Grinding quality management method, controller, system, and storage medium

Abstract

The application discloses a grinding quality management method, a controller, a system and a storage medium, and relates to the technical field of automobile manufacturing. The method comprises the following steps: in response to a grinding instruction for an electrode cap, a grinding structure is controlled to perform one grinding on the electrode cap, and the resistance of the electrode cap after grinding is detected; the contact resistance of the end face of the electrode cap is taken as an evaluation index of the grinding quality; the detection mode of directly measuring the resistance can avoid the problems of hysteresis and low efficiency in the judgment of the grinding quality; when the resistance does not reach a threshold value, the grinding quality is determined to be qualified, and the subsequent detection process is stopped; when the resistance reaches the threshold value, the electrode cap is ground again, the resistance of the electrode cap after grinding is detected, and the grinding quality is judged; the actual measured resistance and the preset threshold value are used to realize the automatic judgment of the grinding quality, and the accuracy of the spot welding grinding quality detection and the standardization of the grinding quality judgment are improved.

Description

Technical Field

[0001] This application relates to the field of automotive manufacturing technology, and more specifically, to a grinding quality management method, controller, system, and storage medium. Background Technology

[0002] In the automotive body manufacturing process, the spot welding connection process requires the electrode caps of the welding gun to be reground to ensure the welding quality of the body parts. After spot welding of the body parts, the wear of the welding gun electrode caps is calculated to measure the quality of the electrode cap reground. However, the wear amount is calculated by repeatedly measuring the same electrode end face with a robot. Due to the large fluctuations and instability of the robot's measurement values, the calculated wear values ​​vary greatly. This leads to a high alarm threshold being set when judging the reground quality, resulting in inaccurate reground quality of the electrode caps below this alarm threshold. Summary of the Invention

[0003] In view of this, embodiments of this application propose a grinding quality management method, controller, system, and storage medium, which can improve the accuracy of spot weld grinding quality detection and the standardization of grinding quality judgment.

[0004] The following technical solution is adopted in this application.

[0005] In a first aspect, embodiments of this application provide a grinding quality management method, the method comprising: responding to a grinding command for an electrode cap, controlling a grinding structure to perform at least one grinding operation on the electrode cap, and detecting the post-grinding resistance of the electrode cap; the electrode cap being used for spot welding of a vehicle body workpiece; and determining that the grinding quality of the electrode cap is qualified when the post-grinding resistance of the electrode cap determined during the at least one grinding operation does not reach a first threshold.

[0006] In some embodiments, after determining that the grinding quality of the electrode cap is qualified, the method further includes: stopping the grinding operation on the electrode cap.

[0007] In some embodiments, the control grinding structure performs at least one grinding operation on the electrode cap and detects the post-grinding resistance of the electrode cap, including: triggering an alarm when the post-grinding resistance of the electrode cap, determined after multiple grinding operations, reaches the first threshold.

[0008] In some embodiments, the control grinding structure performs at least one grinding operation on the electrode cap and detects the post-grinding resistance of the electrode cap, including: controlling the grinding structure to perform a first grinding operation on the electrode cap and detecting that the post-grinding resistance of the electrode cap is a first resistance; determining that the grinding quality of the electrode cap is substandard based on the first resistance reaching a first threshold, and controlling the grinding structure to perform a second grinding operation on the electrode cap.

[0009] In some embodiments, after the grinding structure performs a second grinding on the electrode cap, the method further includes: detecting that the resistance of the electrode cap after the second grinding is a second resistance; determining that the grinding quality of the electrode cap is unqualified based on the second resistance reaching the first threshold, and triggering an alarm.

[0010] In some embodiments, detecting the resistance of the electrode cap in the vehicle body further includes: triggering a device abnormality alarm based on the resistance being lower than a second threshold; the second threshold being less than the first threshold.

[0011] In some embodiments, after controlling the grinding structure to perform at least one grinding on the electrode cap and detecting the post-grinding resistance of the electrode cap, the method further includes: recording the post-grinding resistance of the electrode cap, the time of acquiring the resistance, and the grinding quality of the electrode cap, and generating a production report.

[0012] In some embodiments, after generating the production report, the method further includes: determining, based on the production report, multiple target resistors corresponding to consecutive qualified grinding quality within a certain period of time; and triggering an equipment maintenance warning if multiple target resistors are increasing based on the acquisition time of the target resistors.

[0013] Secondly, embodiments of this application provide a grinding quality management device, which includes: a resistance detection module, used to control a grinding structure to perform at least one grinding operation on the electrode cap in response to a grinding command on the electrode cap, and to detect the post-grinding resistance of the electrode cap; the electrode cap is used for spot welding on a car body workpiece; and a quality judgment module, used to determine that the grinding quality of the electrode cap is qualified when the post-grinding resistance of the electrode cap determined during the at least one grinding operation does not reach a first threshold.

[0014] Thirdly, embodiments of this application provide a controller, including: a processor and a memory; the memory stores instructions or programs, and the processor is configured to: implement the above-mentioned grinding quality management method when executing the instructions or programs.

[0015] Fourthly, embodiments of this application provide a grinding system, which includes a grinding structure and a controller as described in the third aspect; during the process of the controller performing the above-mentioned grinding quality management, the grinding structure is used to perform grinding operations on the electrode cap that has reached a first resistance.

[0016] Fifthly, embodiments of this application provide a computer-readable storage medium storing program code that can be invoked by a processor or electronic device to execute the above-described grinding quality management method.

