Welding method, welding system, and storage medium

Abstract

A welding method, comprising: acquiring weld seam information of a workpiece; controlling a welding device (10) to perform arc-based seam finding on the workpiece, and acquiring a detection result after the arc-based seam finding is performed on the workpiece; on the basis of the weld seam information and the detection result, controlling an image collector (11) to perform a weld seam scanning operation on the workpiece, and acquiring coordinate information of each weld seam of the workpiece; and on the basis of the weld seam information, the detection result, and the coordinate information, controlling a welding portion (102) of the welding device (10) to perform a welding operation on the workpiece. In the welding method, an error between the welding seam information and the detection result can be avoided by means of the arc-based seam finding, the image of the weld seam of the workpiece can be clearly identified and collected by means of the movement of the image collector (11), and the welding portion (102) can be aligned with the weld seam by means of the movement of the welding device (10), thereby improving the positioning accuracy of welding, thus effectively improving the welding quality. The present invention also relates to a welding system and a storage medium.

Description

Welding methods, welding systems and storage media

[0001] Related applications

[0002] This application claims priority to Chinese patent application filed on July 19, 2024, application number 2024109726296, entitled "Welding Method, Welding System and Storage Medium", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of welding technology, and in particular to a welding method, welding system and storage medium. Background Technology

[0004] Pipe-to-pipe and pipe flange welding is mainly used in various industrial fields, such as petrochemicals, energy, aerospace, shipbuilding, and automobile manufacturing. In these industries and scenarios, pipeline systems are an indispensable component for transporting various media such as liquids and gases. The quality and stability of the pipeline system directly affect the safety and efficiency of the entire industrial production process. Therefore, the quality and efficiency of pipe-to-pipe and pipe flange welding are of great significance for ensuring the smooth operation of industrial production.

[0005] However, in some situations, traditional pipe-to-pipe and pipe-flange welding methods have many problems and challenges, such as insufficient positioning accuracy of welding positions, excessive manual intervention, and low degree of automation. These problems limit the quality and production efficiency of pipeline systems.

[0006] Summary of the Invention

[0007] According to various embodiments of this application, a welding method, a welding system, and a storage medium are provided.

[0008] In a first aspect, this application provides a welding method for a welding system, the welding system including a welding apparatus and an image acquisition device, the welding method comprising:

[0009] Obtain weld information of the workpiece, the weld information including different numbering sequences corresponding to different welds of the workpiece, the reference position of the weld corresponding to each numbering sequence, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage and the welding current;

[0010] The welding device is controlled to perform arc positioning detection on the workpiece, and the detection result after the arc positioning detection is performed on the workpiece is obtained;

[0011] The actual rotation speed of the workpiece is determined based on the weld information and the detection results. The workpiece is controlled to rotate around its own axis at the actual rotation speed by a preset angle R. At the same time, the image acquisition device is controlled to perform a weld scanning operation on the workpiece and obtain the coordinate information of the weld of the workpiece.

[0012] Based on the weld information, the detection results, and the coordinate information, the workpiece is controlled to rotate in the opposite direction around its own axis at the actual rotation speed by a preset angle R, while the welding device is controlled to perform welding operations on the workpiece.

[0013] In the technical solution of this application embodiment, the error between weld information and detection result can be avoided by arc positioning detection, the image acquisition device can clearly identify and acquire the image of the workpiece weld by moving, and the welding part can be aligned with the weld by moving the welding device, thereby improving the positioning accuracy of welding and effectively improving the welding quality.

[0014] In some embodiments, controlling the image acquisition device to perform weld seam scanning on the workpiece specifically includes:

[0015] The image acquisition device is controlled to acquire the weld seam image of the workpiece at a preset frame rate, and the rotation angle corresponding to each frame of the weld seam image of the workpiece.

[0016] In the technical solution of this application embodiment, determining the actual rotation speed of the workpiece helps to ensure that the image acquisition device can clearly identify and acquire the image of the workpiece weld, thereby improving the accuracy of the weld scanning operation, obtaining coordinate information of the workpiece weld with high precision, and controlling the workpiece to rotate in the positive direction around its own axis at the actual rotation speed by a preset angle R can ensure that the workpiece rotates in the positive direction around its own axis at the actual rotation speed at least one revolution, so as to ensure that the image acquisition device can acquire a complete weld image.

[0017] In some embodiments, obtaining the coordinate information of the weld seam of the workpiece specifically includes:

[0018] Calculate the weld coordinates relative to the welding device in the weld image of the workpiece in each frame, and form a weld coordinate queue based on the weld coordinates and the corresponding rotation angle.

[0019] In the technical solution of this application embodiment, the relative position of the welding device and the workpiece weld can be determined according to the weld coordinate queue, thereby controlling the welding device to perform welding operation on the workpiece weld more accurately, so as to effectively improve the welding effect.

[0020] In some embodiments, the preset angle R needs to meet the condition: R>360°.

[0021] In the technical solution of this application embodiment, when the preset angle R>360°, after controlling the workpiece to rotate in the positive direction around its own axis at the actual rotation speed by the preset angle R, it can be ensured that the initial position rotates more than one revolution around the workpiece axis. In this way, it can be ensured that the image acquisition device can acquire a complete weld image to obtain complete coordinate information of the workpiece weld.

[0022] In some embodiments, controlling the welding device to perform welding operations on the workpiece specifically includes:

[0023] The welding device is controlled to weld the weld seam of the workpiece, and the position of the welding part of the welding device relative to the weld seam of the workpiece is adjusted in real time according to the weld seam coordinate queue, so that the welding part of the welding device is aligned with the weld seam of the workpiece in real time.

