Welding control method and system

Abstract

A welding control method, comprising the following steps: welding a weldment by means of a welding head; continuously measuring the amount of deformation and welding energy of the weldment during welding; comparing the amount of deformation with an amount-of-deformation threshold and comparing the welding energy with an energy threshold to obtain a welding parameter comparison result, wherein the amount-of-deformation threshold comprises the maximum amount of deformation and the minimum amount of deformation, and the energy threshold comprises the maximum welding energy and the minimum welding energy; and when the welding parameter comparison result satisfies any of determination conditions in a determination condition set, ending the welding, wherein the determination condition set at least comprises more than three determination conditions that are set on the basis of the amount-of-deformation threshold and the welding energy. Further provided is a welding control system, which can solve the problem of a poor welding effect caused by an abnormal weldment or abnormal detection, and achieve a better welding effect.

Description

Welding control method and system Technical Field

[0001] The present application mainly relates to the field of welding, and in particular to a welding control method and system. Background Art

[0002] In the field of welding, welding control methods that adjust and control parameters are usually used to achieve welding automation. However, in the existing technology, the judgment conditions for the end of welding currently only use some relatively simple judgment logic. For example, one or two judgment conditions involving welding control parameters are usually used to determine whether welding is completed. There are some problems with the conclusion of whether welding is completed in these ways. For example, there may be a situation where the weldment height is abnormal, causing the welding to reach the preset depth but the actual welding is not normal, or there may be a situation where the welding energy reaches the preset energy but still does not achieve effective welding due to problems with the weldment or pressure. Therefore, this field still lacks a solution that can comprehensively consider abnormal conditions in the welding process and stop welding at the appropriate time.

[0003] Summary of the Invention

[0004] The technical problem to be solved by the present application is to provide a welding control method and system, which can solve the problem of poor welding effect caused by abnormal welds or detection, and achieve better welding effect.

[0005] In order to solve the above technical problems, the present application provides a welding control method, comprising the following steps: welding the weldment through a welding head; continuously measuring the deformation amount and welding energy of the weldment during the welding process; obtaining a welding parameter comparison conclusion by comparing the relationship between the deformation amount and the deformation amount threshold and the relationship between the welding energy and the energy threshold, wherein the deformation amount threshold includes the highest deformation amount and the lowest deformation amount, and the energy threshold includes the highest welding energy and the lowest welding energy; and when the welding parameter comparison conclusion meets any judgment condition in a judgment condition set, ending the welding, wherein the judgment condition set includes at least three or more judgment conditions set according to the deformation amount threshold and the welding energy.

[0006] Optionally, the judgment condition set includes at least the following three judgment conditions at the same time: the deformation value is greater than or equal to the minimum deformation value and the welding energy is greater than or equal to the minimum welding energy; the deformation value is greater than or equal to the maximum deformation value; and the welding energy is greater than or equal to the maximum welding energy.

[0007] Optionally, the method of welding the workpiece by the welding head includes ultrasonic welding.

[0008] Optionally, the welding control method also includes setting a pre-welding mode or a variable amplitude mode and a formal welding mode, and the step of welding the workpiece through the welding head further includes first welding the workpiece using the pre-welding mode or the variable amplitude mode, and then welding it using the formal welding mode, wherein the first welding amplitude of the pre-welding mode or the variable amplitude mode is different from the second welding amplitude of the formal welding mode.

[0009] Optionally, the pre-welding mode includes a pre-welding stage and a stop stage which are executed sequentially, wherein when the welding control method includes first welding the weldment using the pre-welding mode and then welding it using the formal welding mode, the welding control method further includes welding the weldment using the pre-welding amplitude in the pre-welding stage and stopping welding the weldment in the stop stage.

[0010] Optionally, when the method of welding the workpiece by the welding head includes ultrasonic welding, the welding control method also includes setting the ultrasonic duration to 5 to 50 ms for the pre-welding stage in the pre-welding mode; and setting the stop time to 5 to 50 ms for the stop stage in the pre-welding mode.

[0011] Optionally, the welding control method further includes setting the first moment of entering the formal welding mode as the moment when the deformation amount is 0, and when continuously measuring the deformation amount of the weldment, the measured value of the deformation amount is calculated from the first moment.

[0012] Optionally, the welding control method further includes setting the first moment of entering the formal welding mode as the moment when the welding energy is 0, and when continuously measuring the welding energy of the weldment, the measured value of the welding energy is calculated from the first moment.

