Double-deviation differential control method and system for welding trolley, electronic equipment and medium

Abstract

The application discloses a welding trolley double-deviation differential control method and system, electronic equipment and medium, and relates to the technical field of computers. The application collects the vehicle body distance deviation, the vehicle body angle deviation and the vehicle body speed through a structured light vision sensor and a wheeled encoder, dynamically adjusts the distance weight and the angle weight according to the weld type, converges the corresponding deviation in a targeted manner, realizes the collaborative convergence of the double deviations, introduces a welding gun side placement compensation term when calculating the expected angular velocity, offsets the tracking deviation caused by the welding gun side placement, determines the expected wheel speed difference according to the vehicle body angle deviation and the vehicle body distance deviation, determines the basic linear speed, combines the left and right magnetic suction drive wheel target speed, synchronously controls the vehicle body advancing and turning, stably adapts to the straight line and the slow curve weld, and improves the weld tracking smoothness and the welding gun tracking accuracy.

Description

Technical Field

[0001] This application relates to the field of computer technology, and in particular to a method, system, electronic device and medium for controlling the dual deviation differential speed of a welding trolley. Background Technology

[0002] Magnetic wheel welding trolleys are widely used in the field of automated welding of ships and large steel structure components due to their advantages of magnetic adsorption and flexible movement. The equipment relies on the stable movement of the trolley along the weld seam to achieve continuous welding operations. The convergence effect of the trolley distance deviation and trolley angle deviation directly determines the tracking accuracy of the welding torch end and the weld formation quality. The current mainstream trajectory control schemes for magnetic wheel welding trolleys on the market uniformly adopt a fixed weight allocation strategy when dealing with vehicle distance and angle deviations. This strategy cannot adaptively adjust distance and angle weights based on the weld type identified by the structured light vision sensor. Straight welds cannot prioritize eliminating lateral offsets, and gently curving welds cannot quickly align with the vehicle's heading. Vehicle distance and angle deviations are difficult to converge synchronously. At the same time, the existing control logic does not include a welding torch side-position compensation item, which cannot compensate for the inherent tracking error caused by the lateral offset of the welding torch relative to the vehicle center, further amplifying the weld tracking deviation. In addition, the traditional control architecture lacks a collaborative processing logic for vehicle dual deviations, making it impossible to simultaneously determine the expected angular velocity and basic travel speed corresponding to vehicle steering. The lack of a corresponding differential wheel speed calculation mechanism makes it difficult to synchronously control vehicle travel speed and steering attitude. Ultimately, this results in poor adaptability of the trolley to straight and gently curving welds, low weld tracking accuracy, and an inability to meet the requirements of high-precision welding operations for steel structures. Summary of the Invention

[0003] This application provides a welding carriage dual-deviation differential speed control method, system, electronic device and medium to at least solve the technical problems in the related art where magnetic wheel welding carriages cannot dynamically adjust the deviation weight according to the weld type, do not set welding torch side compensation, and lack dual-deviation collaborative differential speed control logic, resulting in insufficient tracking accuracy of straight and gradual curve welds.

[0004] This application provides a dual-deviation differential speed control method for a welding trolley. The magnetically driven welding trolley includes a trolley body, a left magnetic drive wheel, and a right magnetic drive wheel. The trolley body is equipped with a structured light vision sensor and a wheel encoder. The method includes: The vehicle body distance deviation, vehicle body angle deviation, and vehicle body speed are obtained; the vehicle body distance deviation is the vertical distance from the center of the vehicle body to the center line of the weld, which is used to characterize the degree of lateral offset of the vehicle body; the vehicle body angle deviation is the angle between the heading angle of the vehicle body and the tangent direction of the weld, which is used to characterize the degree of attitude offset of the vehicle body. The distance and angle weights are dynamically adjusted based on the weld type in the weld image acquired by the structured light vision sensor. Based on the vehicle body distance deviation, the vehicle body angle deviation, the distance weight, and the angle weight, combined with the distance gain, the preset welding travel line speed, the wheel distance between the left magnetic drive wheel and the right magnetic drive wheel, and the welding torch side compensation item, the desired angular velocity is determined. The desired wheel speed difference is determined based on the vehicle body angle deviation, and the base linear velocity is determined based on the vehicle body distance deviation and vehicle body speed. Based on the desired angular velocity and the base linear velocity, the target velocities of the left magnetic drive wheel and the right magnetic drive wheel are calculated. The vehicle body is turned by the speed difference between the left and right magnetic drive wheels. The welding travel speed is controlled by the set welding travel linear velocity.

[0005] Furthermore, the step of dynamically adjusting the distance weight and angle weight based on the weld type in the weld image acquired by the structured light vision sensor includes: The weld type is identified based on the weld image acquired by the structured light vision sensor, and the weld type includes straight weld or gently curved weld; When a straight weld is identified, the distance weight is set to be greater than the angle weight in order to prioritize the convergence of distance deviation; When a weld is identified as a gentle curve weld, the distance weight is set to be less than the angle weight in order to prioritize the convergence of angle deviation. A smooth transition function is used during the numerical switching of distance weight and angle weight according to the weld type.