[0024] In the technical solution of this application embodiment, during the welding operation of the workpiece, the workpiece is controlled to rotate in the opposite direction around its own axis at an actual rotational speed by a preset angle R, which corresponds exactly to the weld seam coordinate queue. This ensures that the welding device can adjust the position of the welding part of the welding device relative to the workpiece weld seam in real time according to the weld seam coordinate queue, so that the welding part of the welding device and the workpiece weld seam are aligned in real time, and the welding quality can be effectively improved.

[0025] In some embodiments, the detection results include the measured outer diameter of the workpiece, a first distance between the image acquisition device and the workpiece, and a second distance between the welding device and the workpiece.

[0026] In the technical solution of this application embodiment, by assigning different numbering sequences to different weld seams, it is convenient to manage multiple weld seams. Based on the first distance between the image acquisition device and the workpiece, the distance between the image acquisition device and the workpiece can be adaptively adjusted to achieve weld seam alignment between the image acquisition device and the workpiece. Based on the second distance between the welding device and the workpiece, the distance between the welding part of the welding device and the workpiece can be adaptively adjusted to improve the accuracy of weld seam alignment between the welding part of the welding device and the workpiece, thereby effectively improving the welding effect.

[0027] In some embodiments, determining the actual rotational speed of the workpiece based on the weld information and the detection result specifically includes:

[0028] Compare the measured outer diameter with the theoretical outer diameter;

[0029] If the measured outer diameter is determined to be different from the theoretical outer diameter, then the actual rotational speed of the workpiece is determined based on the measured outer diameter; or

[0030] Compare the measured outer diameter with the theoretical outer diameter;

[0031] If the measured outer diameter is determined to be equal to the theoretical outer diameter, then the theoretical welding speed is taken as the actual rotational speed of the workpiece.

[0032] In the technical solution of this application embodiment, by comparing the measured outer diameter of the workpiece with the theoretical outer diameter of the workpiece, the error between the theoretical outer diameter and the measured outer diameter of the workpiece can be avoided, which is conducive to ensuring the accuracy of the weld scanning operation and thus improving the accuracy of the coordinate information of the workpiece weld.

[0033] In some embodiments, before controlling the workpiece to rotate a preset angle R about its own axis at the actual rotational speed, the welding method further includes:

[0034] The image acquisition device is controlled to move to the first preset position according to the first spacing, so that the image acquisition device and the workpiece meet the preset scanning distance;

[0035] The welding part of the welding device is moved to the second preset position according to the second spacing, so that the welding part of the welding device and the workpiece meet the preset safety distance.

[0036] In the technical solution of this application embodiment, based on the first distance between the image acquisition device and the workpiece, the image acquisition device can be moved to a first preset position so that the image acquisition device and the workpiece meet a preset scanning distance, thereby achieving weld seam alignment between the image acquisition device and the workpiece. This allows the image acquisition device to clearly identify and acquire images of the workpiece weld seam, thereby improving the accuracy of the weld seam scanning operation and obtaining coordinate information of the workpiece weld seam with high precision. Based on the second distance between the welding device and the workpiece, the welding part of the welding device can be controlled to move to a second preset position so that the welding part of the welding device and the workpiece meet a preset safety distance, thereby achieving alignment between the welding part of the welding device and the workpiece weld seam, which is beneficial to improving the welding accuracy and effectively improving the welding effect.

[0037] In some embodiments, before performing a weld scanning operation on the workpiece based on the weld information and the detection results, the welding method further includes:

[0038] A number sequence is selected, and the welding device is controlled to move to a third preset position according to the reference position corresponding to the number sequence, so that the body of the welding device is aligned with the weld seam of the workpiece corresponding to the reference position.

[0039] In the technical solution of this application embodiment, the welding device is controlled to move to a third preset position according to the reference position corresponding to the number sequence, so that the body of the welding device is aligned with the weld seam of the workpiece corresponding to the reference position. In this way, there is enough space around the body of the welding device for the welding part to move, so as to control the alignment of the welding part with the corresponding weld seam.

[0040] In some embodiments, after performing a welding operation on the workpiece based on the weld information, the detection result, and the coordinate information, the welding method further includes:

[0041] Return to the step of selecting a number sequence, reselect a number sequence, and repeat the subsequent steps.

[0042] In the technical solution of this application embodiment, the welding method provided by this application embodiment can continuously realize the welding operation of multiple different welds, with a high degree of automation and convenient operation, which can effectively improve welding efficiency.

[0043] A welding system for the welding method described in the foregoing embodiments, comprising:

[0044] A welding device, comprising a machine body and a welding part fitted onto the machine body, the welding part being used to weld the weld seam of a workpiece;

[0045] An image acquisition device is used to acquire weld images of the workpiece at a preset frame rate; and

[0046] A positioner is used to mount the workpiece and control the workpiece to rotate about its own axis at an actual rotational speed.

[0047] A storage medium containing computer-executable instructions, which, when executed by a computer processor, are used to perform the welding method as described in the foregoing embodiments.

[0048] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the disclosed drawings without creative effort.

[0050] Figure 1 is a schematic flowchart of a welding method in one embodiment of this application.

[0051] Figure 2 is a schematic flowchart of a welding method in another embodiment of this application.

[0052] Figure 3 is a schematic flowchart of a welding method in another embodiment of this application.

[0053] Figure 4 is a schematic flowchart of the welding method in another embodiment of this application.

[0054] Figure 5 is a schematic flowchart of the welding method in another embodiment of this application.

[0055] Figure 6 is a schematic flowchart of a welding method in another embodiment of this application.

