CN113927217A - Intelligent welding system - Google Patents
Intelligent welding system Download PDFInfo
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- CN113927217A CN113927217A CN202111166935.3A CN202111166935A CN113927217A CN 113927217 A CN113927217 A CN 113927217A CN 202111166935 A CN202111166935 A CN 202111166935A CN 113927217 A CN113927217 A CN 113927217A
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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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
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
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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
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
Abstract
The embodiment of the invention discloses an intelligent welding system which comprises a control module, a transmission module, a welding module, a code scanning module and a visual detection module. According to the embodiment of the invention, the bar code on the welding jig is scanned by the code scanning module to generate the data number of the welding jig, the welding quality of the welded welding jig is detected by the visual detection module, the quality detection result is sent to the control module, and after the quality detection result and the data number of the welding jig are bound by the control module, whether a recovery instruction is sent to the transmission module is determined according to the quality detection result, so that when the quality detection result of the welding jig does not pass, the transmission module can transmit the welding jig to the recovery station for recovery, and the production efficiency of the circuit board is improved. The technical problem of automatic welding system among the prior art can't detect the discernment to bad product, lead to having the production efficiency of circuit board low is solved.
Description
Technical Field
The embodiment of the application relates to the field of welding equipment, in particular to an intelligent welding system.
Background
With the continuous development of science and technology, the demand of global automated production is rapidly increased, China is actively promoting the ordered development of 'industry 4.0', and as two new topics required by the development of a new era, 'intelligent factories' and 'intelligent production' are highly concerned by more and more countries and enterprises.
Along with the continuous development of scientific technology, the period of updating and upgrading of electronic products is shorter and shorter, and along with the continuous abundance of functions of electronic products, the circuit structure of the electronic products is more and more complicated, the welding requirement of circuit boards is higher and higher, the traditional manual welding technology can not meet the requirements of current product production in quality and efficiency, the automatic welding system is paid attention to by the world population gradually, however, the existing automatic welding system can not detect and identify defective products, manual further screening is needed, and the production efficiency of the circuit boards is reduced.
In conclusion, the existing automatic welding system cannot detect and identify defective products, so that the technical problem of low production efficiency of the circuit board exists.
Disclosure of Invention
The embodiment of the invention provides an intelligent welding system, which solves the technical problem that the existing automatic welding system cannot detect and identify defective products, so that the production efficiency of a circuit board is low.
The embodiment of the invention provides an intelligent welding system which comprises a control module, a transmission module, a welding module, a code scanning module and a visual detection module, wherein the code scanning module, the welding module and the visual detection module are respectively arranged on a code scanning station, a welding station and a visual detection station, and a bar code is also arranged on a welding jig;
the code scanning module is used for scanning a bar code on the welding jig according to a code scanning instruction sent by the control module to obtain bar code information and uploading the bar code information to the control module;
the transmission module is used for transmitting the welding jig to a welding station or a visual detection station according to a transmission control instruction sent by the control module, and is used for transmitting the welded welding jig to a recovery station according to a recovery instruction sent by the control module;
the welding module is used for executing welding operation on the welding jig according to the welding control instruction sent by the control module;
the visual detection module is used for detecting the welding quality of the welded welding jig according to the visual detection instruction sent by the control module and sending a quality detection result to the control module;
the control module is used for sending the transmission control instruction to the transmission module, sending the welding control instruction to the welding module, sending the visual detection instruction to the visual detection module and sending the code scanning instruction to the code scanning module; the position information of the welding jig is recorded; the data processing module is used for generating and storing a data number corresponding to the welding jig according to the bar code information sent by the code scanning module; and the controller is used for determining a data number corresponding to the welding jig detected at present after receiving the quality detection result, binding the quality detection result with the corresponding data number, and determining whether to send the recovery instruction to the transmission module according to the quality detection result.
Preferably, the control module comprises an upper computer and a lower computer, the upper computer is used for generating a data number corresponding to the welding jig according to the bar code information sent by the code scanning module and sending the data number to the lower computer; the recovery control device is used for acquiring a data number corresponding to the welding jig detected currently from the lower computer after receiving the quality detection result, binding the quality detection result with the corresponding data number, and determining whether to send the recovery control instruction to the lower computer according to the quality detection result;
the lower computer is used for recording the position information of the welding jig; and for; sending the transmission control instruction to the transmission module, sending the welding control instruction to the welding module, sending the visual detection instruction to the visual detection module, and sending a code scanning instruction to the code scanning module; and the data serial number is used for storing the data serial number sent by the upper computer, sending the data serial number corresponding to the welding jig currently positioned at the visual detection station to the upper computer, and sending a recovery instruction to the transmission module according to the recovery control instruction sent by the upper computer.
