resistance calculation process based on the deviation feedback result between the batch detection control amount of the solder joint and the given control amount sequence, so as to obtain the updated given control amount sequence.

[0041] This invention also provides a production control device for the roll welding and forming of reinforcing bars for utility poles, which can be a server. The production control device includes a processor, memory, display screen, input device, network interface, and database connected via a system bus. The processor, designed as a computer, provides computing and control capabilities. The memory of the production control device includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores an operating system, computer programs, and a database. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The database of the production control device stores the data corresponding to this embodiment. The network interface of the production control device is used to communicate with external terminals via a network connection. When the computer program is executed by the processor, it implements the above-described method.

[0042] The present invention also provides a computer-readable storage medium, which can be a non-volatile computer-readable storage medium or a volatile computer-readable storage medium, wherein the computer-readable storage medium stores instructions that, when the instructions are executed on a computer, cause the computer to perform the steps of the production control method for the roll welding forming of the pole reinforcement.

[0043] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0044] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a production control device for the roll welding of rebar poles (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0045] 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 the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A production control method for roll welding of reinforcing bars for utility poles, characterized in that, The method includes: Step S1: Calculate the contact resistance based on the continuously varying tapered structural parameters of the pole along the axial direction to obtain a sequence of given control quantities corresponding to each weld point position. Step S2: Calculate the monotonic drift amount based on the cumulative welding count of the current weld point to obtain the cumulative drift correction amount; and calculate the local deviation amount based on the deviation between the detection diameter of the current weld point and the design taper value of the corresponding position in the given control quantity sequence to obtain the local geometric correction amount. Step S3: Based on the cumulative welding count, the cumulative drift correction amount and the local geometric correction amount are weighted and combined to obtain the adjustment control amount of the next weld point. The adjustment control amount is then superimposed and limited with the given control amount of the next weld point in the given control amount sequence to obtain the execution control amount of the next weld point, which is then output to the execution mechanism. Step S4: Based on the deviation feedback result between the batch detection control quantity of the solder joint and the given control quantity sequence, update the drift calculation parameters corresponding to the cumulative drift correction quantity and the contact resistance coefficient in the contact resistance calculation process to obtain the updated given control quantity sequence.

2. The production control method for roll welding of reinforcing bars for utility poles according to claim 1, characterized in that, Step S1 includes: Based on the total length of the pole, the design diameter of the large end and the design diameter of the small end in the tapered structure parameters, the design diameter of each weld point is calculated to obtain the design diameter sequence corresponding to each weld point position. The design diameter sequence is processed by design radius calculation to obtain the design radius sequence corresponding to each weld point position; Based on the preset stirrup winding tension setting value and the preset contact resistance coefficient, the contact resistance is calculated on the design radius sequence to obtain the contact resistance sequence corresponding to each weld point position. Based on the preset target welding heat input design value and the preset baseline energizing time, the contact resistance sequence is processed by a given control quantity calculation to obtain a given control quantity sequence corresponding to each weld point position.

3. The production control method for roll welding of reinforcing bars for utility poles according to claim 1, characterized in that, Step S2 includes: The counter is incremented based on the number of welding actions completed to obtain the cumulative welding count; The cumulative welding count is processed exponentially based on a preset drift coefficient to obtain a drift growth factor. The drift growth factor is then proportionally calculated based on a preset upper limit for drift saturation ratio to obtain the cumulative drift correction amount. The difference between the detected diameter and the designed taper value is calculated to obtain the diameter deviation. The diameter deviation is then normalized according to the designed taper value to obtain the relative deviation rate. The relative deviation rate is proportionally calculated based on a preset local deviation coefficient to obtain the local geometric correction amount.

4. The method for controlling the production of welded steel bars for utility poles according to claim 3, characterized in that, In step S3, the cumulative drift correction amount and the local geometry correction amount are weighted and combined according to the cumulative weld count to obtain the adjustment control amount for the next weld point, including: The current drift weight coefficient is obtained by assigning values ​​to the preset weight function based on the cumulative welding count. The current drift weight coefficients are subjected to complementary calculation processing to obtain the current geometric weight coefficients; The cumulative drift correction is weighted according to the current drift weight coefficient to obtain the weighted drift correction, and the local geometric correction is weighted according to the current geometric weight coefficient to obtain the weighted geometric correction. The weighted drift correction amount and the weighted geometric correction amount are summed to obtain the adjustment control amount for the next solder joint.