[0013] To solve the above technical problems, the present application provides a welding control system, comprising: a welding head and a control module connected to the welding head, wherein the control module is configured to use the welding control method described above to weld the workpiece with the welding head.

[0014] To solve the above technical problem, the present application provides a computer-readable medium storing computer program code, which implements the above method when executed by a processor.

[0015] Compared with the existing technology, this application can solve the problem of poor welding caused by abnormal welds or detection by continuously measuring the deformation of the weldment and the welding energy and judging whether the welding is completed from multiple dimensions, thereby achieving better welding effects. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings are included to provide a further understanding of the present application. They are incorporated into and constitute a part of the present application. The accompanying drawings illustrate embodiments of the present application and, together with the description, serve to explain the principles of the present application.

[0017] In the attached figure:

[0018] FIG1 is a schematic flow chart of a welding control method according to an embodiment of the present application;

[0019] FIG2 is a logic diagram of a welding control method according to an embodiment of the present application;

[0020] FIG3 is a schematic diagram of a working state of a welding control method according to an embodiment of the present application;

[0021] FIG4 is a schematic diagram of a welding state of a weldment using a welding control method according to an embodiment of the present application;

[0022] FIG5 is a schematic diagram of a working state of a welding control method in another embodiment of the present application; and

[0023] FIG6 is a module diagram of a welding control system in one embodiment of the present application. DETAILED DESCRIPTION

[0024] To more clearly illustrate the technical solutions of the embodiments of this application, the following is a brief introduction to the drawings required for describing the embodiments. Obviously, the drawings described below are merely examples or embodiments of this application. Those skilled in the art can apply this application to other similar scenarios based on these drawings without inventive effort. Unless otherwise apparent from the context or otherwise noted, the same reference numerals in the figures represent the same structure or operation.

[0025] As used in this application and the claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not intended to refer to the singular but may include the plural. Generally speaking, the terms "comprises" and "include" only indicate the inclusion of the steps and elements specifically identified, and these steps and elements do not constitute an exclusive list. A method or apparatus may also include other steps or elements.

[0026] Unless otherwise specifically stated, the relative arrangement of the parts and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present application. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to actual proportional relationships. The techniques, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques, methods and equipment should be considered as part of the authorization specification. In all examples shown and discussed here, any specific values ​​should be interpreted as being merely exemplary and not as limitations. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following figures, and therefore, once an item is defined in one figure, it does not need to be further discussed in subsequent figures.

[0027] In the description of this application, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of this application; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0028] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0029] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is solely for the purpose of distinguishing the corresponding components. Unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application. Furthermore, while the terms used in this application are selected from commonly known and commonly used terms, some terms mentioned in this specification may have been selected by the applicant at his or her discretion, and their detailed meanings are explained in the relevant sections of this description. Furthermore, this application should be understood not only by the actual terms used, but also by the meaning implied by each term.

[0030] This application presents a welding control method (hereinafter referred to as "control method 10") with reference to FIG. The method includes steps S1 through S4. A flowchart is used herein to illustrate the operations performed by a system according to an embodiment of the present application. It should be understood that the preceding or following operations do not necessarily need to be performed in exact sequence. Instead, various steps may be performed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

[0031] Specifically, step S1 includes welding the workpiece by a welding head. Exemplarily, in this embodiment, the welding method of the workpiece by the welding head includes ultrasonic welding.

[0032] Further referring to FIG2 , step S2 includes continuously measuring the deformation of the weldment and the welding energy during the welding process. In this embodiment, the deformation is defined as the depth of the welding operation into the weldment; the welding energy can be directly obtained from the welding machine connected to the welding head.

[0033] Furthermore, step S3 includes obtaining a welding parameter comparison conclusion by comparing the relationship between the deformation variable and the deformation variable threshold and the relationship between the welding energy and the energy threshold, wherein the deformation variable threshold includes the highest deformation variable and the lowest deformation variable, and the energy threshold includes the highest welding energy and the lowest welding energy.

[0034] Finally, step S4 includes ending welding when the welding parameter comparison conclusion meets any judgment condition in the judgment condition set, wherein the judgment condition set includes at least three or more judgment conditions set according to the deformation threshold and welding energy.

