Method for heat treatment control of welded joints of electrically heated alloy wires and related equipment

Abstract

The application discloses a kind of electric heating alloy wire welding joint heat treatment control method and related equipment, it is related to electric heating alloy wire technical field, the method includes: obtaining the material quality identification and size parameter of electric heating alloy wire;Based on material quality identification and size parameter, determine target heat treatment process parameters from preset heat treatment process database;By applying working current to electrode clamped on the two sides of welding joint of electric heating alloy wire, make electric heating alloy wire generate Joule heat, to obtain the real-time temperature at welding joint;Based on target heat treatment process parameters and real-time temperature, adjust working current, so that real-time temperature rises to target holding temperature according to target heating rate and keeps target holding time duration, to complete the heat treatment of welding joint.The application can realize the automatic matching and accurate control of different specifications electric heating alloy wire welding joint heat treatment process, improve heat treatment efficiency, process stability and the consistency of heat treatment quality.

Description

Technical Field

[0001] This application relates to the field of electrothermal alloy wire technology, and more specifically, to a method and related equipment for controlling the heat treatment of welded joints of electrothermal alloy wire. Background Technology

[0002] With the widespread application of electrothermal alloy wires in fields such as electrothermal elements, industrial heating equipment, household appliances, and high-temperature control devices, their welded joints, as important components connecting the electrothermal alloy wires, not only affect the conductivity of the electrothermal circuit but also directly relate to the mechanical strength, service life, and operational reliability of the electrothermal element. In order to eliminate residual stress generated during the welding process, improve the microstructure and properties of the welded joint, and enhance its stability, heat treatment is usually required after welding. Therefore, heat treatment control technology for electrothermal alloy wire welded joints is of great significance for ensuring welding quality and product performance.

[0003] In related technologies, heat treatment of welded joints made of electrothermal alloy wire typically involves pre-setting fixed heat treatment parameters or relying on manual experience to adjust the heating process. Electrothermal alloy wires of different materials and sizes often use the same or similar heat treatment parameters, making it difficult to tailor the process to the specific specifications of the wires. Furthermore, existing heat treatment processes often lack a real-time adjustment mechanism based on the actual temperature of the welded joint. During heating, deviations in the heating rate, holding temperature, or holding time from the target process requirements can easily occur, affecting the quality of the welded joint heat treatment. In addition, some heat treatment methods rely on external heating equipment, resulting in low heat utilization efficiency and the potential for additional heating of non-target areas, hindering precise control of the welded joint heat treatment process. In short, related technologies suffer from poor process matching, low temperature control accuracy, and insufficient heat treatment stability in the heat treatment of welded joints made of electrothermal alloy wire. Summary of the Invention

[0004] In the summary section of this application, the relevant technical solutions are described in general terms, and a series of simplified concepts are introduced. These concepts will be further elaborated in the detailed embodiments section. This summary section should not be construed as limiting the key or essential technical features of the claimed solutions, nor is it intended to limit the scope of protection of the claimed solutions.

[0005] The heat treatment control method and related equipment for electrothermal alloy wire welded joints provided in this application can automatically match heat treatment process parameters according to the material and size of the electrothermal alloy wire, and achieve precise heat treatment of the welded joints through self-resistance heating combined with real-time temperature closed-loop control, thereby improving heat treatment efficiency, temperature control accuracy, process stability, automation level, and consistency of heat treatment quality of welded joints of different specifications.

[0006] In a first aspect, this application provides a method for controlling the heat treatment of a welded joint of an electrothermal alloy wire, comprising: obtaining the material identification and dimensional parameters of the electrothermal alloy wire; determining target heat treatment process parameters from a preset heat treatment process database based on the material identification and the dimensional parameters, wherein the target heat treatment process parameters include a target heating rate, a target holding temperature, and a target holding time; generating Joule heating in the electrothermal alloy wire by applying a working current to electrodes clamped on both sides of the welded joint on the electrothermal alloy wire to obtain the real-time temperature at the welded joint; adjusting the working current based on the target heat treatment process parameters and the real-time temperature to raise the real-time temperature to the target holding temperature according to the target heating rate and maintain it for the target holding time, thereby completing the heat treatment of the welded joint.

[0007] In some embodiments, before the electrothermal alloy wire generates Joule heat by applying a working current to the electrodes clamped on both sides of the weld joint, the heat treatment control method for the electrothermal alloy wire weld joint further includes: applying a preset detection current to the electrodes to obtain the voltage drop across the two ends of the electrothermal alloy wire segment between the two electrodes; determining the initial resistance value of the electrothermal alloy wire segment based on the preset detection current and the voltage drop; and determining the target current adjustment range of the working current based on the initial resistance value and the dimensional parameters.

[0008] In some embodiments, the heat treatment control method for the electrothermal alloy wire welded joint further includes: determining target PID parameters based on the initial resistance value and the dimensional parameters using a preset PID parameter self-tuning model, wherein the target PID parameters include a target proportional coefficient, a target integral time, and a target derivative time; adjusting the operating current based on the target heat treatment process parameters and the real-time temperature includes: adjusting the operating current within the target current adjustment range using the target PID parameters based on the target heat treatment process parameters and the real-time temperature adjustment.

[0009] In some embodiments, the target heat treatment process parameters further include a target cooling rate; after maintaining the target holding time at the real-time temperature, the heat treatment control method for the electrothermal alloy wire welded joint further includes: reducing the operating current based on the deviation between the target holding temperature and the real-time temperature, so that the real-time temperature decreases according to the target cooling rate.

[0010] In some embodiments, the operating current is provided to the electrode by a portable host unit via a flexible cable, the portable host unit being separately disposed from the electrode; obtaining the real-time temperature at the weld joint includes: elastically attaching the end of the thermocouple to the surface of the weld joint by means of an elastic clamping mechanism integrated on a clamp for holding the electrode, thereby obtaining the real-time temperature.

[0011] In some embodiments, before the electrothermal alloy wire generates Joule heat by applying a working current to the electrodes clamped on both sides of the weld joint, the heat treatment control method for the electrothermal alloy wire weld joint further includes: determining a target contact head identifier in a preset contact head specification database according to the dimensional parameters; outputting the target contact head identifier to prompt the installation of a V-groove contact head having a corresponding target contact head identifier onto the electrodes, wherein the V-groove contact head is used to automatically center the electrothermal alloy wire during clamping.

[0012] In some embodiments, the heat treatment control method for the electrothermal alloy wire welded joint further includes: generating a temperature-time curve based on temperature and time data during the heat treatment process; acquiring current and voltage data applied during the heat treatment process; and storing the temperature-time curve, the current data, the voltage data, and the target heat treatment process parameters in association to generate a heat treatment process record.

[0013] In some embodiments, determining the target heat treatment process parameters from a preset heat treatment process database based on the material identifier and the size parameters includes: matching the target heat treatment process parameters from the preset heat treatment process database based on the treatment type identifier of the electrothermal alloy wire to be treated, the material identifier, and the size parameters, wherein the treatment type identifier is preheating before welding or postheating after welding.

[0014] Secondly, this application also provides a heat treatment control device for welded joints of electrothermal alloy wires, comprising: a data acquisition unit for acquiring the material identification and dimensional parameters of the electrothermal alloy wire to be treated; a parameter determination unit for determining target heat treatment process parameters from a preset heat treatment process database based on the material identification and the dimensional parameters, wherein the target heat treatment process parameters include a target heating rate, a target holding temperature, and a target holding time; a temperature acquisition unit for obtaining the real-time temperature at the welded joint by applying a working current to electrodes clamped on both sides of the welded joint on the electrothermal alloy wire to generate Joule heat in the electrothermal alloy wire; and a heating control unit for adjusting the working current based on the target heat treatment process parameters and the real-time temperature, so that the real-time temperature rises to the target holding temperature according to the target heating rate and is maintained for the target holding time, thereby completing the heat treatment of the welded joint.

[0015] Thirdly, this application also provides an electronic device, including: a memory and a processor, wherein the processor is configured to execute a computer program stored in the memory to implement the steps of the heat treatment control method for the electrothermal alloy wire welded joint described in the first aspect.

[0016] Fourthly, this application also provides a computer-readable storage medium storing computer-executable instructions or a computer program, wherein when the computer-executable instructions or the computer program are executed by a processor, the steps of the heat treatment control method for the electrothermal alloy wire welded joint described in the first aspect are implemented.

[0017] Fifthly, this application also provides a computer program product, including a computer program or computer-executable instructions, which, when executed by a processor, implement the steps of the heat treatment control method for electrothermal alloy wire welded joints provided in the embodiments of this application.

[0018] In summary, this application obtains the material identification and dimensional parameters of the heating alloy wire, and determines the corresponding target heat treatment process parameters from a pre-set heat treatment process database based on the obtained information. This allows the heat treatment process to be matched with heating alloy wires of different materials and sizes, rather than using uniform and fixed heat treatment parameters. This reduces the inappropriate selection of process parameters due to differences in material specifications, improves the pertinence and applicability of heat treatment process parameters, and ensures the consistency of heat treatment processes for welded joints of different specifications. By clamping electrodes on both sides of the welded joint and applying a working current to the heating alloy wire, the heating alloy wire itself generates Joule heat to complete the heating of the welded joint. Since the heat is generated directly from the heating alloy wire itself, heat treatment of the welded joint area can be achieved without relying on an external heating device. This allows the heat to act directly on the area to be treated, improving heat treatment efficiency and reducing the impact of heating on non-target areas. During the heat treatment process, the weld... The system monitors the real-time temperature at the joint and adjusts the operating current based on the target heat treatment process parameters and the real-time temperature. This ensures the real-time temperature rises to the target holding temperature at the target heating rate and is maintained for the target holding time, forming a dynamic adjustment process based on temperature feedback. This allows the heat treatment process to continuously correct the temperature according to preset process parameters, reducing deviations from the target process parameters and improving the temperature control accuracy and process stability of the welded joint heat treatment process. By combining material and size information acquisition, process parameter determination, self-resistive heating, and real-time temperature-based operating current adjustment, the heat treatment process of the welded joint forms a complete control flow from process parameter matching to heating control. This allows welded joints with different specifications of heating alloy wires to complete heat treatment according to the corresponding target heat treatment process, reducing the manual setting and adjustment of heat treatment parameters and improving the automation level of the heat treatment process and the consistency of the welded joint heat treatment quality. In summary, the heat treatment control method for welded joints of electrothermal alloy wire provided in this application can automatically match heat treatment process parameters according to the material and size of the electrothermal alloy wire, and achieve precise heat treatment of the welded joint through self-resistance heating combined with real-time temperature closed-loop control, thereby improving heat treatment efficiency, temperature control accuracy, process stability, automation level, and consistency of heat treatment quality of welded joints of different specifications. Attached Figure Description

[0019] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit this specification. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A schematic flowchart illustrating a heat treatment control method for an electrothermal alloy wire welded joint provided in this application embodiment; Figure 2A schematic diagram of the composition structure of a heat treatment control device for an electrothermal alloy wire welding joint provided in an embodiment of this application; Figure 3 This is a schematic diagram of the composition structure of an electronic device provided in an embodiment of this application. Detailed Implementation

[0020] The terms used in the specification, claims, and drawings of this application, such as "first," "second," "third," "fourth," etc. (if any), are used to distinguish similar objects and not to describe a specific order or sequence. Therefore, it is to be understood that these terms can be used interchangeably where appropriate, allowing the described embodiments to be used in different orders, unless specifically required by the illustrations or description. Furthermore, the terms "is" and "has," and any variations thereof, are intended to cover, non-exclusively, all possible constituent elements. For example, a process, method, system, product, or apparatus comprising several steps or units is not necessarily limited to the steps or units explicitly listed, but may also include other steps or units not explicitly listed, or steps or units inherent to the process, method, product, or apparatus.

