CN116810117B - Welding method of resistance welding machine capable of outputting energy in temperature compensation mode - Google Patents
Welding method of resistance welding machine capable of outputting energy in temperature compensation mode Download PDFInfo
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- CN116810117B CN116810117B CN202311082527.9A CN202311082527A CN116810117B CN 116810117 B CN116810117 B CN 116810117B CN 202311082527 A CN202311082527 A CN 202311082527A CN 116810117 B CN116810117 B CN 116810117B
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- 238000003466 welding Methods 0.000 title claims abstract description 219
- 238000000034 method Methods 0.000 title claims abstract description 60
- 230000000694 effects Effects 0.000 claims abstract description 23
- 238000001816 cooling Methods 0.000 claims description 69
- 238000005259 measurement Methods 0.000 claims description 47
- 238000009826 distribution Methods 0.000 claims description 41
- 238000001514 detection method Methods 0.000 claims description 28
- 238000005299 abrasion Methods 0.000 claims description 24
- 238000012544 monitoring process Methods 0.000 claims description 13
- 238000004590 computer program Methods 0.000 claims description 6
- 238000002474 experimental method Methods 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 239000007769 metal material Substances 0.000 claims description 4
- 238000003860 storage Methods 0.000 claims description 4
- 238000004364 calculation method Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 description 17
- 230000001276 controlling effect Effects 0.000 description 10
- 230000008569 process Effects 0.000 description 9
- 238000012545 processing Methods 0.000 description 5
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- 229910052751 metal Inorganic materials 0.000 description 3
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- 238000010923 batch production Methods 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 239000000110 cooling liquid Substances 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000006073 displacement reaction Methods 0.000 description 1
- 238000004070 electrodeposition Methods 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
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- 239000010937 tungsten Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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Abstract
The application relates to a welding method of a resistance welding machine for outputting energy in a temperature compensation way, which belongs to the technical field of welding and comprises the following steps: when the welded workpiece is detected to enter a preset welded station, acquiring an initial temperature T1' of the electrode at the current moment; determining a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; determining a current value I 'corresponding to a resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2; the first corresponding relation table is used for storing temperature and corresponding resistance values; and controlling the resistance welder body to output the constant current for t seconds according to the current value I', and finishing the welding of the welded workpiece. The application has the function of improving the consistency of the welding effect while ensuring the batch welding efficiency.
Description
Technical Field
The application relates to the technical field of welding, in particular to a welding method of a resistance welding machine capable of outputting energy in a temperature compensation mode.
Background
The resistance welder is a device which compresses a welded workpiece (such as metal) between two electrodes, and applies current, and the welded workpiece contact part is processed to a molten or plastic state by resistance heat generated in the process of passing the current through the welded workpiece contact surface and the adjacent area, so that the welded workpiece contact part forms metal combination.
When the existing resistance welder is used for welding, the output current is generally in a constant current mode, namely, the current is output in a set current size and a set time regardless of the load resistance (the resistance of a welded workpiece plus the resistance of an electrode); accordingly, the welding energy q= (i×i×r) ×t for each workpiece, (where r=the resistance of the workpiece to be welded r1+the electrode resistance R2), and the welding energy Q may be used to characterize the welding effect.
Although the above-mentioned method can meet the general welding requirement, the following problems exist in the batch welding production process: when the first workpiece is welded, the temperature of the resistor is assumed to be T1, in the welding process, the welded workpiece and the electrode generate heat due to the current, the output current of normal resistance welding is thousands of amperes or even tens of kiloamperes, the temperature reaches thousands of degrees at the moment of welding, and the resistance of the metal material changes along with the change of the temperature due to the fact that the electrode is normally made of metal materials such as tungsten, molybdenum and the like; after the first workpiece is welded, the temperature of the electrode is T2; the pipeline robot arm grabs the second welded workpiece to the welding position, and starts the constant current mode to start welding of the second workpiece.
Disclosure of Invention
In order to improve the consistency of welding effect in the batch welding process, the application provides a welding method of a resistance welding machine with temperature compensation output energy.
In a first aspect, the present application provides a welding method of a resistance welding machine for temperature compensating output energy, which adopts the following technical scheme:
a welding method of a resistance welding machine with temperature compensation output energy comprises the following steps:
when the welded workpiece is detected to enter a preset welded station, acquiring an initial temperature T1' of the electrode at the current moment;
determining a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; determining a current value I 'corresponding to a resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2; the first corresponding relation table is used for storing the electrode temperature and the corresponding resistance value;
and controlling the resistance welder body to output the constant current for t seconds according to the current value I', and finishing the welding of the welded workpiece.
By adopting the technical scheme, the application provides that before welding a welded workpiece, the initial temperature T1 'of an electrode is detected, then the resistance value R1' and the current value I 'corresponding to the current initial temperature T1' are determined based on the detected initial temperature T1', a prestored first corresponding relation table, an ideal energy value Q and other data, and finally the current value I' is output for T seconds in a constant current manner, so that the welding of the welded workpiece is completed; by combining the technical scheme, the output current value I 'is adaptively adjusted according to the measured initial temperature T1' of the electrode, so that the welding energy generated by each welded workpiece can be close to an ideal energy value under the condition of not affecting the batch welding efficiency, and the consistency of the welding effect in batch welding is improved.