[0006] Furthermore, determining the desired angular velocity based on the vehicle body distance deviation, the vehicle body angle deviation, the distance weight, and the angle weight, combined with the distance gain, the preset welding travel speed, the wheelbase between the left and right magnetic drive wheels, and the welding torch side-position compensation term, includes: Based on the vehicle body distance deviation, the vehicle body angle deviation, and the distance weight, a distance deviation correction term is determined in combination with the distance gain. The correction intensity is adjusted by the distance gain and the distance weight to eliminate the lateral offset of the vehicle body and ensure the alignment of the vehicle body center with the weld centerline. Based on the vehicle body angle deviation and the angle weight, combined with the preset welding travel speed and the wheelbase between the left magnetic drive wheel and the right magnetic drive wheel, the angle deviation correction term is determined. The correction force is adjusted by the angle weight to align the vehicle body heading with the weld tangent direction. The desired angular velocity is determined by summing the distance deviation correction term, the angle deviation correction term, and the welding torch side-position compensation term.

[0007] Furthermore, the distance deviation correction term is: The angle deviation correction term is The desired angular velocity The calculation formula is: ,in For range gain, For vehicle body distance deviation, Due to the deviation in vehicle body angle, Distance weights For angle weighting, The preset welding travel speed is L, the wheel distance between the left and right magnetic drive wheels is L, and the welding torch side compensation is Δ.

[0008] Furthermore, the step of determining the desired wheel speed difference based on the vehicle body angle deviation, and determining the base linear velocity based on the vehicle body distance deviation and vehicle body speed, includes: Construct an outer loop of angle proportional-integral-differential (PI-DI) and an inner loop of distance proportional-integral-differential (PI-DI) to form a proportional-integral-differential (PI-DI) controller. The outer loop of the angle proportional-integral-differential algorithm inputs the vehicle body angle deviation and outputs the desired wheel speed difference. The distance proportional-integral-differential inner loop inputs the vehicle distance deviation and outputs the basic linear velocity.

[0009] Furthermore, the step of calculating the target speed of the left magnetic drive wheel and the target speed of the right magnetic drive wheel based on the desired angular velocity and the base linear velocity includes: The formula for calculating the target speed of the left magnetic drive wheel is as follows: ; The formula for calculating the target speed of the right magnetic drive wheel is as follows: ,in Based on the linear velocity, Let L be the desired angular velocity, and L be the wheel distance between the left magnetic drive wheel and the right magnetic drive wheel.

[0010] Furthermore, the method also includes: The corresponding magnetic attraction force is indirectly obtained by monitoring the drive motor current of the left magnetic drive wheel and the right magnetic drive wheel, and the proportional-integral-derivative gain is dynamically adjusted. When the motor current value, which represents the magnetic attraction force, is greater than the average magnetic attraction force, the proportional gain of the proportional-integral-derivative controller is increased to enhance the correction capability. When the motor current value, which indicates the magnetic attraction force, is less than the average magnetic attraction force, or when the vehicle is in a curved surface / obstacle crossing state, the proportional gain of the proportional-integral-derivative controller is reduced to suppress vehicle vibration and shaking, thus ensuring control stability.

[0011] Furthermore, the method also includes: When a wheel is detected to be off the ground or a sudden change in force is detected, it is determined to be an obstacle crossing condition. Before crossing the obstacle, the preset welding travel speed is reduced to half and the angle weight is increased to adjust the vehicle attitude in advance so that the vehicle is aligned with the obstacle crossing path. During obstacle crossing, the torque output of the left and right magnetic drive wheels is locked, the integral term of the proportional-integral-derivative controller is frozen to avoid attitude loss due to integral saturation; the visual data collected by the structured light vision sensor is frozen to avoid control jitter caused by visual jumps; at the same time, the encoder attitude prediction model is activated to output temporary deviations based on the vehicle's historical attitude and speed data. After overcoming the obstacle, the preset welding travel speed is restored, the proportional-integral-derivative controller parameters are reset, the structured light vision sensor is activated, the vision-encoder fusion perception mode is restored, and the deviation is corrected based on the visual data collected by the structured light vision sensor.

[0012] Multi-layer, multi-pass welding database linkage: It calls the built-in welding parameter database to obtain historical weld trajectory and welding thermal deformation offset data, and performs pre-compensation for the double deviation of the vehicle body in advance to offset the error caused by thermal deformation. After each weld is completed, the deviation convergence data, proportional-integral-derivative parameters and other information of this weld are sent back to the database to realize parameter self-optimization and improve the accuracy and stability of subsequent welding.

[0013] This application also provides a welding trolley dual-deviation differential speed control system, including: The perception module is configured to include a structured light vision sensor, a wheel encoder, and a motor current acquisition unit. The structured light vision sensor is used to acquire vehicle distance deviation and vehicle angle deviation. The wheel encoder is used to acquire vehicle speed. The motor current acquisition unit is used to acquire the drive motor current of the left magnetic drive wheel and the right magnetic drive wheel to obtain the corresponding magnetic attraction force. The control module is configured as the main control chip and integrates a dual-deviation fusion unit, a Stanley controller, a proportional-integral-derivative controller and a working condition adaptive unit. It is used to execute the above-mentioned welding trolley dual-deviation differential speed control method and output wheel speed commands. The execution module is configured to control the DC motors and motor drivers of the left and right magnetic drive wheels, and drive the magnetic wheel welding trolley to move according to the wheel speed command output by the control module. The data module is configured as a local database storing welding parameters and historical deviation data, used for trajectory pre-compensation and optimization of proportional-integral-derivative controller parameters for multi-layer and multi-pass welding. The interaction module is configured as a touch screen and parameter configuration interface for parameter setting, welding status monitoring and fault alarm.