[0035] Compared with the prior art, the control method 10 can effectively achieve the situation where effective welding cannot be achieved under abnormal conditions due to a single dimension of the judgment conditions by setting three or more judgment conditions. Referring to Figure 2, a preferred implementation of the control method 10 is given below. According to Figure 2, the welding deformation is set to H, the minimum deformation is △Hmin, the maximum deformation is △Hmax, the welding energy is E, the minimum welding energy is △Emin, and the maximum welding energy is △Emax. Figure 2 schematically illustrates a preferred judgment logic that requires the above three conditions to be met simultaneously in the judgment condition set. According to Figure 2, when controlling the welding head to weld the weldment, first determine whether the deformation variable H is greater than or equal to the maximum deformation variable △Hmax. When the judgment result is yes, the welding is terminated directly. If the judgment result is no, continue to determine whether the welding energy E is greater than or equal to the maximum welding energy △Emax; similarly, if the judgment result is yes, the welding is terminated directly. Finally, if the judgment result is no, continue to judge whether the deformation variable H is greater than or equal to the minimum deformation variable △Hmin, and whether the welding energy E is greater than or equal to the minimum welding energy △Emin. If the judgment result is yes, end welding, otherwise continue welding.

[0036] It is understandable that after adopting the judgment logic shown in FIG2 , it can be considered that step S4 shown in FIG1 is specifically implemented as including at least three judgment conditions in the judgment condition set:

[0037] Condition 1: When the deformation H is greater than or equal to the minimum deformation △Hmin and the welding energy E is greater than or equal to the minimum welding energy △Emin, welding is terminated;

[0038] Condition 2 is: when the deformation H is greater than or equal to the maximum deformation △Hmax, the welding is terminated; and

[0039] Condition 3: When the welding energy E is greater than or equal to the maximum welding energy ΔEmax, welding is terminated.

[0040] In the above preferred real-time solution, by increasing the lower limit of the deformation amount H and the welding energy E, the weldment can still achieve an effective welding effect under abnormal conditions, thereby improving the welding qualification rate, reducing the scrap rate, and improving production efficiency.

[0041] In a more preferred embodiment of the control method 10 of the present application, a pre-welding mode or a variable amplitude mode and a formal welding mode can also be set. In such an embodiment, the step of welding the workpiece using the welding head in step 11 shown in FIG1 further includes first welding the workpiece using the pre-welding mode or the variable amplitude mode, and then welding using the formal welding mode, wherein the first welding amplitude of the variable amplitude mode is different from the second welding amplitude of the formal welding mode. Furthermore, the above-mentioned pre-welding mode can preferably include a pre-welding stage and a stop stage that are executed sequentially. In such an embodiment, the workpiece can be welded using the pre-welding amplitude in the pre-welding stage, and welding of the workpiece can be stopped in the stop stage.

[0042] To better illustrate these preferred methods, Figure 3 specifically illustrates a specific implementation scheme for the pre-welding mode. Figure 3 shows the relationship between the actual deformation D (y-axis direction) of the weldment and the welding time t (x-axis direction). Curve L represents the relationship between the actual deformation D of the weldment and the welding time t. Furthermore, the dashed lines indicate the relative numerical values ​​of the welding amplitudes corresponding to different stages. In this mode, time period t1 indicates the pre-welding stage, where welding is performed using the pre-welding mode. The welding amplitude used during this stage is always the first welding amplitude a. Time period t2 indicates the stop stage, where welding of the weldment is stopped. Time period t3 indicates the main welding mode, where the welding amplitude used during this stage is always the second welding amplitude b. When time period t3 ends, welding is terminated. As described above, the first welding amplitude a is smaller than the second welding amplitude b of the main welding mode.

[0043] In the present application, preferably, if the welding head uses ultrasonic wave to weld the weldment, the duration of t1 in the pre-welding stage can be set to 5 to 50 ms, that is, the duration of the ultrasonic wave at this time is 5 to 50 ms, preferably 8 to 12 ms. The duration of t2 in the stop stage can be set to 5 to 50 ms, preferably 12 to 18 ms, at which time the ultrasonic welding of the weldment is stopped. In addition, it can be seen from Figure 3 that when the weldment is in the stop stage (t2 time period), the rising amplitude of the curve L on the y-axis tends to be gentle, which means that the deformation of the weldment gradually tends to be constant or the rate of change is less than the preset value. At this time, point P is reached to control the welding head to weld the weldment in the formal welding mode.

[0044] Referring back to Figure 2 , in order to accurately determine the multiple welding completion criteria, it is necessary to continuously measure the weld deformation H during the welding process. In this embodiment, it is more preferred to start measuring the deformation H at time tc, the first moment of entering the formal welding mode, when welding is performed using the second welding amplitude b. In this embodiment, the deformation H value (or the measured deformation H, which can be understood as the concept relative to the actual deformation D) is preferably considered to be zero at time tc, and the weld deformation H is continuously measured.