[0017] In a sixth aspect, a computer program product or computer program is also provided, the computer program product or computer program including computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium, and the processor executes the computer instructions, causing the computer device to perform the above-described grinding quality management method.

[0018] The technical solution provided in this application has at least the following beneficial effects: First, by detecting the resistance of the electrode cap after spot welding on the car body workpiece, the contact resistance of the electrode cap end face is used as an evaluation index for grinding quality. The detection method of direct resistance measurement avoids the problems of lag and low efficiency in grinding quality judgment. At the same time, when the resistance reaches the first threshold, the electrode cap is ground at least once, and the resistance of the electrode cap after grinding is detected. If the resistance does not reach the first threshold, the grinding quality of the electrode cap is determined to be qualified, and the detection process ends. The automated judgment is completed by measuring the resistance and the preset threshold, which improves the accuracy of spot welding grinding quality detection and the standardization of grinding quality judgment.

[0019] In addition, a hierarchical closed-loop control system of "sensing-analysis-execution" is constructed. Through resistance measurement sensing, threshold judgment analysis, and repeated grinding, the detection data and judgment results of each step can be recorded and traced, providing a data foundation for quality analysis and process improvement. It has automatic correction capabilities, improving the coverage of automation and overall production efficiency.

[0020] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0021] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0022] Figure 1 This is a schematic diagram of an implementation environment provided in an embodiment of this application; Figure 2 This is a flowchart of a grinding quality management method provided in an embodiment of this application; Figure 3 This is a flowchart of another grinding quality management method provided in the embodiments of this application; Figure 4This is a flowchart of another grinding quality management method provided in the embodiments of this application; Figure 5 This is a schematic diagram of a first robot control method provided in an embodiment of this application; Figure 6 This is a schematic diagram of a second robot control method provided in an embodiment of this application; Figure 7 This is a schematic diagram of a third robot control method provided in an embodiment of this application; Figure 8 This is a flowchart of another grinding quality management method provided in the embodiments of this application; Figure 9 This is a schematic diagram of a grinding quality management device provided in an embodiment of this application; Figure 10 This is a schematic diagram of a controller structure provided in an embodiment of this application.

[0023] The accompanying drawings have illustrated specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through specific embodiments. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0025] In related technologies, the quality control scheme for spot welding grinding has several shortcomings: First, the use of ultrasonic testing, destructive testing, and manual visual judgment of grinding quality all indirectly determine the grinding effect through defects in the finished weld, resulting in significant lag in detection. Furthermore, ultrasonic testing relies on operator experience, destructive testing is costly and has limited sampling frequency, while manual judgment is highly subjective, lacks standardized quantification, and is prone to missed detections and misjudgments. Second, using total wear to judge grinding quality only counts the total wear of both electrodes, failing to identify wear on one side. Third, using wear on both sides to judge grinding quality is affected by robot positioning and sensor repetitive measurement errors, leading to large fluctuations in measurement data, resulting in overly high judgment thresholds, failure to detect minor grinding defects, and poor consistency in electrode cap grinding quality. Therefore, after spot welding of the vehicle body, it is difficult to achieve accurate quantitative quality detection and closed-loop quality control for electrode cap grinding.

[0026] This application provides a grinding quality management method to solve the above-mentioned technical problems. Please refer to... Figure 1The diagram illustrates an implementation environment provided by an embodiment of this application. This implementation environment may include a grinding system 110 and a vehicle 120; wherein the grinding system 110 includes a grinding structure 111 and a controller 112.

[0027] In one alternative implementation, the grinding system 110 refers to a software module used to detect the resistance of the electrode cap after grinding and to determine the grinding quality based on the detected resistance.

[0028] In one alternative implementation, the grinding system 110 refers to a hardware module. The grinding structure 111 can be an industrial robot used to grind the electrode caps according to grinding instructions. The controller 112 includes at least one or more of the following: an industrial robot, a PLC (Programmable Logic Controller), or an industrial PC (Industrial Personal Computer), or other electronic devices with digital processing capabilities, used to execute grinding quality management methods.

[0029] The following is combined Figure 1 The grinding system 110 and vehicle 120 shown illustrate the grinding quality management method provided in this application: Electric welding is performed on the body workpiece of the vehicle 120 using the welding gun of a welding machine. After the spot welding operation is completed, the electrode cap of the welding gun needs to be ground. The grinding system 110 can then perform multiple grinding operations on the electrode cap using the grinding structure 111. After each grinding operation, a control command can be issued by the controller 112 to control the welding machine to collect the resistance of the ground electrode cap. When the controller 112 determines that the resistance of the electrode cap after multiple grinding operations has reached a first threshold, it triggers a system alarm. When the controller 112 determines that the resistance of the electrode cap after at least one grinding operation has not reached the first threshold, it determines that the grinding quality of the electrode cap is qualified. Based on the determination that the grinding quality of the electrode cap is qualified, the grinding structure 111 stops the grinding operation on the electrode cap.

[0030] Those skilled in the art should understand that the above-described grinding system 110 and vehicle 120 are merely examples. Other existing or future systems or vehicles that are applicable to this application should also be included within the scope of protection of this application, and are hereby incorporated by reference.

[0031] Based on the above Figure 1 The implementation environment shown in this application provides a flowchart of a method for grinding quality management. Figure 2 As shown, taking the application of this method to a terminal as an example, the grinding quality management method can be executed by the terminal or the server, and the method includes steps 210 to 220.