[0021] In this application, a "module" or "unit" refers to a computer program or part of a computer program that has a specific function and works in conjunction with other related parts to achieve a predetermined goal. These modules or units can be implemented by software, hardware (e.g., processing circuitry or memory), or a combination of both. One or more processors or memories can implement one or more modules or units. Furthermore, each module or unit can also be part of a larger module or unit.

[0022] The technical solutions of this application will be described in detail below with reference to the accompanying drawings of the embodiments. It should be noted that the described embodiments are only a part of this application, and not all embodiments. In the following description, the "some embodiments" mentioned are only a subset of all possible embodiments, which may be the same or different subsets, and different embodiments can be combined with each other without conflict.

[0023] Figure 1 This is a schematic flowchart illustrating a heat treatment control method for an electrothermal alloy wire welded joint provided in an embodiment of this application. For example, see [link to example]. Figure 1 The heat treatment control method for electrothermal alloy wire welded joints provided in this application embodiment may include the following steps 101 to 104: Step 101: Obtain the material identification and dimensional parameters of the heating alloy wire.

[0024] In some examples, the heating alloy wire is a functional metal wire with high resistivity and excellent high-temperature oxidation resistance. It is mainly used as a heating element in various electric heating equipment, and can be applied in heat treatment equipment such as industrial electric heating furnaces, photovoltaic semiconductor diffusion furnaces, and annealing furnaces. In this embodiment, the heating alloy wire can be an iron-chromium-aluminum (FeCrAl) based heating alloy wire. This type of alloy can form a dense alumina protective film on its surface under high-temperature conditions, exhibiting excellent long-term high-temperature service performance. The basic property information of the heating alloy wire can be confirmed through the wire's factory quality certificate and the information marked on the product packaging.

[0025] Material identification is a unique identifier used to distinguish the specific grade of the heating alloy wire. Different grades correspond to different chemical element ratios and material performance parameters, and are one of the bases for matching the corresponding heat treatment process. Material identification can be manually selected and entered by the operator through the human-machine interface of the device, or it can be automatically collected by recognizing the graphic code and text label on the wire packaging. In this embodiment, optional examples of material identification include standard grades of commonly used iron-chromium-aluminum heating alloys such as 0Cr25Al5 and 0Cr21Al6Nb.

[0026] Dimensional parameters are physical parameters used to characterize the geometric specifications of the electrothermal alloy wire. They directly determine the heat capacity characteristics and heating power requirements of the wire segment to be treated, and serve as another basis for adapting the heat treatment process. For the filamentous workpiece to be treated in this embodiment, the dimensional parameter specifically refers to the diameter of the electrothermal alloy wire. The dimensional parameter can be manually entered by the operator through the human-machine interface, either by the nominal or measured wire diameter value, or by automatic measurement and uploading through the matching dimensional detection module. In this embodiment, optional examples of dimensional parameters include common electrothermal alloy wire diameter specifications such as 4.0 mm and 6.0 mm.

[0027] For example, the operator can complete the above information input operation on the human-machine interface of the portable heat treatment device; first, select the grade information corresponding to the wire to be treated from the preset material grade option list to complete the upload of the material identification; then, enter the nominal diameter value of the wire to be treated in the wire diameter input field to complete the submission of the size parameters; after receiving the material identification and size parameters, the control unit inside the device will verify the validity of the input information and confirm that the parameters are within the preset processable range, providing accurate basic data for the subsequent process parameter matching steps.

[0028] By implementing step 101, the material identification and size parameters of the heating alloy wire are obtained, which can accurately identify the material type and specification information of the heating alloy wire to be heat-treated. This provides a basis for the selection of subsequent heat treatment process parameters, enabling the subsequent heat treatment process to adopt appropriate process parameters for different materials and sizes, reducing the situation of mismatch in process parameter selection due to specification differences, and improving the pertinence and applicability of the heat treatment process.

[0029] Step 102: Based on the material identification and size parameters, determine the target heat treatment process parameters from the preset heat treatment process database.

[0030] The target heat treatment process parameters may include the target heating rate, the target holding temperature, and the target holding time.

[0031] In some examples, the preset heat treatment process database is a pre-built set of standardized process parameters used to provide matching heat treatment execution standards for welded joints of electrothermal alloy wires with different properties. This database can be built based on the material thermophysical properties of iron-chromium-aluminum electrothermal alloys, the evolution law of welded joint microstructure and properties, and the results of multiple sets of process verification tests, covering mainstream commercial grades and commonly used wire diameter specifications. For example, the entries in this database may include heat treatment parameter sets for each commonly used wire diameter corresponding to the 0Cr25Al5 grade, heat treatment parameter sets for each commonly used wire diameter corresponding to the 0Cr21Al6Nb grade, etc.

[0032] The target heat treatment process parameters are a complete set of heat treatment control parameters obtained by matching the database for the electrothermal alloy wire welding joint to be treated. They serve as the basis for guiding the entire heat treatment process and ensuring the consistency of the treatment effect. The target heat treatment process parameters can be automatically matched and extracted from the preset heat treatment process database based on the input material identification and size parameters, without the need for manual calculation or setting by the operator based on experience. Taking a 0Cr25Al5 electrothermal alloy wire welding joint with a diameter of 6.0mm as an example, the corresponding target heat treatment process parameters can include three control indicators: target heating rate, target holding temperature, and target holding time. The target heating rate is the controlled rate at which the temperature at the weld joint rises over time during the heat treatment heating stage, measured in °C / min. The heating rate needs to balance heat treatment efficiency and joint thermal stress control. Too fast a rate can lead to excessive instantaneous thermal stress inside the joint, while too slow a rate will prolong the processing cycle of a single joint and reduce on-site work efficiency. The specific value of the target heating rate is dynamically adjusted according to the material grade and wire diameter, and is matched and output by a preset heat treatment process database. The selectable value range for this parameter is 5 °C / min to 30 °C / min. For a weld joint made of 0Cr25Al5 electrothermal alloy wire with a diameter of 6.0 mm, the corresponding target heating rate example is 15 °C / min. The target holding temperature is the desired temperature value for the welded joint that needs to be maintained stably during the heat treatment holding stage. This temperature corresponds to the optimal temperature range for eliminating residual stress and restoring the microstructure properties within the welded joint, and is a parameter that determines the final effect of the heat treatment. The target holding temperature needs to be precisely matched with the material characteristics of the heating alloy. Excessive temperature can lead to excessive grain growth in the weld and heat-affected zone, deteriorating the mechanical properties of the joint; insufficient temperature will prevent adequate stress elimination and plastic recovery. The specific value of the target holding temperature is output from a preset heat treatment process database. For the heat treatment of welded joints made of iron-chromium-aluminum heating alloy wire, the selectable range for this parameter is 700℃ to 850℃. For a welded joint made of 6.0mm diameter 0Cr25Al5 heating alloy wire, the corresponding target holding temperature example is 800℃. The target holding time is the length of time that the welded joint temperature needs to be maintained stably after reaching the target holding temperature. The goal of setting the time is to ensure that the temperature of the joint cross-section is uniform and that the internal microstructure transformation and stress relief processes are fully completed. The target holding time is positively correlated with the diameter of the heating alloy wire. The larger the wire diameter, the higher the heat capacity of the wire, and the longer the time required for temperature homogenization and microstructure transformation. The specific value of the target holding time is matched and output by the preset heat treatment process database. The selectable value range of this parameter is 2 min to 30 min. For a 0Cr25Al5 heating alloy wire welded joint with a diameter of 6.0 mm, the corresponding target holding time example is 10 min.

[0033] The process of determining the target heat treatment process parameters from the preset heat treatment process database based on material identification and size parameters involves using the material identification and size parameters obtained in the previous step as search and matching conditions. The database is then traversed and compared with pre-stored entries. Once a completely matching entry is found, the complete set of process parameters under that entry is extracted and determined as the execution parameters for this heat treatment. This matching process is completed automatically by the device, without requiring operators to have professional knowledge of heat treatment process design. This effectively avoids individual deviations caused by manual parameter setting and ensures the consistency of heat treatment effects for different joints.

[0034] For example, after receiving the uploaded material identifier and size parameters, the microcontroller unit of the device calls the retrieval interface of the preset heat treatment process database and compares and matches the two input parameters with the pre-stored entries in the database one by one. After the microcontroller unit matches the parameter group of the corresponding entry, it loads parameters such as the target heating rate, target holding temperature, and target holding time into the heat treatment control program and displays the recommended process parameter information in full on the human-machine interface. The operator can confirm the displayed recommended parameters. After confirmation, the parameters will be locked as the sole execution benchmark for this heat treatment, providing a standardized execution basis for subsequent heating control links.

[0035] By implementing step 102, the target heat treatment process parameters are determined from the preset heat treatment process database based on the material identification and size parameters. The target heating rate, target holding temperature and target holding time can be automatically matched according to the process requirements of different heating alloy wires. There is no need to manually set the heat treatment parameters one by one, which improves the efficiency of process parameter determination and ensures that heating alloy wires of different specifications can adopt the corresponding heat treatment process, thereby improving the consistency and standardization of the heat treatment process.

[0036] Step 103: By applying a working current to the electrodes on both sides of the welding joint clamped on the heating alloy wire, Joule heating is generated in the heating alloy wire to obtain the real-time temperature at the welding joint.