[0045] To better understand this preferred method, Figure 4 illustrates the welding process for two weldments 41. Reference numeral 42 represents the weld pit formed at the final welding completion time (i.e., completion time t3 shown in Figure 3). At time t0, as shown in Figure 3, the actual deformation D of weldment 41 is 0. During the continuous welding process, at time tc, weldment 41 completes the pre-welding phase t1 and the stop phase t2. At time tc, as weldment 41 prepares to enter the formal welding mode, the deformation H of weldment 41 is measured and compared with the minimum deformation ΔHmin or maximum deformation ΔHmax described above during the continuous measurement process, thereby effectively controlling the welding process.

[0046] On the other hand, preferably, in addition to setting the start time for measuring the deformation H in the manner described above, the welding energy E can also be set to begin measuring at time tc. That is, after entering the official welding mode at point P as shown in FIG3 , the deformation H and welding energy E values ​​used for the above-mentioned logical judgment begin to be measured simultaneously.

[0047] By setting the pre-welding mode and the formal welding mode, the welding surface of the weldment in the pre-welding mode can be compacted. Therefore, in the formal welding mode, the weldment will not have inaccurate deformation calculation due to the welding surface not being compacted. In addition, as explained above, some existing relatively single judgment dimensions will ignore some abnormal welding conditions. In this preferred real-time scheme, the measurement starting point of the deformation variable H is distinguished from the moment when the actual deformation variable of the weldment is 0, and combined with the judgment logic of the minimum deformation variable and the minimum welding energy, it can effectively avoid the situation where, for example, the welding reaches the preset depth due to abnormal height of the weldment but is not actually welded normally, or the welding energy reaches the preset energy but still does not achieve effective welding due to problems with the weldment or pressure, thereby improving the reliability and stability of welding.

[0048] On the other hand, referring to the preferred embodiment of the pre-welding mode described above with reference to Figures 3 and 4, the present application can also replace the pre-welding mode with a variable amplitude welding mode. Referring to Figure 5, Figure 5 shows the relationship between the actual deformation D (y-axis direction) of the weldment and the welding time t (x-axis direction) in the variable amplitude welding mode. Curve L' represents the relationship between the actual deformation D of the weldment and the welding time t. In addition, the dashed line indicates the relative magnitude of the corresponding welding amplitude at different stages. As shown in Figure 5, at the beginning of welding, amplitude c is used for welding, and the welding duration is t4. As can be seen from the figure, in the second half of t4, the rise of curve 1 on the y-axis tends to be gentle, indicating that the deformation of the weldment gradually becomes constant or the rate of change is less than the preset value. When the welding position reaches point Q (deformation is 0), the amplitude is increased to amplitude d and the weldment is welded for a welding duration of t5. When t5 ends, the welding is terminated.

[0049] This application also provides a welding control system 20 with reference to FIG6 , comprising a welding head 21 and a control module 22 connected thereto. The control module 22 is configured to control the welding head to weld a workpiece using any of the welding control methods of the present application. For example, the method described with reference to FIG1 to FIG5 is the welding control method 10 and its preferred variant embodiments.

[0050] In addition, the present application further proposes a computer-readable medium storing computer program code, which implements the above-mentioned welding control method when executed by a processor.

[0051] The basic concepts have been described above. It will be apparent to those skilled in the art that the above disclosures are merely examples and do not limit the present application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and revisions to the present application. Such modifications, improvements, and revisions are suggested in the present application and remain within the spirit and scope of the exemplary embodiments of the present application.

[0052] At the same time, this application uses specific terms to describe the embodiments of this application. For example, "one embodiment," "an embodiment," and / or "some embodiments" refer to a certain feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that "one embodiment," "an embodiment," or "an alternative embodiment" mentioned twice or multiple times in different locations in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this application may be appropriately combined.

[0053] A computer-readable medium may include a propagated data signal embodying computer program code, for example, in baseband or as part of a carrier wave. The propagated signal may be in a variety of forms, including electromagnetic, optical, etc., or a suitable combination thereof. A computer-readable medium may be any computer-readable medium other than a computer-readable storage medium that can be connected to an instruction execution system, apparatus, or device to communicate, propagate, or transmit the program for use. The program code on the computer-readable medium may be transmitted via any suitable medium, including radio, cable, fiber optic cable, radio frequency signal, or similar medium, or any combination of the above.