[0014] This application also provides an electronic device, including: a memory for storing a computer program; and a processor for executing the computer program to implement the steps of any of the above-described welding trolley dual-deviation differential speed control methods.

[0015] This application also provides a computer-readable storage medium storing a computer program, wherein when the computer program is executed by a processor, it implements the steps of any of the above-described welding trolley dual-deviation differential speed control methods.

[0016] This application utilizes a structured light vision sensor and a wheel encoder to collect vehicle distance deviation, vehicle angle deviation, and vehicle speed. Distance and angle weights are dynamically adjusted based on the weld type, prioritizing the convergence of corresponding deviations to achieve coordinated convergence of both. A welding torch side-positioning compensation term is introduced when calculating the desired angular velocity to offset the tracking offset caused by the welding torch's side-positioning. The desired wheel speed difference is determined based on the vehicle angle deviation, and the base linear velocity is determined based on the vehicle distance deviation. The target speeds of the left and right magnetically driven wheels are calculated in conjunction with the desired angular velocity, synchronously controlling vehicle movement and steering. This ensures stable adaptation to straight and gently curving welds, improving weld tracking smoothness and welding torch tracking accuracy. Attached Figure Description

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

[0018] Figure 1 This is a flowchart illustrating the dual-deviation differential speed control method for a welding trolley in one embodiment of this application. Figure 2 This is a structural block diagram of the welding trolley dual-deviation differential speed control system in one embodiment of this application; Figure 3 This is an internal structural diagram of a computer device in one embodiment of this application. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this application.

[0020] It should be noted that, in the description of this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. The terms "first," "second," etc., in this application are used to distinguish similar objects and are not used to describe a specific order or sequence.

[0021] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] This application provides a dual-deviation differential speed control method for a welding trolley. The magnetically driven welding trolley includes a body, a left magnetic drive wheel, and a right magnetic drive wheel. The body is equipped with a structured light vision sensor and a wheel encoder. Figure 1 As shown, the method includes the following steps: Step S1: Obtain vehicle distance deviation Vehicle body angle deviation And vehicle speed; specifically, a structured light vision sensor is used to collect vehicle distance deviation. and vehicle body angle deviation The vehicle speed is collected using a wheel encoder; the vehicle distance deviation... The vertical distance from the center of the vehicle body to the center line of the weld is used to characterize the degree of lateral offset of the vehicle body; the vehicle body angular deviation The angle between the vehicle body heading angle and the weld tangent direction is used to characterize the degree of vehicle body attitude deviation. Step S2: Dynamically adjust the distance weight based on the weld type in the weld image acquired by the structured light vision sensor. and angle weight ; Step S3, based on the vehicle body distance deviation The aforementioned vehicle body angle deviation The distance weight and the angle weights Combined with range gain Preset welding travel speed The wheel distance L between the left and right magnetic drive wheels and the welding torch side compensation term Δ are used to determine the desired angular velocity. ; Step S4, based on the vehicle body angle deviation Determine the desired wheel speed difference Δv based on the vehicle body distance deviation. Determine the base linear velocity based on the vehicle body speed. ; Step S5, based on the desired angular velocity and basic linear velocity Calculate the target speed of the left magnetic drive wheel. and the target speed of the right magnetic drive wheel The vehicle body is steered by the speed difference between the left and right magnetic drive wheels, and the welding travel line speed is set accordingly. Control the welding travel speed.

[0023] Specifically, the system collects vehicle distance deviation, vehicle angle deviation, and vehicle speed using a structured light vision sensor and a wheel encoder. It dynamically adjusts the distance and angle weights based on the weld type, prioritizing the convergence of corresponding deviations to achieve coordinated convergence of the two deviations. When calculating the desired angular velocity, a welding torch side-positioning compensation term is introduced to offset the tracking offset caused by the welding torch side-positioning. The desired wheel speed difference is determined based on the vehicle angle deviation, and the basic linear velocity is determined based on the vehicle distance deviation. The target speeds of the left and right magnetic drive wheels are calculated in combination with the desired angular velocity, and the vehicle's movement and steering are controlled synchronously. This ensures stable adaptation to straight and gentle curve welds, improving weld tracking smoothness and welding torch tracking accuracy.

[0024] In this embodiment, the distance weight is dynamically adjusted based on the weld type in the weld image acquired by the structured light vision sensor. and angle weight ,include: The weld type is identified based on the weld image acquired by the structured light vision sensor, and the weld type includes straight weld or gently curved weld; When a straight weld is identified, the distance weight is set to be greater than the angle weight to prioritize the convergence of distance deviation and ensure the straightness of the straight weld. When a weld is identified as a gentle curve, the distance weight is set to be less than the angle weight to prioritize the convergence of angle deviation and ensure the trajectory fit of the curve weld. Distance weighting based on the weld type and angle weight A smooth transition function is used during the numerical switching process to avoid sudden changes in the control quantity caused by abrupt changes in weights, thereby improving control stability.