[0037] In some examples, the electrodes clamped on both sides of the welding joint on the heating alloy wire are conductive components used to form reliable electrical contact with the heating alloy wire and conduct current. Two independent electrode bodies are configured, each clamped and fixed to the wire body on both sides of the welding joint, placing the welding joint at the center of the heating zone defined by the two electrodes. The electrodes are made of a high-conductivity copper alloy material, which can conduct the electrical energy output by the device to the interior of the heating alloy wire with low loss. The distance between the two electrodes and the welding joint is kept consistent, ensuring uniform heating of the welding joint area and avoiding uneven axial temperature distribution. The typical clamping position of the electrodes is set on the wire 30 mm to 50 mm on both sides of the welding joint, and the clamping distance can be adjusted according to the wire diameter. The clamping operation of the electrodes can be performed manually by the operator; after aligning with the preset clamping position, a tight electrical contact with the wire is achieved through a clamping structure.

[0038] The operating current is a controllable electrical energy carrier output from the power module of the heat treatment device and conducted through the electrodes to the heating alloy wire. It is the energy source for achieving self-resistance heating. When the operating current flows through the heating alloy wire segment between the two electrodes, the Joule effect is generated due to the wire's own resistance characteristics, converting electrical energy into heat energy and raising the wire temperature. The output of the operating current can be dynamically adjusted according to the heating requirements to match the temperature control targets of different heating stages. For example, for welding joints of 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm, the typical operating current range is 75 amperes to 80 amperes.

[0039] The real-time temperature at the weld joint is the instantaneous temperature value at the target location of the weld joint during the heat treatment process. It is a parameter reflecting the heated state of the joint and also serves as the feedback basis for the temperature closed-loop control process. The target location for temperature acquisition is the central area of ​​the weld joint surface, where the residual welding stress is most concentrated and the changes in microstructure and properties are most significant. Its temperature value can directly characterize the degree of effect of heat treatment on the joint. The real-time temperature can be acquired by temperature detection elements, which then convert the temperature signal of the joint into readable digital temperature data through the temperature acquisition module of the device. During the heating phase, the real-time temperature continues to rise with the heating process. During the holding phase, the real-time temperature is maintained within a narrow range near the target holding temperature.

[0040] The process of obtaining the real-time temperature of the weld joint by applying a working current to electrodes clamped on both sides of the welding joint on the heating alloy wire, causing the wire to generate Joule heat, utilizes the high resistivity of the heating alloy wire itself to directly convert externally input electrical energy into heat within the wire through the Joule effect, thus heating the weld joint without relying on external heating elements. Throughout the heating process, real-time temperature data at the weld joint is collected simultaneously, allowing for real-time monitoring of the joint's heating status and providing a data basis for subsequent current adjustment and temperature control. This heating method generates heat directly within the wire itself, resulting in higher heating efficiency and a more uniform temperature distribution compared to traditional external conductive heating.

[0041] For example, after the operator clamps and fixes the two electrodes on both sides of the welding joint, the heat treatment program is started. The power module of the device outputs a corresponding working current according to the initial control command. The working current is conducted to the two electrodes through the conductive transmission line, and then flows into the electrothermal alloy wire segment between the two electrodes. When the current flows through the wire, the resistance of the wire itself converts electrical energy into Joule heat, causing the overall temperature of the wire to gradually rise. The heat is evenly conducted to the welding joint area, realizing the heating effect on the joint. At the same time, the temperature detection element arranged at the target position of the welding joint continuously collects the temperature signal of the joint surface, converts it into a corresponding electrical signal, and transmits it to the control unit of the device. The control unit converts and calibrates the received electrical signal to obtain the real-time temperature value at the current moment, completing the temperature data acquisition process.

[0042] By implementing step 103, a working current is applied to the electrodes on both sides of the weld joint, causing the heating alloy wire itself to generate Joule heat to heat the weld joint. The heating alloy wire itself can be used as the heating element, and the heat treatment of the weld joint can be completed without relying on an external heating device. The heat is applied directly to the weld joint area, reducing the heating of non-target areas and improving the heat treatment efficiency. At the same time, the real-time temperature at the weld joint is obtained, providing temperature feedback for subsequent adjustment of the working current.

[0043] Step 104: Based on the target heat treatment process parameters and the real-time temperature adjustment working current, the real-time temperature is raised to the target holding temperature at the target heating rate and maintained for the target holding time to complete the heat treatment of the welded joint.

[0044] In some examples, a control mechanism based on target heat treatment process parameters and real-time temperature adjustment of the working current is used to achieve precise control of heat treatment temperature. A closed-loop feedback control architecture is employed to complete the entire process temperature regulation. This mechanism uses the target heat treatment process parameters as the control benchmark and the real-time temperature of the weld joint as the dynamic feedback signal. By dynamically adjusting the output of the working current, the heating power of the heating alloy wire is changed, thereby achieving continuous and precise control of the weld joint temperature. The target heat treatment process parameters are obtained from a preset heat treatment process database by the preceding steps and serve as the standardized execution basis for the entire process temperature control. The real-time temperature is continuously acquired by the temperature acquisition link of the preceding steps, providing real-time data on the joint's heating status for current adjustment. The working current adjustment command is generated by the device's control unit, and the current output is dynamically adjusted through an inverter DC power supply module. When the real-time temperature is lower than the expected temperature value for the current stage, the control unit outputs a command to increase the working current, increasing the wire heating power to accelerate the temperature rise. When the real-time temperature is higher than the expected temperature value for the current stage, the control unit outputs a command to decrease the working current, reducing the wire heating power to slow down the temperature rise.

[0045] Temperature control during the heating phase is the process of controlling the real-time temperature to rise uniformly to the target holding temperature at the target heating rate. It is the initial execution stage of the heat treatment process. The stability of the heating rate directly affects the thermal stress level of the welded joint. Too fast a rate can easily lead to excessive instantaneous thermal stress inside the joint, deteriorating the mechanical properties of the joint. Too slow a rate will prolong the processing cycle of a single joint and reduce on-site operation efficiency. The start time of the heating phase is the moment when the heat treatment procedure is officially started, and the end time is the moment when the real-time temperature of the welded joint first reaches the target holding temperature. For example, for a welded joint of 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm, the control example of the heating phase is to steadily raise the joint temperature from room temperature to 800 degrees Celsius at a target heating rate of 15 degrees Celsius per minute.

[0046] Temperature control during the holding stage is the process of maintaining the real-time temperature stably at the target holding temperature and continuously maintaining the target holding time. It is a crucial stage in the heat treatment process. The temperature stability and sufficient duration of this stage directly determine the effectiveness of residual stress elimination and microstructural property recovery in the welded joint. Excessive temperature fluctuations or insufficient holding time will lead to substandard heat treatment results, while excessively high temperatures may cause excessive grain growth in the joint, degrading overall performance. The holding stage begins when the real-time temperature reaches the target holding temperature, and the device simultaneously starts the holding timer. The holding stage terminates when the cumulative holding time reaches the preset target holding time. For example, for a welded joint of 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm, the control example for the holding stage is to maintain the joint temperature stably at 800 degrees Celsius for 10 minutes to ensure that the internal stress elimination and microstructural transformation of the joint are fully completed.

[0047] When the cumulative running time of the heat preservation stage reaches the target heat preservation time, the heat treatment process is deemed to be completed, the device automatically stops the output of the working current, and the heating process ends. This determination mechanism can ensure that the duration of each heat treatment meets the process standard, avoid human error caused by manual timing, and ensure that the heat treatment effect performed by different batches and different operators is consistent.

[0048] For example, after the heat treatment process is started, the control unit of the device continuously receives the real-time temperature of the welded joint, compares the real-time temperature with the expected temperature at the current moment corresponding to the target heating rate, generates a corresponding current adjustment command based on the temperature deviation, and controls the power module to adjust the output of the working current so that the temperature of the welded joint always rises steadily according to the target heating rate. When the real-time temperature reaches the target holding temperature, the control unit automatically switches to the holding control mode, finely adjusts the working current according to the deviation between the real-time temperature and the target holding temperature, and keeps the joint temperature stably near the target holding temperature. At the same time, the holding time accumulation time is started. When the accumulated holding time reaches the preset target holding time, the control unit outputs a stop command, the power module cuts off the working current output, and the heat treatment process of this electrothermal alloy wire welded joint is officially completed.

[0049] By implementing step 104, based on the target heat treatment process parameters and the real-time temperature regulation working current, the temperature of the welded joint is raised according to the target heating rate and maintained at the target holding temperature for the target holding time. This forms a closed-loop control process based on real-time temperature feedback, enabling the heat treatment process to be continuously and dynamically adjusted according to the preset process parameters. This reduces the deviation of the temperature from the target process parameters and improves the temperature control accuracy, process stability, and consistency of heat treatment quality in the heat treatment process of the welded joint.

[0050] In summary, this application embodiment obtains the material identification and dimensional parameters of the heating alloy wire, and determines the corresponding target heat treatment process parameters from a preset heat treatment process database based on the obtained information. This allows the heat treatment process to be matched with heating alloy wires of different materials and sizes, rather than using uniform and fixed heat treatment parameters. This reduces the inappropriate selection of process parameters due to differences in material specifications, improves the pertinence and applicability of heat treatment process parameters, and ensures the consistency of heat treatment processes for welded joints of different specifications. By clamping electrodes on both sides of the welded joint and applying a working current to the heating alloy wire, the heating alloy wire itself generates Joule heat to complete the heating of the welded joint. Since the heat is directly generated from the heating alloy wire itself, heat treatment of the welded joint area can be achieved without relying on an external heating device. This allows the heat to act directly on the area to be treated, improving heat treatment efficiency and reducing the impact of heating on non-target areas. During the heat treatment process, the material identification and dimensional parameters of the heating alloy wire are obtained. The real-time temperature at the weld joint is monitored, and the operating current is adjusted based on the target heat treatment process parameters and the real-time temperature to ensure that the real-time temperature rises to the target holding temperature at the target heating rate and is maintained for the target holding time. This forms a dynamic adjustment process based on temperature feedback, which allows the heat treatment process to continuously correct the temperature according to the preset process parameters, reducing the possibility of temperature deviation from the target process parameters and improving the temperature control accuracy and process stability of the weld joint heat treatment process. By combining material and size information acquisition, process parameter determination, self-resistive heating, and operating current adjustment based on real-time temperature, the heat treatment process of the weld joint forms a complete control flow from process parameter matching to heating control. This allows weld joints with different specifications of heating alloy wires to complete heat treatment according to the corresponding target heat treatment process, reducing the manual setting and adjustment of heat treatment parameters item by item, and improving the automation level of the heat treatment process and the consistency of the heat treatment quality of the weld joint. In summary, the heat treatment control method for electrothermal alloy wire welded joints provided in this application embodiment can automatically match heat treatment process parameters according to the material and size of the electrothermal alloy wire, and achieve precise heat treatment of the welded joints through self-resistance heating combined with real-time temperature closed-loop control, thereby improving heat treatment efficiency, temperature control accuracy, process stability, automation level, and consistency of heat treatment quality of welded joints of different specifications.