[0056] Figure 7 is a schematic flowchart of the welding method in another embodiment of this application.

[0057] Figure 8 is a schematic flowchart of a welding method in another embodiment of this application.

[0058] Figure 9 is a schematic diagram of the welding system in this application.

[0059] Welding system 100;

[0060] Welding device 10; fuselage 101; welding section 102;

[0061] Image acquisition unit 11; positioner 12; track 13. Detailed Implementation

[0062] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0063] Please refer to Figure 1. This application embodiment provides a welding method for a welding system 100, which includes a welding device 10 and an image acquisition device 11.

[0064] In this embodiment, both the welding method and the welding system 100 are used in the technical field of pipe welding, and the workpiece corresponds to a pipe. It is understood that the welding method and welding system 100 can also be used in other technical fields, and the workpiece can correspond to other structures.

[0065] Specifically, the welding method includes the following steps:

[0066] S10: Obtain weld information for the workpiece.

[0067] In this application, weld information refers to the theoretical information of the workpiece when assembled into the weld system, the product information of the tooling itself, and the theoretical process parameters required for welding the workpiece. For example, the theoretical information of the workpiece when assembled into the weld system refers to the reference position of the weld seam of the workpiece, that is, the absolute distance of the weld seam along the pipe axis relative to a reference datum; the product information of the tooling itself refers to the theoretical outer diameter of the workpiece; the theoretical process parameters required for welding the workpiece refer to the theoretical welding speed, welding voltage, and welding current of the workpiece, wherein the welding voltage refers to the voltage required for welding the workpiece, the welding current refers to the current required for welding the workpiece, and the theoretical welding speed refers to the theoretical linear velocity of the pipe rotating around its own axis during welding.

[0068] S20: Control the welding device 10 to perform arc positioning detection on the workpiece and obtain the detection results after the arc positioning detection of the workpiece.

[0069] It should be noted that the specific methods and operating procedures for arc positioning detection are conventional techniques for those skilled in the art, and will not be elaborated here.

[0070] In this application, the detection results can be understood as the actual information of the workpiece assembled within the weld system, the actual product information of the tooling, and the actual process parameters required for workpiece welding. For example, the actual information of the workpiece assembled within the weld system refers to the first distance between the image acquisition device 11 and the workpiece, and the second distance between the welding device 10 and the workpiece; the actual product information of the tooling refers to the measured outer diameter of the workpiece; and the actual process parameters required for workpiece welding refer to the actual linear velocity of the pipe rotating around its own axis during welding.

[0071] S30: Based on the weld information and inspection results, control the image acquisition device 11 to perform weld scanning operation on the workpiece and obtain the coordinate information of the weld of the workpiece.

[0072] Understandably, during the weld seam scanning operation on the workpiece, it is necessary to control the image acquisition device 11 to align with the weld seam of the workpiece according to the weld seam information and detection results, so that the image acquisition device 11 can clearly identify and acquire the image of the weld seam of the workpiece, thereby improving the accuracy of the weld seam scanning operation and obtaining the coordinate information of the weld seam of the workpiece with high precision.

[0073] For example, the distance between the image acquisition device 11 and the workpiece can be adaptively adjusted according to the first distance between the image acquisition device 11 and the workpiece to achieve weld alignment between the image acquisition device 11 and the workpiece.

[0074] S40: Based on weld information, inspection results and coordinate information, control the welding part 102 of the welding device 10 to perform welding operations on the workpiece.

[0075] It is understandable that by controlling the welding part 102 of the welding device 10 to perform welding operations on the workpiece based on weld information, inspection results and coordinate information, the welding part 102 of the welding device 10 can be aligned with the weld of the workpiece, thereby effectively improving the welding effect.

[0076] For example, the distance between the welding part 102 of the welding device 10 and the workpiece can be adaptively adjusted according to the second distance between the welding device 10 and the workpiece, so as to improve the accuracy of the weld seam alignment between the welding part 102 of the welding device 10 and the workpiece, thereby effectively improving the welding effect.

[0077] In some embodiments, please refer to Figure 2. The control of the image acquisition device 11 to perform weld seam scanning operation on the workpiece based on weld seam information and detection results in the foregoing embodiments specifically includes:

[0078] S301: Determine the actual rotation speed of the workpiece based on weld information and inspection results.

[0079] During the weld seam scanning operation on the workpiece, the image acquisition unit 11 is first aligned with the weld seam of the workpiece based on the weld seam information and inspection results. Then, the image acquisition unit 11 is kept stationary while the workpiece rotates synchronously around its own axis. This allows the image acquisition unit 11 to continuously acquire complete images and information of the weld seam on the workpiece. Correspondingly, the actual rotation speed of the workpiece can be understood as follows: when the workpiece rotates around its own axis at the actual rotation speed, it helps ensure that the image acquisition unit 11 can clearly identify and acquire the image of the workpiece's weld seam, thereby improving the accuracy of the weld seam scanning operation and obtaining high-precision coordinate information of the workpiece's weld seam.

[0080] It is understandable that, due to the possible errors between weld information and inspection results, when weld information and inspection results are not identical, the inspection results are generally considered to be more consistent with the actual situation of the workpiece, and the operation of the image acquisition device 11 and welding device 10 is controlled based on the inspection results.

[0081] For example, by comparing the measured outer diameter of the workpiece with the theoretical outer diameter of the workpiece, and determining that the measured outer diameter and the theoretical outer diameter are not equal, it is generally believed that the measured outer diameter of the workpiece is more representative of the actual outer diameter of the workpiece. Therefore, in order to avoid the error between the theoretical outer diameter and the measured outer diameter of the workpiece, it is necessary to use the measured outer diameter of the workpiece for weld scanning operation. This helps to ensure the accuracy of weld scanning operation, thereby improving the accuracy of the coordinate information of the weld of the workpiece.