[0025] In this embodiment, the step of determining the distance deviation of the vehicle body is... The aforementioned vehicle body angle deviation The distance weight and the angle weights Combined with range gain Preset welding travel speed The wheel distance L between the left and right magnetic drive wheels and the welding torch side compensation term Δ are used to determine the desired angular velocity. ,include: According to the vehicle body distance deviation The aforementioned vehicle body angle deviation and the distance weight Combined with range gain Determine the distance deviation correction term, wherein the distance gain is used. and the distance weight Adjusting the correction force is used to eliminate lateral offset of the vehicle body and ensure alignment between the center of the vehicle body and the center line of the weld. According to the vehicle body angle deviation and the angle weights Combined with the preset welding travel speed The wheel distance L between the left and right magnetic drive wheels determines the angle deviation correction term, wherein the angle weight is used to determine the angle deviation correction term. Adjust the correction force to align the vehicle body heading with the weld tangent direction; The desired angular velocity is determined by summing the distance deviation correction term, the angle deviation correction term, and the welding torch side-position compensation term Δ. .

[0026] Specifically, the distance weights and angle weight Input to the Stanley controller, combined with the preset welding travel line speed. The wheel distance L between the left and right magnetic drive wheels and the welding torch side compensation term Δ are used to calculate and output the desired angular velocity. The welding torch side-position compensation term Δ is calculated based on the lateral offset distance of the welding torch relative to the vehicle body center and the vehicle body attitude. It is used to correct the tracking error caused by the side-positioning of the welding torch, that is, to correct the error caused by the inconsistency between the vehicle body tracking center and the welding point due to the side-positioning layout of the welding torch, and to improve the tracking accuracy of the welding torch end.

[0027] Wherein, the distance deviation correction term is The angle deviation correction term is The desired angular velocity The calculation formula is: ,in For range gain, For vehicle body distance deviation, Due to the deviation in vehicle body angle, Distance weights For angle weighting, The preset welding travel speed is L, the wheel distance between the left and right magnetic drive wheels is L, and the welding torch side compensation is Δ.

[0028] The Stanley controller is a path tracking algorithm for lateral control of vehicles. It was proposed and successfully applied by Stanford University in the 2005 DARPA Grand Challenge autonomous driving competition. The "Stanley" driverless car it was equipped with won the championship, hence the name of the method.

[0029] In this embodiment, the step of determining the vehicle body angle deviation... Determine the desired wheel speed difference Δv based on the vehicle body distance deviation. Determine the base linear velocity based on the vehicle body speed. ,include: Construct an outer loop of angle proportional-integral-differential (PI-DI) and an inner loop of distance proportional-integral-differential (PI-DI) to form a proportional-integral-differential (PI-DI) controller. The outer ring of the angle proportional integral differential is input to the vehicle body angle deviation. The desired wheel speed difference Δv is output, and the vehicle steering angle is controlled by adjusting the speed difference between the left and right wheels to ensure that the angle deviation converges quickly and improve the vehicle's attitude stability. The distance proportional-integral-differential inner loop inputs the vehicle distance deviation. Output basic linear velocity This controls the vehicle's speed, ensuring precise convergence of distance deviations and preventing lateral drift.

[0030] In this embodiment, the step of determining the desired angular velocity... and basic linear velocity Calculate the target speed of the left magnetic drive wheel. and the target speed of the right magnetic drive wheel ,include: The target speed of the left magnetic drive wheel The calculation formula is: ; The target speed of the right magnetic drive wheel The calculation formula is: .

[0031] In this embodiment, the method further includes: The corresponding magnetic attraction force is indirectly obtained by monitoring the drive motor current of the left magnetic drive wheel and the right magnetic drive wheel, and the proportional-integral-derivative gain is dynamically adjusted. When the motor current value, which represents the magnetic attraction force, is greater than the average magnetic attraction force, the proportional gain of the proportional-integral-derivative controller is increased to enhance the correction capability and improve the tracking accuracy. When the motor current value, which indicates the magnetic attraction force, is less than the average magnetic attraction force, or when the vehicle is in a curved surface / obstacle crossing state, the proportional gain of the proportional-integral-derivative controller is reduced to suppress vehicle vibration and shaking, thus ensuring control stability.