Preferably, the visual detection module comprises a camera module and an analysis module;
the camera sub-module is used for taking a picture of the welded welding jig according to the visual detection instruction sent by the control module and sending the picture of the welding jig to the analysis sub-module;
the analysis submodule is used for comparing the welding jig picture with a pre-shot sample picture to obtain a contrast, determining a quality detection result according to the contrast, and sending the welding jig picture and the quality detection result to the control module.
Preferably, the analysis submodule is configured to compare the welding jig picture with the sample picture, and a specific process of obtaining a contrast ratio is as follows:
the analysis submodule is used for extracting a welding point image in the welding jig picture, extracting a standard welding point image from the sample picture, and performing superposition comparison on the welding point image and the standard welding point image to obtain the contrast.
Preferably, the specific process of the analysis sub-module for determining the quality detection result according to the contrast ratio is as follows:
the analysis submodule is used for comparing the contrast with a preset contrast, and if the contrast is greater than or equal to the preset contrast, the quality detection result is passed; and if the contrast is larger than or smaller than the preset contrast, the quality detection result is failed.
Preferably, if the quality detection result does not pass, the analysis sub-module is further configured to mark a welding point position that is not coincident with the standard welding point image in the welding jig picture, and send the marked welding jig picture and the quality detection result to the control module, so that the control module visually displays the marked welding jig picture and the quality detection result.
Preferably, the system also comprises a reminding module;
the reminding module is used for executing an alarm operation according to the alarm instruction sent by the control module and executing a reminding operation according to the abnormal instruction sent by the control module;
the control module is also used for monitoring the transmission module, the welding module, the code scanning module and the visual detection module, sending the warning instruction to the reminding module when the transmission module, the welding module, the code scanning module or the visual detection module fails, and sending the abnormal instruction to the reminding module when the bar code information is invalid information or the quality detection result is not passed.
Preferably, the control module is further configured to collect welding monitoring data from the welding module in a process that the welding module performs a welding operation on each welding jig, where the welding monitoring data includes state data of the welding module, welding start time, and welding end time.
Preferably, the control module is further configured to generate a welding report for each welding jig according to the welding monitoring data and the quality measurement result.
Preferably, the control module is further provided with a welding diagnosis model, and the control module is further configured to input a welding report corresponding to the currently detected welding jig into the welding diagnosis model if the quality detection result of the currently detected welding jig does not pass, so as to obtain a welding diagnosis result.
The intelligent welding system provided by the embodiment of the invention comprises a control module, a transmission module, a welding module, a code scanning module and a visual detection module, wherein the code scanning module, the welding module and the visual detection module are respectively arranged on a code scanning station, a welding station and a visual detection station, and a bar code is also arranged on a welding jig; the code scanning module is used for scanning the bar code on the welding jig according to the code scanning instruction sent by the control module to obtain bar code information and uploading the bar code information to the control module; the transmission module is used for transmitting the welding jig to the welding station or the visual detection station according to a transmission control instruction sent by the control module, and is used for transmitting the welded welding jig to the recovery station according to a recovery instruction sent by the control module; the welding module is used for executing welding operation on the welding jig according to the welding control instruction sent by the control module; the visual detection module is used for detecting the welding quality of the welded welding jig according to the visual detection instruction sent by the control module and sending a quality detection result to the control module; the control module is used for sending a transmission control instruction to the transmission module, sending a welding control instruction to the welding module, sending a visual detection instruction to the visual detection module and sending a code scanning instruction to the code scanning module; the position information of the welding jig is recorded; the data processing module is used for generating and storing a data number corresponding to the welding jig according to the bar code information sent by the code scanning module; and the controller is used for determining the data number corresponding to the welding jig detected at present after receiving the quality detection result, binding the quality detection result with the corresponding data number, and determining whether to send a recovery instruction to the transmission module according to the quality detection result.
According to the embodiment of the invention, the visual detection module is arranged in the intelligent welding system, the welding quality of the welded welding jig is detected by the visual detection module, the quality detection result is sent to the control module, the control module binds the quality detection result with the data number of the welding jig, and then sends the recovery control instruction to the transmission module when the quality detection result is failed, so that the transmission module transmits the welding jig to the recovery station for recovery.
