Thermal processing condition setting device, thermal processing device, thermal processing condition setting method, and thermal processing condition setting program

Abstract

The present invention provides a thermal processing condition setting device that allows for easy acquisition of combinations of control parameters necessary to obtain desired construction results. [Solution] The welding condition setting device 30 comprises a teaching pendant 60, a storage unit 26, and a calculation unit 25. First information regarding the workpiece 90 is input from the teaching pendant 60. The storage unit 26 temporarily stores the first information and also stores a database and relational formulas that describe the relationship between the first information and a group of control parameters for controlling each part of the laser filler welding apparatus 100. The calculation unit 25 derives a group of control parameters based on the first information and at least one of the database and relational formulas. The first information includes at least work information regarding the shape and material of the workpiece 90 and the required specifications regarding the welding of the workpiece 90.

Description

[Technical Field]

[0001] This disclosure relates to a thermal processing condition setting device, a thermal processing apparatus, a thermal processing condition setting method, and a thermal processing condition setting program. [Background technology]

[0002] Conventionally, when performing arc welding or laser welding, the welding head attached to the tip of the manipulator is taught the movement trajectory in order to move along the desired weld line. Various teaching assistance devices have also been proposed to perform this teaching work accurately.

[0003] For example, Patent Document 1 discloses a teaching assistance device comprising a camera mounted on a rotating shaft continuous with the movement of a laser head, a camera control device, an image holding circuit and processing circuit for images captured by the camera, and an image display device.

[0004] Furthermore, when performing visual inspection using a shape measurement sensor attached to a welding head, it is also necessary to teach the sensor's scanning operation. For example, Patent Document 2 discloses an offline teaching device comprising a generation unit that generates multiple 3D regions scanned by a sensor based on the positional information of multiple welding lines and the scanning range of the sensor, and a control unit that generates and outputs an auxiliary screen in which multiple welding lines and 3D regions excluding overlapping areas with the welding lines are arranged in a virtual space.

[0005] By using these teaching devices or teaching assistance devices, teaching tasks for manipulators and the like can be performed quickly and accurately. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Utility Model Publication No. 03-031079 [Patent Document 2] International Publication No. 2023 / 105980 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] Incidentally, thermal processing equipment, such as welding equipment, is composed of a heat source generating unit, such as a welding power supply or laser oscillator, a processing head, such as a welding torch or laser head, and a manipulator that holds and moves the processing head. In addition, in laser processing equipment, depending on the type of laser processing, the laser beam may be scanned or rotated towards the workpiece in a predetermined direction. In this case, mechanical components are installed inside the laser head to control the optical path of the laser beam emitted from the laser head.

[0008] When attempting to perform a desired machining process, it is necessary to coordinate the operation of the heat source, manipulator, and, if using laser light, the mechanical components within the laser head. However, typically, the laser oscillator, manipulator, and laser head are manufactured by different companies. In this case, while optimal control parameters are set individually for each device, the combination of control parameters when multiple devices operate in conjunction must be set by the user, which is an extremely difficult task. Furthermore, in order to obtain the desired machining results, the user must individually search for combinations of control parameters according to the shape of the workpiece, etc., which is not only an extremely difficult task but also very time-consuming.

[0009] This disclosure has been made in view of the foregoing, and its purpose is to provide a thermal processing condition setting device, a thermal processing device, a thermal processing condition setting method, and a thermal processing condition setting program that can easily obtain a combination of control parameters for obtaining a desired construction result. [Means for solving the problem]

[0010] To achieve the above objective, the thermal processing condition setting device according to this disclosure comprises at least an input unit for inputting first information relating to a workpiece, a workpiece; a storage unit for temporarily storing the first information and storing a database and relational expressions describing the relationship between the first information and a group of control parameters for controlling each part of the thermal processing device; and a calculation unit for deriving the group of control parameters based on the first information and at least one of the database and the relational expressions, wherein the first information includes at least workpiece information relating to the shape and material of the workpiece and the required specifications relating to the thermal processing of the workpiece.

[0011] The thermal processing apparatus according to this disclosure is characterized by comprising the thermal processing condition setting device.

[0012] The thermal processing condition setting method according to this disclosure comprises at least a first step of receiving input of first information relating to a workpiece, which is a workpiece, and a second step of deriving a group of control parameters based on at least one of a database describing the relationship between the first information and a group of control parameters for controlling each part of a thermal processing apparatus and a relational expression, wherein the first information includes at least workpiece information relating to the shape and material of the workpiece and the required specifications relating to the thermal processing of the workpiece.

[0013] The thermal processing condition setting program relating to this disclosure causes one or more processors to execute the thermal processing condition setting method. [Effects of the Invention]

[0014] According to this disclosure, a combination of control parameters for obtaining the desired construction results can be easily obtained. [Brief explanation of the drawing]

[0015] [Figure 1] This is a schematic diagram of a laser filler welding apparatus according to an embodiment. [Figure 2] This is a schematic cross-sectional view of a laser head. [Figure 3]It is a functional block diagram of a controller. [Figure 4] It is a schematic diagram explaining the outline of data stored in a storage unit. [Figure 5] It is a flowchart showing a procedure for setting welding conditions. [Figure 6] It is a diagram showing an example of a first condition and a control parameter group. [Figure 7] It is a schematic diagram showing an irradiation locus of laser light in welding of a butt joint with a fillet weld. [Figure 8] It is a flowchart showing a procedure for setting welding conditions according to a modified example.

Mode for Carrying Out the Invention

[0016] Hereinafter, embodiments of the present disclosure will be described based on the drawings. Note that the following description of the preferred embodiments is merely illustrative in nature and is not intended to limit the present disclosure, its applications, or its uses.

[0017] (Embodiment) [Configuration of Laser Filler Welding Device] FIG. 1 is a schematic configuration diagram of a laser filler welding device according to an embodiment. FIG. 2 is a schematic cross-sectional view of a laser head. FIG. 3 is a functional block diagram of a controller. In FIG. 2, only the optical axis of the laser light LB is shown.

[0018] As shown in FIG. 1, a laser filler welding device 100 includes a laser oscillator 10, a controller 20, an optical fiber 40, a laser head 50, a manipulator 70, and a wire feeder 80.