[0051] In some embodiments, before the electrothermal alloy wire generates Joule heat by applying a working current to the electrodes clamped on both sides of the weld joint, the heat treatment control method for the electrothermal alloy wire weld joint may further include: applying a preset detection current to the electrodes to obtain the voltage drop across the two ends of the electrothermal alloy wire segment between the electrodes; determining the initial resistance value of the electrothermal alloy wire segment based on the preset detection current and the voltage drop; and determining the target current adjustment range of the working current based on the initial resistance value and dimensional parameters.

[0052] In some examples, the preset detection current is a pre-set small-amplitude constant DC current used to detect the resistance characteristics of the heating alloy wire segment before the formal heating is started. The amplitude of this current is less than the working current of the formal heat treatment, and its introduction will not cause a significant temperature rise in the heating alloy wire, ensuring that the detected resistance is the initial resistance value at room temperature. The preset detection current can be accurately output by the device's inverter DC power supply module according to the preset value. Its value setting needs to take into account both detection accuracy and low heat generation requirements, and the typical value does not exceed 5 amps. For example, for the heat treatment scenario of welded joints of conventional iron-chromium-aluminum heating alloy wires, an example of a preset detection current is 3 amps.

[0053] The voltage drop across the heating alloy wire segment between the two electrodes is the potential difference formed at both ends of the wire segment when a preset detection current flows through it. This voltage drop is positively correlated with the resistance of the wire segment and serves as the fundamental data for calculating its resistance. The voltage drop can be acquired in real-time via a built-in voltage acquisition circuit connected to the conductive ends of the two electrodes. The acquired analog voltage signal is then converted from analog to digital and transmitted to the control unit for subsequent calculations. Applying a preset detection current to the electrodes to obtain the voltage drop across the heating alloy wire segment between the two electrodes allows for the acquisition of the true electrical parameters of the heating alloy wire segment under its current clamping state without altering the wire's temperature. This avoids parameter deviations caused by differences in wire batch resistance, electrode contact conditions, and clamping spacing, providing accurate foundational data for subsequent power calculations and current control.

[0054] The initial resistance value is the total DC resistance of the entire section of the heating alloy wire between the two clamping electrodes at room temperature. It includes the inherent resistance of the heating alloy wire itself and the contact resistance at the electrode contact points. This value directly determines the heating power of the wire at the corresponding operating current and is a parameter for calculating heat treatment power and controlling current. For example, for a 6.0 mm diameter 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire within the clamping distance range, the initial resistance value is typically 3 milliohms. The process of determining the initial resistance value of the heating alloy wire section based on the preset detection current and voltage drop involves dividing the collected voltage drop value by the preset detection current value to calculate the initial resistance value of the current wire section.

[0055] The target current adjustment range is the upper and lower limits of the allowable output of the working current during the formal heat treatment process, including two boundary parameters: the minimum working current value and the maximum working current value. This range is used to define a reasonable range for current adjustment during subsequent temperature closed-loop control. It can avoid insufficient current output leading to an unsatisfactory heating rate, and also prevent excessive current output from causing overheating risks. At the same time, it can narrow the control adjustment range, improving the response speed and stability of temperature control. For example, for the heat treatment scenario of welding joints of 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm, the target current adjustment range is 75 amperes to 80 amperes. The process of determining the target current adjustment range based on the initial resistance value and size parameters involves calculating the minimum heating power required to achieve the target heating rate based on the target heating rate and the heat capacity of the wire segment corresponding to the size parameters. Then, the corresponding minimum working current is obtained by combining the initial resistance value. At the same time, the control unit calculates the maximum allowable heating power based on the heat loss and safety margin corresponding to the target holding temperature, and obtains the corresponding maximum working current. The minimum working current and the maximum working current together constitute the target current adjustment range of the working current.

[0056] For example, after the operator completes electrode clamping and starts the heat treatment program, the device first enters a self-test mode. The control unit outputs a command to the inverter DC power supply module, causing the power supply module to output a constant preset detection current with an amplitude of 3 amps to the two electrodes. At the same time, the device's voltage acquisition circuit collects the voltage drop signal across the two ends of the heating alloy wire between the two electrodes in real time. After analog-to-digital conversion, the signal is transmitted to the control unit. Based on the collected 9 millivolt voltage drop and the preset detection current of 3 amps, the control unit calculates the initial resistance of the wire segment as 3 milliohms using Ohm's law. Subsequently, the control unit, combined with the input 6.0 mm diameter parameter, calculates the target adjustment range of the working current for this heat treatment as 75 amps to 80 amps according to the power requirement and safety margin corresponding to the target heating rate. This completes the self-test and current range determination process, providing a limiting benchmark for subsequent formal heating and temperature closed-loop control.

[0057] By implementing the above embodiments, a preset detection current is applied to the electrode before formal heat treatment to obtain the voltage drop across the heating alloy wire segment. The initial resistance value is determined in combination with the detection current. Then, the target current adjustment range of the working current is determined based on the initial resistance value and size parameters. This allows the working current to be set specifically according to the actual resistance state, rather than using a fixed current range for heating control. This adapts to the differences in resistance of heating alloy wires of different materials, specifications, and welding states, reducing the problem of abnormal temperature rise caused by excessive or insufficient current setting. It also improves the matching degree between heat treatment process parameters and actual working conditions, providing a foundation for subsequent stable temperature control.

[0058] In some embodiments, the aforementioned heat treatment control method for electrothermal alloy wire welded joints may further include: determining target PID parameters based on initial resistance values ​​and size parameters using a preset PID parameter self-tuning model, wherein the target PID parameters may include a target proportional coefficient, a target integral time, and a target derivative time; the aforementioned adjustment of the operating current based on target heat treatment process parameters and real-time temperature adjustment may include: adjusting the operating current within the target current adjustment range using the target PID parameters based on the target heat treatment process parameters and real-time temperature adjustment.

[0059] In some examples, the preset PID parameter self-tuning model is an algorithm model that is pre-built and stored in the device's microcontroller unit. This model, officially called the Proportional Integral Derivative (PID) parameter self-tuning model, is used to automatically match the optimal closed-loop control parameters based on the actual characteristics of the heating alloy wire to be processed. The model is trained and constructed based on a large amount of experimental data on the thermal response characteristics of heating alloy wires of different materials and specifications. The inputs are the initial resistance value and dimensional parameters, and the outputs are a complete set of PID control parameters adapted to the current workpiece. This model is built and validated during the device development phase, and is stored along with the control program. During operation, it is automatically called by the control unit, eliminating the need for manual parameter tuning and model configuration by operators.

[0060] The target PID parameters are a set of control parameters specifically designed for the closed-loop temperature control of this heat treatment, calculated using a preset PID parameter self-tuning model. These parameters determine the temperature control response speed, steady-state accuracy, and dynamic stability. The target PID parameters are matched one-to-one with the material, diameter, and resistance characteristics of the heating alloy wire to be treated, avoiding the control performance degradation that occurs when using fixed PID parameters to adapt to different wire specifications. The target proportional coefficient is the coefficient of the proportional control element in the target PID parameters, corresponding to the adjustment gain of the proportional (P) control element. Its function is to proportionally adjust the output amplitude of the working current based on the deviation between the real-time temperature and the current target temperature. The larger the temperature deviation, the larger the current adjustment amplitude of the proportional element, which can quickly reduce the temperature deviation. The value of the target proportional coefficient must match the thermal inertia characteristics of the wire to be treated. An excessively large value can easily cause temperature overshoot, while an excessively small value will lead to temperature response lag. For example, for a welding joint of a 6.0 mm diameter 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire, an example target proportional coefficient of 2.2 amperes per degree Celsius is used. The target integral time is a parameter of the integral control link in the target PID parameters, corresponding to the action strength parameter of the integral (I) control link. Its function is to cumulatively correct the persistent temperature deviation, gradually eliminate the steady-state temperature error, and ensure that the temperature is stably maintained near the target value during the heat preservation stage. The shorter the target integral time, the stronger the integral correction effect and the faster the steady-state error is eliminated. However, if the value is too small, it is easy to cause temperature oscillation. For example, for the welding joint of 0Cr25Al5 grade iron-chromium-aluminum electric heating alloy wire with a diameter of 6.0 mm, the target integral time is 10 seconds. The target derivative time is a parameter in the derivative control loop of the target PID parameters, corresponding to the action strength parameter of the derivative (D) control loop. Its function is to output the adjustment quantity in advance according to the rate of change of temperature deviation, suppress the temperature fluctuation trend, reduce the overshoot during the heating stage and the temperature fluctuation during the holding stage, and improve the dynamic stability of the control process. The longer the target derivative time, the stronger the derivative suppression effect. However, if the value is too large, it can amplify the temperature acquisition noise and cause control oscillation. For example, for the welding joint of 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm, the target derivative time is 2.5 seconds.

[0061] Based on the target heat treatment process parameters and real-time temperature regulation, the process of adjusting the working current within the target current regulation range using target PID parameters takes the target temperature corresponding to each stage of the target heat treatment process parameters as the control benchmark, uses the real-time acquired welding joint temperature as the feedback input, calls the target PID parameters to complete the control quantity calculation, and outputs the corresponding working current regulation command. At the same time, the amplitude of the output working current is limited between the upper and lower limits of the target current regulation range. This execution mechanism can ensure the accuracy and stability of temperature control through the adapted PID parameters, and can also avoid output exceeding the limit by limiting the current range, eliminating the risk of over-temperature and improving the reliability of the control process. The entire calculation process is executed in real time by the device's microcontroller unit in each fixed control cycle, and the control cycle can be set from 100 milliseconds to 500 milliseconds.