[0082] In this application, when the measured outer diameter differs from the theoretical outer diameter, the theoretical rotational speed required for the workpiece with the theoretical outer diameter also differs from the actual rotational speed required for the workpiece with the measured outer diameter. Therefore, when the measured outer diameter differs from the theoretical outer diameter, it is necessary to determine the actual rotational speed of the workpiece by measuring the outer diameter, and control the workpiece to rotate around its own axis based on the actual rotational speed.

[0083] S302: Control the workpiece to rotate a preset angle R around its own axis at the actual rotation speed, and at the same time control the image acquisition device 11 to acquire the weld seam image of the workpiece and the rotation angle corresponding to each frame of the workpiece's weld seam image at a preset frame rate.

[0084] It is understood that, in the embodiments of this application, the workpiece rotating in the forward direction around its own axis at its actual rotational speed can be understood as the workpiece rotating clockwise around its own axis at its actual rotational speed. Correspondingly, the workpiece rotating in the reverse direction around its own axis at its actual rotational speed can be understood as the workpiece rotating counterclockwise around its own axis at its actual rotational speed. It should be noted that "forward" can correspond to either clockwise or counterclockwise, while "reverse" should correspond to the direction opposite to "forward".

[0085] During the weld seam scanning operation on the workpiece, the image acquisition unit 11 is first aligned with the weld seam of the workpiece based on the weld seam information and inspection results. Then, the image acquisition unit 11 is kept stationary while the workpiece rotates around its own axis synchronously. Since the workpiece is a pipe, the weld seam extends and closes around the circumference of the workpiece. Therefore, controlling the workpiece to rotate around its own axis at the actual rotation speed by a preset angle R can be understood as ensuring that the workpiece rotates at least one full revolution around its own axis at the actual rotation speed, so that the image acquisition unit 11 can acquire a complete weld seam image of the workpiece.

[0086] For ease of understanding, the position where the image acquisition device 11 aligns with the weld seam of the workpiece before the workpiece is rotated in the positive direction around its own axis is defined as the initial position. After the workpiece is rotated in the positive direction around its own axis at the actual rotation speed by a preset angle R, the initial position passes through the image acquisition device 11 at least once, or the initial position is aligned with the image acquisition device 11 again.

[0087] The specific range of values ​​for the preset angle R is not limited. In some embodiments, the preset angle R needs to meet the condition: R>360°.

[0088] It is understandable that when the preset angle R > 360°, controlling the workpiece to rotate around its own axis at the actual rotation speed by the preset angle R can ensure that the initial position rotates more than one revolution around the workpiece axis. In this way, it can ensure that the image acquisition device can acquire a complete image of the workpiece's weld seam to obtain the complete coordinate information of the workpiece's weld seam.

[0089] In one embodiment, the preset angle R is 370°. This provides a larger margin of error to ensure that the image acquisition device can capture a complete weld image of the workpiece.

[0090] It should be noted that the specific range of the preset angle R is obtained through experimental testing. The parameters and steps related to the experimental testing of the specific range of the preset angle R are conventional techniques for those skilled in the art and will not be elaborated here.

[0091] In some embodiments, please refer to Figure 3. Obtaining the coordinate information of the weld seam of the workpiece in the foregoing embodiments specifically includes:

[0092] S303: Calculate the weld coordinates relative to the welding device 10 in the weld image of each workpiece frame, and form a weld coordinate queue based on the weld coordinates and their corresponding rotation angles.

[0093] It can be understood that the weld coordinate queue can be understood as follows: during the process of the workpiece rotating around its own axis at an actual rotation speed and a preset angle R, the image acquisition device 11 acquires the weld image of the workpiece at a certain frame rate. At the same time as acquiring the image, the absolute rotation angle of the workpiece is obtained, and the weld image and the absolute rotation angle data of the workpiece are stored in pairs. Then, the algorithm service is started to identify the pixel position of the weld feature point in the weld image of the workpiece, and the absolute position of the weld in the coordinate system of the welding device 10 is calculated through the coordinate transformation algorithm. In this way, the absolute position of the weld in the coordinate system of the welding device 10 and the absolute rotation angle of the workpiece form a weld coordinate queue.

[0094] It should be noted that the coordinate system of the welding device 10 refers to a three-dimensional coordinate system established with the welding device 10 as the origin. Therefore, the obtained weld coordinate queue can be understood as the coordinates of the weld in the coordinate system of the welding device 10 when the workpiece rotates by a corresponding angle. In this way, the relative position of the weld between the welding device 10 and the workpiece can be determined based on the weld coordinate queue, thereby enabling more precise control of the welding device 10 to perform welding operations on the workpiece's weld, effectively improving the welding effect.

[0095] In some embodiments, please refer to Figure 4. The welding operation on the workpiece based on weld information, inspection results, and coordinate information in the foregoing embodiments specifically includes:

[0096] S401: Control the workpiece to rotate in the opposite direction around its own axis at the actual rotation speed by a preset angle R, and at the same time control the welding part 102 of the welding device 10 to weld the weld of the workpiece, and adjust the position of the welding part 102 of the welding device 10 relative to the weld of the workpiece in real time according to the weld coordinate queue, so that the welding part 102 of the welding device 10 and the weld of the workpiece are aligned in real time.