Optionally, the resistance value R1' corresponding to the initial temperature T1' is determined according to the initial temperature T1' and a pre-stored first correspondence table; according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2, determining a current value I 'corresponding to the resistance value R1', wherein the method comprises the following steps:
determining whether the initial temperature T1 'is in a preset temperature interval, and if not, controlling a preset cooling system to adjust the initial temperature T1' to be in the preset temperature interval; determining a current value I 'corresponding to an initial temperature T1' in the preset temperature interval;
determining a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; and determining a current value I 'corresponding to the resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2.
By adopting the technical scheme, for the detected initial temperature T1 'of the electrode, the application provides the following two processing modes to determine the corresponding current value I'. One is: firstly, the initial temperature T1 'is adjusted to be within a preset temperature interval, and then the current value I' corresponding to the preset temperature interval can be directly output, wherein the second step is that: whether the initial temperature T1' of the electrode when the second welded workpiece is welded is consistent with the initial temperature corresponding to the first welded workpiece is welded or not, the resistance value R1' and the current value I ' corresponding to the initial temperature T1' can be directly determined directly based on the initial temperature T1' at the current moment, and the corresponding relation stored in the first corresponding relation table can be obtained through a debugging experiment in advance by a debugging person.
In addition, the processing method is suitable for the occasions that the automatic high-speed welding lines with regular time intervals for replacing the workpieces to be welded are suitable for the welding consistency requirements on the workpieces to be welded are strict; the second treatment method is suitable for the occasions with irregular time intervals for replacing the workpieces to be welded and high requirements on batch welding speed; whichever of the above-mentioned processing methods is adopted, it is possible to reduce the degree of difference in the welding effect at the time of mass welding, and it is also possible to reduce the influence on the mass production speed; because in the prior art, in order to improve the consistency of the welding effect, a method of redundant cooling delay is generally adopted, that is, the time interval between waiting for welding of adjacent workpieces to be welded is set to be long enough, the production efficiency of mass production cannot be ensured in this way, and compared with the prior art, the two processing methods provided by the application can achieve the effects of both consistency of the welding effect and mass efficient production.
Optionally, the method further comprises:
when the welding of the welded workpiece is completed, acquiring the electrode temperature T2 at the current moment; and determining a cooling temperature according to the prestored replacement time slot t 'and a preset ideal temperature value, and controlling a preset cooling system to continuously cool the electrode for t' seconds according to the cooling temperature.
By adopting the technical scheme, the workpiece replacement time slot t' refers to the time length corresponding to the period when the welded workpiece is taken out and the next welded workpiece is placed in the welding area; the ideal temperature value is a temperature value which is preset manually and can be reached by the electrode before the workpiece to be welded is prepared for welding; the cooling temperature refers to the temperature applied to the electrode by the cooling system and capable of reducing the temperature of the electrode from T2 to a desired temperature value within T' seconds; therefore, the step fully utilizes the replacement time slot T 'to reduce the electrode to the ideal temperature value, ensures the consistency of the initial temperature T' of the electrode, and ensures that the welding efficiency is not affected.
Optionally, the determining the cooling temperature includes:
detecting the ambient temperature of the ambient environment around the electrode at the current moment;
determining a cooling temperature required by the electrode temperature to be reduced from T2 to an ideal temperature value in the replacement time slot T' under the current environment temperature of the electrode based on a preset second corresponding relation table; the second correspondence table stores a plurality of ambient temperature ranges, and each ambient temperature range corresponds to a plurality of electrode temperature ranges and a cooling temperature corresponding to each electrode temperature range.
By adopting the technical scheme, the temperature reduction rate of the welded electrode is generally influenced by the cooling temperature applied by the cooling system and the ambient temperature of the electrode, namely, when the same cooling temperature is applied to the electrode under the environments of different temperatures, the temperature reduction rate of the electrode is different, so that the electrode can be further ensured to be reduced to an ideal temperature value.
Optionally, the method further comprises:
when the electrode contacts with the welded workpiece, pressure data from the welded workpiece received by the electrode is monitored in real time, and the resistance welder body is controlled to adjust the contact degree of the electrode and the welded workpiece so that the pressure data is consistent with a preset pressure value.
By adopting the technical scheme, the pressure data are used for reflecting the pressure stress of the mutual contact part (welding point) between the electrode and the welded workpiece, if the pressure stress of the welding point is greater than the yield strength of the electrode at the temperature, the electrode end part is plastically deformed, so that the electrode end part is worn and the diameter is increased, and then the current density flowing through the welding point is reduced during welding, so that the diameter of the welding point is reduced, namely the size of a nugget is reduced and the welding effect is inconsistent; therefore, the application monitors the pressure data in real time and enables the pressure data to be consistent with the preset pressure value, so that on one hand, the conditions of electrode abrasion and electrode grinding replacement frequency increase caused by excessive interference between the electrode and the welded workpiece can be reduced, and on the other hand, the influence of the abutting pressure degree on the resistance value, nugget size and welding energy consistency at the welding point can be reduced.
Optionally, the method further comprises:
when the welding of the welded workpiece is completed, electrode end face images on two sides of the welded workpiece are acquired, the electrode end face images are input into a pre-built electrode abrasion measurement model, a measurement result is output through the electrode abrasion measurement model, and when the measurement result is inconsistent with the preset result, an electrode abrasion prompt signal which can be known by an operator is sent out.