Drawings
Fig. 1 is a schematic structural diagram of an intelligent welding system according to an embodiment of the present invention.
Fig. 2 is a schematic flow chart of obtaining barcode information by an intelligent welding system according to an embodiment of the present invention.
Fig. 3 is a schematic flow chart of obtaining a quality detection result by an intelligent welding system according to an embodiment of the present invention.
Fig. 4 is a schematic structural diagram of another intelligent welding system according to an embodiment of the present invention.
Detailed Description
The following description and the annexed drawings set forth in detail certain illustrative embodiments of the application so as to enable those skilled in the art to practice them. The examples merely typify possible variations. Individual components and functions are optional unless explicitly required, and the sequence of operations may vary. Portions and features of some embodiments may be included in or substituted for those of others. The scope of the embodiments of the present application includes the full ambit of the claims, as well as all available equivalents of the claims. Embodiments may be referred to herein, individually or collectively, by the term "invention" merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed. Herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed. The embodiments are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the structures, products and the like disclosed by the embodiments, the description is relatively simple because the structures, the products and the like correspond to the parts disclosed by the embodiments, and the relevant parts can be just described by referring to the method part.
As shown in fig. 1, fig. 1 is an intelligent welding system provided in an embodiment of the present invention, and includes a control module, a transmission module, a welding module, a code scanning module, and a visual detection module, where the code scanning module, the welding module, and the visual detection module are respectively installed on a code scanning station, a welding station, and a visual detection station, and a welding fixture is further provided with a barcode.
In this embodiment, be provided with on the production line in workshop and sweep sign indicating number station, welding station and visual detection station, install corresponding module in every station, welding jig can reach different stations under transmission module's transmission.
The code scanning module is used for scanning the bar code on the welding jig according to the code scanning instruction sent by the control module to obtain bar code information and uploading the bar code information to the control module.
In this embodiment, before welding the welding jig, place the welding jig on sweeping a yard station by the staff, control module detects that the welding jig is located and sweeps a yard station after, to sweeping a yard module and sending and sweep a yard instruction, sweep a yard module and after receiving and sweep a yard instruction, scan the bar code on the welding jig, obtain bar code information, later, sweep a yard module and send bar code information for control module.
The transmission module is used for transmitting the welding jig to the welding station or the visual detection station according to the transmission control instruction sent by the control module, and is used for transmitting the welded welding jig to the recovery station according to the recovery instruction sent by the control module.
The transmission module is used for transmitting the welding jig to different stations. In one embodiment, the transmission module is a conveyor belt, and the welding jig is transported to different stations by the conveyor belt. When the control module needs to control the welding jig to move, a transmission control instruction is sent to the transmission module, and after the transmission module receives the transmission control instruction sent by the control module, the welding jig is transmitted to the welding station or the visual detection station. When the transmission module receives a recycling instruction sent by the control module, the welded welding jig is conveyed to a recycling station to be recycled.
And the welding module is used for executing welding operation on the welding jig according to the welding control instruction sent by the control module.
The welding module is used for performing welding operation on the welding jig under the control of the control module, specifically, when the control module detects that the welding jig is conveyed to a welding station, a welding control instruction is sent to the welding module, and after the welding module receives the welding control instruction, the welding module performs welding operation on the welding jig. For example, a positioning cylinder on the welding module accurately positions the welding jig, then the servo motor starts to press down, after the servo motor is pressed down to a set pressure, the servo motor stops pressing down, a welding program is started, and the welding machine performs welding operation on the welding jig. It can be understood that the welding module may be an automatic welding machine existing in the market, and the working process of the welding module is described in many documents in the prior art, which is not described in detail in this embodiment.
The visual detection module is used for detecting the welding quality of the welded welding jig according to the visual detection instruction sent by the control module and sending a quality detection result to the control module.
The welding jig is characterized in that a visual detection module is further arranged in the embodiment and installed on a visual detection station, and the visual detection module is used for detecting the welding quality of the welded welding jig under the control of the control module. Specifically, after the control module detects that the welding jig is conveyed to the visual detection station, a visual detection instruction is sent to the visual detection module, the visual detection module shoots the welded welding jig after receiving the visual detection instruction to obtain a welding jig picture, welding quality detection is carried out on the basis of the welding jig picture to obtain a quality detection result, and the quality detection result is sent to the control module.