[0032] It should be noted that the terms "first," "second," etc. (if applicable) in the specification and claims 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 can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0033] Step 210: In response to the grinding command for the electrode cap, control the grinding structure to perform at least one grinding operation on the electrode cap, and detect the resistance of the electrode cap after grinding; the electrode cap is used for spot welding of the vehicle body workpiece.

[0034] In this embodiment, the resistance is the interface contact resistance between the contact surfaces of the upper and lower electrode caps of the welding clamp.

[0035] For example, spot welding uses the vehicle body as the welding object. The welding current is conducted by the electrode caps at both ends of the welding clamp to form the vehicle body connection weld. During long-term spot welding operations, the end face of the electrode cap will form an uneven metal layer, such as welding spatter accumulation, high-temperature oxide layer, surface protrusion, micro-depression and other process defects. These defects will change the geometry and surface contact characteristics of the electrode cap end face. This change will be directly reflected in the resistance measurement value of the electrode cap end face.

[0036] Furthermore, after spot welding is completed and the car body workpiece is removed, the electrode cap of the welding clamp needs to be ground. Under ideal grinding conditions, defects such as oxide layer, spatter, and protruding burrs attached to the end face can be completely removed, forming a flat and clean conductive end face. In this state, the effective conductive area of ​​the electrode cap end face is maximized, the conductive medium is uniform and stable, and the corresponding resistance measurement value will tend to be within a fixed and reasonable range. Moreover, the numerical deviation of repeated measurements is small, which has the characteristics of detection consistency and stability.

[0037] However, under insufficient grinding conditions, such as when the grinding stroke, grinding force, or grinding time does not meet the requirements, or when the grinding tool is severely worn, the electrode cap end face will still have some oxide layer, welding spatter, or microscopic uneven structure. In this state, the effective conductive contact area of ​​the electrode cap end face will be directly reduced, and the overall conductive impedance of the end face will be greatly increased. This will manifest as a significantly higher measured resistance value, indicating that the electrode cap grinding quality is substandard and cannot meet the requirements of subsequent spot welding operations on the vehicle body parts.

[0038] Therefore, by accurately collecting the resistance of a specific detection area after grinding, and comparing the measured resistance value with a pre-set threshold, the grinding quality of the electrode cap can be directly and quantitatively evaluated, thereby determining whether the grinding has met the process requirements of removing defects and forming a good conductive surface.

[0039] In one feasible approach, the industrial robot determines whether electrode cap grinding is required based on grinding conditions (such as preset production count, welding point count, or grinding instructions issued by the host computer). If grinding is required, the robot controls the welding clamp to move along a preset trajectory to the grinding station, calls preset process parameters (such as grinding feed, grinding pressure, and grinding time) to complete the grinding of the electrode cap end face. After a single grinding operation is completed, the robot controls the welding clamp to move to the detection station, drives the upper and lower electrode caps to fit together at a calibrated pressure, and issues a resistance detection start instruction to the welding machine.

[0040] Furthermore, after receiving the resistance detection start command, the welding machine closes the welding clamp under no-load to press the upper and lower electrode cap end faces together, forming a detection circuit. The contact pressure can be monitored synchronously by the pressure sensor of the welding clamp to ensure uniform electrode contact pressure. The detection point is the working surface (welding end face) where the upper and lower electrode caps are in contact. The welding machine outputs a low-amplitude detection current to collect the secondary voltage and secondary current, and calculates the interface contact resistance of the electrode cap end face, providing accurate data support for subsequent quantitative evaluation of grinding quality.

[0041] In this embodiment of the application, the first threshold is a resistance threshold (resistance upper limit threshold) used to determine whether the grinding quality is qualified.

[0042] In one feasible approach, the welding machine incorporates a configurable resistance threshold. During multiple re-grinding processes of the electrode cap, after each re-grinding operation, the welding machine compares the measured resistance with a pre-set first threshold to obtain a comparison result. Specifically, if the measured resistance does not exceed the first threshold, the re-grinding quality is marked as qualified; if the measured resistance exceeds the first threshold, the re-grinding quality is marked as unqualified.

[0043] At the same time, the welding machine outputs a qualified signal (grinding quality qualified) or an out-of-tolerance signal (grinding quality unqualified) to the robot.

[0044] The welding machine records and stores each piece of inspection data, including but not limited to the number of grinding cycles, measured resistance values, comparison results, and corresponding timestamps. It supports uploading to the factory's MES (Manufacturing Execution System) to achieve full-process quality traceability.

[0045] In this embodiment, a single resistance test can be completed in milliseconds to seconds, eliminating the need for offline testing and long-term downtime for manual inspection. It can be integrated with the automated operation process of robots and matched with the continuous production cycle of car body parts, without causing any loss of production line efficiency.

[0046] In step 210, the controlled grinding structure performs at least one grinding operation on the electrode cap and detects the resistance of the electrode cap after grinding, and also includes the following:

[0047] An alarm is triggered when the resistance of the electrode cap reaches the first threshold after multiple grinding cycles.

[0048] In one example, after the electrode cap is re-grinded multiple times, the welding machine compares the measured resistance with a preset first threshold. If the comparison results show that the measured resistance exceeds the first threshold, it indicates that there is an abnormality that cannot be eliminated by automatic grinding, such as permanent deformation of the electrode cap, severe wear of the re-grinding tool, or loosening of the electrode cap. The welding machine outputs multiple out-of-tolerance signals to the robot, and the robot triggers an alarm (such as an audible and visual alarm).

[0049] At the same time, the robot sends a request for human intervention to the human-machine interface, PLC, or PC, and locks the current workstation to suspend production.