By adopting the technical scheme, during welding, the electrode end of the resistance welding machine is in direct contact with the welded workpiece, so that the electrode tip is easy to generate plastic deformation after being frequently subjected to high temperature and pressure, the diameter of the electrode end surface is increased, and the nugget size of the welding point is not in accordance with the production requirement, and therefore, the diameter of the electrode tip end surface needs to be measured, polished and replaced regularly to reduce the influence on the welding effect; the application provides the technical scheme, namely, when a welded workpiece is welded, an electrode end surface image is automatically acquired, image processing and analysis are carried out through a pre-built electrode abrasion measuring model, a measuring result is output, and when the measuring result is inconsistent with a preset result, an electrode grinding prompt signal is automatically sent out. Compared with the prior art, the method for processing the image has the advantages that the detection of the abrasion degree of the end face of the electrode is contactless, and the measurement accuracy and the measurement efficiency of the abrasion degree of the electrode can be improved.
Optionally, the acquiring an electrode end face image of two sides of the welded workpiece, inputting the electrode end face image into a pre-constructed electrode wear measurement model, and outputting a measurement result through the electrode wear measurement model, including:
acquiring end face temperature distribution images of electrodes on two sides of a welded workpiece, wherein the end face temperature distribution images are used for distinguishing and displaying areas where different temperature ranges of the end face of the electrode are located according to preset display rules, comparing the positions of the areas where the different temperature ranges are located in the end face temperature distribution images and the corresponding area with preset reference temperature distribution images through a preset electrode abrasion measurement model, and outputting measurement results;
measuring distance values of a plurality of preset detection points on the electrode end face, generating an axial section image of the electrode end part based on the positions of all the detection points on the electrode end face and the distance values measured corresponding to each detection point, comparing the axial section image with a preset reference section image through a preset electrode abrasion measurement model, and outputting a measurement result.
By adopting the technical scheme, the application provides two methods for carrying out image processing on the electrode end face, firstly, the method is based on the principle of welding and generating heat of an electrode, the temperature distribution image of the electrode end face is obtained, the temperature distribution image can distinguish and display the areas of different temperature ranges of the electrode end face by utilizing the color and other modes, then the temperature distribution image is compared with a preset reference temperature distribution image, if the area of each temperature range and the position of each area are compared, the electrode end face is seriously worn if the comparison result is too large, wherein the reference temperature distribution image refers to the temperature distribution image of the electrode end face after welding and generating heat when the electrode is not worn. The second method is that a plurality of detection points are preset on the electrode end face, then the distance value between the detection points and the electrode end face is measured, if the position of the measuring instrument is fixed and the distance value is changed, the abrasion of the electrode end face at the corresponding detection point is indicated, and the abrasion degree of the electrode end face can be obtained more intuitively by generating an axial section image of the electrode end face.
In a second aspect, the present application provides a temperature compensated output energy resistance welding system comprising a resistance welder body for resistance welding a workpiece to be welded, further comprising:
the temperature monitoring module is used for acquiring the initial temperature T1' of the electrode at the current moment when the welded workpiece is detected to enter a preset welded station;
the current measurement module is used for determining a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; determining a current value I 'corresponding to a resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2; the first corresponding relation table is used for storing the electrode temperature and the corresponding resistance value;
and the welding control module is used for controlling the resistance welding machine body to output constant current for t seconds according to the current value I' so as to finish the welding of the welded workpiece.
In a third aspect, the present application provides a temperature compensated output energy resistance welder comprising a memory and a processor, the memory having stored thereon a computer program capable of being loaded by the processor and performing the method of any of the first aspects.
In a fourth aspect, the present application provides a computer readable storage medium storing a computer program capable of being loaded by a processor and performing any one of the methods of the first aspect.
In summary, the present application includes at least one of the following beneficial technical effects:
the application provides two methods applied to a welding process of a resistance welding machine, which are used for meeting the production requirements of consistency of welding effect and high-efficiency mass production in the mass welding production process. Specifically, the temperature value before electrode welding is monitored, and the corresponding resistance value and current value are determined based on the temperature value, namely, the output constant current value is adaptively adjusted according to the temperature value before electrode welding, so that the welding energy received by each welding workpiece in the batch welding process is ensured to be approximately the same, and the batch production efficiency is not influenced.
Furthermore, the application also provides a non-contact real-time monitoring method for the electrode tip end to form a monitoring image, the electrode tip end shape is displayed according to the monitoring image, whether the electrode tip end has abrasion condition or not is judged based on the monitoring image, and then the influence of electrode abrasion on the welding effect is reduced.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for the description of the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic flow chart of a welding method of a resistance welder with temperature compensated output energy according to an embodiment of the present application.
Fig. 2 is a specific flowchart of step 1021 disclosed in an embodiment of the present application.
Fig. 3 is a specific flow chart of step 1022 disclosed in an embodiment of the present application.
Fig. 4 is a schematic view of an end face temperature distribution image for embodying an electrode in an embodiment of the present application.
Fig. 5 is a schematic diagram showing an image of distribution of detection points on an end face of an electrode tip according to an embodiment of the present application.
Fig. 6 is a schematic diagram of an embodiment of the present application for representing an axial cross-sectional image of an electrode tip.
FIG. 7 is a block diagram of a temperature compensated output energy resistance welding system according to an embodiment of the present application.
Reference numerals illustrate: 1. a temperature monitoring module; 2. a current measurement module; 3. a welding control module; 4. a resistance welder body.
