CN116652440B - Digital welding method and control system for steel structure - Google Patents
Digital welding method and control system for steel structure Download PDFInfo
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- CN116652440B CN116652440B CN202310948456.XA CN202310948456A CN116652440B CN 116652440 B CN116652440 B CN 116652440B CN 202310948456 A CN202310948456 A CN 202310948456A CN 116652440 B CN116652440 B CN 116652440B
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- 238000003466 welding Methods 0.000 title claims abstract description 418
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 59
- 239000010959 steel Substances 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 52
- 238000004364 calculation method Methods 0.000 claims abstract description 4
- 238000010801 machine learning Methods 0.000 claims description 39
- 238000004088 simulation Methods 0.000 claims description 9
- 238000005259 measurement Methods 0.000 claims description 7
- 230000001960 triggered effect Effects 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 description 3
- 210000001503 joint Anatomy 0.000 description 3
- 238000007726 management method Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
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Classifications
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06N—COMPUTING ARRANGEMENTS BASED ON SPECIFIC COMPUTATIONAL MODELS
- G06N20/00—Machine learning
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T17/00—Three dimensional [3D] modelling, e.g. data description of 3D objects
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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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2200/00—Indexing scheme for image data processing or generation, in general
- G06T2200/04—Indexing scheme for image data processing or generation, in general involving 3D image data
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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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
Abstract
The application discloses a digital welding method and a control system for a steel structure, wherein the control system comprises the following steps: an upper computer; the resolving module and the basic control configuration module are arranged in the upper computer; the calculation module is used for sequentially calculating second position data of each welding structure unit and welding structure compensation assignment from a second coding table; the basic control configuration module is used for setting a moving track of the welding gun based on each welding structure unit, setting input current and current control when the welding structure units are welded based on welding structural compensation assignment, setting welding duration based on the corresponding welding structure units, and setting pause and moving speed of the welding gun when the welding structure units are welded through current control. The welding structure model obtained by the application is actually a welding spot filled during welding, so that accurate welding can be formed, and the phenomenon that the welding position is too thin or too thick can not occur.
Description
Technical Field
The application relates to the technical field of welding, in particular to a digital welding method and a control system for a steel structure.
Background
For the groove-free fusion welding technology, the narrow-gap welding technology and the pipeline welding technology, accurate welding needs to be formed, the welding position cannot be too thin, the welding is unstable easily caused by the fact that the welding is too thin, cracks or even breakage is easily caused by later use, and the welding is not too thick, when the thickness exceeds a certain critical value, brittleness is shown, and the welding spot can be subjected to periodic strain in the use process to cause failure. Too thick can also lead to cracking of the weld, reduced toughness and cyclic fatigue resistance, and thus reduced reliability or failure of the weld.
Disclosure of Invention
In view of the above, the present invention aims to provide a digital welding method and control system for steel structures.
On one hand, the invention provides a digital welding method for a steel structure, which comprises the following steps:
scanning the steel structure to obtain three-dimensional scanning data;
modeling the steel structure based on the three-dimensional scanning data to obtain a steel structure model, and performing contour recognition processing on the steel structure model by using a machine learning system to obtain a contour structure model of the region to be welded;
performing reverse modeling on the outline structure model to obtain a welded structure model;
Inputting the contour structure model into a machine learning system, dividing the contour structure model into a plurality of contour structure units according to a set rule, and encoding according to first position information of the contour structure units in the contour structure model to obtain a first encoding table; inputting the welding structure model into a machine learning system by using the same setting rule, dividing the welding structure model into a plurality of welding structure units which are correspondingly matched with a plurality of outline structure units, and encoding according to second position information of the welding structure units in the welding structure model to obtain a second encoding table;
inputting a group of outline structure units and welding structure units into a machine learning system synchronously based on a first encoding table and a second encoding table in sequence to perform outline structure assignment and welding structure assignment respectively, performing assignment compensation on the welding structure assignment of the corresponding matched welding structure units by using the outline structure assignment of each outline structure unit to obtain welding structure compensation assignment, and writing the welding structure compensation assignment under the welding structure units corresponding to the second encoding table correspondingly;
inputting a second coding table into the upper computer, and sequentially calculating second position information of each welding structure unit and welding structure compensation assignment by the upper computer from the second coding table; setting a moving track of a welding gun based on each welding structure unit, setting input current and current control when welding the welding structure units based on welding structural compensation assignment, and setting the welding structure units based on the welding structural compensation assignment correspondingly, thereby setting welding duration, and setting a pause and moving speed of the welding gun when welding through the current control.
Further, the method for inputting the contour structure model into the machine learning system and dividing the contour structure model into a plurality of contour structure units according to the set rule is as follows:
inputting the outline structure model into a structure recognition module in a machine learning system, and setting basic recognition parameters of the structure recognition module;
performing numerical conversion on the basic identification parameters to form division factors, setting division rules for dividing outline structural units by the division factors, and storing the division rules into a memory arranged in a machine learning system;
the structure recognition module recognizes an input outline structure model, selects a reference surface with a set reference rule in the outline structure model, divides the outline structure model into a plurality of outline structure units under the division rule by taking the reference surface as a division measurement surface, and records first position information of each outline structure unit in the outline structure model.