The control module is used for sending a transmission control instruction to the transmission module, sending a welding control instruction to the welding module, sending a visual detection instruction to the visual detection module and sending a code scanning instruction to the code scanning module; the position information of the welding jig is recorded; the data processing module is used for generating and storing a data number corresponding to the welding jig according to the bar code information sent by the code scanning module; and the controller is used for determining the data number corresponding to the welding jig detected at present after receiving the quality detection result, binding the quality detection result with the corresponding data number, and determining whether to send a recovery instruction to the transmission module according to the quality detection result.
In one embodiment, the code scanning station, the welding station and the visual detection station are provided with infrared sensors for detecting the welding jig, and when the infrared sensors detect the welding jig, the infrared sensors are triggered to send a trigger signal to the control module. Exemplarily, when a worker places a welding jig on a code scanning station, an infrared sensor sends a trigger signal to a control module, the control module learns that the welding jig is currently on the code scanning station and sends a code scanning instruction to the code scanning module, the code scanning module scans a bar code on the welding jig after receiving the code scanning instruction to obtain bar code information and uploads the bar code information to the control module, the control module generates and stores a data number corresponding to the welding jig after receiving the bar code information, records the current position information of the welding jig corresponding to the data number as the code scanning station, binds the position information and the data number, and then sends a transmission control instruction to a transmission module, and the transmission module transmits the welding jig to the welding station.
When the infrared sensor on the welding station is triggered, the control module knows that the welding station is provided with the welding jig, and at the moment, the position information of the welding jig is updated. In one embodiment, the number N of the welding jigs existing between the code scanning station and the welding station is fixed, and after the control module records the position information of the first welding jig currently on the code scanning station, if the infrared sensor on the welding station is triggered for the (N + 1) th time, it indicates that the first welding jig reaches the welding station at that time, and the control module updates the position information of the first welding jig. It can be understood that the manner of detecting the position information of the welding jig by the control module may be set according to actual needs, and is not specifically limited in this embodiment. And after receiving the trigger signal, the control module sends a welding control instruction to the welding module, and the welding module performs welding machine operation on the welding jig. After welding, the control module sends a transmission control instruction to the transmission module, and the transmission module transmits the welded welding jig to the visual detection station.
After receiving a trigger signal sent by an infrared sensor on a visual detection station, a control module updates position information of a welding jig and sends a visual detection instruction to the visual detection station, the visual detection station starts to detect the welding quality of the welded welding jig after receiving the visual detection instruction to obtain a quality detection result, and sends the quality detection result to the control module, and after receiving the quality detection result, the control module determines a data number corresponding to the welding jig currently located on the visual detection station according to the position information of the welding jig, binds the quality detection result and the data number, and sends the bound data to an MES system. And then, the control module determines whether the welding quality of the welding jig positioned on the visual detection station is qualified or not according to the quality detection result, if so, a transmission control instruction is sent to the transmission module, the transmission module transmits the welding jig positioned on the visual detection station to the next station, if not, a recovery instruction is sent to the transmission module, and the transmission module transmits the welding jig positioned on the visual detection station to the recovery station after receiving the recovery instruction, so that the station personnel can conveniently recover the welding jig.
On the basis of the embodiment, the control module comprises an upper computer and a lower computer, wherein the upper computer is used for generating a data number corresponding to the welding jig according to the bar code information sent by the code scanning module and sending the data number to the lower computer; and the data processing unit is used for acquiring the data number corresponding to the welding jig detected at present from the lower computer after receiving the quality detection result, binding the quality detection result and the corresponding data number, and determining whether to send a recovery control instruction to the lower computer according to the quality detection result.
In this embodiment, control module is including host computer and lower computer, installs control software on the host computer, and host computer software receives the bar code information that sweeps a yard module and send after, according to bar code information generation with present welding jig corresponding data serial number that is located on sweeping a yard station, send the data serial number to the lower computer in and store. It can be understood that each data number corresponds to one welding jig, and the data numbers can be used for distinguishing different welding jigs. In one embodiment, the upper computer software requests an MES (electronic management system) system to perform routing detection after receiving the bar code information, generates a data number corresponding to the welding jig after the detection is passed, and sends the data number to the lower computer for storage.
