CN115815778A - Ultrasonic welding online monitoring system and method based on power and frequency analysis - Google Patents
Ultrasonic welding online monitoring system and method based on power and frequency analysis Download PDFInfo
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- CN115815778A CN115815778A CN202211522749.3A CN202211522749A CN115815778A CN 115815778 A CN115815778 A CN 115815778A CN 202211522749 A CN202211522749 A CN 202211522749A CN 115815778 A CN115815778 A CN 115815778A
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Abstract
The invention discloses an ultrasonic welding online monitoring system and method based on power and frequency analysis, wherein the system comprises a preprocessing module, an acquisition card module and an industrial personal computer; the preprocessing module acquires power analog quantity P (t) and frequency analog quantity F (t) of ultrasonic welding; the acquisition card module converts the P (t) and the F (t) acquired by the preprocessing module into a power digital quantity P (n) and a frequency digital quantity F (n) respectively and uploads the power digital quantity P (n) and the frequency digital quantity F (n) to the industrial personal computer; and the industrial personal computer evaluates good products and abnormal products of ultrasonic welding according to P (n) and F (n). The ultrasonic welding on-line monitoring system and method based on power and frequency analysis can describe the whole welding process; the power of ultrasonic welding is in direct proportion to the product of amplitude and pressure, so that the energy transfer condition can be reflected better than that of an amplitude curve method, the data is accurate, and the interference is less; the inaccuracy of describing energy transmission by a voltage or current curve method of a capacitive or inductive circuit is overcome, the waveform is more visual, and the correlation is high.
Description
Technical Field
The invention relates to the field of ultrasonic welding quality monitoring, in particular to an ultrasonic welding on-line monitoring system and method based on power and frequency analysis.
Background
In the field of ultrasonic welding, the control of welding quality is always the focus of attention and worry of technical personnel, for an automobile power battery as an example, the welding of a tab and a connecting sheet is carried out through ultrasonic welding, and poor welding may cause the over-high charging and discharging resistance of a battery core, thereby causing safety accidents. Destructive testing can only be performed by tensile force without weld monitoring equipment, which is costly and incomplete. The existing ultrasonic welding monitoring methods mainly comprise the following methods: (1) single value parameter method: detection is performed by single value data uploaded by the welder manufacturer itself, such as: welding time, peak power, welding depth and the like are detected by setting upper and lower limits. In the method, a single-value parameter method is the most comprehensive, the accuracy of an amplitude curve method is not high, pressure information is not contained (the output power of welding is actually determined by amplitude and pressure together), and because a welding system comprises a resistor, a capacitor and an inductor, a current (voltage) curve method can not accurately measure the energy transfer condition only from a single current curve or a single voltage curve. (2) amplitude curve method: measuring a vibration curve of the welding head in the welding process through a vibration sensor, wherein the vibration curve contains certain welding time and welding strength information, but cannot reflect the energy transfer condition, and the data is not accurate enough; (3) current (voltage) curve method: the current is collected from the RF line of the transducer or converted to voltage through a resistor and monitored according to the current or voltage waveform, but is not sufficiently accurate and intuitive.
Disclosure of Invention
The invention aims at: the ultrasonic welding on-line monitoring system and method based on power and frequency analysis are provided, and the defects of the three methods are overcome: (1) The single-value parameter method can only describe a single result, and the power curve can describe the whole welding process; (2) The power of ultrasonic welding is in direct proportion to the product of amplitude and pressure, so that the energy transfer condition can be reflected better than that of an amplitude curve method, the data is accurate, and the interference is less; (3) The inaccuracy of describing energy transmission by a voltage or current curve method of a capacitive or inductive circuit is overcome, the waveform is more visual, and the correlation is high.
The technical scheme of the invention is as follows:
the ultrasonic welding online monitoring system based on power and frequency analysis comprises a preprocessing module, an acquisition card module and an industrial personal computer;
the preprocessing module acquires power analog quantity P (t) and frequency analog quantity F (t) of ultrasonic welding;
the acquisition card module converts the power analog quantity P (t) and the frequency analog quantity F (t) acquired by the preprocessing module into a power digital quantity P (n) and a frequency digital quantity F (n) respectively and uploads the power digital quantity P (n) and the frequency digital quantity F (n) to the industrial personal computer;
and the industrial personal computer evaluates the good products and the abnormal products of the ultrasonic welding according to the power digital quantity P (n) and the frequency digital quantity F (n).
Or the preprocessing module only acquires one of the power analog quantity P (t) or the frequency analog quantity F (t) of the ultrasonic welding; the acquisition card module converts the power analog quantity P (t) or the frequency analog quantity F (t) acquired by the preprocessing module into a power digital quantity P (n) or a frequency digital quantity F (n), and uploads the power digital quantity P (n) or the frequency digital quantity F (n) to the industrial personal computer; and the industrial personal computer evaluates the good products and the abnormal products of the ultrasonic welding according to the power digital quantity P (n) or the frequency digital quantity F (n).