Description of the embodiments
The embodiment of the application discloses a welding method of a resistance welding machine capable of outputting energy in a temperature compensation way. The welding line is suitable for a resistance welding production line with high requirements on mass rapid production and welding performance consistency, such as a welding production line of pins of Schottky diodes in photovoltaic junction boxes on connecting wires. The welding method is mainly used for solving the problem of large difference of workpiece welding effects in the batch production process; the method not only can optimize the welding consistency effect, but also can meet the high-efficiency production efficiency requirement of mass production, and achieves the technical effects of both consistency of the welding effect and high-efficiency production.
The main body of execution of the above method is a resistance welding system (hereinafter simply referred to as resistance welding system) of temperature compensated output energy, which includes a resistance welder body for resistance welding a workpiece to be welded. The process of performing the above welding method in a resistance welding system will be described in detail with reference to fig. 1-6.
Step 101, when the welded workpiece is detected to enter a preset welding station, acquiring an initial temperature T1' of the electrode at the current moment.
In practice, the initial temperature T1' refers to the temperature of the electrode measured before it is ready to weld the workpiece. When a mechanical arm preset on a welding production line takes and places a welded workpiece on a preset welded station, the resistance welding system detects that the welded workpiece exists on the welded station, and at the moment, the resistance welding system detects the electrode temperature (namely the initial temperature T1') at the current moment. The welded workpiece can be detected in real time by the opposite-type photoelectric switch on the welded station, and when the welded workpiece is inserted between the receiver and the transmitter of the opposite-type photoelectric switch, the welded workpiece is indicated to exist on the welded station, and in addition, the electrode temperature can be detected by arranging an infrared thermometer.
Step 102, determining a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; determining a current value I 'corresponding to a resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2; the first corresponding relation table is used for storing the electrode temperature and the corresponding resistance value.
In practice, the first correspondence table is used for storing different metal materialsThe resistance values of the electrodes of the material at different temperatures are used for representing the corresponding relation between the temperature and the resistance of the electrodes. After the resistance welding system obtains the initial temperature T1', the resistance welding system may determine a resistance value (i.e., a resistance value R1 ') corresponding to a temperature corresponding to the temperature value of the initial temperature T1' from the first correspondence table. In addition, the ideal energy value Q, the welding duration t, and the resistance R2 of the workpiece to be welded are all values obtained by multiple debugging experiments after comprehensively considering factors such as the material, the thickness, the nugget size of the workpiece to be welded, and the like in advance, and the values are prestored in the resistance welding system. The ideal energy value Q is used for representing the welding effect, and the welding duration t refers to the duration for welding a single welded workpiece. The resistance welding system can calculate I 'based on the prestored numerical value and the inquired resistance value R1', and the calculation formula is that I' is the constant current value output by the resistance welder body during the subsequent welding.
Preferably, referring to fig. 2 and 3, two methods for calculating the current value I' are provided in the embodiment of the present application, and the step 102 specifically includes the following sub-steps:
step 1021, determining whether the initial temperature T1 'is within a preset temperature interval, and if not, controlling a preset cooling system to adjust the initial temperature T1' to be within the preset temperature interval; determining a current value I 'corresponding to an initial temperature T1' in a preset temperature interval;
step 1022, determining a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first correspondence table; and determining a current value I 'corresponding to the resistance value R1' according to the preset ideal energy value Q, the preset welding duration t and the preset resistance R2 of the welded workpiece.
In the implementation of step 1021, referring to fig. 2, the method is suitable for the case where the welding consistency of the workpiece to be welded is strict in the case where the automatic high-speed welding line is relatively regular in time interval when the workpiece to be welded is replaced. Wherein, the preset temperature interval is an interval value which is manually pre-debugged and pre-stored in the resistance welding system, and can be expressed as (Tmin, tmax); the resistance welding system also prestores a current value I' corresponding to the preset temperature interval, and the corresponding relation satisfies: when the electrode with the electrode temperature in the temperature range is supplied with the corresponding current value I', and after the duration of t seconds, the welding energy Q of the welded workpiece between the electrodes is approximate to the ideal energy value Q.
After the resistance welding system acquires the initial temperature T1', the resistance welding system determines whether the initial temperature T1' is in a preset temperature interval, if not, the resistance welding system controls a cooling system in communication connection with the resistance welding system to cool the electrode, and continuously acquires the initial temperature T1 'of the cooled electrode in the process until the initial temperature T1' of the electrode falls in the preset temperature interval; finally, the resistance welding system can directly take the current value corresponding to the temperature interval as I'. It should be noted that the cooling system may be of the prior art, and an exemplary cooling system may include a cooling tank containing a cooling liquid, where the cooling tank is in communication with a chamber preset inside the electrode, and the chamber may be configured to allow the cooling liquid to flow therethrough, so as to cool the electrode. The cooling system of the application is different from the prior art in that the cooling system is controlled by a resistance welding system, the resistance welding system controls the opening and closing of the cooling system, and the cooling temperature applied by the cooling system to the electrode is detected and regulated in real time.
Preferably, in combination with the specific content of step 1021, in order to enable the cooling system to quickly cool the initial temperature T1' of the electrode to a preset temperature interval during the period of replacing the welded workpiece, the welding method of the present application further includes the following steps:
When the welding of the welded workpiece is completed, acquiring the electrode temperature T2 at the current moment; and determining cooling temperature according to the prestored replacement time slot t 'and a preset ideal temperature value, and controlling a preset cooling system to continuously cool the electrode for t' seconds according to the cooling temperature.