[0032] In this embodiment, the method further includes: When a wheel is detected to be off the ground or a sudden change in force is detected, it is determined to be an obstacle crossing condition. Before crossing the obstacle, set the preset welding travel speed. Reduce to half and increase the angle weight. Adjust the vehicle's attitude in advance to align the vehicle with the obstacle-crossing path; During obstacle crossing, the torque output of the left and right magnetic drive wheels is locked, the integral term of the proportional-integral-derivative controller is frozen to avoid attitude loss due to integral saturation and maintain vehicle attitude stability; the visual data collected by the structured light vision sensor is frozen to avoid control jitter caused by visual jumps; at the same time, the encoder attitude prediction model is activated to output temporary deviations based on the vehicle's historical attitude and speed data to maintain the continuity of vehicle control. After overcoming the obstacle, resume the preset welding travel speed. Reset the proportional-integral-derivative controller parameters to quickly restore the reference linear velocity. The parameters of the proportional-integral-derivative (PID) controller are reset, and the Stanley controller and PID controller fusion control is started to ensure that the double deviation converges within 100ms and quickly returns to the weld trajectory. The structured light vision sensor is enabled, the vision-encoder fusion perception mode is restored, and the deviation is corrected according to the visual data collected by the structured light vision sensor.

[0033] Multi-layer, multi-pass welding database linkage: It calls the built-in welding parameter database to obtain historical weld trajectory and welding thermal deformation offset data, and performs pre-compensation for the double deviation of the vehicle body in advance to offset the error caused by thermal deformation. After each weld is completed, the deviation convergence data, proportional-integral-derivative parameters and other information of this weld are sent back to the database to realize parameter self-optimization and improve the accuracy and stability of subsequent welding.

[0034] In the aforementioned dual-deviation differential speed control method for welding trolleys, the distance deviation, angle deviation, and speed of the trolley are collected by a structured light vision sensor and a wheel encoder. The distance weight and angle weight are dynamically adjusted according to the weld type, and the corresponding deviations are converged preferentially to achieve coordinated convergence of the dual deviations. When calculating the desired angular velocity, a welding torch side-positioning compensation term is introduced to offset the tracking offset caused by the welding torch side-positioning. The desired wheel speed difference is determined based on the angular deviation of the trolley, and the basic linear velocity is determined based on the distance deviation of the trolley. The target speeds of the left and right magnetic drive wheels are calculated in combination with the desired angular velocity, and the trolley's movement and steering are controlled synchronously to stably adapt to straight and gentle curve welds, thereby improving the weld tracking smoothness and welding torch tracking accuracy.

[0035] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods according to the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method.

[0036] In one embodiment, such as Figure 2 As shown, a welding trolley dual-deviation differential speed control system 10 is provided, comprising: Perception module 1 is configured to include a structured light vision sensor, a wheel encoder, and a motor current acquisition unit. The structured light vision sensor is used to acquire vehicle distance deviation. and vehicle body angle deviation The wheel encoder is used to collect the vehicle speed, and the motor current acquisition unit is used to collect the drive motor current of the left magnetic drive wheel and the right magnetic drive wheel to obtain the corresponding magnetic attraction force. Control module 2 is configured as the main control chip, which integrates a dual-deviation fusion unit, a Stanley controller, a proportional-integral-derivative controller and a working condition adaptive unit. It is used to execute the above-mentioned welding trolley dual-deviation differential speed control method and output wheel speed commands. Execution module 3 is configured to control the DC motors and motor drivers of the left and right magnetic drive wheels, and drive the magnetic wheel welding trolley to move according to the wheel speed command output by the control module. Data module 4 is configured as a local database storing welding parameters and historical deviation data, used for trajectory pre-compensation and optimization of proportional-integral-derivative controller parameters for multi-layer and multi-pass welding. Interaction module 5 is configured as a touch screen and parameter configuration interface for parameter setting (such as reference linear velocity, proportional-integral-derivative parameters, etc.), welding status monitoring and fault alarm.

[0037] The hardware selection for the control system in this embodiment follows the principles of low cost and ease of implementation. The specific selection is as follows: Main control chip: STM32F103, low cost and sufficient computing power, which can meet the real-time computing requirements of the improved Stanley algorithm and the dual closed-loop proportional integral differential algorithm; In the perception module: structured light vision sensor: low-cost model, sampling frequency 50Hz, deviation detection accuracy ±0.1mm, used to acquire weld seam images and deviation data; wheel encoder: incremental encoder, 1000 lines, used to acquire the rotational speed of the left and right drive wheels and calculate the vehicle speed and attitude; motor current acquisition unit: uses a current sensor to monitor the drive motor current and indirectly estimate the magnetic attraction force. Execution module: 24V DC motor (with gearbox), magnetic drive wheel (adapted to steel plate adsorption), motor driver (supports PWM speed regulation); Data module: Local Flash memory chip, used to store historical data on welding parameters and deviations; Interaction module: small touch screen (for parameter setting and status display), USB parameter configuration interface (for parameter debugging on computer).

[0038] Based on the hardware selection in this embodiment, the following control parameters are set to ensure the control effect: Structural parameters: wheel track L=0.2m, welding torch lateral offset distance is 5cm, corresponding welding torch lateral compensation term Δ=0.05rad; Control parameters: distance gain =0.8, reference linear velocity =0.1m / s; Proportional-integral-derivative (PID) controller parameters: Angle loop Kp=1.5, Ki=0.2, Kd=0.1; Distance loop Kp=0.8, Ki=0.1, Kd=0.05; Weighting parameter: Straight weld =0.7、 =0.3; Gradual curve weld =0.3、 =0.7; Obstacle crossing parameters: The reference linear velocity drops to 0.05 m / s before obstacle crossing, and the deviation convergence time after obstacle crossing is ≤100 ms.