[0019] The laser oscillator 10 has a laser light source and a power supply (not shown) and generates laser light LB by laser oscillation. The controller 20 controls the operations of the laser oscillator 10, the laser head 50, and the manipulator 70, respectively. The configuration of the controller 20 will be described in detail later.

[0020] The optical fiber 40 is connected to the laser oscillator 10 and the laser head 50, and guides the laser light LB generated by the laser oscillator 10 to the laser head 50.

[0021] As shown in Figure 2, the laser head 50 has a housing 51 having a fiber optic port 51A and an optical output port 51B, and multiple optical components are arranged inside the housing 51. The laser head 50 irradiates the workpiece 90 with laser light LB guided by the optical fiber 40.

[0022] One end of the optical fiber 40 is connected to the fiber connection port 51A, and the laser beam LB guided by the optical fiber 40 enters the interior of the housing 51. The laser beam LB that has passed through the protective glass 56 is emitted from the light emission port 51B toward the workpiece 90. The protective glass 56 prevents fumes and sputter from entering the interior of the housing 51 and adhering to the optical components. By providing the protective glass 56, a deterioration in the emission characteristics of the laser beam LB is prevented.

[0023] The collimating lens 52 parallelizes the laser beam LB emitted from one end of the optical fiber 40. The focusing lens 53 focuses the laser beam LB, which has been parallelized by the collimating lens 52, onto the surface of the workpiece 90. WD, shown in Figure 2, is the distance from the light-emitting surface of the focusing lens 53 to the surface of the workpiece 90.

[0024] Furthermore, a first optical scanning mechanism 54 and a second optical scanning mechanism 55 are provided between the focus lens 53 and the protective glass 56. The first optical scanning mechanism 54 includes a first quartz plate 54A, a first lens barrel 54B, and a first motor 54C. The first quartz plate 54A and the first lens barrel 54B are located inside the housing 51, while the first motor 54C is located outside the housing 51.

[0025] The first quartz plate 54A is a parallel plate made of quartz, and the normal to its surface makes a 45° angle with the optical axis OA of the laser beam LB incident on the inside of the housing 51. The first lens barrel 54B holds the first quartz plate 54A. The first lens barrel 54B is also connected to a rotation mechanism (not shown) connected to the first motor 54C. The first motor 54C is connected to the controller 20 and drives the aforementioned rotation mechanism by control commands from the controller 20. The rotation mechanism drives the first lens barrel 54B around the optical axis OA. The laser beam LB incident on the first quartz plate 54A is shifted along a plane perpendicular to the optical axis OA by a length corresponding to the thickness and refractive index of the first quartz plate 54A and is emitted from the first quartz plate 54A.

[0026] The second quartz plate 55A, the second lens barrel 55B, and the second motor 55C in the second optical scanning mechanism 55 have the same structure and function as the first quartz plate 54A, the first lens barrel 54B, and the first motor 54C in the first optical scanning mechanism 54, respectively. However, the second lens barrel 55B and the second quartz plate 55A held therein are located closer to the light output port 51B than the first lens barrel 54B and the first quartz plate 54A held therein. In addition, the first motor 54C and the second motor 55C are configured to operate independently.

[0027] The first optical scanning mechanism 54 and the second optical scanning mechanism 55 are operated independently or in conjunction. In this way, the optical axis of the laser beam LB emitted from the second quartz plate 55A is shifted by a predetermined length from the optical axis OA along a plane perpendicular to the optical axis OA, and rotates around the optical axis OA. Furthermore, by making the rotational phases of the first optical scanning mechanism 54 and the second optical scanning mechanism 55 different, the aforementioned predetermined length can be changed. This makes it possible, for example, to apply the laser beam LB in a helical pattern on the surface of the workpiece 90, or to trepann the workpiece 90, and to change the diameter when drilling holes.

[0028] The teaching pendant 60 is connected to the controller 20 and functions as an input unit for inputting the first condition, which will be described later. The teaching pendant 60 also functions as a teaching device for teaching the manipulator 70 to move along the weld line. Furthermore, the teaching pendant 60 can also function as a teaching device for teaching the operation of the first optical scanning mechanism 54 and the second optical scanning mechanism 55 mounted on the laser head 50.

[0029] The manipulator 70 is a known articulated robot with a laser head 50 attached to its tip. The manipulator 70 operates according to control commands from the controller 20. The manipulator 70 also moves along the surface of the workpiece 90 according to the welding program stored in the memory unit 26 (see Figure 3), and the workpiece 90 is welded.

[0030] As shown in Figure 1, the wire feeding device 80 includes a welding wire housing section 81, a wire feeding roller 82, a wire feeding motor 83, a wire guide 84, a welding wire (filler) 85, and a guide support section 86.

[0031] The welding wire storage section 81 is a container that houses the welding wire 85. The wire feeding roller 82 grips the welding wire 85 so that it is fed in a predetermined direction in accordance with the rotation of the wire feeding motor 83. The wire feeding roller 82 also corrects any bending or other deformation of the welding wire 85.

[0032] The wire feeding motor 83 rotates the wire feeding roller 82 in response to control commands from the controller 20. The amount, direction, and speed of rotation of the wire feeding roller 82 determine the amount, direction, and speed of welding wire 85 being fed (hereinafter sometimes referred to as the wire feeding speed Vf).

[0033] The wire guide 84 is a fixture that holds the welding wire 85 fed from the wire feeding roller 82 and ensures that the laser beam LB is irradiated onto the tip of the welding wire 85. The guide support 86 is a fixture that connects the housing 51 of the laser head 50 to the wire guide 84. By providing the guide support 86, when the manipulator 70 operates and the laser head 50 moves, the wire guide 84 also moves with the laser head 50. In addition, the angle between the welding wire 85 fed from the wire guide 84 and the direction of travel of the laser beam LB can be kept constant.