The "determining cooling temperature" in the above step further includes:
detecting the ambient temperature of the ambient environment around the electrode at the current moment;
determining a cooling temperature required by the electrode temperature to be reduced from T2 to an ideal temperature value in a piece changing time slot T' under the current environment temperature of the electrode based on a preset second corresponding relation table; the second correspondence table stores a plurality of ambient temperature ranges, and each ambient temperature range corresponds to a plurality of electrode temperature ranges and a cooling temperature corresponding to each electrode temperature range.
In practice, the workpiece replacement time slot t' refers to the time period from the completion of welding of a previous workpiece to the time period from the time when the next workpiece is taken to be placed at the welded site, that is, the time interval when the workpiece is replaced as described above; the replacement time slot t' is a specific value which is manually set and stored in the resistance welding system in advance. The desired temperature value may be any specific temperature value within the predetermined temperature interval as described above. The second corresponding relation table stores a plurality of ambient temperature intervals, and each ambient temperature interval corresponds to a plurality of electrode temperature ranges and cooling temperatures corresponding to each electrode temperature range.
If the initial electrode temperature T1 'can be cooled by the cooling system to a preset temperature range in the replacement time slot T', the batch welding efficiency can be effectively improved. Therefore, after welding is completed each time, the resistance welding system acquires the electrode temperature T2, detects the current ambient temperature of the electrode, determines the ambient temperature range in which the ambient temperature is located from the second correspondence table, determines the electrode temperature range in which the electrode temperature T2 is located, and finally determines the cooling temperature corresponding to the ambient temperature range and the electrode temperature range, and then controls the cooling system to cool the electrode at the cooling temperature, namely, the cooling temperature applied to the electrode by the cooling system is adjusted to enable the electrode to be reduced to a preset temperature range in a limited replacement time slot T'.
With respect to step 1022, reference is made to FIG. 3, which is applicable to automated high speed welding lines with irregular time intervals for replacement of workpieces to be welded, and for a batchAnd in the occasion with high welding speed requirement. The method adopted in the step is not limited by the electrode temperature, namely whether the electrode temperature is reduced to be within a preset temperature interval or not, the electrode temperature (namely the initial temperature T1') can be measured directly when the next workpiece to be welded is positioned at the station to be welded, and then the ideal energy value Q, the preset welding duration T and the preset resistance R2 of the workpiece to be welded which are obtained by pre-debugging are obtained according to a first corresponding relation table, and the formula is combined The current value I' is measured.
In summary, the method used in step 1021 and the method used in step 1022 can ensure the mass production efficiency and simultaneously make the welding effect of the batch of workpieces to be welded nearly the same, so as to improve the consistency of the welding effect.
And 103, controlling the resistance welder body to output the constant current for t seconds according to the current value I', and finishing the welding of the welded workpiece.
In implementation, the electrode on the resistance welder body moves and abuts against the designated position (namely a preset welding point) of the welded workpiece, and constant current is output for t seconds according to the measured current value I', so that the current flows through the contact surface and the adjacent area of the welded workpiece to generate resistance heat, and the contact part is heated and melted to form a nugget, so that the welded workpiece is welded and combined together.
Optionally, in step 103, it is known that, before welding, when the electrode on the body of the resistance welding machine moves and abuts against the designated position (i.e. the preset welding point) of the workpiece to be welded, the electrode tends to apply a certain pressure to the workpiece to be welded; accordingly, the contact position of the electrode tip and the workpiece to be welded will also receive compressive stress applied from the workpiece to be welded. If the compressive stress is greater than the yield strength of the electrode temperature, the electrode end part is subjected to plastic deformation, abrasion and diameter enlargement, so that the current density at the welding point is reduced, the size of nugget formed by welding is reduced, the degree of difference of welding effect is increased and other interlocking conditions are caused; to this end, in order to reduce the probability of occurrence of the aforementioned conditions, i.e. to slow down the wear of the electrodes, the welding method disclosed in the present application further comprises the steps of:
When the electrode contacts with the welded workpiece, pressure data from the welded workpiece received by the electrode is monitored in real time, and the resistance welder body is controlled to adjust the contact degree of the electrode and the welded workpiece so that the pressure data is consistent with a preset pressure value.
In practice, the preset pressure value is a pressure value set by people to ensure that the electrode is contacted with the workpiece to be welded and simultaneously relieve the plastic deformation degree of the electrode. The pressure sensor is installed to monitor the pressure stress of the electrode in real time, the resistance welding system obtains the pressure stress (namely pressure data) and compares the pressure data with a preset pressure value, if the comparison is inconsistent, the resistance welding system controls the resistance welding machine body to drive the electrode to move, and the electrode position is adjusted, namely the abutting force of the electrode and the welded workpiece is adjusted until the pressure data is consistent with the preset pressure value.
Optionally, the disclosed welding method may also be used to monitor the wear of the electrode tip. Specifically, the welding method comprises the following steps:
when the welding of the welded workpiece is completed, electrode end face images on two sides of the welded workpiece are acquired, the electrode end face images are input into a pre-constructed electrode abrasion measurement model, a measurement result is output through the electrode abrasion measurement model, and when the measurement result is inconsistent with a preset result, an electrode abrasion prompt signal which can be known by an operator is sent out.