[0050] In step 210, the controlled grinding structure performs at least one grinding operation on the electrode cap and detects the resistance of the electrode cap after grinding, and also includes the following:

[0051] A device malfunction alarm is triggered if the resistance is lower than a second threshold; the second threshold is less than the first threshold.

[0052] In this embodiment of the application, the second threshold is a resistance threshold (resistance lower limit threshold) used to determine whether the relevant device is abnormal.

[0053] In one example, the second threshold is usually set to an extremely low value, which is difficult to trigger under normal operating conditions. If the detected resistance is lower than the second threshold, it is initially judged to be an abnormal contact in the detection circuit, a failure of the pressure sensor, or a fault in the welding machine detection unit. The welding machine outputs an abnormal signal to the robot, and the robot equipment alarms abnormally.

[0054] At the same time, the robot sends a request for human intervention to the human-machine terminal, PLC or PC to lock the current workstation and suspend production in order to troubleshoot welding machine malfunctions or recalibrate thresholds.

[0055] Step 220: When the post-grinding resistance of the electrode cap, as determined during the at least one grinding process, does not reach the first threshold, the grinding quality of the electrode cap is determined to be qualified.

[0056] In one example, after the electrode cap is refurbished, the welding machine compares the measured resistance with a preset first threshold. Once the comparison result shows that the measured resistance does not exceed the first threshold, the refurbishment quality is marked as qualified, and the refurbishment inspection process ends directly.

[0057] After determining that the grinding quality of the electrode cap is qualified in step 220, the following content is also included.

[0058] Stop the grinding operation on the electrode cap.

[0059] For example, once the grinding quality is marked as qualified, the subsequent grinding operation on the electrode cap is immediately stopped, the welding machine outputs a qualified signal to the robot, and the robot returns to the welding station to wait for the next round of spot welding operations.

[0060] In this embodiment, the contact resistance of the electrode cap end face is used as the evaluation index of grinding quality. The automatic judgment is completed by measuring the resistance and setting a preset threshold. This can directly characterize the conductivity of the electrode end face. Compared with traditional indirect measurement methods such as visual inspection and calculation of wear, this avoids the problems of lag and low efficiency in grinding quality judgment, and improves the accuracy of spot welding grinding quality detection and the standardization of grinding quality judgment.

[0061] In addition, a hierarchical closed-loop control system of "sensing-analysis-execution" is constructed. Through resistance measurement sensing, threshold judgment analysis, repeated grinding and abnormal manual intervention, the detection data and judgment results of each step can be recorded and traced, providing a data foundation for quality analysis and process improvement. Compared with traditional post-event remedial quality control, it has automatic correction capabilities, improving the coverage of automation and overall production efficiency.

[0062] Furthermore, by using the secondary detection circuit of the spot welding machine and the welding clamp pressure sensor, there is no need to add an additional independent external resistance detector. The continuously collected resistance timing data can be used as a basis for assessing the health status of the electrode cap, so as to realize predictive maintenance of the equipment and reduce detection costs and production line operation and maintenance costs.

[0063] In conjunction with the above, regarding how to perform at least one grinding operation on the electrode cap and detect the resistance of the electrode cap after grinding, embodiments of this application provide an optional implementation method, such as... Figure 3 The flowchart of another grinding quality management method shown may specifically include the following steps 310 to 350.

[0064] Step 310: In response to the grinding command for the electrode cap, control the grinding structure to perform the first grinding on the electrode cap, and detect that the resistance of the electrode cap after the first grinding is the first resistance.

[0065] In one example, the acceptable resistance threshold range is set to [R].low R high ], where the first threshold is R high The second threshold is R low By comparing the measured resistance Rm with the threshold range, three categories of judgment conditions are defined: Condition A, indicating that the grinding quality is qualified, is defined as Rm. low ≤Rm≤R high Condition B indicating unqualified grinding quality: Rm > R high C: Rm indicates a device malfunction. <R low .

[0066] Based on the above judgment criteria, combined with Figure 4 The flowchart shown is another grinding quality management method. The electrode cap is ground for the first time. When the first resistance detected after the first grinding meets condition A, it means that the conductivity of the electrode cap end face meets the standard. The robot makes a qualified judgment based on the resistance detection result of the welding machine and executes the "pass" decision based on the judgment result. The grinding inspection process ends directly and the robot returns to the welding station to wait for the next round of spot welding operation. The welding machine simultaneously stores the inspection data and uploads it to the MES system.

[0067] Step 320: Based on the fact that the first resistance reaches the first threshold, it is determined that the grinding quality of the electrode cap is substandard, and the grinding structure is controlled to perform a second grinding on the electrode cap.

[0068] For example, when the first resistance detected after the first grinding meets condition B, it indicates that there is residual oxide layer, spatter, or microscopic unevenness on the electrode cap end face. The robot receives the out-of-tolerance signal sent by the welding machine, and makes a non-compliance judgment based on the resistance detection result of the welding machine. Based on the judgment result, it executes the "request second grinding" decision to perform a second grinding on the electrode cap, thereby achieving one automatic repair.

[0069] Step 330: The resistance of the electrode cap after the second grinding is detected to be the second resistance.

[0070] In the embodiments of this application, please continue to refer to Figure 4 The electrode cap undergoes a second grinding process, and the resistance is retested. The second resistance is then measured. If the measured second resistance meets condition A, the grinding quality is deemed to be up to standard, and the testing process ends.