[0034] When welding a workpiece 90 using the laser filler welding apparatus 100, the laser oscillator 10 is operated, and the generated laser beam LB is guided through the optical fiber 40 and irradiated onto the workpiece 90 from the laser head 50. This creates a molten pool on the workpiece 90 (not shown). The wire feeder 80 is also operated to feed the welding wire 85 towards the irradiation spot of the laser beam LB on the surface of the workpiece 90. The welding wire 85 melts due to the irradiation of the laser beam LB and is deposited on the workpiece 90 so as to overlap with the aforementioned molten pool. In this way, it is possible to prevent a shortage of molten metal in the molten pool and the occurrence of depressions in the molten area. In addition, the amount of weld material can be increased at the weld area. Laser filler welding is often used in tailored plank welding of high-tensile steel, etc., because it is possible to control the width and height of the weld bead and perform high-speed welding.

[0035] [Configuration of the controller and welding condition setting device] Figure 3 is a functional block diagram of the controller. Figure 4 is a schematic diagram illustrating the overview of the data stored in the memory unit.

[0036] The controller 20 has multiple functional blocks. The controller 20 also has multiple CPUs (Central Processing Units). Each functional block of the controller 20, excluding the storage unit 26 and the display unit 27, is implemented by executing predetermined software on one or more CPUs. The controller 20 may also have other functional blocks not shown, such as a communication unit and an input unit. Of the multiple functional blocks of the controller 20, those shown in Figure 3 are described below.

[0037] The laser control unit 21 is connected to the laser oscillator 10 and controls the operation of the laser oscillator 10, specifically the operation of the power supply. The manipulator control unit 22 is connected to the manipulator 70 and controls the operation of the manipulator 70. The laser head control unit 23 is connected to the laser head 50 and controls the operation of the first optical scanning mechanism 54 and the second optical scanning mechanism 55, respectively. The wire feeding control unit 24 is connected to the wire feeding motor 83 and controls the operation of the wire feeding motor 83.

[0038] When welding the workpiece 90, the welding program stored in the memory unit 26 is read out to the laser control unit 21, the manipulator control unit 22, the laser head control unit 23, and the wire feeding control unit 24, respectively. Each functional block controls the respective parts of the laser filler welding apparatus 100 according to the read welding program.

[0039] The calculation unit 25 derives a set of control parameters based on a database and / or relational expression describing the relationship between the first information and a set of control parameters for controlling each part of the laser filler welding apparatus 100. The calculation unit 25 also generates the welding program described above based on the derived set of control parameters.

[0040] The storage unit 26 is composed of semiconductor memory such as ROM (Read Only Memory), RAM (Random Access Memory), or SSD (Solid State Drive), or an HDD (Hard Disk Drive), or both. Alternatively, the storage unit 26 may be composed of a storage medium that can be attached to or removed from the controller 20, such as a USB memory stick.

[0041] As shown in Figure 4, the memory unit 26 stores the aforementioned database and relational formulas, categorized by the material of the workpiece 90. The memory unit 26 also stores the welding program and the welding condition setting program, which will be described later. The memory unit 26 also temporarily stores the aforementioned first information input from the teaching pendant 60.

[0042] The display unit 27 is composed of a display device such as a liquid crystal display or a touch panel. The display unit 27 displays the control parameter group derived by the calculation unit 25. The display unit 27 may also display the first information input from the teaching pendant 60.

[0043] In the following explanation, the teaching pendant 60, calculation unit 25, storage unit 26, and display unit 27 may be collectively referred to as the welding condition setting device 30. In the welding condition setting device 30, the teaching pendant 60 functions as an input unit for inputting first information. If the controller 20 is provided with an input unit, the first information may be input to the controller 20 by operating that input unit. In this case, the entirety of the welding condition setting device 30 is included in the controller 20. The welding condition setting device 30 may also be provided outside the controller 20. In that case, the welding condition setting device 30 and the controller 20 are configured to communicate with each other. The communication method may be wireless or wired. The teaching pendant 60 may also be provided with a display unit.

[0044] [Welding Condition Setting Procedure] Figure 5 is a flowchart showing the procedure for setting welding conditions. Figure 6 is a diagram showing an example of the first condition and control parameter group.

[0045] As mentioned above, when welding a workpiece 90 using the laser filler welding apparatus 100, simply using the recommended conditions for each part of the laser filler welding apparatus 100 may not yield the desired results. Therefore, in this embodiment, a group of control parameters for controlling each part of the welding apparatus is derived using the following procedure.

[0046] First, the first condition is input using the teaching pendant 60, and the welding condition setting device 30 receives the input first condition (step S1 in Figure 5). Specifically, the input first condition is temporarily stored in the storage unit 26. The first condition stored in the storage unit 26 is then read out by the calculation unit 25 in response to a request from the calculation unit 25.

[0047] If the first information contains multiple requirements, the calculation unit 25 determines whether a priority order for achieving the requirements has been determined (step S2 in Figure 5). If the result of the determination in step S2 is negative, that is, if a priority order for achieving the requirements has not been determined, the process proceeds to step S4.

[0048] On the other hand, if the result of step S2 is positive, that is, if a priority is set among the requirements to be achieved, the calculation unit 25 automatically determines the order in which the control parameters in the control parameter group are derived based on the priority (step S2 in Figure 5). After the execution of step S3, the process proceeds to step S4.

[0049] In step S4, the calculation unit 25 derives a group of control parameters based on the first information and at least one of the database and relational expressions stored in the storage unit 26. The calculation unit 25 also automatically generates a welding program based on the group of control parameters derived in step S4 (step S5).

[0050] As shown in Figure 6, the first information includes at least work information regarding the shape and material of the workpiece 90 and the required specifications for welding the workpiece 90. In other words, when this information is input from the teaching pendant 60, the calculation unit 25 derives a set of control parameters for controlling each part of the laser filler welding apparatus 100.

[0051] Figure 6 also shows an example of the order in which control parameters are derived. Depending on the priority of achieving the required specifications, generally, the output P of the laser beam LB has the greatest impact on the welding result, so this parameter is derived preferentially. In addition, since welding time affects the cost of welding, the welding speed Vw is also a control parameter that is derived preferentially.

[0052] Furthermore, the aforementioned database and / or relational formulas are used in deriving the control parameter set. The relationship between the first information and the control parameters will be explained using some of these relational formulas as examples.