Further, the method for inputting the welding structure model into the machine learning system and dividing the welding structure model into a plurality of welding structure units correspondingly matched with the plurality of outline structure units comprises the following steps:
inputting the welding structure model to a structure identification module in a machine learning system, wherein the structure identification module invokes a division rule in a memory;
The structure identification module identifies an input welding structure model, selects a reference surface with a set reference rule in the welding structure model, takes the reference surface as a dividing measurement surface, divides the welding structure model into a plurality of welding structure units under the dividing rule, and records second position information of each welding structure unit in the welding structure model;
and configuring a loading thread for each welding structure unit, presetting a control instruction triggered by each loading thread, storing the control instruction, and simultaneously setting a trigger control unit for controlling the management of the control instruction, wherein when the preset control instruction is triggered, the trigger control unit automatically activates the corresponding loading thread.
Further, the method for synchronously inputting a group of outline structural units and welding structural units into the machine learning system based on the first encoding table and the second encoding table in sequence and respectively carrying out outline structural assignment and welding structural assignment comprises the following steps:
acquiring a first encoding table and a second encoding table, synchronously analyzing the first encoding table and the second encoding table, sequentially acquiring a contour structural unit and first position information corresponding to the contour structural unit through the first encoding table, and sequentially acquiring a welding structural unit and second position information corresponding to the welding structural unit through the second encoding table;
Configuring an assignment model and a control module in a machine learning system, wherein the assignment model is provided with a first assignment module and a second assignment module, a first assignment reference parameter is configured through a first configuration unit arranged in the first assignment module, a second assignment reference parameter is configured through a second configuration unit arranged in the second assignment module, and the first assignment reference parameter is the same as the second configuration reference parameter;
the control module sequentially inputs the outline structure units to the first assignment module according to the first position information, and forms a trigger instruction according to the first position information corresponding to the outline structure unit and stores the trigger instruction in the control module every time one outline structure unit is input, the first assignment module simulates a first modulus of the outline structure unit according to a first assignment reference parameter, and the outline structure assignment is obtained through scaling according to the first modulus and the total modulus of the entity outline unit constructed according to the reference surface; meanwhile, the control module correspondingly loads second position information based on the first position information contained in the trigger instruction, correspondingly calls a control instruction in the trigger control unit according to the second position information, triggers the control instruction to control the trigger control unit to automatically activate a corresponding loading thread, the loading thread loads a welding structure unit matched with the second position information to be input into the second assignment module, the second assignment module simulates a second module of the welding structure unit according to a second assignment reference parameter, and obtains welding structure assignment through scaling of the second module and the total module of the entity profile unit, wherein the sum of the profile structure assignment and the welding structure assignment is 1.
Further, the first assignment module simulates a first modulus of the outline structure unit according to a first assignment reference parameter, and the method for obtaining the outline structural assignment by scaling the first modulus and the total modulus of the entity outline unit constructed according to the reference surface comprises the following steps:
setting a first assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the outline structure unit by taking the block as a dividing unit to obtain a plurality of first dividing units, and marking and taking values of the first dividing units, wherein the first dividing units are complete blocks and marked as first standard moduli, the first dividing units are incomplete blocks and marked as second standard moduli, counting the numbers of the first standard moduli and the second standard moduli, and obtaining the first modulus according to the following formula:;
wherein the first modulus is N i ; A i Is the sum of the first standard modulus; b (B) i Is the sum of the second standard modulus; i represents the encoding of the first position information; c is the total modulus of the entity outline unit;
the method for determining the total modulus of the entity outline unit comprises the following steps:
And matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, as C.
Further, the second assignment module simulates a second modulus of the welding structural unit according to a second assignment reference parameter, and the method for obtaining the welding structural assignment by scaling the second modulus and the total modulus of the entity profile unit comprises the following steps:
setting a second assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the welding structure unit by taking the block as a dividing unit to obtain a plurality of second dividing units, recording the position coordinates of each second dividing unit, and marking and taking values of the second dividing units, wherein the second dividing units are complete blocks and marked as third standard moduli, the dividing units are incomplete blocks and marked as fourth standard moduli, counting the numbers of the third standard moduli and the fourth standard moduli, and obtaining second moduli according to the following formula: ;
Wherein the second modulus is M j ; I j Is the sum of the third standard modulus; k (K) j Is the fourth standard modulus sum; j represents the encoding of the second position information; c is the total modulus of the entity outline unit;
the method for determining the total modulus of the entity outline unit comprises the following steps:
and matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, and marking the total modulus as C.
Further, performing assignment compensation on the welding structure assignment of the corresponding matched welding structure units by using the contour structure assignment of each contour structure unit, and obtaining the welding structure compensation assignment by the following method:
acquiring outline structuring assignment and welding structuring assignment; summing the profile structural assignment and the weld structural assignment to see if it is 1;
if not, revising the welding structural assignment by taking the outline structural assignment as a reference, and enabling the sum of the outline structural assignment and the welding structural assignment to be 1.