[0097] Understandably, during the process of controlling the image acquisition unit 11 to perform weld seam scanning on the workpiece, it is necessary to control the workpiece to rotate a preset angle R around its own axis at the actual rotational speed. Therefore, when the forward direction is clockwise, the reverse direction corresponds to the counterclockwise direction. Furthermore, the range of rotation angles in the weld seam coordinate queue obtained through the weld seam scanning operation corresponds to the preset angle R of the workpiece rotating forward around its own axis. Thus, during the welding operation, controlling the workpiece to rotate a preset angle R backward around its own axis at the actual rotational speed precisely corresponds to the weld seam coordinate queue. This ensures that the welding device 10 can adjust the position of the welding part 102 relative to the weld seam of the workpiece in real time according to the weld seam coordinate queue, so that the welding part 102 of the welding device 10 is aligned with the weld seam of the workpiece in real time, effectively improving the welding quality.

[0098] Understandably, during the welding process, the workpiece needs to be rotated in the opposite direction around its own axis at a preset angle R greater than 360° to ensure that the starting and ending points of the weld overlap fully, effectively improving the stability of the weld and making the ending point of the weld smooth and aesthetically pleasing.

[0099] In some embodiments, the weld information includes different numbering sequences corresponding to different welds on the workpiece, the reference position of the weld corresponding to each numbering sequence, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage, and the welding current.

[0100] The welding method provided in this application embodiment can perform welding operations on multiple different weld seams.

[0101] Understandably, assigning different numbering sequences to different welds facilitates the management of multiple welds. Each weld also has a corresponding reference position, workpiece theoretical outer diameter, theoretical welding speed, welding voltage, and welding current. Therefore, in the specific welding operation of the above welding method, a numbering sequence must first be selected. Then, based on this numbering sequence, the corresponding weld reference position, workpiece theoretical outer diameter, theoretical welding speed, welding voltage, and welding current are determined. Finally, based on the corresponding weld reference position, workpiece theoretical outer diameter, theoretical welding speed, welding voltage, and welding current, the various steps of the above welding method are executed sequentially.

[0102] The test results include the measured outer diameter of the workpiece, the first distance between the image acquisition device 11 and the workpiece, and the second distance between the welding device 10 and the workpiece.

[0103] Understandably, based on the first distance between the image acquisition device 11 and the workpiece, the distance between the image acquisition device 11 and the workpiece can be adaptively adjusted to achieve weld alignment between the image acquisition device 11 and the workpiece.

[0104] Based on the second distance between the welding device 10 and the workpiece, the distance between the welding part 102 of the welding device 10 and the workpiece can be adaptively adjusted to improve the accuracy of the weld seam alignment between the welding part 102 of the welding device 10 and the workpiece, thereby effectively improving the welding effect.

[0105] In some embodiments, please refer to Figure 5. The determination of the actual rotation speed of the workpiece based on weld information and inspection results in the foregoing embodiments specifically includes:

[0106] S3011: Compare the measured outer diameter with the theoretical outer diameter.

[0107] S3012: If the measured outer diameter is not equal to the theoretical outer diameter, then the actual rotational speed of the workpiece is determined based on the measured outer diameter.

[0108] It is understandable that, due to the possible errors between weld information and inspection results, when weld information and inspection results are not identical, the inspection results are generally considered to be more consistent with the actual situation of the workpiece, and the operation of the image acquisition device 11 and welding device 10 is controlled based on the inspection results.

[0109] In this application, by comparing the measured outer diameter of the workpiece with the theoretical outer diameter of the workpiece, and determining that the measured outer diameter and the theoretical outer diameter are not equal, it is generally believed that the measured outer diameter of the workpiece is more representative of the actual outer diameter of the workpiece. Therefore, in order to avoid the error between the theoretical outer diameter and the measured outer diameter of the workpiece, it is necessary to use the measured outer diameter of the workpiece for weld scanning operation. This helps to ensure the accuracy of weld scanning operation and thus improve the accuracy of the coordinate information of the weld of the workpiece.

[0110] Correspondingly, when the measured outer diameter differs from the theoretical outer diameter, the theoretical rotational speed required for a workpiece with the theoretical outer diameter also differs from the actual rotational speed required for a workpiece with the measured outer diameter. Therefore, when the measured outer diameter differs from the theoretical outer diameter, it is necessary to determine the actual rotational speed of the workpiece by measuring the outer diameter, and control the workpiece's rotation around its own axis based on the actual rotational speed.

[0111] In some embodiments, please refer to Figure 6. The determination of the actual rotational speed of the workpiece based on weld information and inspection results in the foregoing embodiments specifically includes:

[0112] S3013: Compare the measured outer diameter with the theoretical outer diameter;

[0113] S3014: If the measured outer diameter is determined to be equal to the theoretical outer diameter, then the theoretical welding speed shall be taken as the actual rotation of the workpiece.

[0114] In some embodiments, referring to Figure 7, before controlling the workpiece to rotate a preset angle R around its own axis at an actual rotational speed, the welding method further includes:

[0115] S304: Control the image acquisition device 11 to move to the first preset position according to the first spacing so that the image acquisition device 11 and the workpiece meet the preset scanning distance.

[0116] Understandably, based on the first distance between the image acquisition device 11 and the workpiece, the image acquisition device 11 can be moved to a first preset position so that the image acquisition device 11 and the workpiece meet the preset scanning distance, thereby achieving the alignment of the weld seam between the image acquisition device 11 and the workpiece, so that the image acquisition device 11 can clearly identify and acquire the image of the weld seam of the workpiece, thereby improving the accuracy of the weld seam scanning operation and obtaining the coordinate information of the weld seam of the workpiece with high precision.