Preferably, the preprocessing module comprises a multiplier and a frequency counting circuit;
respectively inputting a voltage signal V (t) and a current signal I (t) of an RF wire of the ultrasonic welding machine into the input end of a multiplier, and performing product operation on the multiplier to obtain a power analog quantity P (t);
the frequency counting circuit acquires a frequency analog quantity F (t) of the voltage signal V (t).
Preferably, the current signal I (t) of the RF wire of the ultrasonic welding machine is transmitted to the multiplier through a mutual inductor.
Preferably, the input ends of the voltage signal V (t) and the current signal I (t) of the multiplier are provided with amplitude limiting circuits.
Preferably, the acquisition card module comprises analog acquisition channels A and B, a first AD converter, a second AD converter and an FPGA controller; the analog acquisition channels A and B respectively acquire power analog quantity P (t) and frequency analog quantity F (t), convert the power analog quantity P (n) and the frequency digital quantity F (n) into power digital quantity P (n) and frequency digital quantity F (n) through a first AD converter and a second AD converter respectively, transmit the power digital quantity P (n) and the frequency digital quantity F (n) to the FPGA controller, and upload the power digital quantity P (n) and the frequency digital quantity F (n) to the industrial personal computer through a PCI bus by the FPGA controller.
Preferably, the acquisition card module further comprises a DTR trigger circuit for receiving an ultrasonic start signal sent by the welding machine and sending the ultrasonic start signal to the FPGA controller, and the FPGA controller immediately controls the first AD converter and the second AD converter to perform AD conversion after receiving the ultrasonic start signal.
Preferably, the acquisition card module further comprises a precision reference source and a calibration circuit which are sequentially connected, wherein the output end of the calibration circuit and a power analog quantity P (t) signal are simultaneously input into the analog acquisition channel A, and the output end of the calibration circuit and a frequency analog quantity F (t) signal are simultaneously input into the analog acquisition channel B.
An ultrasonic welding online monitoring method based on power and frequency analysis comprises the following steps:
s1, acquiring an initial standard center and an abnormal center of a power digital quantity P (n) and a frequency digital quantity F (n);
s2, feeding back more curves with quality labels to the system through a feedback mechanism, and further increasing a standard center and an abnormal center;
and S3, if the user changes the system parameters or replaces parts, emptying all the standard centers and the abnormal centers, and repeating the steps S1 and S2.
Preferably, in step S1, a frame of welding curve with acceptable welding quality is obtained as an initial standard center, and the subsequent processing first uses the bar as a reference.
Preferably, in step S1, a plurality of curves with qualified or abnormal labels are provided, and then the initial standard center and the abnormal center are obtained by clustering.
The invention has the advantages that:
the ultrasonic welding on-line monitoring system and method based on power and frequency analysis provided by the invention make up for the defects of three methods in the prior art:
(1) The single value parameter method can only describe a single result, and the power curve can describe the whole welding process;
(2) The power of ultrasonic welding is in direct proportion to the product of amplitude and pressure, so that the energy transfer condition can be reflected better than that of an amplitude curve method, the data is accurate, and the interference is less;
(3) The inaccuracy of describing energy transmission by a voltage or current curve method of a capacitive or inductive circuit is overcome, the waveform is more visual, and the correlation is high.
Drawings
The invention is further described with reference to the following figures and examples:
FIG. 1 is a schematic view of an ultrasonic welding on-line monitoring system according to the present invention;
FIG. 2 is a functional block diagram of a pre-processing module of the present invention;
FIG. 3 is a functional block diagram of the acquisition card module of the present invention;
FIG. 4 is a flow chart of an ultrasonic welding on-line monitoring method based on power and frequency analysis.
Detailed Description
As shown in FIG. 1, the software and hardware schematic diagrams related to the present patent are arranged inside the left side frame line, and the power waveform of the welding machine is acquired through the acquisition circuit and uploaded to an industrial computer for real-time online monitoring.
The ultrasonic welding online monitoring system based on power and frequency analysis comprises a preprocessing module, an acquisition card module and an industrial personal computer; the preprocessing module acquires a power analog quantity P (t) and a frequency analog quantity F (t) of ultrasonic welding; the acquisition card module converts the power analog quantity P (t) and the frequency analog quantity F (t) acquired by the preprocessing module into a power digital quantity P (n) and a frequency digital quantity F (n) respectively and uploads the power digital quantity P (n) and the frequency digital quantity F (n) to the industrial personal computer; and the industrial personal computer evaluates the good products and the abnormal products of the ultrasonic welding according to the power digital quantity P (n) and the frequency digital quantity F (n).