Further, the method for setting the movement track of the welding gun based on each welding structure unit comprises the following steps:
acquiring a plurality of second dividing units of each welding structure unit, acquiring the position coordinates of each second dividing unit, and acquiring the marks of the corresponding second dividing units;
and constructing a moving track of the welding gun by the coordinate data of the second dividing unit.
On the other hand, the invention also provides a control system which is applied to the digital welding method of the steel structure, and the control system comprises:
an upper computer;
the resolving module and the basic control configuration module are arranged in the upper computer;
the calculation module is used for sequentially calculating second position information of each welding structure unit and welding structure compensation assignment from a second coding table;
the basic control configuration module is used for setting a moving track of the welding gun based on each welding structure unit, setting input current and current control when the welding structure units are welded based on welding structural compensation assignment, setting welding duration based on the corresponding welding structure units, and setting pause and moving speed of the welding gun when the welding structure units are welded through current control.
The application utilizes a three-dimensional scanner to perform three-dimensional scanning on a steel structure to-be-welded area according to the structural characteristics of a welding position, obtains a steel structure and a three-dimensional contour of the to-be-welded area, models the steel structure and the three-dimensional contour of the to-be-welded area based on the three-dimensional contour of the steel structure to-be-welded area to obtain a contour structural model and a steel structure model of the to-be-welded area, performs reverse modeling on the contour structural model by taking the steel structure model as a reference to obtain a welding structural model of the welding area, respectively inputs the contour structural model and the welding structural model into a machine recognition system, respectively divides the contour structural model and the welding structural model into a plurality of contour structural units and welding structural units which are matched with each other correspondingly according to a set rule, that is, when the corresponding matched outline structure unit and the welding structure unit are butted to form a whole, the formed integral structure model is the same, the corresponding matched outline structure unit and the welding structure unit are butted to form a cube model, then the corresponding matched outline structure unit and the welding structure unit are synchronously input into a machine learning system to respectively carry out outline structural assignment and welding structural assignment, the sum of the outline structural assignment and the welding structural assignment is 1, if the sum of the outline structural assignment and the welding structural assignment is not 1, the welding structural assignment is revised by taking the outline structural assignment as a reference, and the sum of the outline structural assignment and the welding structural assignment is 1.
Writing the welding structural compensation assignment under the welding structural unit corresponding to the second coding table; inputting a second coding table into the upper computer, and sequentially calculating second position information of each welding structure unit and welding structure compensation assignment by the upper computer from the second coding table; setting a moving track of a welding gun based on each welding structure unit, setting input current and current control when welding the welding structure units based on welding structural compensation assignment, setting welding duration based on the corresponding set welding structure units based on welding structural compensation assignment, and setting a pause and moving speed of the welding gun during welding through the current control.
The welding structure model obtained by the application is actually a welding spot filled during welding, the input current and current control of each welding point position and the corresponding welding time length are set by digitally dividing and carrying out track planning on the welding structure model, and meanwhile, the pause and the moving speed of a welding gun during welding are set by the current control, so that accurate welding can be formed, and the phenomenon that the welding position is too thin or too thick can not occur.
Drawings
FIG. 1 is a flow chart of the method of the present application;
FIG. 2 is a flow chart of a method of inputting a contour structure model into a machine learning system according to the present invention, the contour structure model being divided into a plurality of contour structure units according to a set rule;
FIG. 3 is a flow chart of a method of inputting a welded structural model of the present invention into a machine learning system divided into a plurality of welded structural units that are correspondingly matched to a plurality of outline structural units;
fig. 4 is a schematic diagram of the system framework of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Example 1:
referring to fig. 1 to 4, the present invention provides a digital welding method for a steel structure, comprising the steps of:
scanning the steel structure to obtain three-dimensional scanning data;
modeling the steel structure based on the three-dimensional scanning data to obtain a steel structure model, and performing contour recognition processing on the steel structure model by using a machine learning system to obtain a contour structure model of the region to be welded;
Performing reverse modeling on the outline structure model to obtain a welded structure model;
inputting the contour structure model into a machine learning system, dividing the contour structure model into a plurality of contour structure units according to a set rule, and encoding according to first position information of the contour structure units in the contour structure model to obtain a first encoding table; inputting the welding structure model into a machine learning system by using the same setting rule, dividing the welding structure model into a plurality of welding structure units which are correspondingly matched with a plurality of outline structure units, and encoding according to second position information of the welding structure units in the welding structure model to obtain a second encoding table;
inputting a group of outline structure units and welding structure units into a machine learning system synchronously based on a first encoding table and a second encoding table in sequence to perform outline structure assignment and welding structure assignment respectively, performing assignment compensation on the welding structure assignment of the corresponding matched welding structure units by using the outline structure assignment of each outline structure unit to obtain welding structure compensation assignment, and writing the welding structure compensation assignment under the welding structure units corresponding to the second encoding table correspondingly;
inputting a second coding table into the upper computer, and sequentially calculating second position information of each welding structure unit and welding structure compensation assignment by the upper computer from the second coding table; setting a moving track of a welding gun based on each welding structure unit, setting input current and current control when welding the welding structure units based on welding structural compensation assignment, and setting the welding structure units based on the welding structural compensation assignment correspondingly, thereby setting welding duration, and setting a pause and moving speed of the welding gun when welding through the current control.