[0062] For example, after the device completes the initial resistance value detection and determines the target current adjustment range, the microcontroller unit automatically calls the preset PID parameter self-tuning model. The measured initial resistance value of 3 milliohms and the diameter parameter of 6.0 mm are input into the model. After the model calculation, a complete set of target PID parameters corresponding to this heat treatment are obtained, namely the target proportional coefficient of 2.2 amps per degree Celsius, the target integral time of 10 seconds, and the target derivative time of 2.5 seconds. After entering the formal heating stage, the microcontroller unit uses the expected temperature at each moment corresponding to the target heat treatment process parameters as a reference, collects the real-time temperature of the welded joint every 200 milliseconds, calculates the deviation between the current temperature and the expected temperature, substitutes it into the target PID parameters to complete the control quantity calculation, outputs the corresponding working current adjustment command, and at the same time checks whether the output current is within the target current adjustment range of 75 amps to 80 amps. If it exceeds the boundary, it is limited to the boundary value and then output to the power module to achieve precise and stable temperature closed-loop control.

[0063] Through the implementation of the above embodiments, combined with the initial resistance value and size parameters, the target proportional coefficient, target integral time and target derivative time are determined by using a preset PID parameter self-tuning model. The corresponding target PID parameters are then used to perform closed-loop regulation of the working current within the target current regulation range. This allows the control parameters to be adaptively adjusted according to different heating alloy wires and welding joint states, without the need to use uniform PID parameters for control. This reduces temperature overshoot, oscillation or slow response caused by control parameter mismatch, improves the temperature tracking capability and dynamic control accuracy of the welding joint during heat treatment, and further enhances the stability of heat treatment.

[0064] In some embodiments, the aforementioned target heat treatment process parameters may further include a target cooling rate; after the real-time temperature is maintained at the aforementioned target holding time, the heat treatment control method for the electrothermal alloy wire welded joint may further include: reducing the operating current based on the deviation between the target holding temperature and the real-time temperature, so that the real-time temperature decreases according to the target cooling rate.

[0065] In some examples, the target cooling rate is the target controlled rate at which the temperature of the welded joint decreases over time after the heat treatment holding stage, expressed in °C / min. It is a process parameter for perfecting temperature control throughout the heat treatment process and ensuring a smooth transition of the joint's microstructure and properties. The rationality of the cooling rate directly affects the residual stress relief effect of the welded joint. An excessively fast cooling rate can easily lead to new instantaneous thermal stress inside the joint due to a sudden temperature drop, offsetting some of the stress relief results from the holding stage and even causing the risk of micro-cracks in the joint. An excessively slow cooling rate will prolong the overall heat treatment cycle of a single joint, reducing on-site operational efficiency. The target cooling rate can be obtained by the device from a preset heat treatment process database, corresponding one-to-one with the material identification and size parameters of the heating alloy wire, and is synchronously loaded with the complete set of process parameters composed of heating and holding parameters. For example, for the heat treatment scenario of iron-chromium-aluminum heating alloy wire welded joints, the selectable value range for the target cooling rate is 5 °C / min to 20 °C / min; for a 6.0 mm diameter 0Cr25Al5 grade heating alloy wire welded joint, an example of a target cooling rate is 10 °C / min.

[0066] The process of reducing the operating current based on the deviation between the target insulation temperature and the real-time temperature, so that the real-time temperature decreases according to the target cooling rate, is achieved by using the target insulation temperature at the end of the insulation stage as the cooling start temperature and calculating the expected temperature at each control moment based on the target cooling rate. The heating power of the wire is adjusted by dynamically reducing the output amplitude of the operating current, which, together with the natural heat dissipation process of the wire and the environment, allows the real-time temperature of the welded joint to decrease steadily along the target cooling rate. When the rate of decrease of the real-time temperature is faster than the expected rate corresponding to the target cooling rate, the control unit appropriately retains a small amount of operating current for heating to slow down the temperature decrease trend. When the rate of decrease of the real-time temperature is slower than the expected rate corresponding to the target cooling rate, the control unit further reduces the output of the operating current to accelerate the temperature decrease rate. This control method replaces the traditional uncontrolled natural air cooling mode, which can achieve a stable and controllable cooling process and avoid the adverse effects of sudden temperature changes on the mechanical properties and stress state of the joint.

[0067] For example, when the cumulative heat preservation time of the welded joint reaches the target heat preservation time of 10 minutes, the microcontroller unit of the device automatically ends the heat preservation control stage and switches to the cooling control mode. The microcontroller unit uses the target heat preservation temperature of 800 degrees Celsius as the cooling starting point, combined with the target cooling rate of 10 degrees Celsius / min, to calculate the expected temperature value corresponding to each fixed control cycle. At the same time, it continuously collects the real-time temperature of the welded joint, calculates the deviation between the real-time temperature and the corresponding expected temperature, and dynamically adjusts the output amplitude of the working current according to the deviation, gradually reducing the current output. If the real-time temperature drop rate is detected to be faster than expected, the microcontroller unit appropriately maintains a small working current to reheat the wire and slow down the cooling rate. If the real-time temperature drop rate is detected to be slower than expected, the working current amplitude is further reduced to accelerate the cooling process, so that the temperature of the welded joint always drops steadily along the target cooling rate. When the joint temperature drops to the preset cooling termination temperature of 500 degrees Celsius, the microcontroller unit completely cuts off the working current output, and the remaining temperature range is naturally cooled to room temperature by the wire, completing the temperature control of the entire heat treatment process.

[0068] Through the implementation of the above embodiments, after the target heat preservation time ends, the working current is gradually reduced according to the deviation between the target heat preservation temperature and the real-time temperature, so that the welded joint is cooled according to the target cooling rate. The cooling process is included in the heat treatment process control range, rather than natural cooling or artificially controlled cooling process. This allows the welded joint to complete the entire heat treatment process according to the preset cooling regime, reducing the adverse effects of cooling rate fluctuations on the microstructure and residual stress of the welded joint, and improving the integrity and stability of the heat treatment process of the welded joint.

[0069] In some embodiments, the aforementioned operating current is provided to the electrode by the portable host unit via a flexible cable, and the portable host unit is separately disposed from the electrode; obtaining the real-time temperature at the weld joint may include: using an elastic clamping mechanism integrated on a clamp for holding the electrode to elastically attach the thermocouple end to the surface of the weld joint to obtain the real-time temperature.

[0070] In some examples, the portable main unit serves as the control and power supply core of the entire heat treatment unit. It features a portable, box-like design, with a total weight under 15 kg, allowing for single-person transport and adaptability to deployment needs at various work locations. The main unit integrates an inverter DC power module, a microcontroller unit, a human-machine interface, a temperature acquisition module, and a data storage module, providing complete functions such as current output control, temperature closed-loop calculation, process parameter management, and operational data recording. As an integrated assembly product shipped from the factory, the portable main unit can be flexibly placed on the ground, on a work trolley, or next to a workbench during on-site use, without requiring fixed installation. For example, in the assembly station scenario of a photovoltaic equipment manufacturing workshop, the portable main unit can be placed directly on the ground beside the workbench, without occupying workbench space.

[0071] Flexible cables serve as the transmission medium for electrical connections between portable main unit and electrodes. They are constructed using multi-strand fine copper core conductors with a high-temperature resistant insulating sheath, exhibiting excellent bendability and drag resistance, adaptable to complex on-site wiring requirements. Flexible cables transmit the operating current output from the main unit to the electrodes with low loss, and can also integrate temperature signal transmission cores to transmit temperature signals collected by thermocouples back to the temperature acquisition module of the main unit. Flexible cables are supplied with the device and can be selected according to the on-site working distance; common lengths include 3 meters, 4 meters, and 5 meters. For typical assembly workstation scenarios, a 4-meter flexible cable is the typical configuration, meeting the wiring requirements when the main unit is placed on the ground and the clamps are operating on a workbench. The portable main unit and the clamping electrodes are physically independent, and the two are only electrically connected and transmit signals through a flexible cable. This design is different from traditional heat treatment equipment that integrates the main unit and the heating end. It allows the main unit to be kept away from high-temperature working areas and narrow work positions, and only the lightweight electrode clamps are placed at the work point, which greatly improves the adaptability of the site space. It is especially suitable for assembly stations with limited working space, maintenance positions inside equipment and other scenarios. Operators only need to hold the lightweight clamps to complete the clamping operation, without having to move the main unit to adjust its position, which can effectively reduce the labor intensity of on-site operation.

[0072] The clamps used to hold the electrodes are handheld operating components that support the electrodes and enable clamping and connection with the heating alloy wire. The conductive contact part at the front end of the clamps is the electrode body. The clamps are ergonomically designed, with the main conductive structure made of high-conductivity copper alloy. The handle is covered with insulating and heat-insulating material to balance conductivity and operational safety. The clamps have a built-in elastic clamping mechanism that provides stable clamping pressure to ensure low-resistance and reliable electrical contact between the electrode and the heating alloy wire. For example, the entire device is equipped with two independent electrode clamps, corresponding to the electrodes on both sides of the welding joint, which are held by the operator with both hands to complete the clamping and disassembly operations.

[0073] The elastic clamping mechanism integrated into the clamp for holding the electrode is an elastic clamping component fixedly mounted on the clamp body for fixing the temperature sensing element. It usually adopts an independent cantilever structure with spring pressure, which can provide a continuous and stable clamping force. The function of this mechanism is to fix the temperature measuring end of the thermocouple, so that the thermocouple end can be synchronously attached to the surface of the welding joint during the clamping action of the clamp. This eliminates the need for the operator to hold the thermocouple separately, simplifying the operation process while ensuring the stability of the temperature measuring contact.

[0074] The process of elastically attaching the thermocouple tip to the surface of the welded joint to obtain real-time temperature involves using the clamping force of an elastic clamping mechanism to ensure that the temperature-sensing tip of the Type K thermocouple is tightly fitted to the center of the welded joint surface. The thermoelectric effect is used to collect the instantaneous temperature signal of the joint, which is then transmitted to the temperature acquisition module of the main unit. After signal conversion and calibration, the real-time temperature value of the welded joint is obtained. This elastic fit avoids gaps between the temperature-sensing tip and the joint surface, eliminating temperature measurement deviations caused by environmental heat dissipation and ensuring accurate temperature detection. Simultaneously, the elastic clamping structure can accommodate slight positional deviations, maintaining reliable contact at all times. For example, in heat treatment scenarios involving welded joints of iron-chromium-aluminum heating alloy wires, Type K thermocouples can meet temperature measurement requirements ranging from room temperature to 1000 degrees Celsius, with a measurement accuracy within ±3 degrees Celsius.