[0053] [Relationship between penetration depth, laser output, and welding speed] First, let's consider the case where the joint shape in the first piece of information is a butt joint, and the required specifications include the amount of penetration at the weld. A butt joint consists of two plates that are in contact with each other so that their end faces abut each other.

[0054] When the penetration depth is Pdw, the welding speed is Vw, and the output of the laser beam LB is P, the relationship shown in equation (1) holds.

[0055] Pdw = α × P × Vw ... (1) Here, α is a coefficient determined according to the characteristics of the laser beam LB and the optical characteristics of the optical system arranged inside the laser head 50. Also, when the thickness of the workpiece 90 is T, the relationship shown in equation (2), for example, holds.

[0056] Vw = A² × T 2 +B2×T+C2 ···(2) Here, A2, B2, and C2 are coefficients experimentally determined according to the welding results of workpiece 90 when the plate thickness was changed.

[0057] Equation (3) is derived from equations (1) and (2).

[0058] Pdw = A1 × T 2 +B1×T+C1 ···(3) Here, A1, B1, and C1 are coefficients experimentally determined according to the output P of the laser beam LB actually used, the optical characteristics of the optical system inside the laser head 50, and the welding results of the workpiece 90 when the plate thickness is changed, respectively.

[0059] The memory unit 26 stores equations (1) to (3) as relational expressions. When the plate thickness T value is input as work information, the calculation unit 25 calculates the penetration depth Pdw based on equation (3) and the welding speed Vw based on equation (2). The calculation unit 25 also substitutes the calculated penetration depth Pdw, welding speed Vw, and coefficient α into equation (1) to calculate the output P of the laser beam LB.

[0060] As part of the requirements, even if the penetration depth Pdw value is input from the teaching pendant 60, the penetration depth Pdw evaluated after welding may differ from the input value depending on the material and shape of the workpiece 90. On the other hand, based on the aforementioned formula (3), the penetration depth Pdw can be calculated as a recommended value close to both the input penetration depth Pdw value and the actual penetration depth Pdw value obtained after welding.

[0061] The same applies to the welding speed Vw; based on equation (2) described above, the welding speed Vw, which is a control parameter, can be calculated as a recommended value close to the input welding speed Vw and the actual welding speed Vw, respectively. In addition, the output P of the laser beam LB, which is a control parameter, can be easily calculated based on equation (1). As is clear from Figure 4, the coefficients A1, A2, B1, B2, C1, C2, and α described above are organized for each material of the workpiece 90 and stored in the memory unit 26.

[0062] Furthermore, these values ​​are reflected in the welding program created by the calculation unit 25. The calculated values ​​may also be displayed on the display unit 27, or on a display unit (not shown) provided on the teaching pendant 60.

[0063] Regarding equation (2), it may also be expressed as an nth-degree polynomial of the plate thickness T, as shown in equation (2A) below. While this increases the computational load, it improves the accuracy of the derivation of the welding speed Vw.

[0064] Vw = Dn × T n +D(n-1)×T (n-1) +···+D ···(2A) Here, n is an integer greater than or equal to 2. Also, Dn, D(n-1), ..., D are coefficients experimentally determined according to the output P of the laser beam LB actually used, the optical characteristics of the optical system inside the laser head 50, and the welding results of the workpiece 90 when the plate thickness is changed, respectively.

[0065] The memory unit 26 stores equation (2A) as a relational expression, and also stores the aforementioned coefficients Dn, D(n-1), ..., D for each material of the workpiece 90.

[0066] In this case, when the plate thickness T is input, the calculation unit 25 calculates the welding speed Vw based on equation (2A). This value is reflected in the welding program created by the calculation unit 25. Alternatively, the calculated value may be displayed on the display unit 27, or on a display unit (not shown) provided on the teaching pendant 60.

[0067] [Relationship between welding volume, laser beam output, and wire feeding speed] If the required specifications include the amount of welding wire 85 deposited, and the amount of welding deposited is Pdf, the wire feeding speed is Vf, and the output of the laser beam LB is P, then the relationships shown in equations (4) and (5) hold, for example.

[0068] Pdf = A3 × Vf 2 +B3×Vf+C3 ···(4) Vf = A4 × P 2 +B4×P+C4 ···(5) Here, A3, B3, and C3 are coefficients experimentally determined according to the welding results of the workpiece 90 when the wire feed speed Vf is changed. Also, A4, B4, and C4 are coefficients experimentally determined according to the welding results of the workpiece 90 when the output P of the laser beam LB is changed.

[0069] The memory unit 26 stores equations (4) and (5) as relational expressions, and also stores the aforementioned coefficients A3, A4, B3, B4, C3, and C4 for each material of the welding wire 85.

[0070] In this case, when the value of the welding amount Pdf is input, the calculation unit 25 calculates the wire feeding speed Vf based on equation (4). Furthermore, the calculation unit 25 calculates the output P of the laser beam LB by substituting the calculated wire feeding speed Vf into equation (5). These values ​​are reflected in the welding program created by the calculation unit 25. Alternatively, the calculated values ​​may be displayed on the display unit 27, or on a display unit (not shown) provided on the teaching pendant 60.

[0071] It should be noted that the welding volume Pdf is often not the direct requirement, but rather a quantity that correlates with the welding volume Pdf, such as the amount of fillet weld or the leg length in fillet welds. In such cases, if the correlation between the amount of fillet weld or leg length and the welding volume Pdf is known in advance, the welding volume Pdf can be determined from the values ​​of the amount of fillet weld or leg length, and then the wire feed speed Vf and the output P of the laser beam LB can be calculated based on the aforementioned equations (4) and (5).

[0072] Regarding equation (4), it may also be expressed as an nth-degree polynomial of the wire feeding speed Vf, as shown in equation (4A) below. While this increases the computational load, it improves the accuracy of the derivation of the welding amount Pdf.

[0073] Pdf = En × Vf n +E(n-1)×Vf (n-1) +···+E ···(4A) Here, n is an integer of 2 or more. Also, En, E(n - 1), ···, E are coefficients experimentally obtained according to the welding results of the work 90 when the wire feeding speed Vf is changed, respectively.