And after receiving the quality detection result, the upper computer software sends a data acquisition instruction to the lower computer, acquires a data number bound with the current position information as the visual detection work position from the lower computer, binds the quality detection result and the data number, and sends the bound data to the MES system. Meanwhile, the upper computer software can also send a recovery instruction to the lower computer according to the quality detection result. The quality detection method is interesting, and if the quality detection result is that the quality detection result passes, the upper computer software sends a recovery instruction to the lower computer, so that the lower computer controls the transmission module to transmit the welding jig to the recovery station.
The lower computer is used for recording the position information of the welding jig; and for; sending a transmission control instruction to a transmission module, sending a welding control instruction to a welding module, sending a visual detection instruction to a visual detection module, and sending a code scanning instruction to a code scanning module; and the data number is used for storing the data number sent by the upper computer, sending the data number corresponding to the welding jig currently positioned at the visual detection station to the upper computer, and sending a recovery instruction to the transmission module according to the recovery control instruction sent by the upper computer.
In this embodiment, the lower computer is a PLC, and the PLC is further configured to receive a data number sent by the upper computer software, and store the data number; the PLC is further configured to record and update the position information of the welding jig, and the specific process may refer to the process of recording and updating the position information by using the control module, which is not described herein again.
In one embodiment, the PLC is further used for sending an instruction to the module on the corresponding station when receiving the trigger signal sent by the infrared sensor. Illustratively, when the PLC receives trigger information sent by the infrared sensor on the code scanning module, a code scanning instruction is sent to the code scanning module to start the code scanning module to perform a corresponding operation, as shown in fig. 2. And when the PLC receives trigger information sent by the infrared sensor on the welding module, sending a welding control instruction to the welding module to start the welding module. When the PLC receives the trigger information sent by the infrared sensor on the visual inspection module, it sends a visual inspection instruction to the visual inspection module to start the visual inspection module to execute a corresponding operation, as shown in fig. 3. In one embodiment, the trigger signal of the infrared sensor comprises a sensor identifier, and the PLC can recognize the trigger signal of the corresponding station according to the sensor identifier, thereby sending an instruction to the corresponding module.
After receiving a data acquisition instruction sent by an upper computer, the PLC determines a data number bound with the current position information as a visual detection station, and sends the data number to upper computer software, and the upper computer software can acquire the data number corresponding to the welding jig currently positioned at the visual detection station. When receiving a recovery control instruction sent by upper computer software, the PLC can generate a recovery instruction and send the recovery instruction to the transmission module, so that the transmission module transmits the welded welding jig to a recovery station.
On the basis of the above embodiment, the visual detection module includes a camera sub-module and an analysis sub-module.
In this embodiment, the visual detection module includes a camera module and an analysis module, and a shooting angle of the camera module faces a welding fixture on the visual detection station.
The camera shooting submodule is used for shooting the welded welding jig according to the visual detection instruction sent by the control module and sending the welding jig picture to the analysis submodule.
In this embodiment, the camera sub-module is a camera, and the camera takes a picture of the welding jig welded on the visual detection station after receiving the visual detection instruction sent by the PLC, obtains a picture of the welding jig, and sends the picture of the welding jig to the analysis sub-module.
The analysis submodule is used for comparing the welding jig picture with a pre-shot sample picture to obtain a contrast, determining a quality detection result according to the contrast, and sending the welding jig picture and the quality detection result to the control module.
The analysis submodule is stored with a sample photo shot in advance, the sample photo is a standard photo of the welding jig after welding is completed, and the sample photo is marked with position information of a standard welding point of the welding jig. And after receiving the welding jig picture, the analysis sub-module performs superposition comparison on the welding jig picture and a pre-shot sample picture to obtain the imaging contrast of the two pictures, determines the quality detection result of the welded welding jig according to the contrast, and sends the welding jig picture and the quality detection result to the upper computer software together.
On the basis of the embodiment, the analysis submodule is used for comparing the welding jig picture with the sample picture, and the specific process of obtaining the contrast is as follows:
the analysis submodule is used for extracting a welding point image in the welding jig picture, extracting a standard welding point image from the sample picture, and performing coincidence comparison on the welding point image and the standard welding point image to obtain the contrast.
The analysis submodule extracts a welding point image in the welding jig picture after receiving the welding jig picture, extracts a standard welding point image from the sample picture, compares the welding point image with the standard welding point image, and determines the contrast of the welding jig picture and the sample picture according to the contact ratio of the welding point image and the standard welding point image.