[0075] For example, the operator places the portable main unit on the ground beside the assembly workbench, pulls out a 4-meter-long flexible cable, and guides the two electrode clamps to the work point on the workbench. The operator holds the two electrode clamps with both hands, aligns them with the wire positions 30 to 50 millimeters on both sides of the welding joint, and presses down the clamping handles to firmly clamp the electrodes onto the wire body. At the same time, the elastic clamping mechanism integrated on the clamps synchronously moves the temperature measuring end of the K-type thermocouple, elastically pressing it against the center of the surface of the welding joint, completing the clamping and temperature measurement deployment. After starting the heat treatment program, the inverter DC power module inside the portable main unit outputs a controllable working current. The working current is transmitted to the electrodes on both sides through the flexible cable, and then flows into the electrothermal alloy wire segment to generate Joule heat to achieve heating. The K-type thermocouple collects the temperature signal of the welding joint in real time, and transmits it back to the temperature acquisition module of the main unit through the signal transmission core in the flexible cable. After conversion and calibration, the real-time temperature value is obtained, providing a stable and reliable feedback basis for temperature closed-loop control.

[0076] The complete heat treatment apparatus described in this article (hereinafter referred to as the "apparatus") mainly consists of a portable box-type main unit, a detachable clamping electrode assembly, and supporting auxiliary components. The main unit is designed for portability, with a total weight controlled to within 15 kg, supporting single-person transport to adapt to deployment requirements at different work sites. The main unit integrates an inverter-type DC power supply module employing high-frequency inverter technology to achieve wide-range adjustable current output; a microcontroller unit running proportional-integral-derivative temperature control algorithms and PID parameter self-tuning algorithms, capable of comprehensively managing the entire heat treatment process, including resistance detection, current control, process curve execution, and data recording; a human-machine interface for process parameter setting and real-time operation data display; a temperature acquisition module supporting K-type thermocouple signal input; and a universal serial bus (Universal Serial Bus) supporting the storage of process curves and heat treatment records. The data storage module (USB-exported) can be flexibly placed on the ground, on a work cart, or next to a workbench during field use, without the need for fixed installation. The detachable clamping electrode assembly includes two independent electrode clamps, each electrically connected to the main unit via a flexible cable. The clamp body is made of high-conductivity copper alloy and features an ergonomic design for handheld operation. The front end has replaceable V-groove contact heads, allowing for matching contact heads of different wire diameters. The V-groove structure enables automatic wire alignment during clamping, ensuring good electrical contact. The contact heads can be quickly replaced via threads or snap-fit. The clamps have a built-in elastic clamping mechanism that provides stable contact via spring or pneumatic means. The clamp body integrates a thermocouple holding mechanism, which ensures low contact resistance under high current conditions. This allows the K-type thermocouple tip to be elastically attached to the surface of the welding joint of the wire to be heat-treated, enabling real-time temperature detection. The supporting auxiliary components include a heat insulation protective cover and a process parameter database module. The heat insulation protective cover is an openable cover made of semi-transparent heat insulation material, which can be wrapped around the outside of the area to be heat-treated to reduce heat loss and improve temperature control accuracy, while protecting the operator from high-temperature radiation. The process parameter database module is pre-set with recommended process parameters for preheating and post-weld heat treatment of various grades of iron-chromium-aluminum heating alloys corresponding to different wire diameters. Users only need to select the grade and wire diameter, and the system will automatically match and recommend the corresponding process parameters.

[0077] By implementing the above embodiments, the portable host unit is separated from the electrode, and the working current is provided to the electrode through a flexible cable, enabling the heat treatment equipment to adapt more flexibly to different installation positions and on-site welding environments. At the same time, the elastic clamping mechanism set on the clamp ensures that the thermocouple end is always elastically attached to the surface of the welding joint to obtain real-time temperature, which can reduce temperature measurement errors caused by unstable thermocouple contact, improve the accuracy and continuity of welding joint temperature acquisition, and thus improve the reliability of working current regulation and the accuracy of heat treatment temperature control.

[0078] In some embodiments, before the electrothermal alloy wire generates Joule heat by applying a working current to the electrodes clamped on both sides of the weld joint, the heat treatment control method for the electrothermal alloy wire weld joint may further include: determining a target contact head identifier in a preset contact head specification database according to size parameters; outputting the target contact head identifier to prompt the installation of a V-groove contact head with a corresponding target contact head identifier onto the electrode, wherein the V-groove contact head is used to automatically center the electrothermal alloy wire during clamping.

[0079] In some examples, the preset contact head specification database is a set of contact head specification parameters pre-built and stored in the portable host unit's data storage module. This database is used to match corresponding contact head components to heating alloy wires of different diameters. It contains a complete set of standardized parameters for replaceable contacts, with each entry corresponding to a specific contact head. This includes the contact head's unique identifier, compatible wire diameter range, V-groove structure parameters, rated current carrying capacity, and other information. All entries have undergone conductivity testing and clamping reliability verification. The preset contact head specification database completes data entry and validity verification during the device development phase and is stored along with the device control program. End users can directly access and retrieve this information without manually entering or modifying parameters. For example, for conventional heat treatment scenarios involving iron-chromium-aluminum heating alloy wires, typical entries in this database include contact head information for commonly used wire diameters of 4.0 mm, 5.0 mm, 6.0 mm, and 8.0 mm.

[0080] The target contact head identifier is a unique identification mark that matches the size parameters of the current electrothermal alloy wire to be processed. It is used to distinguish contact heads of different specifications and guide operators to quickly complete the selection. The target contact head identifier is obtained by the microcontroller unit of the device after traversing and matching the preset contact head specification database with the input size parameters as search conditions. It is the index field of the corresponding entry in the database. The target contact head identifier can adopt an alphanumeric encoding format, which contains the contact head structure type and the compatible wire diameter information, making it easy for operators to identify intuitively. For example, for a V-groove contact head that is compatible with a wire diameter of 6.0 mm, the corresponding target contact head identifier is "CT-V6.0", where "CT" represents the contact head, "V" represents the V-groove structure, and "6.0" represents the compatible wire diameter of 6.0 mm.

[0081] The V-groove contact head is a conductive component installed at the front end of the electrode clamp, directly contacting the surface of the heating alloy wire. It is made of a high-conductivity, wear-resistant copper alloy, and its working surface in contact with the wire has a V-shaped groove structure. The V-groove structure has an automatic centering characteristic; during clamping, wires of different diameters fall into the V-groove and automatically slide to the center position, ensuring accurate relative positioning between the wire and the contact head without manual adjustment. It also forms two stable contact lines, ensuring low contact resistance and uniform current distribution under high current conditions, avoiding localized overheating. The V-groove contact head is a replaceable component, fixed to the electrode ends of the clamp via threaded connection or snap-fit. Operators can quickly replace it according to the specifications of the wire to be processed. For example, for a 6.0 mm diameter iron-chromium-aluminum heating alloy wire, the typical parameters for the corresponding V-groove contact head are a 90-degree groove angle, and the groove depth and opening size are adapted to a 6.0 mm diameter wire, ensuring stable contact and accurate centering after clamping.

[0082] The device outputs target contact head markings to guide the installation of V-groove contact heads with corresponding markings onto the electrodes. This automatic matching prompt reduces the need for operator experience and avoids problems such as excessive contact resistance, localized overheating, and wire misalignment caused by selecting the wrong contact head specifications, ensuring electrical stability and temperature uniformity during heat treatment. The device can output target contact head markings through text display and icon prompts on the human-machine interface, and in some scenarios, it can also provide audible reminders. After the operator selects the corresponding V-groove contact head according to the prompt information, completes the installation of the contact heads of the two electrode clamps, and confirms the installation, the subsequent wire clamping steps can be performed.

[0083] For example, after the operator inputs the size parameter of the electrothermal alloy wire to be processed as a diameter of 6.0 mm into the human-machine interface of the portable host unit, the microcontroller unit automatically calls the preset contact head specification database and matches it with the wire diameter of 6.0 mm as the search condition. The target contact head identified as "CT-V6.0" is found in the search results. The microcontroller unit then outputs this identification information to the display screen of the human-machine interface, displaying the recommended contact head model in a prominent font, along with the text prompt "Please install the V-shaped contact head that is compatible with φ6.0 mm wire" to guide the operator to complete the selection. According to the interface prompts, the operator finds the V-groove contact head identified as "CT-V6.0" from the accessory box, and fixes the two contact heads to the front electrode ends of the two electrode clamps by screwing them on. After confirming that the installation is secure and the contact end faces are flush, the operator clicks the confirmation button on the human-machine interface to complete the contact head selection and installation process, and can then proceed to the subsequent wire clamping and temperature measurement deployment steps.

[0084] Through the implementation of the above embodiments, the corresponding target contact head identifier is determined from the preset contact head specification database according to the size parameters of the heating alloy wire, and the installation of a contact head with a corresponding V-groove structure is prompted, so that heating alloy wires of different diameters can obtain a matching clamping structure. Automatic centering is achieved during the clamping process, reducing the impact of factors such as electrode offset, inconsistent contact position and contact resistance changes on heating uniformity, and improving the stability of current transmission and the consistency of heat treatment process during the heat treatment of welded joints.

[0085] In some embodiments, the aforementioned heat treatment control method for electrothermal alloy wire welded joints may further include: generating a temperature-time curve based on temperature and time data during the heat treatment process; acquiring current and voltage data applied during the heat treatment process; and associating and storing the temperature-time curve, current data, voltage data, and target heat treatment process parameters to generate a heat treatment process record.

[0086] In some examples, the temperature-time curve is a continuous curve plotted with time on the x-axis and the real-time temperature of the weld joint on the y-axis. It comprehensively presents the temperature evolution trend of the joint over time throughout the entire heat treatment process, covering the entire temperature change process during the heating, holding, and cooling stages. This curve visually reflects process indicators such as the stability of temperature control, the compliance of the heating rate, the fluctuation range of the holding temperature, and the consistency of the cooling rate. It serves as a visual basis for evaluating heat treatment quality and tracing the compliance of process execution. The temperature-time curve can be automatically generated by the device's microcontroller unit based on the collected time-series temperature data. During the processing, the interface can be updated and displayed in real time. After the heat treatment is completed, the process record can be exported and saved. For example, for the heat treatment of 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm after welding, the typical shape of the corresponding temperature-time curve is as follows: the initial segment rises at a uniform rate from room temperature with an approximately linear trend, and the heating rate is maintained at 15 degrees Celsius per minute; after the temperature reaches 800 degrees Celsius, it turns into an approximately horizontal linear segment, with temperature fluctuations controlled within ±3 degrees Celsius, lasting for 10 minutes; after the heat preservation is completed, it turns into a uniform descent segment, with the cooling rate maintained at 10 degrees Celsius per minute.