[0071] Step 340: Based on the fact that the second resistance reaches the first threshold, it is determined that the grinding quality of the electrode cap is unqualified, and an alarm is triggered.

[0072] For example, please continue reading Figure 4When the detected second resistance meets condition B, it indicates that there is an abnormality that cannot be eliminated by automatic grinding. Based on the resistance detection result of the welding machine, the robot makes a non-compliance judgment and executes the "alarm request for manual intervention" decision according to the judgment result, triggering the on-site audible and visual alarm and sending a manual intervention request to the workstation human-machine terminal and PLC.

[0073] Furthermore, once the operator arrives at the site, they will conduct a visual and on-site inspection of the electrode cap end face. If the quality of the electrode cap end face grinding is confirmed to be up to standard, production can continue and the process ends. If it is confirmed that the electrode cap has irreversible damage, the grinding mechanism is faulty, or the process parameters are invalid, the operator will perform manual grinding, replace the electrode cap, or report the equipment for repair.

[0074] In the first example, such as Figure 5 The diagram shows a control method executed by the first robot. PULSE OT#(284) T=0.20 indicates that the pulse output IO284 lasts for 0.2s and sends an alarm reset signal to the spot welding machine; SVSPOT GUN#(1) WP=255.1 indicates that the resistance detection function of the welding machine is called, and the corresponding electrode pressure is 2500N; WHILEEXPIN#(286)=ON indicates that the resistance over-tolerance input signal fed back by the welding machine, and the signal ON means that the measured resistance exceeds the qualified threshold; MACRO1 MJ#(0) ARGF89 ARGF"TipDress Error" indicates that the alarm is displayed on the robot interface; MACRO1 MJ#(0) ARGF0 ARGF"" indicates that the alarm display on the robot interface is cleared; where, if LB001<1, the count is increased by 1, JUMP LABEL indicates secondary automatic grinding and re-inspection. If LB001>=1, output 46 is set to ON, sending a manual intervention request signal to the PLC. The robot moves to the manual display position and resets the welding machine alarm. It waits for 47 to turn ON. After manual confirmation, 46 is turned off, and the manual request signal is cleared.

[0075] In the second example, such as Figure 6The diagram shows a second robot control method. DO

[284] =PULSE,0.2sec, pulse output DO284, lasting 0.2s, sends an alarm reset signal to the spot welding machine; SPOT[SD=1,P=25,t=0.0,S=55555,ED=1] indicates calling the welding machine resistance detection function; IF DI

[286] =OFF THEN JMPLBL[2] indicates the welding machine feedback resistance over-tolerance input signal; UALM

[89] ="TipDress Error" indicates a robot grinding alarm; UALM[0]="" indicates clearing the alarm information; if R

[55] <1 (first detection exceeds tolerance) count +1, JMPLBL[1] jumps back to the program start point and performs the second resistance detection; if R

[55] ≥1 (second retest still exceeds tolerance), DO46 is set to ON, notifying the PLC to intervene manually, the robot moves to the manual display position, and resets the welding machine alarm, waiting for the DI47 manual confirmation signal, and after confirmation, DO46 is turned off.

[0076] In the third example, such as Figure 7 The diagram shows a third type of robot control method. PULSE(OUT

[284] ,TRUE,0.2) indicates that the pulse output is 284, lasts for 0.2s, and the welding machine alarm is reset; SPOT[1]={PRESSURE 255.1,TIME 55555,STEP 1} indicates the welding machine resistance detection; WHILE IN

[286] ==TRUE indicates the resistance is out of tolerance; MSG_NOTIFY("TipDress Error",89) indicates that the pop-up window pushes the 89th grinding alarm; MSG_CLEAR(0) indicates that all fault prompts are cleared; when the first error exceeds the tolerance (LB001<1), the count is increased by 1, and the jump is GOTO LABEL_START to perform the second resistance detection; when the second error exceeds the tolerance, OUT

[46] is set to TRUE, and a manual intervention request is sent to the PLC. The robot moves to the manual display position and pulses to reset the welding machine, waiting for the IN

[47] manual confirmation signal. After the confirmation is completed, the OUT

[46] manual request signal is turned off.

[0077] Step 350: When the post-grinding resistance of the electrode cap, as determined during the at least one grinding process, does not reach the first threshold, the grinding quality of the electrode cap is determined to be qualified.

[0078] After determining that the grinding quality of the electrode cap is qualified, the grinding operation on the electrode cap is stopped.

[0079] The specific steps of step 350 can be found in step 220, and will not be repeated here.

[0080] In this embodiment, the resistance of the welding machine after grinding is used as the judgment criterion. The automatic control automatically executes the process of releasing the machine after one grinding if it is qualified and re-grinding it if it is unqualified. In the case of abnormal situation where the resistance is still out of tolerance after two grindings, the robot alarm signal calls for manual intervention to complete the manual re-inspection and release the machine at the workstation or reset the fault. This constructs a complete closed loop of "detection-judgment-automatic reprocessing-re-detection-manual backup", realizing the automatic interception and graded processing of grinding quality problems and avoiding welding quality problems caused by unqualified grinding.

[0081] Based on the foregoing, this application provides an optional implementation method, such as... Figure 8 The flowchart shown is another method for quality management of grinding, which may specifically include the following steps 410 to 450.

[0082] Step 410: In response to the grinding command for the electrode cap, control the grinding structure to perform at least one grinding operation on the electrode cap, and detect the resistance of the electrode cap after grinding; the electrode cap is used for spot welding of the vehicle body workpiece.