The step of acquiring the electrode end face images on two sides of the welded workpiece, inputting the electrode end face images into a pre-constructed electrode wear measurement model, and outputting a measurement result through the electrode wear measurement model further comprises the following sub-steps:
acquiring end face temperature distribution images of electrodes on two sides of a welded workpiece, wherein the end face temperature distribution images are used for distinguishing and displaying areas where different temperature ranges of the end face of the electrode are located according to preset display rules, comparing the areas where the different temperature ranges are located in the end face temperature distribution images and corresponding area with preset reference temperature distribution images through a preset electrode abrasion measurement model, and outputting a measurement result;
measuring distance values of a plurality of preset detection points on the electrode end face, generating an axial section image of the electrode end part based on the positions of all the detection points on the electrode end face and the distance values measured corresponding to each detection point, comparing the axial section image with a preset reference section image through a preset electrode abrasion measurement model, and outputting a measurement result.
In practice, the present application is characterized in that the electrode end face state is represented in an image form by performing image processing on the electrode end face in combination with the above steps, and two image processing methods are proposed to obtain an end face temperature distribution image of the electrode end face and an axial section image of the electrode end portion, respectively.
Specifically, referring to fig. 4, since heat is generated during the welding process of the electrode, after the welding is completed, there is a difference in temperature between different portions of the end surface of the electrode, that is, between the temperature at the contact point (welding point) of the electrode and the workpiece and the temperature at the non-welding point, that is, a temperature step is formed, and if the end surface of the electrode is worn, the area of the contact point (welding point) of the electrode and the workpiece increases, so that the area of the contact point (welding point) corresponding to the temperature range increases. Therefore, the thermal infrared imager may be used to detect and obtain an end face temperature distribution image of the electrode, where each pixel point in the end face temperature distribution image corresponds to one temperature value, a plurality of temperature ranges may be roughly set, the temperature value of each pixel point is classified into the corresponding temperature range, and then different colors are used to distinguish, on the end face temperature distribution image, where the area corresponding to the different temperature ranges is located on the end face, and the area size of the corresponding area of the different temperature ranges (such as the area 1 and the area 2 shown in fig. 4.
The preset electrode wear measurement model can be used for comparing the end face temperature distribution image with a preset reference temperature distribution image, and specifically can be used for comparing the position of the area where each temperature range is located, the size of the area where each temperature range is located and the like. The reference temperature distribution image is an end surface temperature distribution image after the electrode is welded when the electrode is not worn. The measurement result may be the area difference value of the two corresponding areas in the two images; if the area difference is larger than the preset difference, the electrode is considered to be worn, and the resistance welding system sends out an electrode grinding prompt signal which can be known by an operator, for example, a prompt content similar to electrode grinding is displayed on a preset touch display screen.
In another embodiment, for region a in the end face temperature distribution image, and region B corresponding to region a in the reference temperature distribution image, the resistance welding system may determine whether there is region C in region a, wherein region C satisfies: the region C belongs to the region A, the area of the region is larger than the preset area, and the region C is located at the periphery of the region B and does not intersect with the region B. If the inclination angle exists, the possibility that the workpiece is inclined during welding is considered, the inclination direction and the inclination angle can be determined according to the included angle between the straight line connected with the center point of the area C and the center point of the area B and the horizontal plane, at the moment, the resistance welding system can send prompt contents similar to 'pay attention to the workpiece placement angle', and the area C and the area B are displayed for operators to refer to whether the workpiece is inclined or not.
In another embodiment, the resistance welding system further pre-stores an electrode image, and defines a plurality of cooling areas in advance on the electrode image, and stores cooling temperatures required to be applied by each cooling area, wherein the cooling areas correspond to areas corresponding to different temperature ranges in the end face temperature distribution image one by one, and each time the resistance welding system determines that the end face temperature distribution image is obtained, the stored cooling areas and the corresponding applied cooling temperature values are updated based on the area positions and the area sizes in the end face temperature distribution image, and the cooling areas, required to be cooled, of the electrode end face are stored, if different cooling temperatures are applied to different areas, and after the next welding is completed, the cooling system is controlled to apply corresponding cooling temperatures to the positions corresponding to the cooling areas on the upper end face of the actual electrode, so as to realize targeted efficient cooling. In the above-mentioned scheme, the position and area of the cooling region can be regulated, so that the cooling cavity formed in the electrode or the cooling pipeline inserted in the electrode can include several circular ring structures, and all the circular ring structures are concentric.
In another embodiment, the resistance welding system further determines a temperature interval corresponding to each region in the end face temperature distribution image, and takes a maximum temperature value and a minimum temperature value of all pixel temperature values falling within the same set temperature range as end point values of the temperature interval. And comparing the end face temperature distribution images of the two electrodes on the two sides of the workpiece, and calculating the coincidence ratio of the areas corresponding to each temperature range in the end face temperature distribution images corresponding to the two electrodes, wherein the end face temperature distribution images corresponding to the two electrodes, the temperature interval of each area and the coincidence ratio of the areas corresponding to each other are respectively calculated, so that operators can intuitively analyze the temperature difference of the end faces of the two electrodes.
The specific method for generating the axial section image of the electrode tip is as follows: referring to fig. 5 and 6, a plurality of detection points are set in advance on the electrode end face, the detection points may be distributed on the electrode end face in a grid-like form as shown in fig. 5, the reference sectional image is a sectional view in the axial direction of the electrode end portion when not worn, and the detection points may be displayed in the reference sectional image. And detecting a linear distance value between the distance measuring sensor and each detection point by means of a distance measuring sensor such as a laser displacement sensor, comparing the linear distance value of each detection point with a pre-stored reference distance value of the detection point by a pre-built electrode abrasion measuring model, and correspondingly, if the linear distance value of the detection point is inconsistent with the reference distance value, indicating that the detection point is abraded at the position on the end face of the electrode, wherein the position of the detection point on an axial section image is changed. The axial section image of the current electrode can be finally obtained by comparing the linear distance values of all the detection points one by one (as shown in fig. 6). In addition, in the embodiment, if the straight line distance value of any detection point is inconsistent with the reference distance value and the difference is greater than the specified difference, the measurement result is not inconsistent with the preset result.