The preprocessing module can also only obtain one of power analog quantity P (t) and frequency analog quantity F (t) of ultrasonic welding; the acquisition card module converts the power analog quantity P (t) or the frequency analog quantity F (t) acquired by the preprocessing module into a power digital quantity P (n) or a frequency digital quantity F (n), and uploads the power digital quantity P (n) or the frequency digital quantity F (n) to the industrial personal computer; and the industrial personal computer evaluates the good products and the abnormal products of the ultrasonic welding according to the power digital quantity P (n) or the frequency digital quantity F (n).
As shown in fig. 2, the preprocessing module includes a multiplier and a frequency counting circuit; respectively inputting a voltage signal V (t) and a current signal I (t) of an RF wire of the ultrasonic welding machine into the input end of a multiplier, and performing product operation on the multiplier to obtain a power analog quantity P (t); the frequency counting circuit acquires a frequency analog quantity F (t) of the voltage signal V (t). And the current signal I (t) of the RF wire of the ultrasonic welding machine is transmitted to the multiplier through the mutual inductor. And the input ends of a voltage signal V (t) and a current signal I (t) of the multiplier are provided with amplitude limiting circuits.
The preprocessing module can be omitted when the welder control box already integrates the multiplier module and the frequency counter module.
As shown in fig. 3, the acquisition card module includes analog acquisition channels a and B, a first AD converter, a second AD converter, and an FPGA controller; the analog acquisition channels A and B respectively acquire power analog quantity P (t) and frequency analog quantity F (t), convert the power analog quantity P (n) and the frequency digital quantity F (n) into power digital quantity P (n) and frequency digital quantity F (n) through a first AD converter and a second AD converter respectively, transmit the power digital quantity P (n) and the frequency digital quantity F (n) to the FPGA controller, and upload the power digital quantity P (n) and the frequency digital quantity F (n) to the industrial personal computer through a PCI bus by the FPGA controller.
The acquisition card module further comprises a DTR trigger circuit which is used for receiving an ultrasonic starting signal sent by the welding machine and sending the ultrasonic starting signal to the FPGA controller, and the FPGA controller immediately controls the first AD converter and the second AD converter to execute AD conversion after receiving the signal.
The acquisition card module further comprises a precision reference source and a calibration circuit which are sequentially connected, wherein the output end of the calibration circuit and a power analog quantity P (t) signal are simultaneously input into the analog acquisition channel A, and the output end of the calibration circuit and a frequency analog quantity F (t) signal are simultaneously input into the analog acquisition channel B.
The invention relates to an ultrasonic welding online monitoring method based on power and frequency analysis, which comprises the following steps:
s1, acquiring an initial standard center and an abnormal center of a power digital quantity P (n) and a frequency digital quantity F (n); acquiring a welding curve with qualified welding quality as an initial standard center, and taking the welding curve as a reference for subsequent processing; if conditions allow, if multiple frames of curves with qualified or abnormal labels can be provided, the initial standard centers and the abnormal centers are obtained through clustering.
S2, feeding back more curves with quality labels to the system through a feedback mechanism, and further increasing a standard center and an abnormal center;
and S3, if the user changes the system parameters or replaces parts, emptying all the standard centers and the abnormal centers, and repeating the steps S1 and S2.
The data volume collected by the embodiment is about 50-200, whether the data volume is marked as a defective part or not is used as a machine learning sample, and 0-7 grades are given according to the probability that the workpiece is a good part, wherein the 0 grade represents normal, the 1-7 grades represent abnormal, and the abnormal degree is increased along with the grade.
The ultrasonic welding on-line monitoring system and method based on power and frequency analysis provided by the invention make up for the defects of three methods in the prior art:
(1) The single value parameter method can only describe a single result, and the power curve can describe the whole welding process;
(2) The power of ultrasonic welding is in direct proportion to the product of amplitude and pressure, so that the energy transfer condition can be reflected better than that of an amplitude curve method, the data is accurate, and the interference is less;
(3) The inaccuracy of describing energy transmission by a voltage or current curve method of a capacitive or inductive circuit is overcome, the waveform is more visual, and the correlation is high.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and the purpose of the embodiments is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All modifications made according to the spirit of the main technical scheme of the invention are covered in the protection scope of the invention.