[0074] Regarding Equation (5), as shown in the following Equation (5A), it may be a function of the nth power of the output P of the laser beam LB. By doing so, although the computational load increases, the derivation accuracy of the welding amount Pdf is improved.

[0075] Vf = Fn × P n + F(n - 1) × P (n-1) + ··· + F ···(5A) Here, n is an integer of 2 or more. Also, Fn, F(n - 1), ···, F are coefficients experimentally obtained according to the welding results of the work 90 when the output P of the laser beam LB is changed, respectively.

[0076] The storage unit 26 stores Equations (4A) and (5A) as relational expressions, and stores the aforementioned coefficients En, E(n - 1), ···, E, Fn, F(n - 1), ···, F for each material of the welding wire 85.

[0077] In this case, when the value of the welding amount Pdf is input, the calculation unit 25 calculates the wire feeding speed Vf based on Equation (4A). Further, the calculation unit 25 substitutes the calculated wire feeding speed Vf into Equation (5A) to calculate the output P of the laser beam LB. These values are reflected in the welding program created by the calculation unit 25. Also, the calculated values may be displayed on the display unit 27. Alternatively, they may be displayed on a display unit (not shown) provided on the teaching pendant 60.

[0078] [Example of the relationship between other first information and control parameters] Consider the case where the joint shape of the work 90 is a butt joint of two plates 91 and 92 with different plate thicknesses. FIG. 7 is a schematic diagram showing the irradiation locus of the laser beam in the fillet welding of the butt joint.

[0079] Through the inventors' studies, it was found that, as shown in Figure 7, good fillet welding can be performed by changing the rotation direction of the laser beam LB relative to the welding direction according to the relative thicknesses of the two plate materials 91 and 92. In other words, in the welding condition setting device 30 of this embodiment, when the thicknesses of the plate materials 91 and 92 are input from the teaching pendant 60, the calculation unit 25 derives the rotation direction of the laser beam LB when the laser beam LB is spin-scanned on the surface of the workpiece 90 as a control parameter. The rotation direction and rotation speed of the first optical scanning mechanism 54 and the second optical scanning mechanism 55 are also derived. Note that the joint shape of the workpiece 90 in this case is not limited to a butt joint; other joints, such as a T-joint, may be used as long as the type of welding is fillet welding.

[0080] Furthermore, consider the case where the material of the welding wire 85 is specified as work information, the welding speed Vw is specified as a required specification, and the output P of the laser beam LB is specified or calculated by another relational expression. In this case, the reverse feed speed of the welding wire 85 can be derived as a control parameter. In other words, in the welding condition setting device 30 of this embodiment, when the material of the welding wire 85 and the welding speed Vw are input from the teaching pendant 60, and the output P of the laser beam LB is directly specified or derived by the calculation unit 25, the calculation unit 25 derives the reverse feed speed of the welding wire 85.

[0081] Furthermore, the calculation unit 25 derives the following control parameters based on the calculated control parameters, such as the output P of the laser beam LB, the welding speed Vw, or other control parameters. The derived control parameters are the acceleration and deceleration of the tip of the manipulator 70 at the welding start point (the irradiation start point of the laser beam LB) and the welding end point (the irradiation end point), and the time coefficient of change of the output P of the laser beam LB.

[0082] Thus, the welding condition setting device 30 of this embodiment can derive the control parameters mentioned above, which are difficult to derive from the recommended conditions for individual parts, during the transient periods in laser filler welding, namely at the start and end of welding.

[0083] Next, we will explain the case where a database is used to derive control parameters. In this case, the database organizes the correlation between any of the first conditions and any of the control parameters not as an equation, but as a correspondence between numerical values, for example in a tabular format.

[0084] Therefore, in the welding condition setting device 30 of this embodiment, when first information is input from the teaching pendant 60, the calculation unit 25 checks for the existence of a corresponding relation and / or database. If a database exists, it derives the value of the first information in the database and the corresponding control parameter value as a recommended condition. If the input value of the first information does not match the value of the first information described in the database, it searches the database for the value closest to the input value of the first information and derives the found value of the first information and the corresponding control parameter value as a recommended condition. Alternatively, it searches the database for two values ​​close to the input value of the first information, interpolates the control parameter values ​​corresponding to the two values, and derives the interpolated value obtained as a recommended condition.

[0085] Furthermore, as is clear from the above, when the relationship between the first information and one control parameter is described by a relational expression, and the relationship between the first information and another control parameter is described in a database, the calculation unit 25 derives a group of control parameters based on the first information, the relational expression, and the database.

[0086] [Effects, etc.] As described above, the welding condition setting device 30 according to this embodiment comprises at least a teaching pendant 60 (input unit), a storage unit 26, and a calculation unit 25.

[0087] First information regarding the workpiece 90, which is the object to be welded, is input from the teaching pendant 60 (input unit). The storage unit 26 temporarily stores the first information and also stores a database and relational formulas that describe the relationship between the first information and a group of control parameters for controlling each part of the laser filler welding apparatus 100. The calculation unit 25 derives the group of control parameters based on the first information and at least one of the database and relational formulas.

[0088] The first information includes at least work information relating to the shape and material of the workpiece 90 and the required specifications for welding the workpiece 90. In this embodiment, in order to derive the control parameters of the laser filler welding apparatus 100, the work information further includes information relating to the shape and material of the welding wire 85. In this case, the shape information includes, for example, the wire diameter.

[0089] As mentioned above, when the number of parts that operate in response to commands from the controller 20 increases, such as in the laser filler welding apparatus 100, it takes a great deal of time to obtain combinations of control parameters for each part, and it is extremely difficult to obtain an appropriate combination.

[0090] According to this embodiment, by configuring the welding condition setting device 30 as described above, a combination of control parameters for obtaining the desired construction result can be easily obtained.

[0091] The calculation unit 25 generates a welding program to operate the laser filler welding apparatus 100 based on the derived control parameter group.

[0092] In this way, the amount of work required to modify the welding program can be significantly reduced for users of the laser filler welding apparatus 100.