The embodiment of the application also discloses a resistance welding system for outputting energy by temperature compensation. Referring to fig. 7, the resistance welding system includes a resistance welder body 4 for resistance welding a workpiece to be welded, and further includes:
the temperature monitoring module 1 is used for acquiring the initial temperature T1' of the electrode at the current moment when the welded workpiece is detected to enter a preset welded station;
the current measurement module 2 is configured to determine a resistance value R1' corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first correspondence table; determining a current value I 'corresponding to a resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2; the first corresponding relation table is used for storing the electrode temperature and the corresponding resistance value;
and the welding control module 3 is used for controlling the resistance welding machine body to output constant current for t seconds according to the current value I' so as to finish the welding of the welded workpiece.
Optionally, the current measurement module 2 is configured to determine whether the initial temperature T1 'is within a preset temperature interval, and if not, control the preset cooling system to adjust the initial temperature T1' to be within the preset temperature interval; determining a current value I 'corresponding to an initial temperature T1' in a preset temperature interval; the resistance value R1' corresponding to the initial temperature T1' is determined according to the initial temperature T1' and a pre-stored first corresponding relation table; and determining a current value I 'corresponding to the resistance value R1' according to the preset ideal energy value Q, the preset welding duration t and the preset resistance R2 of the welded workpiece.
Optionally, the welding machine further comprises a cooling adjusting module, wherein the cooling adjusting module is used for acquiring the electrode temperature T2 at the current moment when the welding of the welded workpiece is completed; and determining a cooling temperature according to the prestored replacement time slot t 'and a preset ideal temperature value, and controlling a preset cooling system to continuously cool the electrode for t' seconds according to the cooling temperature.
The cooling regulation module is also used for detecting the ambient temperature of the ambient environment around the electrode at the current moment; the method is also used for determining the cooling temperature required by the electrode temperature from T2 to an ideal temperature value in a piece-changing time slot T' under the current environment temperature of the electrode based on a preset second corresponding relation table; the second correspondence table stores a plurality of ambient temperature ranges, and each ambient temperature range corresponds to a plurality of electrode temperature ranges and a cooling temperature corresponding to each electrode temperature range.
Optionally, the welding machine further comprises a pressure control module, wherein the pressure control module is used for monitoring pressure data from the welded workpiece received by the electrode in real time when the electrode is in contact with the welded workpiece, and controlling the resistance welding machine body to adjust the contact degree of the electrode and the welded workpiece so that the pressure data is consistent with a preset pressure value.
Optionally, the welding machine further comprises a wear monitoring module, wherein the wear monitoring module is used for acquiring electrode end face images on two sides of a welded workpiece when the welding of the welded workpiece is completed, inputting the electrode end face images into a pre-constructed electrode wear measurement model, outputting a measurement result through the electrode wear measurement model, and sending an electrode coping prompt signal which can be known by an operator when the measurement result is inconsistent with a preset result;
the wear monitoring module is also used for acquiring end face temperature distribution images of the electrodes on two sides of the welded workpiece, the end face temperature distribution images are used for distinguishing and displaying areas where different temperature ranges of the end face of the electrode are located according to preset display rules, the positions of the areas where the different temperature ranges are located in the end face temperature distribution images and the corresponding area are compared with a preset reference temperature distribution image through a preset electrode wear measuring model, and a measuring result is output.
The wear monitoring module is also used for measuring distance values of a plurality of preset detection points on the electrode end face, generating an axial section image of the electrode end part based on the positions of all the detection points on the electrode end face and the distance values measured by each detection point, comparing the axial section image with a preset reference section image through a pre-built electrode wear measuring model, and outputting a measuring result.
The embodiment of the application also discloses a temperature-compensated output energy resistance welder, which comprises a memory and a processor, wherein the memory stores a computer program which can be loaded by the processor and execute the welding method of the temperature-compensated output energy resistance welder.
The embodiment of the present application also discloses a computer-readable storage medium storing a computer program capable of being loaded by a processor and executing the resistance welding machine welding method of temperature compensated output energy as described above, the computer-readable storage medium including, for example: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (Random Access Memory, RAM), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.
The above embodiments are only for illustrating the technical solution of the present application, and not for limiting the scope of application. It will be apparent that the described embodiments are merely some, but not all, embodiments of the application. Based on these embodiments, all other embodiments that may be obtained by one of ordinary skill in the art without inventive effort are within the scope of the application.
Claims (10)
1. A method of welding with a temperature compensated output energy resistance welder, comprising the steps of:
when the welded workpiece is detected to enter a preset welded station, acquiring an initial temperature T1' of the electrode at the current moment;
determining a resistance value R1' of an electrode corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; determining a current value I 'corresponding to a resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2; wherein the first correspondence table is used for storing electrodes of different metal materials at different temperaturesThe resistance value is used for representing the corresponding relation between the temperature of the electrode and the resistance; the ideal energy value Q, the welding duration t and the resistance R2 of the welded workpiece are values obtained through multiple debugging experiments after comprehensively considering the material and thickness of the welded workpiece and the nugget size factors required to be welded in advance, and the values are prestored in a resistance welding system; the ideal energy value Q is used for representing the welding effect, and the welding time t refers to the time for welding a single welded workpiece; the calculation formula is that ；
And controlling the resistance welder body to output the constant current for t seconds according to the current value I', and finishing the welding of the welded workpiece.