It should be further explained that, in this embodiment, the specific process of extracting the welding point image in the welding jig photo by the analysis submodule is as follows:
the method comprises the steps of carrying out graying processing on a welding jig picture to obtain a grayscale image, and then carrying out median filtering denoising processing on the grayscale image to remove Gaussian noise and salt-pepper noise in the grayscale image and protect edge information of the grayscale image because some noise points are frequently contained in the picture collected by a camera to cause image degradation and reduce the recognition rate of welding points.
After the median filtering is performed on the grayscale image, the binarization processing is performed on the grayscale image, specifically, in this embodiment, the binarization processing is performed on the grayscale image by using an algorithm of tsu. The basic idea of the Otsu algorithm is: a threshold t is set which divides a gray image into two groups, one group corresponding to the target image in gray and the other group corresponding to the background image. Assuming that the gray value of the gray image is in the level of 0-k, T is taken from 0 until k, when T is T, the inter-class variance of the two groups of gray values is the largest, and the intra-class variance is the smallest, the difference between the target image and the background image is maximized, and if the threshold value T at this time is taken as the threshold value for binarization, the optimal binarization effect is obtained. In this embodiment, the welding point image is the target image, and after the threshold t is obtained after traversal, the welding point image in the gray level image can be extracted through the algorithm of the great amount of money.
On the basis of the above embodiment, the specific process of the analysis submodule for determining the quality detection result according to the contrast is as follows:
the analysis submodule is used for comparing the contrast with a preset contrast, and if the contrast is greater than or equal to the preset contrast, the quality detection result is passed; and if the contrast is larger than or smaller than the preset contrast, the quality detection result is failed.
And after the analysis submodule obtains the contrast, comparing the contrast with a preset contrast, if the contrast is greater than or equal to the preset contrast, the quality detection result of the welding jig is passed, and if the contrast is less than the preset contrast, the quality detection result of the welding jig is not passed. It can be understood that, in the present embodiment, the value of the preset contrast may be set according to actual needs, and specific data of the preset contrast is not limited in the present embodiment.
On the basis of the embodiment, if the quality detection result does not pass, the analysis sub-module is further configured to mark a welding point position which is not coincident with the standard welding point image in the welding jig picture, and send the marked welding jig picture and the quality detection result to the control module, so that the control module visually displays the marked welding jig picture and the quality detection result.
And if the quality detection result of the welding jig does not pass, the analysis submodule is also used for determining the position of the welding point where the welding point image is not coincident with the standard welding point image and marking the position of the welding point which is not coincident with the standard welding point image in the picture of the welding jig. For example, a red NG symbol is marked at a position of a welding point which is not overlapped, it can be understood that a specific marking mode can be set according to actual needs, and the specific marking mode is not limited in this embodiment. After the mark is accomplished, send welding jig photo and quality testing result to host computer software again to make host computer software still carry out visual show to welding jig photo and quality testing result after the mark, make things convenient for the staff to learn the welding point position that is not conform to the requirement in welding jig's quality testing result and the welding jig. In one embodiment, the upper computer software also uploads the welding jig picture and the quality detection result to the MES system for storage.
On the basis of the embodiment, the device further comprises a reminding module;
the reminding module is used for executing the alarming operation according to the alarming instruction sent by the control module and executing the reminding operation according to the abnormal instruction sent by the control module;
the control module is also used for monitoring the transmission module, the welding module, the code scanning module and the visual detection module, sending an alarm instruction to the reminding module when the transmission module, the welding module, the code scanning module or the visual detection module has faults, and sending an abnormal instruction to the reminding module when the bar code information is invalid information or the quality detection result is invalid.
It should be further explained that, in this embodiment, as shown in fig. 4, the intelligent welding system further includes a reminding module, and the reminding module plays a role of reminding the worker.
In this embodiment, the PLC is further configured to monitor operating states of the transmission module, the welding module, the code scanning module, and the visual detection module, and when the PLC detects that any one of the transmission module, the welding module, the code scanning module, and the visual detection module fails, the PLC sends an alarm instruction to the reminding module, and the reminding module executes an alarm operation after receiving the alarm instruction. In another embodiment, after the upper computer software acquires the bar code information, the bar code information is detected, and if the bar code information is invalid, the upper computer software sends an abnormal indication instruction to the PLC; and when the quality detection result of the welding jig is failed, the upper computer software also sends an abnormal instruction to the PLC, the PLC sends an abnormal instruction to the reminding module after receiving the abnormal instruction, and the reminding module executes reminding operation.