In some embodiments, the area to be welded is generally provided with a fracture, a dent position and the like, taking the fracture as an example, the outline structure model is actually a part of the steel structure models at two sides of the fracture, and during reverse modeling, structural filling modeling is actually carried out at the fracture position to completely fill the fracture; taking the concave position as an example, a connecting part is arranged at the butt joint of the steel structure, the connecting part is concave downwards relative to the steel structure, the outline structure model is actually obtained by taking the connecting part as a main body to perform three-dimensional scanning for modeling, and the welding structure model is positioned in an area on the outline structure model and is used for connecting and fixing the butt joint of the steel structure while filling the concave position.
According to structural features of welding positions, a three-dimensional scanner is utilized to perform three-dimensional scanning on a steel structure area to be welded to obtain a three-dimensional outline of the steel structure area and a three-dimensional outline of the area to be welded, a coordinate system is built in three-dimensional software according to measured three-dimensional coordinate data, modeling is performed on the basis of the three-dimensional outline of the steel structure area and the three-dimensional outline of the area to be welded to obtain a outline structure model and a steel structure model of the area to be welded, reverse modeling is performed on the outline structure model by taking the steel structure model as a reference, the outline structure model and the welding structure model are respectively input into a machine identification system, the outline structure model and the welding structure model are respectively divided into outline structure units and welding structure units which are matched correspondingly, namely, when the outline structure units and the welding structure units which are matched correspondingly are butted into a whole, the formed integral structure model is identical, the outline structure units which are matched correspondingly are butted to form a cube model, then the outline structure units and the welding structure units which are matched correspondingly are synchronously input into a machine learning system to perform outline structure assignment and welding structure assignment respectively, and the assignment of the outline structure and the welding structure assignment are not 1, and the assignment of the welding structure assignment and the assignment of the assignment and 1 are made.
In some embodiments, the method of inputting the outline structure model into the machine learning system to divide the outline structure model into a plurality of outline structure units according to a set rule is as follows:
inputting the outline structure model into a structure recognition module in a machine learning system, and setting basic recognition parameters of the structure recognition module;
performing numerical conversion on the basic identification parameters to form division factors, setting division rules for dividing outline structural units by the division factors, and storing the division rules into a memory arranged in a machine learning system;
the structure recognition module recognizes an input outline structure model, selects a reference surface with a set reference rule in the outline structure model, divides the outline structure model into a plurality of outline structure units under the division rule by taking the reference surface as a division measurement surface, and records first position information of each outline structure unit in the outline structure model.
In some embodiments, when modeling the outline structure model and the welding structure model, the application takes the steel structure model obtained by three-dimensional scanning of the corresponding steel structure as a reference, and selects a regular form as the construction of the outline structure model and the welding structure model, in order to obtain the outline structure model and the welding structure model with the regular form, when constructing the outline structure model and the welding structure model, the application determines the edge contour of a butt joint part (a fracture or a dent) of the steel structure model according to the scanning result, acquires the corresponding cross section according to the edge contour as the surfaces of the outline structure model and the welding structure model, and takes the corresponding cross section as an implementation reference, wherein the outline structure model and the welding structure model are in the regular form, such as a cuboid or a cube or a regular circular ring after being butt-jointed; in this way, the separate contour structure model and welding structure model have at least more than two planes, the presence of which provides a reliable reference surface for the division of the structure identification module.
In combination with the above, the method for inputting the welding structure model into the machine learning system and dividing the welding structure model into a plurality of welding structure units correspondingly matched with a plurality of outline structure units comprises the following steps:
inputting the welding structure model to a structure identification module in a machine learning system, wherein the structure identification module invokes a division rule in a memory;
the structure recognition module recognizes the input welding structure model, selects a reference surface (a plane with the outline structure model and the welding structure model as the reference surface with the set reference rule) in the welding structure model, takes the reference surface (a plane with a long side in a cuboid as the reference surface, and takes the inner/outer surface of the ring as the reference surface if the ring is the ring) as a dividing measurement surface, divides the welding structure model into a plurality of welding structure units under the dividing rule, and records second position information of each welding structure unit in the welding structure model;
and configuring a loading thread for each welding structure unit, presetting a control instruction triggered by each loading thread, storing the control instruction, and simultaneously setting a trigger control unit for controlling the management of the control instruction, wherein when the preset control instruction is triggered, the trigger control unit automatically activates the corresponding loading thread.
In the above description, the division rule may be divided according to a division coefficient set as an input, for example, when the division coefficient is 5, it means that the welding structure model is equally divided into 5 parts according to the reference plane according to the division rule.