2. The welding method of a temperature compensated output energy resistance welding machine according to claim 1, wherein the resistance value R1' of the electrode corresponding to the initial temperature T1' is determined according to the initial temperature T1' and a pre-stored first correspondence table; according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2, determining a current value I 'corresponding to the resistance value R1', wherein the method comprises the following steps:
determining whether the initial temperature T1 'is in a preset temperature interval, and if not, controlling a preset cooling system to adjust the initial temperature T1' to be in the preset temperature interval; determining a current value I 'corresponding to an initial temperature T1' in the preset temperature interval; the preset temperature interval is an interval value which is manually debugged in advance and stored in advance, and a current value I' corresponding to the preset temperature interval is also prestored;
determining a resistance value R1' of an electrode corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; and determining a current value I 'corresponding to the resistance value R1' according to a preset ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2.
3. The method of welding a temperature compensated output energy resistance welder of claim 1, further comprising:
when the welding of the welded workpiece is completed, acquiring the electrode temperature T2 at the current moment; and determining a cooling temperature according to the prestored replacement time slot t 'and a preset ideal temperature value, and controlling a preset cooling system to continuously cool the electrode for t' seconds according to the cooling temperature.
4. A method of welding a temperature compensated output energy resistance welder according to claim 3, wherein said determining a cooling temperature comprises:
detecting the ambient temperature of the ambient environment around the electrode at the current moment;
determining a cooling temperature required by the electrode temperature to be reduced from T2 to an ideal temperature value in the replacement time slot T' under the current environment temperature of the electrode based on a preset second corresponding relation table; the second correspondence table stores a plurality of ambient temperature ranges, and each ambient temperature range corresponds to a plurality of electrode temperature ranges and a cooling temperature corresponding to each electrode temperature range.
5. The method of welding a temperature compensated output energy resistance welder of claim 1, further comprising:
When the electrode contacts with the welded workpiece, pressure data from the welded workpiece received by the electrode is monitored in real time, and the resistance welder body is controlled to adjust the contact degree of the electrode and the welded workpiece so that the pressure data is consistent with a preset pressure value.
6. The method of welding a temperature compensated output energy resistance welder of claim 1, further comprising:
when the welding of the welded workpiece is completed, electrode end face images on two sides of the welded workpiece are acquired, the electrode end face images are input into a pre-built electrode abrasion measurement model, a measurement result is output through the electrode abrasion measurement model, and when the measurement result is inconsistent with the preset result, an electrode abrasion prompt signal which can be known by an operator is sent out.
7. The welding method of a temperature compensated output power resistance welder according to claim 6, wherein the acquiring electrode end face images of both sides of the workpiece to be welded, inputting the electrode end face images into a pre-constructed electrode wear measurement model, and outputting a measurement result through the electrode wear measurement model, comprises:
acquiring end face temperature distribution images of electrodes on two sides of a welded workpiece, wherein the end face temperature distribution images are used for distinguishing and displaying areas where different temperature ranges of the end face of the electrode are located according to preset display rules; comparing the positions of areas where different temperature ranges are located in the end face temperature distribution image and the corresponding areas with a preset reference temperature distribution image through a pre-constructed electrode wear measurement model, and outputting a measurement result;
Measuring distance values of a plurality of preset detection points on the electrode end face, generating an axial section image of the electrode end part based on the positions of all the detection points on the electrode end face and the distance values measured corresponding to each detection point, comparing the axial section image with a preset reference section image through a preset electrode abrasion measurement model, and outputting a measurement result.
8. A temperature compensated output energy resistance welding system comprising a resistance welder body (4) for resistance welding a workpiece to be welded, further comprising:
the temperature monitoring module (1) is used for acquiring the initial temperature T1' of the electrode at the current moment when the welded workpiece is detected to enter a preset welded station;
the current measurement module (2) is used for determining a resistance value R1' of an electrode corresponding to the initial temperature T1' according to the initial temperature T1' and a pre-stored first corresponding relation table; according to a presetAn ideal energy value Q, a preset welding duration t and a preset welded workpiece resistance R2, and determining a current value I 'corresponding to the resistance value R1'; the first correspondence table is used for storing resistance values of electrodes of different metal materials at different temperatures, namely, correspondence between the temperatures and the resistances of the electrodes is represented; the ideal energy value Q, the welding duration t and the resistance R2 of the welded workpiece are values obtained through multiple debugging experiments after comprehensively considering the material and thickness of the welded workpiece and the nugget size factors required to be welded in advance, and the values are prestored in a resistance welding system; the ideal energy value Q is used for representing the welding effect, and the welding time t refers to the time for welding a single welded workpiece; the calculation formula is that ；
And the welding control module (3) is used for controlling the resistance welding machine body to output constant current for t seconds according to the current value I' so as to finish the welding of the welded workpiece.
9. A temperature compensated output energy resistance welder comprising a memory and a processor, the memory having stored thereon a computer program capable of being loaded by the processor and performing the method of any of claims 1 to 7.
10. A computer readable storage medium, characterized in that a computer program is stored which can be loaded by a processor and which performs the method according to any one of claims 1 to 7.
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