[0087] The process of generating a temperature-time curve based on temperature and time data during heat treatment involves the microcontroller unit synchronously collecting real-time temperature values ​​of the weld joint and corresponding system timestamps at a fixed sampling period throughout the entire operating cycle after the heat treatment program starts. This forms a one-to-one time-series temperature data set. The sampling period can be set according to the control accuracy requirements, with a typical value of 200 milliseconds, ensuring sufficient continuity and detail in the curve. During the heat treatment process, the microcontroller unit connects new data points to existing curves synchronously with the data acquisition, achieving real-time updates to the temperature-time curve. After the heat treatment process is completed, the microcontroller unit fits and smooths all time-series data points in chronological order to generate a complete final temperature-time curve.

[0088] The current and voltage data applied during heat treatment are time-series operational data reflecting the electrical input status of the entire heat treatment process. The current data is the real-time sampled value of the operating current output from the inverter DC power module to the two electrodes, while the voltage data is the real-time sampled value of the output voltage across the heating alloy wire segment between the two electrodes at the corresponding moment. Both are collected synchronously with the same sampling period and correspond one-to-one. This data can be used to calculate the actual heating power at different stages, verify the electrical contact stability between the electrodes and the wire, and troubleshoot contact anomalies during operation. It serves as a parameter for tracing the electrical operating status of the heat treatment process. For example, in the heat treatment scenario for a 6.0 mm diameter 0Cr25Al5 heating alloy wire, the typical variation pattern of the current data is as follows: the current gradually increases to the target range in the initial heating stage, stabilizes in the 75 to 80 ampere range during the heating stage, and dynamically adjusts slightly during the holding stage according to the temperature closed-loop control. The corresponding voltage data changes synchronously with the current, with a typical value range of 225 mV to 240 mV.

[0089] The heat treatment process record is a standardized, structured data file that fully records the entire process of heat treatment for a single welded joint. It includes three types of content: process reference information, process operation data, and result curves. It is used to achieve traceability, verifiability, and replayability of the heat treatment process. This record can meet the quality control requirements of the production site, support subsequent process optimization, quality problem investigation, and production compliance verification. End users can export and archive it or upload it to the enterprise production management system. Each heat treatment process record has a unique record number and generation timestamp, and can be searched by material, wire diameter, treatment type, and other dimensions. The process of associating and storing temperature-time curves, current data, voltage data, and target heat treatment process parameters to generate a heat treatment process record involves using the target heat treatment process parameters corresponding to this heat treatment as reference information, specifically including the heating alloy wire material identification, size parameters, treatment type, target heating rate, target holding temperature, target holding time, and target cooling rate; using the synchronously collected temperature-time curves, full-cycle current time-series data, and full-cycle voltage time-series data as process operation information; and binding a unified unique record number and heat treatment start timestamp to all information, storing them in a complete structured data file after association, thus generating the corresponding heat treatment process record.

[0090] For example, in the post-weld heat treatment of a 6.0 mm diameter 0Cr25Al5 grade electrothermal alloy wire welded joint, after the operator starts the heat treatment program, the microcontroller unit synchronously collects real-time temperature data, working current data, and output voltage data of the welded joint according to a fixed sampling period of 200 milliseconds, and binds a corresponding system timestamp to each set of data. During operation, the microcontroller unit generates and updates the temperature-time curve on the human-machine interface in real time based on the collected temperature and time data, and synchronously displays the current current and voltage values. When the cumulative holding time reaches 10 minutes and the cooling stage reaches the preset termination temperature, the heat treatment program officially ends. The microcontroller unit organizes and smooths all the data collected throughout the cycle, generating a complete final temperature-time curve. Subsequently, the microcontroller unit binds the target heat treatment process parameters, complete temperature-time curve, full-cycle current timing data, and full-cycle voltage timing data obtained in this matching to a unified record number, associates and stores them in the data storage module, and generates a corresponding heat treatment process record. The operator can export this record as an electronic file through the universal serial bus interface for quality department review and archiving and subsequent process optimization analysis.

[0091] By implementing the above embodiments, a temperature-time curve is generated during the heat treatment process, and temperature data, time data, current data, voltage data, and target heat treatment process parameters are associated and stored to form a complete heat treatment process record. This ensures that the heat treatment process of each welded joint has traceable data, which facilitates subsequent analysis of heat treatment quality, verification of process execution, and optimization of heat treatment parameters. It also improves the standardization of heat treatment process management and provides data support for the continuous optimization of heat treatment processes for different materials and specifications of electric heating alloy wires.

[0092] In some embodiments, the aforementioned step 102 may include: matching target heat treatment process parameters from a preset heat treatment process database based on the treatment type identifier, material identifier, and size parameters of the electrothermal alloy wire to be treated, wherein the treatment type identifier is preheating before welding or heat treatment after welding.

[0093] In some examples, the processing type identifier is an identification mark used to distinguish the heat treatment process type of the electrothermal alloy wire welded joint. It is one of the search dimensions of the preset heat treatment process database. This identifier corresponds to two different heat treatment processes in the welding process: preheating before welding and postheating after welding. The process objectives and parameter settings of the two are significantly different, and the corresponding parameter groups need to be matched separately. The processing type identifier can be selected and confirmed by the operator through the human-machine interface of the portable host unit before the heat treatment program is started. After receiving the selection instruction, the device uses it as one of the search conditions and substitutes it into the database matching process. The selectable values ​​of the processing type identifier are fixed to two categories, corresponding to the preheating process and the postheating process, respectively. The typical identifier presentation form can be the text option preheating before welding and postheating after welding, or it can be in the form of code for internal indexing, such as PRE-01 and POST-02.

[0094] Preheating before welding is a heat treatment process that preheats the weld joint and its surrounding heating wire area before welding. It is a key pre-process for improving the welding quality of iron-chromium-aluminum (FeCrA) heating alloys. FeCrA alloys have poor plasticity, and the heat-affected zone is prone to grain coarsening and embrittlement. Large temperature gradients during welding can induce significant thermal stress, easily leading to weld cracks. Preheating reduces the temperature difference between the welding area and the base material, minimizes the thermal gradient and stress during welding, and inhibits the formation of weld cracks. This can slow down the cooling rate after welding and prevent the joint from developing a hard and brittle structure. The preheating process parameters are generally characterized by lower temperatures and shorter holding times. The target holding temperature is usually in the range of 200 degrees Celsius to 400 degrees Celsius, and the holding time is in the range of 2 minutes to 10 minutes depending on the wire diameter. For example, for a 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire with a diameter of 6.0 mm, the typical preheating process parameters are a target heating rate of 20°C / min, a target holding temperature of 300 degrees Celsius, and a target holding time of 5 minutes.

[0095] Post-weld heat treatment is a heat treatment process that involves heating and maintaining the temperature of the formed welded joint area after the welding operation is completed. It is a process that ensures the high-temperature service reliability of the electrothermal alloy wire welded joint. After welding of iron-chromium-aluminum alloys, significant residual welding stress exists in the joint area. Simultaneously, the heat-affected zone exhibits coarse grains and reduced plasticity. Directly placing these components into high-temperature service can easily lead to joint cracking and premature failure. Post-weld heat treatment aims to effectively eliminate residual welding stress, improve the microstructure of the joint area, restore the joint's plasticity and toughness, stabilize its dimensions and performance, and ultimately enhance the high-temperature oxidation resistance and creep rupture life of the welded joint, extending the overall service life of the heating element. The process parameters for post-weld heat treatment are generally characterized by high temperatures and long holding times. The target holding temperature is typically between 700°C and 850°C, and the holding time varies from 5 to 30 minutes depending on the wire diameter. For example, for a 6.0 mm diameter 0Cr25Al5 grade iron-chromium-aluminum heating alloy wire, the typical process parameters for post-weld heat treatment are a target heating rate of 15°C / min, a target holding temperature of 800°C, and a target holding time of 10 minutes.

[0096] The process of matching target heat treatment process parameters from a pre-set heat treatment process database based on the treatment type identifier, material identifier, and size parameters of the electrothermal alloy wire to be treated is a three-dimensional precise matching process retrieval logic. Each process parameter entry in the pre-set heat treatment process database uses the three dimensions of treatment type, material grade, and wire diameter as a joint index, corresponding to a set of exclusive target heat treatment process parameters, which can simultaneously meet the triple adaptation requirements of process objectives, material characteristics, and specifications. Compared with the method of using only material and size as search conditions, this matching logic further refines the process granularity, avoids the problem of mixing preheating and postheating processes, and ensures that the heat treatment effect under different processes can meet the standards. The matching process is automatically executed by the microcontroller unit of the device. The operator only needs to complete the selection and input of three parameters and does not need to have professional heat treatment process design capabilities to obtain standardized and adapted process parameters.

[0097] For example, after the operator starts the heat treatment parameter setting process through the human-machine interface of the portable host unit, they first select the treatment type for this heat treatment in the process type option. If this is a preheating process before welding, they select the preheating label; if this is a performance recovery process after welding, they select the post-weld heat treatment label. Then, the operator selects the 0Cr25Al5 grade corresponding to the wire to be treated from the material grade list, completing the material label input. Finally, they enter the nominal diameter of the wire to be treated, 6.0 mm, in the wire diameter input field, completing the submission of the dimensional parameters. After receiving the three input parameters, the microcontroller unit will... The system uses a pre-defined heat treatment process database as a joint search condition to perform precise matching of the pre-stored entries in the database. If the operator selects a preheating treatment type, the system matches the target heat treatment process parameters with a holding temperature of 300 degrees Celsius and a holding time of 5 minutes. If the operator selects a postheating treatment type, the system matches the target heat treatment process parameters with a holding temperature of 800 degrees Celsius and a holding time of 10 minutes. After matching, the microcontroller unit displays the complete set of target heat treatment process parameters on the human-machine interface for the operator to confirm. Once confirmed, these parameters serve as the execution benchmark for this heat treatment.

[0098] Through the implementation of the above embodiments, when determining the target heat treatment process parameters, a treatment type identifier is further introduced, and the target heat treatment process parameters are matched together with the material identifier and size parameters. This allows the preheating before welding and the post-weld heat treatment to adopt the corresponding heat treatment regimes, rather than selecting the process solely based on the material and size. This approach can take into account the process requirements of different heat treatment stages, improve the precision of heat treatment process parameter matching, and ensure that appropriate temperature control can be achieved at different process stages. This further improves the stability of the heat treatment of the electrothermal alloy wire welded joint and the final treatment quality.