[0083] Step 420: When the post-grinding resistance of the electrode cap, as determined during the at least one grinding process, does not reach the first threshold, the grinding quality of the electrode cap is determined to be qualified.

[0084] Step 430: Record the resistance of the electrode cap after each grinding, the time of obtaining the resistance, and the grinding quality of the electrode cap, and generate a production report.

[0085] For example, the measured resistance value, number of grinding cycles, judgment result, manual intervention record, timestamp, etc. corresponding to each grinding cycle are stored and a production report is generated and uploaded to the MES system.

[0086] Step 440: Based on the production report, determine the target resistors corresponding to multiple consecutive grinding quality qualified within a certain period of time.

[0087] For example, the resistance measured in a single test can be directly used to determine the current electrode cap grinding quality; while based on the resistance test data of consecutive batches of the same electrode cap and the same workstation, multiple resistances with qualified grinding quality can be obtained according to the measured resistance value, the number of grinding cycles and the judgment results, and thus the trend curve of resistance change can be obtained.

[0088] Step 450: Based on the acquisition time of the target resistor, if multiple target resistors are increasing, trigger an equipment maintenance warning.

[0089] For example, based on the resistance change trend curve, if the resistance value is detected to be rising slowly and systematically, it indicates that the wear of the electrode cap end face is intensifying, the cutting ability of the regrinding tool is decreasing, or the standard regrinding parameters are no longer suitable for the current working conditions. The robot can then proactively output equipment maintenance warnings.

[0090] The specific steps of steps 410 to 430 can be found in steps 210 to 230, and will not be repeated here.

[0091] In one possible specific example, the robot determines whether to perform grinding based on the grinding conditions and automatically performs grinding according to a pre-programmed path.

[0092] Specifically, after receiving the grinding instruction, the robot grinds the end face of the electrode cap and receives the resistance detection result from the welding machine. Based on the resistance detection result, it makes a judgment on whether the grinding quality is qualified or unqualified, and then executes subsequent decisions based on the judgment result. For example, if the grinding quality is qualified, it executes the subsequent decision of "pass"; if the first grinding quality is unqualified, it executes the subsequent decision of "requesting a second grinding"; if the second grinding quality is still unqualified, it executes the subsequent decision of "alarm requesting manual intervention".

[0093] The welding machine performs resistance detection, collecting the resistance Rm of the electrode cap and combining it with a pre-set threshold (R). low R high The determination is made based on the following three conditions: Condition A is R. low ≤Rm≤R high This indicates that the grinding quality is acceptable and condition B is Rm>R. high This indicates suspected insufficient grinding / poor surface finish, with condition C being Rm. <R low This indicates a device malfunction or a need to change the alarm threshold, as the lower limit of the resistance value (R) is generally set. low The settings are relatively low, so this situation is unlikely to occur. If it does occur, further technical analysis is required.

[0094] After the robot finishes its grinding process, it makes subsequent comprehensive decisions based on the resistance test results of the welding machine.

[0095] Specifically, Decision 1 is the case of a single pass, meaning that when the first grinding meets condition A, it is judged as "grinding quality qualified" and the process ends directly. Decision 2 is the case of triggering a second automatic grinding, meaning that when the first grinding meets condition B, it is judged as "grinding quality not up to standard, can be automatically repaired," and the system immediately notifies the grinding robot to perform a second grinding of the welding clamp. Decision 3 is the case of a second pass, meaning that when the second grinding meets condition A, it is judged as "grinding quality qualified" and the process ends directly. Decision 4 is the case of requesting manual intervention, meaning that when the second grinding meets condition B, it is judged as "grinding abnormal," immediately triggering an audible and visual alarm and sending a message to the manual workstation, prompting the operator to go to the site for visual inspection and manual handling. Decision 5 is the case of manual judgment of pass, meaning that when manual judgment of no abnormalities in grinding is made, it is judged as "grinding quality qualified," and the process ends directly. Decision 6 is the case of manual judgment of fail, meaning that when manual judgment of abnormality in grinding is made, it is judged as "grinding quality unqualified," requiring manual grinding or the involvement of relevant professionals for analysis and handling.

[0096] Among them, by continuously monitoring and analyzing the resistance data trend of the same welding clamp after grinding over a period of time, when the resistance value of the welding clamp at a certain workstation shows a systematic and slow increase after grinding, it may indicate that the grinding quality of the electrode cap of the welding clamp has declined, and predictive maintenance warnings or grinding parameter optimization suggestions can be issued in advance.

[0097] In this embodiment of the application, by clearly categorizing processes such as automatic pass-through, automatic rework, and manual judgment, simple and reproducible grinding problems are handled automatically by the equipment, while complex and abnormal grinding problems are handled manually. This improves the coverage of automation and overall production efficiency, and avoids the waste of human resources.

[0098] Furthermore, the robot's decisions are mostly based on objective data and quantitative standards, eliminating subjective human biases. Each step's detection data and judgment results can be recorded and traced, providing a data foundation for quality analysis and process improvement. Additionally, by setting up "human judgment and manual grinding" as the final safeguard, it ensures that when extreme or complex situations arise in the automated process that cannot be resolved, they can be properly handled through human judgment, guaranteeing 100% control over grinding quality. Simultaneously, by statistically analyzing the resistance data trends of electrode caps after grinding with the same welding clamp, it is possible to promote source improvement and predictive maintenance.

[0099] In one possible specific example, this application embodiment provides another electrode grinding system, which may include: a spot welding machine and welding clamp, an industrial robot, and a control unit. All hardware components work together to automatically complete electrode grinding, resistance detection, quality assessment, anomaly handling, and data traceability, achieving automated, quantitative, and traceable control over electrode grinding quality.