[0093] If there are multiple requirements, the calculation unit 25 automatically determines the derivation order of the control parameters in the control parameter group based on the priority of the multiple requirements that should be achieved.

[0094] As the number of components that operate in response to commands from the controller 20 increases, as is the case with the laser filler welding apparatus 100, the number of control parameters for each component increases, and the number of combinations of these parameters increases rapidly. In such cases, it is difficult for the welding condition setting device 30 to derive all the control parameters necessary to obtain the desired welding results.

[0095] Therefore, by determining the order in which control parameters are derived according to the priority of achieving the required specifications, the number of control parameters derived by the welding condition setting device 30 can be narrowed down, and the derivation work can be made more efficient. For example, a few high-priority control parameters can be derived, and the recommended conditions of the manufacturers of each part can be used as is for the rest. In this case, test welding is performed under the set conditions, and if there are any control parameters that need to be modified according to the results, they are modified as appropriate.

[0096] Generally speaking, in laser welding, including laser filler welding, the parameter that most significantly affects the shape and quality of the weld is the laser beam output P (LB), followed by the welding speed Vw. In laser filler welding, the wire feed speed Vf is also an important control parameter to ensure the strength and build-up of the weld. Therefore, as shown in Figure 6, the derivation order of the control parameters is determined. However, Figure 6 is merely an example, and the derivation order is appropriately changed depending on the type of welding and the priority of achieving the required specifications.

[0097] The laser filler welding apparatus 100 according to this embodiment is equipped with a welding condition setting device 30. This makes it possible to easily obtain a combination of control parameters necessary to obtain the desired welding results.

[0098] Furthermore, the laser filler welding apparatus 100 also includes a laser oscillator 10, a controller 20, a laser head 50, a manipulator 70, and a wire feeder 80.

[0099] The laser head 50 emits laser light LB, which is output from the laser oscillator 10 and guided by the optical fiber 40, toward the workpiece 90. The manipulator 70 has the laser head 50 attached to its tip and moves the laser head 50. The wire feeder 80 feeds welding wire 85 to the vicinity of the irradiation point of the laser light LB on the workpiece 90. The controller 20 controls the operation of at least the manipulator 70 and the wire feeder 80.

[0100] Furthermore, part or all of the welding condition setting device 30 is integrated into the controller 20. This reduces the number of components in the laser filler welding apparatus 100. Alternatively, the welding condition setting device 30 may be located outside the controller 20 and connected to it for communication. In this case as well, the control parameters derived from the welding condition setting device 30 can be reflected in the operation control of the manipulator 70 and the wire feeder 80.

[0101] An optical scanning mechanism may be provided inside the laser head 50 for scanning the laser beam LB across the surface of the workpiece 90. The controller 20 controls the operation of the optical scanning mechanism, and the control parameter group includes the operating parameters of the optical scanning mechanism. In the example shown in this embodiment, a first optical scanning mechanism 54 and a second optical scanning mechanism 55 are provided in the laser head 50.

[0102] According to this embodiment, a combination of control parameters for obtaining the desired construction result can be easily obtained, including the operation control parameters of the optical scanning mechanism. Furthermore, by providing an optical scanning mechanism, the irradiation width of the laser beam LB and, consequently, the heat input distribution to the workpiece 90 can be changed, enabling welding to be performed on workpieces 90 of various shapes.

[0103] Furthermore, in this embodiment, the laser beam LB was scanned on the surface of the workpiece 90 by rotating the first quartz plate 54A and the second quartz plate 55A around the optical axis OA of the laser beam LB incident inside the laser head 50, respectively. However, the optical scanning mechanism is not particularly limited to this. For example, a known galvanometer mirror and galvanometer motor may be used to manipulate the laser beam LB on the surface of the workpiece 90. Also, when scanning the laser beam LB on the surface of the workpiece 90, it may be scanned not only in a spin scan, but also in a figure-eight pattern or an elliptical pattern. In other words, even when rotating and scanning the laser beam LB two-dimensionally on the surface of the workpiece 90, the calculation unit 25 derives the rotation direction of the laser beam LB as a control parameter.

[0104] The welding condition setting method according to this embodiment comprises at least the following first and second steps.

[0105] In the first step (step S1 in Figure 5), the input of first information is received. In the second step (step S4 in Figure 5), the control parameter group is derived based on at least one of a database describing the relationship between the first information and the control parameter group and a relational expression. The first information includes at least work information regarding the shape and material of the workpiece 90 and the requirements specification regarding the welding of the workpiece 90.

[0106] In this way, it is possible to easily obtain combinations of control parameters necessary to achieve the desired construction results.

[0107] When there are multiple requirements, it is preferable to automatically determine the derivation order of the control parameters in the control parameter group based on the priority of the requirements that need to be met.

[0108] By doing so, the number of control parameters derived by the welding condition setting device 30 can be reduced, and the derivation process can be made more efficient. For example, a few high-priority control parameters can be derived, and the remaining parameters can be the recommended conditions of the manufacturer of each part.

[0109] The welding condition setting program according to this embodiment causes one or more CPUs (processors) in the controller 20 to execute the welding condition setting method described above.

[0110] In this way, the control parameters of the laser filler welding apparatus 100 can be easily and quickly derived based on the first information input from the teaching pendant 60.

[0111] <Variation> Figure 8 is a flowchart showing the procedure for setting welding conditions related to a modified example.

[0112] Step S11 in Figure 8 is the same process as step S1 in Figure 5, so its explanation is omitted. Similarly, steps S14 and S18 in Figure 8 are the same process as step S4 in Figure 5, and step S19 in Figure 8 is the same process as step S5 in Figure 5, so their explanations are omitted.

[0113] Steps S12 and S13 in Figure 8 differ from steps S2 and S3 in Figure 5 in the following respects. First, in step S12, not only the achievement priority in the requirements specification but also the presence or absence of setting constraints in the laser filler welding apparatus 100 is determined. Furthermore, in step S13, if the determination result in step S12 is positive, the derivation order and / or number of control parameters are changed based on the achievement priority and setting constraints. The processing in step S13 is executed by the calculation unit 25, similar to step S3.

[0114] Furthermore, in the flowchart shown in Figure 8, steps S16 to S18 are provided between step S14 and step S19.