In one embodiment, the reminding module is provided with a red indicator light, a yellow indicator light and a green indicator light, and when the reminding module does not receive an alarm instruction or an abnormal instruction, the green indicator light is normally on; when the reminding module receives the alarm instruction, the green indicating lamp is turned off, the red indicating lamp is turned on, and a prolonged sound is sent out; when the reminding module receives the abnormal instruction, the green indicating lamp is turned off, the yellow indicating lamp is turned on, and a short sound is emitted.
On the basis of the above embodiment, the control module is further configured to collect welding monitoring data from the welding module in a process that the welding module performs a welding operation on each welding jig, where the welding monitoring data includes state data of the welding module, welding start time, and welding end time.
In the process that the welding module executes welding operation on each welding jig, the upper computer software is further used for collecting welding monitoring data from the welding module, the welding monitoring data comprise state data, welding starting time and welding finishing time of the welding module, and the state data of the welding module comprise pressure data of a servo motor in the welding module and temperature data of a welding machine.
In one embodiment, the control module is further configured to generate a welding report for each welding fixture based on the welding monitoring data and the quality measurements.
After the welding monitoring data of each welding jig in the welding process and the quality detection result of each welding jig are obtained, the control module is further used for generating a welding report of each welding jig according to the welding monitoring data and the quality detection result of each welding jig. For example, in one embodiment, the welding report includes the quality detection result of the corresponding welding jig, the welding start time, the welding end time, the pressure variation curve of the servo motor during the welding process, and the temperature variation curve of the welding machine during the welding process.
On the basis of the above embodiment, the control module is further provided with a welding diagnosis model, and the control module is further configured to input a welding report corresponding to the currently detected welding jig into the welding diagnosis model if the quality detection result of the currently detected welding jig does not pass, so as to obtain a welding diagnosis result.
In one embodiment, the upper computer software of the control module is also provided with a welding diagnosis model which is trained in advance. Illustratively, in one embodiment, the fault diagnosis model is a neural network model, a worker obtains a historical welding report corresponding to a welding jig with a quality detection result of failing historically, marks a reason for failing welding quality on the historical welding report, inputs the marked historical welding report into the fault diagnosis model for training, and adjusts parameters of the fault diagnosis model until an output error of the fault diagnosis model is within a preset range, so as to obtain a trained welding diagnosis model.
And after receiving the quality detection result of the welding jig detected currently, the subsequent control module generates a corresponding welding report according to the welding monitoring data and the quality detection result of the welding jig detected currently, and if the quality detection result of the welding jig detected currently does not pass, the subsequent control module inputs the corresponding welding report into the welding diagnosis model to obtain a welding diagnosis result, wherein the welding diagnosis result comprises the reason that the welding quality does not pass.
In the embodiment of the invention, the visual detection module is arranged in the intelligent welding system, the welding quality of the welded welding jig is detected by the visual detection module, the quality detection result is sent to the control module, the control module binds the quality detection result with the data number of the welding jig, and then sends the recovery control instruction to the transmission module when the quality detection result is failed, so that the transmission module transmits the welding jig to the recovery station for recovery.
It should be noted that the foregoing is only a preferred embodiment of the present invention and the technical principles applied. Those skilled in the art will appreciate that the embodiments of the present invention are not limited to the specific embodiments described herein, and that various obvious changes, adaptations, and substitutions are possible, without departing from the scope of the embodiments of the present invention. Therefore, although the embodiments of the present invention have been described in more detail through the above embodiments, the embodiments of the present invention are not limited to the above embodiments, and many other equivalent embodiments may be included without departing from the concept of the embodiments of the present invention, and the scope of the embodiments of the present invention is determined by the scope of the appended claims.