In the above, the method for synchronously inputting a group of outline structural units and welding structural units to the machine learning system based on the first encoding table and the second encoding table in sequence and respectively carrying out outline structural assignment and welding structural assignment comprises the following steps:
acquiring a first encoding table and a second encoding table, synchronously analyzing the first encoding table and the second encoding table, sequentially acquiring a contour structural unit and first position information corresponding to the contour structural unit through the first encoding table, and sequentially acquiring a welding structural unit and second position information corresponding to the welding structural unit through the second encoding table;
configuring an assignment model and a control module in a machine learning system, wherein the assignment model is provided with a first assignment module and a second assignment module, a first assignment reference parameter is configured through a first configuration unit arranged in the first assignment module, a second assignment reference parameter is configured through a second configuration unit arranged in the second assignment module, and the first assignment reference parameter is the same as the second configuration reference parameter;
The control module sequentially inputs the outline structure units to the first assignment module according to the first position information, and forms a trigger instruction according to the first position information corresponding to the outline structure unit and stores the trigger instruction in the control module every time one outline structure unit is input, the first assignment module simulates a first modulus of the outline structure unit according to a first assignment reference parameter, and the outline structure assignment is obtained through scaling according to the first modulus and the total modulus of the entity outline unit constructed according to the reference surface; meanwhile, the control module correspondingly loads second position information based on the first position information contained in the trigger instruction, correspondingly calls a control instruction in the trigger control unit according to the second position information, triggers the control instruction to control the trigger control unit to automatically activate a corresponding loading thread, the loading thread loads a welding structure unit matched with the second position information to be input into the second assignment module, the second assignment module simulates a second module of the welding structure unit according to a second assignment reference parameter, and obtains welding structure assignment through scaling of the second module and the total module of the entity profile unit, wherein the sum of the profile structure assignment and the welding structure assignment is 1.
In the above, the method for obtaining the outline structural assignment by the first assignment module by simulating the first modulus of the outline structural unit according to the first assignment reference parameter and performing scaling according to the first modulus and the total modulus of the entity outline unit constructed according to the reference surface comprises the following steps:
setting a first assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the outline structure unit by taking the block as a dividing unit to obtain a plurality of first dividing units, and marking and taking values of the first dividing units, wherein the first dividing units are complete blocks and marked as first standard moduli, the first dividing units are incomplete blocks and marked as second standard moduli, counting the numbers of the first standard moduli and the second standard moduli, and obtaining the first modulus according to the following formula:;
wherein the first modulus is N i ; A i Is the sum of the first standard modulus; b (B) i Is the sum of the second standard modulus; i represents the encoding of the first position information; c is the outline of the entityThe total modulus of the cell;
the method for determining the total modulus of the entity outline unit comprises the following steps:
And matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, as C.
Further, the second assignment module simulates a second modulus of the welding structural unit according to a second assignment reference parameter, and the method for obtaining the welding structural assignment by scaling the second modulus and the total modulus of the entity profile unit comprises the following steps:
setting a second assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the welding structure unit by taking the block as a dividing unit to obtain a plurality of second dividing units, recording the position coordinates of each second dividing unit, and marking and taking values of the second dividing units, wherein the second dividing units are complete blocks and marked as third standard moduli, the dividing units are incomplete blocks and marked as fourth standard moduli, counting the numbers of the third standard moduli and the fourth standard moduli, and obtaining second moduli according to the following formula: ;
Wherein the second modulus is M j ; I j Is the sum of the third standard modulus; k (K) j Is the fourth standard modulus sum; j represents the encoding of the second position information; c is the total modulus of the entity outline unit;
the method for determining the total modulus of the entity outline unit comprises the following steps:
and matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, as C.
Taking a welding body obtained by one-time spot welding of a welding gun under set rated current, voltage and standard temperature as a minimum measurement unit to obtain a certain amount of welding bodies of one-time spot welding, testing the volume of each welding body, and obtaining the average value of the welding bodies of one-time spot welding by obtaining the average value; and taking a standard block obtained by performing three-dimensional modeling simulation on the welding body obtained by one-time spot welding as a standard unit, and obtaining a standard block when one-time spot welding is performed at set rated current, voltage and standard temperature, wherein the outline structural unit and the welding structural unit are formed by a plurality of standard blocks.
In the above, the assignment compensation is performed on the welding structure assignment of the corresponding matched welding structure unit by using the contour structure assignment of each contour structure unit, and the method for obtaining the welding structure compensation assignment is as follows:
acquiring outline structuring assignment and welding structuring assignment; summing the profile structural assignment and the weld structural assignment to see if it is 1;
if not, revising the welding structural assignment by taking the outline structural assignment as a reference, and enabling the sum of the outline structural assignment and the welding structural assignment to be 1.
Further, the method for setting the movement track of the welding gun based on each welding structure unit comprises the following steps:
acquiring a plurality of second dividing units of each welding structure unit, acquiring the position coordinates of each second dividing unit, and acquiring the marks of the corresponding second dividing units;
and constructing a moving track of the welding gun by the coordinate data of the second dividing unit.
The principle of the application is as follows: the application utilizes a three-dimensional scanner to perform three-dimensional scanning on a steel structure to-be-welded area according to the structural characteristics of a welding position, obtains a steel structure and a three-dimensional contour of the to-be-welded area, models the steel structure and the three-dimensional contour of the to-be-welded area based on the three-dimensional contour of the steel structure to-be-welded area to obtain a contour structural model and a steel structure model of the to-be-welded area, performs reverse modeling on the contour structural model by taking the steel structure model as a reference to obtain a welding structural model of the welding area, respectively inputs the contour structural model and the welding structural model into a machine recognition system, respectively divides the contour structural model and the welding structural model into a plurality of contour structural units and welding structural units which are matched with each other correspondingly according to a set rule, that is, when the corresponding matched outline structure unit and the welding structure unit are butted to form a whole, the formed integral structure model is the same, the corresponding matched outline structure unit and the welding structure unit are butted to form a cube model, then the corresponding matched outline structure unit and the welding structure unit are synchronously input into a machine learning system to respectively carry out outline structural assignment and welding structural assignment, the sum of the outline structural assignment and the welding structural assignment is 1, if the sum of the outline structural assignment and the welding structural assignment is not 1, the welding structural assignment is revised by taking the outline structural assignment as a reference, and the sum of the outline structural assignment and the welding structural assignment is 1.