[0115] In step S16, the workpiece 90 is test-welded based on the control parameters derived in step S14, and its shape is evaluated. In this case, not only the shape of the welded area but also the surrounding shape, specifically the presence or absence of welding defects such as spatter, is evaluated. In addition, the welding quality, such as the strength of the welded area, may also be evaluated in step S16.

[0116] In step S17, it is determined whether the evaluation result from step S6, i.e., the shape evaluation result, is satisfactory according to predetermined evaluation criteria. The processes in steps S16 and S17 are performed by a welding operator using the laser filler welding apparatus 100 and the visual inspection apparatus, etc.

[0117] In step S18, if the judgment result in step S16 is negative, that is, if there is some problem with the shape of the welding area of ​​the workpiece 90, the derivation order and / or number of control parameters are changed based on the shape evaluation result. The processing in step S18 is performed by the calculation unit 25. Note that the processing in step S17 may be skipped if there is no particular need to perform it.

[0118] In other words, in the welding condition setting device 30 according to this modified example, the calculation unit 25 is configured to at least change the order in which the control parameters are derived, according to the shape evaluation result of the workpiece 90 after it has been welded or constraints relating to the settings of the laser filler welding device 100.

[0119] Furthermore, in the welding condition setting method according to this modified example, if there are constraints on the settings of the laser filler welding apparatus 100, the derivation order of the control parameters in the control parameter group can be changed at least based on those constraints.

[0120] Furthermore, if the workpiece 90 is welded based on the control parameter group derived in the second step (step S14 in Figure 8) and the shape of the workpiece 90 is evaluated, the third step (steps S17 and S18 in Figure 8) is executed after the shape evaluation of the workpiece 90. In the third step, the control parameter group is re-derived based on the first information and at least one of the database and relational formulas. In addition, the derivation order of the control parameters in the control parameter group can be changed depending on the shape evaluation result of the workpiece 90.

[0121] For example, due to constraints such as the shape and arrangement of the jigs used for welding, the posture of the laser head 50 held by the manipulator 70 may not be changeable. In this case, for example, the control parameters that can be changed are substantially limited to the output P of the laser beam LB and the welding speed Vw. However, if there are constraints on the arrangement of each component in the laser filler welding apparatus 100, there may also be control parameters that cannot be changed.

[0122] In this modified example, such cases are taken into consideration, and by making it possible to change the derivation order and / or number of control parameters, a set of control parameters tailored to the actual equipment can be derived and presented to the welding operator.

[0123] Furthermore, depending on the evaluation results of the shape of the workpiece 90 after welding, it may be necessary to change the recommended conditions. In that case, the control parameters for improving the shape will differ on a case-by-case basis. For example, if there is a lot of spatter, measures such as reducing the output P of the laser beam LB or gradually increasing the output P of the laser beam at the welding start point may be taken.

[0124] According to this modified example, by making it possible to change the derivation order and / or number of control parameters according to the evaluation results of the shape, etc., a set of control parameters that yield a good shape, etc. can be derived and presented to the welding operator.

[0125] (Other embodiments) In this specification, the controller 20 controlled the operation of the laser oscillator 10, laser head 50, manipulator 70, and wire feeder 80, but separate controllers may be provided to control the operation of each component. For example, a first controller may be provided to control the operation of the laser oscillator 10, a second controller to control the operation of the laser head 50, a third controller to control the operation of the manipulator 70, and a fourth controller to control the operation of the wire feeder 80. In this case, the welding condition setting device 30 is provided independently of the first to fourth controllers, and the welding condition setting device 30 and the first to fourth controllers are configured to communicate with each other, making it easy to obtain a combination of control parameters to get the desired construction results.

[0126] Furthermore, although this specification uses laser filler welding as an example, it is not limited to this. The welding condition setting device 30 and welding condition setting method described in this specification may also be applied to ordinary laser processing, such as laser cutting, laser drilling, and arc welding, as well as thermal processing using both arc or laser light and arc, such as laser-arc hybrid welding. In that case, "welding" can be read as "thermal processing." For example, in arc welding, the control parameter that has the greatest influence on the welding result is the welding current, followed by the welding speed Vw. In the case of consumable electrode type arc welding, the wire feeding speed Vf changes in conjunction with the welding current. [Industrial applicability]

[0127] The welding condition setting device of this disclosure is useful because it allows for easy acquisition of combinations of control parameters for obtaining desired construction results. [Explanation of Symbols]

[0128] 10. Laser Oscillator 20 controllers 21 Laser control unit 22 Manipulator Control Unit 23 Laser head control unit 24 Wire feeding control unit 25 Arithmetic section 26 Memory section 27 Display section 30 Welding Condition Setting Device 40 Fiber Optics 50 laser heads 51 cabinets 51A Fiber Optic Connection Port 51B Light exit port 52 Collimating Lenses 53 Focus Lens 54. First Optical Scanning Mechanism 54A 1st quartz plate 54B First Telescope Tube 54C First Motor 55 Second Optical Scanning Mechanism 55A 2nd quartz plate 55B Second Telescope Tube 55C Second Motor 56 Protective Glass 60 Teaching pendant (input unit) 70 Manipulators 80 Wire feeder 81 Welding wire housing 82 Wire feeding roller 83 Wire feeding motor 84 Wire Guide 85 Welding Wire 86 Guide support section 90 Work 91 Board material 92 Board material 100 Laser Filler Welding Equipment

Claims

1. An input unit for inputting at least first information regarding the workpiece, which is the object to be processed, A storage unit that temporarily stores the first information and stores a database and relational expressions that describe the relationship between the first information and a group of control parameters for controlling each part of the heat processing apparatus, The system comprises at least a calculation unit that derives the control parameter group based on the first information, the database, and at least one of the relational expression, The thermal processing condition setting device is characterized in that the first information includes at least work information relating to the shape and material of the workpiece and required specifications relating to the thermal processing of the workpiece.

2. In the heat processing condition setting device according to claim 1, The thermal processing condition setting device is characterized in that the calculation unit generates a thermal processing program for operating the thermal processing device based on the derived group of control parameters.