Claims (10)
1. An intelligent welding system is characterized by comprising a control module, a transmission module, a welding module, a code scanning module and a visual detection module, wherein the code scanning module, the welding module and the visual detection module are respectively arranged on a code scanning station, a welding station and a visual detection station, and a bar code is also arranged on a welding jig;
the code scanning module is used for scanning a bar code on the welding jig according to a code scanning instruction sent by the control module to obtain bar code information and uploading the bar code information to the control module;
the transmission module is used for transmitting the welding jig to a welding station or a visual detection station according to a transmission control instruction sent by the control module, and is used for transmitting the welded welding jig to a recovery station according to a recovery instruction sent by the control module;
the welding module is used for executing welding operation on the welding jig according to the welding control instruction sent by the control module;
the visual detection module is used for detecting the welding quality of the welded welding jig according to the visual detection instruction sent by the control module and sending a quality detection result to the control module;
the control module is used for sending the transmission control instruction to the transmission module, sending the welding control instruction to the welding module, sending the visual detection instruction to the visual detection module and sending the code scanning instruction to the code scanning module; the position information of the welding jig is recorded; the data processing module is used for generating and storing a data number corresponding to the welding jig according to the bar code information sent by the code scanning module; and the controller is used for determining a data number corresponding to the welding jig detected at present after receiving the quality detection result, binding the quality detection result with the corresponding data number, and determining whether to send the recovery instruction to the transmission module according to the quality detection result.
2. The intelligent welding system of claim 1, wherein the control module comprises an upper computer and a lower computer, the upper computer is configured to generate a data number corresponding to the welding jig according to the barcode information sent by the barcode scanning module, and send the data number to the lower computer; the recovery control device is used for acquiring a data number corresponding to the welding jig detected currently from the lower computer after receiving the quality detection result, binding the quality detection result with the corresponding data number, and determining whether to send the recovery control instruction to the lower computer according to the quality detection result;
the lower computer is used for recording the position information of the welding jig; and for; sending the transmission control instruction to the transmission module, sending the welding control instruction to the welding module, sending the visual detection instruction to the visual detection module, and sending a code scanning instruction to the code scanning module; and the data serial number is used for storing the data serial number sent by the upper computer, sending the data serial number corresponding to the welding jig currently positioned at the visual detection station to the upper computer, and sending a recovery instruction to the transmission module according to the recovery control instruction sent by the upper computer.
3. The intelligent welding system of claim 1, wherein the visual detection module comprises a camera sub-module and an analysis sub-module;
the camera sub-module is used for taking a picture of the welded welding jig according to the visual detection instruction sent by the control module and sending the picture of the welding jig to the analysis sub-module;
the analysis submodule is used for comparing the welding jig picture with a pre-shot sample picture to obtain a contrast, determining a quality detection result according to the contrast, and sending the welding jig picture and the quality detection result to the control module.
4. The intelligent welding system of claim 3, wherein the analysis submodule is configured to compare the welding jig picture with the sample picture, and a specific process of obtaining the contrast is as follows:
the analysis submodule is used for extracting a welding point image in the welding jig picture, extracting a standard welding point image from the sample picture, and performing superposition comparison on the welding point image and the standard welding point image to obtain the contrast.
5. The intelligent welding system of claim 4, wherein the analysis submodule is configured to determine the quality test result based on the contrast by:
the analysis submodule is used for comparing the contrast with a preset contrast, and if the contrast is greater than or equal to the preset contrast, the quality detection result is passed; and if the contrast is larger than or smaller than the preset contrast, the quality detection result is failed.
6. The intelligent welding system of claim 5, wherein if the quality detection result does not pass, the analysis sub-module is further configured to mark a welding point position that is not coincident with the standard welding point image in the welding jig photo, and send the marked welding jig photo and the quality detection result to the control module, so that the control module visually displays the marked welding jig photo and the quality detection result.
7. The intelligent welding system of claim 6, further comprising a reminder module;
the reminding module is used for executing an alarm operation according to the alarm instruction sent by the control module and executing a reminding operation according to the abnormal instruction sent by the control module;
the control module is also used for monitoring the transmission module, the welding module, the code scanning module and the visual detection module, sending the warning instruction to the reminding module when the transmission module, the welding module, the code scanning module or the visual detection module fails, and sending the abnormal instruction to the reminding module when the bar code information is invalid information or the quality detection result is not passed.
8. The intelligent welding system of claim 6, wherein the control module is further configured to collect welding monitoring data from the welding module during the welding operation performed by the welding module on each of the welding jigs, the welding monitoring data including status data of the welding module, a welding start time, and a welding end time.
9. The intelligent welding system of claim 8, wherein the control module is further configured to generate a welding report for each of the welding fixtures based on the welding monitoring data and the quality measurements.
10. The intelligent welding system of claim 9, wherein the control module further comprises a welding diagnosis model, and the control module is further configured to input a welding report corresponding to the currently detected welding jig into the welding diagnosis model if the quality detection result of the currently detected welding jig does not pass, so as to obtain a welding diagnosis result.
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