The first assignment module simulates a first modulus of the outline structural unit according to a first assignment reference parameter, and the outline structural assignment is obtained by scaling the first modulus and the total modulus of the entity outline unit constructed according to the reference surface, and the method comprises the following steps:
setting a first assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the outline structure unit by taking the block as a dividing unit to obtain a plurality of first dividing units, and marking and taking values of the first dividing units, wherein the first dividing units are complete blocks and marked as first standard moduli, the first dividing units are incomplete blocks and marked as second standard moduli, counting the numbers of the first standard moduli and the second standard moduli, and obtaining the first modulus according to the following formula:;
wherein the first modulus is N i ; A i Is the sum of the first standard modulus; b (B) i Is the sum of the second standard modulus; i represents the encoding of the first position information; c is the total modulus of the entity outline unit;
the method for determining the total modulus of the entity outline unit comprises the following steps:
And matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, and marking the total modulus as C.
Further, the second assignment module simulates a second modulus of the welding structural unit according to a second assignment reference parameter, and the method for obtaining the welding structural assignment by scaling the second modulus and the total modulus of the entity profile unit comprises the following steps:
setting a second assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the welding structure unit by taking the block as a dividing unit to obtain a plurality of second dividing units, recording the position coordinates of each second dividing unit, and marking and taking values of the second dividing units, wherein the second dividing units are complete blocks and marked as third standard moduli, the dividing units are incomplete blocks and marked as fourth standard moduli, counting the numbers of the third standard moduli and the fourth standard moduli, and obtaining second moduli according to the following formula: ;
Wherein the second modulus is M j ; I j Is the sum of the third standard modulus; k (K) j Is the fourth standard modulus sum; j represents the encoding of the second position information; c is the solid outline unitA total modulus;
the method for determining the total modulus of the entity outline unit comprises the following steps:
and matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, and marking the total modulus as C.
Writing the welding structural compensation assignment under the welding structural unit corresponding to the second coding table; inputting a second coding table into the upper computer, and sequentially calculating second position information of each welding structure unit and welding structure compensation assignment by the upper computer from the second coding table; setting a moving track of a welding gun based on each welding structure unit, setting input current and current control when welding the welding structure units based on welding structural compensation assignment, setting welding duration based on the corresponding set welding structure units based on welding structural compensation assignment, and setting a pause and moving speed of the welding gun during welding through the current control.
The welding structure model obtained by the application is actually a welding spot filled during welding, the input current and current control of each welding point position and the corresponding welding time length are set by digitally dividing and carrying out track planning on the welding structure model, and meanwhile, the pause and the moving speed of a welding gun during welding are set by the current control, so that accurate welding can be formed, and the phenomenon that the welding position is too thin or too thick is avoided.
Example 2:
referring to fig. 4, the application further provides a control system applied to the above-mentioned digital welding method for steel structures, where the control system includes:
an upper computer;
the resolving module and the basic control configuration module are arranged in the upper computer;
the calculation module is used for sequentially calculating second position information of each welding structure unit and welding structure compensation assignment from a second coding table;
the basic control configuration module is used for setting a moving track of the welding gun based on each welding structure unit, setting input current and current control when the welding structure units are welded based on welding structural compensation assignment, setting welding duration based on the corresponding welding structure units, and setting pause and moving speed of the welding gun when the welding structure units are welded through current control.
The application utilizes a three-dimensional scanner to perform three-dimensional scanning on a steel structure to-be-welded area according to the structural characteristics of a welding position, obtains a steel structure and a three-dimensional contour of the to-be-welded area, models the steel structure and the three-dimensional contour of the to-be-welded area based on the three-dimensional contour of the steel structure to-be-welded area to obtain a contour structural model and a steel structure model of the to-be-welded area, performs reverse modeling on the contour structural model by taking the steel structure model as a reference to obtain a welding structural model of the welding area, respectively inputs the contour structural model and the welding structural model into a machine recognition system, respectively divides the contour structural model and the welding structural model into a plurality of contour structural units and welding structural units which are matched with each other correspondingly according to a set rule, that is, when the corresponding matched outline structure unit and the welding structure unit are butted to form a whole, the formed integral structure model is the same, the corresponding matched outline structure unit and the welding structure unit are butted to form a cube model, then the corresponding matched outline structure unit and the welding structure unit are synchronously input into a machine learning system to respectively carry out outline structural assignment and welding structural assignment, the sum of the outline structural assignment and the welding structural assignment is 1, if the sum of the outline structural assignment and the welding structural assignment is not 1, the welding structural assignment is revised by taking the outline structural assignment as a reference, and the sum of the outline structural assignment and the welding structural assignment is 1.