[0054] Similarly, it should be noted that, in order to simplify the description of this application and thus facilitate understanding of one or more embodiments of the application, the foregoing description of the embodiments of this application sometimes combines multiple features into a single embodiment, figure, or description thereof. However, this disclosure method does not mean that the subject matter of this application requires more features than those recited in the claims. In fact, the features of an embodiment may be fewer than all the features of the individual embodiments disclosed above.

[0055] In some embodiments, numbers are used to describe the quantity of components and attributes. It should be understood that such numbers used in the description of the embodiments are modified by the modifiers "about", "approximately" or "substantially" in some examples. Unless otherwise stated, "about", "approximately" or "substantially" indicate that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the description and claims are approximate values, which may change according to the required features of individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and adopt the general method of retaining digits. Although the numerical domains and parameters used to confirm the breadth of their range in some embodiments of the present application are approximate values, in specific embodiments, the settings of such numerical values ​​are as accurate as possible within the feasible range.

[0056] Although the present application has been described with reference to the current specific embodiments, ordinary technicians in this technical field should recognize that the above embodiments are only used to illustrate the present application, and various equivalent changes or substitutions can be made without departing from the spirit of the present application. Therefore, as long as the changes and modifications to the above embodiments are within the scope of the essential spirit of the present application, they will fall within the scope of the claims of the present application.

Claims

1. A welding control method, characterized in that, It includes the following steps: Weld the workpiece by a welding head; Continuously measure the deformation amount and welding energy of the workpiece during the welding process; Obtain a welding parameter comparison conclusion by comparing the relationship between the deformation amount and the deformation amount threshold and the relationship between the welding energy and the energy threshold, wherein the deformation amount threshold includes a maximum deformation amount and a minimum deformation amount, and the energy threshold includes a maximum welding energy and a minimum welding energy; and When the welding parameter comparison conclusion meets any judgment condition in the judgment condition set, end the welding, wherein the judgment condition set includes at least three or more judgment conditions set according to the deformation amount threshold and the welding energy.

2. The welding control method according to claim 1, wherein, The judgment condition set at least simultaneously includes the following three judgment conditions: The deformation amount is greater than or equal to the minimum deformation amount and the welding energy is greater than or equal to the minimum welding energy; The deformation amount is greater than or equal to the maximum deformation amount; and The welding energy is greater than or equal to the maximum welding energy.

3. The welding control method according to claim 1, wherein The method of welding the workpiece by the welding head includes ultrasonic welding.

4. The welding control method according to any one of claims 1 to 3, characterized in that, It further includes setting a pre-welding mode or a variable amplitude mode and a formal welding mode. The step of welding the workpiece by the welding head further includes first welding the workpiece in the pre-welding mode or the variable amplitude mode and then welding it in the formal welding mode, wherein the first welding amplitude of the pre-welding mode or the variable amplitude mode is different from the second welding amplitude of the formal welding mode.

5. The welding control method according to claim 4, wherein The pre-welding mode includes a pre-welding stage and a stop stage executed in sequence. When the welding control method includes first welding the workpiece in the pre-welding mode and then welding it in the formal welding mode, the welding control method further includes welding the workpiece with the pre-welding amplitude in the pre-welding stage and stopping welding the workpiece in the stop stage.

6. The welding control method according to claim 5, wherein When the method of welding the workpiece by the welding head includes ultrasonic welding, the welding control method further includes setting the ultrasonic duration to 5 - 50 ms for the pre-welding stage in the pre-welding mode; and setting the stop time to 5 - 50 ms for the stop stage in the pre-welding mode.

7. The welding control method according to claim 4, characterized in that, It further includes setting the first moment to enter the formal welding mode as the moment when the deformation amount is 0, and when continuously measuring the deformation amount of the workpiece, the measured value of the deformation amount starts from the first moment.

8. The welding control method according to claim 7, wherein, It further includes setting the first moment to enter the formal welding mode as the moment when the welding energy is 0, and when continuously measuring the welding energy of the workpiece, the measured value of the welding energy starts from the first moment.

9. A welding control system, characterized in that, It includes: A welding head and a control module connected to the welding head, wherein the control module is configured to weld the workpiece by the welding head using the welding control method according to any one of claims 1 - 8.

10. A computer-readable medium storing computer program code, wherein the computer program code, when executed by a processor, implements the method according to any one of claims 1 - 8.

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