5. The production control method for roll welding of reinforcing bars for utility poles according to claim 4, characterized in that, The adjustment control quantity is superimposed and limited with the given control quantity of the next solder joint in the given control quantity sequence to obtain the execution control quantity of the next solder joint, which is then output to the execution mechanism, including: The superimposed control quantity is calculated by superimposing the adjustment control quantity with the given control quantity of the next weld point in the given control quantity sequence to obtain the superimposed control quantity. The superimposed control quantity is compared with the preset upper limit value of the control quantity to obtain the upper limit correction control quantity. The upper limit correction control quantity is compared with the preset lower limit value to obtain the execution control quantity of the next welding point, and the execution control quantity is output to the execution mechanism.

6. The production control method for roll welding of reinforcing bars for utility poles according to claim 5, characterized in that, The step of superimposing the adjustment control quantity with the given control quantity of the next weld point in the given control quantity sequence to obtain the superimposed control quantity includes: The solder joint number of the next solder joint is obtained by incrementing the solder joint number of the current solder joint. The given control quantity sequence is indexed according to the solder joint number of the next solder joint to obtain the given control quantity of the next solder joint. Based on the actual rotation position of the rotary disk, the given control quantity of the next welding point is subjected to timing verification processing to obtain the given control quantity after verification. The superimposed control quantity is obtained by summing the adjustment control quantity and the given control quantity after verification.

7. The production control method for roll welding of reinforcing bars for utility poles according to claim 1, characterized in that, Step S4 includes: The difference between the batch detection control quantity of the solder joint and the given control quantity at the corresponding position in the given control quantity sequence is calculated to obtain the batch deviation set. The mean value of the batch deviation set is calculated to obtain the deviation feedback result. Based on the deviation feedback result, the drift calculation parameters are updated by gradient processing to obtain the updated drift calculation parameters. The contact resistance coefficient is corrected based on the deviation feedback result to obtain an updated contact resistance coefficient. The contact resistance calculation process is then re-executed based on the updated contact resistance coefficient to obtain the updated given control quantity sequence.

8. A production control system for the roll welding forming of reinforcing bars for utility poles, characterized in that, The method for controlling the production of roll welding of reinforcing bars for utility poles as described in any one of claims 1-7, wherein the production control system for roll welding of reinforcing bars for utility poles comprises: The calculation module is used to calculate the contact resistance based on the continuously varying tapered structural parameters of the pole along the axial direction, and to obtain a sequence of given control quantities corresponding to the position of each weld point. The correction module is used to perform monotonic drift calculation based on the cumulative welding count of the current weld point to obtain the cumulative drift correction amount, and to perform local deviation calculation based on the deviation between the detection diameter of the current weld point and the design taper value of the corresponding position in the given control quantity sequence to obtain the local geometric correction amount. The processing module is used to perform weighted combination processing on the cumulative drift correction amount and the local geometric correction amount according to the cumulative welding count to obtain the adjustment control amount of the next weld point, and to perform superposition and amplitude limiting operation processing on the adjustment control amount and the given control amount of the next weld point in the given control amount sequence to obtain the execution control amount of the next weld point, and output it to the execution mechanism. The update module is used to update the drift calculation parameters corresponding to the cumulative drift correction amount and the contact resistance coefficient in the contact resistance calculation process based on the deviation feedback result between the batch detection control amount of the solder joint and the given control amount sequence, so as to obtain the updated given control amount sequence.

9. A production control device for roll welding and forming of reinforcing bars for utility poles, characterized in that, The method includes a memory and a processor, the memory storing a computer program that can run on the processor, and the processor executing the computer program to implement the production control method for the roll welding of pole reinforcement bars according to any one of claims 1 to 7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is run by the processor, it causes the processor to execute the production control method for the roll welding of pole reinforcement bars as described in any one of claims 1 to 7.

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