Claims (10)
1. The ultrasonic welding online monitoring system based on power and frequency analysis is characterized by comprising a preprocessing module, an acquisition card module and an industrial personal computer;
the preprocessing module acquires a power analog quantity P (t) and a frequency analog quantity F (t) of ultrasonic welding;
the acquisition card module converts the power analog quantity P (t) and the frequency analog quantity F (t) acquired by the preprocessing module into a power digital quantity P (n) and a frequency digital quantity F (n) respectively and uploads the power digital quantity P (n) and the frequency digital quantity F (n) to the industrial personal computer;
and the industrial personal computer evaluates the good products and the abnormal products of the ultrasonic welding according to the power digital quantity P (n) and the frequency digital quantity F (n).
2. The power and frequency analysis based ultrasonic welding online monitoring system of claim 1, wherein the preprocessing module obtains only one of a power analog quantity P (t) or a frequency analog quantity F (t) of the ultrasonic welding;
the acquisition card module converts the power analog quantity P (t) or the frequency analog quantity F (t) acquired by the preprocessing module into a power digital quantity P (n) or a frequency digital quantity F (n), and uploads the power digital quantity P (n) or the frequency digital quantity F (n) to the industrial personal computer;
and the industrial personal computer evaluates the good products and the abnormal products of the ultrasonic welding according to the power digital quantity P (n) or the frequency digital quantity F (n).
3. The power and frequency analysis based ultrasonic welding online monitoring system of claim 1, wherein the preprocessing module comprises a multiplier and a frequency counting circuit;
respectively inputting a voltage signal V (t) and a current signal I (t) of an RF wire of the ultrasonic welding machine into the input end of a multiplier, and performing product operation on the multiplier to obtain a power analog quantity P (t);
the frequency counting circuit acquires a frequency analog quantity F (t) of the voltage signal V (t).
4. The power and frequency analysis based ultrasonic welding online monitoring system according to claim 2, characterized in that the current signal I (t) of the ultrasonic welder RF line is transmitted to the multiplier through a mutual inductor; and the input ends of a voltage signal V (t) and a current signal I (t) of the multiplier are provided with amplitude limiting circuits.
5. The ultrasonic welding online monitoring system based on power and frequency analysis according to claim 2, characterized in that the acquisition card module comprises analog acquisition channels a, B, a first AD converter, a second AD converter, an FPGA controller; the analog acquisition channels A and B respectively acquire power analog quantity P (t) and frequency analog quantity F (t), convert the power analog quantity P (n) and the frequency digital quantity F (n) into power digital quantity P (n) and frequency digital quantity F (n) through a first AD converter and a second AD converter respectively, transmit the power digital quantity P (n) and the frequency digital quantity F (n) to the FPGA controller, and upload the power digital quantity P (n) and frequency digital quantity F (n) to the industrial personal computer through a PCI bus by the FPGA controller.
6. The power and frequency analysis based ultrasonic welding online monitoring system according to claim 5, wherein the card acquisition module further comprises a DTR trigger circuit for receiving an ultrasonic start signal sent by the welding machine and sending the signal to the FPGA controller, and the FPGA controller controls the first AD converter and the second AD converter to perform AD conversion immediately after receiving the signal.
7. The power and frequency analysis based ultrasonic welding online monitoring system according to claim 6, wherein the acquisition card module further comprises a precision reference source and a calibration circuit connected in sequence, an output end of the calibration circuit is simultaneously input to the analog acquisition channel A along with a power analog quantity P (t) signal, and an output end of the calibration circuit is simultaneously input to the analog acquisition channel B along with a frequency analog quantity F (t) signal.
8. The ultrasonic welding online monitoring method based on power and frequency analysis is characterized by comprising the following steps of:
s1, acquiring an initial standard center and an abnormal center of a power digital quantity P (n) and a frequency digital quantity F (n);
s2, feeding back more curves with quality labels to the system through a feedback mechanism, and further increasing a standard center and an abnormal center;
and S3, if the user changes the system parameters or replaces parts, emptying all the standard centers and the abnormal centers, and repeating the steps S1 and S2.
9. The method for monitoring ultrasonic welding on line based on power and frequency analysis as claimed in claim 8, characterized in that in step S1, a frame of welding curve with qualified welding quality is obtained as an initial standard center, and the strip is used as a reference for subsequent processing.
10. The on-line ultrasonic welding monitoring method based on power and frequency analysis as claimed in claim 9, wherein in step S1, a plurality of curves with qualified or abnormal labels are provided, and then the initial standard center and the abnormal center are obtained by clustering.
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| CN117733308A (en) * | 2024-02-19 | 2024-03-22 | 浙江大学 | Ultrasonic welding robot path planning method and device |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117733308A (en) * | 2024-02-19 | 2024-03-22 | 浙江大学 | Ultrasonic welding robot path planning method and device |
| CN117733308B (en) * | 2024-02-19 | 2024-05-17 | 浙江大学 | Ultrasonic welding robot path planning method and device |
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