[0100] wherein the control unit and the industrial robot work in coordination to implement Figure 1 the functions of the controller, and the spot welding machine, the welding tongs and the industrial robot work together to implement Figure 1 the action of the dressing structure, which is used for dressing the electrode cap according to a dressing instruction.

[0101] wherein the spot welding machine and the welding tongs serve as units for detecting resistance and storing data, and the welding tongs with pressure sensing are matched with the high-precision spot welding machine to realize real-time resistance collection. A resistance threshold interval is built in the unit, the welding machine automatically compares the actually measured resistance with the threshold, if the actually measured resistance value is within the threshold interval, the dressing is determined to be qualified, and the process ends; if the actually measured resistance value exceeds the threshold interval, an out-of-tolerance signal is output to the robot.

[0102] Optionally, the spot welding machine supports on-line configuration of process parameters such as the resistance threshold and detection parameters, and can display the resistance value, the determination result and the alarm state in real time.

[0103] Optionally, the spot welding machine automatically records production data such as resistance data, determination results, operation time and station information of each dressing, stores the data locally and can upload the data to the MES system.

[0104] wherein the industrial robot, as a scheduling and execution unit, is used for electrode dressing and coordinated control among all units of the system. On the one hand, according to the production count or the dressing instruction, the dressing operation on the end face of the electrode cap is automatically completed according to a preset track and process parameters; on the other hand, the resistance detection result fed back by the welding machine is received, secondary determination of the dressing quality is completed, and different working conditions such as qualification and insufficient dressing are identified, which includes: directly releasing and ending the process if the dressing quality is qualified, automatically executing secondary dressing compensation if the dressing quality is unqualified, and determining that the electrode or the equipment is abnormal if the secondary dressing quality is still unqualified, sending a manual intervention request to the central control unit, and triggering station abnormity early warning.

[0105] wherein the control unit, such as a PLC or an Industrial Personal Computer, is used for abnormal scheduling outside the automatic flow, station interlocking or manual reset closed loop and the like. By receiving the manual determination request sent by the robot, the on-site acousto-optic alarm and station prompting device are driven to notify an operator to go to the site to determine the dressing result, and meanwhile, a manual determination operation port is provided, so that the operator can perform on-site inspection, manual dressing or equipment troubleshooting on abnormal working conditions that cannot be eliminated by automatic dressing, and after the electrode state is manually confirmed to be qualified or fault processing is completed, a release operation can be executed at the PLC end to release station interlocking and clear the alarm.

[0106] To achieve the functions of the above embodiments, the grinding quality management method includes hardware structures and / or software modules corresponding to each function. Those skilled in the art should readily recognize that, based on the units and method steps described in conjunction with the embodiments disclosed in this application, this application can be implemented in hardware or a combination of hardware and computer software. Whether a function is executed in hardware or by computer software driving hardware depends on the specific application scenario and design constraints of the technical solution.

[0107] exist Figures 2 to 8 Based on the grinding quality management method shown, this application further describes a grinding quality management device, such as... Figure 9 The schematic diagram of the grinding quality management device shown is shown. The grinding quality management device 500 includes: a resistance detection module 510 and a quality judgment module 520.

[0108] The resistance detection module 510 is used to control the grinding structure to perform at least one grinding operation on the electrode cap in response to the grinding command on the electrode cap, and to detect the resistance of the electrode cap after grinding; the electrode cap is used for spot welding on the car body workpiece.

[0109] The quality judgment module 520 is used to determine that the grinding quality of the electrode cap is qualified when the post-grinding resistance of the electrode cap, as determined in the at least one grinding process, does not reach the first threshold.

[0110] In some embodiments, the quality judgment module 520 includes: a tool for stopping the grinding operation on the electrode cap.

[0111] In some embodiments, the quality judgment module 520 further includes: triggering an alarm when the resistance of the electrode cap after multiple grindings reaches the first threshold.

[0112] In other embodiments, the resistance detection module 510 includes: a first detection module, used to perform a first grinding on the electrode cap and detect that the resistance of the electrode cap after the first grinding is a first resistance; and a grinding module, used to determine that the grinding quality of the electrode cap is substandard based on the first resistance reaching a first threshold, and to perform a second grinding on the electrode cap.

[0113] In other embodiments, the resistance detection module 510 further includes: a second detection module, used to detect that the resistance of the electrode cap after the second grinding is a second resistance; and a first judgment module, used to determine that the grinding quality of the electrode cap is unqualified based on the second resistance reaching the first threshold, and to trigger an alarm.

[0114] In some embodiments, the resistance detection module 510 includes: recording the resistance of the electrode cap after each grinding, the time of acquiring the resistance, and the grinding quality of the electrode cap, and generating a production report.

[0115] In some embodiments, the resistance detection module 510 further includes: a determination submodule, configured to determine, based on the production report, multiple target resistances corresponding to consecutive grinding quality qualified within a certain period of time; and a judgment submodule, configured to, based on the acquisition time of the target resistances, trigger an equipment maintenance warning if multiple target resistances are increasing.

[0116] In some embodiments, the quality judgment module 520 further includes: triggering a device abnormality alarm based on the resistance being lower than a second threshold; the second threshold being less than the first threshold.