[0117] S305: The welding part 102 of the welding device 10 is moved to the second preset position according to the second spacing, so that the welding part 102 of the welding device 10 and the workpiece meet the preset safety distance.

[0118] It is understandable that, based on the second distance between the welding device 10 and the workpiece, the welding part 102 of the welding device 10 can be controlled to move to the second preset position so that the welding part 102 of the welding device 10 and the workpiece meet the preset safety distance, thereby achieving the alignment of the weld seam between the welding part 102 of the welding device 10 and the workpiece, which is beneficial to improving the welding accuracy and effectively improving the welding effect.

[0119] In some embodiments, as shown in Figure 8, before performing a weld scanning operation on the workpiece based on weld information and inspection results, the welding method further includes:

[0120] S50: Select a number sequence and control the welding device 10 to move to the third preset position according to the reference position corresponding to the number sequence, so that the body 101 of the welding device is aligned with the weld of the workpiece corresponding to the reference position.

[0121] It is understood that the welding device 10 is moved to the third preset position according to the reference position corresponding to the number sequence so that the body 101 of the welding device 10 is aligned with the weld seam of the workpiece corresponding to the reference position. In this way, there is enough space around the body 101 of the welding device 10 for the welding part 102 to move so as to control the alignment of the welding part 102 with the corresponding weld seam.

[0122] In some embodiments, as shown in Figure 8, after performing welding operations on the workpiece based on weld information, inspection results, and coordinate information, the welding method further includes:

[0123] S60: Return to the step of selecting a number sequence, reselect a number sequence, and repeat the subsequent steps.

[0124] It is understandable that after selecting a number sequence and sequentially executing and completing each step of the above welding method according to the reference position of the weld seam corresponding to that number sequence, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage, and the welding current, thus completing the welding of the weld seam corresponding to that number sequence, it is necessary to return to step S50, reselect a number sequence, and again sequentially execute and complete each step of the above welding method according to the reference position of the weld seam corresponding to the reselected number sequence, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage, and the welding current. In this way, the welding method provided in this application embodiment can continuously realize the welding operation of multiple different weld seams, has a high degree of automation, is easy to operate, and can effectively improve welding efficiency.

[0125] In some embodiments, the weld information also includes the weld type.

[0126] In this application, the weld types include circumferential welds and flange fillet welds. By determining the weld type, the image acquisition device 11 can be controlled to move along the specific path and scan posture when scanning the workpiece, and the welding device 10 can also be controlled to move along the specific path and weld posture when welding the workpiece. This improves the accuracy of welding and surface scanning operations, thereby enhancing the welding quality.

[0127] It is understandable that there is no limit to the specific types and number of welds.

[0128] In some embodiments, the welding method further includes, before controlling the welding apparatus 10 to perform arc positioning detection on the workpiece:

[0129] Perform a torch cleaning operation on the welding device 10.

[0130] Specifically, the gun cleaning operation includes steps such as cutting wire, scraping slag, and spraying oil. It should be noted that the specific methods and procedures for gun cleaning are standard techniques for those skilled in the art and will not be elaborated here.

[0131] In some embodiments, please refer to Figure 8, the welding method includes the following steps:

[0132] S10: Obtain weld information for the workpiece.

[0133] S50: Select a number sequence and control the welding device 10 to move to the third preset position according to the reference position corresponding to the number sequence, so that the body 101 of the welding device is aligned with the weld of the workpiece corresponding to the reference position.

[0134] S20: Control the welding device 10 to perform arc positioning detection on the workpiece and obtain the detection results after the arc positioning detection of the workpiece.

[0135] S3011: Compare the measured outer diameter with the theoretical outer diameter.

[0136] S3012: If the measured outer diameter is not equal to the theoretical outer diameter, then the actual rotational speed of the workpiece is determined based on the measured outer diameter.

[0137] S302: Control the workpiece to rotate a preset angle R around its own axis at the actual rotation speed, and at the same time control the image acquisition device 11 to acquire the weld seam image of the workpiece and the rotation angle corresponding to each frame of the workpiece's weld seam image at a preset frame rate.

[0138] S304: Control the image acquisition device 11 to move to the first preset position according to the first spacing so that the image acquisition device 11 and the workpiece meet the preset scanning distance.

[0139] S305: The welding part 102 of the welding device 10 is moved to the second preset position according to the second spacing, so that the welding part 102 of the welding device 10 and the workpiece meet the preset safety distance.

[0140] S303: Calculate the weld coordinates relative to the welding device 10 in the weld image of each workpiece frame, and form a weld coordinate queue based on the weld coordinates and their corresponding rotation angles.

[0141] S401: Control the workpiece to rotate in the opposite direction around its own axis at the actual rotation speed by a preset angle R, and at the same time control the welding part 102 of the welding device 10 to weld the weld of the workpiece, and adjust the position of the welding part 102 of the welding device 10 relative to the weld of the workpiece in real time according to the weld coordinate queue, so that the welding part 102 of the welding device 10 and the weld of the workpiece are aligned in real time.

[0142] S60: Return to step S50, select a new number sequence, and repeat the subsequent steps.

[0143] Specifically, the process for implementing welding room fees is as follows:

[0144] The first step is to obtain the weld information of the workpiece. The weld information includes different numbering sequences corresponding to different welds, the reference position of the weld corresponding to each numbering sequence, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage, and the welding current.

[0145] The second step is to select a number sequence and control the welding device 10 to move to a third preset position according to the reference position corresponding to the number sequence, so that the body 101 of the welding device 10 is aligned with the weld seam of the workpiece corresponding to the reference position. In this way, there is enough space around the body 101 of the welding device 10 for the welding part 102 to move, so as to control the welding part 102 to be aligned with the corresponding weld seam.