[0039] In the aforementioned welding trolley dual-deviation differential speed control system, the vehicle body distance deviation, vehicle body angle deviation, and vehicle body speed are collected by a structured light vision sensor and a wheel encoder. The distance weight and angle weight are dynamically adjusted according to the weld type, and the corresponding deviations are converged first to achieve dual-deviation coordinated convergence. When calculating the desired angular velocity, a welding torch side-positioning compensation term is introduced to offset the tracking offset caused by the welding torch side-positioning. The desired wheel speed difference is determined based on the vehicle body angle deviation, and the basic linear velocity is determined based on the vehicle body distance deviation. The target speed of the left and right magnetic drive wheels is calculated in combination with the desired angular velocity, and the vehicle body movement and steering are controlled synchronously to stably adapt to straight and gentle curve welds, thereby improving the weld tracking smoothness and welding torch tracking accuracy.

[0040] The control flow of this embodiment is as follows: Upon system power-up, the sensing module, control module, data module, and interaction module are initialized, and preset control parameters (such as...) are read. (Proportional, integral, and differential parameters, weighting parameters, etc.) Structured light vision sensors acquire weld seam images and calculate vehicle body distance deviations. Vehicle body angle deviation The wheel encoder collects the rotational speed of the left and right drive wheels and calculates the actual speed and attitude angle of the vehicle body. The dual-deviation fusion unit dynamically adjusts the distance weight based on the weld type (straight line / curve). and angle weight Generate weighted deviation values; simultaneously determine whether the obstacle crossing condition is in progress. If the obstacle crossing condition is in progress, freeze the visual deviation data and enable the encoder attitude prediction model to output temporary deviations. The Stanley controller receives the weighted deviation value and combines it with... Calculate and output the desired angular velocity using L and Δ. ; The proportional-integral-derivative (PID) controller operates as follows: Angle proportional-integral-derivative outer loop input. Output the desired wheel speed difference Δv; distance proportional-integral-differential inner loop input. Output basic linear velocity ; Control module according to and Calculate the target speed of the left and right magnetic drive wheels. and Output control commands to the motor driver; The motor driver drives the DC motor to move, which in turn drives the magnetic drive wheel to move and achieve weld seam tracking. At the same time, the working condition adaptive unit monitors the motor current (magnetic force state) and obstacle crossing status, dynamically adjusts the proportional-integral-derivative gain, and executes obstacle crossing timing control. During the welding process, the data module stores welding parameters and deviation convergence data in real time; during multi-layer and multi-pass welding, historical data from the database is called up for deviation pre-compensation. Determine if welding is complete. If not, repeat the above steps. If complete, stop the system, save the welding data, and end the control process.

[0041] Using the control method and system of this embodiment, a prototype was built for testing. The test scenarios included straight weld seam welding, gradual curve weld seam welding, and obstacle-crossing welding. The test results are as follows: Straight weld: vehicle body distance deviation ≤ ±0.2mm, welding torch end deviation ≤ ±0.25mm, control response time ≤ 80ms, weld straightness meets welding process requirements; For the gentle curve weld: the body angle deviation is ≤ ±0.5°, there is no trajectory lag, the end of the welding torch fits the weld trajectory without deviation; Obstacle crossing condition: During the obstacle crossing process, the vehicle body attitude is stable, without shaking or derailment. The double deviation converges within 100ms after the obstacle crossing and quickly returns to the weld seam trajectory. Hardware cost: The hardware cost of the entire control system is reduced by at least 500 yuan, which is far lower than similar solutions that use complex algorithms, and is easy to mass-produce and promote in engineering.

[0042] Compared with the prior art, the present invention has the following significant advantages: Significantly improved control stability: The vehicle-level dual-deviation control avoids the flexible coupling problem at the end of the welding torch, reduces the impact of vehicle vibration on welding accuracy, and ensures stable posture and no derailment when crossing obstacles, completely solving the technical defect of easy shaking in the control of the end of the welding torch. Good engineering feasibility and low cost: The control algorithm adopts a simple architecture of "improved Stanley + dual closed-loop proportional integral derivative", which has a small amount of computation, does not require a high-performance MCU, and can meet the computing power requirements with STM32 series chips. The hardware cost is reduced by more than 50%, the debugging cycle is short, and it is easy to mass-produce and implement in engineering. High tracking accuracy: By correcting the side offset through the welding torch side offset compensation term Δ, after the vehicle body deviation converges, the steady-state accuracy of the welding torch end can reach ±0.2~0.3mm, which fully meets the welding process requirements; Wide adaptability to working conditions: It integrates adaptive magnetic adsorption force, obstacle crossing timing control, and multi-layer multi-pass welding database linkage functions, which can adapt to various working conditions such as straight / gradual curve welds, curved surface welding, and obstacle crossing welding, and has a wide range of applications. Dual-deviation synchronous convergence: Through a dynamic weighted fusion strategy, the deviation weights are adjusted according to the weld type. Combined with the Stanley controller and the proportional-integral-derivative controller for fusion control, the angular deviation is quickly converged and the distance deviation is finely corrected. There is no deviation lag problem, which improves the smoothness of weld tracking.