[0117] According to one aspect of the embodiments of this application, Figure 10 This is a schematic diagram of the controller provided in an embodiment of this application. Figure 10 As shown, the controller 600 includes a processor 610 and one or more memories 620. The one or more memories 620 are used to store instructions or programs executed by the processor 610. When the processor 610 executes the instructions or programs, it implements the above-mentioned grinding quality management method.

[0118] Furthermore, the processor 610 may include one or more processing cores. The processor 610 runs or executes instructions, programs, code sets, or instruction sets stored in the memory 620, and retrieves data stored in the memory 620. Optionally, the processor 610 may be implemented using at least one hardware form selected from Digital Signal Processing (DSP), Field-Programmable Gate Array (FPGA), and Programmable Logic Array (PLA). The processor 610 may integrate one or a combination of several of the following: Central Processing Unit (CPU), Graphics Processing Unit (GPU), and modem. The CPU primarily handles the operating system, user interface, and applications; the GPU is responsible for rendering and drawing the displayed content; and the modem handles wireless communication. It is understood that the modem may also not be integrated into the processor and may be implemented using a separate communication chip.

[0119] According to one aspect of this application, a computer-readable storage medium is also provided, which may be included in the electronic device described in the above embodiments; or it may exist independently and not assembled into the electronic device. The computer-readable storage medium carries computer-readable instructions that, when executed by a processor, implement the methods in any of the above embodiments.

[0120] It should be noted that the computer-readable medium shown in the embodiments of this application can be a computer-readable signal medium or a computer-readable storage medium, or any combination of the two. Computer-readable storage media can be, for example, but not limited to: electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatuses, or devices, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to: electrical connections with one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, optical fiber, portable compact disc read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this application, a computer-readable storage medium can be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, apparatus, or device. In this application, a computer-readable signal medium can include data signals propagated in baseband or as part of a carrier wave, carrying computer-readable program code. Such transmitted data signals can take various forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination thereof. The computer-readable signal medium can also be any computer-readable medium other than a computer-readable storage medium, which can send, propagate, or transmit a program for use by or in connection with an instruction execution system, apparatus, or device. The program code contained on the computer-readable medium can be transmitted using any suitable medium, including but not limited to wireless, wired, etc., or any suitable combination thereof.

[0121] The units described in the embodiments of this application can be implemented in software or hardware, and the described units can also be located in a processor. The names of these units do not necessarily limit the specific unit itself.

[0122] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this application. Each block in a flowchart or block diagram may represent a module, segment, or portion of code, which contains one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram or flowchart, and combinations of blocks in a block diagram or flowchart, can be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0123] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the embodiments disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein.

[0124] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A method for quality management of grinding and polishing, characterized in that, include: In response to a grinding command for the electrode cap, the grinding structure is controlled to perform at least one grinding operation on the electrode cap, and the resistance of the electrode cap after grinding is detected; the electrode cap is used for spot welding of the vehicle body workpiece. When the post-grinding resistance of the electrode cap, as determined during the at least one grinding process, does not reach the first threshold, the grinding quality of the electrode cap is deemed qualified.

2. The method according to claim 1, characterized in that, After determining that the grinding quality of the electrode cap is qualified, the method further includes: Stop the grinding operation on the electrode cap.

3. The method according to claim 1, characterized in that, The controlled grinding structure performs at least one grinding operation on the electrode cap and detects the resistance of the electrode cap after grinding, including: An alarm is triggered when the resistance of the electrode cap reaches the first threshold after multiple grinding cycles.

4. The method according to claim 3, characterized in that, The controlled grinding structure performs at least one grinding operation on the electrode cap and detects the resistance of the electrode cap after grinding, including: The grinding structure is controlled to perform the first grinding on the electrode cap, and the resistance of the electrode cap after the first grinding is detected to be the first resistance; Based on the first resistance reaching the first threshold, it is determined that the grinding quality of the electrode cap is substandard, and the grinding structure is controlled to perform a second grinding on the electrode cap.

5. The method according to claim 4, characterized in that, After the controlled grinding structure performs a second grinding on the electrode cap, it further includes: The resistance of the electrode cap after its second grinding was detected to be the second resistance. If the second resistance reaches the first threshold, it is determined that the grinding quality of the electrode cap is unqualified, and an alarm is triggered.

6. The method according to claim 1, characterized in that, The method for detecting the resistance of the electrode cap in the vehicle body also includes: A device malfunction alarm is triggered if the resistance is lower than a second threshold; the second threshold is less than the first threshold.

7. The method according to claim 1, characterized in that, After the controlled grinding structure performs at least one grinding operation on the electrode cap and detects the post-grinding resistance of the electrode cap, the method further includes: Record the resistance of the electrode cap after each grinding, the time of obtaining the resistance, and the grinding quality of the electrode cap, and generate a production report.

8. The method according to claim 7, characterized in that, After generating the production report, the method further includes: Based on the production report, determine the target resistance corresponding to multiple consecutive grinding quality qualified tests within a certain period of time; Based on the acquisition time of the target resistors, if multiple target resistors are increasing, a device maintenance warning is triggered.

9. A controller, characterized in that, include: A processor and a memory; the memory storing instructions or programs, the processor being configured to, when executing the instructions or programs, implement the method of any one of claims 1-8.

10. A grinding system, characterized in that, include: The grinding structure and the controller as described in claim 9; During the execution of the method according to any one of claims 1-8 by the controller, the grinding structure is used to perform a grinding operation on the electrode cap that has reached the first resistance.

11. A computer-readable storage medium, characterized in that, The computer-readable storage medium contains program code that can be invoked by a processor or electronic device to execute the method as described in any one of claims 1 to 8.

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