3. In the heat processing condition setting device according to claim 1, A thermal processing condition setting device characterized in that, when there are multiple requirements, the calculation unit automatically determines the order in which the control parameters in the control parameter group are derived based on the priority of which of the multiple requirements should be achieved.

4. In the heat processing condition setting device according to claim 3, The thermal processing condition setting device is characterized in that the calculation unit is configured to change at least the order of derivation of the control parameters according to the shape evaluation result of the workpiece after the workpiece has been thermally processed or constraints relating to the settings of the thermal processing device.

5. In the heat processing condition setting device according to claim 1, The type of heat processing is laser filler welding, The heat processing condition setting device is characterized in that the workpiece information further includes information regarding the shape and material of the welding wire.

6. In the heat processing condition setting device according to claim 5, When the aforementioned workpieces are butt-welded, and the required specifications include the amount of penetration at the weld, When the penetration depth is Pdw, the welding speed is Vw, and the laser beam output is P, Pdw=α×P×Vw...(1) A thermal processing condition setting device characterized in that the relationship shown in [the given formula] holds, and α is a coefficient determined according to the characteristics of the laser light and the optical characteristics of the laser head that irradiates the workpiece with the laser light.

7. In the heat processing condition setting device according to claim 6, When the thickness of the workpiece is T, Vw=Dn×T ｎ +D(n-1)×T （ｎ－１） +・・・+D ・・・(2A) The relationship shown holds, n is an integer greater than or equal to 2, Dn, D(n-1), ..., D are coefficients experimentally determined according to the welding results of the workpiece when the plate thickness is changed, The thermal processing condition setting device is characterized in that the memory unit stores equation (2A) as the relational expression, and also stores the coefficients Dn, D(n-1), ..., D for each material of the workpiece.

8. In the heat processing condition setting device according to claim 5, If the aforementioned requirement specification includes a known welding amount or a known correlation with the welding amount, When the amount of welded material is Pdf, the feeding speed of the welding wire is Vf, and the output of the laser beam is P, P$f=En×Vf ｎ +E(n-1)×Tf （ｎ－１） +・・・+E・・・(4A) Vf=Fn×P ｎ +F(n-1)×P （ｎ－１） +・・・+F ・・・(5A) The relationship shown holds, n is an integer greater than or equal to 2, En, E(n-1), ..., E are coefficients experimentally determined according to the welding results of the workpiece when the feed rate is changed, Fn, F(n-1), ..., F are coefficients experimentally determined according to the welding results of the workpiece when the output of the laser beam is changed, The thermal processing condition setting device is characterized in that the memory unit stores equations (4A) and (5A) as relational equations, and also stores the coefficients En, E(n-1), ..., E, Fn, F(n-1), ..., F for each material of the welding wire.

9. In the heat processing condition setting device according to claim 5, If the type of heat treatment is fillet welding, A thermal processing condition setting device characterized in that, according to the thickness of each of the two plate materials included in the workpiece, the calculation unit derives the rotation direction of the laser beam when the laser beam is rotated two-dimensionally on the surface of the workpiece as a control parameter.

10. In the heat processing condition setting device according to claim 9, If the type of heat treatment is fillet welding, the workpiece information includes the material of the welding wire, the required specifications include the welding speed, and the output of the laser beam is specified, The thermal processing condition setting device is characterized in that the calculation unit derives the reverse feed speed of the welding wire as the control parameter.

11. In the heat processing condition setting device according to claim 5, When a laser head that irradiates the workpiece with laser light is attached to the tip of the manipulator, The thermal processing condition setting device is characterized in that the calculation unit derives the acceleration and deceleration of the tip of the manipulator at the welding start point and welding end point, and the time coefficient of change of the laser beam output.

12. A heat processing apparatus characterized by comprising a heat processing condition setting device according to any one of claims 1 to 11.

13. In the heat processing apparatus according to claim 12, A laser oscillator, A laser head that emits laser light output from the laser oscillator to the workpiece, A laser head is attached to the tip of a manipulator for moving the laser head, A wire feeding device that feeds welding wire to the vicinity of the laser beam irradiation point on the workpiece, The system further comprises at least a controller that controls the operation of the manipulator and the wire feeding device, A thermal processing apparatus characterized in that the thermal processing condition setting device is connected to the controller in a manner that allows communication, or that part or all of the thermal processing condition setting device is incorporated into the controller.

14. In the heat processing apparatus according to claim 13, Inside the laser head, there is an optical scanning mechanism for scanning the laser beam across the surface of the workpiece. The controller controls the operation of the optical scanning mechanism. A thermal processing apparatus characterized in that the control parameter group includes the operating parameters of the optical scanning mechanism.

15. The first step involves receiving input of primary information regarding the workpiece, which is the object to be welded, The system comprises at least a second step of deriving the control parameter group based on a database describing the relationship between the first information and a group of control parameters for controlling each part of the heat processing apparatus, and at least one of the relational formulas, A method for setting thermal working conditions, characterized in that the first information includes at least work information relating to the shape and material of the workpiece and required specifications relating to the thermal working of the workpiece.

16. In the method for setting heat processing conditions according to claim 15, A method for setting thermal processing conditions, characterized in that, when there are multiple requirements, the order in which the control parameters in the control parameter group are derived is automatically determined based on the priority of which of the multiple requirements should be achieved.

17. In the method for setting heat processing conditions according to claim 15, A method for setting thermal processing conditions, characterized in that, if there are constraints on the settings of the thermal processing apparatus, the derivation order of the control parameters in the control parameter group can be changed based on the constraints.

18. In the method for setting heat processing conditions according to claim 15, When the workpiece is heat-processed based on the control parameter group derived in the second step and the shape of the workpiece is evaluated, The third step further comprises, after evaluating the shape of the workpiece, re-deriving the control parameter group based on the first information, the database, and at least one of the relational expression, The third step is a method for setting thermal processing conditions, characterized in that the order in which the control parameters in the control parameter group are derived can be changed at least according to the shape evaluation result of the workpiece.

19. A thermal processing condition setting program for causing one or more processors to perform the thermal processing condition setting method according to any one of claims 15 to 18.

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