Writing the welding structural compensation assignment under the welding structural unit corresponding to the second coding table; inputting a second coding table into the upper computer, and sequentially calculating second position information of each welding structure unit and welding structure compensation assignment by the upper computer from the second coding table; setting a moving track of a welding gun based on each welding structure unit, setting input current and current control when welding the welding structure units based on welding structural compensation assignment, setting welding duration based on the corresponding set welding structure units based on welding structural compensation assignment, and setting a pause and moving speed of the welding gun during welding through the current control.
The welding structure model obtained by the application is actually a welding spot filled during welding, the input current and current control of each welding point position and the corresponding welding time length are set by digitally dividing and carrying out track planning on the welding structure model, and meanwhile, the pause and the moving speed of a welding gun during welding are set by the current control, so that accurate welding can be formed, and the phenomenon that the welding position is too thin or too thick can not occur.
Although embodiments of the present application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the application, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. The digital welding method for the steel structure is characterized by comprising the following steps of:
scanning the steel structure to obtain three-dimensional scanning data;
modeling the steel structure based on the three-dimensional scanning data to obtain a steel structure model, and performing contour recognition processing on the steel structure model by using a machine learning system to obtain a contour structure model of the region to be welded;
performing reverse modeling on the outline structure model to obtain a welded structure model;
inputting the contour structure model into a machine learning system, dividing the contour structure model into a plurality of contour structure units according to a set rule, and encoding according to first position information of the contour structure units in the contour structure model to obtain a first encoding table; inputting the welding structure model into a machine learning system by using the same setting rule, dividing the welding structure model into a plurality of welding structure units which are correspondingly matched with a plurality of outline structure units, and encoding according to second position information of the welding structure units in the welding structure model to obtain a second encoding table;
inputting a group of outline structure units and welding structure units into a machine learning system synchronously based on a first encoding table and a second encoding table in sequence to perform outline structure assignment and welding structure assignment respectively, performing assignment compensation on the welding structure assignment of the corresponding matched welding structure units by using the outline structure assignment of each outline structure unit to obtain welding structure compensation assignment, and writing the welding structure compensation assignment under the welding structure units corresponding to the second encoding table correspondingly;
Inputting a second coding table into the upper computer, and sequentially calculating second position information of each welding structure unit and welding structure compensation assignment by the upper computer from the second coding table; setting a moving track of a welding gun based on each welding structure unit, setting input current and current control when welding the welding structure units based on welding structural compensation assignment, and setting the welding structure units based on the welding structural compensation assignment correspondingly, thereby setting welding duration, and setting a pause and a moving speed of the welding gun when welding through the current control;
the method for inputting the contour structure model into the machine learning system and dividing the contour structure model into a plurality of contour structure units according to the set rules comprises the following steps:
inputting the outline structure model into a structure recognition module in a machine learning system, and setting basic recognition parameters of the structure recognition module;
performing numerical conversion on the basic identification parameters to form division factors, setting division rules for dividing outline structural units by the division factors, and storing the division rules into a memory arranged in a machine learning system;
the structure identification module identifies an input contour structure model, selects a reference surface with a set reference rule in the contour structure model, takes the reference surface as a dividing measurement surface, divides the contour structure model into a plurality of contour structure units under the dividing rule, and records first position information of each contour structure unit in the contour structure model;
The contour structure model and the welding structure model are in a regular shape after being butted, at least more than two planes exist in the independent contour structure model and the welding structure model, the existence of the planes provides a reliable reference surface for the division of the structure identification module, and the planes existing in the contour structure model and the welding structure model are used as the reference surfaces for setting the reference rules.
2. The digitized welding method of steel structure of claim 1 wherein the method of inputting the welded structure model into the machine learning system divided into a plurality of welded structure units that are correspondingly matched to the plurality of profile structure units is:
inputting the welding structure model to a structure identification module in a machine learning system, wherein the structure identification module invokes a division rule in a memory;
the structure identification module identifies an input welding structure model, selects a reference surface with a set reference rule in the welding structure model, takes the reference surface as a dividing measurement surface, divides the welding structure model into a plurality of welding structure units under the dividing rule, and records second position information of each welding structure unit in the welding structure model;
and configuring a loading thread for each welding structure unit, presetting a control instruction triggered by each loading thread, storing the control instruction, and simultaneously setting a trigger control unit for controlling the management of the control instruction, wherein when the preset control instruction is triggered, the trigger control unit automatically activates the corresponding loading thread.