[0043] For a description of the features in the embodiment corresponding to the welding carriage dual-deviation differential speed control system, please refer to the relevant description of the embodiment corresponding to the welding carriage dual-deviation differential speed control method, which will not be repeated here.

[0044] Embodiments of this application also provide an electronic device, including a memory and a processor, wherein the memory stores a computer program and the processor is configured to run the computer program to perform the steps in any of the above embodiments of the welding trolley dual-deviation differential speed control method.

[0045] In one embodiment, the electronic device may be a server, and its internal structure diagram may be as follows: Figure 3As shown, the electronic device includes a processor, memory, network interface, and database connected via a system bus. The processor provides computational and control capabilities. The memory includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores the operating system, computer programs, and 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 stores dual-deviation differential speed control data for the welding carriage. The network interface communicates with external terminals via a network connection. When the computer program is executed by the processor, it implements a dual-deviation differential speed control method for a welding carriage.

[0046] Embodiments of this application also provide a computer-readable storage medium storing a computer program, wherein the computer program is configured to execute the steps in any of the above embodiments of the welding trolley dual-deviation differential speed control method when running.

[0047] In one exemplary embodiment, the aforementioned computer-readable storage medium may include, but is not limited to, various media capable of storing computer programs, such as a USB flash drive, read-only memory (ROM), random access memory (RAM), portable hard disk, magnetic disk, or optical disk.

[0048] The embodiments of this application also provide a computer program product, which includes a computer program that, when executed by a processor, implements the steps in any of the above embodiments of the welding trolley dual-deviation differential speed control method.

[0049] Embodiments of this application also provide another computer program product, including a non-volatile computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps in any of the above embodiments of the welding trolley dual-deviation differential speed control method.

[0050] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0051] The foregoing has provided a detailed description of the welding trolley dual-deviation differential speed control method, system, electronic equipment, and medium provided in this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only intended to aid in understanding the method and core ideas of this application. It should be noted that those skilled in the art can make various improvements and modifications to this application without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. A dual-deviation differential speed control method for a welding trolley, used for a magnetically driven wheel welding trolley, characterized in that, The magnetically attached wheeled welding trolley includes a body, a left magnetically attached drive wheel, and a right magnetically attached drive wheel. The body is equipped with a structured light vision sensor and a wheel encoder. The method includes: The vehicle body distance deviation, vehicle body angle deviation, and vehicle body speed are obtained; the vehicle body distance deviation is the vertical distance from the center of the vehicle body to the center line of the weld, which is used to characterize the degree of lateral offset of the vehicle body; the vehicle body angle deviation is the angle between the heading angle of the vehicle body and the tangent direction of the weld, which is used to characterize the degree of attitude offset of the vehicle body. The distance and angle weights are dynamically adjusted based on the weld type in the weld image acquired by the structured light vision sensor. Based on the vehicle body distance deviation, the vehicle body angle deviation, the distance weight, and the angle weight, combined with the distance gain, the preset welding travel line speed, the wheel distance between the left magnetic drive wheel and the right magnetic drive wheel, and the welding torch side compensation item, the desired angular velocity is determined. The desired wheel speed difference is determined based on the vehicle body angle deviation, and the base linear velocity is determined based on the vehicle body distance deviation and vehicle body speed. Based on the desired angular velocity and the base linear velocity, the target velocities of the left magnetic drive wheel and the right magnetic drive wheel are calculated. The vehicle body is turned by the speed difference between the left and right magnetic drive wheels. The welding travel speed is controlled by the set welding travel linear velocity.

2. The welding trolley dual-deviation differential speed control method according to claim 1, characterized in that, The step of dynamically adjusting the distance and angle weights based on the weld type in the weld image acquired by the structured light vision sensor includes: The weld type is identified based on the weld image acquired by the structured light vision sensor, and the weld type includes straight weld or gently curved weld; When a straight weld is identified, the distance weight is set to be greater than the angle weight in order to prioritize the convergence of distance deviation; When a weld is identified as a gentle curve weld, the distance weight is set to be less than the angle weight in order to prioritize the convergence of angle deviation. A smooth transition function is used during the numerical switching of distance weight and angle weight according to the weld type.

3. The welding trolley dual-deviation differential speed control method according to claim 1, characterized in that, The step of determining the desired angular velocity based on the vehicle body distance deviation, the vehicle body angle deviation, the distance weight, and the angle weight, combined with the distance gain, the preset welding travel linear speed, the wheelbase between the left and right magnetic drive wheels, and the welding torch side-position compensation item, includes: Based on the vehicle body distance deviation, the vehicle body angle deviation, and the distance weight, a distance deviation correction term is determined in combination with the distance gain. The correction intensity is adjusted by the distance gain and the distance weight to eliminate the lateral offset of the vehicle body and ensure the alignment of the vehicle body center with the weld centerline. Based on the vehicle body angle deviation and the angle weight, combined with the preset welding travel speed and the wheelbase between the left magnetic drive wheel and the right magnetic drive wheel, the angle deviation correction term is determined. The correction force is adjusted by the angle weight to align the vehicle body heading with the weld tangent direction. The desired angular velocity is determined by summing the distance deviation correction term, the angle deviation correction term, and the welding torch side-position compensation term.