[0099] Furthermore, as an implementation of the aforementioned method embodiments, this application also provides a heat treatment control device for electrothermal alloy wire welded joints, used to implement the aforementioned method embodiments. This device embodiment corresponds to the aforementioned method embodiments. For ease of reading, this embodiment of the heat treatment control device for electrothermal alloy wire welded joints will not repeat the details of the aforementioned method embodiments one by one, but it should be clear that the device in this application embodiment can correspondingly implement all the contents of the aforementioned method embodiments. For example... Figure 2 As shown, the heat treatment control device 20 for the welding joint of the electrothermal alloy wire includes: a data acquisition unit 201, a parameter determination unit 202, a temperature acquisition unit 203, and a heating control unit 204. The data acquisition unit 201 acquires the material identification and dimensional parameters of the electrothermal alloy wire to be treated. The parameter determination unit 202 determines target heat treatment process parameters from a preset heat treatment process database based on the aforementioned material identification and dimensional parameters. The target heat treatment process parameters may include a target heating rate, a target holding temperature, and a target holding time. The temperature acquisition unit 203 applies a working current to the electrodes clamped on both sides of the welding joint on the electrothermal alloy wire to generate Joule heat, thereby acquiring the real-time temperature at the welding joint. The heating control unit 204 adjusts the working current based on the target heat treatment process parameters and the real-time temperature, causing the real-time temperature to rise to the target holding temperature at the target heating rate and maintain the target holding time to complete the heat treatment of the welding joint.

[0100] In some embodiments, the temperature acquisition unit 203 is further configured to apply a preset detection current to the electrodes to obtain the voltage drop across the two ends of the electrothermal alloy wire segment between the two electrodes; determine the initial resistance value of the electrothermal alloy wire segment based on the preset detection current and voltage drop; and determine the target current adjustment range of the operating current based on the initial resistance value and size parameters.

[0101] In some embodiments, the heating control unit 204 is further configured to determine target PID parameters based on the initial resistance value and size parameters through a preset PID parameter self-tuning model. The target PID parameters include a target proportional coefficient, a target integral time, and a target derivative time. Based on the target heat treatment process parameters and real-time temperature regulation, the operating current is adjusted within the target current regulation range using the target PID parameters.

[0102] In some embodiments, the target heat treatment process parameters further include a target cooling rate; the heating control unit 204 is also used to reduce the operating current based on the deviation between the target holding temperature and the real-time temperature, so that the real-time temperature decreases according to the target cooling rate.

[0103] In some embodiments, the operating current is provided to the electrode by the portable host unit via a flexible cable, and the portable host unit is separately disposed from the electrode; the temperature acquisition unit 203 is also used to elastically attach the thermocouple end to the surface of the welding joint by means of an elastic clamping mechanism integrated on the clamp for holding the electrode, so as to obtain the real-time temperature.

[0104] In some embodiments, the heat treatment control device 20 for welding electrothermal alloy wire joints includes an installation prompting unit for determining a target contact head identifier in a preset contact head specification database based on size parameters; and outputting the target contact head identifier to prompt the installation of a V-groove contact head with a corresponding target contact head identifier onto the electrode, wherein the V-groove contact head is used to automatically center the electrothermal alloy wire during clamping.

[0105] In some embodiments, the heat treatment control device 20 for electrothermal alloy wire welding joints includes an installation prompting unit for generating a temperature-time curve based on temperature and time data during the heat treatment process; acquiring current and voltage data applied during the heat treatment process; and associating and storing the temperature-time curve, current data, voltage data, and target heat treatment process parameters to generate a heat treatment process record.

[0106] In some embodiments, the parameter determination unit 202 is further configured to match the target heat treatment process parameters from a preset heat treatment process database based on the treatment type identifier, material identifier, and size parameters of the electrothermal alloy wire to be treated, wherein the treatment type identifier is preheating before welding or heat treatment after welding.

[0107] This application also provides a computer-readable storage medium storing computer-executable instructions or computer programs, which, when executed by a processor, will cause the processor to perform any step of the heat treatment control method for electrothermal alloy wire welded joints provided in this application.

[0108] In some embodiments, the computer-readable storage medium may be a random access memory (RAM), a read-only memory (ROM), flash memory, a magnetic surface memory, an optical disc, or a compact disc read-only memory (CD-ROM); or it may be a variety of devices that include one or any combination of the above-mentioned memories.

[0109] In some embodiments, computer-executable instructions may take the form of programs, software, software modules, scripts, or code, written in any form of programming language (including compiled or interpreted languages, or declarative or procedural languages), and may be deployed in any form, including as stand-alone programs or as modules, components, subroutines, or other units suitable for use in a computing environment.

[0110] In some embodiments, computer-executable instructions may, but do not necessarily, correspond to files in a file system, and may be stored as part of a file that holds other programs or data, for example, in one or more scripts in a HyperText Markup Language (HTML) document, in a single file dedicated to the program in question, or in multiple co-located files (e.g., files that store one or more modules, subroutines, or code sections).

[0111] In some embodiments, computer-executable instructions may be deployed to execute on an electronic device, or on multiple electronic devices located at one location, or on multiple electronic devices distributed across multiple locations and interconnected via a communication network.

[0112] like Figure 3 As shown, this application also provides an electronic device 30, including a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor. When the processor 320 executes the computer program 311, it implements any step of the above-mentioned heat treatment control method for the welding joint of the electrothermal alloy wire.

[0113] This application also provides a computer program product comprising a computer program or computer-executable instructions stored in a computer-readable storage medium. A processor of an electronic device reads the computer program or computer-executable instructions from the computer-readable storage medium and executes the computer program or computer-executable instructions, causing the electronic device to perform any step of the heat treatment control method for the electrothermal alloy wire welded joint described above.

[0114] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A method for controlling the heat treatment of welded joints of electrothermal alloy wires, characterized in that, include: Obtain the material identification and dimensional parameters of the heating alloy wire; Based on the material identifier and the size parameters, target heat treatment process parameters are determined from a preset heat treatment process database, wherein the target heat treatment process parameters include target heating rate, target holding temperature and target holding time; By applying a working current to the electrodes clamped on both sides of the welding joint on the heating alloy wire, Joule heating is generated in the heating alloy wire to obtain the real-time temperature at the welding joint. The operating current is adjusted based on the target heat treatment process parameters and the real-time temperature, so that the real-time temperature rises to the target holding temperature at the target heating rate and is maintained for the target holding time, thereby completing the heat treatment of the welded joint.

2. The heat treatment control method for welded joints of electrothermal alloy wires according to claim 1, characterized in that, Before the electrothermal alloy wire generates Joule heat by applying a working current to the electrodes clamped on both sides of the weld joint, the heat treatment control method for the weld joint of the electrothermal alloy wire further includes: A preset detection current is applied to the electrode to obtain the voltage drop across the two ends of the electrothermal alloy wire segment between the two electrodes; Based on the preset detection current and the voltage drop, the initial resistance value of the electrothermal alloy wire segment is determined; Based on the initial resistance value and the size parameters, the target current adjustment range of the operating current is determined.

3. The heat treatment control method for welded joints of electrothermal alloy wires according to claim 2, characterized in that, The heat treatment control method for the electrothermal alloy wire welded joint further includes: Based on the initial resistance value and the size parameters, the target PID parameters are determined by a preset PID parameter self-tuning model. The target PID parameters include the target proportional coefficient, the target integral time, and the target derivative time. The adjustment of the operating current based on the target heat treatment process parameters and the real-time temperature includes: Based on the target heat treatment process parameters and the real-time temperature regulation, the operating current is adjusted within the target current regulation range using the target PID parameters.

4. The method for controlling the heat treatment of welded joints of electrothermal alloy wires according to claim 1, characterized in that, The target heat treatment process parameters also include the target cooling rate; After maintaining the target holding time at the real-time temperature, the heat treatment control method for the electrothermal alloy wire welded joint further includes: The operating current is reduced based on the deviation between the target insulation temperature and the real-time temperature, so that the real-time temperature decreases according to the target cooling rate.

5. The heat treatment control method for welded joints of electrothermal alloy wires according to claim 1, characterized in that, The operating current is supplied to the electrode by the portable host unit via a flexible cable, and the portable host unit is separately disposed from the electrode; The step of obtaining the real-time temperature at the weld joint includes: The thermocouple end is elastically fitted to the surface of the weld joint by an elastic clamping mechanism integrated into the clamps used to hold the electrode, so as to obtain the real-time temperature.

6. The method for controlling the heat treatment of welded joints of electrothermal alloy wires according to claim 1, characterized in that, Before the electrothermal alloy wire generates Joule heat by applying a working current to the electrodes clamped on both sides of the weld joint, the heat treatment control method for the weld joint of the electrothermal alloy wire further includes: Based on the aforementioned size parameters, the target contact head identifier is determined from the preset contact head specification database; The target contact head identifier is output to prompt the installation of a V-groove contact head with a corresponding target contact head identifier onto the electrode, wherein the V-groove contact head is used to automatically center the heating alloy wire during clamping.

7. The method for controlling the heat treatment of welded joints of electrothermal alloy wires according to claim 1, characterized in that, The heat treatment control method for the electrothermal alloy wire welded joint further includes: Based on the temperature and time data during the heat treatment process, a temperature-time curve is generated. Acquire the applied current and voltage data during the heat treatment process; The temperature-time curve, the current data, the voltage data, and the target heat treatment process parameters are associated and stored to generate a heat treatment process record.

8. The method for controlling the heat treatment of welded joints of electrothermal alloy wires according to claim 1, characterized in that, The step of determining the target heat treatment process parameters from a preset heat treatment process database based on the material identifier and the size parameters includes: Based on the processing type identifier of the electrothermal alloy wire to be processed, the material identifier, and the size parameters, the target heat treatment process parameters are obtained by matching from the preset heat treatment process database, wherein the processing type identifier is preheating before welding or heat treatment after welding.

9. A heat treatment control device for welding joints of electrothermal alloy wires, characterized in that, include: The data acquisition unit is used to acquire the material identification and dimensional parameters of the electrothermal alloy wire to be processed; The parameter determination unit is used to determine target heat treatment process parameters from a preset heat treatment process database based on the material identifier and the size parameters, wherein the target heat treatment process parameters include target heating rate, target holding temperature and target holding time; The temperature acquisition unit is used to obtain the real-time temperature at the welding joint by applying a working current to the electrodes clamped on both sides of the welding joint on the heating alloy wire to generate Joule heat in the heating alloy wire. The heating control unit is used to adjust the operating current based on the target heat treatment process parameters and the real-time temperature, so that the real-time temperature rises to the target holding temperature at the target heating rate and is maintained for the target holding time, so as to complete the heat treatment of the welded joint.

10. An electronic device, comprising: A memory and a processor, characterized in that the processor, when executing a computer program stored in the memory, implements the steps of the heat treatment control method for electrothermal alloy wire welded joints as described in any one of claims 1 to 8.

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