[0146] The third step involves controlling the welding device 10 to perform arc positioning detection on the workpiece and acquiring the detection results after the arc positioning detection. These results include the measured outer diameter of the workpiece, the first distance between the image acquisition device 11 and the workpiece, and the second distance between the welding device 10 and the workpiece.

[0147] The fourth step involves comparing the measured outer diameter of the workpiece with its theoretical outer diameter. When the measured outer diameter is not equal to the theoretical outer diameter, it is generally believed that the measured outer diameter of the workpiece is more representative of its actual outer diameter. Therefore, to avoid the error between the theoretical and measured outer diameters, the measured outer diameter of the workpiece is used for weld scanning. This helps to ensure the accuracy of the weld scanning operation and improves the accuracy of the coordinate information of the weld seam.

[0148] The fifth step involves determining the difference between the measured outer diameter and the theoretical outer diameter. This difference stems from the fact that the theoretical rotational speed required for a workpiece with the theoretical outer diameter differs from the actual rotational speed required for a workpiece with the measured outer diameter. Therefore, when the measured outer diameter differs from the theoretical outer diameter, it is necessary to determine the actual rotational speed of the workpiece by measuring the outer diameter and then control the workpiece's rotation around its own axis based on this actual rotational speed.

[0149] The sixth step involves moving the image acquisition device 11 to a first preset position based on the first distance between the image acquisition device 11 and the workpiece, so that the image acquisition device 11 and the workpiece meet the preset scanning distance, thereby aligning the weld seam of the image acquisition device 11 with the workpiece. This allows the image acquisition device 11 to clearly identify and acquire the image of the weld seam of the workpiece, thereby improving the accuracy of the weld seam scanning operation and obtaining coordinate information of the weld seam of the workpiece with high precision.

[0150] The seventh step involves controlling the welding part 102 of the welding device 10 to move to a second preset position based on the second distance between the welding device 10 and the workpiece. This ensures that the welding part 102 of the welding device 10 and the workpiece meet the preset safety distance, thereby aligning the weld seam of the welding part 102 of the welding device 10 with the workpiece. This improves the accuracy of the welding and effectively enhances the welding effect.

[0151] Step 8: Control the workpiece to rotate positively around its own axis at the actual rotational speed by a preset angle R. Simultaneously, control the image acquisition unit 11 to acquire the weld seam image of the workpiece at a preset frame rate, and the rotation angle corresponding to each frame of the workpiece's weld seam image. Specifically, during the process of the workpiece rotating positively around its own axis at the actual rotational speed by a preset angle R, the image acquisition unit 11 acquires the weld seam image of the workpiece at a certain frame rate, and simultaneously acquires the absolute rotation angle of the workpiece, storing the weld seam image and the absolute rotation angle data of the workpiece in pairs. The preset angle R ensures that the workpiece rotates at least one full revolution around its own axis at the actual rotational speed, ensuring that the image acquisition unit 11 can acquire a complete weld seam image of the workpiece.

[0152] The ninth step is to calculate the weld coordinates relative to the welding device 10 in the weld image of each workpiece frame, and form a weld coordinate queue based on the weld coordinates and their corresponding rotation angles. Specifically, the algorithm service is activated to identify the pixel positions of weld feature points in the weld image of the workpiece, and the absolute position of the weld in the coordinate system of the welding device 10 is calculated through a coordinate transformation algorithm, and finally the weld coordinate queue is obtained.

[0153] Step 10: Control the workpiece to rotate counter-clockwise by a preset angle R around its own axis at its actual rotational speed. Simultaneously, control the welding part 102 of the welding device 10 to weld the weld seam of the workpiece. Adjust the position of the welding part 102 relative to the weld seam of the workpiece in real time according to the weld seam coordinate queue, ensuring real-time alignment between the welding part 102 and the weld seam. Specifically, during the welding operation, controlling the workpiece to rotate counter-clockwise by a preset angle R around its own axis at its actual rotational speed corresponds precisely to the weld seam coordinate queue. This ensures that the welding device 10 can adjust the position of its welding part 102 relative to the weld seam of the workpiece in real time according to the weld seam coordinate queue, effectively improving welding quality.

[0154] Step 11: Return to step S50, reselect a number sequence, and again execute and complete each step of the above welding method according to the reference position of the weld seam, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage, and the welding current corresponding to the reselected number sequence. Thus, the welding method provided in this embodiment can continuously weld multiple different weld seams, has a high degree of automation, is easy to operate, and can effectively improve welding efficiency.

[0155] Please refer to Figure 9. Another aspect of this application provides a welding system 100, which includes a welding device 10, an image acquisition device 11, and a positioner 12.

[0156] The welding apparatus 10 includes a body 101 and a welding section 102 mounted on the body 101. The welding section 102 is used to weld the weld seam of the workpiece. An image acquisition unit 11 is used to acquire images of the weld seam of the workpiece at a preset frame rate. A positioner 12 is used to mount the workpiece and control the workpiece to rotate around its own axis at an actual rotational speed.

[0157] In some embodiments, see FIG9, the image acquisition device 11 is coupled to the welding part 102.

[0158] In some embodiments, see FIG9, the welding system 100 also includes a track 13 on which the body 101 of the welding device 10 is movably coupled.

[0159] It is understandable that during the process of controlling the welding device 10 to move to the third preset position according to the reference position corresponding to the number sequence, it is necessary to control the body 101 to move relative to the track 13 so that the body 101 of the welding device 10 is aligned with the weld seam of the workpiece corresponding to the reference position. In this way, the periphery of the body 101 of the welding device 10 has enough space for the welding part 102 to move so as to control the welding part 102 to be aligned with the corresponding weld seam.