4. The welding carriage dual-deviation differential speed control method according to claim 3, characterized in that, The distance deviation correction term is: The angle deviation correction term is The desired angular velocity The calculation formula is: ,in For range gain, For vehicle body distance deviation, Due to the deviation in vehicle body angle, Distance weights For angle weighting, The preset welding travel speed is L, the wheel distance between the left and right magnetic drive wheels is L, and the welding torch side compensation is Δ.

5. The welding trolley dual-deviation differential speed control method according to claim 1, characterized in that, The step of determining the desired wheel speed difference based on the vehicle body angle deviation and determining the base linear velocity based on the vehicle body distance deviation and vehicle body speed includes: Construct an outer loop of angle proportional-integral-differential (PI-DI) and an inner loop of distance proportional-integral-differential (PI-DI) to form a proportional-integral-differential (PI-DI) controller. The outer loop of the angle proportional-integral-differential algorithm inputs the vehicle body angle deviation and outputs the desired wheel speed difference. The distance proportional-integral-differential inner loop inputs the vehicle distance deviation and outputs the basic linear velocity.

6. The welding trolley dual-deviation differential speed control method according to claim 1, characterized in that, The step of calculating the target speed of the left magnetic drive wheel and the target speed of the right magnetic drive wheel based on the desired angular velocity and the base linear velocity includes: The formula for calculating the target speed of the left magnetic drive wheel is as follows: ; The formula for calculating the target speed of the right magnetic drive wheel is as follows: ,in Based on the linear velocity, Let L be the desired angular velocity, and L be the wheel distance between the left magnetic drive wheel and the right magnetic drive wheel.

7. The welding trolley dual-deviation differential speed control method according to claim 5, characterized in that, The method further includes: The corresponding magnetic attraction force is indirectly obtained by monitoring the drive motor current of the left magnetic drive wheel and the right magnetic drive wheel, and the proportional-integral-derivative gain is dynamically adjusted. When the motor current value, which represents the magnetic attraction force, is greater than the average magnetic attraction force, the proportional gain of the proportional-integral-derivative controller is increased to enhance the correction capability. When the motor current value, which indicates the magnetic attraction force, is less than the average magnetic attraction force, or when the vehicle is in a curved surface / obstacle crossing state, the proportional gain of the proportional-integral-derivative controller is reduced to suppress vehicle vibration and shaking, thus ensuring control stability.

8. The welding trolley dual-deviation differential speed control method according to claim 1, characterized in that, The method further includes: When a wheel is detected to be off the ground or a sudden change in force is detected, it is determined to be an obstacle crossing condition. Before crossing the obstacle, the preset welding travel speed is reduced to half and the angle weight is increased to adjust the vehicle attitude in advance so that the vehicle is aligned with the obstacle crossing path. During obstacle crossing, the torque output of the left and right magnetic drive wheels is locked, the integral term of the proportional-integral-derivative controller is frozen to avoid attitude loss due to integral saturation; the visual data collected by the structured light vision sensor is frozen to avoid control jitter caused by visual jumps; at the same time, the encoder attitude prediction model is activated to output temporary deviations based on the vehicle's historical attitude and speed data. After overcoming the obstacle, the preset welding travel speed is restored, the proportional-integral-derivative controller parameters are reset, the structured light vision sensor is activated, the vision-encoder fusion perception mode is restored, and the deviation is corrected based on the visual data collected by the structured light vision sensor.

9. A dual-deviation differential speed control system for a welding trolley, characterized in that, include: The perception module is configured to include a structured light vision sensor, a wheel encoder, and a motor current acquisition unit. The structured light vision sensor is used to acquire vehicle distance deviation and vehicle angle deviation. The wheel encoder is used to acquire vehicle speed. The motor current acquisition unit is used to acquire the drive motor current of the left magnetic drive wheel and the right magnetic drive wheel to obtain the corresponding magnetic attraction force. The control module is configured as a main control chip and integrates a dual-deviation fusion unit, a Stanley controller, a proportional-integral-derivative controller and a working condition adaptive unit. It is used to execute the welding trolley dual-deviation differential speed control method according to any one of claims 1 to 8 and output wheel speed commands. The execution module is configured to control the DC motors and motor drivers of the left and right magnetic drive wheels, and drive the magnetic wheel welding trolley to move according to the wheel speed command output by the control module. The data module is configured as a local database storing welding parameters and historical deviation data, used for trajectory pre-compensation and optimization of proportional-integral-derivative controller parameters for multi-layer and multi-pass welding. The interaction module is configured as a touch screen and parameter configuration interface for parameter setting, welding status monitoring and fault alarm.

10. An electronic device, characterized in that, include: Memory, used to store computer programs; A processor, configured to implement the steps of the welding trolley dual-deviation differential speed control method as described in any one of claims 1 to 8 when executing the computer program.

11. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program, wherein when the computer program is executed by a processor, it implements the steps of the welding trolley dual-deviation differential speed control method as described in any one of claims 1 to 8.

Images