3. The digitized welding method of steel structures according to claim 1, wherein the method for synchronously inputting a group of contour structural units and welding structural units to the machine learning system based on the first coding table and the second coding table in sequence and respectively carrying out contour structural assignment and welding structural assignment comprises the following steps:
acquiring a first encoding table and a second encoding table, synchronously analyzing the first encoding table and the second encoding table, sequentially acquiring a contour structural unit and first position information corresponding to the contour structural unit through the first encoding table, and sequentially acquiring a welding structural unit and second position information corresponding to the welding structural unit through the second encoding table;
configuring an assignment model and a control module in a machine learning system, wherein the assignment model is provided with a first assignment module and a second assignment module, a first assignment reference parameter is configured through a first configuration unit arranged in the first assignment module, a second assignment reference parameter is configured through a second configuration unit arranged in the second assignment module, and the first assignment reference parameter is the same as the second configuration reference parameter;
the control module sequentially inputs the outline structure units to the first assignment module according to the first position information, and forms a trigger instruction according to the first position information corresponding to the outline structure unit and stores the trigger instruction in the control module every time one outline structure unit is input, the first assignment module simulates a first modulus of the outline structure unit according to a first assignment reference parameter, and the outline structure assignment is obtained through scaling according to the first modulus and the total modulus of the entity outline unit constructed according to the reference surface; meanwhile, the control module correspondingly loads second position information based on the first position information contained in the trigger instruction, correspondingly calls a control instruction in the trigger control unit according to the second position information, triggers the control instruction to control the trigger control unit to automatically activate a corresponding loading thread, the loading thread loads a welding structure unit matched with the second position information to be input into the second assignment module, the second assignment module simulates a second module of the welding structure unit according to a second assignment reference parameter, and obtains welding structure assignment through scaling of the second module and the total module of the entity profile unit, wherein the sum of the profile structure assignment and the welding structure assignment is 1.
4. The digitized welding method of steel structure of claim 3 wherein the first assignment module simulates a first modulus of the outline structure unit according to a first assignment reference parameter, and the method for obtaining the outline structured assignment by scaling the first modulus to a total modulus of the solid outline unit constructed according to the reference surface comprises the steps of:
setting a first assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the outline structure unit by taking the block as a dividing unit to obtain a plurality of first dividing units, and marking and taking values of the first dividing units, wherein the first dividing units are complete blocks and marked as first standard moduli, the first dividing units are incomplete blocks and marked as second standard moduli, counting the numbers of the first standard moduli and the second standard moduli, and obtaining the first modulus according to the following formula:wherein the first modulus is N i ; A i Is the sum of the first standard modulus; b (B) i Is the sum of the second standard modulus; i represents the encoding of the first position information; c is the total modulus of the entity outline unit;
The method for determining the total modulus of the entity outline unit comprises the following steps: and matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, as C.
5. The digitized welding method of steel structures of claim 3 wherein the second assignment module simulates a second modulus of the welded structural unit according to a second assignment reference parameter, and the method for obtaining the welded structural assignment by scaling the second modulus to the total modulus of the solid profile unit comprises:
setting a second assignment reference parameter as follows: a welding body obtained by one-time spot welding of a welding gun under set rated current and voltage and standard temperature is subjected to three-dimensional modeling simulation to obtain a standard block, wherein the block is a cube;
dividing the welding structure unit by taking the block as a dividing unit to obtain a plurality of second dividing units, recording the position coordinates of each second dividing unit, and marking and taking values of the second dividing units, wherein the second dividing units are complete blocks and marked as third standard moduli, the dividing units are incomplete blocks and marked as fourth standard moduli, counting the numbers of the third standard moduli and the fourth standard moduli, and obtaining second moduli according to the following formula: ;
Wherein the second modulus is M j ; I j Is the sum of the third standard modulus; k (K) j Is the fourth standard modulus sum; j represents the encoding of the second position information; c is the total modulus of the entity outline unit;
the method for determining the total modulus of the entity outline unit comprises the following steps: and matching and butting the corresponding matched outline structure units and the welding structure units according to the first position information and the second position information to form an entity outline unit, dividing the entity outline unit by taking the block as a dividing unit to obtain a plurality of entity units, and recording the total number of the entity units, namely the total modulus of the entity outline unit, and marking the total modulus as C.
6. The digitized welding method of steel structures of claim 1 wherein the assignment compensation is performed on the welding structure assignment of the corresponding matched welding structure units by using the contour structure assignment of each contour structure unit, and the method for obtaining the welding structure compensation assignment is as follows:
acquiring outline structuring assignment and welding structuring assignment; summing the profile structural assignment and the weld structural assignment to see if it is 1;
if not, revising the welding structural assignment by taking the outline structural assignment as a reference, and enabling the sum of the outline structural assignment and the welding structural assignment to be 1.
7. The digital welding method for steel structures according to claim 1, wherein the method of setting the movement trajectory of the welding gun on a per welding structure unit basis is:
acquiring a plurality of second dividing units of each welding structure unit, acquiring the position coordinates of each second dividing unit, and acquiring the marks of the corresponding second dividing units;
and constructing a moving track of the welding gun by the coordinate data of the second dividing unit.
8. Control system for a digital welding method of steel structures according to any one of claims 1 to 7, characterized in that it comprises:
an upper computer;
the resolving module and the basic control configuration module are arranged in the upper computer;
the calculation module is used for sequentially calculating second position information of each welding structure unit and welding structure compensation assignment from a second coding table;
the basic control configuration module is used for setting a moving track of the welding gun based on each welding structure unit, setting input current and current control when the welding structure units are welded based on welding structural compensation assignment, setting welding duration based on the corresponding welding structure units, and setting pause and moving speed of the welding gun when the welding structure units are welded through current control.
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