[0160] In another aspect, this application provides a control system for the welding method described in the above embodiments. The control system is used to control the welding device 10, the image acquisition device 11, and the positioner 12 to execute the various steps of the welding method described in the above embodiments based on the weld information.

[0161] It is understood that before executing the welding method provided in this application embodiment, it is necessary to determine the specific content of the weld information in advance and import the determined weld information into the program of the control system. In this way, during the execution of the welding method, the control system can sequentially select different number sequences corresponding to different welds according to the imported weld information, and control the welding device 10, image acquisition device 11 and positioner 12 to execute each step of the welding method according to the reference position of the weld corresponding to the number sequence, the theoretical outer diameter of the workpiece, the theoretical welding speed, the welding voltage and the welding current.

[0162] In another aspect, this application provides a storage medium containing computer-executable instructions, which, when executed by a computer processor, are used to perform the welding method as described in the foregoing embodiments.

[0163] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0164] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A welding method for a welding system, the welding system comprising a welding device and an image collector, characterized in that, The welding method comprises: obtaining welding seam information of a workpiece, the welding seam information comprising different numbered sequences corresponding to different welding seams of the workpiece, reference positions of the welding seams corresponding to each numbered sequence, a theoretical outer diameter of the workpiece, a theoretical welding speed, a welding voltage and a welding current; controlling the welding device to perform arc positioning detection on the workpiece and obtaining a detection result of the workpiece after arc positioning detection; determining an actual rotating speed of the workpiece according to the welding seam information and the detection result, controlling the workpiece to rotate forward by a preset angle R around its own axis at the actual rotating speed, simultaneously controlling the image collector to perform welding seam scanning operation on the workpiece and obtaining coordinate information of the welding seam of the workpiece; controlling the workpiece to rotate reverse by the preset angle R around its own axis at the actual rotating speed according to the welding seam information, the detection result and the coordinate information, and simultaneously controlling the welding device to perform welding operation on the workpiece.

2. The welding method according to claim 1, characterized in that, The control of the image collector to perform welding seam scanning operation on the workpiece specifically comprises: controlling the image collector to obtain welding seam images of the workpiece and a rotating angle corresponding to each frame of the welding seam images of the workpiece at a preset frame rate.

3. The welding method according to claim 2, characterized in that, The obtaining of the coordinate information of the welding seam of the workpiece specifically comprises: calculating welding seam coordinates of the welding seam in each frame of the welding seam images of the workpiece relative to the welding device, and forming a welding seam coordinate queue according to the welding seam coordinates and the rotating angles corresponding thereto.

4. The welding method according to any one of claims 1 to 4, characterized in that The preset angle R needs to satisfy the condition: R>360°.

5. The welding method of claim 3, wherein, The control of the welding device to perform welding operation on the workpiece specifically comprises: controlling the welding device to perform welding on the welding seam of the workpiece, and adjusting a position of a welding part of the welding device relative to the welding seam of the workpiece in real time according to the welding seam coordinate queue, so that the welding part of the welding device is aligned with the welding seam of the workpiece in real time.

6. The welding method according to any one of claims 1 to 5, characterized in that, The detection result comprises a measured outer diameter of the workpiece, a first distance between the image collector and the workpiece and a second distance between the welding device and the workpiece.

7. The welding method of claim 6, wherein, The determination of the actual rotating speed of the workpiece according to the welding seam information and the detection result specifically comprises: comparing the measured outer diameter with the theoretical outer diameter; determining that the measured outer diameter is not equal to the theoretical outer diameter, and then determining the actual rotating speed of the workpiece according to the measured outer diameter; or comparing the measured outer diameter with the theoretical outer diameter; determining that the measured outer diameter is equal to the theoretical outer diameter, and then taking the theoretical welding speed as the actual rotating speed of the workpiece.

8. The welding method of claim 6, wherein, Before the control of the workpiece to rotate forward by the preset angle R around its own axis at the actual rotating speed, the welding method further comprises: controlling the image collector to move to the first preset position according to the first distance, so that a preset scanning distance is satisfied between the image collector and the workpiece; controlling a welding part of the welding device to move to the second preset position according to the second distance, so that a preset safety distance is satisfied between the welding part of the welding device and the workpiece.

9. The welding method of claim 6, wherein, Before the welding seam scanning operation is performed on the workpiece according to the welding seam information and the detection result, the welding method further comprises: selecting a number sequence, and controlling the welding device to move to a third preset position according to the reference position corresponding to the number sequence, so that the machine body of the welding device is aligned with the welding seam of the workpiece corresponding to the reference position.

10. The welding method of claim 9, wherein, After the welding operation is performed on the workpiece according to the welding seam information, the detection result and the coordinate information, the welding method further comprises: returning to the step of selecting a number sequence, reselecting a number sequence, and repeating the subsequent steps.

11. A welding system for use in the welding method according to any one of claims 1 to 10, characterized in that comprise: a welding device, the welding device comprising a machine body and a welding part matched with the machine body, the welding part being used for welding a welding seam of a workpiece; an image collector, used for acquiring a welding seam image of the workpiece at a preset frame rate; and a positioner, used for mounting the workpiece and controlling the workpiece to rotate around its own axis at an actual rotation speed.

12. A storage medium containing computer-executable instructions, wherein: The computer executable instructions, when executed by the computer processor, are used to perform the welding method as claimed in any one of claims 1 to 10.

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